Faulty Common Rail High Pressure Fuel Pump mk5 ford mondeo

[@OverBoostMPH79982]

You're a legend Alan!! Been trying for weeks finding out why my injectors weren't getting any fuel and it was the spring. I have the 2005 MK2 2.0L TDCI 150bhp and this fixed it. Thank you!!

[@roystonhutton486]

Nice one, I like not only the content but the way you explain it, No bullshit and straight to the point.

[@mariuskub]

Well done Alan, you are very good mechanic fuel pump always give as headache

[@keithmatthews9043]

Again Alan great video and free knowledge well appreciated 👍

[@kisdobos]

Nagyon köszönöm a segítséget!

[@alan4x]

your welcome

[@TK42138]

Looking at that HP pump spring and it reminded me of the broken cylinder head valve spring that featured in one of your other videos. Be interesting to compare spring sizes. 🤔

[@TheDaf95xf]

Great video Alan 👍🏻 Typical car manufacturers only selling the whole pump instead of the spring 🙈 They must know it’s a week part of the too ☹️ Anyway good watching you fix the mondingos lol 😆 Nice one Stevie 😎🇬🇧

[@borianm]

It is actually B**ch making car manufacturers unable to sell any parts to customers.

[@alan4x]

cheers

[@kadiriosmam]

Thank you a million times for the info

[@spg243]

Nice work alen and good videos with monika, psa have a bulletin to replace the internal gears to stop the pump wearing, had many faults myself with this unit

[@alan4x]

thanks, thats interesting, just replaced one of these pumps for putting metal fillings into the fuel system

[@spg243]

@@alan4x it was noise and vibration the gears chatter then soon after fail

[@prawny12009]

Fuel pump is geared 4-1 With the pump timed correctly the pump will reach maximum pressure in time with the injector pulses (kind of like a rotary pump) If the pump is out of timing you could (if the fuel pressure regulator fails) in theory be reaching higher than expected pressure in between injector pulses loading the timing belt.

[@miladinseratlic5984]

I hope u'll see this question... Any idea pls... 1.6tdci/66kw focus 2009. Engine starts easy but it lost si much power and horrible acceration that it's not safe to drive... Not a single error code. Simply for example in 2nd gear when trying to accerate 2500, 3000 rpm car is moving like a dead horse, switching to 3rd gear i goes up to 70km/h. Earlier it was like a rocket. Turbo solenoid was stucked and turbo was working in oberboost probably for 1.5-2months but that was 2yrs ago, since then car started loosing power until this day when its hard to drive it. Still, no error codes. Egr was blanked, ecu remaped but old SW was loaded back when trying to figure out what's wrong. Turbo wastgate is moving when engine starts end goes back when engine off. In this 2yr period car "fixed" it self for 3 times but only for few days flying like a rocket but again it lose power. Clutch is new btw. Turbo whistle pressent and weird whoosh from moment when I turn key to engine off, like some old vacuum cleaner

[@paulpreston11]

Hi alan wish the mechanic had watched your video instead of 4 trips back and forth over a month to get this sorted if they had found this from the start would not have cost them 8 new injectors(replaced twice), rail,the hp pump, cleaning of fuel lines and tank , oh well least wont have to worry about this failing to soon now

[@richiec9077]

If they replaced the pump they'd have surely fitted a new pump with a new spring?

[@davidsidney2252]

Alan, great video and has given me huge hope that my M50d doesnt have a failed pump. My question for you is, my fuel rail pressure goes to 33 bar when trying to start, would this be more the sensor at fault or could the pump still be knackered?

[@alan4x]

that's very low fuel pressure, i would first read any fault codes in the engine ecu..check your fuel filter is not blocked then carry out a fuel injector leak off test before condemning the high pressure pump

[@Shananigins09]

I have found you video more useful than anything or anyone. I have Program software tells me codes and programming the engine. I have been dealing with a Fuel issue similar but completely different vehicle, to be specific a Maxxforce 13, has a similar injection head on the high pressure pump. Same symptoms, however it is leaking near the base of the injection head on the pump. The injectors themselves are running well within specs and no issues. I was thinking pressure relief valve, which I will change but will take those off as well and inspect them. The unit itself they want a ridiculous amount close to 3,000 for just the part. Anyways thanks again! If you could recommend anything else let me know. Codes= *fuel pressures rail exceeds maximum *fuel pressure below minimum with maximum command .

[@mohammedsajjad5943]

Did the check "engine light" show up?

[@marenghi123]

What happens when the retainer cap breaks that the spring sits on would that make the car cut out ?

[@Antsummerfield83]

Hi, I have a 308 1.5 bluehdi, I have a pump similar to this and if I tap the accelerator I get a buzzing noise like a electrical noise from the top I think it’s that top bit it has a electric connector going to it and also can remove like yours with 4 bolts. I am trying to find a problem as I keep having a rough idle when cold slightly erratic idle, fine when warm.

[@zoidberg444]

I wonder if a good hydraulics supply place might be able to locate a suitable spring for these pumps.

[@Antsummerfield83]

It's that the fuel regulator that's bolted to the pump?

[@initialb5009]

I heard of the driving shaft, run by the camshaft, just snapping inside the pump. Keep an eye out for that one

[@m998hmmwv7]

Would you still get smoke out of the exhaust?

[@outdoorsguy1535]

these videos interesting to watch. Keep it up :) Ford mondeo 2.0 tdci mk4 Fault code P1169 Going above 50mph power reduces. It doesn't cut the engine, i sense it is forcing to drive slow aka limp mode, i assume this is to protect the engine etc! The traction control light comes, makes sense as that automatically puts your hazard lights on alerting other drivers. I wouldn't necessarily link it to the car thinking there is a traction issue! When i pushed the car again the above happen, plus oil light briefly came on and then off. In the lead up to this, I noticed the fuel gage was misreading when filling car full! Approx 110k, new clutch, timing belt, water pump. Fully serviced 5 months ago. Car booked in, 2 weeks wait. I hope it's a sensor and not ecu or high pressure fuel pump (mentioned in another video) yikes! I inherited the car from my late father, so trying to keep it on the road as long as possible for sentiment reasons as well as been a good drive! Any ideas what it could be? Thanks.

[@williamgreaves1770]

Has the mk 4 mondeo high pressure pump got the same (spring) on the pump

[@SimomJames]

Hi Alan, we have a 69 plate ford Smax which is a 2.0l diesel. It broke down 7 weeks ago. The car only has 40k miles. They are saying the fuel was contaminated and need to replace the whole fuel system at a cost of 5k plus. Would a fault high pressure pump cause this sort of damage? Thanks Simon

[@rebeccarbk8131]

Have you experienced diesel leaking from high pressure fuel pump? Diesel ending up under air filter box / on gearbox. ??

[@davidrichardson8934]

Can u swap spring of another pump as long as spring is complete is the pump and this spring (matched) or can the spring be universal fit?? Sorry 4 lack technical terms hope u understand Great videos learnt a lot

[@alan4x]

hi yes you can fit another spring no problem . i just purchassed 10 springs off ebay for when the taxis break down

[@davidrichardson8934]

@@alan4x brilliant thanks 4 the reply cheers

[@alanreeder9459]

@@alan4x hi alan have you a link for the replacement springs on Ebay, keep up the brilliant vlogs btw

[@JP-lz4fp]

@@alan4x Alan we really need a link for this please mate...

[@danielobrien7281]

Hi mate is it the same on a mk3 tdci mondeo I'm having exactly the same problem. Car runs perfect until your going uphill and put your foot down. Iv cleaned injectors and changed fpr

[@alan4x]

yes its the same principle although different engine

[@Стелла-п5л]

Hi/ Whot pressure must be input to the pump Bosch CP1 from pump in fuel tank

[@zzhughesd]

Alan - P0091 nd P0092 together, Fuel Pressure Regulator Circuit 'Low' for 91 and High for 92. Reckon this is pump or the regulator??? It's on a 1.6 MUltijet Diesel Punto. thanks

[@erikgranerd5070]

Is this a commen fault on Mondeo mk4 2 lit. diesel?

[@alan4x]

no, the mk4 2litre diesel has an entirely different fuel pump

[@kevinrobertfrasier1309]

Brilliant Vids buddy. Suggestion! Would it not be a good idea to remove that pump spring body assembly from a naffed pump that has an intact spring and re-use that unit on a pump that has a broken spring instead of puchasing pumps when that spring failed?

[@alan4x]

at the time of this video used pumps were hard to find, springs were nowhere but now we have a good supply of springs, thanks

[@13rz31]

@@alan4x can you share some more info on that, please? Are springs from ebay? Part name/number? Link? Thank you for all your videos! 👍👍👍

[@13rz31]

@@alan4x Hi Alan. Can you please share some more info about part number for repair kit, for HP fuel pump spring? Thanx!

[@brandonjcollins1062]

Hey bud, thanks very much for the information. I have a Nissan Pathfinder that’s having the same problem and believe it may be the high pressure pump. Not sure if I can check the spring but will have a look.

[@mondodaftasabrush]

I assume you changed the complete unit due to potential fragments of metal within the pump / fuel from the broken spring ? Last time I changed my fuel filter I found fragments of chrome / metal and researched to find fuel pump u/s but due to high cost and bangernomics I have just ran it for 5 years even though I bought a second hand engine complete (1.4HDI) 80K for 70 quid and saw it running in car before it was removed still sat there till it goes bang still awaiting 35K on ???

[@alan4x]

yes, second hand pump lol

[@mondodaftasabrush]

@@alan4x But if you only changed the broken part or if available to replace just a spring Still risk of fragments of steel within the fuel ?

[@mib2john]

hello Sir! my car is 2012 ford mondeo tdci 2.0 Recently it occasionally have faulty codes follow : P1168:86-26, P0201: 13-26,P1168-p, U0401:68-0A. I had changed injectors,but no get better. what's the problem with my car?And how to fix it?

[@nebunilabz]

Hello, Alan, i have a question for you, i scanned my Ford Mondeo Mk5 2.0 tdci and i found with red Fuel Injection Timing 203.555 degress. The car starts but si very noisy. Can u help me pls? Thanks a lot

[@Tomyp89]

Dfp6 same style pump is in VAG TDI engines 1.4 up to the lower power 2.0 like p/n 04B 130 755F . I do belive that the springs are avalible seperatley.

[@Richard-ps7ht]

Where can you buy the springs?

[@chrisbell-pctechnician3784]

Just had to replace my high pressure pump. Genuine Ford pump was £495 plus VAT and £180 surcharge until old pump returned.

[@Pargie96]

Any chance of a video removing fuel pump? Or links where to find out how?

[@MinecraftChester]

Yes please

[@MrDiegulec]

Hi Alan. Thanks for all your videos about Mk5, they are very very helpful because this car is quite new, and it is difficult to have reliable information like you provide! I have a question for you and maybe you can advise something. Recently I started to have an error P228C on which there is almost no information, but it looks for me very similar like on your other video with error P0251. Fuel pressure drop (as I test it on scanner pressure dropped very fast to 0 and cars stopped, after clearing codes all is ok) but only when I want to accelerate from ~90-120km/h on 5th gear (pedal to the floor, load is almost 100%). I did leak of test on injectors. After 4min I got results 1-35ml, 2-90ml, 3-50ml, 4-83ml. So, 2 and 4 need to be replaced, you think I should also replace 3th and maybe 1st to have all new? Second question is that I want to check also fuel regulator (spring on it) on high pressure pump. I can just unscrew 3 screws like on movie and after I just put it into its hole and do not need to timed up something? You know what kind of fuel pressure I should have on idle and accelerating (as I accelerate, I got maximum about 1600-1700 bar)?

[@alan4x]

i would change injectors 2 and 4...... unless you want to splash out on a set but they are not cheap. yes you can unbolt the spring unit from the pump and just refit it with no adjustments needed

[@ukwithusy]

Hi Alan your channel is great , can we buy second hand pump and just replace spring without removing pump ? Will it work

[@markmorris6002]

Did anyone try that?

[@patrykszenfeld2655]

@@markmorris6002 yeah he did it in one of his videos

[@eoghanhennessy443]

Thank you for making this video

[@alan4x]

My pleasure😊

[@eoghanhennessy443]

Have u ever seen a 2015 1.6 tdci breaking a spring​@@alan4x

[@eoghanhennessy443]

Have one in the garage we have replaced everything but the pump its self . We have little to no fuel pressure. No electric pump in tank . Replaced rail sensor . Injectors are good . And solenoid on pump all so is there anything that might stop fuel pressure

[@eoghanhennessy443]

P2291 is fault no rail pressure

[@alan4x]

@@eoghanhennessy443sounds like the pump to me. Probably worth taking it off and having it checked

[@seydoubaba3313]

Thank you. You are the best

[@voydnaught1397]

Legend! Content excellent as usual.

[@crazyflod]

I’ve got the opposite High pressure in common rail Diesel MG ZT 2.0 CDTI Any suggestions?

[@markn6246]

My 2007 2.0tdci ford smax is having same issue, don't suppose you know if same thing happens to them aswell? Cheers 👍

[@KKTR3]

For 2 days before mine broke When you turn it off it kept trying to start a few times On the last day it started to do it on stop start then it gave up totally

[@MrSeagoon2]

Hi Alan I have an vauxhall astra with what i thinjk maybe the same problem, Ive changed the injectors, changed the pressure control valve and the rail pressure sensor but when I switch on the ign the intank pump runs for 25 sec and then the engine battles to start, my opcom reader shows when I switch off the pressure in the rail goes to zero, could this be the high pressure pump which is a 0445010157 Regards Dave

[@alanreeder9459]

Hi alan ,when the spring goes on the pump would it put metal particals in the fuel filter ?

[@alan4x]

i have replaced many springs in these pumps and never had particals in the fuel system

[@alanreeder9459]

@@alan4x cheers alan my mk5 mondeo drives fine until i put it under load in top gear the goes into limp mode ,changed the fuel filter and there was a few metal particles in it

[@stephenbarnes5341]

Hi Alan do you know if the 2008 Focus 1.6 tdci has the same spring in its fuel pump? Would it leave small deposits in the fuel tank also, cheers.

[@stephenbarnes5341]

Only reason i ask is have a car with same symptoms although the turbo had blown as well. so far i have done the following and nothing seems to get the car started. After doing the turbo injector seals and oil lines the car started and ran for 20 minutes but lacked power then started getting diesel knock so re-seated the injectors with new seals again. We had it towed to the place where i am working on it but completely running out of places to look other than the pump. No codes or anything in Forscan. But having just inspected the diesel from the tank there are very light silver metallic bits in there. Are these likely from the spring if present or the cam in the pump itself? 1.Replaced Turbo and oil lines, removed oil line gauze. 2. resealed all injectors as they were leaking 3. Dropped and cleaned oil tank, cleaned pick up and resealed 4. Cleaned DPF off car and refitted. 5.Cleaned intake manifold and EGR due to heavy carbon deposits. 6. Dropped fuel tank and cleaned lines 7. Replaced fuel filter and primed humpteen times.

[@huntman9485]

Hi Alan. I have an issue with a 2012 Plate ford kuga 2.0 tdci 140BHP same as mk4 mondeo. When under load or towing the engine is constantly cutting out on the road engine malfunction coming up with fault code P0093 002f large fuel leakage and also p0002 84-2E fuel volume regulator. So far iv replaced the Fuel Filter with a genuine one. And also the fuel regulator but same problem occurs when the Jeep is under load or pulling uphill with a trailer I can drive from one end of the country to the next without a trailer no issues however iv noticed now its starting to struggle starting in the morning im thinking is it the high pressure pump on the way out or worn? Thanks Brendan

[@alan4x]

hi, you need to carry out an injector leak off test..chances are one or more of your fuel injectors are leaking too much fuel back to the tank.. the high pressure fuel pump is not able to maintain the correct pressure in the fuel rail hence you ecu putting the engine into limp mode

[@huntman9485]

@@alan4x thanks Alan. Did I mention to you that it has 190.000miles on the clock! But there is no other signs of injector failure no smoke no tapping nothing. Have you came across this issue before? I mean the caravan i tow is only 1100kg should be well able for it!

[@alan4x]

@@huntman9485 yes i have had many injectors fail on those engines...generally they don't cause running issues,,, just cause the engine to cut out under load

[@huntman9485]

@@alan4x hi Alan. Carried out leak off test came back ok. Replaced HPP with second hand unit on first impressions it ran like shit off a shovel with loads of power but the very minute I hooked up the caravan it died on the first hill but this time had a different fault code p1169 86-26 Fuel Rail Pressure Sensor within range but high. Im really pulling my hair out with this problem at the minute

[@mattyg8132]

I have a 08 plate mk 4 mondeo titanium 2ltr desiel ......so when I start the car it idles perfectly...but if I rev car in neutral it takes some time for rwvs to puck up and sometimes when driving takes time for the turbo to kick in could this be a fuel pump problem ....now baring in mind my serpantine belt needs replacing also the tensioner

[@alan4x]

you need to have a mechanic scan your car for fault codes first

[@mattyg8132]

@@alan4x hi mate I had the serpantine belt and tensioner.....along with idle n pully he scanned the codes it's the egr valve what would you recommend...new or clean

[@alan4x]

@@mattyg8132 don't think there is much you can do with those valves, i would just fit a new one

[@mattyg8132]

@@alan4x cheers mate 👍

[@dean-gm1lg]

Spring manufactures would make you a charge spring for not a lot of money

[@RemusKingOfRome]

What ? you cannot buy a spring from China or get an old one from a wreckers ? Reminds me of the problem LDV vans use to have in their 2.5 l diesel . The spring in the rail overpressure relief value would break, sending fuel back to the tank and not allowing the engine to run at all.

[@Richytbiscuit]

Where do you get this spring?

[@sdhfpiuswrh]

Search for dfp6 plunger spring

[@dewzr]

Mine 2.0 tdci 150 under 50000 miles on the clock. I done my first fuel filter change and find a lot of metal flakes under the filter.

[@Vespastendert]

dewzr normal sadly

[@peraltamenta]

Thanks you Master !!!

[@adrianshaw4067]

Hi mate would this be the same on a 2011 focus 1.6 tdci. I've just had 2 new injectors put in it's starting up but running rubbish it's like I have an engine knock cheers

[@alan4x]

the pump on the mk5 will be different to the focus 1,6..if you have a diesel knock i would say you still have injector issues

[@adrianshaw4067]

@@alan4x Hi all the injectors seem to be reading the same on the diagnostic machine

[@andreicringanu5629]

Hi, i see you from Romania. I think i have this prb with my car. Focus 2015, T7DB engine. The engine is very noise and its start not quickly. If i tri to remove this part with the spring, and it s not problem with the spring, can i put back, and start? Sorry for my english.

[@misiaelkruk]

Have you done it? I have the same problem with my 2.0 HDI. That high pressure pump is very loudly and I'm considering what I should do...

[@andreicringanu5629]

@@misiaelkruk hi, i hale done. I sell The car and buy a vw golf 7.

[@misiaelkruk]

@@andreicringanu5629 oh :D I have to take it into account... SpaceX build incredible things and we have to bother with fu**** faulty pumps and other weak stuff... It's sad. So, now TSI engine?

[@andreicringanu5629]

@@misiaelkruk i understant you :)) no tsi, it s 2.0 tdi 150 ps... it s a litte slow like The focus, but the engeine is more stabile and is not so noiee inside, and also it s with dsg. I hope to run ok for long time.

[@claudioagmfilho]

🇧🇷🇧🇷🇧🇷👏🏻👏🏻, Awesome vídeo !

[@humayunkhan8101]

Need same pump have got spare working one

[@aussie1ben]

Does anyone know the part number of the replacement spring repair for this pump

[@sdhfpiuswrh]

Search for dfp6 plunger spring

[@aussie1ben]

@@sdhfpiuswrh thanks for the reply, I ended up finding a bag of 10 spares to import from the UK.

[@johnmagee6524]

Good man 👍

[@glenng1938]

28476661 Delphi part number for pump spring

[@danielesbordone1871]

I have a Mondeo mk3 and it's been a nightmare , injectors , HP fuel pump ect. , but I'm seeing that even the mk5 has the same problems. Never again Ford.

[@Clicksystems]

If you can remove the old spring. Send it to, springcoil.co.uk And they will make you a replacement spring to same specifications. I do this now with OE suspension springs also. Out the factory they are all colour coded depending on engine and gearbox combo, and trim level etc. Loads of OE combinations but only 1 fits all in aftermarket which never exactly replaces the original spring characteristics. But if able to wait or have an old broken one lying around, contact them, send the spring to them and they will knock up an exact replacement in any quantity.

[@alan4x]

excellant, thanks

[@claymane91]

Hi! I bet you are the right person to ask. I have a 1.6 hdi 80 kw 109 hp engine which is shaking at idle, the car runs good but there is a very annoying vibration. I changed the injectors DMF fuel filter Egr, defapped the engine but the vibration is still there. I have no check engine light but I am suspecting a problem with the high pressure fuel pump look at the fuel pressure rail graph kzbin.info/www/bejne/nYGrqKKjepiifNE it is jumping up and down. Do you have any idea? Thanks mate!

[@closertothetruth9209]

maybe you coould referbish these and sell them

[@robertgibson7716]

welcome to the age of fitters and not a Mechanic like yourself throw it away and fit a new one ahh back in the day Alan we repaired as much as poss to save money

[@dewzr]

Alan doing very good job and sharing his knowledge. Find spare parts for this pump first

[@omidkhalvandi2721]

Ok

[@stefanoancona7642]

HO MI GOD SONO TUTTI POMPISTI

[@goldenlee8961]

Too talkative