Mondeo Mk4 2.0 EcoBoost: Restoration and Upgrade Project

4 November 2022 - Reading time: 9 minutes

A while back, a Facebook listing caught my attention: a facelift Mondeo Mk4 Titanium, 2.0 EcoBoost, accident-damaged, at an unusually low price. Suspicious? Sure. Worth a closer look? Absolutely. The car had light damage on the right side, with deployed curtain and passenger seat airbags. Asking price: €2,800. By the next day, I was in Ploiești, ready to make it mine.

I know the Mk4 platform well - I previously owned a 2.2 TDCi pre-facelift for years and regretted selling it. When the opportunity for a new project appeared, I didn’t hesitate.

History and Initial Repairs

Digging into the VIN history revealed something unusual: this Mondeo began life as a Danish police car and even appeared in a local news article (https://ekstrabladet.dk/krimi/75-aarig-mand-stukket-ihjel/6814701). That sealed the deal.

At inspection, the story had a few “extra details.” The engine had a pronounced knocking sound, downplayed over the phone as “something minor.” After a quick video call with the team at AlexCars (https://www.facebook.com/FordAlexCars), I decided the risk was worth it. We agreed on €200 less, and the car was on a flatbed to Bucharest.

The noise turned out to be a failed balance shaft — quickly resolved by removing it entirely, a known fix among Focus Mk3 ST owners (https://www.focusst.org/threads/delete-your-balance-shafts-already.11081/). Body repairs followed: the right-side doors were replaced and repainted.

first look - not bad

the damage. Again, not too bad

Deep Interior Overhaul

The interior showed every bit of its 235,000 km in police service. I stripped it completely, cleaned and restored every component, replaced scratched plastics, worn seals, and missing fasteners. I also removed the leftover wiring for police radios and auxiliary lights. The leather upholstery was professionally reconditioned by MS Tapiserie Auto (https://www.facebook.com/profile.php?id=100063765574483).

Mechanical Work

A careful inspection found minor oil and coolant leaks — fixed with fresh gaskets and hoses. The AC compressor was rebuilt, and the timing was corrected (apparently the previous mechanic had been a bit optimistic). The Powershift gearbox had a small hydraulic leak, so I replaced a seal, changed filters, and fitted a new clutch pack — not strictly necessary, but it’s now worry-free for years.

The headlights had worn reflectors; I sourced a refurbished set and had them installed with expert help. Light output is now like new.
Fresh: back from the body shop

Factory Spec

From the factory, the car came with:

• 2.0 EcoBoost, 240 PS
• Powershift dual-clutch transmission
• Blazer Blue paint
• Cruise Control
• Standard 6000CD audio
• Convers+ instrument cluster
• Heated windshield
• Light & rain sensor
• Xenon headlights
• Front & rear parking sensors
• Automatic climate control
• Heated, memory seats
• 17″ alloy wheels with TPMS

Built: 11 June 2014, Genk plant.

Phase 1 – Major Upgrades

Once the car was roadworthy, I moved on to upgrades and preventive maintenance:

• Keyless Entry & Go – a 12-hour+ install with major help from DGAlexandru.
• Titanium S center console – with sliding cupholder cover, matching the piano black trim.
• Sync 3 retrofit – from a Kuga Mk3, integrated with Convers+ and the parking sensors, plus a reversing camera and ambient lighting.
• Suspension refresh – Eibach Pro-Kit springs and Motorcraft dampers replaced an odd rear setup with self-leveling shocks.
• Complete bushing and arm replacement
• Brake overhaul – ATE front discs/pads, TRW rears, two calipers, new fluid.
• Factory-tinted glass – replaced the tailgate and door glass to avoid aftermarket film; rear quarter windows to follow.
• Engine bay detailing – added missing covers, deflectors, and clips.
• Summer wheels – 18″ Titanium S alloys with new tires. Original 17″ Titanium alloys were refurbished by Top Wheels (https://topwheelsauto.ro) and fitted with winter tires, TPMS, and new caps.

Sync3 installed

Phase 2 – Fine Tuning & Comfort Upgrades

With the essentials done, I focused on refining comfort, technology, and audio:

• Seats – replaced the leather/textile front seats with heated and ventilated Alcantara units. Rear bench upgraded with integrated booster seat.
• Audio – installed a DSP amplifier from a Mk5 Mondeo, paired with the original Mk4 speakers and subwoofer. The improvement was immediate. A low front parking sensor volume issue was solved by adding the central dashboard speaker and reconfiguring the DSP.
• Subwoofer prep – sourced and installed the required spacers for proper fitment.
• Lane Assist & Driver Assistance – fitted a heated, IR-protection windscreen with integrated camera mount. Added Lane Assist, automatic high beam, and Driver Alert functions.
• BLIS (Blind Spot Information System) – installed radar modules, wiring, and mirrors with LED indicators. Required updated front door modules and rear bumper harness.
• Rear glass – fitted fixed tinted quarter windows, difficult to source but worth the effort.
• Door lights – replaced simple reflectors with illuminated Galaxy door lamps.
• Fueling reliability fix – replaced the fuel tank purge valve, a common 2.0 EcoBoost issue causing second-try starts. Likely placebo, but the car does feel livelier.

Mk5 Sony DSP

New Windshield


Fresh, new look

Parts and Sourcing

Most repair parts were brand new. For retrofits and airbags, I relied on a trusted dismantler (https://www.facebook.com/DJ95VLY) who sourced exactly the right parts, in perfect condition, and verified compatibility.

Status

From retired Danish patrol car to a fully restored and extensively upgraded Titanium Mk4, the car is now mechanically solid, highly specced, and tailored for long-term enjoyment. The project took time, patience, and more than a few late nights — but the result is a factory-look build with modern comforts and OEM quality.

The story isn’t over — but for now, she’s exactly where I want her to be.
On the first trip: with her powerful, blue sisters