MajorCommonEngine

Ford Mondeo: Blocked diesel particulate filter (DPF) and fuel vaporiser failure on short trips

Blocked diesel particulate filter (DPF) and fuel vaporiser failure on short trips is a common engine fault on the Ford Mondeo on the 2007–2014 cars, and we rate it major. Putting it right costs $500 to $2,500 at New Zealand independent workshop rates. Below is what goes wrong, the symptoms to notice on a test drive, where to look, and what to ask the seller before you hand over any money. It is one of 15 documented faults on the Ford Mondeo.

Vehicle: Ford Mondeo
Years: 2007–2014
Fuel: diesel
System: Engine

This page covers the Ford Mondeo as a model. Some faults only affect particular engines or build years — enter a plate below to narrow the list to one car.

All Ford Mondeo faults15 documented faults on this model

What you are looking at

No photograph available

We do not hold a verified photograph of the Diesel particulate filter yet. We would rather show none than show a picture of a different part.

What goes wrong

The Mk4 diesel needs regular longer runs to burn soot out of its diesel particulate filter (DPF). A Mondeo used mostly for short city trips never gets hot enough to clean itself, so the DPF clogs, throwing warning lights and eventually dropping the car into limp mode. These engines also use a fuel vaporiser to help the DPF regenerate, and it commonly sools up and fails around 150,000-160,000km, which then clogs the DPF. A blocked DPF that can't be regenerated has to be cleaned or replaced.

What you would notice

DPF or engine warning light on the dash
Reduced power / limp mode
Poor fuel economy and extra smoke
Cooling fan running hard and a hot smell after short trips

How to check it

Where to look. DPF is in the exhaust under the car; the fuel vaporiser feeds the exhaust ahead of it

Ask how the car has been used - a diesel driven only on short suburban trips is a red flag. On the test drive, get it up to open-road speed for a good stretch and watch for warning lights or a limp-mode power drop. Have it scanned for DPF/regeneration and differential-pressure codes.

Parts involved: Diesel particulate filter.

What it costs to put right

$500 to $2,500 at New Zealand independent workshop rates. That is for this job on its own, not for the car.

An estimate, in NZD, for the repair as normally carried out. What a specific car costs depends on which part has failed and what it damaged on the way — treat this as the floor for a negotiation, not a quote.

Ask the seller

“Is this car driven mostly on short trips or does it get regular longer runs?”
“Has the DPF ever been cleaned or replaced, or the fuel vaporiser renewed?”

Now check the Ford Mondeo you are actually looking at

Everything above is true of the model, and it is free. What it does not tell you is whether THIS car has been looked after: its odometer history and whether the reading has ever gone backwards, whether there is still money owing on it, whether it has been reported stolen, how many owners it has had and what it is really worth today. That comes from the official records for that plate. Enter the plate for the free details, or get the full history and a market valuation from $13.49.

Not sure what you would be paying for? See what a full KickTyres check includes.

Where this comes from

The failure described above is documented in the sources below. The inspection instructions and the cost estimate are KickTyres’ own interpretation of them.

ClickMechanic blog 'Common problems with Ford Mondeo'
Ford Owners Club forum 'Yet another Mondeo with DPF problems' thread
WhoCanFixMyCar 'Ford Mondeo common problems'

Ford Mondeo buyer questions

Is blocked diesel particulate filter (dpf) and fuel vaporiser failure on short trips serious on a Ford Mondeo?

We rate it major and common on the Ford Mondeo. The Mk4 diesel needs regular longer runs to burn soot out of its diesel particulate filter (DPF). A Mondeo used mostly for short city trips never gets hot enough to clean itself, so the DPF clogs, throwing warning lights and eventually dropping the car into limp mode. These engines also use a fuel vaporiser to help the DPF regenerate, and it commonly sools up and fails around 150,000-160,000km, which then clogs the DPF. A blocked DPF that can't be regenerated has to be cleaned or replaced.

How much does it cost to fix on a Ford Mondeo?

$500 to $2,500 at New Zealand independent workshop rates. That figure is for this job on its own. A car showing the symptoms on this page is usually worth either walking away from or negotiating down by at least the repair figure.

Which Ford Mondeo years are affected?

Our research records this fault on the 2007–2014 Ford Mondeo. Build dates move around, especially on imported cars, so treat the range as the years to look hardest at rather than a guarantee either way. The official records tell you the exact build and first registration date for the car in front of you.