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Old 21-01-2023, 04:40 PM   #335
AlanM
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Join Date: Dec 2022
Posts: 102
Default Re: What problems have you had with your Mondeo?

On new years day, started the car (2011 TDCI Wagon) and it sounded awful, running on 3 cylinders, and after a few moments there was smoke coming out from under the bonnet!

A quick look found a broken injector clamp. Pretty amazing as these are very solid looking appear to be cast steel of some kind.

Anyway because it was new year, and finding a replacement would take too long, we mig welded it back together.

A few days later we drove from Sydney to Queensland, no problems.

A few days after that, it happened again. No surprise, half expected the cast steel to not weld well. So a quick look, and the welded clamp was fine, another one had broken!

A bit of forum and YouTube searching found this wasn't rare, and the specified torque is very low, so these clamps seem to be very fragile.

I didn't fancy having this happen regularly, so bought a lump of 12mm steel bar, spent a few hours with a drill press and a grinder and made 4 of my own. Had to bend them in a 20 tonne press to get the right shape. These won't break.

So far, a couple of thousand more kms and all good.
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