I’ll get straight to the point:
2019 Ford Focus 1.5 EcoBlue 8A/T ST Line, 74,000 kilometers on the odometer.
Engine oil is at the maximum level, changed 7,000 km ago.

I was driving on the highway at around 130 km/h while the DPF regeneration process was taking place. Nothing unusual. After 20 minutes, the engine started making a loud knocking noise.

Two days later, after disassembling it, I found that the rod bearings on piston 3 were completely destroyed, the crankshaft was bent, and after measuring the engine block, I discovered that it was also affected, even though the other bearings weren’t completely destroyed.

My first question is, what caused this? No error messages, no prior warning signs, on an engine with so few kilometers?
My second question: is there any place where I can buy a complete used engine block and be sure that the mileage is correct?

I’m attaching photos of the disassembled engine.

Thank you

What spec of oil was used in the oil change also was the oil filter nipple properly lined up after installation? Although on these engines there are two specs one thinner, one thicker, I always put the thicker grade in as lots of dpf regens cause oil dilution. Also when you drained the oil, did it have a diesel smell to it?

1 hour ago, Neb_engineer said:

What spec of oil was used in the oil change also was the oil filter nipple properly lined up after installation? Although on these engines there are two specs one thinner, one thicker, I always put the thicker grade in as lots of dpf regens cause oil dilution. Also when you drained the oil, did it have a diesel smell to it?

thanks for your quick answer

its the Ford original oil (changed by dealer). I think it's the thinner one - 0W-30.
no diesel smell. Also the oil level on the dipstick never went above the max level.

no oil leaks. 

The most obvious cause of engine failure would be a serious issue with the oil lubrication system. If the oil level was correct and there was no oil pressure warning light on, it would suggest to me that the grade of oil used was incorrect.

There is no point in trying to rebuild the engine, it will never be fully repaired no matter how you try.

Get a replacement engine from a scrapyard, it will be cheaper and less likely to have problems.

no warning light, nothing.

I was thinking to buy a new fully equipped engine block like this one in the link bellow + new oil pump and new oil cooler, as the rest of the engine / turbo / everything else seems fine. 

 https://www.piese-ford.ro/bloc-motor/ford-ecosport-2019-2023-1.5-tdci-ecoblue-125-cai-diesel-2189133-mmjkfkpeekbf 

8 hours ago, mihai F said:

no warning light, nothing.

I was thinking to buy a new fully equipped engine block like this one in the link bellow + new oil pump and new oil cooler, as the rest of the engine / turbo / everything else seems fine. 

 https://www.piese-ford.ro/bloc-motor/ford-ecosport-2019-2023-1.5-tdci-ecoblue-125-cai-diesel-2189133-mmjkfkpeekbf 

Please let us know what will happen and the result.

Further to what @unofix said, I would say oil spec is wrong, it has always baffled me that ford speed 0w 30 for a diesel when most other are at least 5w30 if not more viscous.

On 9/27/2024 at 11:04 PM, mihai F said:

no warning light, nothing.

I was thinking to buy a new fully equipped engine block like this one in the link bellow + new oil pump and new oil cooler, as the rest of the engine / turbo / everything else seems fine. 

 https://www.piese-ford.ro/bloc-motor/ford-ecosport-2019-2023-1.5-tdci-ecoblue-125-cai-diesel-2189133-mmjkfkpeekbf 

Hi Mihai,

I am a bit surprised by the extent of the damage. I don't think I have read of anything like this before. What could have caused this is really anyones guess. Maybe it was the wrong oil spec, or maybe there was a problem with the oil flow. I am not sure where the oil preassure is measured, as far as I know it is after the oil filter, but that isn't a very good indication of the actual oil flow. Does the engine have extensive wear on piston rings, cylinder sleeves? What about on the cam shafts?

As for buying the engine from the link, it is probably a good idea as long as you can find out the root cause for the damage, so you can avoid it with the new engine.

Hi, Radu, 

I think it has to do with the oil quality 

my guess: the combination between highway speed, car at full capacity and the oil temperature reached during the DPF regeneration process was fatal to this poorly designed engine. there's no other explanation.

camshafts are in perfect condition.

the exhaust pipe is super clean

the oil level on the dipstick never passed the max level

no oil consumption / smoke

no error, no warning light, nothing

cylinder sleeves and rings are looking perfect, no visible wear

the other bearings if you look in the pictures still have the yellow paint with the QR code. Of course some of them are a bit damaged but this is because I had to drive back home (30 minutes) after the engine started knocking.

__

I will buy a new and complete engine block, oil pump and oil cooler hoping this will never happen again.
and probably choose a thicker oil (anyone - please advice here)

__

!!! 8AT oil !!!: when taking out the engine we lost some of the AT oil. I know they say the 8 speed AT is maintenance free but I had the chance to take a look at the transmission oil and it was almost black (70.000 km). my advice? search for the gearbox specs as I'm pretty sure the producer recommends changing the oil at some point

cheers

Can you not send some of the oil away to have it examined?

If it shows that the wrong oil was used then the bill would be getting thrown at the dealer

9 hours ago, mihai F said:

!!! 8AT oil !!!: when taking out the engine we lost some of the AT oil. I know they say the 8 speed AT is maintenance free but I had the chance to take a look at the transmission oil and it was almost black (70.000 km). my advice? search for the gearbox specs as I'm pretty sure the producer recommends changing the oil at some point

That MERCON/DEXRON ATF does go black.

Yes, change it, they say maintenance free, but ignore that and change it every 60,000 miles

Helo ! What append next ? Did you fix it ? Did you find the source of desaster ? 

4 hours ago, Baca said:

What append next ?

It's been environmentally recycled in to baked bean cans 🤣

That but I also wonder if the op's original failure was infact incorrect oil related, I hadn't realised at the time when I originally commented on this post, I have since got myself one and also found out they are the same engine as the stellantis dv5rc which had a new oil spec issued for it a bit ago (I can't remember exactly when) which changed the recommended oil to total energies 5w30 ineo rcp and other oils that met the same spec.