2004 Ford Mondeo ST TDCI

[tonycocacola]

Many thanks to HoTWire for creating somewhere for us to post.

This is my daily, I've had it about a year, and was supposed to be a rolling project.
On paper it seemed perfect, and ripe for some mods. Three owners, full history, some Ford and some not and 82k on the clock.
So far I've only managed to do one mod, fitting a boost gauge. Everything else has been fixing broken stuff.
So far what's been replaced...

Top pulley on the water pump side as it was bent.
Water pump
Power steering pump
These have been done again because the water pump failed after 6 months and took the power steering pump with it.
Both front wheel bearings.
A solid power steering pipe that had the cold air intake rubbing on it and had worn through.

Anyhoo, here's some pics







The brakes needed doing for MOT so I bought some grooved dimpled discs from MTec and some Mintex pads. They're quite good. I've just fitted a Pipercross panel filter to aid breathing.

As it is today it's going quite well. I'm currently saving up for some power increasing mods.
I'm looking at a hybrid turbo, huge Airtech intercooler and then a re-map.
Future plans include lows, wheel spacing and a change of rims. I also want to swap the seats over to Recaros.
All in due course though.
I'll post and update as funds allow.

😃

[astranaut]

Lovely, I have one of these I've done a fair amount to, but doesn't seem right putting an 07 plate up on here

[tonycocacola]

Feb 27, 2022 19:19:32 GMT astranaut said:

Lovely, I have one of these I've done a fair amount to, but doesn't seem right putting an 07 plate up on here

Thanks.
I really like yours, I've seen it in Chas's ST220 thread. Yours has the wheels and stance I'm going for. Looks pretty cool.

😃

[dandam]

Feb 27, 2022 19:19:32 GMT astranaut said:

Lovely, I have one of these I've done a fair amount to, but doesn't seem right putting an 07 plate up on here

Well a picture or two, and a spec sheet would be nice to see  

[tonycocacola]

Just clocked up 100k on my way to work.



😃

[astranaut]

Apr 5, 2022 13:48:39 GMT tonycocacola said:

Just clocked up 100k on my way to work.



😃

Mines just ticked over double that




Still gets similar mpg though, up to 60 on a good run. For all their faults they're great all round cars.

[tonycocacola]

Haha, nice one
My last one, a 56 plate estate was on 198k when I had to get rid of it.
That mpg reading is round the doors, school and work runs.
Mine too, gets 58-60 on a good motorway journey.

😃

[tonycocacola]

Just a quick update on what has, or more like what hasn't been done since my last post.
Nothing has been done as we've been away on holiday, so I've had to save for that.
We drove to Cornwall for a week. We took two cars, the ST and the wifes Grand Picasso 7 seater.
Driving at a steady 65-70 mph the Citroen averaged around 48 mpg with the roof box on.
And what did the ST average? Well, with 4 people and a full boot, it did this...



We didn't use it for driving about when we were there, we used the Citroen.

Since we've been back we've had a day out to Scarborough and a day at York, all 3 trips without any issues. Or so I thought.
This happened yesterday.



Hasn't sounded any louder as it's been snapping, and tbh, it's not any different with only half a system. Lmao.
Ordered the bits I need which will get done sometime next week.
Were going to the Euro Finals at the Pod next month, then I'll be able to start saving for some long awaited mods.

😃

[astranaut]

Keep an eye out for full second hand system, I got my 3' stainless turbo back for 100 on ebay, best thing I did to it apart from the annoying coo good to see its being used, mines alive again after changing the fuel filter 🙄 which I'm glad about.

[tonycocacola]

Heard a 'boing' type metal sound. Thought it was the spring.
Got under, not the spring.





🙁

[thebaron]

Now that is a spectacular failure. Are they hard mounted or just a bolt out and bolt in fix?

[tonycocacola]

I'm not sure, and I'm not in a position to find out myself, so I'll have to wait to see what the garage I go to have to say.

🙄

[ChasR]

Wow, that is nasty!

Rusy subframes aren't uncommon, but you can get new ones fairly simply.

[welshpug]

Are these euro 4 pre dpf?

Wondering whats the easiest way to get more out of my 2007 peugeot boxer puma 120, they only map to 140 where the euro5 maps to 190...

Fixed geometry wastegate turbo vs vnt I believe!

[tonycocacola]

Nov 15, 2022 16:10:29 GMT welshpug said:

Are these euro 4 pre dpf?

Wondering whats the easiest way to get more out of my 2007 peugeot boxer puma 120, they only map to 140 where the euro5 maps to 190...

Fixed geometry wastegate turbo vs vnt I believe!

These ST's are a 2.2 with 153 bhp (155 ps), and are a Euro 4. This one is standard power. The last one I had was mapped to 196.
I don't know the cross over year but early ones have a vacuum actuated turbo, whereas later cars have an electronically operated unit. This 54 is vacuum, and my old 56 was electric.
Lots of stuff has broken on this one eating into into my modifying funds.
But what's planned is...
Bigger intercooler
Hybrid turbo
De cat
Egr blank
Silicon hoses
And a remap to suit.
Going off what I've read online the above mods should put it in the region of 220 to 240 bhp with around 440 lb/ ft of torque.

😁

[welshpug]

Awesome bit of information thanks!!

Seems the euro4 sevel vans have a vac actuated wastegate and a pretty small turbo, euro5 is full electric variable geometry, different exhaust manifold and egr, supposedly a detuned 155 bhp engine

[astranaut]

220 will be about right, anything after that you're into uprated injectors etc, but they're such a fragile engine they really don't take much power anyway, new problem on mine lately is just randomly losing all boost, no warning lights, switch off and on again it comes back. I won't be retesting mine when it runs out, literally lost all patience with it now.

[tonycocacola]

Noooooo, fix it, fix it, fix it.

😃

[SilverMachine]

my old 2.0 tdci did like its remap and 2.2 transit injectors... sounds like astranut needs a wastegate actuator or injector they don't always put a light on dash and will loose boost temporarily. miss my old mondog. wrote off by a numpty texting and not paying attention.