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How Can I Prevent A Major Turbo Failure (Focus 1.6 Tdci 05)


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#1 d0gMa

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Posted 26 January 2013 - 04:56 PM

Hi Everyone,

I bought a Focus 1.6 TDCI 05 reg, second hand about a year ago and its done 130k miles.
Ive replaced the air filter and a complete oil change myself, but a few weeks ago I started having problems.

I noticed a lack in engine power and a ticking noise, so I took it in to my garage and they said it was a faulty inhector seal (first injector) which they replaced and everything was fine again (albeit with a lot of oil under splattered everywhere on the engine).

A week later I noticed a performance drop again and took it in, they replaced the intercooler pipe which had a split in it.... everything went fine again. A few weeks later and I had another power drop, now on taking it to a different garage I was informed that the 1.6 had major turbo problems, so I read up and scared myself in the process.The mechanic stated I had a bit of a leak still on inhector 1 and that maybe there was a slight breather pipe problem.

Now Ive read that injectors leak ---> oil burns --> carbon build up and muck in breather pipe ---> expensive turbo failure which nobody wants to fix.

What can I do to ensure that this doesnt happen? is there anything I can ask to be fixed? is there anything I can do such as more frequent oil changes? or even anything that I can keep my eye on. I dont have the money for a full engine transplant. Any help would be greatly appreciated. Thank You.

Ian

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#2 Stoney871

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Posted 26 January 2013 - 10:11 PM

It's recommended to have an oil change about every 5k.
Allow the car to warn up a bit before booting it so the oil has time to circulate around the turbo first and allow the car to idle for a bit before switching off so the turbo has time to spin down and that should reduce wear and tear a bit.

#3 Carl0s

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Posted 26 January 2013 - 11:07 PM

Regular... oil... change... I cant imagine what they have been smoking when they decided that the intervall for oilchange should be 12k miles... Mine was serviced by the book, every 12k on ford, and at 180k miles the valvetrain failed, and now im looking for replacement engine (ironicly the 180k is the last possible stamp you can put on the service record book, so guess according to ford then the car is done :P ). my mondeo did 280k miles whit 5k oilchange interval, and it worked like a dream :)


But for the topic, its pretty easy to check the vacuumpumps mesh for oil sludge, and check the oilfilter for sludge. I would check the oilpumps pickup tube also, but the oilpan is gluesealed, and nearly impossible to take off whitout bending it, witch will cause it to leak. (new one was like 40e from ford).

If these look clean, then i wouldnt stress so much about it. Reguar oilchange should be enough... Tho, if you want to play for sure, you could use forte engine flush, and then rechange the oils.

If you think you got leaking injector seal, take the engine cover of, and pour some soap water on the injectors root. Turn the engine on, and you should easily see if any of the injectors leak.

#4 lottysvdub

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Posted 27 January 2013 - 09:42 PM

Regarding this topic I've had quite a lot to do with the 1.6TDCI engine. I work for Citroen as a tech and we have had loads of total engine failures with this model on the C4 Picasso.
We regularly have to take the sumps off to clear the oil strainers of carbon. Quick tip to.remove the sump without trashing it is to undo all the 8mm bolts and then the 2 x 10mm nuts..... When there off undo the 2 studs that the 10mm nuts fit to...... They have a small lip on them on the inner edge of the sump....As you draw the studs down they will pop the sump off with out much effort and leave just a small impression on the face of the sump. This you simply turn upside down and tap flat with the use of a 3/8th drive socket extension bar and then re seal with a decent silicone sealer.
Other points we clean / replace are like mentioned the small oil way gauze filter in the vac pump and also the oil feed pipe to the turbo..... A little awkward to do but remove the turbo if you can and replace the pipe for a new one...... They have a small gauze filter in them too which blocks. Some people have actually removed the gauze filters completely but I think a little bit of maintenance on them from time to time is better than large chunks of carbon floating around the system.

I will add it too have a focus 1.6TDCI and love it to bits...... I change the oil around every 3 months bit I get it free so it's no real issue for me...... But good quality oil and decent filters changed at regular intervals will definitely help keep your car going.

#5 Carl0s

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Posted 28 January 2013 - 06:22 AM

Thumbs up for the tip using the studs as puller didnt eaven think about that :)

Forgot to mention the turbo pipe, the bolt for turbo oil intake is in a kind of awkward place like mentioned (its like under the exhausmanifold, you can spot it under the car), its not as good as taking it apart and cleaning, but what i did, is that i took out the bolt from the turbo, and then using compressed air i blowed the oilpipe clean (hard to explain, but when you press air in it, the oil flows back, and hopefully, pushes off any sludge in the mesh)

I use the ford motocrafts 5W-30 oil, that costs 29€ / 5litre and the oilfilter costs 9.90€, so 40€ for a oilchange is not going to bankrub anyone, even if done every 5k :)

And, personaly, i would blank out the EGR. Done it to every car that i have owned (still under progress on focus, but since i need to change the whole engine, its not that urgent). not realy that big of a deal, but eaven by looking how the intake pipes look on an egr engine, you start to wonder that it cant be healthy for the engine.

#6 grahamp

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Posted 29 January 2013 - 06:33 PM

Good question, and this is a job I need to do fairly urgently myself. Mine's on 55K now so getting close to the time when they start going bang.

My plan is clean and replace the following parts. For me clean means a liberal dousing in brake cleaner and wipe out, I haven't got an air line..

Sump off,
oil pickup pipe off and cleaned or replaced,
replace the turbo supply banjo bolt+gauze
remove & clean out the oil cooler

Got a few questions for the pros...
- Can I get away with just cleaning out the pick up pipe rather than replacing it, they're about £35+vat. I'd imagine they're not so easy to clean out properly. On refitting it, should I use threadlock? The book just specifies torque values.
- The front exhaust inc cat has to come off to access the turbo oil supply banjo and get the sump off? According to the book (Ford ETIS) the whole flexible part of the exhaust should be removed taking care not to damage it- can I get away with just unbolting the front pipe/catalyst at the flexible pipe joint? Its going to be on axle stands and the subframe is in the way, I'd rather just leave the flexible part alone. I wonder why the book reckons the whole lot needs to come off??
- is it worth cleaning out the oil cooler or just leave it be?
- is it worth replacing the turbo feed pipe?

Going to wait for a nice spring weekend, could be a while....

#7 JonnyRotten

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Posted 01 February 2013 - 12:36 AM

Hello there,
Been crawling round the internet for the last few days as have noticed what I thought was oil on the top of the rocker cover, I tried to wipe it away to find out where exactly it was coming from, but it was solid and black and shiny. I have now found out that it is a seal for the 3rd injector (the one 3 away from the transmission) that has gone and the black shiny stuff is a carbon build up, the start of bigger and badder problems, this affects the oil ways in the engine and will affect the turbo by restricting oil flow to it and thus killing it! I have seen posts from several people and mechanics that have owned one and have serviced it far beyond the regular intervals and used the correct oil etc who are getting the problems too! Ford recognise that there is a problem but will not compensate anyone, they should of recalled all the 1.6 tdci units but because there are so many out there and they're earning a tidy profit from them in todays high priced fuel climate. Other parts ie the air hose from the air box to the turbo which has a smaller pipe coming off which goes into the head has plastic clips which are very prone to breaking and if you need a new one from Fords it is £95 + VAT, just show you that Ford are only after money on this unit! I am now either going for a 2.0 unit or never buying a Ford again!!

#8 lottysvdub

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Posted 01 February 2013 - 07:17 AM

I disagree with some of your comments..... Yes the 1.6 tdci is a problematic engine but ford wouldn't recall them because of carbon build up internally to the engine.
If you have injector seals leaking simply get them done...... Any decent garage can do them or even if your computational with tools you can do them. The parts are cheap enough and with a little patience you won't have a problem.
I work for Citroen but own a 1.6 tdci focus and love it..... I've seen some of the horror stories your referring too but I've also seen taxi's with over 250000 miles on the clock..... Running the original engine. Just serviced regularly and maintained quite well by the owners. Not sure if you know but the tdci engine is a PSA engine..... Made by Peugeot and Citroen and supplied to ford. I honestly don't know how many of these engines I've either rebuilt or replaced but they are normally due to missed services and poor quality parts used at service.
Regarding the injector seals.....we must do at least 1 set a week..... Not just to the 1.6 but the 1.4 and occasionally the 2 litre. So to me it's not just a problem with the 1.6 its a diesel issue and poor maintenance or missed problems on service.

#9 grahamp

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Posted 04 February 2013 - 08:47 AM

There's a long-running thread over on the Honest John site which has pretty well become "ITS THE INJECTORS LEAKING!!!" to the exclusion of all other possibilities.


There are shed loads of cars on the road with these engines.. some have had serious problems with carbon build up and oil that turns to sludge, others are ok. As for the causes - I think it pays to have an open mind - yes, possibly a leaking injector could contaminate the oil, but as mentioned poor servicing could equally be a cause, as could perhaps a blocked DPF... read what Sinspeed reckon on the subject:

http://www.sinspeed....stock-available

As an owner its wise to be aware of the possible issues... my car didn't have a great start in life, the first owner had it serviced at 15k intervals and Ford put semi-syn in, but hopefully I can avert disaster by changing the feed pipe and ensuring the sump pick up isn't blocked, giving it a clean out and then sticking to 6 month oil changes.

#10 talksy

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Posted 04 February 2013 - 10:37 AM

You mention about the regular oil changes like 5 k. I think mine is supposed to be done every 12k.
I dont have a clue about the engine on the car and dont really want to start messing with it. How much would it cost me roughly to have the oil changed at my local garage? If I was to do it every 5 k, I would begoing back and forth quite a lot!

#11 grahamp

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Posted 04 February 2013 - 04:16 PM

the 1.8TDCi in your signature is an altogether different engine, so don't worry about it.

It never hurts to change the oil more regularly than manufacturer specified intervals though, and should cost less than a fill of the fuel tank.

#12 talksy

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Posted 04 February 2013 - 06:57 PM

the 1.8TDCi in your signature is an altogether different engine, so don't worry about it.

It never hurts to change the oil more regularly than manufacturer specified intervals though, and should cost less than a fill of the fuel tank.


Thanks very much for your post :)

#13 JonnyRotten

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Posted 05 February 2013 - 07:17 PM

I disagree with some of your comments..... Yes the 1.6 tdci is a problematic engine but ford wouldn't recall them because of carbon build up internally to the engine.
If you have injector seals leaking simply get them done...... Any decent garage can do them or even if your computational with tools you can do them. The parts are cheap enough and with a little patience you won't have a problem.
I work for Citroen but own a 1.6 tdci focus and love it..... I've seen some of the horror stories your referring too but I've also seen taxi's with over 250000 miles on the clock..... Running the original engine. Just serviced regularly and maintained quite well by the owners. Not sure if you know but the tdci engine is a PSA engine..... Made by Peugeot and Citroen and supplied to ford. I honestly don't know how many of these engines I've either rebuilt or replaced but they are normally due to missed services and poor quality parts used at service.
Regarding the injector seals.....we must do at least 1 set a week..... Not just to the 1.6 but the 1.4 and occasionally the 2 litre. So to me it's not just a problem with the 1.6 its a diesel issue and poor maintenance or missed problems on service.

Ok thank you lottysvdub
I think I've been drawn in to a state of panic after reading from the horror stories on the web. I do very high mileage so I have good reason to panic! Although I have to point out that although the engine is made by Peugeot, Citroen, the parts attached to it are not. I don't want to scare anyone else who has one of these cars, so I'll keep my mouth shut now.

#14 Carl0s

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Posted 05 February 2013 - 08:02 PM

Ok thank you lottysvdub
I think I've been drawn in to a state of panic after reading from the horror stories on the web. I do very high mileage so I have good reason to panic! Although I have to point out that although the engine is made by Peugeot, Citroen, the parts attached to it are not. I don't want to scare anyone else who has one of these cars, so I'll keep my mouth shut now.


Naah, panicing doesent help at all... :)

And look for the bright side: Since there is shedloads of cars whit these engines, if things go down, you can buy replacement fairly cheap. I just bought 15k driven engine for 800 to my car. If you can do the swap your self, its a weekend job. :)

#15 JeffFocus

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Posted 24 April 2013 - 10:02 AM

Hi there,

 

My Focus 1.6 tdci (06 reg and 70k miles) has just had a leak on the 3rd injector. A local garage sorted it out for me but after reading all about turbo failure due to clogged up oil galleries, I'm thinking it's probably a wise move to look into some simple preventative measures I can do myself. I've also got concerns as it looks like the inject had been leaking for a while (maybe a couple of months - wife's car and she didn't notice the oily smell etc)

 

What are your thoughts about using an oil flush (only this once) to remove any unwanted sludge etc?  I've read a lot of good and bad articles about them and apparently Ford uses Wynns oil flush as part of their turbo replacement procedure.  Before we just relied on the annual service which came around every 12k miles so now I'm a little bit worried that I've not changed the oil enough in the past.

 

Also, would briefly disconnecting the oil feed pipe on the turbo to check the oil flow be a really bad idea? Just thinking that this would be a real simple test to see if the pipe is blocked etc. I'm assuming it's the small pipe that connects to the top of the turbo? 

 

thanks

 

Jeff



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