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Heard Of 1.6 Tdci Engine (Turbo) Failure?


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Poll: TDCi Engine faults? (9 member(s) have cast votes)

Are you aware of faults with the 1.6 TDCi engine causing turbo failure?

  1. Yes, I have been affected. (2 votes [22.22%])

    Percentage of vote: 22.22%

  2. Yes, someone I know has been affected. (0 votes [0.00%])

    Percentage of vote: 0.00%

  3. Yes I am aware of the problem but don't know anyone affected. (4 votes [44.44%])

    Percentage of vote: 44.44%

  4. No, never heard of the problem (3 votes [33.33%])

    Percentage of vote: 33.33%

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#1 DayV

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  • Ford Model: C Max 1600 Diesel
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Posted 08 January 2012 - 04:46 PM

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Please can you help with a problem experienced on my wife’s C-Max. Recently the engine started to make a noise like a police siren. Taking it to my local Ford dealer, (where it is also serviced), I was advised the turbo was failing. The chief mechanic removed the rubber inlet pipe and showed me how the movement in the turbo shaft indicated significant wear and that it could fail at any time, effectively writing off the engine.

The mechanic then explained how the Peugeot engine fitted to the 1.6 TDCi’s has a flaw in that the sump plug is higher than the base of the sump so all the debris is never really cleared out. This combined with small filters in the pipes and vac pump which then catch the debris and clog up, result in failed turbo’s. It is a known fault and some turbo’s are replaced and then the engine still fails due to either oil starvation from the original problem or the new turbo failing because of debris making the new turbo seize thus sending lots of pieces of the turbo vanes around the engine. I was assured that the problem is seen less on newer versions but has not been totally resolved.

The car has covered 80K miles with full Ford service history. I was quoted £1700 as I have a ‘loyalty card’. Another dealer quoted £2000 because of all the work that needed doing.

I tried to get the parts from a family member at a local Vauxhall dealer. His supplier refused to supply the turbo unless a main garage was fitting it and even then the garage had to sign an agreement to follow a procedure and change certain components to keep the warranty valid.

The engine is fitted to other vehicles including the Citroen C4. Citroen have a special procedure for all their dealers that must be followed when changing the turbo’s on this engine.
I approached the local turbo specialist in Essex who my Ford dealer referred me to and who they use for recon turbo’s. The specialist responded “Sorry but we no longer supply or work on these turbos. There are a number of problems on the 1.6 litre diesel engines that cause the turbos to failure prematurely and because of this we would recommend that you would deal with a main dealer”.

I have complained to Ford. They sent a very condescending letter basically saying this was an abnormal failure and could be caused by all sorts of things possibly soot in the oil.

Please can you help. Is this an isolated case? Have you heard of other cases? There will be many people purchasing 3 to 6 year old cars with 1.6TDCi engines in that can ill afford £2000 for a new turbo or worse need a whole new engine.

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#2 rojariggs

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  • Name: Roger
  • Ford Model: Fiesta 1.6 TDCI Titanium
  • Year: 2011
  • Location: Hertfordshire

Posted 08 January 2012 - 07:02 PM

I haven't heard of this specific issue but the turbo is one of the weak points of any diesel engines.

In addition, these PAG/Ford engines need oil changes done properly with the correct specific oil being used or else turbo problems are likely.

Also, if any work is done on the turbo, oil feed system or sump on these engines it is imperative that the sump and pipes are handled correctly and, again, that the correct oil is used as even only very brief running with the wrong oil can cause turbo or other problems.

#3 ging

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  • Name: alan
  • Ford Model: s max 2.5 turbo
  • Year: 2006
  • Location: Yorkshire

Posted 08 January 2012 - 09:23 PM

dont quote me on it but i think that they used the garrett gt15 now if i was in your shoes i would be looking at a more reliable unit to put in into its place if the gt 15 was used then you should be able to put a gt25 in its place if i remember rightley they are a slightly bigger unit this would give you a little more turbo lag but should be more reliable and produce the boost alitle better too also you can get a brand new one from ebay for less than £400 not a reconditoned unit also they use the same flanges etc on the turbo so very little modification will be needed to fit it

#4 Simofish76

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  • Ford Model: CMAX
  • Year: 2005
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Posted 14 May 2012 - 06:58 PM

I am dealing with Arnold Clark as I bought the car from them and had it all services completed by AC, I bought this vehicle after the last vehicle I had blew a turbo while the wife was driving and ran off the oil (total write-off) which basically scared the hell out of her, now she knows that the engine is prone to turbo failure she will no way drive that car again even if I get it repaired.

I rang Citizens Advice who advised me to issue a letter claiming that the goods are 'not of satisfactory quality' as per the 'sales of good act 1979' so that my next step, will look at watch dog as well.

Was on the brink of just paying for it but based on the amount of similar issue might be worth perusing as it seems like a nightmare engine.

Rang BTN turbo http://www.btnturbo.com/ and spoke to someone called Gemma who said they have a extremely high failure rate and they will not warranty the turbo if it turns out to be due to the external influences, they issue a memo which basically states they will not sell the turbo without the additional components to fix the root cause and even then they are seeing 15% failure rate, they even state this is the only engine they see this issue with.

I also spoke to a diesel specialist who said he has replaced 40-50 of there units so seems very common although Ford and AC won't acknowledge that at all and wont provide any stats.

#5 Rob Hopper

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Posted 29 June 2012 - 08:54 AM

Yeah, I had an 05 Focus Tdci 1.6, and the turbo blew twice. Once straight after the thing had been replaced. From reading around it looks like there are a few causes, mostly by the oil not clearing the debris properly, causing things like the turbo's oil return/breather pipe to clog.

I bought an 09 focus after trading in the 05, as I thought lightening wouldn't strike twice. It's currently in the garage for a diagnostic because it's exhibiting exactly the same symptoms I had before the turbo blew last time.

- Hesitation around 2,500 revs
- Noisier engine
- taking longer to get up to speed
- cooling fan coming on earlier

After phoning the garage ( I think they were scared to phone me, they have said it needs a DPF Regen and the diagnostic re-run, which will cost me another £72 on top of what I have already paid.

I'm rapidly loosing patience. The Focus 1.6 Tdci is a great little car, being let down by some poor engineering. I wouldn't mind if i thrashed it, but I don't!

#6 Stoney871

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  • Ford Model: Focus mk2 1.8 TDCI Sport
  • Year: 2007
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Posted 29 June 2012 - 08:59 AM

Yeah, I had an 05 Focus Tdci 1.6, and the turbo blew twice. Once straight after the thing had been replaced. From reading around it looks like there are a few causes, mostly by the oil not clearing the debris properly, causing things like the turbo's oil return/breather pipe to clog.

I bought an 09 focus after trading in the 05, as I thought lightening wouldn't strike twice. It's currently in the garage for a diagnostic because it's exhibiting exactly the same symptoms I had before the turbo blew last time.

- Hesitation around 2,500 revs
- Noisier engine
- taking longer to get up to speed
- cooling fan coming on earlier

After phoning the garage ( I think they were scared to phone me, they have said it needs a DPF Regen and the diagnostic re-run, which will cost me another £72 on top of what I have already paid.

I'm rapidly loosing patience. The Focus 1.6 Tdci is a great little car, being let down by some poor engineering. I wouldn't mind if i thrashed it, but I don't!


Sounds like you had a bad run of luck with cars.

BTW nice profile picture.
Particularly like the H&K MP7 PDW, not real I assume?
I have fired the real deal and it's quite nifty.

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