2009 Mk 2.5 Tdci 1.6 Problems

[smj43]

Hello everyone, this is my first post on the forum though have been a lurker for a while now. Let me start by saying I know next to nothing about cars! So please go easy on me with your replies.

I bought a 2009 1.6 diesel about 6 months ago. Since buying it I've had a few problems with it. This is my first car and I have no idea if these problems could be the sign of a serious issue or not or what I should do about them? They are all intermittent problems and although I have a guarantee on the car, I know the garage will try to weasel out of doing any work or fob me off if it's clear I know nothing and I can't demonstrate the problem. So though I'd get some advice on here first.

1. When the clutch is at biting point and starting to accelerate, the highlights flicker? This is the least intermittent problem and happens most times. It's a very quick small flicker, like the dim slightly really quickly, but it's definately noticeable and passengers have even commented on it.

2. I sometimes have problems starting the car. This can happen at literally any time and there doesn't appear to be anything that triggers it. Often it happens if I park up somewhere and when I get back in the car it doesn't start. It can sometimes take up to 5 minutes to get it started after trying the inition repeatedly. This can happen maybe once a month but seems to be getting more frequent.

3. When I start the car and start going, I sometimes hear a loud spring noise like a recoil of some sort. This seems to happen around about changing from 1st to 2nd gear and seems to happen a lot when cornering or going over potholes or bumpy roads but again can happen at anytime intermittently.

Any ideas? I'm sure a few of these might be common well known issues amongst Ford owners so thought best to check on here.

[TomsFocus]

1. Sounds like alternator issue

2. I would say related to alternator/battery but seems odd it'll start after a few attempts. Needs mre investigation.

3. That's the ABS self test and perfectly normal, happens at about 11mph iirc.

[smj43]

Thanks for that TomsFocus. How would I know if it is definately the alternator causing my first couple of issues? Are there any other tell tale signs to look for or any tests I can do?

Also I have read up on the ABS self testing noise which is experienced on some Fords. The only question I have is why my car doesn't make the noise every time? Surely the ABS would test every time I start the car and set off? The noise I'm referring to is quite loud and sounds quite worrying, not a normal noise a car should make, and only happens once in a while?

[Dee_82]

do you have a multi meter? if so from the cigarette lighter socket tell us the voltage when the engine is off and also once started.

if you don't, go and buy one, best use of £20 youll ever have

[TomsFocus]

Hmm, yes the ABS should self test every time...if it didn't you'd get the ABS light on afaik.

It is quite loud, loud enough to think somethings broken...it still catches me out nearly every day haha.

[mjt]

From the description no. 3 sounds to me like a suspension issue, possibly a broken spring.

[smj43]

Ok so today I was driving on the dual carriageway at about 60 and suddenly I hear a chime and I've got 'Engine Malfunction' warning light on dash. Called out RAC he couldn't clear it and reckons its an ash build up in DPF. He tried to do a regeneration but wasn't able to do it.

Does this sound right and could have been causing my startup issues? If so, how costly is this going to be to replace?

[TomsFocus]

Could explain start and headlight issues!

The blocked DPF causes a huge amount of backpressure.

It sounds like yours is beyond cleaning now as well, so really removal (now technically illegal) or replacement is the only way to go. Not cheap unfortunately. :( How many miles has your car done out of interest?

Also, did anything else happen? Car cut out or run rough or anything?

[Dee_82]

Get it gutted, save you a fortune in the long run, but as mentioned, removal is a fail on MOT if they see it gone, if they cant see its been removed however....

[smj43]

It's done 70k miles and I only got it 8 months ago and it's just had a supposed service, though this was carried out by the garage that sold me it so not confident they have done it right.

[TomsFocus]

Ah, the Eolys DPF's need replacing at 75k on the Ford service schedule anyway, so that's about ready for it. Unless yours is the newer type DPF?

The service around 60k will have nothing to do with the DPF.

[smj43]

I'm not sure how I would know what type I have?

Was going to ring Ford and get it booked in but worried about cost. I have all my servicing covered for 3 years but the next service isn't due for a year so can't really just get them to replace it as recommended by Ford as it's not going to go a year.

[TomsFocus]

I'm not sure if there are any easily noticeable differences either, mine an Eolys but I haven't seen the newer style yet to compare.

Though with Eolys there's a small separate tank behind the fuel tank. And also a magnet in the fuel filler flap. I would assume these are not fitted at all with the newer cDPF.

Sorry, I misread, thought you had the service done 8 months ago when you bought it. If it was serviced around 70k they really should've at least asked you about replacing the DPF as it's recommended before the mileage of the next service (if that makes sense!).

The cost at Ford will be ridiculous...but if you ask them for a quote, I'd be interested to hear exactly how much it'll be!

[smj43]

Ok I have figured out I do not have an Eolys tank so must have the newer DPF. Ford has quoted £800 for a replacement all in which quite frankly is ridiculous and I definately don't have that sort of cash spare at the moment. Is it worth a try taking it on a long run at high revs to try and get it to regen and clear itself? Got to be worth a try? Or is it too late for that now?

[TomsFocus]

I was expecting 4 figures if I'm honest, £800 sounds quite reasonable for genuine parts and main dealer labour lol!

If its filled with soot you can try hammering it down the motorway, the forced static regen (which your AA guy couldn't do) puts it at 4000rpm for about 5-10 minutes....but not sure I'd dare try that on the road, probably be about 70 in 3rd or something like that. You can also force a static regen with a laptop and a copy of Forscan as I've shown in one of my recent DPF threads on here, but if the AA couldn't it's probably beyond that now.

If its full of ash (ash is left after the regen where it burns the soot) there is no way to clear that out. It'll only come back out the way it came in so it's never going to do that in situ. The DPF can be removed and cleaned with specialist equipment but I'm not sure how effective that is, or how much it costs.

[smj43]

Ah see my error code is ash build up. How does that occur then? Since regen has taken place isn't it supposed to expel any waste out the exhaust?

[TomsFocus]

Nope, I did try to explain earlier but maybe wasn't clear, I'll try again lol.

Basically the DPF catches particluates (soot) from partly burnt fuel.

When it fills up causing a pressure difference across the DPF, the ECU detects this and starts a regen, the regen just burns this soot at ~500c BUT as with burning anything, there is a small amount of ash left behind. This ash is still too big to pass through the DPF so will remain there indefinitely!

Eolys DPF's were only designed to 'hold' about 75k miles worth of ash before needing replacement. I'm not sure about the newer DPFs though, I thought they were supposed to last a lot longer, but maybe not.

[smj43]

I see think the penny has dropped now. Should have really done some research and expected to fork out for this eventually since Ford recommends 75k, although I have heard that many non-Ford DPF's will last a lot longer than this!

Might have a look into the cleaning option, seems silly to me that it can't just be 'emptied' of ash every now and then.

[TomsFocus]

Its a shame the ends of the DPF on the DV6 engine are bent over, I was tempted to try this otherwise lol!

[TomsFocus]

Lol...could always try compressed air I guess, seemed to work well for these guys....or maybe not!

https://www.youtube.com/watch?v=8AixffdL-V8

[smj43]

Yes, think I might give those 2 methods a miss. Going to have a look around some local garages next week I'm sure I'll get a better price than dealer. In the meantime, will be cutting down driving the car significantly, not sure if I should drive it at all? Don't want to damage the engine.

[TomsFocus]

Fair enough, let us know how you get on with prices etc.

As for driving it, I wouldn't drive it hard at all, would be worried about putting backpressure against the turbo. But personally I'd carry on driving normal/carefully. Other people may have different opinions there though.

[leicsguyuk]

I got a DPF for my 2009 focus 1.6 TDCI from Euro Car Parts it was £300. and £50 to have it fitted!

[smj43]

Ok I got some quotes from a few local garages. The cheapest full DPF replacement quote I got (which I assume is an aftermarket part) was £560. I also got a quote from another garage that claims it is a 'DPF specialist' who claim they can clean and restore the curent DPF to 'like new' as well as reset fault codes and top up the Eolys tank (which I have found out I do have) for a total of £400 which is tempting. Has anybody had their DPF cleaned and does it really work? The garage have told me they have a machine to flush it out.

[smj43]

Alternitively I've just got another quote from Cats2U for just under £400 for a new part as well as diagnostics and reset and Eolys refill. Anybody used them?