grahamp

A common place for a crack is in the long metal pipe from the turbo outlet to the intercooler... its the large metal pipe that runs around in front of the turbo heat shield in your pic above. Have a look where it bends down for any cracks as that is a known weakness.

Not hugely accurate but you could carefully stick some bluetac in the hole, measure it and compare against this chart..

http://www.wihatools...ng/torxspec.htm

and then get a couple of the nearest ones. Something like a T55 on a 1/2" socket would cost you about £4 all in.

I could be wrong but I think those bolts are 65Nm torque, so a T40 or T45 are in spec for that.

Oof, another one bites the dust, sorry to hear about your problems :-(   There's a very long thread on the Honest John forum of people with the same problem, though the chat there is a bit fixated on injector leak as the only possible cause.

AFAIK Ford don't normally recommend engine replacement - the turbo should be warranted if the work is carried out as per Fords Tech Service Bulletin 46/2008 mentioned on page 2 of this convo. Though it has come to engine replacement in some cases where they've tried to clean the engine and its gone on to blow its 2nd and 3rd replacement turbo...   Well good luck and hope yours has a happy ending. There was a modification done during production to try and stop it happening- I think they modified the turbo feed pipe so it was away from exhaust heat, to stop it baking the oil in the pipe. If your car is 2005 it'll predate the modification, so that's another possible cause along with carbonised sludgy oil caused by blocked DPF, leaking injector, etc. 

Hmmm, should've been a large-ish o-ring that fits in a recess at the top of the screw thread on the plastic filter housing.

I've had exactly the same on mine, a little bit of carbonized oil at the breather pipe joint, the carbon here is nothing to worry about. There is a breather valve and filter that AFAIK ought to stop oil coming up here, but unfortunately they are integral with the rocker cover so fixing them means a replacement rocker cover- I wouldn't disturb the injectors myself, so I'll just have to live with it. But where does the oil end up? There's a chance it could get blown through the intercooler and over time could get everything sticky... I've heard of oil  damaging the throttle body seal and leaking from it. Something else to check out sometime I guess.

Yep, I've bought the bits so there's no putting it off now. I've probably wasted a fair bit of money on parts that could be cleaned and refitted, but I figured I'd best do it by the book. I can't promise a Haynes-style guide but I'll try and put something together

And yep there are some scary pics of gummed up 1.6's, but there is either some underlying fault or poor maintenance as a cause and you can find similar pics for other makes' engines.

As for turbo cost, no idea. If it has gone they need to figure the cause first and rectify, otherwise the replacement will go as well.

NP. Might be worth getting a fluid extractor at some point for removing that last bit of oil in the bottom of the sump. I'll have a think about that when I get the sump off. But its not happening for at least the next 3 weekends, its seems to be kids birthday party season again..