2007 Ford Mondeo Mk4 2l Diesel Odd Camshaft Fault

2007 Ford Mondeo Mk4 2l Diesel Odd Camshaft Fault.
The exhaust camshaft high pressure fuel pump drive came loose causing the pump to spin slowly, thus loosing fuel pressure and the engine cutting out. The exact same engine shown in this video can be found in a 2005 Volvo S40 2.0d. Volvo calls it the D4204T, and used it in the 2.0D C30/S40/V50 range from 2004 to 2012 with only a few minor differences .. The same engine is in the Peugeot 407 2.0HDi and the Ford Focus/C-max 2.0tdci

[@richardtyrrell3126]

You wonderful man, Alan! My 2007 mondeo estate had an odd fuel problem 3 years ago: parked it at an airport overnight, when I got back, it started fine, but died after a couple of minutes (luckily, I was still in car park, setting up sat nav to get home). Rescue on insurance to garage back home, much puzzlement, in the end bled it all and away it went, but no understanding of why it stopped - 'was definitely fuel. Move on 3 years and 25,000 miles with no trouble at all to last week - total mileage now 195,000. Started up fine, drove maybe 1/2 mile, and it stopped: clearly fuel starvation. Got it back to garage (friends, just up the road), and again no idea what was wrong after they spent Friday afternon scracting heads and checking this and that. Then I found your (this) video over weekend. Today I asked the (very sceptical) garage to look at the exhaust cam drive - and YES! - exactly the fault you describe. So here's another very grateful mondeo driver (mine's grey as well .. is that a coincidence or clue?) ... who is still puzzled how come it decided 3 years ago to "catch" again and work fine for another 25,000 miles. Thank you!

[@alan4x]

lol, thanks for that, I'm not the only one....when i repaired the car i was working on i fitted an aftermarket camshaft as it was a lot cheaper than ford prices but the drive on the cheap camshaft was all part of the cam and not a piece pressed onto the end, glad you found the problem, unfortunately its a days work to replace the cam but good luck

[@petermastenbroek5264]

Excellent video and info (as usual), this shows again that you shouldn't immediatly trust what a garage is telling you, as you could end up with a pretty huge an unnneccesary high bill for stuff they did without any need for it. I really do like your humorous way of telling and explaining of how you came to your conclusions, and straight forward repair. Atb, Peter.

[@Badgertronix]

Weird problem. Trying to think of a scenario where that could happen but I'm stumped. Thanks for sharing

[@manuelsousa254]

Thank you Alan, i suffer same problem with my v50 2.0 d. Same thing as happen, unfortunately i only realize the problem when she broke the piece that holds the camshaft (springing oil under the admission manifold). She work fine even like that. Then i have to swap the engine because they don´t sell that part separately and then the problems never cease. Low fuel pressure even after change the fuel pump and the injectors.

[@diptgill4160]

Very helpful and clear video, I just experienced the same problem. Keep up the great work

[@smploaded]

Jee wee, I've just removed my high pressure pump and voilà, my camshaft is broken too and the pump is working :) Now back to the show

[@keithk5256]

Just found the same fault on my 2008 mondeo, thanks for the helpful video

[@Fifthgear08]

Your videos are the best please keep it up 👍👍👍

[@kramsniggah4333]

Always informative, always funny!

[@morphx86]

Greetings! Awesome video! Helped me a lot. I had a same story like yours and this video helped me to say bye to the car. Cheers and thanks a lot for sharing!

[@berkman7040]

Teşekkürler Usta

[@Hillfortgaragecustoms]

Spot on, I've just found this exact same fault! 👌

[@fletch3576]

Great video Guess why I'm here 😅😅 So after working on an 07 smax I came across this same fault...end of the camshaft broken in half The adapter block was battered.. the weird thing was that it couldn't create enough pressure to start but start on brake clean and run very rough and fuel pressure pegged at max...little bit of head scratching went on today 😅😅

[@gt1749v]

Iv had this on a citroen dispatch rkr engine. Same engine.

[@Xenonsport]

Excellent, what kind of job is cam replacement?

[@TheDaf95xf]

Good thanks one Allen 👍🏻

[@eddydar]

Alan you little beauty. Keep em coming. I can see u getting an Oscar Yee haa

[@alan4x]

lol

[@lurchy666]

My mate had it on his 2ltr dw10 peugeot expert, broke down i towed him home put lexia on it and was low fuel pressure so replaced the pump with a spare he had and exactly the same when we shone a torch in the end of the cam was snapped..... Chucked a new cam in it and away it went......

[@juliak1628]

Hello guys, I have a question - where this broken camshaft peace can go? Can it get to the engine? Has anyone ever looked for this particle or just replacement of camshaft and fuel pomp will do the trick without looking for this missing particle of broken camshaft? Thanks in advance for anyones answer :)

[@superseven220]

Hi Alan, out of interest why didn't you include psi as a measure of pressure? 1 bar= 14.7psi, not trying to pick you up on anything just curious, great videos by the way

[@alan4x]

Peter Gillam Hi... that is a good question. I compared the fuel pressure on the 2007 Mondeo in this video to a 2014 2 litre diesel mondeo. Using live data on the snap on ultra scan tool one of the mondeos was being measured in kpa and the other in bar.... that's why I talked about bar and kpa. Psi was not used on the scan tool to measure fuel pressure so I did not mention it lol

[@superseven220]

@@alan4x no problem Alan, thanks for clarifying

[@nicam49]

Love it!!

[@sailboatskipper]

i know i'm replying a bit too late for this vid but...... i've just come across a mk4 mondeo exhaust camshaft with the first lobe on number 1 cylinder knocked around 180 degrees to the other lobe and no bent valves and the engine was still running, albeit a bit lumpy.the follower had jumped off the valve and jammed underneath. now thats a problem you don't see everyday. I suppose if the fuel pump drive can spin then the actual cam lobes can too.

[@alan4x]

lol, that's an odd one, as i have found these engines do not bend valves and at the worst they will break just the rockers

[@bormisha]

Yeah, repairing is relatively easy. What is hard is to correctly diagnose the problem!

[@Timberjagi]

i have the exact same issue ;) only with a S-max ;)

[@alan4x]

obviously a bad camshaft design

[@Timberjagi]

@@alan4x that is for sure, now waiting on the new camshaft and lets hope the problem will not come back anymore. is it common for these engines to leak oil via the turbopiping? and thank you very much for your video's!

[@alan4x]

@@Timberjagi yes you will get oil in the turbo hoses, the connections need to be tight as the pressure in the hoses will force oil out of any joints

[@skypixxaviergregory2835]

Hey mate, My MK4 mondeo randomly stopped on the highway a few days ago and won't start. It threw an engine malfunction warning at me and turned off. No codes came up on the OB2 sensor. I'm really stumped. Cambelt is fine, battery is fine??

[@danieltrowbridge3721]

Thanks for the vid, we got a S-max in yesterday with low fuel pressure and we have the same story here, including the missing bit off the camshaft drive. I'm guessing this breaks first and then the collar looses it's friction.

[@alan4x]

i would also replace the high pressure pump..i reckon the pump locked to break the camshaft drive and loosen the end

[@juliak1628]

Hello, we have the same exact problem in our Form Mondeo MK4 2007, it is on repare right now :) And I have a tricky question to all how may know - where this broked particle of camshaft may go? Can it get to the engine somehow? Do we have to look for it in the system? or just replace the camshaft and the pomp and it be good to go? Thanks in advance for anyones answer :)

[@danieltrowbridge3721]

@@juliak1628 mine was just below the camshaft but I can't see it getting into the sump, it'll be in the head somewhere. Maybe near an oil drain

[@melissamills2464]

Hi there just wondering if you could help we got a ford mondeo mk4 2.2 diesel starts up fine and drives completely fine for 15 mins the goes in to idle mode but no light on dashboard then if switch car if and on then it goes back to normal for 15 mins again thank you

[@toyotoe3732]

Thank you for video. Does the Mk4 have a fuel pump in the fuel tank pumping diesel upto the high pressure fuel pump?

[@alan4x]

toyo toe Hi..... none of the mk4 diesels have an in tank fuel pump. The mk5 does

[@sulze1]

Why does the piece of the camshaft break off? This is the second time I've had this problem with the same car. What can I do that it doesn't happen again?

[@ViralBiz510]

For me, IT s the third time. So please give us an explanation. (high pressure fuel pump? )

[@robeaton2191]

Grerat video, i have a problem with this same engine in a 2009 Mondeo, it would cut out randomly and if left would restart after 15-30 mins, after a week or two it cut out completely and wont restart. This happened just after an overtake manouver and the revs were leveling out. It now refuses to start and i have faults P0087/P0088/P0089 all relating to fuel system. I have replaced the fuel filter as a first port of call and it didnt look great, reprimed the system but still no go. Looking at live data i have a healthy cranking speed avergaing 250 rpm but the fuel pressure is reading way too low at roughly 30-50kpa. When the vehicle was recovered he tried some easy start but would have non of it. Belt has only done 3000 miles fitted by ford, still tensioned and turning. Please help me im going bald trying to get to the bottom of this. Thankyou

[@alan4x]

hi, if you have low fuel pressure, the first thing is your filter...you done that..second..carry out an injector leak off test to see if one or more injectors are sending way too much fuel back to the tank so the pump cannot maintain fuel pressure...3..now you are probably looking at your high pressure fuel pump...i would remove the pump and try turning the drive on the end of the camshaft with a lever to see if its turning on the camshaft like the one in my video..maybe also have your cam belt timing checked at the same time as well..you never know...if all is good then i would replace the high pressure fuel pump...usually when these pumps fail they put metal specs into the fuel system..if you tip the fuel out of the pump into a clean container and there are metal specs then you would need to clean or replace your entire fuel system as the metal will block your injector nozzles..hope thats not the case, anyway hope this helps

[@robeaton2191]

@@alan4x Hi Alan, thanks for the response. I will address this items next. Is it worth checking/changing the fuel pressure sensor in the rail and the fuel volume valve on the pump? Many thanks

[@BELALI]

Hello ... I want to ask a question if possible: What is the symptoms of a crack or hole in the air tube between the filter and the turbo? Precisely at the entrance of the turbo ... I say between the filter and the turbo and not between turbo and engine ... Thanks pls

[@alan4x]

i would say you would hear the turbo sucking air

[@BELALI]

surely yes, but how about the engine and fuel consumption ...etc

[@BELALI]

thank's ... 👍🏻

[@makonm]

hi alan. is the camshaft end rotation normal or is it a fault?

[@alan4x]

the end of the camshaft should not turn at all as the slot drives your high pressure fuel pump

[@simonedwards3571]

Hi Alan working on a s max same engine no start low fuel pressure code removed high pressure pump cam ok but when I turn the pump it feels like there’s no resistance is this not normal

[@len1.977]

I have the same problem, could You solve it?

[@simonedwards3571]

High pressure pump fixed it and starter motor

[@bavi-auto-solutions]

Mate same situation it's cut off and stopped middle of the drive and wouldn't start but after resetting the battery it starts and drives normal but 70% of the time it won't start again unless you reset the battery. 63k miles 2017 ford galaxy 2L diesel. Code stored: p0014-85 camshaft position timing over advanced on bank 1

[@alan4x]

i would start at checking the timing belt

[@bavi-auto-solutions]

@@alan4x belt is good not slipped still on the original markings. Changed the ocv solenoid, Cam sensor, oil and filter. But still the same. P0014 and p0340 do you think bad voltage from the alternater? Because every time it doesn't start it throws p340 camshaft position sensor circuit no signal?

[@michaelrauschmayer178]

Hi Alan, a little bit off topic, but I need to find aditional jacking points underneath the front and also underneath the back of my mk4 Mondeo to place the car on jack stands... Could you give me advice? Subframe? Rear axis? thank you!

[@alan4x]

hi at the back of the front wheels under the car is a chassis member which is pretty strong you can jack on then put stands on the outer sill where the arrows are. at the rear just jack on the sill and put the stand on the sill next to the jack... the sills are strong

[@Fliosch18]

Hello My name is cosmin and i am a big fan of yours But i contacted you beecause I have a odd problem with my car And i changed 3 mechanics but nobody knows what is wrong with it

[@JayJayJaroo]

Something i have seen only once before on a late model 407

[@eddydar]

JayJayJaroo yep u will do same engine.

[@JayJayJaroo]

E Dar yes i know 👍

[@Fliosch18]

How can I contact you

[@Squirt200]

Ive had a DW do this exact same thing but broke on both machined edges, it would run but rattle its brains out!

[@bensnare1181]

Hello was wondering if I could get some.advice from you I have a mk4 2.2 diesel Mondeo and I have a metal knocking sound coming from the rear end when I hit bumps/pot holes I just had the rear trailing arm.bushes done thinking this could be the problem but not solved it it's a recent development was wondering if you have encountered this with you working on so many thanks

[@alan4x]

hi, more than likely it will be your rear anti roll bar drop link ball joints worn out...very common...i would check them first..they can be quite noisey

[@bensnare1181]

alan howatt thank you

[@radekrogo]

In your's opppinion what was the reason ?

[@eddydar]

radekrogo talk to any decent engine rebuilding outfit. Reclaimed metals and cutting of production costs. Maximising profits does that make any sense?

[@christophersimmonds3989]

I had this same problemon my galaxy 2.0 tdci snapped piece was in sump

[@t147han]

You normaly show the repair.Was this a big job.

[@alan4x]

to change the camshaft is quite a lengthy job...this one is very similar........kzbin.info/www/bejne/m6i5YZxvgtaAmJo

[@interceptor-ss8kb]

What sort of mileage was this old 57 plate on?

[@alan4x]

the jonah is on 212k miles lol...looking for a good home

[@barryporteous4904]

Kilopastels - LOL

[@68gulfstream]

Maybe kilo pasTIES ? ...not sure, but I'm from Cornwall ...