Hello I have a mk 2 ford focus 1.6 TDCI My turbo was whistling when I brought it. 

 

I have found the issue which is the the plastic pipe that bolts on to the turbo, the bolt holes have snapped. 

But I do not no where to get a replacement pipe or what the part is for if anyone could offer some help it will be greatly appreciated 

Hi must be common fault with the 1.6 someone posted pic of this part few weeks back I looked over eBay as didn't know what part was I had no joy.

cheeky way is go to ford ask for price and just say out of curiosity what's it called then search round eBay or local dealers.

tdci Peter would be your best bet if he sees this post

Thats not a bad idea thanks mate 

No worries it what I do when stuck lol 

Blimey just found it. Intercooler resonator. 

 

Look at that price oh well no treats for me this week lol 

Well done pal should be an easy fit diy n sure can manage few jars local pub still lol

3 minutes ago, Liam121093 said:

Look at that price oh well no treats for me this week lol 

Ouch, that is about 20 jars of good ale!

But it should improve the fuel economy a tad, less work for the turbo without the leak. And if the MAF is confused by the leak that will cause over-fueling, waste diesel & clog up the DPF. So it could be a good buy in the long run!

Peter.

That's a very good point Peter. 

Well I would rather pay for this than a DPF ha ha.

 

I wonder why they put a resonator on a diesel, thought they were only for noise on petrols, a straight pipe would've done there surely.

How they can charge £80 for some cheap moulded plastic I have no idea though!  

4 hours ago, TomsFocus said:

I wonder why they put a resonator on a diesel

There is an odd shaped pipe on the turbo compressor outlet of the 1.8TDCI too, metal though, not nasty plastic! (Photo)

I wonder if it is to take out the turbo whistle. My turbo is virtually silent. (It works 'cos I can see the boost pressure goes up to 2.4 Bar abs!).

As the turbo compressor outlet goes way over 100C when on full boost, a plastic outlet seems a dodgy idea.

As for the £80, that is because they are wicked. And I mean that in the old fashioned, bad way!

(Though the >100C does suggest they can't just use the cheapest, low melting point plastic.)

It still bolts in so I'm going to try and silicone the pipe as the gap is only about 2 mm I just hope it will hold.

 

Hopefully it will save me £80 until I can spare it 

1 hour ago, Liam121093 said:

silicone the pipe as the gap is only about 2 mm I just hope it will hold.

Might need a bit more strength than that. Remember you've got 20psi of air at over 100C in there at times. Some thin bent ali wrapped around, and wired or clipped in place, perhaps? (in addition to the sealant, to stop it being squeezed out).

Be a bit careful not to get bits of metal or silicone inside, it will go into the intercooler, and maybe even into the engine.

Have you looked at 2nd hand bits? It is not like some hyper critical part.

Yeah I did have a look at some but the only one I can see is the one I showed.

The breakers near me don't have one. So I think best option is to see if this will work if not I'll be parting with my hard earned cash. 

 

I have found one that looks similar (photo) but not sure whether they are the same as there is no description.

37 minutes ago, Liam121093 said:

I have found one that looks similar

1473404 is marked as Fiesta, and shows as Not compatible with Focus 1.6tdci, using Ebay via desktop computer.

1465155 come up as the right part. Pity about that! Good try though.

I have been getting a whooshing noise when turbo kicked in and thought it was the pipe I pictured earlier. However i have now found this (pictured) 

 

Do you think this could be causing it, there is a split on the inside of the boost pipe but it does not go all the way through. 

3 hours ago, Liam121093 said:

there is a split on the inside of the boost pipe but it does not go all the way through. 

Needs replacing, but if it is not all the way through, I do not see how it could make a sound audible inside the car. The gap at the end of the other pipe looked a much better candidate.

 

Ok mate I will let you no how I get on as will be taking them all of today. 

Could anyone tell me what this is please 

1 hour ago, Liam121093 said:

Could anyone tell me what this is please 

Also think I found the issue £44 from ford but going to go to a place that make pipes for the diggers at work and ask if they can make me up a straight pipe to put on 

 

Any idea why it has a metal ring round it 

10 hours ago, Liam121093 said:

Could anyone tell me what this is please

Does that butterfly valve link the Turbo outlet pipe (the damaged one with the "resonator" chambers) to the inlet manifold? In which case it is the intercooler by-pass valve.

When it is open, hot air from the turbo can pass directly into the engine. This can increase exhaust temperature for DPF regen, it can shorten engine warm up time, and possibly improve combustion in cold weather. I do not know which of these is used on the 1.6, maybe only DPF regen.

But I am a little confused here! The Turbo outlet pipe you selected from Ebay (above, no 1465155) does not seem to have the by-pass connection port. Only some engine versions have this by-pass valve.

The photo of a 1.6TDCI in the link below fairly clearly shows a different outlet pipe, with the by-pass connection. Which type does your car have? (Ignore title of thread, its just for a handy photo!)

 

Yeah the resonator connects to the butterfly valve. Photo 

 

I have just ordered a resonator for £20 on eBay but just noticed it does not have the additional slot for the butterfly valve. Which is strange as it has come off a 2005 1.6 TDCI the exact same as mine.

And can't find one anywhere.

4 hours ago, Liam121093 said:

just noticed it does not have the additional slot for the butterfly valve.

You could try fitting the new resonator, if you blank off the by-pass butterfly valve, but see note (*)!. Needs to be a robust seal, for the 20PSI boost, thought this side of the intercooler will not usually be so hot.

As far as I can see, the only downside to this would be a bit lower exhaust gas temperature during re-gen, especially in Winter, when the intercooler is often rather too effective.

This by-pass valve seems a complete mystery, I have searched for references to it, and found very few. That photo (above) I found on this site is the only picture I have seen. Tom (Tomsfocus) mentioned it in passing (blocking the intercooler, though that valve actually short-circuits or by-passes it (*), but same effect). The engine photo in Haynes seems to have something, but no mention anywhere. The Focus wiring diagram clearly shows the drive connections for it, though marked "DPF/CDPF only".

2005 was still in the Mk1/Mk2 changeover period though, I believe. I am fairly sure Mk1 did not have it, and maybe not some earlier Mk2s.

Toms reference was in:

http://www.fordownersclub.com/forums/topic/62426-16-tdci-dpf-fault-code-p2458/?do=findComment&comment=419962

As a side note, I am interested in the intercooler  by-pass because I have continuous in-car monitoring of air intake temp (after intercooler), and have fitted a thermostatically controlled blind, to keep the air temp up a bit, especially in WInter. My car has no DPF, but I wanted to shorten the warm-up time (made no appreciable difference), and see if it increased mpg (seems to have added 1 - 3 mpg). Diesels always seem to deliver better mpg in summer, but there are many possible reasons for this.

(*) I can not see which side of the throttle / anti-shudder valve that by-pass is connected to. If the by-pass is on the engine side of the throttle, then Tom was quite right in saying the intercooler can be blocked, by closing the throttle & opening the by-pass. In that case, the by-pass can not be blanked off, or the engine would get no air!!!

 

 

Been a while but this is how far I have got so far.

 

Got a new resonator for £30 on fleabay 

Fixed the pipe that was split and still happening, 

Found out it was (see picture) had a big hole on the underside. 

Got one for £10 as soon as that turns up should be able to let you no if it's fixed. 

16 hours ago, Liam121093 said:

Fixed the pipe that was split and still happening, Found out it was (see picture) had a big hole on the underside

Resonator, Split pipe, Hole in pipe:

Seems like your intake system has more holes than a Swiss cheese!

Did you manage to find a resonator with the by-pass connection?

Hope it works, and that is the last of the holes! Let us know how it goes.

Yeah the resonator had all the correct parts didn't need to block off or bypass anything.