Sixteen Broken Valve Rockers Ford Mondeo Mk5 2L Diesel psa engine. Under circumstances unknown the camshaft drive belt has shed 10 of its teeth resulting in 16 broken valve rockers. ford mondeo 2litre duratorq diesel engine....
Thanks to you Alan! If I wouldn`t found your video I wouldn`t repaired my wifes 2.2d mk4 after timing belt failure. Had also 16 broken valve rockers. Changed all what was reasonable and carbon cleaned the intake and it drives like it should be!
Back in maybe 2014 or 2015, when I was running my first shop in a different town a customer came up to me and asked me to change the engine on his Fiat Scudo which had the old 90hp 2.0 HDi psa engine. I asked him why and he said because the cambelt had snapped. I didn't have personal experience on those kind of situations yet but I knew they would snap the rockers rather than bend the valves. A friend of mine had a spare head with rockers and we made a deal that my friend would provide the used rockers and I would fit the engine with those and a new belt-kit. It was a success and the customer was astonished that I saved him from a situation in which another shop would have swapped the whole engine. But when it comes to these newer psa diesel engines you have provided some very valuable insight for me because I don't work on these every day - as I do work on with anything with an engine. But the knowledge on those special situations and trouble codes and how to cope with them has shed some important light for me. And that is what I wanted to thank you for!
Great video. The dw10 is a great engine. The valves on this engine are perpendicular to the piston so don’t bend. Had a Similar problem on my Citroen Picasso.
I was thinking that the sacrificial Valve Rockers were a brilliant idea but the price is shocking, i wouldn't let a timing belt go more than 50000 miles dont care what the manufacturers say, they want to sell £200 rockers, thanks for the video you deserve a beer or two.
Oh man, that trash can scene went wrong! Thanks for making the video, it's good to know that these engines can survive a cam belt rupture. Btw, I also liked the scene of drinking tea prior to turning the key. I also know this feeling when you like to postpone the verdict!
I've been using your video's as a guide to doing the cambelt on my S Max as it's the same engine. Failed at the first attempt as I couldn't get the crank pulley bolt out put will have another go tomorrow this, time heating the bolt with a heat gun as you recommended in another video. Needs doing as it's done 135000 miles though the belt looks pristine. They do seem to last well past the recommended interval as long as they're not contaminated with oil. Anyway, thanks for making such informative videos.
Thanks alot for the Video Alan I work at this shop where we got this Mondeo and had the same problem now with your videos made my job very easy and for these video the issue with this Mondeo still unsolved because we stil don’t know what causes the issue 😂 cheers from Valencia,Spain 🇪🇸👍🏼
cheers miguel, i have a video here which is probably the reason your cam belt teeth sheered.. ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-eDgkG_lZeJo.html
Hello Alan now everything make sense to me thanks a lot I really appreciate it I will remove the Pump in the morning and put it back as it goes and align it with the camshaft in the right position.... I learn something different everyday!!!
@@alan4x I saw and hear a few problems like these it seems to be only on automatic gear. What do you think about it? Two problems was under 80000 miles.
2017 peugeot traveller and 55k miles. Aux belt snapped and crept through a gap into into the cambelt. And guess what! 16 broken rockers :( Peugeot wanted £7500 to replace the engine. Thieves and tosspots. No warranty cover despite low milage. Brought it home and at £6.29 a rocker a cheap fix. Water pump set £99, new aux belt kit, crank sensor, fingers crossed its one in the eye for main dealerships. Many thanks for sharing the vid and outcome. It was like watching an episode of Jasper Carrott! : )))
Had some fun and games with my mk4 petrol mondeo. Had some new petrol injectors fitted and it turned out one of them was faulty. It was so bad it stopped the oxygen sensor from switching! Threw up a fault code telling me a misfire on cylinder 3. Cleaned the sensor up put the old injector in and no more problems. Even new parts can be faulty like that feckin n/s rear wheel bearing! Also fitted a new intake manifold because there was a slight rattle coming from the old one it turned out there was a bit of play from the control rod but a bit of peace of mind. A new one cost me £79 and fitted perfect with no problems. 37mpg from a 2.0 petrol ain't bad at all.....
Top video Alan 😄 But keeping us in suspense is not funny haha 😂You should of got Monica to turn the engine and made her jump 🤣🤣 Great stuff as always thanks Stevie 😎
Love your vids mate, good spot on knowledge, good visual detail on what you are doing - and a few laughs chucked in. That's mental, I don't even own a Mk5 and now I'm racking my brain, what could have stripped all those teeth and smashed 16 rockers - yet not totally pumped the engine!! Had any oil, even a tiny bit, leaked onto the belt?? Bizarre
@@ripkosr I had the exact same problem, same engine with Powershift. It was in S, overtook a car, then slowed down, the powershift changed gears (downshifting, of course) at somehow higher revs that in Drive, then suddenly the belt snapped. One of the cams simply changed position, and spun on the camshaft, and all cams were scratched on that camshaft. The other was perfectly fine, yet the shop asked to be changed for warranty to be given, they also changed the chain, the water pump, the chain tensioner and the fuel pump \o/. After the repair, few miles later, the car stopped while climbing. The injectors were contaminated with debris. It had 65000 miles. New repair bill. This isn't a car, is a sad joke. Something is very wrong with these engines, this shouldn't happen ....
I've got a focus st tdci with that engine 31k all she's done took engine cover off and I really dont wanna fix it if owt goes wrong with it haha. Great video alan. I've been watching your video since the lynx wet belt job!
I did a Pug 208, 1.6 diesel 8 valve, snapped it's camshaft for no reason that I could find, replaced the rockers ( only snapped 5 although I did replace all 8 for new ones ) and new camshaft, and the car ran fine afterwards and yes I did a little dance when it started not as good as Alan's
We had 1 similar come through the door the other day was an auto and had downshifted randomly and over revved the engine so you maybe correct in your case!
I think that your right. Over reved to slow down or selected the wrong gear. Someone I know used to replace transit gearboxes because of the same drivers error.
@@alan4x probably the best idea they have had for a long time! shame the rest of the cars are so rubbish (when in a PSA shell, naturally. the Fords at least seem better wired up than the french ones!)
Great vid thanks! Ford parts are stupid money, I paid £150 for a temp sensor for my Mk4 Mondeo. Almost no generic parts available, unlike my Land Rover! Thought I recognised your cars, you're just up the road from me!
Just done 14 deisel fiesta I rocker broke and cam twisted , I am wondering if vacuum pump faulty as it was completely full of oil spun ok , perhaps vacuum pump filling up with oil ? Jamming it ?
Do you know the part numbers for the rocker clips? My Fiesta 1.4 TDCI snapped the cambelt, Only two broken rockers but there is not one clip on the rockers so i think it has done it before and they forgot to move them over Best regards Martin
How is the hp fuel pump driven. Mine was a very poor quality fuel issue resulting in seized fuel pump snapping the intake cam pulley clean off and 2 snapped followers.
hey buddy, i have problem with my chevy Aveo 1.5 , 8 rocker arms are damaged some are broken , i would like to know what are the causes to avoid them in future. thanks
This happened to my Audi, automatic, as I pulled off the cam belt snapped. Took the engine cover off and 5 rockers were snapped, and 2 completely in half. Still to this day don’t understand how. No loud bangs when the cam belt snapped, no bent vales, no marks on the pistons! Crazy
Hi mate.. I have seen this before on the dv10 or the mk 5 mondeo and 5.5 The reason is the pump timing is pf related to the cam. This happens often when people dont time the pump.. it will run mint with the timing way off.. People often remove the pump due to oil leaks But the load on the belt is way of and over time this happens or it shreeds
EUROREPAIRS Hi. Brilliant Thanks for your info.. I have just found out this information which certainly rings true. I think I will put out a short video explaining this
Hi Alan, I’m a big fan of your videos and I really appreciate your expertise in automotive mechanics. I have a question regarding the flywheel timing of my PSA 2.0L BlueHDi engine. I need to pin the flywheel to perform some maintenance, but I’m not sure about the exact diameter of the pin to use. Additionally, I’ve noticed that there are two holes on the gearbox (MANUAL GEARBOX!!!!!) and I’m unsure which one to use. Could you give me some advice on the correct pin diameter and which hole to use? Thanks in advance for your help!
if that's the same engine as goes in the mk5 Mondeo it will be the lower hole..I made a vid on it, check the link. .ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-JH3KBlkAYAI.htmlsi=YNU_mu-WM62TUCab
Becks is not a beer my friend, try a real bavarian beer like Augustiner or Augustiner Edelstoff (Premium Version of the "normal" Augustiner) more Alc and more bitter. But both works very well 😉 If u want some, just tell me 😄
Even without knowing the reason for the missing 10 teeth of the timing-belt, you managed to get the engine running again, and let's hope the same problem won't come back. I just checked the prices of the parts and have the impression that you paid way too much for all the new pieces. I live in France but can't imagine that there's such a difference in price of the parts between the UK and France. One thing I didn't know, and that I didn't hear you talking about is that there is supposedly a difference (looking at the part N°'s), between inlet and exhaust rockers. ATB, Peter.
@@alan4x So it looks like Ford is filling their pockets, I don't think that they make these parts themselfs, and not even the boxes with "FORD genuine parts" marked on them. Found a set of 16 in the UK too, not in a Ford marked box though www.lymmengineparts.co.uk/ford-2-0-16v-tdci-roller-rocker-arm-set-of-16 or are these different ? ATB, Peter.
For what it's worth I worked for a very well known brand of car parts, particularly on the power-train division. From under the same roof came out parts for Peugeot/Citroen, Ford, Volvo, Fiat, Mercedes, Mini, GM/Opel/Vauxhall... etc. Even for the good ol' Harley Davidson motorcycles!! So when you guys think about the "sweet lovely brand" from US, UK, France, Germany or whatever. Please keep this in mind. BTW Just by curiosity, the factory is in Portugal!! No French, Germans, etc. in the vicinity! LOL 😂 The name of the game is cost per unit. Full stop. Nothing more, nothing less. Quality is an individual choice of a particular brand. Meaning they individually set their goals, quality control level, quality control tests, etc. When you see the old Top Gear, Jeremy Clarkson stating that payed >800 pounds for his Mercedes V8 or V12 OEM ignition coils. That costed about 12.5 EUROS/unit at the factory...without the "Mercedes" box or transportation. Just the plain part at the end of the production line. Curiously the PSA (Peugeot/Citroen) equivalent went for around 2.5€ in the same conditions. Makes you think it's a damn nice business for someone! ;-)
Lost some teeth on my mk4 mondeo belt so will be checking the rocker arms this weekend, my local garage mentioned the cam lobs can move as they are an interference fit on the camshaft, have you ever known this to happen on a mk4 mondeo??
Hello Alan, why does the timing belt often lose teeth in the engine? Is the belt itself a problem or a water pump? It looks like the motor is somehow blocked and the toothed belt loses its teeth
My dad has a daily 35s11 from 2002 and the only problem so far is the rust. 260.000 km on the clock. He hauls 3 tons with that thing. Wich generation you think is the best?
@@IliescuBenyamin your dad has the best iveco anything up to 2006 is great most of our fleet it 2012 plus with the 3ltr fiat engine constant dpf problems
that surprises me. not had a decent experience with an iveco since about a 2005 model (the vans with the rectangle headlights and the gearstick into the floor rather than on the dash). they were RUBBSIH after that.
Happaned on mine, the dealership said needed a new engine £8k later, ford contributed £4k but was still a bitter peel to swallow. My milage was 96k at the time from New.
I just had the exact same issue with the timing belt (10 teeth) just put a new one on and no start so will follow your video and open up the engine a bit. Thanks a lot for your help. Did the car run fine after that? still no idea what caused the problem?
hi, you will probably find that all the valve rockers are cracked in the middle and will need replacing although none of the valves will be bent so no need to remove the cylinder head. the car i did was perfectly fine....chances are the reason the teeth stripped on your cam belt is because the high pressure fuel pump on the other end of the exhaust camshaft has probably been removed at some point and not timed up when it was refitted...i have a video on how to time up the fuel pump if it has been removed so if you can't find it on my channel let me know and i will send you the link
Alan have you got a video for the led light upgrade? I will be moving my 2nd taxi to the mark v mondeo soon, a light bulb going on a Saturday night will be costly for me so I will do the up grade if the car doesn’t come with led lights
@@wullieg87 i only have a video for the aux beam led lamps i fitted which work out a few pound more than ordinary headlamp bulbs..so far they have been ok. ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-oXXbC6dIVh4.html
Could be to much oil pressure getting to hydraulic tappets , heard of it on some v 8 yanks , mind you it normally inflates oil filter housing , you can tell roughly if it has bent valves turn it over before fitting cam shafts you can fill compression , if not sure hold down each valve fill difference
Good morning Alan, I was trying to look for contact details for you but struggling to find any. I wanted to ask you if you'd know does the mk4 Mondeo share the same chassis as the generation 1 smax, in particular a 2011 smax? I'm after a few aftermarket performance bits for my smax but sadly theres nothing available but there appears to be bits for the Mondeo especially the Mondeo ST, and I wanted to find out if these will fit on an S-max. Any advice will be appreciated. Thank you
@@alan4x thank you so much. Do you have a website or an email address? Are you close to London? If yes, if/when I need mechanically work, I'd get you to do it.
For the purpose shown in this video; to create a weak link in the chain that will save the engine from destruction and can be fixed without removing the head. If it had a cam-on-bucket valve train, this event would have destroyed the whole engine.
Hi Alan, brilliant videos, I followed instructions on a Galaxy 2.0tdci 2007 there is 8 broken rockers, rebuilt motor and it was a tw_t to bleed, eventually got it running on easy start then gradually on it,s own fuel. Problem is it wont start without a second or so of easy start, then runs but loads of white smoke, rev counter not working, any ideas what my problems are? Cheers Steve
@@vs6300 spot on mate, thanks, all sorted now. part of auxiliary belt that broke last year must have been trapped at edge of reluctor wheel wearing timing pick up marks or magnetism of, so no signal. 2006/7 the crankshaft pully was changed, different thickness of reluctor wheel, new sourced on ebay and now runs like a dream again. Thanks for your input and a Great big thanks to Alan for a brilliant video. Steve
Hi Alan. I have a focus st with this same engine. Recently had a problem with shell on conrod 3. And oil pump pick up caught all the swarf. Question is... the chain for the oil pump yo crankshaft seemed very loose. Do you have any knowledge regarding this please?. Or any videos?
@@alan4x OK thanks. I always wondered about the tapping from cold. People always said it was normal. Will fit a new chain anyway. I don't suppose you have a video of this chain in situe? Thanks mate.. And keep making the videos.
@@keithmullins2895 hi, yes you can probably pull the piston out from below but problem is to refit it you would need a piston ring compressor and i don't think you will be able to refit the piston
Hi buddy. My 2.0L Kuga has just stripped the timing belt too (albeit my own fault for not changing it in time). My rockers are all destroyed too. The timing belt went under hard accelleration. Just when I shifted from 2nd to or 4th. I didn't overrev, but it was actually a drop in RPM. I'd assume that the innertia of the head vs the reduciton in speed of the counterrotation shaft is enough to slip the belt and that causes it to just tear itself ot part inside the engine. I hope my valves and camshaft survived.
never had a bent valve on those engines but pay good attention to camshaft lobes....that they are all sitting in order...new camshafts are not that expensive but chances are they will be ok
If you ever suspect that an engine was over revved enough to float valves,, look closely at the cam lobes for pitting on the closing ramp. That will tell a story.
This may be a dumb question, but why would you physically remove the water pump if it was spinning freely, the tensioner also could have been tested in situ, so the next thing i would done was checked the rotation of the crank and camshaft?...or am i missing something?...also you can do a compression test without camshafts as all valves will be closed?
I have a possible theory about the cause of this. Is it possible a rocker arm snapped and momentarily jammed the cam? The belt would grip the cam pulley as it has far more teeth but would rip the teeth on the smaller Crankshaft pulley. Once the snapped rocker fell away the cams could rotate again but, with the timing now a long way out causing piston to valve contact on the other cylinders. Resulting in breaking the other rocker arms.
It's strange how you say you've had loads of Mk4s with broken rockers...every one we've encountered has spun the pressed-on lobes on the camshaft, resulting in two new camshafts required. Haven't seen a broken rocker. Same with Kuga.
I've just had the same thing on my mk4 mondeo, one of the lobes on my exhaust cams has spun 180 degrees and broken the rockers but still no bent valves
Hello from Germany. Why is the toothed belt torn? How many kilometers did the Mondeo run? Have the same with 130000 km. Should I change the toothed belt? Greetings Dennis
@@alan4x would you please give some more hints about? I have 4 times the same problem and locally no mechanic solve it correctly! :( Engine is MK4 2.0 140hP PSA
you don't bleed the fuel...there is a pump in the tank that pushes the fuel around, just switch the ignition on a few times and the system will self prime
@@alan4x got it all figured out Stupid me forgot to tight down a line from the injector to the common rail everything works flawlessly thanks alot for the video it really helped me alot 😊
