Hi guys,

after years of lurking, I decided to write about an issue which has been plagued me for a while.

My Fiesta MY2010 with the 1.6 TDCi (90hp) PSA diesel engine (pre-facelift) has 210k miles on the clock and has had some repairs over the span of its life.

It developed a weird habit in which it drives fine for a couple of meters, after which (seemingly random) it enters a sort of limp mode and loses all acceleration until I stop and restart the engine. Forscan live data shows it stops boosting. It seems to enter a torque limiting mode, but it doesn't show any lights or codes any faults like a tradition limp mode (scanned via Forscan). This happens most (but not every time) when going to work in the morning

Weirdly, if I stop and restart, that issue is gone until I arrive at my destination and leave the car for a couple of hours. It doesn't matter if its a 15min or a 4h drive.

Other than that, the car drives fine, has good idle, good mileage and reaches its top speed.

I assumed it was temperature related, but it happens regardless of weather conditions. It doesn't matter if it's cold or warm outside. It almost always happens when applying higher loads (e.g. going uphill on 3rd/4th gear, 4th gear on motorway or acceleration into 2nd gear when downshifting) after immediately starting the car.

Things replaced:

- DPF removed and deleted from ECU

- EGR deleted from ECU (and blanked)

- New injectors

- New high pressure pump

- intercooler

- turbo and pipes

- vacuum pipes

- turbo solenoid

- vacuum pump

- turbo actuator

- MAF, MAP, IAT, FRP sensors

- new fuel filter

Glow plugs couldn't be replaced due to them being stuck to the engine. However, they seemed to be in good condition.

Little history: All injectors have been replaced after the car gradually lost power over a period of years and started to develop a very rough idle. After that was repaired, it went into limp mode when driving faster than 70 mph (on motorways). This was extremely frustrating because it meant that you had to stop every time it went into limp mode and restart the engine. It was a nightmare when trying to travel longer distances, though you would always reach your destination.  A new turbo solenoid didn't fix this issue. It was only after I bought a second solenoid from another manufacturer which fixed that (huh). Because I drove in this condition for almost a year, it's DPF gunked up couldn't regen by its self, even a static regen wouldn't help, so I decided to remove it entirely (everything was deleted from ECU). After that it got very strange. The engine would turn off immediately when applying a short burst of gas while idle. You would wait at the light and when trying to drive away it would always stop. After some research and various FRP & fuel filter changes, I suspected the high pressure pump and changed it. The problem disappeared and the 'no boost' issue started to happen. It was during this time when I manually installed a EGR blanking plate.

I'm beginning to believe its because I blocked off the EGR. I seem to remember a short time when it worked without the blanking plate (while the EGR was already deleted from the ECU). Is that even possible? When pulling off the EGR connector nothing changes.

I'm slowly beginning to lose hope..

Apologizes for the long post. Do you guys have any experience with that issue or tips?

Much appreciated

4 minutes ago, ktelrahim said:

My Fiesta MY2010 with the 1.6 TDCi (90hp) PSA diesel engine (pre-facelift) has 210k miles on the clock and has had some repairs over the span of its life.

I'd say having reached 210,000 miles the engine is due retirement. 🤔

He hasn't yet fulfilled his duty 😅

I have the same model and at 250k it's nearly run in....nearly 

Edit: I just noticed that injector no 4 is leaking visibly. You can smell and hear that. I think the copper seal or maybe the whole injector is leaky.

I'll replace the injector and reseat it properly. Maybe that'll fix it..

On 4/15/2024 at 12:21 PM, ktelrahim said:

Edit: I just noticed that injector no 4 is leaking visibly. You can smell and hear that. I think the copper seal or maybe the whole injector is leaky.

I'll replace the injector and reseat it properly. Maybe that'll fix it..

Update?