Ford Fiesta

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 copper washers and O-ring seals on the injectors burn through, allowing combustion gases and fuel to escape into the valve cover area. This leads to hardened oil deposits.

Symptoms: Diesel smell in the engine bay, oily soot deposit around the valve cover, rough idle, visible smoke from the crankcase ventilation system.

The mesh filter in the oil feed line to the turbocharger clogs with metal swarf and oil carbon. The turbo runs without sufficient lubrication, leading to bearing damage.

Symptoms: Sudden power loss, whistling or howling from the turbo area, 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

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.