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Common problems with the 4-cylinder engine?


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#1 Nick

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Posted 11 March 2011 - 02:48 AM

I'm updating the Mondeo Mk3 Buyers Guide. Apart from the inlet manifold problem, are there any other areas of this engine that need looking at / be wary of?

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#2 bigcraigy

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Posted 11 March 2011 - 03:16 AM

When i first got my 2.0 petrol it developed a misfire under heavy load which someone on here informed me the HT leads were at fault as its common. They were right too.
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#3 D_C

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Posted 11 March 2011 - 06:42 AM

Coil pack and Aux belt tensioner

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#4 Bo

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Posted 11 March 2011 - 06:48 AM

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Poor piston rings quality on first models (before facelift 2003).
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#5 Nick

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Posted 11 March 2011 - 06:59 AM

Coil pack and Aux belt tensioner


Fail prematurely or people not replacing them when required under the service schedule? (thinking more of the aux belt tensioner)

2011 Mondeo Titanium X Sport (240PS with Powershift)


#6 stevenfairley

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Posted 11 March 2011 - 03:22 PM

cat converter falling to bits

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#7 compuwiz_uk

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Posted 11 March 2011 - 07:58 PM

coil failure is a problem ( big problem if it goes badly as it fries the ECU too which blows future coils till its reconned/replaced )
HT leads generally fail due to being removed from the engine badly when changing the plugs ( easier to grab the wire that the big head of the lead & thus causes damage )

Intake Mainfold can fail at the swirl plates & cause all kinds of trouble ( from high idle & very lean running to broken engine after the metal bar of the swirlies gets eaten )

Aux belt tensioner & also the idler pulley are prone to rattling ( not a service item & can go anytime ( seen from 13-130k miles from em - the belt they work has a very long service interval ( somat daft like 150k miles or something for the petrol 4-pots )

the oil needs checking regular as these engine can drink the oil a wee bit when they start ( mine never used a drop when i got it but as the miles racked up its started using a wee bit ( sometimes catches me out & i get a flicker of the oil warning light under heavy braking & it needs a good couple of litres then :whistling: )

the thermostat is a begger for failure & its a begger to access easily too ( not cheap either as its a combined thermostat.temp sensor & its got some electronic gubbins too to open the stat early to pre-empt an increase engine temp when you floor the throttle etc.

the EGR valves can clog up/become glitchy ( mine often glitch's & brings on the engine management light ( mostly this is when slowing down using the engine & you get the magic combo of around 1700-1900RPM's & 28-32mph ) again expensive to buy & a real begger to change due to stuff in the way


cold re-starting can be a problem ( normally happens after starting the car, moving a small distance & stopping before a re-start a few mins later - closing gate/garage etc ) the workround for it to to press the accelerator just after the engine stops ( there is normally a 'thunk' kinda noise from the intake system when you do this ) & 99% of the time the engine will fire up again the next time without a problem, otherwise its a case of foot flat to the floor while cranking till it starts ( normally a few seconds before it fires )

coolant loss can occasionally take place & from reading on here there is 3 common causes ( plenty more places for it to go but these are the ones that i remember )

Coolant header tank can split on the underside & lo0ok fine when cool ( but when upto temp it expands & leaks )
Thermostat housing cracks ( same expansion prblem so only noticable when hot )
header tank cap lost its seal leading to the coolant boiling away ( these engine run at near on 100degrees normal so it can boil away quickly if the cap seal fails )


all i can think of for now

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#8 marky b

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Posted 08 April 2011 - 12:34 PM

coil failure is a problem ( big problem if it goes badly as it fries the ECU too which blows future coils till its reconned/replaced )
HT leads generally fail due to being removed from the engine badly when changing the plugs ( easier to grab the wire that the big head of the lead & thus causes damage )

Intake Mainfold can fail at the swirl plates & cause all kinds of trouble ( from high idle & very lean running to broken engine after the metal bar of the swirlies gets eaten )

Aux belt tensioner & also the idler pulley are prone to rattling ( not a service item & can go anytime ( seen from 13-130k miles from em - the belt they work has a very long service interval ( somat daft like 150k miles or something for the petrol 4-pots )

the oil needs checking regular as these engine can drink the oil a wee bit when they start ( mine never used a drop when i got it but as the miles racked up its started using a wee bit ( sometimes catches me out & i get a flicker of the oil warning light under heavy braking & it needs a good couple of litres then :whistling: )

the thermostat is a begger for failure & its a begger to access easily too ( not cheap either as its a combined thermostat.temp sensor & its got some electronic gubbins too to open the stat early to pre-empt an increase engine temp when you floor the throttle etc.

the EGR valves can clog up/become glitchy ( mine often glitch's & brings on the engine management light ( mostly this is when slowing down using the engine & you get the magic combo of around 1700-1900RPM's & 28-32mph ) again expensive to buy & a real begger to change due to stuff in the way


cold re-starting can be a problem ( normally happens after starting the car, moving a small distance & stopping before a re-start a few mins later - closing gate/garage etc ) the workround for it to to press the accelerator just after the engine stops ( there is normally a 'thunk' kinda noise from the intake system when you do this ) & 99% of the time the engine will fire up again the next time without a problem, otherwise its a case of foot flat to the floor while cranking till it starts ( normally a few seconds before it fires )

coolant loss can occasionally take place & from reading on here there is 3 common causes ( plenty more places for it to go but these are the ones that i remember )

Coolant header tank can split on the underside & lo0ok fine when cool ( but when upto temp it expands & leaks )
Thermostat housing cracks ( same expansion prblem so only noticable when hot )
header tank cap lost its seal leading to the coolant boiling away ( these engine run at near on 100degrees normal so it can boil away quickly if the cap seal fails )


all i can think of for now



#9 Bin_Man

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Posted 08 April 2011 - 12:50 PM

Coil packs for sure - seem to fail left right and centre.

Contrary to popular belief, the inlet manifold issue is NOT confined to the pre-facelift cars - can happen on any variant/age although I believe the design was improved over production.
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#10 6evil9

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Posted 05 May 2011 - 01:20 AM

I'm updating the Mondeo Mk3 Buyers Guide. Apart from the inlet manifold problem, are there any other areas of this engine that need looking at / be wary of?


Alternator intermitent failures- symptom, battery is flat after half day of not driving

(sounds weird, but it somehow drains the battery)
no battery light comes on.

Thermostat failures




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