My Mondeo Smells Of Cooked Meat!! Leaking diesel fuel injector seal.

My Mondeo Smells Of Cooked Meat!! 2014 ford mondeo 2litre peugeot diesel engine, leaking fuel injector seal.
A replacement of the copper washer fitted to the base of a diesel fuel injector to stop engine compression leaking past the injector and building up tar like deposits.
The engine shown can be found in ford mondeo 2litre diesel and peugeot expert vans, euro cabs and peugeot e7 taxi cabs.

[@paulchester656]

Thanks for taking the time to reply Alan. Really enjoy the way you do your videos, very informative, very easy to follow along with, with a touch of humour.

[@ciprianwinerElectronicManiac]

Sooo, I'm not the only guy who dresses up improperly for the job ahead and then trows away his clothes when he overheats, haha. Thanks for sharing mate. :)

[@alan4x]

lmao, have a good one😁

[@cheeseyphil]

Alan another great video. Had a smell in the cabin over the last week or so. Thought it was an exhaust leak at first but found it was a leaking injector seal. Got just before it turned the head to tar. The smell is awful and as you say is on my clothes. Just heading to ford to get the replacement washer. The washer isn't too far off the condition you one is here in the video. Once agin this video has helped me through the process. Thanks again!

[@alan4x]

Glad it helped..cheers phil😊

[@krehlick]

you have no idea how much insight you just gave me. Pretty sure that I have the same thing. I thought that the noise was the lifters but it didn't really sound like metal, more like air. And the asshol smokes a bit under the hood and all the injectors are covered with this crud. Now I know exactly what I'm up against, which is mostly not the case. Thanks matte

[@zdenekoldrichmarek2867]

I was getting injector washers out 60years ago so there is nothing new you know. Be Blessed.

[@leeregan8017]

Valvoline egr and turbo cleaner is great for spraying on and leaving it softens and starts dissolving the carbon! Great video Alan 👍👍👍👍👍

[@richardanderson4796]

Having watched your video gave me the conference to tackled my problem with broken injector clamps never worked on a diesel before too so big thank you 😍

[@drivelaughing7905]

Mr muscle oven cleaner. Best thing I have found for breaking down diesel gunk.

[@pit_stop77]

The merc CDI engine also suffers a similar fault. Good to see you back! 👍👍

[@alan4x]

thanks

[@daddydan1000]

I found using a long head bolt from a rover K-series engine seems to get these copper washers out if they’re stuck in the injector hole excellent video as always

[@richardcallison1637]

Great stuff! Top tap tip too!!( couldn’t say that quick after a few beers) Keep em coming, mate👍

[@alan4x]

lol

[@lukeanderson7169]

Thanks mate you put my mind at Eze with the black tar build up grate video

[@edi8656]

Great video mate thanks for posting, big help 👍

[@zoidberg444]

DAMN. I saw something similar on a C-Class Merc. The injectors were not only leaking but they were also bad. Which was lucky because i destroyed 2 of them trying to get them out. The old TD5 motors used to have issues with the copper washers. My uncle had terrible problems with his Discovery back in the day until he found someone who knew about them and was able to fix it.

[@EstebanViquez]

Thanks for the video bro!!

[@johnmagee6524]

Alan you should be the British diesel ⛽ ambassador to Ireland have to write the queen 👑 a letter see what she thinks 😂

[@alan4x]

lmao, cheers john

[@maverick9767]

Good video I like your sense of humor 😎🤣

[@meknownothing]

Another great video thanks

[@Cameron1804]

Ever thought of doing a q and a? Great stuff once again 👍

[@seanwhiting48]

Love your videos alan. Happily share a pint and chat about mk4 potatoes but damn we need to see to more of mrs M in the videos

[@armunro]

Peugeot 1.4 tdci on Fords was notorious for leaking injectors. Remembered doing one and it was a horrible mess as you described. A coat hanger with a hook is another way to get the copper washer out of the hole.

[@cipmars]

1.6hdi too. I've got injector seals and a rocker cover gasket on the way.

[@miranalimirani6103]

*Hello my friend Alan, I have a Ford S-Max 1.8 2006, and a week ago I removed the diesel injectors and cleaned them both inside and outside. Especially from the inside the color was black and full of dirt. After that, the car is in good shape and responds better than before and has also decreased fuel consumption. have a good day* _Thank you very much my friend_

[@alan4x]

your very brave taking that job on, well done, glad it worked well

[@dudies10]

This video has saved me so much grief!! I’m going through the same issue with my garage. They fixed it then it broke again I’m currently cleaning off all the tar the engine myself as the garage won’t do it… then going back to get them to replace the seal. What a nightmare!

[@austenite239]

Thanks so much for this video! Had this happen to my Mk4 Mondeo with 160,000km on the Thursday before Easter, and because I had watched your video a few weeks earlier was able to get it fixed in time for the Easter road trip.

[@mikeyp1977]

Released on the same day as I had to the exact same job on a fiesta. 2 chuffers but replaced all four. 3 hours of fun and only one lost bolt 😂

[@alan4x]

chuffers lol

[@petecurran3995]

Excellent work, squire. Pretty sure I've this issue on 1.4hdi - fun times ahead. Rotten pork! 😂

[@bartoszk4812]

Those lousy injector washers killed many Mazda's 2.0 and 2.2 diesel engines.. I was lucky enough to have caught mine in time to save the engine! It seems they make cars of paper these days. Another great video Alan!

[@alan4x]

cheers

[@marknicholson4132]

Can't believe you've not filmed that job before Alan.... Poxy gunge is a real mare ....

[@tpax3p]

8:43 Thank you for the tip! I didn't have the tap to remove copper washer. But I did had Steel threaded rod from Wickes) It does the same job, due the softness of the copper.

[@spierchips]

Yer quality mate keep it up

[@TheDaf95xf]

The Black Death 💀 That was a bad one. Nice fix Alan 👍🏻

[@alan4x]

lol.. i got black lungs now

[@williamharper1551]

I had the same problem with the johnah engine lol red lined it and broke all rocker arms your video was very helpful in rebuilding the engine but I'm having issue with leaking injectors

[@boomshakalaka2275]

great tip on getting the washer out with the tap alan, i also normally go for a drive till the engine gets warm and that gunk becomes like soft caramel and makes it easier to clean it. theres also injectors reamers to help getting those injector seats and wells clean. great video as usual alan, keep em coming!

[@alan4x]

cheers, i have been lucky, i never had a eroded injector seat as yet..now i just said it i probably will get one lol

[@kevinhancock4064]

I just ordered a reamer kit . Have my washers already wether it's only seals I don't know car is running OK I guess but can feel bit lumpy at times thinking it could be those and shit etc shouod come out OK as ove had head work done

[@doncodman913]

Alan... it almost appeared that you put that new copper washer on that injector with a a load of crud trapped in the corner. Safety glasses would possibly be a good idea as I believe the injectors can spray high velocity particles. Interesting stuff Alan . Well done. Regards Don.

[@alan4x]

lol...i was waiting for someone to notice that....that crud was in a ridge at the base of the injector so i left it as it had no bearing on the sealing washer but i do wish i had removed it at the time as it does look bad...i was being lazy

[@hondarodeagain4264]

Old video I know but I now have this exact issue. Looking left to right at the injectors from the front of the Mondeo 1 and 3 are clean, 2 and 4 are full of crap. When I removed the leak off pipes 2 and 4 sheared of in the injector, do you think the leak off pipes could have been the problem or is it still worth checking the washers too? I only knew because the car made a pop sound when I started the engine a few times, the top cover had about 4 holes blown in it. Great video by the way, it's helped loads.

[@taxidude]

We have an injector seat cutter to insure the new washer seals properly. Also, if you bring the offending piston to the top of the stroke, you can hoover the shit you've scraped out of the tube with less fear of it going through the bore!

[@tdi1505]

Always waiting for the next video 👍on another subject 1.8 tdci 08 heavy on fuel black smoke good injectors no boost leaks plug out egr valve better fuel Economy and a lot less smoke blanking the erg makes no difference when it’s plugged in

[@alan4x]

those egr valves are best left unplugged lol

[@peraltamenta]

Thanks you Master !!!

[@TUMBLINJEST]

ran my old 200tdi landrover on cooking oil, and that left yukie deposits like you will find in an old chip frier

[@lionatelier]

Very funny video, one thing I have used on Diesels for cleaning that mess around the injectors funnily enough is oven cleaner, it absolutely eats through that carbon build up. Just a thought.

[@alan4x]

Great point!

[@Aleksander9003]

The best thing to use on them is fireplace cleaner, works every time for me, last time I used it on sprinter van withe 2.1cdi engine like in your van

[@alan4x]

cool, thanks for that

[@timbattleday7275]

Hi Alan just removed and cleaned injector replaced copper washer and blead system but focus now juddering under load any magic idears cheers

[@redibasha9096]

Hello Alan, how are you ? Thank you for the videos so helpfull. I need a help for my car. I have a focus 1.8 tdci 2006 year bought it before 5 months i love ford cars have owned before but with this one not so happy. I havent managed to fix everything but i need an opinion from you because here in Albania is so difficult to find good car mechanics. When my car is warm and i turn ingition off if i try to restart sometimes long crank sometimes start right away. No error codes under the diagnose nothing. Have asked so many mechanics everyone explain different things. Sorry for the long explanation and thank you.

[@Runeakb]

On the 1.6 TDCI the studs that keep the injectors down are stretch bolts. That means one has to change them when refitting injectors. I suspect the studs to be too thin so even though they are tightened to their yielding point they still don't supply sufficient clamping force on the injectors. Maybe one can fit fatter studs?

[@alan4x]

your probably right there, i have heard on those 1.6 engines the injectors are common for coming loose

[@mickya7829]

I used Mr muscle oven cleaner, hosed it off, cleaned it all .perfect. Cleaned all the tar off my Mercedes engine, the injectors were very hard to remove,

[@amwap12]

Get in touch with innotec ask for a demo of deblock oil and power clean.. best thing to get the build up off and injector out

[@alan4x]

cheers for that info

[@hamie55]

Get hold of some 3m citrus based cleaner. Breaks down oil so well

[@TheDaniels5s]

what is the torque for tightening those injectors? Thanks

[@capnskiddies]

Autoglym tar remover. Worked on a D5 Volvo. Just liquifies it

[@jothain]

That's good to know. I'll keep that in mind

[@cheesyeurotrance95]

just replaced 2 copper washers on my punto 1.3 diesel, was leaking fuel and knocking like mad because the old washers were horribly worn out

[@gberish602]

Hi Alan, do you happen to know what the torque setting is for the injector clamp bolt? Ford don't seem to know.

[@johneisen6341]

Same happens with the Mk7 Transits. Gunk is good stuff to use. I got shot of that van in the end..

[@alan4x]

😊

[@danielp9721]

What do u think about the mk4 .mondeo 1.8 tdci engines

[@nickgee6408]

Hiya have enjoyed watching the videos, has saved me a small fortune. When you next do a MK4 mondeo video which engine is better 2.0TDCI or the 2.2TDCI would like to know your view. Thanks

[@mikementzer923]

I had a 2.2l 155ps and I never had the slightest problem (250.000km). I currently have the 2.2l 200ps (2012), with 220,000km, and still no problem. The 2.2l are actually more reliable.

[@cerijones3797]

Hi Alan, wondering can you help I have a mondeo 1.8tdci 59 plate how do I find the injectors configuration number for it.. I have a small vibration on standstill when reving around 1200 to 1500 rpm. Hope you help thank you Ceri

[@marcus0018]

traffic film remover did it for me on a Mercedes vito M8

[@uiscebeatha9476]

I used ASDA (Orange Box) Oven cleaner on a hot engine. Use extreme caution and PPE

[@awaywayye]

I had a volvo s40 2.0d 2008 model...white smoke billowed from it when started from cold, stopped when engine was warm and mpg was way down...i thought it was a faulty injector but they were all fine. Put it into volvo and they never found out what the problem was...does this sound like over fuelling?

[@molajat6133]

Hi Alan I have got an injector stuck on a Peugeot boxer 2.0 hdi 2017 what sort of a puller do you use or how do you get them out? I am based in basildon Essex.

[@steverpcb]

Since your short on things to make a video about, how about a look at the idle up / anti stall on the mondeo and transit. On the transit it operates both in and out of gear where as on the mk5 mondeo it only operates in gear, on our work transit it is out of sinc with the bite point, is there an adjustment ? With the keyless entery / ignition there is a key hidden inside the keyless thingy, does it actually fit anywhere ? How about dropping of a side skirt an refitting it ?

[@alan4x]

the hidden key is a good one... it is fidly and annoying to use so will cover that one soon, cheers but had no experience with the idle up yet, although if i get another mk5 side skirt will do that

[@steverpcb]

@@alan4x You could change the keyless batterys while doing the hidden key, the best tool for the job is a 1p coin :)

[@johncrawford6782]

What are you going to work on when ford stop making the mondeo fleet

[@zamfirvicleanu8268]

Hy there, do you have any idea why my 1.6 tdci 115hp has no power , and there isn't a single eror regarding the engine(the only eror i have is the led headbulb intermitent) 10x .

[@outdoorsguy1535]

Hi, I have had leaky fuel injectors. I took the mondeo to Ford and they clean up the injectors and put new seals on. It still looks messy around there, similar to as Alan implies 13:00 Should I be concerned about MOT failure due to the mess or is it only if they are leaking? Thanks

[@Robyrama76]

Ciao !! Alan 👍👋👋

[@MarkWilson-qb5kr]

Had to do it myself once ,their rubber washers also leak from inside the injector as well

[@davidcarr3052]

Hi mate am having issue with the black seal the goes in the injectors I can't be the black washer to go over the injectors it's like the hope too small is there a method for this

[@PatriciaSilva-sg8kc]

Hi l Alan I remove all 4 injector so that I can clean them and I forgot w Where the injector goes where, could you please tell me which injector goes in wich cylinder And how do you program them

[@clayyahsharala407]

what is the voltage to the injector on a ford connect 2008

[@aaronjackson7184]

Had a 2009 c220 with all 4 injectors burried in that gunge.. was an absolute grim job!

[@kristjankruse]

Suma grill cleaner helps to get off this sticky carbon. But I dont know, how you will use high pressure washer to clean this, without blowing this stuff everywhere!

[@eduardostalinberrucruz1808]

Tanks

[@sicks6six]

common problem, when you take the copper washer out getting a clean seal with the new one is hard due to the crud, is there a sealant you can use to help create a good seal, like a silicon sealant or something, some silicon sealants are high temperature, like cylinder head sealants,

[@alan4x]

not that i know of... the seat in the cylinder head the washer sits on just needs to be cleaned well with a flat end of a screwdriver...if the seat is burnt and eroded away it will need to be recut with a special tool but if all is cleaned well it should seal

[@Automotive_Solutions]

👍I got the impression you are didn't like the smell then. Did the seat in the head survive the gas leaking past the washer?

[@alan4x]

hi, yes the seat was really good, in fact i have never had a eroded seat but have heard about it and the need to recut the seats

[@maryussuceava]

Thanks for the video , what a great job ! Just a quick question Alan I’ve done similar job to my Mondeo but the black plastic oring who sit in the top of injectors when I remove my injectors that plastic oring remains inside the hole is that correct? Coz your come out tougher with injector . Thank you

[@alan4x]

You need to remove that spacer and clean the injector hole out as best you can. If the spacer is burnt and breaks up best just replace it

[@maryussuceava]

@@alan4x you mean that black o ring needs to stay on injector ?

[@the1andonlyFilbey]

mine had this, the seat was recut with a tool new injectors and new washer installed. I still get whiffs of fuel like smells when accelerating on occasion. I also get a weird judder at 2000rpm or so until about 3000/3500. Assumed it was the overrun pulley but its not fixed it, im hoping the tensioner and a new belt help but at present i feel like im just firing the parts cannon at it. 2012 TDCI Mondeo 163

[@the1andonlyFilbey]

fired the parts cannon new belt and tensioner, rumble/resonance still apparent, injectors not leaking. Whats your availability looking like >

[@t5jerry]

GREAT video as always, if you could include the mileage on ALL the vehicles you work on, this would make it HELPFUL and useful to your viewers..........

[@conorturton]

Trouble is that unless you're using the vehicle the same as they are the mileage is irrelevant. I hardly do any short journeys at all so some of the stuff he talks about has never happened, for example the clutch and DPF filter is still fine at 142,000 miles on mine.

[@t5jerry]

@@conorturton ...the reason I ask Alan to quote the mileage is simple, for example, if all MK4 Mondeo's had clutch problems between 140-170000 miles, when buying a MK4 Mondeo privately, you'd know to look if that car had recently had a clutch fitted or you'd be wary of that car 'potentially" needing a clutch.....yes, I know 1 clutch can last 200000 miles on 1 car and on an identical car, a clutch can last 10000 miles, but Alan's in the IDEAL position to make a database of all potential faults as he has had access to all high mileage Mondeo's over the years, in fact, his video's are detailed enough to make a DVD, let's face it he deserves to earn a few Bob out of it 😁😁😁😁

[@alan4x]

i always forget the mileage lol... the car was on 218k miles so will put that in the description as well

[@philzambo]

@@alan4x kzbin.info/www/bejne/oaG5g32Al6aFpK8 I feel your pain! Great video buddy, very informative

[@onsight2822]

His Alan - just a quick question ,,,, Do you know if the mk4 2.2 tdci is also a Peugeot engine? Cheers

[@RikAindow]

Yes it is.

[@cipmars]

I've seen this happen on e39 525 and 530 diesels. That crap is like burned sugar mixed with coal dust and violin rosin. Really nasty stuff.

[@paulchester656]

I know that this video is nearly a year old but just watched it. A quick question on it. When you have the injector out, if you blow around the hole with an air gun, don’t you risk blowing any crap or debris into the cylinders. Thanks.

[@alan4x]

if you have to do this and are concerned then put a pencil in the injector nozzle hole then blow an air blower in there and any debris should not enter the cylinder

[@daveswarbrick5576]

Did a merc 5 pot not so long ago in a jeep OMG kin nightmare, 3 injectors leaking badly and had been for ages, what a mess took 3 days to get the injectors out, hot air guns,solvents,engine hot. to get to the back injector it's under the bulk head!, your supposed to drop the whole sub frame and engine! i cut part of the bulk head to gain access and welded it back up! i replaced all the washers as due coarse, but i'll never do another one again, well not in a jeep Cherokee.

[@alan4x]

reminds me of some of the early peugeot experts with seized injectors under a bulkhead...nightmare

[@dexxdexter9916]

Oven cleaner also bilt hamber sufex hd neat removes the tar stuff oven cleaner is caustic protect eyes and hands

[@BillSikes.]

Mine used to smell like a fish and chip shop when I used to run it on biodiesel

[@alan4x]

lol

[@robg5513]

Can you/do you re-use the bolts holding in the injector (6mm allen)? If so, know the torque spec? I'm about to go through the exact same process......

[@alan4x]

yes i always reuse the old bolts...dont know what torque but just tight...most mechanics will know how tight to go

[@BOGDAN8270]

Good

[@tehseenkhan4249]

Hi my gallaxy smells like burning tyres what's should I do¿

[@mondodaftasabrush]

When I did my pug 1.4hdi it was like coal and hard like a diamond in some clumps I had the chuff not the smelly pork smell Is is bio diesel Are you just awaiting the rest to go instead of doing preventative maintenance and doing all of them?

[@alan4x]

its not bio ... no i only doing the one injector washer.. all the others looked ok so just checked tightness of the clamp bolts

[@johnchamberlain11]

Use expanding foam gun cleaner. Work's a treat.

[@MrAmos911]

What I need a video on changing the cam belt on the 1.6 econetic mondeo mk4. Doesn’t seem to be any on KZbin! Hanynes manual no good either as it doesn’t cover that engine! My mondeo is in need of some TLC!

[@Alexander_l322]

Give it a go mate if you know what you're doing then you'll be fine just get eh technical data for it.

[@alan4x]

we don't have any of those engines or i would have already done the belt change vid but i will keep it in mind if the opportunity does arise

[@RumelM]

Hi Alan, is the tap an m4 or m6?

[@steverpcb]

He said it is m9 in the video

[@colinhamer6506]

over time have you changed anything with how you solve this problem do you think using a injector seat cutting tool is needed every time or are they normally ok without

[@alan4x]

you only use a cutting tool if the cylinder head surface where the injector sits is burnt and needs to be made flat again for the injector sealing washer to seat on properly

[@colinhamer6506]

@@alan4x I commented before I started this job it's a kuga same setup as this I spotted it early just a waxy build up and a haze of smoke when could it was from second from the right I changed all 4 seals and cleaned the injectors etc and it still had a little haze when could I nipped it up as much as I dear what is the correct tork setting I'm struggling to find it

[@alan4x]

@@colinhamer6506 i usually get a long flat screwdriver down the injector hole to scrape where the washer has to seal to make sure it is a good clean seal

[@pauloneill8912]

hi alan quick question, where do you get your injector washers from

[@BillSikes.]

Eurocar parts sells them, they're £2 a peice

[@pauloneill8912]

@@BillSikes. thanks

[@alan4x]

buy them from ford dealer although many motor part suppliers will sell them

[@pauloneill8912]

@@alan4x many thanks

[@alexalan9017]

why is it always number 3 every time i have to do this job its number 3 (or 2 on some french cars)

[@gatisbezdeliga2726]

I had the same problem on my ba7 Mondeo

[@MrVicos]

i have got a s-max with ticking injectors. The engine is the same like in the mondeo mk5 2,0TDCI. How can i unmount the cover obove the injectors with the leokoff pipes in it. Is there anywhere a repair-manual? The Injectors at the s-max are very deep under the windscreen so u can't look behind.

[@alan4x]

if your injectors are leaking and you dont want to fix it yourself your best getting a mechanic to sort it as the fumes are very poisonous and will enter the vehicle

[@MrVicos]

@@alan4x Thank you for your quick feedback. There is no smell or other issues yet. Just this ticking sound under load. I am very confident in my ability to work on the injectors. I have also done this and other more difficult work myself on the Mercedes R350 CDI. That's the fun of the whole thing. I just don't know how to get this housing over the injectors with the cables or hoses in it disassembled. On the 2015- S-Max, it's all hidden very far under the windshield, so I can't see all the mounting points. A little guidance would be helpful. Go on with your entertaining and helpful videos. I like this kind of humor.

[@alan4x]

@@MrVicos i am not really familiar with the s max but worked on peugeot experts where the injectors were hard to get to. i would see if any of the plastic panelling at the base of the windscreen can be removed to gain better access or worst case you may have to use a mirror but i am sure there should be some panel around the wipers or lower screen that can be removed

[@DavidMoralee]

I guess hes been putting chip shop oil into it. :)

[@m.hussien7130]

i have a mondeo mk4 that is a real pain to start when hot, been at the garage for 2 months and still no joy would you think it is injector problem?

[@tazba5551]

Sounds like fuel pump

[@777mazzy]

Białe ściany angielskich biur są przerażające... ;)

[@carlospeixoto9379]

Hi Alan If I change the injectors in a transit connect 1.8tdci 2005, delphi ejbr02201z. Do I need to code the new one's? Thanks

[@alan4x]

no you don't have to code those injectors

[@carlospeixoto9379]

@@alan4x thanks for the info. Cheers

[@aldoscarpino4713]

Hi Alan, thanks for your video and your tips, I've been watching your videos for years when I can find the time here down under! My wife drives a Mondeo MK V diesel 2.0, it has 82,000km and the dealer has informed me that the injector seal is leaking. They've quoted $1250 AUD for the repair. In your opinion do you think it is reasonable to expect a leak with a diesel injector seal @ 82,000km? the car does about 30% highway driving the rest city but mainly school runs and weekend sports. Here in Australia we have consumer law that requires goods to be manufactured with reasonable durability if not the OEM is obligated to replace it but I've yet to test it to see if it is worth more than the paper it is written on and that's why I've asked for your expert opinion.

[@alan4x]

hi aldo, yes it is rare for an injector to leak past the sealing washer on one of those engines and also what they are charging to replace a copper washer is criminal...i would have that sealing washer replaced in 20 mins tops if the old washer was stuck down the injector hole so it really is a simple job to replace the washer..if i were you i would buy the washer yourself and get someone else to fit it...its a $60 fix with labour

[@aldoscarpino4713]

@@alan4x Alan thanks for your reply but I may have it wrong, looking back at the report from the dealer it's a leaking injector pump seal not injector seal. I assume that's different and more expensive to repair but none the less should last much longer than 82,000kms? How much should this cost to fix?

[@alan4x]

@@aldoscarpino4713 sounds like they want to sell you a complete high pressure pump, i never had one leak myself apart from a pipe union leaking but if they replace the pump it won't be cheap so i guess where you are it sounds about right for a dealer price but if you bought the pump yourself and had a competent mechanic fit it, you would probably half that price

[@xapatanx-ray4634]

Dish wash?