I've been having a few problems with My 2006 focus 1.6 tdci ( non dpf), thick black smoke out the rear when ( only when turbo kicks in the more I put my foot down heavier the smoke ),

Also when I'm in 5th and accelerate on an incline I get earning message engine system failure and limp mode, when I stop and restart the car it's like nothing happend it's normall again ( mpg is normall)

Took it for a diagnostic scan and the car brought up numerous fault codes:

Eml

P0299- turbo charger underboost

U0122-lost communication with dynamic control module

P13813- glow plugs control module system voltage below minimum threshold

P1180 fuel delivery system malfunction- above maximum threshold

P1632- smart alternator fault circuit malfunction

P020101- injector circuit malfunction cylinder 1,2,3,4 there is no charge in signal

Eps

B1342- ecu defective

C1956 steering angle sensir circuit failure

Instrument cluster

b1601 -passive anti theft system received I correct key

B1318-battery voltage low

U1900- cab cunmunication bus fault

Audio control module p1628- module ignition supply input malfunction

Wow that list drags I'm just wondering if any one had ever heard if this or experienced it before

The funny thing is these fault codes are not active but stored on my ecu so ivd been told

I've been told it may of been remapped in past and has done this, or take it to fords for a ecu update ?

Sounds like you haev a split intercooler hose or pipe, and a bad one at that!

I had the same thing on my CMAX, the pipe was split, put foot down, turbo kicks in, smokes like there is no tomorrow and then it runs rough.

Start off by looking at the hoses and feel for splits. Start the engine and rev it a little, listening out for any whistling noise to track it down. The biggest culptir ius the elbow at the top of the engine where the air leaves the turbo. The other possibility is where the air goes down to the intercooler, this could also be affected.

I would say wipe the error codes and see wht happens, but heres what I think:

P0299- turbo charger underboost - Definately likely to be due to a split hose - more air goes in and it doesnt all go out.

U0122-lost communication with dynamic control module - sounds like its had a loose wire once upon a time.

P13813- glow plugs control module system voltage below minimum threshold - Had this before - its no major issue, it just takes a little longer for the car to warm up.

P1180 fuel delivery system malfunction- above maximum threshold - This is because the engine thinks its taken X air in so needs to throw Y fuel in, but when it all gets there the numbers are skewed so it tries to overcompensate.

P1632- smart alternator fault circuit malfunction - Sounds like its had a bad connection at some point. Unless you have your battery light regularly on, I wouldnt worry.

P020101- injector circuit malfunction cylinder 1,2,3,4 there is no charge in signal - Sounds like it could be a bad wire, but to be honest if th ecar is running, then the injectors are - its probably an ancient code never cleared.

Eps

B1342- ecu defective - Sounds like its not getting a good signal from one sensor at least - do you have the ABS light on at all?

C1956 steering angle sensir circuit failure - sounds wiring related.

Instrument cluster

b1601 -passive anti theft system received I correct key - Sounds like someone has tried to put the wrong car key in to start this one at some point.

B1318-battery voltage low - flat battery, but if its had an issue with the smart charge before, then its probable the battery discharged enough to throw this warning.

U1900- cab cunmunication bus fault - This is just an issue communicating with a module, can be caused by a sticky barrell through to a wiring fault.

Audio control module p1628- module ignition supply input malfunction - Wiring issue.

If you have already reset the codes and these have come back, then I would be looking at a major wiring issue at the engine side. probably a loose connection or a bad wire somewhere. If however you reset the errors and say only one or two codes come back, then its highly likely the car was bodged before you bought it, but the issues never cleared.

Wow thanks for detailed reply, yeah this elbow on top of the engine were the air leaves the turbo, my turbo was not so long ago replaced and were the air leaves the turbo, seems to be black soot around the connection point top of the turbo and all over the bAck of the turbo, I've cleaned this off and went drive for 40 miles and it was covered again perhaps that's were I should start, and would this be corsing excess smoke ?

And as for the error codes I carnt clear as they are not valid codes ( they are just stored on my ecu ?) this is from my local mr clutch, I've tried clearling with my obd connector and that carnt read the fault codes ?

Sent from my iPhone using Ford OC

Hi Jack,

Where abouts in Kent are you? I recon I could clear them for you?

if you have this muck on the car, its either blown the turbo seals, and the oil is squirting out, or its so full of carbon that its blowing chunks out under pressure, either way, I dont think it looks good...

Let me know where abouts you are anyway, I might be of service.

In based in chatham, yea sounds like you no a lot more than me, and yea if I can get them cleared that will be great if you can, I can come down your way

Sent from my iPhone using Ford OC

not far at all then! I will need to sort out my laptop and the cable and should be able to do you a favour, I will drop you a PM.