ford 2012 mondeo titanium x sport (Auto) - 2.0 ecoboost piston destroyed - ian j roberts

Hi, while accelerating, engine noise, lose of acceleration. Result no sign of a piston in cylinder 2, whats left of the con rod is dangling vertically from the crank, spark plug smashed. 47000 miles on clock, pretty sure its legit. owned for 2 months, selling ford dealership have been very good so far, can not fault them. No engine faults warnings or codes diplayed prior to failure, coolant display temp normal. Sudden fluid ingress into cylinder would explain this sudden failure without prior signs/ warnings. Possible reduction in mpg over last 2 weeks. Now the questions. Can a head gasket fail suddenly to the extent it causes hydrolok? Could an injector fail to allow liquid fuel to enter cylinder to do the same without a fault code? Material fault in piston or con rod are also possibilities. I have found very little info on 2.0 engine failure of standard tune engine, does anyone have a similar story? For economic reasons the engine in question is not going to be stripped for analysis, which leaves me with the mental anguish of not understanding the full reason for failure. Any on topic answers and info would be very welcome.

ford 2012 mondeo titanium x sport (Auto) - 2.0 ecoboost piston destroyed - Oli rag
I doubt very much whether a leaking head gasket could cause hydraulic lock in the time between compression strokes.
No idea about an injector failure causing the problem but would have thought it's unlikely.

My money would be on material failure.
ford 2012 mondeo titanium x sport (Auto) - 2.0 ecoboost piston destroyed - ian j roberts

thanks oli rag, I tend to agree with you, the head gasket failure is what the dealership is pushing, i too think it is unlikely for the same reasons.

ford 2012 mondeo titanium x sport (Auto) - 2.0 ecoboost piston destroyed - RobJP

Unfortunately, you'll find it's a pretty rare engine in the mondeo, so problems will be even more rare. Happily the dealership is taking car of matters though.

You hadn't driven through any floodwater recently ? That could have caused a hydrolock.

ford 2012 mondeo titanium x sport (Auto) - 2.0 ecoboost piston destroyed - ian j roberts

Thanks robjp, I am interested in any 2.0 ecoboost fitment, not just mondeos, and no standing water at the time. The hydrolok theory has come from the dealership and I am very happy with their reaction to the failure, guess I was lucky it blew up so soon.

ford 2012 mondeo titanium x sport (Auto) - 2.0 ecoboost piston destroyed - Railroad.

The only way the ECM would store a fault code is if it knows there's a problem. If a fuel injector were to stick open how would the ECM know that? The only way it could know is via the O2 sensor which would be reporting the engine running rich. But if the catastrophic failure occurred very suddenly there may not have been time for the ECM to become satisfied that an emission fault existed. If coolant or oil entered the cylinder the ECM would be none the wiser. If the ECM held the injector open or if the wiring was shorted to earth then you would've expected a fault code.

Too many people place far too much reliance on fault codes without really understanding how and why they're generated. Essentially they fall into two categories.

1. A component or wiring either open or short circuit.

2. A mechanical fault whose effect is causing a sensor to report outside of the ECM programmed parameters. These type of faults are much more common, and are not necessarily the fault of the sensor itself.

ford 2012 mondeo titanium x sport (Auto) - 2.0 ecoboost piston destroyed - ian j roberts

Thank you Railroad for your contribution.

If an injector had a flow rate indicator it could be read by ECM couldnt it? Excuse me for saying but my post contains stuff I have been told by Ford representatives, I have questioned the validity of some of these statements. I had hoped to gain an insight from others knowledge if what I have been told could or could not be a viable explanation. Some posts contain useful info and I thank the posters for that. My knowledge of modern motor engines is very limited, if it was a crossflow i would have quite in depth knowledge, but it isnt. I was told by fords that if an injector was faulty it would produce a fault code, that information was duplicated by an independant mechanic. My issue is that I will be returned a vehicle with a new engine, brilliant and many thanks to the dealership. It will have the same ECU/ ECM, I do not know to what extent the fuel system will be replaced. Fitting forged pistons and rod seems to solve the probem (from what I have found online). But does that mean its a OE piston/ rod issue or that by fitting much stronger/ heat resistant replacement masks the actual cause because they can take the condition that damages the OE parts? The facts are that these engines are failing in standard form while tuning companies are increasing output to 350 hp on the original pistons and rods only requiring upgrading to get to 400. That indicates to me there is no problem with the pistons or rods unless the dodgy batch theory is true. The cause of the failure of my and others engines is likely to be something else, something still in my car. Ive seen posts of an individual whos 3rd engine is failing, horror stories are out there and so is the truth.

ford 2012 mondeo titanium x sport (Auto) - 2.0 ecoboost piston destroyed - focussed

Unfortunately, you'll find it's a pretty rare engine in the mondeo, so problems will be even more rare. Happily the dealership is taking car of matters though.

You hadn't driven through any floodwater recently ? That could have caused a hydrolock.

On just one piston out of four? Unlikely.

ford 2012 mondeo titanium x sport (Auto) - 2.0 ecoboost piston destroyed - ian j roberts

Thanks for your input focussed.

You are correct regarding mondeo fitment, I am interested in all fitments of this engine and piston failure related to them.

ford 2012 mondeo titanium x sport (Auto) - 2.0 ecoboost piston destroyed - Big John

Even with a hydraulic lock situation - The piston would still exist - usually conrod deforms and/or small end attachment within the piston is damaged/ cracked. A friend had an old Citroen that suffered a hydraulic incident in the floods a few years ago. Car wouldn't start afterwards due to lack of compression - the problem was the top of the pistons were now lower in the bores! Con rods were badly damaged and deformed - end of a Citroen!

I have seen this before - but way back when on a Cotina mkII. This was caused by overheating of a cylinder bore and eventual melting of a piston. In this case the root cause was a cooling system failure/big hole in radiator - temperature gauge didn't show a problem as the coolant level dropped so quickly the sensor was soon above the water line. I did rebuild this engine but it took me hours to remove the remnants of the old piston from everywhere (including being welded to the cylinder head!) - Suprisingly bore was OK

This can also be just a localised cooling issue because of a blockage or air lock (common on early Fiat Puto's after the coolant is changed as part of a service - it is difficult to properly bleed the cooling system so you can get supposed "head gasket failure" or worse just after!)

ford 2012 mondeo titanium x sport (Auto) - 2.0 ecoboost piston destroyed - ian j roberts

Thank you Big John for sharing your Knowledge, your suggested cause/failure mode would seem to fit what happened to my engine very well. It also fits other failures I have read about with holed or cracked pistons and some sort of localised cooling failure could also explain why piston 4 is often but not always the one that goes. Ford has said it completely redesigned the ecoboost engine due to "rapid improvements in engine technology" I except many changes including an improved head design would fit this reason for change. but the expense of binning and redesigning an engine type after only 4 years that includes totally redesigning the block smells fishy to me. The question now in my mind is what changes have been made to the waterways/ cooling system in the new 2.0 ecoboost engine? Thanks again Big John very interesting post.

ford 2012 mondeo titanium x sport (Auto) - 2.0 ecoboost piston destroyed - craig-pd130

Firstly, sorry to hear about the problem but the dealer seems to be (quite rightly) taking it on the chin: as the fault happened only 2 months into your ownership then it's assumed to have been present or developing at the time or purchase.

In terms of a cause, it sounds to me like a one-off, unlucky failure - either a material fault, as you mentioned, or a related fault. With modern engine management and anti-knock sensors etc, it's extremely unlikely to have been a fuelling or ignition-related problem. We are so used to engines being ultra-reliable, it's easy to forget that catastrophic component failures like this can happen. Such failures are rare, but still possible.

One thing that can happen in high-output turbocharged engines (especially when they are tuned with higher boost, etc) is the piston ring gap can close up because of high combustion pressures and temperatures. If this happens, it puts big stresses on the piston and can crack it above the ring groove, or even cause chunks of the crown to break off. If the latter happens then the engine's internals will become shrapnel pretty quickly. Perhaps #2 cylinder had a piston ring with an end-gap that was too small, or carbon build-up jammed the ring.

ford 2012 mondeo titanium x sport (Auto) - 2.0 ecoboost piston destroyed - ian j roberts

Thanks Craig-pd130 for your post and insight.

Lucky that the consumer law 2015 gives us all protection from this and I am sure dealerships wish to keep their good name for customer care.

Glad you think a fueling/ignition problem is unlikely and although probably rare compared to units sold worldwide this is not a totally isolated event. In a lot of the cases I have found the damage to the piston is not as extreme as it appears to have been in my case, the failure being the crown rim of the piston above the gudgeon pin that your explanation of ring gap could well cause. There is also a fair bit of info about carbon build up and not to conduct any of the de-coke processes around as it fries the turbo. As I have chosen to have the car back, I was given the chose of a refund, I hope it is a design or material issue with the pistons that has been addressed by Fords and solved.

 

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