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1.6 TDCi - Ford Focus - turbo problems  
1.6 TDCi - Ford Focus - turbo problems - Foxit

My Focus Studio TDCi suffered turbo failure last February. I took it to my garage and they quoted me £1300 to replace and flush out the engine etc. At that time I wasn't aware of the problems surrounding turbos on these models. Apparently the engine is manufactured by Peuoget and is used across a number of different manufacturers cars including the Stuido TDCi.

Last week, just four months later the turbo failed again. My garage then took it to the local Ford main dealer.

When I rang to enquire about the repair, they said they were still having problems getting parts and cleaning out the engine. When I questioned them more closely, I asked what would they do if after this repair the turbo went again.

Their reply was basically nothing - apparently you only get one chance at a warranty claim such as this, and after that you are on your own. The guy in the showroom told me to contact the orginal supplier of the vehicle.

Ford it seems just walk away from warranty claims on an engine which is known to have major turbo problems.

Is this right, can they refuse to repair the turbo again? The car has been serviced regularly, is a 55 plate with 50.000 on the clock - hardly old for a diesel.

Tags: technical issues legal and consumer advice warranties repairs turbochargers

1.6 TDCi - Ford Focus - turbo problems - injection doc

I have written a post about these before! its most unlikley that the turbo failed as in failed ! its caused by a diesel injector seal leaking in the cylinder head. The combustion gases leak past the seal and clog up the oil feed galleries to the turbo, casuing failure.

When a turbo is fitted, its imperative that not only is the sump removed and cleaned but the rocker cover is removed and close inspection of the injector seals is carried out or even replaced ! no 3 usually seems to be the culprit!

When the injector seal is leaking it doesnt effect performance and its not leaking diesel, its allowing carbon directly into the engine ! causing the clogging.

On my files I have some pics of 1.6tdci engines with leaking injector seals causing turbo failure.

So in answer to your question it doesnt directly have major turbo problems, they are caused by defective injector seals !

1.6 TDCi - Ford Focus - turbo problems - Foxit

I appear to be on a steep learning curve here - that is all new to me, I will mention this to the Ford main dealer who are dealing with my warranty claim for the repair of the second turbo unit.

I'm not holding my breath on this one - they are less than enthusiastic about the whole thing.

Thanks for the information.

1.6 TDCi - Ford Focus - turbo problems - Ian D

When the turbo is replaced on these cars it should also be accompanied by new banjo bolts and new turbo feed pipes and I believe a sump clean out, as the root cause of the turbo failure can be loss of oil supply to the turbo and hence a straight turbo replacement will be followed by a another turbo failure.

There was a Ford Technical Service Bulletin to this effect, the engine is a PSA unit but the oil supply was better on the Peugeots hence only problems on the installations in the Focus, Ford dealers/specialists will know this but smaller garages maybe not.

1.6 TDCi - Ford Focus - turbo problems - HyundaiOwnersClubAdmin

The banjos have a gauze in the end of then which block up and Peugeots suffer badly as well.

The problems in my opinion stem from lack of oil changes and incorect draining,filling and grade of oil.

You must not fill the engine to it max mark on the dipstick-- 3/4 is the mark now recommended.

When draining the engine must be hot the oil filter released or removed,oil sucked out of the filter housing, dipstick out and drained for at least 20mins.

My recommendation for oil would be 5w/30 C3

Edited by HyundaiOwnersClubAdmin on 26/06/2011 at 23:14

1.6 TDCi - Ford Focus - turbo problems - Raman

Ian D

Can you send me an email of this "Ford Technical Service Bulletin" concerning the turbo please.

Thank you

1.6 TDCi - Ford Focus - turbo problems - mrs liptrot

Please could I have the Ford technical Service Bulletin concerning the turbo as well please?

My email is michelleharkin04@aol.co.uk

Thanks

Michelle

Edited by mrs liptrot on 09/12/2011 at 13:08

1.6 TDCi - Ford Focus - turbo problems - So the car don't work... It ju

Hi Could you please forward all info regarding this issue, came across your thread while looking for help with an oil leak. so you may have saved me just in time.

Pics would be great too

dw_barnsey@hotmail.com

Thanks again

1.6 TDCi - Ford Focus - turbo problems - Half-a-daily

Our 07 Focus C-Max has just joined the turbo club.

Could you send me a copy of the Ford technical bulletin, please?

It sounds as though it could help my friendly local repairer, who's banging his head on his workshop walls after replacing three turbos on on customer's car and two on another.

My email address is pr at ambergate dot biz.

Many thanks.

1.6 TDCi - Ford Focus - turbo problems - PhilTr

Hi, could you email me the info you got on this too please?
My email address is philtr@hotmail.co.uk

I've just had a turbo failure on my 2009 1.6 TDCi Focus that I've owned for less than a fortnight.

Thanks,

PhilTr

1.6 TDCi - Ford Focus - turbo problems - craign

Hiya Ian, could you send me the bulletin please. I am due to see the sellers mechanic this Friday and will INSIST the measures laid out in the bulletin are done otherwise I want my other car back.

I'm afriad, very afraid now. I should have spent the extra 2k and bought the VW

thanks C

1.6 TDCi - Ford Focus - turbo problems - injection doc

Craign

If you want the details you will need to post your e-mail and please post at the very bottom of all the posts, trailing through takes longer

ID

1.6 TDCi - Ford Focus - turbo problems - giggsy13
Hi I have 2007 Focus Diesel. The turbo blew and I had it towed to local garage and they said they couldn't fix it as no warranty can be provided.

I was forced to tow it to Ford and they say they have completed the ENTIRE technical bulletin and want £2500 off me.

I don't understand what is going on. I didn't authorise the work and I don't have that sort of money. They are now refusing to give my car back and I'm at a complete loss.

Christmas is coming and now I have no car and small family. I literally can't afford to get anymore finance in my life.

How can Ford do this? Do I have any leg to stand on of is that that? The dealer is not interested & thus far has described the bulletin as 'a list of work that needed completing'.

He was also moaning they won't make much money in the job.

If you can mail me the bulletin to neillmartin@me.com I would be really grateful. Also just any general info - what the bulletin is, will the work that's been completed totally cure the car?

Thank you for any help
1.6 TDCi - Ford Focus - turbo problems - colinwhitt

. i have a hard carbon deposit around 1 of the injectors is this the issue you had?? can you please send me some pics and what you did to resolve the issue.

Any info would be greatfully recieved.

cwhittingham80@gmail.com

1.6 TDCi - Ford Focus - turbo problems - susiedh

Hi can you please send me the report on these Turbo problems which I would really appreciate (email suzannedarby@eircom.net)

Without Predjudice:

I have a 2007 1.6TDCI Ford Focus and the turbo on my car went about 4 weeks ago and I had to bring it back to my mechanic who did the original work on it about 2 weeks later, there was a clicking noise and she was pulling so he went through the car again and it was working fine for about two weeks and then she start smoking again and he told me the Turbo had blown again (After less than 4 weeks)

He brought the Turbo back to the supplier who basically said Carbon Particles suspended in the oil supply have caused scoring to the turbo's journal bearing and turbine shaft assembly, carbon has built up on the shaft and because of this build up there is not enough of an oil film to adequately lubricate/seperate the 2 components. Result; total bearing failure and loss of control of shaft motion and because of the failure of the floating bearing system the compressor impellor and turbine wheel have rubbed their respective housings.


I went down to the dealer who supplied the car as an ex demo model and he basically laughed at me and try to push the blame on our local and trusted mechanic saying he did not use the correct oil and he should only be using oil supplied by Ford!!

So on one hand I have my mechanic saying he has done everything right, the motor factors have given me a full report and pictures with the state of the carbon build up which I can only describe as shocking and they are saying that putting a new turbo into the car wont make a blind bit of difference unless all traces of carbon is removed from the engine, that this issue is well known and now I know how common it is from the 126 posts in the last 12 months

So why are Ford able to wash their hands of any responsibility? Has anyone tried to take them to court over this? I for one owe them another €5,000 for this car and I will not be paying another red cent until they acknowledge this is a common problem as I now have a car I cant drive nor sell and they have effectively robbed me of €18,000 because they sold a defective product which they knew about but they also know that this problem is unlikely to occur within the first year which is what the car is covered under warranty and outside of that they can shrug their shoulders and pass the book.

So if you can send me that report I would be most grateful so I can gather as much evidence and put it to a solicitor and see if I can salvage anything from this disastor.

1.6 TDCi - Ford Focus - turbo problems - 123focususer

Hi can you please send me the report on these Turbo problems which I would really appreciate (email suzannedarby@eircom.net)

Without Predjudice:

I have a 2007 1.6TDCI Ford Focus and the turbo on my car went about 4 weeks ago and I had to bring it back to my mechanic who did the original work on it about 2 weeks later, there was a clicking noise and she was pulling so he went through the car again and it was working fine for about two weeks and then she start smoking again and he told me the Turbo had blown again (After less than 4 weeks)

He brought the Turbo back to the supplier who basically said Carbon Particles suspended in the oil supply have caused scoring to the turbo's journal bearing and turbine shaft assembly, carbon has built up on the shaft and because of this build up there is not enough of an oil film to adequately lubricate/seperate the 2 components. Result; total bearing failure and loss of control of shaft motion and because of the failure of the floating bearing system the compressor impellor and turbine wheel have rubbed their respective housings.


I went down to the dealer who supplied the car as an ex demo model and he basically laughed at me and try to push the blame on our local and trusted mechanic saying he did not use the correct oil and he should only be using oil supplied by Ford!!

So on one hand I have my mechanic saying he has done everything right, the motor factors have given me a full report and pictures with the state of the carbon build up which I can only describe as shocking and they are saying that putting a new turbo into the car wont make a blind bit of difference unless all traces of carbon is removed from the engine, that this issue is well known and now I know how common it is from the 126 posts in the last 12 months

So why are Ford able to wash their hands of any responsibility? Has anyone tried to take them to court over this? I for one owe them another €5,000 for this car and I will not be paying another red cent until they acknowledge this is a common problem as I now have a car I cant drive nor sell and they have effectively robbed me of €18,000 because they sold a defective product which they knew about but they also know that this problem is unlikely to occur within the first year which is what the car is covered under warranty and outside of that they can shrug their shoulders and pass the book.

So if you can send me that report I would be most grateful so I can gather as much evidence and put it to a solicitor and see if I can salvage anything from this disastor.

Hi Susie

I have the same problems and cannot afford to throw money at several expensive repairs.

Can you advise if you had any luck with the solicitors and Ford? I would be interested to know.

Many thanks

1.6 TDCi - Ford Focus - turbo problems - xtypemondeo

Hi ID

Hope yoy are not yet getting bored by requests - I, too would be most extremely grateful for a copy of the Ford TSB re the 1.6 tdci turbo.

Many Thanks

Ken

kenncb@googlemail.com

1.6 TDCi - Ford Focus - turbo problems - jack12

hi ken would you happen to have the copy of the ford tsb re the 1.6 tdci turbo

jack-owen-williams1@hotmail.co.uk

1.6 TDCi - Ford Focus - turbo problems - jon t
hi injecion doc

can you email me the tsb please, it looks like i have to take my focus to be looked at. but could do with tsb

jtipton@sky.com

many thanks
1.6 TDCi - Ford Focus - turbo problems - charz1001
Hi,

I realise this thread started a long time ago but is there any chance you could forward me the information on the turbo and what garages need to look at?

We've just bought a second hand focus 1.6 55,000, had it 24 hours and it started smoking and leaking oil out the back. Returned it to the garage who said it was the turbo.. They then had a look at the car and said that turbo in there was already new and it's probably left over oil which needs burning out.

Now I know nothing about cars but this is the second one we've had from them due to the first being faulty. The garage seems incompentent, they didn't even know the car had been fitted with a new turbo so what checks they carry out on them before they sell I do not know. I'm obviously not happy, it has no paperwork for the turbo fitting so I have no idea whether they carried out the correct procedure. I'm at a loss what to do now, as it seems a massive risk. One I wouldn't have take if I had been told that when buying the car.

I you could email me it I'd appreciate it.

Thanks

cdefreitas1988@googlemail.com
1.6 TDCi - Ford Focus - turbo problems - ReemaD

Hi, please would you also email me the Ford Technical Service Bulliten for 2006, concerning the turbo.

Bought our car less than a month ago.. and turbo died 200 miles away from home. Discovered from previous owner that its the fourth turbo to have gone in the car :(

Please would email it to dada_reema@hotmail.com

Many thanks.

Edited by ReemaD on 24/08/2013 at 21:22

1.6 TDCi - Ford Focus - turbo problems - mbirkin

Hi,

I would be very grateful if you could send me a copy of the technical service buletin too.

My '06 1.6 TDCi has had a leaky no 3 injector for quite some time which I recently fixed but I am concerned about the amount of carbon/sludge buildup elsewhere and particularly the turbo. It had the same leak around three years ago which again, I thought I had fixed at the time.

The injector was heavily surrounded by hard carbon type material on the outside which I eventually managed to chip away and clean. It was the removal of the injector that was the real fun part this time as the carbon buildup jammed it in its bore. It took me about 10 minutes of gentle persuation to loosen the injector clamp from the head and injector. The injector itself was really stuck fast. I managed to rotate it very slightly using a spanner, but it was still jammed in a vertical direction. However, I persisted and after about half an hour of carefully rocking the injector slightly from side to side using two very strong screwdrivers, one on each side of the injector to tease it sideways and upwards, it eventually worked its way loose. So if your injector feels like it is absolutely stuck, do persist with it.

Previously when I had disconnected the high pressure pipes from the injectors, the fuel drained back leaving me with major problems of priming the fuel circuit again. This time I had a chat with the local ford main dealer and the informed me that Ford do a kit of protective covers and caps that can be used to protect the fueling components and the caps can seal over the end of the high pressure pipes. Ford sell these kits, but he went out the back to their workshop to get a partially used kit for me FOC. I guess the Ford mechanics use a kit each time and throw away what is not used. There was more than enough left for me in the pack to work on one injector.

I am away on business at the moment, but I will post the part number of the kit when I return.

Thanking you again in advance for the TSB.

Martin.

1.6 TDCi - Ford Focus - turbo problems - mbirkin

Sorry - I fort the email address it's martin dot birkin at virgin dot net

1.6 TDCi - Ford Focus - turbo problems - jon t

hi Ian

Forgive for asking, but can you send me the Ford Technical Service Bulletin, I,m experincing power loss on this model

jtipton@sky.com

Many thanks Jon t

1.6 TDCi - Ford Focus - turbo problems - benji73
Hi ID, could you please email me the tsb via email.

Thank you so much

Ben

Ben@horizonnetworksolutions.co.uk
1.6 TDCi - Ford Focus - turbo problems - ReemaD

Hi, please would you also email me the Ford Technical Service Bulliten for 2006, concerning the turbo.

Bought our car less than a month ago.. and turbo died 200 miles away from home. Discovered from previous owner that its the fourth turbo to have gone in the car :(

Please would email it to dada_reema@hotmail.com

Many thanks.

Edited by ReemaD on 24/08/2013 at 21:18

1.6 TDCi - Ford Focus - turbo problems - ladymechanic

When the turbo is replaced on these cars it should also be accompanied by new banjo bolts and new turbo feed pipes and I believe a sump clean out, as the root cause of the turbo failure can be loss of oil supply to the turbo and hence a straight turbo replacement will be followed by a another turbo failure.

There was a Ford Technical Service Bulletin to this effect, the engine is a PSA unit but the oil supply was better on the Peugeots hence only problems on the installations in the Focus, Ford dealers/specialists will know this but smaller garages maybe not.

Hi Ian,

I know this was posted a while ago and your probably sick of being asked but could you please email me the Ford TSB for this? Thanks

biker19819@hotmail.com

1.6 TDCi - Ford Focus - turbo problems - AMinhas

Hi Ian D,

I will be ever so grateful if you could kindly please send me the Ford technical service bulletin about the turbo issue at:

abbad.minhas@gmail.com

Many thanks for your help in advance and sorry to know that people haven't been as kind as they should have been to you for sharing this information. Most gateful. Thanks again.

1.6 TDCi - Ford Focus - turbo problems - andnorr

Hi ID,

Please can you send me the TSD information. I am having the same problems reported by others

andrewnorris1964@o2.co.uk

Many Thannks

1.6 TDCi - Ford Focus - turbo problems - Auds

Hi Ian D I know its a while since ur post but could u send me this bulletin. Low power and also oil light keeps coming on, plenty of oil in car and pump has been checked and all ok. Bought car about 5 months ago but garage have it last 5 weeks trying to sort it out, turbo has ben replaced twice and still not working. My email address is audrey_darren@hotmail.com. thanks

1.6 TDCi - Ford Focus - turbo problems - ashman
Hi Ian
Can you please email me a copy of the ford technical service bulletin. I have just had a turbo go on me with complete loss of power on my 2007 Ford focus diesel estate tdci. Only bought car last December so not having much luck. A trusting mechanic will be removing sump before replacement. Any photos would also be appreciated if you have any. Has done 130,000 but seems oil changes were not carried out that frequently.

My email is ashlondon06@gmail.com

Thanks for your help.

Regards

Ash
1.6 TDCi - Ford Focus - turbo problems - Raman

injections doc

Could you load up somewhere the pics you have showing injectors leaking and causing turbo failure

Thanks

1.6 TDCi - Ford Focus - turbo problems - injection doc

e-mailed too you

Rgds ID

1.6 TDCi - Ford Focus - turbo problems - dh1983
Is it only the focus 1.6 tdci engine that suffers this problen. I have the fiesta 90 ps unit?
1.6 TDCi - Ford Focus - turbo problems - injection doc

It appears to be a lot more common on the Focus than the other range of vehciles that has the 1.6PSA unit fitted !

One of the turbo remanufactures that i was having a discussion with says the Call for turbo's on the fiesta is amost zero compared with the Focus.

1.6 TDCi - Ford Focus - turbo problems - dh1983
Thats great puts my mind at rest alittle.
1.6 TDCi - Ford Focus - turbo problems - glassback

any help please would be appreciated

i bought a ford focus 2007 tdci 4 weeks ago from main dealer brought it home after a day or so thick white smoke intermittently coming out of exhaust thick white and stayed low down back of car this went on for a week as told by garage to monitor it a week later had to have it back to garage as white smoke was so bad we noticed oil level was higher than it shoud be garage dropped oil out of it and put fresh oil in and said that the oil was contaminated but they didnt know what with but they thought that it was ok now

2 days later it started to smoke again so i called the garage back they said it was probably turbo and that they would get consent to do it from warranty company so off we go again to the garage the warrenty company said they could fit new turbo but told them they must do it a cetain way and fit new pipes they also fitted new sump and drained oil out and refilled twice at the cost of 1000 pound so great its done they said just bring it back 2 days later and get the oil and filter changed again so monday came and back to the garage they changed the filter and drained the oil ready to go

took it home fine thought great 2 days later it started to smoke again though not as thick as it had been and only on over run so we took the engine cover off and had a look round injectors by the way when we smelt the white smoke this time it smelt of diesel so looked at the injectors first two looked dry but the third one looked we tis it likely that both the turbo and the injector seals was at fault could it be anything else other than the seal also it has had a new dpf filter and an egr valve its done 56 thousand miles and the only other thing i can say is the smoke has changed density and its slightly darker with a very slight blue tint to it also only getting 40 mpg which seem very low any help would be great as this is now driving me crazy of course it covered by warranty but however it getting them to find the correct fault many thanks to those who can help in anyway

Edited by glassback on 29/06/2011 at 20:29

1.6 TDCi - Ford Focus - turbo problems - glassback

further update on ford focus so following on from my last post we had the new turbo fitted brought it home fine for 2 days then white smoke coming out of exhaust again so took it back to garage again this time they booked it into a ford dealer so now it was gonna be definatley fixed right,,,,,,,,, wrong so they put it on there machine and say all is working properly with the injectors and only error code coming up is dpf filter needed regenerating even though this new filter has only been on since april they bring it back and say thats it its fixed and it seemed it was went down the road mpg we were getting was 40 mpg most we got out of it was 42 mpg and since we got the filter done it suddenly shot up to 60 mpg so we thought great it must be fixed well we ran it for two days again then today it starts smoking again so now i am going to have to call the garage again tomorrow and tell them its not fixed and i dont know if it ever will be any one else any ideas on this cause it seems nobody knows so they cant fix it all coolant levels are ok the car runs fine no blips no noises nothing but we cant drive a car that continues to throw white smoke out to the point that drivers have to back off cause they cant see and now we felt sure that ford dealer would know but still we have same problem anyone else know what it might be any suggestions at this point would help cause we are running out of ideas

1.6 TDCi - Ford Focus - turbo problems - unthrottled

A failed turbo won't cause white smoke unless the engine has started to runaway on its own oil from a failed oil seal in the turbo. It doesn't surprise me that the new turbo hasn't fixed the problem because the turbo almost certainly isn't at fault.

Originally you had a problem with rising oil levels-almost certainly a symptom of unburned diesel getting washed own the cylinder liners into the sump. White smoke is another symptom of unburned diesel. The fact that the problem is intermittent means it is unlikely to be a loss of compression. Far more likely is that the injectors are not injecting fuel at the right time or at sufficient pressure. Does the engine start ok-from hot as well as cold? Does it run roughly whilst it is smoking?

1.6 TDCi - Ford Focus - turbo problems - glassback

the car is running fine there is no start up problems at all and runs well from cold or hot no noises or hissing sounds nothing even when it starts to smoke it doesnt run any differently ... all i can say is when the engine get warm and after 2 days after it has been in garage then it starts all over again if you put the turbo on then change into 4th gear and let it go on over run then it starts to smoke but it doesnt do it all the time seems like once it starts smoking it takes ages for it to stop all i did notice when it came back from garage is after regenerating filter was that the miles per gallon suddenly went to around where it shold be at between 58 60 where as previously it was at 39 or 40 to gallon all i know is nobody seems to know why ... the car has had just about every new part going and i dont know but someone has said that you cant test the injectors on the vehicle by just bringing up error codes that the injectors need to be taken out and tested on ai machine so maybe that is the next step that they are gonna have to take because everything else has been renewed

new turbo... new sump... all pipes replaces ...oil and filters changed 3 time new dpf filter... new egr valve ... dpf regenerated .... and still it smokes ??

1.6 TDCi - Ford Focus - turbo problems - markd123

I have a ford focus 1.6 tdci and yesterday car lost all power and ended up getting towed to ford dealership. They have advised me that the turbo bearings have gone and they do not recommend fitting a new turbo as the problem will still exist - even after engine strip down and clean (from potential bearng damage)

In order to fix car - they are recommending a new turbo, plus new engine at a cost of 5K.

They could potentially do the TSB detalls and fit new turbo - but would recommend selling car asap as engine damage will have occured and loss of power will return - turbo will fail again.

Would you recommend new engine and turbo

1.6 TDCi - Ford Focus - turbo problems - CH84

I have recently had the same problem. Whilst this car had been fantastic to drive and had only a few minor issues with it (new alternator) I have been severly let down.

On a journey home I felt a loss of power and a whirring noise, I got the car home and rang the garage I usually use and we agreed I would drive it over on the monday after. I didn't drive it all weekend and then proceeded to drive it to the garage on Monday morning. On the way I heard a loud clunking sound and a complete loss of power and pulled it over to the hard shoulder. I knew I could not get it to my usual garage but got it started again and hobbled it to a garage I could see from where I had broken down.

They noticed that the turbo had blown due to this injector fault and proceeded to replace it and the pipes around quoting me £1500. I asked my usual garage who said this seemed reasonable considering the extent of the problem on the model. After the replacement they noticed a clicking in the engine - a piece of the turbo had come off and had found it's way into the engine making a mess of the big end along with other damage. They said it needed a new engine (this was confirmed by my trusted garage) and replacement other parts. The total cost (including the initial turbo work) was £4,100, nearly the value of the car when I bought it but more than it's value if I were to sell it. I realised whilst expensive this was cheaper than selling the car especially considering the garage were still owed £1500 for replacing the turbo. I have decided to go ahead with the engine replacement but can only afford a second hand engine as a recon from ford would be £3500.

As they can not provide a guarantee on some of the work and parts, I want to ensure this does not happen again. Is there anything I can do to ensure this does not happen again - I want to try and get my money's worth out of this car now. I am no mechanic and would have no idea what to do if I were to look inside the engine. Has anyone got any tips as to how I can keep this car running smoothly with no future hitches from now on?

Thanks

1.6 TDCi - Ford Focus - turbo problems - kevinhy

Hi -

I have also suffered a near identical chain of evernts. Bought a 1.6 2008 TDci Focus last year that developed a ticking noise in the engine. I brought it to my local ford dealing who test drove it and reported a failed bottom end bearing - the car sounds like a tractor now (he said it failed during the test drive). Result - the engine needs to be replace.

On examining the engine, the mechanic informed me that the turbo had been replaced before I bought it and that the oil tray had been off. Looking at this thread, I believe that when the turbo went, metal got into the engine.

Can someone *PLEASE* send me the FTB too - I'd like to make sure the replacement engine has the work detailed in that carried out before I fit it.

kev.hyland@gmail.com

thanks

1.6 TDCi - Ford Focus - turbo problems - Raman
injection doc thank you for the email.

1.6 TDCi - Ford Focus - turbo problems - Head Room

injection doc,

my 05 studio focus has had 4 turbos fitted in a year. The last time apparently had everything fitted as per TSB but it still blew. Your post regarding the injector seals sheds new light on the problem. Thanks.

I would be grateful if you could send me the TSB and anything that might help, as i want to sort the problem out before selling the car.

Thanks

Head Room

1.6 TDCi - Ford Focus - turbo problems - injection doc

Headroom,

i will gladly forward information and pics , but will iether need an e-mail address to forward the details too or perhaps a Moderator can intervene and contact me ?

rgds ID

1.6 TDCi - Ford Focus - turbo problems - Badluck

Same problem 15.000 miles .I changed the turbo twice .At first;everything changed bonjos pipes oil...But no way turbo has gone again;Could you send me the pictures of leaking points please?tonaymete@yahoo.com

1.6 TDCi - Ford Focus - turbo problems - injection doc

Replied to your request ID

1.6 TDCi - Ford Focus - turbo problems - Badluck

I agree; i guess something stucking the oil feed,hope this helps.

1.6 TDCi - Ford Focus - turbo problems - Head Room

Injection Doc,

Thanks for the reply, sorry for the delay in getting back to you.

My email address is hroom75@yahoo.com.

Many thanks for the posts and in advance for the info/email.

Regards

Headroom

1.6 TDCi - Ford Focus - turbo problems - injection doc

Headroom

Sent

rgds ID

1.6 TDCi - Ford Focus - turbo problems - kebabular

im am having problems with the turbo failing on my 1.6 tdci Focus.Could you please send me all the information you have on this problem.

any help and info would be grateley appreciated

my email is iag67@yahoo.co.uk

thanks

ian

1.6 TDCi - Ford Focus - turbo problems - zrx

Hi,i have a focus 1.8 tdi 07 plate.

I think my turbo is playing up,when i reach 2000 revs,the engine seems to judder and loss of power like as if it was starving of fuel.

I have been told its the turbo,but it doe"s not happen everytime.

I see on here people are saying injecxtor seals.?

Could you please help,as the warranty has now finished,and we cannot afford a new turbo.

Regards, zrx.

My email..garyliversidge@yahoo.co.uk

1.6 TDCi - Ford Focus - turbo problems - CJH_30

Hi Injection Doc, I am about to get my turbo replaced, as the my mechanic is saying that it is causing my DPF to get clogged. Apparently there is considerable play in the turbo, which is causing oil to get sucked in a spread throughout the engine, including exchaust. So looking at getting both replaced at a massive expense.I would like to avoid the issues outlined here, so if you can send over the TSB and pics to camhawkins@hotmail.com would be great.

1.6 TDCi - Ford Focus - turbo problems - stuggyzx10

Would it be possible for you to forward me the info/bullitin you on Focus turbo probs..looks like i have joined the club, any help and info would be very much appreciated, my email is stuartbogle6@aol.com

1.6 TDCi - Ford Focus - turbo problems - The Bees

Would it be possible for you to forward me the info/bullitin you on Focus turbo probs..looks like i have joined the club, any help and info would be very much appreciated, my email is stuartbogle6@aol.com

I am replyiing to your posting as it seems to be one of the most recent. We too have had three turbos go on us (we live in France however) - the most recent yesterday. I won't go into the details but have not yet made any claims on the manufacturer. Our local Ford man seems to be stumped, bvt no doubt is reading the french forums dealing with exactly the same situation as I write. What I would like to know is did the information from the bulletin help and have your garage/you now resolved the problem. I can't find anywhere on the site a posting saying that the problem has been satisfactorily sorted. Apart from emailing direct all the members with problems - You were a random choice!!

1.6 TDCi - Ford Focus - turbo problems - caldern

Hi injection doc,

Could you please Email me any information you have. nick_6@live.co.uk. I have just taken my Focus to a garage and they have told me that the turbo has seized and that it will have damaged the engine beyond repair due to lack of oil pressure.

Thanks.

Caldern

1.6 TDCi - Ford Focus - turbo problems - Stingray

Hi Injection doc

Just joined the club turbo is knackered. I would appreciate it if you could send me a copy of the bulletin.

xtreem_gb@hotmail.com

Cheers

1.6 TDCi - Ford Focus - turbo problems - restore

I have written a post about these before! its most unlikley that the turbo failed as in failed ! its caused by a diesel injector seal leaking in the cylinder head. The combustion gases leak past the seal and clog up the oil feed galleries to the turbo, casuing failure.

When a turbo is fitted, its imperative that not only is the sump removed and cleaned but the rocker cover is removed and close inspection of the injector seals is carried out or even replaced ! no 3 usually seems to be the culprit!

When the injector seal is leaking it doesnt effect performance and its not leaking diesel, its allowing carbon directly into the engine ! causing the clogging.

On my files I have some pics of 1.6tdci engines with leaking injector seals causing turbo failure.

So in answer to your question it doesnt directly have major turbo problems, they are caused by defective injector seals !

Hi injection doc could you please email your info

simonpick@tiscali.co.uk

1.6 TDCi - Ford Focus - turbo problems - injection doc

Sent

Rgds ID

1.6 TDCi - Ford Focus - turbo problems - rayb

I to am having problems with the turbo failing on my 1.6 tdci Focus.Could you please send me all the information you have on this problem.

My email address is ray.biggs@hotmail.co.uk

Many thanks

Regards

Ray

1.6 TDCi - Ford Focus - turbo problems - darragh15

hi injection doc

could you please send me the tsb on theford focus 1.6tdci turbo/injector seal failure and flushing

i have the same problem with my 2006 car with 86,000 miles.

my email is darraghconnelly@gmail.com.

thank you

regards

darragh

1.6 TDCi - Ford Focus - turbo problems - HansW

Hi everyone

Thanks for the valuable information on the Turbo, I just checked mine in the partner van I bought this afternoon, and the play is far to great, --- so this will be replaced before its going up in smoke.

At the same time I want to make sure, that there is not injector seal issue.

Would it be possible to get a copy of that document?

send it to hans_weitbrecht eat Yahoo.de

this would be great, Thanks, Hans

1.6 TDCi - Ford Focus - turbo problems - ReemaD

Hi, please would you also email me the Ford Technical Service Bulliten for 2006, concerning the turbo.

Bought our car less than a month ago.. and turbo died 200 miles away from home. Discovered from previous owner that its the fourth turbo to have gone in the car :(

Please would email it to dada_reema@hotmail.com

Many thanks.

Edited by ReemaD on 24/08/2013 at 21:20

1.6 TDCi - Ford Focus - turbo problems - neilmac

Hi, I also have had the problem with turbo failure just after buying the car, and I am currently stripping parts of the engine to clean them, the plastic manifold on the top of the engine is particullarly full of carbon deposits, which I am currently soaking in Jizzer. Can anyone tell me how I can clean the 'tubes/ports' which follow on from the plastic manifild into the cylinder head? These have about 2-3mm of oily carbon deposited inside them. I have a photo (not sure if I can attach it?).

  • Having removed the injectiors one in particular was covered in soot and carbon. I will be replacing the seals.
  • I also noted the clamp bolts were not very tight
  • .Any info on cleaning out the 'tubes/ports' would be gratefully accepted as the car is on the drive and its a b***** riding my bike to work in this wind!
  • Thanks

1.6 TDCi - Ford Focus - turbo problems - william m
Could u please send me the info as wel as i have the same problem in my focus 1.6tdci also 4 times in ford garage and has to go again !
1.6 TDCi - Ford Focus - turbo problems - Kimmy1977

I have written a post about these before! its most unlikley that the turbo failed as in failed ! its caused by a diesel injector seal leaking in the cylinder head. The combustion gases leak past the seal and clog up the oil feed galleries to the turbo, casuing failure.

When a turbo is fitted, its imperative that not only is the sump removed and cleaned but the rocker cover is removed and close inspection of the injector seals is carried out or even replaced ! no 3 usually seems to be the culprit!

When the injector seal is leaking it doesnt effect performance and its not leaking diesel, its allowing carbon directly into the engine ! causing the clogging.

On my files I have some pics of 1.6tdci engines with leaking injector seals causing turbo failure.

So in answer to your question it doesnt directly have major turbo problems, they are caused by defective injector seals !

Hi injection doc could you please email your info

simonpick@tiscali.co.uk

I have same problem as you guys with my 2005 1.6 tdci focus could some one email me the tsb from ford if they have it ?

1.6 TDCi - Ford Focus - turbo problems - Kimmy1977

I have same problem as you guys with my 2005 1.6 tdci focus could some one email me the tsb from ford if they have it ?

1.6 TDCi - Ford Focus - turbo problems - endriu

Hi Injection doc,

Can you send me the pictures as well.

My email is: endriu4@hotmail.com

Many thanks,

Endriu

1.6 TDCi - Ford Focus - turbo problems - Olliebr

Hi Injection doc,

Can you send me the pictures as well.

My email is: olliebr@hotmail.com

I had my Injector seals replaced about 6months ago in my Fiesta 1.6tdci 80,000miles. Today I had no noises or smoke, but the car is hardly pulling above 2500rpm, wont pull in 4th or 5th, and doesnt feel like the turbo is working, if anything it feels like the brakes are on, so ill take it to the local garage tomorrow am :-(

Many thanks,

Olliebr

1.6 TDCi - Ford Focus - turbo problems - Kevin47

My focus 1.6 tdci brokedown six weeks after purchase It just lost power first then it went slower and slower till I had to stop. Garage claims it's only a turbo but I saw leak from injectors as well, so I think it make sens what injection doc said

Injection doc could you please email your info

kppiech@gmail.com

Many Thanks

1.6 TDCi - Ford Focus - turbo problems - dadbif
In light of their popularity, could ID's TSB and pics be posted as a sticky in technical?
1.6 TDCi - Ford Focus - turbo problems - Badluck

Same as mine.

1.6 TDCi - Ford Focus - turbo problems - ron@hj

Hello injection doc. Very interesting information on turbo replacement. Would this be the same for a 1.8 TDCI (2004) ? Last week my car went into white smoke screen mode and then within 10 seconds died. Got towed home by my neighbour but now it will not start. Turns over OK and diesel is getting to the injectors. A mechanic who works at Fords told me that the turbo had gone, but would this stop the engine from starting ? Anyway, I'm going to put a new turbo on but obviously don't want to kill it quick by not cleaning up the engine and checking the injector seals, if the same applies to a 1.8. Also, could you send me a copy of the TSB, please. My email is ron.havill@yahoo.com. Many Thanks in advance and keep up the good work. Ron

1.6 TDCi - Ford Focus - turbo problems - brianw119

Hi, thinking of buying a ford focus, but this issue with the turbo is putting me off.

Is there anyway I can buy a focus and be sure the turbo wont blow up on me?

Do the 1.8 diesels have this issue?

1.6 TDCi - Ford Focus - turbo problems - IanParris

Hi Injection doc,

Great work and thanks.

Could you please send me the tsb as well?

Also I had a failure of Power steering coupled with the ESP lights coming on on the dash, any ideas.

Its a 2006 1.6DCI focus.

Thanks in advance.

ihparris@hotmail.com

1.6 TDCi - Ford Focus - turbo problems - shurdycarper

hi i am also having problems with my 06 focus, could you please forward the details to me also and it would be greatly appreciated! email is benji_steger@hotmail.com, thanks again

1.6 TDCi - Ford Focus - turbo problems - RDelaCourt

Hi there, i like many have expericed problems with my turbo. I have a 2005 mk6 fiesta TDCI and the blew, since then i have gone though three turbo units! any advise? also would you be kind enough to send me a copy of those pictures you mentioned.

Regards

1.6 TDCi - Ford Focus - turbo problems - injection doc

Thats because whoever is fitting the turbo's isnt doing their job correctley.

there is no excuse whatsoever for three failed turbo's !

any decent garage wouldnt fit more without further investigation

1.6 TDCi - Ford Focus - turbo problems - tikkytoe
I am having terrible trouble with my ford main dealer turbo failed which was replaced and then 2000 miles later failed again they replaced and told me to get rid of the car as they don't know what is causing into fail it has now failed again after 114miles they are saying they will look at it but it will cost me and they did say to get rid!!! 114 miles and it went!!! Could you please send me the doc you have mentioned thanks
Email: tikkytoe@aol.com
1.6 TDCi - Ford Focus - turbo problems - bednall1982

Can you please email the details regarding the injector seal please as im buying a focus 1.6 tdci due to my scenic dying on me and i want to check injector seal you are on about as soon as i get it. Cheers My email is bednall82@googlemail.com

Edited by bednall1982 on 28/09/2012 at 21:45

1.6 TDCi - Ford Focus - turbo problems - mr_focusCmax

There is almost no one says anything about mileage. My focus c-max has driven 160,000 km (Norway) and now is starting to fail. Black clouds of smoke while the engine loses some force. This lasts only a few seconds. Happens several times a week. Some black smoke when I accelerate. Somewhat increased fuel consumption. There are people who say that this turbo will not cope with more than 160000 km.

1.6 TDCi - Ford Focus - turbo problems - Ryme

Hello and thank you for spending so much time advising all of us here about the injector seal failure on the Ford Fiesta 1.6TDci and subsequent potenial failure of the turbo.

When I'd seen and smelt fumes in the cabin of the car last Summer (August 2012), I printed off and took this "Honest Jon/Ijection Doc" forum thread to the garage and asked them to inspect the injectors as part of the annual service.

However, they gave me the car back but palmed me off with some excuse that the injectors are not to blame and that the exhaust was to blame.

The exhaust (cat) was faulty, fair enough. However, I was not wholly convinced but what else could I do?

Anyway, today (15th Feb 2013), some 6 months after the above service, I was driving along when my good lady said "Look! Quick! Smoke!" Indeed, a plume of smoke was coming from the hood and the engine power dropped right off. I got out and opened up the bonnet to find a column of exhaust or unburnt diesel fumes shooting out of injector second from the right! Argh!

Immediately I remembered this thread, came home and Googled it and noted many others had since experienced the same, unforunately.

Therefore, I am not sure if you are still responding to requests but if you are, could I ask you if you can please send the said Ford Service Bulletin which has the service proceeedure to replace the injector seals and the remaining cleaning process? If you can help, I should be most grateful as I will do the repair myself. My Email address is at the foot of this mail.

I am going to do the repair myself as this vehicle has been nothing but problems since new. So far it has had a new gear box, new clutch, air mass detector, radiator, two wheel bearings, whole new exhaust (inc cat) and now what may be the turbo!

I have the car serviced every year and use Castrol Magnetec oil with proper filters changed at the same time and sometimes changed twice a year too. The car has done 103,000 miles and is a '57 plate. I am not optimistic the turbo has survived but will give the seals a go and try it out from there. Else, the car will have to be scrapped.

If you can help with supplying the Ford Service Bulletin, I should be most grateful to you for your help,

Kind regards,

Mark

Email address:-

ryme.intrinseca1962@gmail.com

That is:-

ryme dot intrinseca1962 at gmail.com

Thanks again,

Mark

1.6 TDCi - Ford Focus - turbo problems - stucat

another lost soul in need of the tsb and any other info on dealing with this .

Ive just bought an 05 focus 1.6tdci that has already had a new turbo fitted and also has a leaky no.3 injector. reading this thread has already taken the fun out of owning this car.

please send tsb to mackenziestu@aol.com

many thanks in advance,

Stuart

1.6 TDCi - Ford Focus - turbo problems - gjt

Hi Injection Doc,

Also having turbo problems on a 1.6TDCI C-Max.......please could you send me a copy of the technical service bulletin? gregthompson.gt at googlemail.com.

Thanks in advance

1.6 TDCi - Ford Focus - turbo problems - Dragos

Hy injection doc,

I'm interested on your infos about ford focus turbo. I have a 1.6 TDCI Focus, 2008 model with one turbo replaced. If you can send me, my E-mail is dragos_angl@yahoo.com

Thank you very much

1.6 TDCi - Ford Focus - turbo problems - ford focus 1,6 tdci

Hello Injection doc,

I reed this forum to find help to my problem with 1,6 TDCI Ford Focus.I dont start complean

my problems, its allready done by lot of Ford owners before in this forum.If its possible

please send me this TSB e-mail: mati@exportbridges.com

I will be very grateful.PS I am from ESTONIA

1.6 TDCi - Ford Focus - turbo problems - mlh681

Injection Doc,

Just to thank you for the invaluable information posted here.

Same old story, boy buys 1.6TDCI Estate, routinely services it, takes it to 100,000 over 5 years with absolutely no issues and then experiences a "very interesting" 12,500 miles... and I would suggest that every 1.6TDCi owner must buy something like a "D900" OBD scanner (£25-30 from a well-known internet trading site) whenever a car moves into six-figure mileage territory.

I was already aware of this thread and so immediately after smelling fumes in the car I dropped it with my local independent for attention. £200 and 4 new Injector Seals later no smell in the cabin, and my independent confirmed that because we caught the problem very early the turbo is not at risk anytime soon. (We also changed the front suspension bushes due to vibration at A-road speeds; a very common fault apparently; the rears are an MoT advisory, but no need for action to be taken.)

The only thing I would add as a general comment is that after 105,000 miles of returning a true 52mpg the MIL light illuminated due to perished DPF sensor hose (so an easy fix was available but I chose the more challenging option given the high mileage the DPF had covered). So, 'correcting' the DPF resulted in 56mpg and a much more driveable car (low revs, towing, etc.). Similarly the EGR started to stick at 110,000 - so again, 'correcting' the EGR has resulted in an increase to a true 58mpg over the past 2,500+ miles. My wallet is beginning its recovery already!

Hopefully my driving style (rev-matching when going through the gears etc.) is sympathetic to the DMF, as that seems to be the next thing on the big list of expected 1.6TDCi 100k+ failures. That said, it is definitely worth giving the Engine a good work-out at least once a week (I suspect that I also experienced the effects a sticky turbo actuator for a couple of weeks too after a little too much constant-speed cruise control on the Motorways; although I mainly blame the faulty EGR)!

The good news is that car is now beyond 112,500 and is performing better than ever - And I was -**very**- close to spending an awful lot more to change it, which was never part of the plan... I want at least another 150k out of this car!

And Injection Doc - Thanks once again; if you're anywhere in the South West, I owe you a very very large pint!

Cheers,

M

Edited by mlhindley on 23/04/2013 at 08:53

1.6 TDCi - Ford Focus - turbo problems - Ian with a dodgy motor...
Hi ID,

I thought I'd dodged a bullet by avoiding the dreaded scenic 1.5 dci, when I decided to go for a trusty Ford 1.6 tdci....

How wrong..

The car had already done 97k, so the 1500 that I put on it in 2 weeks pushed the turbo over the edge.. Had a warranty in place, so not an astronomical figure to replace the turbo, feed pipes etc, but I saw your thread and the amount of people with the same problem and thought it would be prudent to ask you for the technical email to make sure I get everything done before it goes again...

I've got her booked back in for the seal repairs, but if there's anything else I should ask them to do whilst she's in, I'd more than appreciate any info you could send me..

And, as an aside, if I get the work done that's needed, will the 1.6 engine comfortably get up to the 200k mark??

Thanks for your help...

Iandforshaw@gmail.com
1.6 TDCi - Ford Focus - turbo problems - jack12

hi their please could you send me over the infomation for this please

kind regards jack

2006 2.0 TDCi - Ford Focus - turbo problems - 2LANIE

I HAVE A 2006 2.0 TDCi - Ford Focus, I NOTICED WHEN I ACCELERATE IT HAS A WHISTLING SOUND (HISSING NOISE) AND ITS A BIT SLOW WHEN PICKING UP;

ALSO IN THE MORNING WHEN I RUN THE ENGINE, THERE ARE EXHUAST FUMES UNDER THE HOOD; THE FUMES SIM TO BE COMING FROM THE OUTLET MANIFOLD; BUT STOPS AS SOON AS THE ENGINE WARM (THE CAR ONLY SMOKE WHEN I START IT IN THE MORNING)

I WANT TO TAKE IT TO THE MECHANIC KNOWING WHAT COULD BE THE PROBLEM AND THE BEST WAY TO FIX IT.

Can you ALSO send me an email of this "Ford Technical Service Bulletin" concerning the turbo please. Thank you

cool.2lanie@yahoo.com

1.6 TDCi - Ford Focus - turbo problems - Ork

I have a suspected blocked EGR valve and the turbo is much reduced and not really boosting till 3500rpm. I have little hope that the turbo isnt badly damaged but going in for discussion with the local dealer. If reconditioning is possible i want them to cover all the bases. Have them check the injector seals, replace the feed pipe etc. Can you please email me a copy of the relevant TSB for the replacement turbo. So i can go in prepared for a battle.

ralfkenworthy at hotmail.com

2008 reg 82k.

Many Thanks

1.6 TDCi - Ford Focus - turbo problems - shaunppl

Can you please send ne a copy of the Ford TSB for the 1.6 TDCi 2005 version

shaun@exeterflyers.co.uk

1.6 TDCi - Ford Focus - turbo problems - batley

Hi. I have joined this turbo clud also. Coyuld you please forward the information regarding correct replacement and also prevetative measures for future if there are any.

Many thanks Steve

stephenbolt@hotmail.co.uk

1.6 TDCi - Ford Focus - turbo problems - shawaj

Hi Injection Doc,

Any chance you can send me the docs also?

Just had a turbo blow on a 1.6 TDCI focus, 116,000 on the clock.

Any info you have on how to prevent this in future etc would also be greatly appreciated. I did notice MPG going down to around 40 over recent months...would this be related?

Shawaj at gmail dot com

Thanks a lot!!

1.6 TDCi - Ford Focus - turbo problems - Sidetrak

Hi ID,

Hope you are well

Please can you send me the TSD information. I think my turbo may be on the way out. I hope this info is still availble

jcfuntimeuk at gmail.com

Many Thanks in advance

Cheers

1.6 TDCi - Ford Focus - turbo problems - Its Skippy
Please could you explain how the leaking injector seal lets carbon directly into the engine?
If carbon is going underneath the seal, would it not just seal itself back up in time?
Any idea why it always seems to be number 3?

Has anyone actualy taken Ford on? This is obviously a design fault.
Even if its a PSA engine, its in a Ford, so they are accountable.

1.6 TDCi - Ford Focus - turbo problems - chrismarsden95

Hello.

Ive had my 2007 tdci focus for 6 days and having the turbo problem. although the dealer who sold it to me said he'd get it repaired I would like any info that may help. Would it be possible for you to email it to me? chrismarsden95@googlemail.com

Many thanks

Chris

1.6 TDCi - Ford Focus - turbo problems - eltrev

Hi All wished i'd seen this post earlier just bought a focus estate test drove it all felt lovley on the way back from bristol had a sudden loss of power limped the car all the way home to be told the next day the turbo had gone, i've read some of the stories on here but i was told by this mechanic that these are very difficult to fix is this true because a ford trained mechanic i've been in touch with say that it can be fixed so confused,

may i have a copy of the ford service bulletin please i really need to get this fixed?

elterv@blueyonder.co.uk

Thanks

1.6 TDCi - Ford Focus - turbo problems - MikeHenderson89

Hi ID, any chance you could get all your relevant bits over to my email, have a 57 plate turbo diesel focus, just replaced the DPF and turbo only to stumble across your post. Photos would be helpful if possible. Email is Mike-Henderson@Hotmail.co.uk

Thanks for your help, really appreciate it. Mike

1.6 TDCi - Ford Focus - turbo problems - prasanth

my fiesta tdci is having same problem....i already changed turbo but it shows same problem again..let me know how much it will cost if i am going to change the injector.

1.6 TDCi - Ford Focus - turbo problems - mahonm

Have just bought ford focus 2010- 97000 miles found this article and hope to take preventive action would appreciate TSB article as I can present it to my mechanic also would like to see pics all help very much appreciated, mick on

michaelpjmahon@gmail.com

Thanks

1.6 TDCi - Ford Focus - turbo problems - mrs liptrot

Hi

I have had the same problem can you give me any advise?

Thanks

Michelle

1.6 TDCi - Ford Focus - turbo problems - MikeTorque

When was this issue fixed by Ford in their new car builds? (i.e. what year or registration should we expect to not see this problem occuring)

1.6 TDCi - Ford Focus - turbo problems - caldern

Hi injection doc,

Could you please Email me any information you have. nick_6@live.co.uk. I have just taken my Focus to a garage and they have told me that the turbo has seized and that it will have damaged the engine beyond repair due to lack of oil pressure.

Thanks.

Caldern

1.6 TDCi - Ford Focus - turbo problems - thunderbird

We had a 2005 1.6 TDCi and never had a problem.

1.6 TDCi - Ford Focus - turbo problems - MikeTorque

A couple of turbo failure prevention and longevity tips worth noting :

It's absolutely vital that quality fresh oil is kept circuiting inside these engines. The sump is fairly low capacity and so doesn't hold that much oil. The oil can become very thick black within a few thousands of miles, hence the oil will require changing asap once in that state (preferable sooner) otherwise wear will occur throughout the engine with the turbo being most vulnerable.

Also the engine should never be turned off until the revs have fallen back to idle and the turbo has had a few seconds to run down, otherwise there is a risk the oil will flow off the turbo bearing and premature wear and eventual failure will result.

1.6 TDCi - Ford Focus - turbo problems - Badluck

rapidshare.com/files/3668332251/Injector_seal_leak...g

rapidshare.com/files/2761452098/1.6tdci_Turbo_fail...f

1.6 TDCi - Ford Focus - turbo problems - grimep

Nasty. I was aware of the general issues with this engine but not the cause - effect between malfunctioning injectors and oil degradation. The pic of the injector shows it covered in muck, is it possible for a dodgy injector to look clean on the outside? Are there other ways of telling that damage is being done, without actually dropping the sump?

1.6 TDCi - Ford Focus - turbo problems - mpgMad

I note this thread with interest because our C-Max 1600 TDCi turbo failed a couple of months ago. The Ford mechanic explained most of the issues noted above, even explaining that he was involved in some of the original fault finding and attempted cures with Ford. It is important to wash out the sump because as he explained the sump plug on this engine is slightly higher than the bottom of the sum causing debris to build up even after an oil change, which may eventually get drawn in / pumped around the engine and blocking the small filter in the vac pump or block the oil pipe attached to the Turbo. It cost me almost £2000 to have the 2005 80K mile turbo replaced only to be told that they could not guarantee a repeat. The local Turbo Specialist, Essex Turbo's, refused to touch the unit "because of the known faults leading to premature failure". My complaint to Ford met with a very poorly written response saying that there are no problems with the engine and a build up of carbon in the oil probably caused the failure. They would not comment on the fact that Citroen have written a report and special procedure that must be followed when these failures occur in their vehicles. I suggest you advise your friends to keep well clear of all Fords with this engine. The local Ford dealer explained the problem is not yet resolved but the number of incidents is reducing the newer the vehicle. Could this just be due to less miles and a cleaner engine? The answer was "no because some reps 1.6 TDCi cars with 120K on the clock come through with no faults but they are getting a bit rattly by then". I will keep on at Ford and then try Watchdog and Which. The more complaints the merrier I say. Food for thought: How many people purchase a car that is say 4 to 7 years old for a few thousand £. Do you then want to pick up a £2K bill for a turbo, £1K for a new clutch and still not know if the turbo/engine will last?

Edited by mpgMad on 10/03/2012 at 17:13

1.6 TDCi - Ford Focus - turbo problems - kaluki

Hi, I have had this problem with my 55 focus. bought it back in oct 11 turbo failer jan 2012, Bought frm dealer, after a great deal of investigation and reading of forums like this, I decided to claim my momey back through the sale of goods act for the car, as car was not of satisfactoey quality, but I had already purchased a new turbo. the dealer did not reply to any of my emails or the 3 letters sent by recored post, but he did contact me after the letter from the small claims court! Any way 4th may they fitted a new turbo, and regenerated the dpf, new oil feed pipe, oil filter and oil.. According to the paper work i got with the new turbo the job should have taken 5-6 hours with a whole list of new parts that were also needed. the job took them 1 hour 50 mins accoding to invoice i have a copy of... Yesterday, guess what........ turbo goes again ! Can any one email me the ford TSB for this engine fault, as trying to gather as much evidance as i can to carry on with small claims court, I would be very graeful.

thank you in advance

email is jillsdexter@aol.com

1.6 TDCi - Ford Focus - turbo problems - injection doc

Done, its not a Ford TSB but sent anyway.

1.6 TDCi - Ford Focus - turbo problems - kaluki

Thank you!

1.6 TDCi - Ford Focus - turbo problems - stuggyzx10

Would it be possible for you to forward me the info/bullitin you on Focus turbo probs..looks like i have joined the club, any help and info would be very much appreciated, my email is stuartbogle6@aol.com

1.6 TDCi - Ford Focus - turbo problems - injection doc

stuggy ZX10

Done

1.6 TDCi - Ford Focus - turbo problems - djaychela

Injection Doc - I would greatly appreciate it if you could email the information to me too. My email is djaychela (at) gmail (dot) com.

Thanks

Darren

1.6 TDCi - Ford Focus - turbo problems - injection doc

Done

1.6 TDCi - Ford Focus - turbo problems - djaychela

Thanks - hugely appreciated!

1.6 TDCi - Ford Focus - turbo problems - gary2213

Injection Doc - I would greatly appreciate it if you could email the information to me too. My email is gazmann2213@googlemail.com

many thanks

1.6 TDCi - Ford Focus - turbo problems - robsurf70
Hi injection doc-I would also really appreciate the info. Also any tips or advice on changing the injector seals,such as what to use to clean the injectors and the area around them, how tight to do the bolts for the injector clamps etc any help would be greatly appreciated.

Rob

Robsurf70@hotmail.com
1.6 TDCi - Ford Focus - turbo problems - robsurf70
Injection doc, hi would really appreciate the info as well please. Also any advice or tips on when replacing the injector seals, such as what to clean the injectors with,how to clean around the injector holes,how tight to do the clamp bolts,I ve done cam belts amongst other jobs fairly easily so I'm pretty confident in doing it myself. Any advice would be great

Robsurf70@hotmail.com
1.6 TDCi - Ford Focus - turbo problems - Kieran23

Injection doc - can you send me a copy of the TSB also please?

kierano_23@rocketmail.com

I did a bit of (admittedly minor) research before selecting the Ford Focus 1.6 TDCi as preferred car and was delighted with handling, etc. until two turbo changes later. Why does this issue not come up with large red notices on main reviews of this car?

1.6 TDCi - Ford Focus - turbo problems - madf

Why does this issue not come up with large red notices on main reviews of this car?

Most motoring journalists never own a car and as for driving a three year old one?: Please wash your mouth out.

After all they rarely refer to real life but talk about things really important like 0-60mph times.. Some of them are little better than semi literate boy racers and the rest are illiterate:-)

Edited by madf on 22/07/2012 at 21:43

1.6 TDCi - Ford Focus - turbo problems - Jon Chaloner
Hello all,

I think as of 4 hours ago I joined the club...!

"Engine Malfunction" has appeared and cannot really get upto 3000RPM.
The turbo is not at any point kicking in.

I think this is where I would kindly ask that injection doc; please could you drop me that TSB email?!

Jon_chaloner (at) hotmail.co.uk

Thank you in advance!
1.6 TDCi - Ford Focus - turbo problems - grimep

Jeez, sorry to hear that. Have yuo stopped and restarted? Sometimes the control unit gets a duff message and puts the car into limp-home mode, which basically feels like you are driving without a turbo. Happened to me 3 times over the last year, but the fault code didnt stay in memory as it wasn't confimed by the system, and was cleared next time I started.

If you pull the air intake pipe off the turboyou should be able to feel whether the impellor is ok

1.6 TDCi - Ford Focus - turbo problems - Jon Chaloner
I did the lazy thing and limped it to dagenhams... They mentioned the codes have come up to say something has happened to my Diesel Part' Filter! In a way it's a releif as it means no turbo headaches! But they're still pricey I have heard. What causes them to go? I know short journeys is the main culprit but I do best part of 500 miles a week, so can't be down to that.

I'll see what dagger's say tomorrow - whether they can confirm it's actually that, that has gone.

...to be continued
1.6 TDCi - Ford Focus - turbo problems - dankelly

Hi Injection Doc, could i please have the info as well? I may have joined the club this morning! I know my turbo has been changed once before i bought it 6 months ago, and now im having the 'engine systems fault' warning, and the car is sluggish. It will get beyond 70-80 mph but takes a while to get there. Thanks anyway

Dankelly@fsmail.net

1.6 TDCi - Ford Focus - turbo problems - fletcham

Hi Injection Doc,

I would be very grateful if you could also forward me the info as well. I have a Focus 06 1.6 TDCI and it too has just suddenly started to wheeze and has lost power. It has been diagnosed as the turbocharger. Can't believe it happened on the day I was going to list it on autotrader in immaculate condition, only 49K and with 12 months MOT, just my luck!

Please see my email address below, and thanks in advance.

Brian

fletcham@f2s.com

1.6 TDCi - Ford Focus - turbo problems - injection doc

I am astonished at just how many e-mails I have sent as requested.

Worst of all is I have only ever recived 3 thank you's for the effort.

1.6 TDCi - Ford Focus - turbo problems - kaluki

I have gone to watchdog with this one.

My question to them

Why are ford ignoring this TDCI issue!

www.bbc.co.uk/watchdog/gotastory/

give them your story, Ford may have to answer to them!

1.6 TDCi - Ford Focus - turbo problems - unthrottled

That is very disappointing.

1.6 TDCi - Ford Focus - turbo problems - gordonbennet

That is very disappointing.

but not surprising, i'd have got the 'ump long ago with ungrateful chumps and spat me dummy out, Injection Doc is made of strong stuff.

1.6 TDCi - Ford Focus - turbo problems - madf

It's amazing how many people cannot even be bothered to search for something so a "Thank you" is out of the question.

Like many people who get summat for free- ungrateful.

1.6 TDCi - Ford Focus - turbo problems - Collos25

I so much agree with you.

1.6 TDCi - Ford Focus - turbo problems - emjlc02

Oh no ive joined this group as well. What did everyone do and if possible can you email me this service info please? It waould be a massive help. madveryhappy@hotmail.co.ok

1.6 TDCi - Ford Focus - turbo problems - injection doc

emjlc02

Sent e-mail but returned !

1.6 TDCi - Ford Focus - turbo problems - emjlc02

Hi thanks for your time, sorry my mailbox had got full. Please can you send it again. It would be a massive help. Thans

1.6 TDCi - Ford Focus - turbo problems - page65

Hi ID,

Please can you send me the TSD information. I am having the same problems reported by others. I have an 06 C Max just past 92k and suddenly lots of issues.

Many thanks

SB(underscore)PAGE@HOTMAIL.COM

1.6 TDCi - Ford Focus - turbo problems - abela

hi ,i have the same problem...my car lost power but no alarm came out...can i have this service info please? adon79@gmail.com

1.6 TDCi - Ford Focus - turbo problems - w_jason

Hello Injection Doc, it looks like I too have joint the turbo (failure) club today, my 06 plate 1.6 TDCI Focus, which I owned for 18 months, lost (turbo) power on a steady 40 mile drive home from work.

I had the DPF (and fluid) replaced around a month ago and re-generated at the same time.Quite interesting reading the above comments, as a few weeks before having the DPF replaced, there was a strong smell of diesel fumes in the car when stationary in traffic, upon investigation, the 4th (from the left) injector was 'hissing' when running. I too had a big build up of carbon deposits around this injector. Me and my mechanic friend cleaned all this off, cleaned the black plastic unit on top of sooty oily build up and tightened the injector down - problem solved it seemed.

Now the turbo has gone - it's whirring and when I took the plastic pipe off to the right - you can wobble the 'fan blade' around - not good. Hopefully there hasn't been any part that has snapped off, visually, all the blades look in-tact.

Now before I go through multiple turbos, what would you recommend that I do? I see that cleaning the sump out and some pipes (which ones?) are essential.

I also see that some people have requested some additional info. Would you be able to send it through please to: w_jason87@hotmail.com ?

Appreciate your help here.

Thanks,

Wayne

1.6 TDCi - Ford Focus - turbo problems - injection doc

Replied e-mail sent

1.6 TDCi - Ford Focus - turbo problems - w_jason

Thank you very much, I will let you know how it goes!

Merry Christmas

1.6 TDCi - Ford Focus - turbo problems - jonny10buds

A motor trader friend of mine put three turbos on his wife's 55 plate Focus 1.6 TDCi including one fitted by a Ford dealer along with all the relevent pipes, in the end he gave up and sold the car through a car auction.

1.6 TDCi - Ford Focus - turbo problems - madf

A motor trader friend of mine put three turbos on his wife's 55 plate Focus 1.6 TDCi including one fitted by a Ford dealer along with all the relevent pipes, in the end he gave up and sold the car through a car auction.

No doubt the sump was never removed and the pump oil filter not cleaned.

It never ceases to amze me that with the internet going - in volume form - for at leat 12 years.. people buy products without checking.. All it takes is a simple search..

Edited by madf on 07/10/2012 at 19:50

1.6 TDCi - Ford Focus - turbo problems - injection doc

No Doubt he wasnt removing the cam cover and inspecting the injectors for seal leakage ! Its the carbon leaking past the seal that contaminates the oil and causes the blockages and failures.

You could fit 100 ne wturbos but if you dont cure the leaking injector seal you have wasted your money !

Its the fitters failing to inspect and repair that causes these issues in the fisrt place !

My motto is "if somethings failed find the cause of the failure !"

1.6 TDCi - Ford Focus - turbo problems - NeilyH

Just joined the turbo club with my 54 plate 2.0 C-max ghia.

Ford have run their diagnostics and recomended a new tubo and all the trimmings - £1200+labour - so probably not worth it given the age and the 105k on the clock

would love the technical doc & pics etc (to show ford or my even my normal garage) if still available? (mnhaddow@yahoo.co.uk) and I will say thank you.

Thanks.

1.6 TDCi - Ford Focus - turbo problems - injection doc

turbo failure on a 2.0ltrs C-max is not related to the same issue.

i would just consider an excahnge turbo from a specialist. cheaper than a ford dealer

1.6 TDCi - Ford Focus - turbo problems - emjlc02

So have many people actually had there turbo and everything else repaired/changed then the car worked ok? What are the chances it will go again?

1.6 TDCi - Ford Focus - turbo problems - injection doc

I have sent 5 e-mails to your address even with variations and everyone comes back !

I suggest you check your e-mail address and your posting

1.6 TDCi - Ford Focus - turbo problems - NeilyH

doc received by email - really helpful thank you.

1.6 TDCi - Ford Focus - turbo problems - ipsga

I had to re-read this message as I thought it was me!! That, is the exact same case, same story, same time of year even. Worst car I've ever experienced. Ironically the lay out really suited me so I may look for a similar non Pug model but for now, I am happily enjoying a Honda...Touch wood!

1.6 TDCi - Ford Focus - turbo problems - injection doc

rapidshare.com/files/3668332251/Injector_seal_leakg

rapidshare.com/files/2761452098/1.6tdci_Turbo_failf

1.6 TDCi - Ford Focus - turbo problems - df2512
Please could you send me the information to fix this problem?

I would really appreciate any help I can get with my turbo failure.

Thank you very much

Daniel.fitzpatrick@sky.com
1.6 TDCi - Ford Focus - turbo problems - grimep

other possible causes may include blocked DPF, Search s i n s p e e d for info

"ford-focus-dpf-1-6tdci-16v-turbocharger-failed-rebuilds-stock-available"

or not sticking to the reduced service intervals, or perhaps failing to fully drain old oil before refilling.. the sump has a slightly recessed plug so not all old oil will drain through the hole.

Edited by grimep on 05/11/2012 at 16:14

1.6 TDCi - Ford Focus - turbo problems - injection doc

quite correct, the drain time is 20 mins when warm.

1.6 TDCi - Ford Focus - turbo problems - emmo1210

Hi,

Having same issues as described. Would be grateful for information regarding fix

email is emmett@hotmail.co.uk

Thanks

1.6 TDCi - Ford Focus - turbo problems - emmo1210

Hello Injection doc, could you please forward the info to me as am requiring a fix and would really appreciate

emmett@hotmail.co.uk

thanks

1.6 TDCi - Ford Focus - turbo problems - injection doc

i have a hard carbon deposit around 1 of the injectors is this the issue you had?? can you please send me some pics and what you did to resolve the issue.

Any info would be greatfully recieved.

Colin

You must have new seals fitted and have the lube system, banjo filter and oil pick up gauze cleaned thouroughly

1.6 TDCi - Ford Focus - turbo problems - lexei90

hi, i have just bought a 05 focus and the turbo has blown, i have already bought a recon turbo but i have been told you need 2 replace or clean some parts, could you please tell or email me all the things 2 do when replacing the turbo? thanks

1.6 TDCi - Ford Focus - turbo problems - injection doc

an e-mail would help

just put an underscore where the @ would be and write DOT for the dot.

(Edit - spam deleted which this refers to.)

Edited by Avant on 19/11/2012 at 21:32

1.6 TDCi - Ford Focus - turbo problems - Jever

Sad to say, I've just become a member of the Ford 1.6 TDCi 'Turbogonewrong' club.

I took it to the Ford dealer (who had done a service on it only a couple of weeks before) and they say it will cost € 2,400 to repair, plus or minus, depending on how it turns out.

Given that the car is worth € 5,000-6,000, I can't justify the cost and thought it might be more cost effective to get a remanufactured turbo fitted at an independent garage.

However, looking at this thread, the procedure looks very particular and I'm not sure a smaller workshop will have the knowledge required to do it.

Has anyone here been successful with this solution?

Any guidance/advice/shared experience most gratefully received.

Jever

1.6 TDCi - Ford Focus - turbo problems - JJoes

Hello we are having the same problem, could you please send me the information, many thanks.

donna .joesbury@hotmail.co.uk

1.6 TDCi - Ford Focus - turbo problems - Norrisnewport

Please can you email th TSB please, second time of joining this club :-(

emma.norris@aol.co.uk

Thanks

1.6 TDCi - Ford Focus - turbo problems - Norrisnewport

Thank you in advance, noticed they don't say it

1.6 TDCi - Ford Focus - turbo problems - Jever

Could I also have a copy of the TSB?

johns2827 [at] googlemail.com


Thanks in advance

Jever

1.6 TDCi - Ford Focus - turbo problems - injection doc

Thank you. Sent. Your only the 4th to say thank you !

1.6 TDCi - Ford Focus - turbo problems - gwilko

hey injection doc. sorry to be a pain could you send a copy of th tsb to

gwilko1984@yahoo.co.uk

got a 2005 focus 1.6 tdci. in my workshop at the mo. turbo got a huge whine! replaced injector seals and cleaned engine ages ago. egr is also showing stuck closed for some reason. thes engines are horrid people!!

thank u in advance

Edited by gwilko on 28/11/2012 at 18:46

1.6 TDCi - Ford Focus - turbo problems - dannymc1309
Please please please can you send me the information? Felt like pushing this off Barton bridge earlier!

Dannymc1309@hotmail.co.uk

Hoping the garage that fitted the new turbo will show some goodwill tomorrow when i go and see them. How a garage can think replacing a part without investigation of the cause is acceptable is beyond me!

Regards

Dan

Edited by dannymc1309 on 29/11/2012 at 17:08

1.6 TDCi - Ford Focus - turbo problems - injection doc

Hi Dan

Sent.

Rgds ID

1.6 TDCi - Ford Focus - turbo problems - dannymc1309

thanks a lot

Does anybody know where the officlal TSB for the turbo can be found?

I have the Fiesta 1.6 TDCI if this makes any difference, 57 plate.

Edited by dannymc1309 on 29/11/2012 at 20:05

1.6 TDCi - Ford Focus - turbo problems - dannymc1309
Ignore me, didn't see the attachment on my phone!

Printed that bulletin out and handed it to the garage, he said they did everything they fitted a turbo and pupe as they should but all the stuff in there is excessive and would cost me more than the car is worth?!

Eventually conceded to take a look at it on Monday for me, however he said he expects to find no damage like this and just suggests an oil and filters change. Baffled
1.6 TDCi - Ford Focus - turbo problems - injection doc

" but all the stuff in there is excessive "

Well if the injector seal is leaking then the new turbo will fail ! often within 6 weeks !!!!!

so how excessive is that.

If the oil supply filter for the air pump is blocked that will also sieze ! how excessive is that ?

If the oil pick up pipe is almpost blocked and they havent removed the sump and cleaned then the engine will suffer oil starvation and further damage and how excessive is that ?

I trust the garage will gve you a writen garentee that they are 100% satisfied with what they have carried out and will give you 100% warranty on the turbo ?

If they do remove the camcover and find carbon around the base of one of the injectors normally number 3 then I guess "A" they will owe you an apology and "B" its quite clear they dont know what they are talking about ! & should never ever of fitted a turbo !!!!!

I think its quite clear from reading the many posts above that most have suffered a 2nd and third turbo failure ! caused by restricted oil supply!!!!!!!!!!

Edited by injection doc on 01/12/2012 at 14:19

1.6 TDCi - Ford Focus - turbo problems - dannymc1309
The plot thickens in my case...

The garage yesterday morning said they would have a look around some of the suggested areas from the bulletin and fit new filters along with a flush and oil change, free of charge. I went just now to see how it went and he tells me there is more. Shown me my old turbo which had a bolt missing off the end of it, just where the fan on the inside is, saying that this had originally come loose and gone through the turbo damaging it. He says they then failed to notice this and refit a new turbo, to which the bolt has also gone through and now ruined. Shown me the new turbo with chunks missing on the fan aswel as the bolt on there that was missing from the old one. Says there was nothing elsewhere comparable to the bulletin and it was this that caused the damage not carbon/clogs.

He has ordered a new turbo and said it will be fitted free of charge, i am baffled. What are your thoughts on this? When i first went to the garage his first diagnosis was the timing belt!

Edited by dannymc1309 on 04/12/2012 at 16:57

1.6 TDCi - Ford Focus - turbo problems - injection doc

OK so it sounds like the nut came off the turbo and he failed to spot that and debris was left in the system which has damaged the new turbo ! wow thats gonna cost them !

They dont sound very competent ! sound more like fitters than techs !

Is he 100% confident that the injector seals are 100% ? thinking for the future.

1.6 TDCi - Ford Focus - turbo problems - dannymc1309

Going to question him tomorrow when i pick the car up and get a definitive answer as to what exactly has been done/not done. I get the feeling he has began to have a look around and noticed this nut on the turbo, which has more than likely meant he hasn't bothered to look anywhere else assuming this is the cause of the damage.

I am hoping he will be going ahead with the planned flush and filter changes in addition to fitting the new system, surely he can't think just fitting a new turbo will suffice after all this trouble.

I am hoping i can pin them down with a signed warranty of the turbo before i leave.

1.6 TDCi - Ford Focus - turbo problems - MikeTorque

Please do a search for "Thu 13 Dec 2012 00:45 " for the latest entry into this thread.

1.6 TDCi - Ford Focus - turbo problems - dannymc1309
The garage refitted a turbo and changed my filters free of charge, claiming it was their error but there was no damage shown similar to the bulletin. They said the bolt coming off the turbo and causing the damage should have been noticed, making it their fault, but were convinced of no sludge or blocked up pipes. Had the car back for a week now and getting 37mpg rather than the previous 47, with an overly noisey turbo as soon as the revs reach 1500 in any gear. Not sure what to do other than take it back yet again, very fed up.
1.6 TDCi - Ford Focus - turbo problems - injection doc

dannymc1309

Write to the garage ! contact ttrading standards and get an independant assesment done. sounds like its going to be drama. If your turbo is nosiy my guess is they have put the new one back with damage.

Mike, many thanks. On this occassion i did spot it and have been e-mailing direct.

1.6 TDCi - Ford Focus - turbo problems - injection doc

Sump reoved to reveal a spotless engine

WELL WELL WELL


On thursday I had to take my wife's Fiesta 1.6 TDCi in for an oil leak, (very very small) as the sump seal had started to leak. Well its almost 5 years old now and the sump had to be removed.
In the afternoon I had a call from the garage to say all done and they had taken some pictures ( hadn't mentioned running on 2 stroke oil ) as they had never ever seen such a clean engine !
I am yet to see the pictures and have asked them to e-mail me the pics , the fitter said it was spotless, there was nothing to even wipe out and the gauze strainer was spotless. Infact he went on to say that when he refilled the engine with oil it was so clean he was having difficulty reading the dipstick.
Now the oil does stay very clean for long periods ! so it it because I always run on BP diesel and leave the supermarket stuff alone ? or is it the 2 stroke oil I add as I have always done on this car ?
once the garage send me the pictures I will post a link but it must of been clean for the garage to be that impressed for them to take the trouble to take pictures & ring me up to tell me !

At least these engine sdont have to clog up if they are looked after properly so that was quite encouraging.

Edited by injection doc on 22/12/2012 at 12:15

1.6 TDCi - Ford Focus - turbo problems - injection doc

link to how clean the engine was internally after 5 years & 50K run with TSO ( two stroke oil added to the fuel )

i739.photobucket.com/albums/xx33/injectiondoc/Fies...g

The garage removing the sump didnt know I added TSo to the fuel and just took the picture out of amazment of how clean it was internally for its age and mileage.

The amaxing thing is that 5 yaers ago when i read about a guy who had used TS0 for 200,000Km then stripped his engine to find no carbon in the inlet ports or EGR valve and the injectors were perfect and didnt need reconditiong I was a little scepticle but now I do wonder if he was spot on ?

Edited by injection doc on 22/12/2012 at 16:46

1.6 TDCi - Ford Focus - turbo problems - bryan6610

Hi looks like I have joined the Ford Focus 1.6tdci turbo problem club.

Would greatly appreciate being e-mailed the info everybody is requesting

bryanvincent@hotmail.co.uk

1.6 TDCi - Ford Focus - turbo problems - Cyd{P}

That is impressively clean.

Does anyone have any theories as to how adding tso to diesel helps keep the engine clean?

And in what concentration should it be added?

1.6 TDCi - Ford Focus - turbo problems - injection doc

Best explained here ! www.freel2.com/forum/topic878.html?highlight=two+s...e

Lots of reading but its worth while.

Since I have run mine on TSO I never get any smoke at all and at every MOT they cant get a smoke reading it runs that clean & its so much quieter its fantastic.

The picture with the sump removed says it all really ! as you may of noticed the oil stays so clean even the strainer hasnt tarnished in colour.

1.6 TDCi - Ford Focus - turbo problems - injection doc

ABELA

info sent 21.1.13

1.6 TDCi - Ford Focus - turbo problems - CraigW

Hi all

I too seem to have joined the turbo failure club. I am hoping to repair the vehicle myself. If you could send me the TSB's for the injector seals and cleaning out etc, then that would be much appreciated.

my email is craig (at) wymo17.plus.com

I will keep you posted on my progress!

Regards
Craig

1.6 TDCi - Ford Focus - turbo problems - kev_g
Hi

This seems to have happened to a 57 plate 1.6 estate owned by a mate of mine. Can you email me the info etc. kevandsarahg@hotmail.com

Thanks in advance!

Kev
1.6 TDCi - Ford Focus - turbo problems - injection doc

Both sent

1.6 TDCi - Ford Focus - turbo problems - hullboy

Hi would it be possible to send me the tsb everyone is talking about it would be greatly appreciated Thank you greatly hull-boy@live.co.uk

1.6 TDCi - Ford Focus - turbo problems - dino321

Hi Injection Doc,

Im having turbo problems with my 2007 Focus tdci, Any chance you could send me the info to dino.321@hotmail.co.uk

Much appreciated, Many thanks, Dino

1.6 TDCi - Ford Focus - poss injector seal problems - Brig40

Hi Injection Doc

Having diesel fume problems with my Focus 1.6 TDCi Diesel

Please could you send me the information about checking and replacing the faulty injectors.

From all the forum messages I have read it would seem to be a good place to start.

My email is bridgettturner@hotmail.com

Thank you very much in advance !

B

1.6 TDCi - Ford Focus - turbo problems - shawaj

Hi Injection Doc,

What 2 stroke oil would you recommend using? Mineral? Part synthetic? Fully synthetic?

Also, in what amount to a full tank of fuel?

Thanks

1.6 TDCi - Ford Focus - turbo problems - debw

rapidshare.com/files/3668332251/Injector_seal_leakg

rapidshare.com/files/2761452098/1.6tdci_Turbo_failf

Hello Injection doc,

Apologies in advance for the essay, but...

I've never posted on a tech car forum before but am desperate, as many of the posters, with a problem car, dogdy bank balance, and seemingly no specific reason as to why my Ford 58 C MAX is breaking down.

End of last year it started sometimes sputtering a bit and sometimes almost like it was having a cough (not a backfire just a pause in power) to clear it's system and then on it's way it went. Power occaisionally felt like you were towing something heavy, but again very intermittent. Then in December it, twice, slowed right down and the engine malfunction light came on, in addition to the anti-skid amber light on the dash lighting up. Both times I pulled over, stopped, sat a while, and then restarted the engine and it was OK. The garage, that we took it to both times, said try using a better quality diesel as the viscosity varies so much between cheap supermarket fuel and the BP advanced, and also ran the diagnostics to see injector 4 was the problem. It was cleaned and put back, and then cleaned and sent off for testing (the second time), nothing to report so the garage swapped 2 and 4 around to see what the diagnostics would make of that should it go wrong again. After two months of decent fuel in the engine we though YEAH that must have been the problem... alas no, it came to the same juddering halt this afternoon, wouldn't reset at all to start with this time - only after limping back at 10 miles an hour to work car park and leaving it for 15 minutes did it then reset itself (somehow) and allowed me to drive back home, and take it to the local garage which is where it is now. They are going to run the diagnostics again, hopefully it will say injector 2 and we can just replace it and be sorted... but if it's not then could it be that my car is having the same carbon leakage/contimination issue these other guys are having?

I did ring the garage once I'd come your great advice on this forum but they haven't got to my car yet and so couldn't advise either way... could you perhaps email me the info that several have requested so that I can pass it on to the garage in case it's of use?

Any help would be much appreciated... blooming cars they are just a money pit!!

Thanks

Debbie - debbie_ward16@hotmail.com

1.6 TDCi - Ford Focus - turbo problems - injection doc

The problem you are having doesn't sound like the same issue & a good idea of the garage to swap injectors over to see if the problem moves. I have a little concern that you said your warning lights came on including the anti-skid warning, these would normally only appear if the engine had physically stalled, but both lights could appear if the alternator had stopped charging even momentarily. This would need the diagnostics checking in the ABS to see if it had recorded a low voltage flag. This may give some idea of an electrical fault. The staring issue could be caused by a faulty injector causing low fuel pressure, due to the fact that an injector when faulty can prevent the fuel rail maintaining its correct pressure. You don't mention the year or engine size ? Defective EGR valves can cause rough running, misfire & poor or non starting as well.

Ford Focus - turbo problems - debw

Thanks a lot for your email and attachments - it's 58 plate 1.8 diesel - to make it worse we had engine problems with our previous diesel cmax that was a couple of years older too though that just went into limp mode randomly with no lights on the dash - we won't be getting another which is a real shame as with two kids in tow it's great for space and a comfy driving position too.

kind regards
Debbie

Ford Focus - turbo problems - debw

Thanks a lot for your email and attachments - it's 58 plate 1.8 diesel - to make it worse we had engine problems with our previous diesel cmax that was a couple of years older too though that just went into limp mode randomly with no lights on the dash - we won't be getting another which is a real shame as with two kids in tow it's great for space and a comfy driving position too.

kind regards
Debbie

Looks like it's the injector as the diagnostics pointed to number 2... phew, let's hope that it sorted.

Ford Focus - turbo problems - gjt

Hi Injection Doc,

Apologies for posting twice, I just read one of your earlier comments that it is easier for you to see new posts at the bottom of the thread.

Also having turbo problems on a 1.6TDCI C-Max.......please could you send me a copy of the technical service bulletin? gregthompson.gt at googlemail.com.

Thanks in advance

Ford Focus - turbo problems - injection doc

Done, much easier when messages are tagged on the end. Well done

Ford Focus - turbo problems - blackapparel

Hi Injection Doc,

Very same issue as everyone else - just looking to get the TSB to go through what this entails, and discuss with garage. Can't believe this problem exists!

Thanks in advance! Cormac. email: xbizcitz@live.com

xbizcitz at live dot com

Ford Focus - turbo problems - Roy G.

Hi injection Doc,

i have a problem with my turbo as well,can you please send me a ford service bulletin on how to properly change turbo and injector seal,thanks a lot my email is lumberjack1805@yahoo.com

Ford Focus - turbo problems - paul.mar

Hi Injection Doc,

Our Ford Focus Sport TDCi, suffered loss of power and Engine Malfunction warning on Sunday (24/2/13). AA could find to fault codes and towed us back to the garage from where we purchased.

Still under manufacturer's warranty, our garage took the car to Ford, who also cannot find any fault codes on ther Diagnostics???

After finding this - while trying to find some answers - can you please send me a copy of the Ford Service Bulletin?

Thanks in advance

Marion

paul.mar@blueyonder.co.uk

Edited by paul.mar on 28/02/2013 at 16:20

Ford Focus - turbo problems - mick80

Just joined and i too for the last year have had alot of bother with the injectors/seals. This is the third time inside a year i'll have taken my car for repairs on this issue! My mechanic told me today to buy 4 new injectors like i'm made of money! Not only that but now i cant open the bonnet with that silly design on the 06 model and the boot only opens the odd time. Can you please forward the information on that so many have asked for please.

michael80xox@gmail.com

Ford Focus - turbo problems - Borisimmo

Hi Injection doc

Just joined the club turbo hasblown. I would appreciate it if you could send me a copy of the bulletin,pics etc

loungefly67-red@outlook.com

Ford Focus - turbo problems - injection doc

Done Borisimo

Ford Focus - turbo problems - Borisimmo

Thank you Injection Doc

Ford Focus - turbo problems - moblik

Hi guys, just joined the club.

My garage diagnosed a blown turbo and were going to replace turbo, intercooler, oil feed pipes etc. but the technichian that came in to do the work actually refused to do it on the basis that he knew about this issue and didn't want me coming back in a few months with another blown turbo.

Could someone forward me the TSB mentioned so I can go into the Ford dealership properly armed please?

moblik@hotmail.com

Thanks

Ford Focus - turbo problems - injection doc

Done

Ford Focus - turbo problems - jpresident
Hiya injection doc

Sad to say, I have just joined the club.You seem to be very familiar with this issue from what I've read.

I'd appreciate any help you could provide. Please email me the bulletin from Ford and any pictures/ diagrams/ tutorials to topting@me.com

Many thanks
JP
Ford Focus - turbo problems - jpresident
Thank you very much Injection doc...hope I can fix it. Im not getting any white smoke but the car is very sluggish especially in 4th and 5th. The turbo looks brand new, and so does one of the injectors- previous owner must have replaced it. Is it possible that the turbo isnt blown but just not working? As you can tell, im not too familiar with turbos but Im a quick learner. Any help will be greatly appreciated.

Thank again injection doc

And thanks in advance to anyone who can help

JP
1.6 TDCi - Ford Focus - turbo problems - abbas22

Hi I recently bought a ford focus 1.6tdci within a week I had turbo blown. Turbo has been replaced, pipe kit, sump was remowed and cleaned 2 oil change including 2oil filters. Every part that had oil war car has thouroughly My email abdulazizsameja@yahoo.co.uk Thanks.

Regards

Abdul

1.6 TDCi - Ford Focus - turbo problems - sykogsn
Hi injection doc,
sadly i have joined the club, I am having problems with the turbo failing on my 1.6 tdci Focus.Could you please send me all the information you have on this problem please.

My email address is sykogsn@gmail.com

Many thanks

Regards

Sonny
1.6 TDCi - Ford Focus - turbo problems - smithies
Hi injection doc,
Please can you send me the information you mentioned above too? My email is bee@redsmith.eu.
The exact same thing happened to our ford focus today. Three and out of four garages we have spoken to say they won't touch them anymore as repairs always fail. Ford say it needs a new engine & turbo and quoted £5000. This car is only 6 years old and already we are being told it is not worth fixing.
We a desperate for information now.
Huge thanks in advance.
Kind Regard
Ruth
1.6 TDCi - Ford Focus - turbo problems - injection doc

Done

1.6 TDCi - Ford Focus - turbo problems - smithies
Thank you so much, very detailed information and so useful to see how little carbon can cause such major problems. Really kind of you to forward so quickly. Thanks again, I really appreciate it.
Ruth
1.6 TDCi - Ford Focus - turbo problems - Dragos

Hy injection doc,

I'm interested on your infos about ford focus turbo. I have a 1.6 TDCI Focus, 2008 model with one turbo replaced. If you can send me, my E-mail is dragos_angl@yahoo.com

Thank you very much

1.6 TDCi - Ford Focus - turbo problems - injection doc

you have new mail !

1.6 TDCi - Ford Focus - turbo problems - rosst2
Hi i am new to the site and i too am having trouble with a 58 plate 1.6 focus and would relay appreciate the information to my email is.

rosst2@hotmail.co.uk

Many thanks ross
1.6 TDCi - Ford Focus - turbo problems - injection doc

moved MLH

Its great to read some positive outcomes & someone who has the common sense to realise when somethings wrong & get it fixed rather than wit till it goes bang !

Injection Doc,

Just to thank you for the invaluable information posted here.

Same old story, boy buys 1.6TDCI Estate, routinely services it, takes it to 100,000 over 5 years with absolutely no issues and then experiences a "very interesting" 12,500 miles... and I would suggest that every 1.6TDCi owner must buy something like a "D900" OBD scanner (£25-30 from a well-known internet trading site) whenever a car moves into six-figure mileage territory.

I was already aware of this thread and so immediately after smelling fumes in the car I dropped it with my local independent for attention. £200 and 4 new Injector Seals later no smell in the cabin, and my independent confirmed that because we caught the problem very early the turbo is not at risk anytime soon. (We also changed the front suspension bushes due to vibration at A-road speeds; a very common fault apparently; the rears are an MoT advisory, but no need for action to be taken.)

The only thing I would add as a general comment is that after 105,000 miles of returning a true 52mpg the MIL light illuminated due to perished DPF sensor hose (so an easy fix was available but I chose the more challenging option given the high mileage the DPF had covered). So, 'correcting' the DPF resulted in 56mpg and a much more driveable car (low revs, towing, etc.). Similarly the EGR started to stick at 110,000 - so again, 'correcting' the EGR has resulted in an increase to a true 58mpg over the past 2,500+ miles. My wallet is beginning its recovery already!

Hopefully my driving style (rev-matching when going through the gears etc.) is sympathetic to the DMF, as that seems to be the next thing on the big list of expected 1.6TDCi 100k+ failures. That said, it is definitely worth giving the Engine a good work-out at least once a week (I suspect that I also experienced the effects a sticky turbo actuator for a couple of weeks too after a little too much constant-speed cruise control on the Motorways; although I mainly blame the faulty EGR)!

The good news is that car is now beyond 112,500 and is performing better than ever - And I was -**very**- close to spending an awful lot more to change it, which was never part of the plan... I want at least another 150k out of this car!

And Injection Doc - Thanks once again; if you're anywhere in the South West, I owe you a very very large pint!

Cheers,

M

Edited by mlhindley on 23/04/2013 at 08:53

1.6 TDCi - Ford Focus - turbo problems - give me an SU!

Hi there (I'm new to this so please excuse me if I am ignorant of protocols)-

It seems my partner (75 miles away) is now a member of this club - 55 plate 1.6 tdci sport 86K. New (non Ford) turbo just advised and fitted by brothers friend. I can get new turbo to kick in on acceleration on light throttle sometimes. She cannot!. Oily puddles around injectors 2&3. Didn't get to see old turbo.....so don't know if it was intact - I am told it "had movement in it" (yes I Know!). Have not yet noticed any smoke, startup fine

Is turbo working on light throttle only due to pipes being partially blocked?

Have we got away with it - if we do injector seals and major pipe etc. cleanup without driving it any further do you think?

Do I need to clean sump if old turbo ok (intact)?

Please please please could you send all info referred to earlier to;

andysmessages2@yahoo.co.uk

Many, Many Thanks - for that and all usefull info I have learned from your posting or thread or whatever it is called!

Cheers!

1.6 TDCi - Ford Focus - turbo problems - Collos25

"and fitted by brothers friend"

Does it have a vacuum or electronic actuator.

1.6 TDCi - Ford Focus - turbo problems - Javer

i think im on the way to join this club and i hope to prevent it from going into a totalled turbo

so anyone that can pass me the original photos showing what a leaking injector looks like and the ford/psa/volvo advisory id be very much obliged

Janhardeng at hotmail.com

1.6 TDCi - Ford Focus - turbo problems - injection doc

Sent, Rgds ID

1.6 TDCi - Ford Focus - turbo problems - jon t
hi injection doc

sorry if you already got a message from me, i'm new to this talk forum.

however i am suspecting my focus is going this same way as the eariler treads i have read, as i am losing power etc

i am going to send it into a garage soon and would greatly appricate the tsb on this subject so that i can look into it and pass onto the garage that will carry out the repair. hopefully i can get it repaired before it fully goes wrong, lets see

email address is jtipton@sky.com

many thanks
1.6 TDCi - Ford Focus - turbo problems - 309jazzpanda

the.1600 tdci 110 engine does suffer with very high oil degradation due to a service gap that is far too long for a small capacity high output engine. when replacing the turbo the sump MUST be removed checked for excess build up and cleaned , the oil pick up pipe MUST be replaced, turbo oil feed pipe MUST be replaced as well as the gauze removed from the new pipe. you should remove the vacuum pump and check for any contamination in the filter in the vac pump, the inlet manifold.must be removed and all build up removed. NEVERfill the oil to the max on the dipstick,cars with dpf's should only be filled to3/4 on the dipstick mark as the oil level will rise over time.

I still cant work out how a leaking injector seal contaminates the oil, when the gases are vented to atmosphere when the seals leak.

On a side note when removing injectors to replace the seals if the collar comes out of the cylinder head with the injector it must sit back in correctly as you cannotbuy these seperate the collars are mechined with the head in the factory.

1.6 TDCi - Ford Focus - turbo problems - Javer

thx doc for the documents, now new turbo and new pipes are on the way, after dismounting turbo+oilsump i found to much carbon and slack in the turbo for it to remain working for long, ended up cleaning the existing pipes and then running the engine with a hot flush system at a mates work place, the amount of slag this produced was just amazing, the hot flush system is the same used to flush automatic gearboxes

1.6 TDCi - Ford Focus - turbo problems - asht88

Hi injection doc

Please could you send me the information too.

My email is :- ashley1plumb@aol.com

Thank you

1.6 TDCi - Ford Focus - turbo problems - rob_cart

Hi ID,

Think my 08 plate with 95k is about to join the club. Felt almost like the car was labouring in 5th at about 70mph on acceleration then happened in 3rd accelerating out of a roundabout.

Reading what I've read could you please send me the docs too ? Also any ideas how long it may take to totally fail as I'm 300 miles from home at moment !!

Rob_cart@hotmail.com

Many thanks

Rob

1.6 TDCi - Ford Focus - turbo problems - m.angus0
Hi ID I'm finking of buying a '09 focus 1.6 tdci with 52000 miles. Could you send me the info on the injector issues please. My email is hello_im_angus@yahoo.co.uk. Thanks
1.6 TDCi - Ford Focus - turbo problems - flewx3

Hi, I apologise in advance if I've posted this wrong (1st timer) however, I have learnt a lot over the last few hours reading previous posts regarding this 'surprisingly' common problem so thank you all! I would be very grateful of any further advice and if possible a copy of the much asked for tsb/picture documents from 'injection doc' to hopefully rectify the problem before it gets out of hand. Initially, a large crack was found (by the welding) of the pipe from the turbo to the intercooler. After purchasing a new pipe (not cheap) and on further investigation by my trusteed bro-in-law it is possible/probable that the turbo charger is also on its way out?? The new replacement pipe is taking a backseat until this is dealt with incase it exacerbates the new found problem. I have an '06 focus cmax 1.6 tdci. My contact is: kaz(dot)flew(at)gmail(dot)com. Thanks in anticipation.

1.6 TDCi - Ford Focus - turbo problems - NatalieM

Injection Doc I need your help!

So I've fallen foul to the buying a car that the turbo is failing on. The garage sold me the car with the turbo howling, having never had a car with a turbo before i thought this is what they should sound like hearing people raving about "turbo whistle", oh god how wrong i was! Luckily (but now the cynic in me is saying they sold it with one because that's the only way it would sell) I got a 12 month warranty with the car and they replaced the turbo free of charge. Now though the turbo has gone a second time and reading this thread they didn't do any of the cleaning and just fitted a new turbo and sent me on my way as it's been less than two months since it was replaced.

So here i am without the car for the second time and they're saying it needs a new exhaust because it was blocked and a new turbo as the one they fitted was faulty. I'm starting to smell a very big rat. They're not charging me as it is still covered under the warranty but how can i be sure they do the job properly this time and not just do the same thing again?

Any advice would be very gratefully received.

NatalieM

smurphit@hotmail.com

1.6 TDCi - Ford Focus - turbo problems - weldersworld

Hi Doctor

I have been reading all the Mail that people have been sending You regarding all

the Problems with the 1.6 TDCi engine and Turbo . . I have a 56 plate car that has

been through 2 recon Turbo,s in 10,000 miles . . My Garage have now washed there

hands of my Problem with car, . so I have to try to sort it out myself or scrap the car

I have just join this Forum would You Please be so Good as to email me all the

info You have been sending others ? .namely The Ford Service Bulletin on how

to change Turbo + injector seals and the Photo,s + other info You have ?

You May be getting a bit wound up at the number of times you have sent

out this info, . But Please be Assurred I often give out free Advise on Welding

Probs that people some times like to tweek my brain on my limited

Knowledge of, . so if You would like to do the same Be my Guest

Let us hope that my welding is better than my Spelling ! !

Thank-you very much in antisipation !!

simonmauricereadesq@hotmail.co.uk

1.6 TDCi - Ford Focus - turbo problems - gordong1982
Hi guys looking for a bit of advise. I have an 04 c max 1.6tdci. Had it for over a year and every thing has been pretty good.

Since I have had the car when I was driving on the meteor way around 60mph and around 2000rpm every now and then it felt like the car would loose power for a split second and then drive ok again. In the last month this has got a lot worse and now every time it does it I get a puff of smoke out the exhaust. And the power loss it worse.

I got the car with 80,000 on it it has now just done 100,000 I have changed the oil and filter 3 times this year.

As the problem was getting worse i put the computer on it at work and it came up with the fault P138b heater plug module malfunction. I checked the wiring on the loom and module visually and it looked ok. I checked the voltage going on to plugs all where good and then I pulled I plug out and put on the jump leads and nothing so it needs plugs. I have been told on some cars the heater plugs heat diesel constantly so this could affect the running of a car if the plugs don't work.

I also checked the bearings on my turbo just in case. There was no play but the impela was very tight to turn. But I am un sure if this is some thing to worry about as I have not got much experience dealing with turbos. I also blew an air line down the main oil feed pipe to check for a block. I could hear the air blowing in the sump and oil poured out with the release in the pressure of the air line.
Then I put an engine flush through and done an oil filter change. I have not driven it far enough to see if its better.

Any help would be great I am unsure if its a poss turbo fault.

Could some one please e mail the information use are talking about

Gordongray1982@yahoo.co.uk
1.6 TDCi - Ford Focus - turbo problems - voludo

Hi ID, sadly, I too have joined the club - '06 plate 1.6 TDCi with a failing turbo. Can you possibly e-mail me the TSB & photos as well, so that I can ensure the job is done properly?

My email address is scotnisbet (at) gmail (dot) com

Thank you very much in advance.

p.s. Just off to buy some 2-stroke oil... if you'll excuse the pun, that is a stroke of genius! :-)


1.6 TDCi - Ford Focus - turbo problems - pahiggi

hi, just bought 2nd hand focus 1.6tdc1 with 106k. A fella just told me about clogged engine vanes. What can i do to prevent an expensive eposide that i CANT afford. Will cleaning/replacing seals , the bigger sump and very regular oil/filter changes with proper oil be good enough.

thanks

1.6 TDCi - Ford Focus - turbo problems - pchelka

Greetings from Poland

Guys the info you post over here are very valuble - this may infact save my freind A LOT of problems

Can i ask to sent this Buletin info on pwilkutowski@gmail.com ? If I may i will post this on some other sites so this info wont get lost over time

1.6 TDCi - Ford Focus - turbo problems - HansW

Hi

I am facing the same issues. could you please forwrd the two documents to:

hans_weitbrecht@yahoo.de

Thanks, Hans

1.6 TDCi - Ford Focus - turbo problems - HansW
documents arrived, thanks
1.6 TDCi - Ford Focus - turbo problems - flewx3

Hi, would it be possible to forward the tsb/pics documents to kaz.flew@gmail.com please?

Thanks

1.6 TDCi - Ford Focus - turbo problems - stace879
Hi

I have become the latest victim of a problem with the turbo failing my car is still on finance would appreciate anyone with any supporting ford documentation to the turbo problems if anyone has anything please email to Stacey.brown2@ntlworld.com

If I could pls have the ford documentation everyone has asked for it would be much appreciated

Thank you

Stacey
1.6 TDCi - Ford Focus - turbo problems - flewx3

thanks ID for forwarding the info, fingers x'd!! Will absolutely be utilising this helpful site again!x

1.6 TDCi - Ford Focus - turbo problems - 73arm3

Just had a phone call from the garage servicing my 59 ford focus 16 tdci, looks like I`m suffering the same fate..24,000 on the clock :(

Could you send me those TSB`s too please

luckyputt@hotmail.com

Thank you.

1.6 TDCi - Ford Focus - turbo problems - 73arm3

Received the information....

Thank you.

1.6 TDCi - Ford Focus - turbo problems - sparky100

Hi, could someone tell me if all these problems with 1.6 tdi focus's apply to 2011 onwards models and have ford solved these troubles or just left them to keep happening. Thanks. Copyright.

1.6 TDCi - Ford Focus - turbo problems - bellend

Hi,

I've got the same issue with my ford fiesta and its been with the dealer for the last 4 weeks. They've replaced the turbo, intercooler and ECU and still no luck fixing this issue of "no boost"

It would be really appreciated if you could send me the Ford TSBs and any photos that may help with diagnosing the problem, so i can get my car back as soon as possible.

my email is bell_timothy@hotmail.com

Cheers

Tim

1.6 TDCi - Ford Focus - turbo problems - fozzmonster

Hi Injection Doc,

My Ford Focus 1.6 tdci has also just started to suffer from these problems. I'd be most grateful if you could forward all relevant information to me at;

fozzmonster@googlemail.com

Many thanks in advance!

1.6 TDCi - Ford Focus - turbo problems - gareth_d
Hi

50k on an 07 Focus and turbo has been replaced and has gone again within 1k!

Can you please send the TSB to gareth230380@gmail.com so I can pass to the garage that replaced it so I can get their views.

Can I ask, are people having this work done as per the TSB and does it cure the problem?

My garage suggested they put on another turbo in under warranty as they only replaced it 1000 miles ago and then I consider part exchanging my car for something else.....

Thanks

Gareth
1.6 TDCi - Ford Focus - turbo problems - jack12

hi thie do you happen to have the tsb if so can you please send it to me

jack-owen-williams1@hotmail.co.uk

kind regards jack

1.6 TDCi - Ford Focus - turbo problems - rammers2001
Hi,

We think we are having same problems with our 55 plate ford tdci, local garage has said new turbo, the car is still running but it has no power at all, so thinking we need to do all the other things first before changing the turbo??

Could you please send me the document with the info? To joramsey2001 at hotmail dot com. Thank you very much

Jo
1.6 TDCi - Ford Focus - turbo problems - NMooney

Hi

I am experiencing similar problems. I would be very grateful if you could send me the relevant document.

Thank you very much.

nicola@tmenzies.co.uk

Nicola

1.6 TDCi - Ford Focus - turbo problems - Kibex

Hi now our turbo has failed for the 4th time in a year. And I can see we are not alone with this problem.

I would be grateful if you could send me the TSB.

kibex@hotmail.com

1.6 TDCi - Ford Focus - turbo problems - page65

Hi ID,

Please can you send me the TSD information. I am having the same problems reported by others. I have an 06 C Max just past 92k and suddenly lots of issues.

Many thanks

SB(underscore)PAGE@HOTMAIL.COM

1.6 TDCi - Ford Focus - turbo problems - NMooney

Recieved info today.

Thank you very much for your help.

Nicola

1.6 TDCi - Ford Focus - turbo problems - page65

Tanks for sending on the info I'm sure it will be a big help.

Really appreciate there are folks like you who will tirelessly share this sort of useful tech.

Thanks again

Steve

1.6 TDCi - Ford Focus - turbo problems - timmyt79

Hi All

Guess what?.......yep indeed i would also very much appreciate the info regarding this issue.

My email is timmy.tambling@hotmail.com

Kindest Regards

Chris

1.6 TDCi - Ford Focus - turbo problems - stepwhite

Hi,

I am also having turbo problems with my 55 Focus, could you possibly forward the service bulletin on to me as well, would be very grateful..

Thanks Steve.

stepwhite6@blueyonder.co.uk

1.6 TDCi - Ford Focus - turbo problems - rs2kmk5

Hi All,

If anyone could forward the details to me on rs2kmk5@yahoo.co.uk I'd be truly appreciative. My 55 plate Focus 109PS 1.6tdci is displaying similar signs to what has been described.

DPF has been replaced with pattern jobbie, turbo was replaced at about 80000 - just now she's hesitating intermittently, whispy black smoke out the back, and unusually high oil level even though no oils been added...

Many thanks indeed,

Mike

1.6 TDCi - Ford Focus - turbo problems - slider66

hi could you forward the ford tsb on to me please .slider66@hotmail.co.uk

i think mine on its way out.thanks phill.

1.6 TDCi - Ford Focus - turbo problems - brk109
I would love this Bulletin if it's still available, I have a 2005 1.6 TDCi that's starting to act up myself, so if it's possible send to

bk_is_here@hotmail.co.uk

Greatly appreciated if you can still help
1.6 TDCi - Ford Focus - turbo problems - ElCani

I too would love the TSB if still available. Many thanks in advance, Injection Doc! :-)

Email address: samusiskin (at) gmail (dot) com

I'm not sure if my car's problems are the turbo so if anyone has any views, I'd love to hear them. I started a thread here:

www.honestjohn.co.uk/forum/post/index.htm?t=101898

1.6 TDCi - Ford Focus - turbo problems - Collos25

Why not find out what is wrong with the car before jumping to what maybe wrong conclusions.

1.6 TDCi - Ford Focus - turbo problems - ElCani

Why not find out what is wrong with the car before jumping to what maybe wrong conclusions.

A good idea, which is why I'm seeing if anyone has any views on here. I will see if I can get it looked at early next week but not sure whether to take it to Pye Motors (Morecambe) or an independant. Can anyone recommend a good mechanic in the Lancaster area?

1.6 TDCi - Ford Focus - turbo problems - rs2kmk5

Mechanic has advised turbo has gone (lasted 84000miles on 2nd one so not bad really)...but, and it's a big but, the local turbo suppliers (Essex Turbo's) will no longer supply replacement turbos for these lumps and pretty much everyone is advising for a car of this age (164k FSH), it's just not worth spending the money getting new or recon turbo fitted, new sump, and all the associated parts.

Don't know what to do now, great car other than having had the DPF replaced with a pattern one apx 12 months ago, and a cracked inlet manifold just 3 months ago. Not that many cars out there that interest me/fit the bill.

What sort of mileages have people achieved with these PSA lumps, and regular shorter service intervals?

1.6 TDCi - Ford Focus - turbo problems - shawaj

Hi Injection Doc,

Any chance you can send me the docs also?

Just had a turbo blow on a 1.6 TDCI focus, 116,000 on the clock.

Any info you have on how to prevent this in future etc would also be greatly appreciated. I did notice MPG going down to around 40 over recent months...would this be related?

Shawaj at gmail dot com

Thanks a lot!!

1.6 TDCi - Ford Focus - turbo problems - Stein_R

Hey doc

Experiencing my 4th faulty turbo in 2 months now. Did'nt know about the clogging-problems before i blew the third turbo.

Before replacing the last time, I did my homework. Cleaned the sump, replaced sump-pickup, replaced the banjo-plugs and the turbo oil-pipe, and thought I would be ok this time around.

After just 4 days, my last turbo is now faulty...

Could you please send me the documentation and pictures you have, so I can investigate more before I replace the turbo again? I would be very grateful.

Kind regards

Stein

1.6 TDCi - Ford Focus - turbo problems - dstarr
Hi doc,

A new member to the blown turbo club! Ford c max 06 1.6tdci. Only had the car a week :(

Could you please send me the documents and pics you have so I can investigate more before I decide what to do!!

Many thanks

Dave

davestarr0@googlemail.com
1.6 TDCi - Ford Focus - turbo problems - 123focususer
Hi injection doc

The same problem I'm afraid. Ford focus econetic 1.6 dci going great for 3 years and now RAC called out twice, including waiting 4 hours at a service station with two small children until late whilst we were towed home last week!

Diagnosed as failed turbo due to lack of soil supply as previously stated in this thread.

I f you could send the Renault TSB by e mail to twiggerfamily@talktalk.net please?

Many thanks
1.6 TDCi - Ford Focus - turbo problems - 123focususer
oops.. Ford TSB not Renault!!
1.6 TDCi - Ford Focus - turbo problems - abadab

this engine is very high performance compared to a tradtional 1.6 diesel it goes in various models of peugot also synthetic oil must be used at all times servicing must be carried out regularly the dpf must be cleaned or replaced as regeneration doesnt seem to work reliably hope this helps we use mobil1 at 9000 service interval eg half the manufacturers mileage and have had no turbo probs ,replaced one fuel pump so far at85600 !

1.6 TDCi - Ford Focus - turbo problems - offshore

Would you buy a new Focus diesel I ask myself. It seems stupid to suggest that Ford would sell car with engines that have a known history of of being unfit for for purpose , but ...

NB. My knowledge of cars/engines is very limited; hence why I ask.

1.6 TDCi - Ford Fiesta - turbo problems - anro

Dear Injection Doc,

I quite appreciate your effort in helping people solve thier car technical problems. I have fallen a victim of this turbo problem.

I have an '06 ford fieta tdci which suddenly started loosing power as smokes heavily whenever i start it in the morning with the smokin fading as the engine is heated up. At the moment after it was diagnosed by ford dealer that the problem was turbo, the local mechanic i gave it to has fitted the third turbo which has just broken. The worst of the problem is the fact that the mechanic does not seem to know the cause of the braking of the turbo. But this forum has enlightened me well regarding issues like this, however i would appreciate it more if you could throw more light as to what could the solution to my car problem be so that i dont continue to waste money on what does not work.

I shall also be delighted if you could send me the TSB that relates to my car spec. My email is

ghnlwl@yahoo.com

Thanks

1.6 TDCi - Ford Focus - turbo problems - injection doc

yes but double the oil changes ! and ensure the correct spec oil is used

1.6 TDCi - Ford Focus - turbo problems - anro

Dear Injector Doc.

Thank you so much for the quich response to my query, i so much appreciate it.

My greeting for the TSB sent to me through my email, i do hope my mechanic adheres to all the directive.

Many more regards.

Anro

1.6 TDCi - Ford Focus - turbo problems - 123focususer

Thank you for the prompt response and TSB.

Ford have now looked at my car and said it is the diesel particle filter at a cost of £700 plus vat. Also charges of around £300 to send the oil injectors off for inspection.

They don't seem to be aware of the TSB and don't think there is a problem with the turbo even though the RAC said there is. They seem to be avoiding the issue.

Would it be better to give to a cheaper garage to carry out the full works as specifiied in the TSB instead?

1.6 TDCi - Ford Focus - turbo problems - Lithril

Could you email me a copy of the doc as well please. lithril@gmail.com

Many thanks



1.6 TDCi - Ford Focus - turbo problems - Hank Hill

Hi injection doc

Many thanks for your sterling work helping everyone out with this issue. I have an 07 plate Ford Focus which is exhibiting exactly the same symptoms. The mechanic at the garage we normally use has also had bad experiences in the past with the same thing. Could you please email me the technical doc so that I can pass it along to him

hanknhill@yahoo.co.uk

Many thanks

1.6 TDCi - Ford Focus - turbo problems - ralphhufflepuff
Hi, yep, yet another Ford turbo problem here. I would be very grateful for that document if at all possible. Email is ralphhufflepuff at googlemail dot com
Many thanks!
I can't believe there's so many people with such similar problems (at least those posting on here), sure ford sell hundreds of these cars but seems like an awful lot going wrong, is this just a really poor engine then?
1.6 TDCi - Ford Focus - turbo problems - Auds

Hi I post earlier but not sure if it was in right section. I am unable to open the links posted previously by another user, would really appreciate if u could send mea copy of the tsb. Bought car 5 months ago 05 focus car van tdci, garage have it last 5 week's trying to fix this problem. Low power and oil light keeps coming on, oil pump has ben checked and all ok so hoping this solution can get it sorted out for me, have had a few sleepless nights over this, its people like urself that restore my faith in humanity, my email address is audrey_darren@hotmail.com. thanks

1.6 TDCi - Ford Focus - turbo problems - Tregolow

Hi, just joined the forum as I have just been quoted £1200 to replace turbo on my 59 plate tdci only 6 weeks after a service by the same garage (a Ford supermarket). Could you email the TSB to tim.wharton1959@btinternet.com and I will ask my local independent if they can sort this for me?

Thanks in advance1

1.6 TDCi - Ford Focus - turbo problems - shawaj

Hi everyone,

I have received this information from Injection Doc (ID) now and it was very useful so I thought it would be good to paste it here and to upload the documents to the net.

I have therefore now uploaded these documents to two locations and linked below (the links both lead to the same file saved in different places - so you only need to click on ONE of the links, not both):

db.tt/GmqqFfRw

app.box.com/s/mb29idydex5804g69crq

Hopefully this will help to take the load off of ID a bit!

Thanks and best of luck with your turbo troubles!

Here is the information sent to me from ID:

Please find attached information requested, as you can see from the photo the injector seal fails and causes fouling of the oil which in turn fouls the oil feed and banjo bolt to the turbo and oil strainer etc, and causes oil starvation which then causes the turbo failure!and other engine damage.

The injector seals must be checked if a new turbo is required & the sump removed and all the components cleaned.its a major job and has to be carried out with due care and consideration. The oil flow must be checked to the turbo. The best thing would be to find out if the engine is contaminated inside to an extensive degree and if its is flushing and cleaning will not work. If its clean inside it may of just suffered turbo failure and as long as the supply line and filter in the banjo are clean & oil pick up strainer then there shouldn't be an issue. The 1.6HDI engine in the peugeot is the same engine as in the Ford Focus/Fiesta and I think you can see from the thread just how badly they suffer ! partly due to lazy servicing. I have been horrified how many people skip services or have them done late ! These engines really must have regular oil changes ! even doubling the changes help ! I hope this helps

Edited by shawaj on 16/09/2013 at 22:36

1.6 TDCi - Ford Focus - turbo problems - Hoopsbhoy

Hi everyone, great informaion here.

I am meant to pick up a 2009 focus tdci 1.6 this week. My understanding was that these had been modified sodid not suffer from this problem? However the dealer I am buying from has replaced, the dpf, the turbo and the egr valve. Should I stay clear or is it likely this was a dpf failure and not as such something to worry about?

Any information or help would be appreciated, I haven't spoke to dealer since I became aware of this problem, so I will be tomorrow and would like as much information as possible. Thanks.

Edited by Hoopsbhoy on 20/10/2013 at 13:02

1.6 TDCi - Ford Focus - turbo problems - dieselnut

I would guess the order of events were that the turbo failed. That dumped oil into the DPF necessitating its replacement. The EGR may have shown up on a code read after so was also replaced. I would be very carefull buying this car & question the dealer about whether the other things outlined in the TSB were also done.

1.6 TDCi - Ford Focus - turbo problems - Hoopsbhoy

Well was up with the dealer today. Apparently the turbo was not actually gone but he checks them all along with dpfs before selling them and he had the turbo reconditined here in ireland by a reputable company with stronger internals (receipts to proove). Dpf, egr and turbo guaranteed for 12 months, and 6 months parts and labour on everything else down to a bulb blowing (his words).

So still considering it.

Has anyone got the information on what was meant to be changed in these from 2008 to help with the original problem?

1.6 TDCi - Ford Focus - turbo problems - Collos25

There are hundreds of thousands of these engines running to star ship mileages with no bother at all you here about a few mistreated cars and all of a sudden every car is a disaster.My advice is if you like it buy it and stop listening to doom mongers.

1.6 TDCi - Ford Focus - turbo problems - grimep

I think they changed the oil feed pipe to move it away from exhaust heat, not sure about that one. One thing they've definitely changed is the infamous banjo bolt filter in the oil feed pipe. It now has a much bigger surface area of filter than the original, lessening the chance of it blocking up. Not sure if/when that was fitted as standard but its what they now fit as replacement.

I agree with the sentiments above about these engines, they have their weaknesses but so long as you are aware of them and service them well you've as good a chance as any to have a reliable car. You don't get 60mpg/ £30 tax disc in a cheap to buy car for nothing.

My advice - get a 90bhp non-DPF car with a regular oil change history.

Edited by grimep on 30/10/2013 at 22:35

1.6 TDCi - Ford Focus - turbo problems - jehc79

Hi,

I'm hoping to avoid a massive expense in the near future but here's my situation:

My car is a 2008 90bhp non-DPF Focus, currently just done under 67000 miles, regularly serviced (always a full service apart from odd interim one) and not a lot of hard motorway-type journeys done in it either.

I took it for its service & MOT at a reputable local (independant) garage, and their advisory note was that there is a small leak showing around the turbo pipe and 'slight play' in the turbo bearing. This is the first diesel I've owned and run so naturally I looked into this (via this forum among others) and yesterday I emailed the garage in question to query this and this is their response:

"It is not just a case of replacing the turbo as you also need to replace various oil feed pipes, washers and gaskets. In addition the vehicle has to undergo 3 Oil & Filter changes to remove contamination otherwise the warranty on the replacement part would be invalid. In addition the oil strainers in the sump have to be cleaned & flushed meaning the procedure will take more than one day due to sealer drying times etc.

As you can tell it is quite an extensive process which is the correct way to complete this work to avoid repeat problems. There will without doubt be people that will replace the turbo only at a lower cost but be assured this is not the correct procedure and will lead to problems again although I am sure your research will have identified this.

To give you a ball park figure based on the same job completed on a Citroen with the same engine late last year the cost would be around £1230 including all parts, labour & VAT."

My question is do I bite the bullet and get it done there or face a potentially long winded battle with a Ford main dealer to try and get it done under warranty, given my car's otherwise good credentials? Obviously I will ask for quotes from other dealerships etc., possibly even a PSA-group garage.

1.6 TDCi - Ford Focus - turbo problems - grimep

Sounds a bit drastic for a slight leak from turbo pipe (which pipe? oil feed? vacuum?) and slight (how much, is it serious?) play in bearings. You only need the full monty done if blockages have caused oil starvation which has caused the turbo to fail completely.

1.6 TDCi - Ford Focus - turbo problems - jhsmith78
Thanks shawaj

I can't open download the file and have a blown turbo. Am absolutely desperate to try and stop another one!

Seems absolute madness that we are all on here asking this legendary injection doc if we can have the tsb.....but please, please could you send it to me.

Email is jhsmith78@hotmail.com

I get a smell when driving the car so thing the injector seal might well be the problem.

I'd be really interested in finding out if those people who had received the tsb had had success.

Many, many thanks in advance!
1.6 TDCi - Ford Focus - turbo problems - Elv82
Hi I have a ford fiesta 1.6 tdci and my symptoms seem similar. The turbo has gone and but im getting a noisy top end and the oil warning light is on constant with the oil where it should be. Does this sound like a blocked engine and does it sound like its gone to far to be fixed without replacing the entire engine.

Thanks Elv :)

1.6 TDCi - Ford Focus - turbo problems - skidpan

I took it for its service & MOT at a reputable local (independant) garage, and their advisory note was that there is a small leak showing around the turbo pipe and 'slight play' in the turbo bearing.

Its probably the garage just trying it on. Play in the turbo is not an MOT issue so god knows why they put it on as an advisory.

If the car is running OK and has had regular maintenance using the correct Ford spec oil (essential) then it should be fine.

Its fair to say there have been more than a few cases of turbo failure in this type of engine but when you consider how many of these engines have been fitted to Ford's, Citroen's, Peugeot's Volvo's, Mazda's, Mini's (and probably more) then its hardly surprising more people have problems than with less populus engines. Most of the failures have been on engines with a sporadic (at best) service history.

If it worries you get it looked at by another garage but don't spend that amount of money based on a pointless MOT advisory.

1.6 TDCi - Ford Focus - turbo problems - stumps

HELP !!!

I too have been told that I have to have a new Turbo on my 1.6 TDCI FIESTA.

I went through exactly the same as everybody else on an 05 FOCUS 1.6 TDCI.

I had 4 Turbos fitted before the garage gave up and said it needed a new engine.

I then sold it to the garage at a significant loss and bought this FIESTA from FORD Direct and it had only done 3500 miles.

It is now 4 years ols and done 80000.

Surely these Turbos should last longer than this.

Does anybody think that it's worth getting solictors or Which involved ?

Also would this Ford Technical Service Bulliten for the Focus be pertinent for the FIESTA ?

Thanks in advance for any info,

Stumps

1.6 TDCi - Ford Focus - turbo problems - sambino

Hi

Please can I have the tsb

email :info@samatkinson.co.uk

I have or had a 2007 focus TDCI until this week.

Unfortunately I had not read about the fault and my garage which serviced the car from new at the recommended intervals never pointed this out.

I had the 4 year plus minor service last week and thought id be fine for another 12 months.

Unfortunately I had just driven 90 miles on a motorway this Tuesday and it was running really well I then pulled off the motorway and noticed a loss of power. No warning lights and temp normal I pulled over just as steam was pouring out from under the bonnet engine was dead.

As just been serviced had the 12 months free cover so it was towed to the nearest main dealer. Who charged me to check it over and a complete new engine flywheel turbo is required at 6k inc labour so ive had to get the car scrapped ive just spent £800 on servicing and new typres and brakes complained to my dealer said not there fault and could not spot that on a minor service

I liked the car and if I had known about the fault would have spent the money on getting the preventive work done before it blew.

Anyone managed to make a claim against Ford or a dealer ?

1.6 TDCi - Ford Focus - turbo problems - godot

Hello, Im new to this forum , and have had a second turbo failure on my Focus 1.6tdci a month after vthe original repair.

My local garage is non franchised , but I still would have expected them to be aware of problems with this engine. They have just begun to repair it..again...and Im expecting lots of excuses why they didnt succeed first time.

Ive seen mention of a Ford tech service bulletin on the forum ...can anyone email me a copy at godo.t@gmx.com , it might give me some leverage when it comes to paying up for a second time as I cant afford this.

Thanks in advance.

1.6 TDCi - Ford Focus - turbo problems - stevebritton

hi there i am now also a member of the dead turbo club could someone please forward the ford technical bulletin regarding this

many thanks in advance

my email is stevebritton1@hotmail.co.uk

1.6 TDCi - Ford Focus - turbo problems - jpslang

Hello,

I would also greatly appreciate anyone sending me the Ford technical service bulletin. We're stuck with the same problem.

jpslangserv@gmail.com

Many sincere thanks!

1.6 TDCi - Ford Focus - turbo problems - Gorbyrev

Ladies and gentlemen, this is my first post though I have long enjoyed the beneifts of your wisdom. ID, would you kindly email the tsb to mark@gorepc.com. My son has just bought an '05 Focus 1.6tdci with 99,000miles on the clock. The injector seals have just been done but the oil in the feed pipe from the rocker cover to the air intake pipe is black and gloopy. Thankfully the turbo is still working but I want to take appropriate preventative measures before trouble strikes. Also, do you have an opinion about using two stroke oil as an additive for turbo diesels as suggested in the discussion above? Many thanks in advance.

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