2007 Ford Mondeo Mk4 2L Diesel, Turbo Removal

[@prototix9071]

No need to remove the drive shaft or the subframe for this job. I did this job a week ago and you need to remove the catalytic convertor holder and the 2 bolts in the middle of the exhaust so you can have more wiggle room when you remove the clamp from the exhaust side of the turbo. You can then remove the 3 bolts from the turbo bracket at the bottom and then unscrew the oil feed line from the bottom. After that you can remove the 2 bolts from the intake side of the turbo, and then unscrew the 3 nuts from shown at 2:13 with a long extension and a ratchet and a spanner. You can then remove the turbo with ease. 3-4,5 hour job max. 25Nm for the 3 nuts holding down the turbo at the exhaust manifold, same for the oil feed line too.

[@anthonykatgert7159]

what parts did you remove to gain full access to the catalytic convertor? Can you elaborate?

[@Mike-hv3de]

Just changed mine today on a Galaxy 2007, thank you for this comment it helped !

[@jaket9198]

Watching these vids made me realise I now never want to become a mechanic as a day job

[@gaborerdei7529]

2:14. It's easy to remove those 3 bolts. 2 bottoms nut, long 1/4 extenson bar and 11mm socket. Top nut with a normal 11mm spanner. Don't need to remove the exhaust manifold. I did it yesterday :)

[@thomasaddison6957]

Did you have to remove much to get to the nuts mate ?

[@gaborerdei7529]

@@thomasaddison6957 I have a 2008 Ford Galaxy. I've removed the driver side driveshaft, front subframe and the turbo pipe. Not too bad, but not an easy job. You need a 2 post lift for this job.

[@Mike-hv3de]

⁠@@gaborerdei7529 just changed mine today same car. Only had to remove the cat and it worked out just fine. Wasn’t a easy job tho and it took me all day 😂

[@boomshakalaka2275]

hi alan, i have managed to get that turbo off without getting the engine off the car, and without getting the manifold out as well, subframe off, driveshaft off, and 1st cat of as well very hard but doable

[@alan4x]

well done, that is a horrible job, i sure you will be glad when its done

[@boomshakalaka2275]

it was hard, but i had no way of getting the engine out as this was done in my drive, its bloody hard as the turdo sits right in the back of the engine and the engine is tilyed to the back making this hard to do engine in situ. btw i have just come across your channel this week and have watched most of your videos and find it great allan!

[@deankirk544]

Boom Shaka Laka how did you go about doing this without engine or subframe removed as I'm intreagued before I strip my Mrs car to bits to do it 🤔

[@stevenspiers5190]

Hi ALAN wondered if you could answer quick question my turbo has just gone bang ...and is the euro 4 140 turbo same as the 163 euro 5 turbo do they both fit ..what would recommend fitting a used one from ebay or get a new one .. car has a stage 1 map and is the QXBA 140 engine 2009 ...thanks for sharing this video very helpful

[@richh1452]

Alan is the Mondeo 2.2TDCi turbo removal pretty similar? I need to remove my turbo to send away for rebuild

[@eddydar]

Alan we want you on tv. Why cant tv producers get u a prime time slot. It would be more popular than top gear.

[@alan4x]

lol, cheers

[@sturlastensholttveten2135]

I just removed the turbo on the same car, same engine. Did not remove the subframe, nor the exhaust manifold, and "airbox". Took me one and a halv hour, without a lift. 😊

[@zernestro]

How did you manage to do that? I'd like to try :)

[@sturlastensholttveten2135]

@@zernestro I removed the axle on the right side, had too loosen the bolts for the control arm in order to swing it out of the way. Loosened the exhaust from the turbo, and the plastic air pipe going into the turbo. Removed the air pipe from the turbo to the intercooler, and the brackets holding the turbo and the driveshaft. Managed to get to the nuts holding the turbo to the manifold using a long 1/4" extension and a ratchet. A bit tight squeeze, but all in all an ok job. The worst part was to get the exhaust clamp on the turbo off. After a lot of swearing i ended up using a pry bar to pry it off.

[@marke293]

Evening Alan can you tell me if the latter MK5 engine is the same set up ? I ask because I have a 2015 HDI Peugeot engine that I need to remove the turbo from and I have looked up all my new gaskets and part I will require for reassembly and niticed the exhaust manifold gaskey only has 4 porh holes ? Thanks

[@SRSpoony]

so in short its a pain in the ass and a garage job not a simple home job.

[@aboynamedtom]

no i did it it took me a day to get out at a doddle rate

[@chrisfranklin723]

Hi Alan seen most of your videos really helpful. My question is does the turbo have a gasket where it bolts to the manifold. Ford say it's a flush fit with no gasket. thanks in advance.

[@marke293]

Hi there Alan thanks for sharing all these videos it is a great resorce for many DIY Guys like myself. Can you tell me what sensor that is on top of the waste gate accuator is Please. And I hope you have a great Christmas

[@alan4x]

hi, it is an electronic turbo wastegate actuator which will be computer controlled using elctronic solenoids and vacuum pipes, merry xmas

[@sdgelectronics]

Thanks for the video. Can you show a bit of detail on the oil feed pipe on the turbo and how it might be replaced in situ? It's a common place for oil leaks apparently.

[@alexanderlilljebjorn2157]

I'm wondering the same thing. But on the 2.2 litre engine. I can reach the lower banjo bolt, but the lower is far to crammed up there. Thanks!

[@yassine-wadlaw8606]

Buenas tardes, hay alguna manera de cambiar el colector de escape sin levantar todo el motor? Gracias

[@neanderthalbc]

hi alan i have a volvo v50 se lux 2007, but my turbo looks very similar to yours i have lost oil and blue smoke is coming from the exhaust and can hear a whooshing sound when revving the car.and can see a small amount of oil from the exhaust side.i have checked all pipes for holes slits etc but all fine.i have removed the turbo and intercooler.but hardly any oil was in the intercooler....the vanes on the turbo look fine.and only a small amount of movement in the fans.. could my seals have gone....if yes can i strip the turbo and replace whatever is needed. thanks alan your a star with your videos.

[@alan4x]

i would have the turbo rebuilt by a specialist but sounds like you do have a boost leak somewhere

[@neanderthalbc]

@@alan4x thank you some much alan for having the time to reply to my question...sending the turbo off today i will let you know how i get on kind regards

[@amana1480]

0:38 If I have black oily soot exactly where your fingers are, as well as on top of the intake pipe that goes under the egr valve, what does this mean? Where is it coming from? Thanks

[@robinj5]

Hi Alan, I love your channel. Have you experienced many oil leaks around the inlet side of the turbo on these engines? I have 2010 S-Max with this engine and it seems to be leaking oil around there and down on to the drive shaft bearing so I'm guessing it could be the turbo oil return hose. If so what is the easiest way to fix it?

[@Grooby84]

Hi have you found why is leaking there as mine dose that as well...

[@garyxperia7725]

Hi Allan, i have the engine malfunction light come on, on my mk4 mondeo 2L tdci i have hooked it upto a scan tool and its says P003a turbo charger boost control A - limit exceeded - no symptom - pending, could you point me in the right direction for curing this issue thanks for all the great content, Gary

[@stianskoglund1728]

I've got the same one mine. thought it might had anything to do with the EGR blanking maybe. But the oil was bad when I changed it so I suspect that the turbo is running when it should not and getting mighty hot at times...

[@miranalimirani6103]

*Hello dear Alan, I have a problem with my Ford Ford S-Max, which is when switching from slow speed to fast speed the car slows down and barely swallows the diesel! Is it a turbo failure or in the fuel system* ? good day

[@chrishill228]

Hi Alan you have some very useful videos! Can I ask, working in the same area, I need to replace my exhaust flexihose and Cat on my Mondeo Mk4 2.0 tdi 140 as the flex hose is blowing! Do you need to remove the sub frame or will it slide out. Looks like there might be enough space but not sure for definite! Thanks

[@alan4x]

no you don't need to remove the subframe...the clamp on the downpipes is a bit awkward though

[@aboynamedtom]

0:50 can anyone help, I did not find any washers on the oil feed pipe at the connection to the engine block, it seems the bolt is just screwed in!

[@hockingham7160]

Buddy your video was super helpful. I'm currently trying to figure out why I'm getting turbo whistle, I'm hoping it's a split pipe otherwise it looks like a big job to replace. Do you have any experience with turbo whistle on these engines?

[@WędkarzZPółnocy]

i have a whistle on my turbo and i did 20k km so far

[@WędkarzZPółnocy]

hello, in 2:26 you can see turbo covered with oil, i have same on my turbo, is this something to worry about?

[@mrSKphotography]

Alan, can you check the actuator arm and remove the actuator without removing the turbo?

[@alan4x]

yes you can check and remove the actuator without removing the turbo but if the actuator is not working there is more chance of the vacuum pipes and solenoids above the thermostat housing being at fault

[@mrSKphotography]

@@alan4x thanks. Ive changed the solenoids already as 1 was playing up and cant find any leaks. Still getting code P0031:17-6c which relates to the actuator. What do i need to remove to get to the actuator, egr and intake from the top? Need to test the arm movement to make sure there is no blockages before replacing the actuator. (Thanks to your other video) thanks for your help mate honestly! The forums aren't helping haha

[@alan4x]

@@mrSKphotography from underneath you can see the solenoid...if you watch the solenoid arm with someone else starting the engine..the arm should move in very quickly on startup...if it does not the next step is to disconnect the vacuum pipe from the actuator and see if there is a vacuum through the pipe with engine running

[@MyJarrus]

wow thats a lot easier than some other cars like vag group and vauxhall

[@erikgranerd5070]

Great video. Is it common for turbos to die on these engines? This is the 140 hp version. Here in Norway there is a lot of 115 hp versions. Do you know if this is the same engines? Or are they perhaps equipped with smaller turbos? Cheers

[@alan4x]

hi, i have found the turbos to be very reliable on the 115 and 140 hp engines as long as the cars get regular oil changes... as for our taxis.. the turbos last from new till well over 300k miles when they are sold off with no problems

[@erikgranerd5070]

alan howatt Thanks for the answer. Do you know what's the difference is on the 115 vs 140 hp version? Best regards

[@alan4x]

you won't see any physical difference...just the 140 is a bit more powerful

[@oluskloc]

Only difference is Engine software. You can easily remap your car by chip tuning up to 165-170 bhp safely and it will also lower the average fuel consumption about 0,5l/100km or more. I have my remaped 60,000km ago and running without issues, I already saved more on fuel than the remap cost. But go only to good recommended tuner to maitain car relability. In Poland it cost about 200-300 euro

[@danielkatona1866]

@@oluskloc actually it depends on what engine you have. If you have the 2 litre DW10C engine the software is already in the car's ECU. You only have to change from 140 map to 163. It's a 10 minute job.

[@jensrasmussen6814]

Peugeot engine?

[@mrblackygaming5056]

Need assistance with this badly, same turbo on mine but it won't come off.

[@lukascorej4489]

The air box do I need to remove the driveshaft out or just the supframe

[@aboynamedtom]

driveshaft needs to come out, subframe doesn't. I did it today. Lots of wiggling

[@DJThing1234]

Hey Alan. I got a oilmess around the turbo on the right side. Any known issues for where the leakage can occure?

[@robinj5]

Did you ever figure what it was? I have the same issue.

[@richardgunning4304]

Quick question alan, can the air intake pipe be removed out from the top once released from the turbo? I need to replace mine not sure if there's enough space to do it that way.

[@alan4x]

hi.. if you mean that huge air box down the back of the engine that connects onto the turbo then i would say no...i had to remove the subframe and remove it from the bottom

[@nemzrepairs]

@@alan4x it can come out if you remove the plastic intake on the top and the EGR valve engine mount on the right side and yes turbo can come out with out removing subframe and drive shaft on 2007 mondeo if your remove most of the top part

[@deaenburke3841]

Is it possible to do this with the engine being in the car any advice is greatly appreciated

[@alan4x]

if your car is around 2007 i sure the turbo bolts to the manifold with three nuts so you can remove the turbo and leave the manifold in place. it is difficult in the car as the air box at the rear of the engine needs to be removed and its a lot easier with the subframe off but can be done with the engine in

[@madfaz]

Love the videos mate, very informative and you come across as a top mechanic! For mondeos anyway haha. I have a 2014 mondeo 2.0 tdci and it's got a constant faint knocking noise at idle which sounds like a flywheel but does not go away when u dip the clutch? (and the clutch flywheel have just been replaced) any ideas?

[@alan4x]

that does not sound good.. i would have said flywheel straight away...cant really say without hearing it but might be worth getting it checked in case it is a big or little end bearing in the early stages

[@krisjones5125]

i had my turbo taken off my 58 2l diesel to clean which cured my car going into limp mode. but ever since if i put my foot down hard on the accelerator it surges. like kangarooing power on and off. any ideas what it could be? seen many people ask, but yet to see a definitive answer

[@iliescusilviu4196]

Hi there. Any update with your issue?

[@krisjones5125]

@@iliescusilviu4196 hi ileescu i found the surging power on and off was actually a loose air hose, that connected to the air filter box. it would work its way loose and allow to much air to be sucked in. so i would check that pipe first the jubilee clip is quite useless. i used some dish washing up liquid to lubricate it which made it easier to push further on. on a negative side the turbo clean only lasted about a year before it started sticking again and going into limp mode

[@motokierownik5091]

Alan, great movie as always. I'm writing here for the first time. I know that you are very good experienced on Mondeo MK5, 2015 year. Please help me with this case. I have a turbo leaking oil. Engine 2.0 TDCi 180PS, 200k miles mileage. Engine was serviced as in schedule. Could you give me an advice if this is a common failure of turbos on this mileage level or it can be a reason of other engine failure like for example engine breather, worn piston rings or something? Engine has still a lot of power and it's very flexible. Turbine is working quitely and smooth without any problems. I am not sure to replace this turbo. Do you met this problem on MK5 and what can be fault? If turbo I would like to replace for a brand new. The turbo is made by BorgWarner. Thanks in advance for any input. Kind regards from Poland.

[@alan4x]

what do you mean by a turbo leaking oil? there will be oil in the intake pipes and turbo....if your turbo is worn it may be noisy , leave a trail of blue smoke out the exhaust tailpipe or the engine will run on its own oil and rev out of control but i have had zero mk5 mondeo turbo issues as yet but i do get oil leaks from components near the turbo

[@motokierownik5091]

@@alan4xThank you for your reply. I saw only leak directly from turbo and the oil is visible on the rear side of the engine. I dont see any blue exhaust or other improper working. Thats why I am not sure to replace the turbo. Hovewer I am affraid of DPF condition if I leave this unrepaired.

[@motokierownik5091]

Alan, I have one more question. I am now at the service with my MK5. After close look on the engine they told me that my oil leak is not from turbo but from injection pump and vacuum pump however a part of turbo case is wet. I've checked by myself intake manifold and intercooler hoses and there is no oil at all. About injection pump and vacuum pump - have you met this problem in your Mondeos? Is this a common problem and is this heavy to fix? Thanks in advance for your reply.

[@alan4x]

@@motokierownik5091 hi, chances are your oil leak is from the unit that your high pressure pump bolts to....so you will have to remove the high pressure pump...there is a unit with a cog in it that then bolts to the cylinder head which connects to the camshaft...if you unbolt that unit and replace all gaskets associated with it you will cure the oil leak....they are very common leak

[@motokierownik5091]

@@alan4x Thank you Alan once again for your input and help. I will set my service for this. Kind regards and I'm waiting for next great videos from you :)

[@robertasviskupaitis9195]

do u have to take an entire engine for this job?

[@aboynamedtom]

no

[@przemysawstepien1129]

hello Doctor from Mondeo repairs. Do you know where the air-conditioning outflow in the mondeo mk5 is? Maybe on the example of mondeo mk4 with the engine removed you are able to locate it. Sorry for my English

[@dziekujeizapraszam7363]

do not be sorry for ur english!U R from POLAND!! U must be POLIS PROUD. POORLAND RULES

[@przemysawstepien1129]

Typowa cebula nie pomoże Nie zna się ale będzie obrażał

[@dziekujeizapraszam7363]

proud of u SON. Tea time

[@alan4x]

sorry i don't know what an air conditioning outflow is ?

[@tanglewood777]

is this engine in my volvo c30

[@dziekujeizapraszam7363]

Yo Alan my mate thank you very much for this vid. Keep it going with that mondeo mk4 07 2.0tdci content, very helpful shit my mate, but make this vid even longer like u know 10 min. Greetings from Poland love u. OOOOO BTW to much zoom i this vid still dont know wher that one bolt is

[@onsight2822]

Another brilliant video - can I ask a question? Have you any experience with mk4 rear bushes and or rear wheel bearing ? Don't suppose you can recommend any particular bearings 🤔 No worries if not keep up the exellent videos ( and comedy 😁 👍

[@alan4x]

hi, i would just use any bearing from a motor factors as a bearing/hub assembly from ford would be quite expensive. the rear bushes are here...kzbin.info/www/bejne/ZomvoqenhbmDotE

[@onsight2822]

@@alan4x Cheers for the reply Alan, top man 👍

[@4YouWHOyou]

I replaced that without taking off frame and exhaust manifold

[@thomasaddison6957]

How did you do it mate ?

[@4YouWHOyou]

@@thomasaddison6957 unscrew 3 bolts one is at the top and two on the bottom of exhaust manifold.

[@thomasaddison6957]

@@4YouWHOyou thankyou very much, did more need to be removed? A lot of people mention the drive shaft

[@4YouWHOyou]

@@thomasaddison6957 Honestly i dont remember but i dont think i touch drive shaft

[@Cupat1]

Weird why they never answer

[@danielkatona1866]

The turbo for my mk4 has an small oil filter, I do not know if all of them have this or not. Did you ever had to replace it, or had problems because of it ?

[@chrish3901]

is this the same for the mk1 Ford Kuga 134bhp

[@alan4x]

i think it is the same engine

[@dannybrown438]

Chrish did you change your kuga turbo? I'm about to change mine and wondering if I have to remove drive shaft and subframe etc

[@JayJayJaroo]

Hi Alan did you ever run any mondeos with the 1.8TDCI ?

[@alan4x]

yes we had many mondeos with the 1.8tdci engines

[@JayJayJaroo]

@@alan4x how do you rate them against the Peugeot engines

[@alan4x]

they are very good engines...bullet proof engines as long as it does not have a wet timing belt in the lower crankcase

[@JayJayJaroo]

@@alan4x i have an 11 plate in at the moment and the wet belt has broken converting it back to chain now

[@paulturner6498]

Is it a Mondeo or a Peugeot

[@ahti221]

Same engine

[@BOGDAN8270]

Спасибо за информацию топ 💯🔥🔥🔥🔥🔥🔥🔥🔥🔥🔥🔥 огонь

[@hoobsgroove]

got a problem I just sucked in a whole big cloth into the internet I put it there to stop mice getting in and I forgot it was there! but I've got the pipe disconnected to the valve body from the intercooler I'm surprised it sucked in the cloth! I think it must be on the inlet of the turbo late 2010 model. I can't remove the engine I haven't got enough tools I haven't even got a lift can I get the inlet manifold off? otherwise I have to scrap the car, I can't afford to take it anywhere that's 900£ down the drain anybody want it for parts?

[@mushtaqahmed5415]

Loosing power up hil feels sluggish .ok on flat Mondeo mak 4 2:0tcdi diesel over load

[@Luckypusher]

it is easy to do while engine is off from its location and out of the car,ain't it?!!!... :)