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Originally Posted by Rohan24 My friend is suffering from this unusual engine related issue with his Endy 2.2. He has had 2 breakdowns in a matter of months and dealer is now blaming it on his usage..
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My All new Endeavour just 2 days after delivery suffered a breakdown at 11pm on a highway which left me and 2 of my cousins stranded on a state highway which was fortunately only 4km away from home. Later when we repeatedly tried starting the vehicle we could reach home steadily at 20km/hr but the vehicle had severe vibrations at idle and wouldn't accelerate leaving heavy black smoke. This was due to the intercooler and ford fixed it under warranty. |
Boy! I hope the best would come out of this for your friend. But allow me add a few tips based on the info you shared.
The 1st issue above, with black smoke, I am not convinced it has anything to do with intercooler. Black smoke is a sign of incomplete combustion. It can happen due to excessive fuel injection, a blocked air filter, turbo not spooling enough etc. Basically anything that significantly alters the air to fuel ratio. So much so that there is not enough combustion and the partially burned fuel exits as black smoke. If intercooler fails, by this I mean fails to cool the incoming air, then the engine will derate noticeably with probably 'some' smoke. But should not emit the kind of smoke in the video. Excessive fueling typically happens with worn out injectors (heavy usage over years).
Can you get the exact work done on the engine the first time. I guess there is more to it than "intercooler". The dealer must have shared the work details with Ford for sure. You need to dig that up. What did dealer share with Ford as the problem, root cause and repair. What parts were replaced etc. Put it here on this forum and we can help diagnose our share.
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Then 4months passed and here comes in the 2nd surprise. I suddenly experience abnormal fan noise from the engine and this is accompanied with loss of power. This happens 3-4 times in an hour. I have given the vehicle at the dealership and they try to blame me that I've used adultered diesel which is the cause for this issue. I always make sure to tank up in the city before going for any long drive to avoid filling in rural areas where there is a possibility of fuel adulteration and that is what I did even this time before going for a roadtrip from Theni to Munnar to Coimbatore. I did a tank full at a Reliance bunk at Theni and then filled at a HP bunk at Coimbatore. Both of which are well reputed bunks and I've been filling from these 2 bunks regularly that there are no chances of fuel adulteration.
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Typical adulterated diesel fuel, found in some of the pumps, will not cause this kind of black smoke, unless diesel and petrol are mixed, which I doubt but not improbable. Diesel is much more robust than petrol in coping with adulteration. Diesel ECU will simple shift the injection timing and quantity to accommodate for the changed burn rate characteristics for the adulterated fuel.
In this 2nd issue, what I suspect happening is that the radiator fan is failing and hence the coolant temperature is going up. To bring down the coolant temperature, the ECU is derating the engine, which you experience as loss of power. This issue is aggravated by the summer temperatures. Once the coolant temperature is below a threshold value, ECU gives back the required power. This repeats.
But why is the fan failing now. It is separate from engine and should be run by an electric motor. As you said there is abnormal fan noise, can you check and see if the cowl is touching the fan. Be careful, make sure the engine is fully shutdown and cool. This time I suggest you get an OBD tool diagnostics data as well, from the dealer. Preferably with a different dealer.
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I feel this 2nd issue might be related to the first, and the 1st was caused due to negligence by the dealer during PDI. It could be that they don't want to own up and report to Ford and are trying to fleece the customer. Being barely months old, Ford should definitely honour warranty in this case.
I look forward to hearing your thoughts on this.
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Yes there is a possibility the 2 issues are related. May be some sensor or some dealer goof up. You, as a customer, should exercise your right to know the full details of the problem and the repair work done. Ford, from my experience is way better than some of their dealers make them out to be. Write to Ford.
Also ask your friend to PM me. I am willing to share some knowledge.