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.

injections doc

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

Thanks

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

Hi Injection doc,

Can you send me the pictures as well.

My email is: endriu4@hotmail.com

Many thanks,

Endriu

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

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

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

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?

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

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

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

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 22:45

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.

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

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

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

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

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 09:53

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

kind regards jack

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

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

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

shaun@exeterflyers.co.uk

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

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!!

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

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

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

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

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.

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

Hi injection doc,

can you sending me the Ford technical service bulletin. I have now the same problem.

stas.ff@gmail.com

Best Regards,

Stanislav

Hi injection doc im really new to Ford Cars and I have just Purchused a 2005 1.6TDCi Ford Focus Titanium. Sofar it is not acting up as far as i am aware I still have 2 months warranty on the engine and on the grearbox I am taking to my usual mechanin just for him to check if the injector is leaking or not and also just to check if everything is ok with the DPF. Can you also email me the ford technical service bullten bord concering this turbo issue. just incase i need it for future reference. HOPE NOT :) Many thanks

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)

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

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

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

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

Done, its not a Ford TSB but sent anyway.

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 20:50

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.

rapidshare.com/files/3668332251/Injector_seal_leakg

rapidshare.com/files/2761452098/1.6tdci_Turbo_failf

Done

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.

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 14:02

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

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.

the TSB i mean

thx

Hello all,

I would also greatly appreciate if someone could send me the Ford technical service bulletin. I'm stuck in the same situation... ljdavies@live.co.uk

Thanks in advance!

Luke