Ford Fiesta
Ford 1.6L Duratorq TDCi diesel. Multiple power variants: 75, 90, 95 hp in Fiesta Mk7.
Lethargic Diesel
90 hp diesel in the Fiesta: the sluggish character doesn't suit the agile small car. No energy.
Engine Weaknesses 6
The copper sealing washers at the injector seat fail and allow soot to enter the engine oil. The soot blocks the mesh filter in the turbo oil feed. This is the primary cause of turbocharger damage on this engine. Replacing all injector seals is a known maintenance item.
Symptoms: Diesel smell inside the cabin, black deposits around injectors, smoke from the engine bay, subsequent turbocharger damage
Soot from leaking injector seals blocks the fine mesh filter in the turbo oil feed (banjo bolt). Below 0.8 bar oil pressure the turbocharger fails. A complete repair includes the turbo, oil sump, oil strainer, oil filter housing and intercooler. Costs run to £1,300–£2,200.
Symptoms: Whistling from the turbo area, power loss, blue smoke clouds, oil in the intake tract
The injector fire rings and O-ring seals burn through, allowing combustion gases and fuel to escape into the cam cover area. Results in hardened oil deposits.
Symptoms: Diesel smell in the engine bay, oily grime around the cam cover, rough idle, visible smoke from the crankcase breather system.
The mesh filter in the turbocharger oil feed line blocks up with metal swarf and oil carbon. The turbo runs without adequate lubrication, causing bearing damage.
Symptoms: Sudden power loss, whistling or whining from the turbo, blue exhaust smoke, increased oil consumption.
The 1.6 TDCi is particularly prone to DPF blockages. In predominantly short-trip use the engine never reaches sufficient exhaust temperature for self-cleaning. Fuel entering the engine oil through failed regeneration cycles raises the oil level measurably.
Symptoms: Engine management light, power loss, elevated oil level, frequent prompts to take a motorway run
The EGR system is prone to fault code P0487 (EGR throttle position control circuit). The cause is often mechanical stiffness of the throttle flap or carbon buildup on the EGR valve, not necessarily a failed valve. Repeated expensive EGR replacements are frequently unnecessary.
Symptoms: Engine management light with P0487, no limp mode, no noticeable power restriction
Vehicle Weaknesses 6
Brake lines and fuel lines corrode faster than comparable competitors. TÜV inspection failures due to brake line corrosion are common. Leaking lines are a safety-critical issue.
Brake lines corrode faster than on comparable competitors. On older vehicles there is a risk of line fractures, which can cause complete brake failure. Check thoroughly before buying.
Rear springs break through corrosion at the lowest coil, similar to the predecessor. Shock absorbers leak prematurely and ride quality deteriorates.
A defective auxiliary heater relay results in inadequate cabin warming. The heater blows little or no warm air in cold temperatures. Solution: relay replacement per TSI 70/2010.
Window regulator mechanisms fail and the glass refuses to move or sticks. Steering column stalk (indicators/wipers) responds unreliably or fails completely.
Worn driveshafts create vibrations when accelerating and cornering. Common on vehicles over 100,000 km. Driveshaft bearings and CV boots wear prematurely.
Reports & Tests
3010 owner complaints filed with NHTSA (2008–2017). Most reported: Powertrain (1461), Engine (485), Body Structure (406).