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2007 Ford S-Max 1.8TDCI 125 - Smokey Ford S-Max 1.8TDCI 125 - Samregjones

Hi All

Hoping someone might be able to help/has seen the same symptoms.

I have a 2007 Ford S-Max 1.8TDCI 125 with 93K on the clock.

I recently serviced the car; oil, oil filter and air filter.

Before the service the car was really reluctant to rev out until it had warmed up fully, once warm, it drove without any hesitance.

This hesitance has gone since the service was completed. However, after the service the car has started making a hissing noise when I put my foot down, which I am assuming is the turbo but not a good turbo noise?

I had a garage check it out when they did the MOT about a four days after the service and they said it's nothing to worry about.

Since then (4 weeks after the service) the car has started to get more and more smokey.

At first it was only when the boost kicked in but now it is dropping a small black cloud if I rev it stationary and I've now noticed black smoke when driving at motorway speeds. I can see a little cloud pop up around the rear window.

I've done a load of searching and reading but so far it has pointed at a number of things which isn't helping me pin point the problem.

I still have boost and the car gets up to speed reasonably well, so I'm hoping that points to something other than the turbo failing.

I've looked over most of the intake system from airbox to EGR as best as I can. I've not had it all out to inspect fully, I only found a pin prick hole in the intercooler to EGR pipe, is that enough to cause issues?

Has anyone had the same symptoms and if so, can they advise what it turned out to be?

Thanks in advance,

Sam

2007 Ford S-Max 1.8TDCI 125 - Smokey Ford S-Max 1.8TDCI 125 - elekie&a/c doctor

A small hole in the intercooler pipe is enough for you to lose boost pressure and cause a hissing noise. Failing turbos don't usually hiss.

2007 Ford S-Max 1.8TDCI 125 - Smokey Ford S-Max 1.8TDCI 125 - Samregjones

Thanks for the reply, I'll change that pipe and hope it seal the intake system and hopefully stops the smoking.

Next is fuel filter to see if that stops smoking.

Thinking I'll attack air/ fuel first before getting into EGRs and turbos!

2007 Ford S-Max 1.8TDCI 125 - Smokey Ford S-Max 1.8TDCI 125 - Samregjones

Hi all

Thought I'd post the results/fix.

Turned out to be the intercooler to EGR pipe. Its solid plastic up to where it link to the EGR which is rubber, this rubber had a tiny slit in.

I've wrapped the end in self amalgamating tape and now no more hissing and no more smoke!

2007 Ford S-Max 1.8TDCI 125 - Smokey Ford S-Max 1.8TDCI 125 - craig-pd130

Good result. The tape repair may well hold indefinitely but I would consider fitting a new replacement pipe at some point for peace of mind, turbodiesels do run high boost pressures which quickly causes boost leaks at any weak points.

2007 Ford S-Max 1.8TDCI 125 - Smokey Ford S-Max 1.8TDCI 125 - Samregjones

Update, self amalgamating tape doesn't work, too hot and too much boost pressure for the tape to contain.

Ok as temporary fix while waiting for new parts to arrive.

I fitted a 100mm section of silicone tube to replace the worn out part of the original pipe.

Cut the old pipe back to where it narrows, the fit the silicon and secured with jubilee clips. Really secure, no air leaks and no engine management lights. A solid fix!

Edited by Samregjones on 24/07/2021 at 08:31

2007 Ford S-Max 1.8TDCI 125 - Smokey Ford S-Max 1.8TDCI 125 - Samregjones

<500Miles later;

The IAT popped out of the pipe (The sensor before the elbow of the pipe at the EGR end/The silicon pipe fixed end) Loss of power and after puling over to see what had happened, I really struggled to get the car moving again. Managed to limp it home though for the last couple of mile.

I would recommend replacing the pipe as soon as possible once it starts showing signs of leaks or fatigue.

You can order the pipe from here;

Genuine Ford Galaxy S-Max Mondeo Mk4 1.8 TDCi Intercooler Air Duct Hose 1521483 | eBay

You don't need the IAT sensor (took me ages to find the info for this!) Ford sent a technical advisory out in 2008 detailing its not needed, so don't drill the pipe as I read in another post on another forum!!

You have 2 options;

Cable tie it to the pipe or find a garage who can do an IAT sensor delete.

Ford quoted £85, an independent has quoted £70.

I'll be going to my local independent.