DieselMonkey

1.6 TDCi upgrade suggestions?

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Hi all, for the last 4 years, I've owned a 2009 Focus Zetec 1.6TDCi 110, and now that I've come into some money I'd like to know what the options are for making the DLD-416 a better, stronger engine. I know the smarter thing would be to buy a new car, but I love my Focus too much to let her go! I'd love to hear if anyone has any suggestions on power upgrades without compromising the longevity of the engine. Anything which increases the strength of the engine is also gratefully appreciated, as I've spent hundreds on replacing fuel, oil and air filters recently as well as a CV joint and injector. 

 

Thanks all,

Morgan.

 

Edit: The car is scheduled for a CelticTuning remap soon to allegedly get 148hp and 330nm without compromising parts, the engine is completely stock as far as I know and I'm not sure if this is at all achievable from this already problematic DPF engine. Anyone got any experience with this? I've heard nothing but good things about Celtic's remaps but most other companies offer the rinse and repeat 136hp/310nm remap and I'm just worried about my baby being overstressed.

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It is possible to have the DPF cut open on the factory weld and remove the filter but leave the catalyst, then refit to the vehicle to appear stock followed by a remap will still pass MOT as they only monitor carbon not hydro carbon.

The dpf turns hydro carbon in to carbon.

Alternatively theres a straight through pipe built by puma speed for the fiesta which will fit the focus as it's the same engine in that regard http://www.pumaspeed.co.uk/product-15-OFF-DEAL-Fiesta-Mk6-TDCi-High-Flow-Down-Pipe_990.jsp 

Also theres a stronger build hybrid turbo available from nbstyling https://nbstyling.co.uk/product/hybrid-turbo-fiesta-1-6-tdci-90hpfocus-1-6-tdci-110hp-peugeot-1-6-hdi-mini-1-6d-volvo-1-6d/ 

Aswell as an oil catch can to prevent oil contamination to the intercooler system 

https://nbstyling.co.uk/product/cp123-package-induction-kit-catch-tank-egr-blank/ 

Finally then; you will only hit top performance by driving st top speed; what I'm saying is; you wont do any damage from remapping and driving normally most of the time, only if your thrashing it then the injectors may start leaking as it's a common problem on the 1.6TDCi engine 

 

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First off, thank you very much for the reply. 

That DPF filter delete might just save me a grand down the line, and even after tonnes of research I couldn't find a legal option for taking off the DPF. 

I've always wanted to get into hybrid turbos, even though the variable geometry one on the 110 isn't half bad. I'm quite a spirited driver, I must say, so do you think replacing the injectors is a viable option?

As for the gains provided by the remap, I'm still not sure this stock turbo/injector setup can cope with 150bhp.

Thank you for the suggestions! 🙂

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13 hours ago, Lenny said:

The dpf turns hydro carbon in to carbon

The DPF only traps the soot (carbon) particulates, it's the catalytic converter that turns the unburnt hydrocarbons to carbon dioxide and water.

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DPF removal won't pass MOT under the new regs anyway.  It's also fineable by DVSA stop checks and could impact your insurance if you were to make a claim.  I've done it in the past, it's not worth the risk now.

150bhp/330Nm is pushing a bit far on the stock injectors imo, the clutch may not be able to take the torque either.  140bhp with a limited torque map is the safest option...but a bit boring (from experience).  

If you've come into enough money to do so, just buy something else without such a delicate engine. :smile: 

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That does seem to be a growing solution. Damn thing's just entered limp home mode on me, and on further inspection the injectors are bubbling which is sure to take a lovely bite out of that money. Anyone know how much injectors cost to replace/upgrade or if it's just the seals? 

As far as I've seen, the clutch is OK for the torque but as you speculated the injectors are going to be the bottleneck, any suggestions on just better injectors?

I know she's delicate, but I love my Focus 😞

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If the injectors are bubbling where they meet the engine then it's probably just the seals.  Leaky seals is a major cause of carbon deposits in the oil ways on the DV6 so don't leave them too long.  Shouldn't cause limp mode though so would be worth checking for fault codes there.

I don't know about injector upgrades for these I'm afraid, HDi Tuning can probably offer some good advice on them.  Mine was the first Focus they mapped back in 2015 but they've been doing the Peugeot equivalents for years.

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Thanks for the tip, I hope it's just the seals, mechanic said they were looking leaky and carbon-y, but said he didn't know what it would cost unless he inspected further. Car persistently smells of diesel on startup so I'm hoping this myriad of problems will go with the injectors haha. Any idea on cost either way? Sorry if I'm being naive, or naggy, I just don't want to blow my engine up. 

My only real experience with tuning is a remap of my dad's 430d, which was painless, but obviously the BMW diesels are a lot stronger than my poor old "Tiger." In an ideal world, I'd get the injectors replaced, along with a stronger clutch, induction kit, oil catch and stage 2 turbo but you know how these things go. The only reason I'm reluctant to go petrol is that my second car is a Kuga 1.5 EcoBoost (148hp) and I hate it.

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on my previous 1.6tdci fiesta all injectors leaked at the base at different times (gooey diesel deposit puddles cooking and smelling). each time one leaked I just did the two securing nuts up tighter. That was a twincam egine , I don't know if yours is the earlier twin cam or later single cam. Of course don't overdo it as a snapped or stripped bolt will be a severe problem.I suspect if it's been leaking for a long time doing the nuts up might not cure it as the longer it's leaked, the more the copper sealing washer will have been eroded.

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1 hour ago, isetta said:

I don't know if yours is the earlier twin cam or later single cam.

It's a late 2009 model, but I'm honestly not sure. Didn't know there even was a SOHC version, but upon further research some places say that it's the 260nm version? Some places deny the existence of this version and claim only the 240nm engines exist so I'm completely at odds as to what the hell to believe.

As for the nuts, I'll take your advice and have a look tomorrow to see if there's anything I can do. The diesel smell is recent and I've heard nothing about the injectors from my mechanic until a few days ago so hopefully I can catch it early. Thank you for the response.

Attached are the performance gains for the TDCi, my registration plate directs the website to the latter with more 20nm more torque, are these the DOHC/SOHC? (I'm only using this as an example to highlight the different figures, even though this is the map I'm going for once the engine is in tip-top shape)

SmartSelect_20190730-223325_Chrome.jpg

SmartSelect_20190730-223307_Chrome.jpg

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10 minutes ago, DieselMonkey said:

 

It's a late 2009 model, but I'm honestly not sure. Didn't know there even was a SOHC version, but upon further research some places say that it's the 260nm version? Some places deny the existence of this version and claim only the 240nm engines exist so I'm completely at odds as to what the hell to believe.

As for the nuts, I'll take your advice and have a look tomorrow to see if there's anything I can do. The diesel smell is recent and I've heard nothing about the injectors from my mechanic until a few days ago so hopefully I can catch it early. Thank you for the response.

Attached are the performance gains for the TDCi, my registration plate directs the website to the latter with more 20nm more torque, are these the DOHC/SOHC? 

Single over head cam 

You really don't want the double over head cam 1.6TDCi or HDi its really a Peugeot engine the 1.4TDCi 1.6TDCi and 2.0TDCi are all Peugeot engines handy to know for price comparison on some parts, the earlier 2006 twin cam diesel never survived after 90,000 miles the sump was filled with carbon and blew turbos, the single over head is revision 1.0 ☺️

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1 minute ago, Lenny said:

The earlier 2006 twin cam diesel never survived after 90,000 miles the sump was filled with carbon and blew turbos, the single over head is revision 1.0 

Well there's that cleared up then! Thank you for the speedy reply. I'm at 122,000 miles right now, which I know is quite a few even for a diesel. I do a lot of motorway driving so the DPF is always passively regenerating hence its painless life until this year. 

As for the torque figures, is it just me who can find absolutely nothing to verify the existence of a more torque-y TDCi from my era? I read something about overboost but God forbid I throw that fact around before verifying it. If it matters, she overrevs all the time and the traction light doesn't flash when she does?

Sorry for all the questions but I love this sort of thing.

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Just to confirm, the 8v engine (SOHC) was never used in the Mk2/2.5 Focus.  The 16v engine (DOHC) was never used in the Mk3 Focus.  

Yours will be the earlier 16v DOHC engine which is the one that suffers from carbon deposits and eventually turbo issues.  On a 2009 model you should have the more efficient coated DPF which reduces the risk of turbo issues due to less frequent regens and less backpressure against the turbo.  You should also have the revised turbo oil feed pipe which is slightly further from the DPF so doesn't cook the oil every time it does a regen.  There are still oil faults despite the revisions though though, particularly the poor sump design and leaky injectors.  The 8v engine is the Mk3 doesn't suffer with the same oil & turbo issues, but it likes to eat injectors, drives like utter ***** and you have to put up with all the faults of the Mk3 model lol...

There is no overboost on these engines.  It's on the petrol EcoBoost models.  With regard to the 107 and 108bhp models, the difference is due to emissions regs and getting the Mk2.5 into the cheap £30 tax bracket.  They use the same parts, just a slightly different map, the remap is the same for both of them though.

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Right, OK. That does make sense because it goes through fuel filters like they're pringles and clogs various parts every five minutes.

With regards to the overboost, I did some reading online and some people say that the overreving is relating to the variable geometry turbo giving a little more boost but maybe their and my cars are just broken. Did a weird thing earlier, in fourth at 50, floored it and she revved from 2.5k to 4k to 3k and back up to 4k, lost what felt like 50hp but didn't limp home mode on me (this time). I don't have a boost gauge so I've no clue if she's making required or too much boost. I suspect the car's got a ******* awful remap on it because sometimes she's hecking quick. 

Either way I'm getting the injectors fixed, the DPF cleaned and the car better mapped by people who know what they're doing. Might I ask what car you drive?

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11 minutes ago, DieselMonkey said:

Might I ask what car you drive?

It's a bit embarrassing to say on here... :laugh: 

I currently drive a 2012 Golf Match BMT, 2.0TDI 140bhp.  Done over 100k and previous cat N write off.  It was cheap, local, and fitted my needs last year.  £30 tax, 55mpg, comfortable, high spec, working air con.

I previously had a Mk2.5 1.6TDCi Titanium (with X pack) for 3.5 years which I still miss.  Mapped to 140bhp with DPF & EGR delete for 2.5 of those years after constant DPF issues.  When the new MOT DPF regs came if I wasted a load of money buying a Mk3 1.6TDCi Titanium to replace it.  Most expensive, lowest mileage car I've ever bought and complete rubbish, wish I'd never bought it.  This is what forced me to find something better locally on a very tight budget hence the Golf.  It does the job, but I can't say I particularly 'like' it, like I did the Mk2.5 Focus...

 

Back on topic, I'm not sure what you mean by over-revving?  Overboost is just an extra 'kick' when you accelerate hard, it's not really anything to do with revs. 

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Blasphemy! No, the Golf's a respectable car, that 2.0 is great in all fairness, despite the emissions scandal. Best mate's got a Mk5 2.0 GT TDI which goes like a train. Other mate (who's 16) just inherited a Mk1 Escort which upsets me. Always been a Ford man myself, although my love for cars extends to all. 

By overrevving, I mean when I apply throttle in a harsh way the car jumps from 1.5k to 3kish and stays there for a bit climbing speed pretty rapidly but there's no traction loss or light flashing. Does it in 3rd to 5th. I guess I'll need to buy a boost gauge to work out what's going on. There's something about that 1.6 TDCi that I love so much more than the respective 1.5 EcoBoost in my lumbering Kuga, even though it's less powerful and sounds worse. 

My dad's got a Stage 1 430D with ~320hp and 650nm+ which is obviously an absolute rocket compared but I love my Focus more than any of those "well-engineered and balanced" German cars. I've seen some DV6's go to 180hp but I'm sure the reliability of those engines is far from reputable, as for mine, I think it might have an economy map on it because it doesn't like full throttle and gets 73mpg at 80mph (as opposed to less at 70, 56 and any other speed)

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Well that would be bad news. Doesn't smell at all, she drives brilliantly and shifts perfectly but it's a possibility 

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From what you're describing 3rd to 5th where the revs jump then the engine speed catch's up is screaming clutch slip. Sorry to be the bearer of bad news.

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The engine doesn't catch up per se, it sort of just revs up, accelerates for a bit, then drops back so it's not that they aren't syncing all the time or anything, happens when I really need power and in all fairness it does assist in acceleration. It is indicative of a clutch tap and then the engine catching at a higher rpm before dropping, which could be it slipping but it's done it for 4 years without any further symptoms. I've already got enough to deal with the injectors ****ing up hahaha but life, eh? 

I'll get it checked out, maybe upgrade it to something capable of 400nm which'll cost me a bucket of my finest earnings but hey ho

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Right, round 2 of problems has arrived in full effect. Drove to and from Saundersfoot yesterday (about 200 miles round trip), perfect on the way up but entered limp home mode on the way back a few times. Normally, 30 seconds with the engine off cures this but she kept going again and again for a bit before finally coming back to me and performing well again. Regen'd the DPF in fifth at 3200rpm for a while (any of you with knowledge of the ratios will understand what that means) and she seemed much more spritely after that.

Now, we've got another suspicious noise! 70% of the time, when applying throttle, there's a little clunking noise coming from [somewhere] and I'm worried that this is in some way related to the new CV joint? It seems the moment I join this brilliant forum, my car spanks me with an array of problems for me to ponder online. I must say I'm a little worried, because she's going in on Monday to look for the noise and to see what can be done for the injectors and I'd really rather not be faced with a £1000+ bill so soon after the last one (she's not worth much more than that!).

For any interested, "the last one" was a combination of changing the timing belt and failing an MOT because the traction control sensor had stopped working (came to £1007 lol)

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Turbo's blown. RIP Focus :( 

 

 

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Turbo's blown. RIP Focus :( 
 
 
Turbos are an easy change on these btw.

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2 minutes ago, bashbarnard said:

Turbos are an easy change on these btw. emoji106.png

Turbo itself yeah...  But then you have the pain of cleaning out the whole oil system to avoid blocking the new turbo with carbon deposits as well... :rolleyes: 

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Turbo itself yeah...  But then you have the pain of cleaning out the whole oil system to avoid blocking the new turbo with carbon deposits as well... :rolleyes: 
Yeah, it's not a difficult job though is it. Set yourself a day aside and go nuts. Buy a few cans of brake clean and some blue roll. You're golden.

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