Mondeo 2.0 tdci Injector Replacement - How to 

Well done, seriously! What a daunting task, and undertaken by someone who was learning as they went. You saved yourself some serious money doing this job, and this video acts as a perfect tutorial for the rest of us! Well done, keep up the good work...you've gained another subscriber!

I have to thank you and your dad for this. I have been toying with the idea of removing my mondeo injectors to have them refurbished, the injector place wanted an extra £100 to remove and refit. I watched your video yesterday and have just finished removing my injectors, and am taking them to be reconditioned tomorrow! Great work guys, inspired me!!!

Sounds like you fixed it! I had a similar issue with my CDTI Astra. Im so glad I didn't go ahead and buy injectors. It turned out to be one of the injector cables had warn through over time and was shorting on the engine. The ECU was storing codes like fuel pressure, Multiple misfires, and injector no 2 open circuit! Worth checking cabling every time as well. Good Work!

Another brilliant video mate it's so inspiring watching you take on jobs that are new to you and doing them well, Your attention to detail with everything you do on the channel is some of the best I've seen proper quality content from an honest down to earth lad looking forward to the next videos 👍

I have a mondeo tdci i use for the winter and its just started doing the same thing under hard acceleration, watching your video made it look easy, just need to find some good injectors and ill give it a go, keep up the good work you have a new subscriber.

Good video mate, I've recently been following your channel and your work is fantastic! I used to have a VW Golf MK4 GT TDI, it was my first diesel car and originally it turned out to be a total lemon with 170K on the clock - I hadn't a clue about diesel's at the time in my younger days and I was just looking to join the TDI clan. Anyway it soon developed a nasty like misfire when you would put your foot down, basically two garages, lots of stress & £800 later it turned out to be a knackered tandem fuel pump. However as you probably gathered with various diesels it really can be a guessing game at times with them & the ECU didn't really give anything away with the error codes, my old garage first replaced the fuel filter as it's always the cheapest option but I also had to have the car sent away to have all four injectors removed & tested, when the results came back as within normal measurements the specialist really were scratching their heads with what it could really be... until one of the staff started testing other parts from a donor TDI and the tandem fuel pump was the cause. I learnt a lot about diesel's when I owned that car, how the engines work and also ways of fault finding. Keep up the good work mate, you're a credit to RU-vid!

I enjoy watching this video and I have always wonder how to program injectors into your car, thank you very much for taking the time to a video like this, i love it

The first run the ECU was most likely running a correction value procedure as I saw no pilot injection learn? Thats presuming this management system requires pilot injection learn. I haven't had much experience Ford in recent years since being at a Citroën dealer but I have had issues with the fuel waxing up in the filter and particles of that wax getting through the filter in to the pump and clogging the injectors as the holes in the injectors are smaller than a hair. For future reference as well pal it is always best practice to re-cut the injector seats and to replace the HP pipes. Good video pal, if you ever need some technical advice or guidance dont hesitate to message me, 10 years in the trade and a Diagnostic Technician at Citroën I know a thing or two.

As others have said, excellent video. I wish I'd had it to refer to when I changed two injectors on my Mondy tdci 3 years ago!

From this video and (another couple you did on the Mondeo) .I successfully tackled the same task on my x-type Jaguar (2008) ,, kudos to you saved me a fortune

Surprised how easy it fired after the repair usually have to crack the fuel pipes off slightly till the fuels up to each injector else they’re a nightmare with air in the system. Nice to see a DIYer doing a good job!

Just started following your work, and very well impressed , cracking job on the Injections, the coding side of thing like this scares me to bits !!!

another a great upload bud, keep them coming.

Great video James, very consice and full of insight, looking forward to some great new videos in the coming year.

Thank you so much for this video! I've never been near injectors before until warning lights showed on my Mk3 Mondeo. This video gave me the confidence to remove the injectors (easier than I thought). I actually cleaned them and put the same ones back in. Car still didn't start so I then used your suggested OBD tool to clear the fault codes and program the same injector codes back in. And now I have a working Mondeo! I may need to replace injectors for new/recon ones in the future but a clean did the job for now. Couldn't have done it without you! Katie

Nice job and video Savage :-) Well organized and systematic. I like these longer videos.

Went to ford with same problem. £2800. Or £1908 just to buy injectors. What a rip off. Bought 4 injectors,software and diagnostic cable plus a cd player for my notebook to read the cd. And a socket. for a total of £140. Always try diy. Save a fortune. Good instructional videos like this on are a fantastic help. Cheers.

Fuel filter it probably the cause a lot of diesel issues caused by blocked filter I’d put one of them on before any thing else

Mate of my mine had the exact some issue, had to replace 4 injectors, Went to ford and they quoted over £2500 for this job parts and labour! Let's say he was shocked and left immediately and got them done far cheaper else where!

Well done young sir! Very helpful video.

Just found your channel mate and enjoying watching the content. Had an ST220 back in 2005 to 2007

Excellent vid. Suspect I will get to same point with my identical Mk3 as it’s just reached 90000 miles. Interesting that other posts say it’s the turbo with no other details why - check the error code first! I’ve had the turbo problem and had the turbo error code. Guide vanes fine, actuator jammed, there’s a bloke who sells refurbed actuators and mine been great for last 18 months. I also did the hole in the turbo outlet and cleaned inside with oven cleaner, the hole is sealed with M6 bolt so I can do it again when I want. Next got fuel error code, warning light, limp mode and horrible flat spots in engine revs. Replaced diesel filter and has driven like a dream ever since. Old filter had weird mouldy lumps in it. Did rear wheel bearings last week, no noise from them any more. Can’t recommend the WiFi OBD2 dongles and smartphone apps to monitor car during driving highly enough. Watch out though for apps that cause engine to stop whilst it reads codes, not good when pulling away from the house!

I wish you made videos on the corsa for this long I just got my self a 1.8 corsa goes really well

Yet another top notch savage fix

Serious money saved there mate! Very good job and impressive! Thumbs up and subscribed!

it can sometimes be the Actuator on top of the turbo that can bring the coil light on and put in limp mode

2006 Mondeo TDCI with only 100000 on clock is pretty rare these days! Mine had 190000 and engine was still sweet as a nut before some clown hit it

Nice to hear you playing jungle by ELO in your mini. Love your vids

Nice one mate ,enjoyed that 👍🏻

Nice one. I like the way you put the video together.

Good video, did this back in 2012, saved myself a fortune .

nice video, i also had the "glow plug of death" on my mk3 tdci, it was the IMV.

sound, something I've been keen to know 'How To' for a while. Thanks

Oh snap! Same thing happened on my Dad's transit, two new injectors sorted it. (Remember to code them to the ECU with Forscan, you can use one of those VAG KKL cables to do the job). Theoretically you can buy the replacement valve that fails inside and refurb them, but unsure how you'd code them given that the new valve would change the flow characteristics.

Great video, I like the style of little editing

Thanks Geezer.. You have just saved me a fortune. You are a Diamond.

I took mine out got it refurbished and start back in, no coding Cheers for the help getting it out * thumbs up.. I am now waiting for your mondeos starter motor to go,, I have a lazy one that need replacing :)

great video. The ECU is adapting the new injectors. It needs some time cca 20-40km to achieve the adapted values. Great job, thanx

You need more subscribers mate. Your vids are the best 👌🏻

Really enjoyed the video. What do you do as a job

Loved the content you used to put out detailed yet easily to follow, hope your doing well out there!!!

What a great video. Thanks for all your help

Excellent video, you could have tried a diesel purge on the injectors, liqui moly is very good on old injectors. I usually use a litre with filter to inlet side of high pressure pump. Does not always work if injectors are too far gone, but I experience if would sorted your issue out, a cheap fix if it works

Ah reminds me of my time spent fixing my diesel Focus. All fun until the high pressure pump went. Nice video.

Great video, very useful. I've changed one injector, #1, and my doubt is if I have to input in the ForScan only the new injector code or I have to do it with the four codes, so, in that case, the rest of the houses would remain with zeros (0000000000000)? Thank you in advance to everyone.

Really interesting video nice one . Hope it stays good 😊

My #1 injecor just failed its leak off test spectacuarly, thank you for this!

The Glow Plug light and then limp mode shortly after was cause in my car by the arm of the turbo actuator just being stiff. All you need to do is spray a load of oil on it , have one person rev the car so the arm moves forward and back while you spray the oil on it. This solved the problem for me.

Fuel pipes are recommend, had a few Ford's leak

I done fords injector recalls on the commercial you really do not need to be so carefull putting them in the cylinder head theyre very robust parts nice to see that you used such caution with it

On my mondeo it was the same symptoms and it turned out to be CAM POSITION SENSOR. About a tenner from euro parts. It kept happening to me when over 50% throttle and was intermittent.

I put Shell nitro diesel in now after changing brand new injectors twice never had any problems after that, suspect muck gets through filter too easily so keep tank topped up car seems to run better with tank topped up too.

It’s the map sensor or map sensor wiring. Had exactly same light coming on with my Audi . Mass air pressure

I used to work on a production line making the nozzle (or tip if you like) of your replacement injectors. Sadly the factory won't be there much longer....

My money on this fault is the injector pump, the bearings in the pump will be shagged, unless the oil is sent off for analysis it's very hard to tell if it's swarf. Changing injectors and fuel filter etc. Is only buying a bit of time. My advice would be to get shot of the the car before it becomes an even bigger money pitt or has to be scrapped because of engine failure from the pump bearings collapsing etc. Great video as always!

I have just bought a 2.0 tdci mondeo 130 6 speed with 61000 miles on it. with p0251 code and wont start. Paid £200. Might have to do the same job on this. Only getting 74bar of fuel pressure and requires 200+ to start i believe. I will be checking for metal and doing a leak back test soon. Great video 👍

I had this problem with my wife’s Vauxhall Insignia, was throwing engine warnings up left right and centre. The car would stutter and go into limp mode, I went onto the motorway and slowed down from 60 to 30 and then floored it to 120 and a large cloud of black smoke blew from the rear and it’s drove fine ever since.

Hello Great video and very helpful. Just about to remove my injectors on my s-max to replace the copper washers. I’ve ordered the socket but to ensure I have everything I need before starting. What size spammers did you use to remove the high pressure lines and to hold the injectors straight? Thanks

@the savage garage, loving the bids mate did you bleed the fuel system after fitting the new injectors? Cheers

Had the same problem as you. Mine turned out to be turbo. The way to diagnose. Unclip the turbo actuator arm (little Circlip) if the arm moves back and forth freely your good. If it is rough turbo is knackered. Mine was an 06 plate. Just ticked 200k miles.

Hi .I had a similar problem on my focus 1.6tdi .and it was the fuel filter..hope it helps

My ST has just started doing the flashing glow plug light thing. Only really happens when idling. Going to get an injector test kit and might film it. You’ve inspired me to fix my car! Should I start a RU-vid channel to document it?

Change the vertical hose on the EGR for a silicon one, the original type split. It is worth cleaning the MAP sensor as muck on it will cause black smoke that most will blame the EGR for, its on top of the pipe drivers side of the intercooler.

Loving your channel Bud, can I ask you did you torque the Bolts of the Rail to specks? Or just hand tied?

Hi, Loved the video. When you bought the item off eBay how did you know that it covered your year and model of car for the injector programming.

Ya man love the content and its good to mix up the cars 🙌👌 i would love you see a corsa b 1.0l turbo build 😂

Great video, my brother having trouble with Ford transit, told the injectors on those need programming if replaced, will look in to getting the software you used in this vid including plug in module. Being a biker myself could not help but notice motorbike in background, is it a Yamaha xs250 fourstroke, great bike back in the day, had a Honda cb250n superdream myself. Thanks, vinny. :-).

Nice video, learnt a bit :) Thanks.

Just for good measure, cut open old fuel filter and check for swarf if replacing. Replace with a decent brand filter. As mentioned before check operation of turbo actuator. Make sure egr is clean and operates as it should. These and the inlets get really gunked up with crud over time so a good clean won't hurt. Confirm all the above is ok and if the injectors and pump are good i'm 99% sure you'll have a sweet running diesel mondeo.

Hi can you ask your dad if he's had a problem with vacuum leaks and how to find the a smoke test it's quit common on these models I've replaced the front egr intercooler pipe and checked the rear turbo pipe all seems good under load I can here a whooshing noise only jobs I've done it replace egr and remove and clean intake manifold sounds like it's on passenger side but can be very difficult to detect as the this engine is quit noise very helpful vid and I've just ordered the scan tool

the hard part is finding good injectors new ones cost an arm and a leg

Change fuel filter will be water condensation in the fuel lines I had a Volvo with a ford engine in at the shop once and was getting a similar problem would die now and again when you were hard on the throttle

Had same problem on mine with coil light and car going in limp mode the drive gear in turbo actuator Knackered got a reconditioned one problem solved

When the injectors went on mine i sent it to a specialist the light came back on once restarted the car it was good

I have never used that particular software myself but every single time I've had to code injectors in always had to have the engine to operating temperature first even without coding the injectors you can start the engine it does tickover very rough but the engine will start and get up to operating temperature and then code the injectors in

Super poradnik, jestem właśnie przed wyciąganiem wtryskow, mam kabel diagnostyczny, ktory połączy się z Mondeo jest na obd2, moje pytanie do Ciebie to jaki program uzywacie do kodowania fordscan ? czy coś innego

Your a great teacher and a brilliant mechanic keep it up

All those numbers are the calibrations for the injectors & they need to be coded to the ECU. You should replace the injector seals on the valve cover as part of the job 😊👍

Did you have to prime or bleed it after reinstalling the injectors?

Good job lads 👍

PHEW! thank god it started.!!! I watched this spellbound..I have the same car same year 6 gears and cruise control I LOVE IT. I never thought changing the injectors was as complicated as that was!! I hope for gods sake mine doesnt need that or im GOOSED !! Well done top vid i enjoyed it. Keep Rockin!

hi mate just saw your video ive got the exact same problem with my 2006 mondeo,would you advise that i should go straight for injector/injectors? rather change fuel filter ect? love your video's and have subscribed

Good evening Did you find the reason for lighting the yellow bulb in this video? What is the solution to this problem because I have it in my car

Can the software adjust the idle on the mondeo.My injectors are on their way out but it only has rough idle at the moment so would like to raise the idle slightly until i can get to put some injectors in.

I've got a similar problem 2 days ago my car went into limp home mode. Had a look on the diagnostic + no codes, which was a bit strange. Further inspection + found that the oil breather hose had a hole in,so put that down for the cause. Replaced at a price of £45 from ford. But still limping after driving 3-5miles of driving. Changed the fuel filter today (Mann), got a little bit further mileage wise but still went into limp home mode, but the engine didn't stall like it did before I changed the filter. So now I believe it to be new injectors or pour some redex into the fuel system to clean the injectors + hope for it to fix the issue. Otherwise could be looking at replacement injectors. I have a Mondeo MK3 2.5 V6 so any help or suggestions from anyone would be brilliant.

Have you checked the glow plugs ??

also another question, maybe you will answer this time ;) did you bleed the injectors before crank the engine or which procedure have you adopt?

Well done! I have a 55 Mondeo which had the same problem after about 130k miles. I paid £714 to have my injectors refurbished, it's now on 198k and still going strong bless it!

Can you tell me exactly what the removal tool was please?

I have a 1.9 150 goes into limp mode all the time done a filter and that fixed it,it can cause a limp home mode

When You see error P0251 on those cars as usual is related to water in the filter or/and blocked fuel filter. Another symptoms of that is the light injector light came on on increased rpm over 2500-3000. When is related to specific injector issue you have the light come on on idle or slightly above 1000 rpm.

Quite interesting to see a diesel on the channel :)

quality video james what do u do as a day job buddy

Glow plugs had same simtom on my 1.8 tdci focus 56 plate

I wish you was local to me, 2 years ago a diesel specialist Burton-on-Trent wanted £900 plus vat for 2

Had same issue with my Mondeo with the same engine, I was devastated because the car was immaculate and drove amazing until then. I ended up scrapping it due to the cost, just wish I had your confidence to attack any job. Fair play you saved not only money but potentially the car being scrapped too 😀

Didn't you changed the copper injectioner seals

I have the same problem, mate. How did you resolve that? Can someone help me or say something? When im in 4º and I step on the accelerator sharply, this bulb jumps and my engine stops! Its so stupid, because the engine works well.

Who did the injector refurb? How much were all 4. I have one that might not be worth repairing

hi amazing here. im getting a lot of tip top using your suggestions and workaround issues. only question pops up, after the first test drive (after installing and deconding injectors) the coil light came out and you said you were going to read the codes but after you did not mention about it anymore. did you check it? there was any or no codes at all? cheers