This fault first happened at 75mph while overtaking. Selected neutral, switched engine OFF / ON now engine started again. All OK at 60 mph but dangerous to risk any faster especially in the outside lane.
Had to fix this quick so purchased a code reader from Amazon but no code was stored. Only way to get a fault code was to drive hard to get car to cut out then pull over and stop WITH IGNITION STILL ON and then connect code reader. Fault code was PO 251 Injection pump fuel metering Control A malfunction.
I suspected fuel starvation so replaced fuel filter. The contents of the old filter was emptied into a jam jar and checked for metal particals which is a sign of faulty injection pump but all OK no metal in the filter. Also blew air into fuel pipe to the tank, bubbles came up in the tank so no blockage there.
Next day had 600 mile round trip job , so purchased BG244 injection cleaner and full tank of Shell V Power. Found car ok on cruise control set to 70 mph but still cut out when trying to hold 70 mph up a hill. Car cut out at least 10 times that day. This still seems to be low fuel pressure. The injector nozzles should be clean by now so can't be that.
On internet found injectors have spray nozzles plus a pressure relief valve which opens to let excessive fuel back to the tank. A common problem is this valve leaks and fuel pressure is reduced in the fuel rail. That seems to be my problem.
Got a quote from a diesel specialist garage at £1300 + VAT = £1560. This included diagnostic test plus injector leak back test and 4 reconditioned injectors plus coding the injectors. Decided not to bother with the garage I will take the injectors out myself and get them repaired.
Removing the injectors on a 2004 Mondeo is the easiest job I have ever done on this car. I followed the Haynes manual. See quick guide below.
1) Remove battery negative lead
2) Wait about 2 minutes for fuel pressure to drop in the rail. Mark the position of the 4 high pressure pipes to the injectors and remove these 4 pipes.
3) Remove the front camshaft cover screws and lift the two triangle metal plates so that you can now unplug the 4 injector electric leads and remove the 4 leakback clips.
4) IT IS VERY IMPORTANT THAT NO SPECKS OF DIRT ENTER THE FUEL RAIL OR INJECTORS so cover the open holes with Duck Tape ( photo 1 )
5) Unplug the electric plug at the right hand side of the camshaft cover using a bent screwdriver to lift the clip inside plug ( photo 2 ). Also disconnect the crankcase vent pipe ( lever this off with screwdriver ). Unclip the wiring loom and position to the left side with the triangle plates still attached to the wiring loom.
6) Lever out the 4 injector oil seals then remove all screws holding the camshaft cover. Remove camshaft cover.
You will now see a brilliant design of an engine. The 4 injectors are in an oil bath and so you will have no problems unbolting them. Most other cars including the expensive ones have the injectors fitted to the outside of the engine block and corrode solid, new engines are needed in some cases but no problems for a Mondeo TDCI.
It is now very important to understand that the 4 injectors have a different 16 bit code on their labels and the engine management has to be told what 16 bit number injector is fitted in what cylinder 1.2.3 or 4. I counted 188.8.131.52 from left to right and marked the injectors with a hacksaw blade one at a time as I removed them and also WROTE DOWN THE 16 BIT NUMBER in a diary for future reference. Each injector must be refitted in the same cylinder after reconditioning. IF YOU GET THIS WRONG THE CAR WILL NOT START. ( photo 3 ).
If you get a rough idle after refitting the reconditioned injectors the engine management computer will have to have this 16 bit number re-entered. When the injector is fitted you will not be able to see the 16 bit number so don't forget to write it down while its out. You can re-code the engine management yourself as injector programmers / code readers are available on ebay at only £16-95 each. Give it a few days to settle down first though, as the engine management has a built-in learning curve and should automatically do minor adjustments itself.
7) Unbolt the 4 injectors, I used a box spanner with long ring spanner very easy. ( photo 4 )
8) My local injector reconditioner company was C.A.E. DIESEL LTD Chingford London 0208 527 8077. John the owner was very helpful with advice. At 10am he had the injectors and I collected at 4pm same day. All injectors were fitted with new leak back valves and spray pattern checked. ( £95 each + VAT ).
9) Keep the protective covers on the injectors and refit them in the correct order also make sure the flat part where electric leads fit is facing front. Use a metal rule to line them up. I found it easier to finger tight first and then turn injector 45 degrees back then tighten with the box spanner. The injector turns as the bolt is tightened so as you cannot see the flat part, its a bit hit and miss but its easy enough to get them tight and lined up. ( photo 5 )
10) Refit the camshaft cover and then the injector oilseals. Dont forget to connect the vent pipe and the electric plug. Refit the high pressure pipes in the same order. Connect the battery negative lead.
I did not replace any oilseal or pipes, all were reused. The Haynes manual advised renewing everything but to me all parts were still good and I checked with Fords they do the same as me.
There is no need at all to bleed the fuel rail. Any air thats inside will be compressed to nothing when the injector pump starts.
I turned the key and it started within 4 seconds. Road tested all OK now and tick-over perfect.
Total cost including VAT was £456 I saved over £1000 and learnt a lot.
Good Luck with yours.