Ford Focus
Ford 1.6L Duratorq TDCi 109 hp HP variant. Focus II. Also HHDB.
Sensible Estate Diesel
Good torque for touring, economical. A solid choice for families.
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 11
Despite full galvanising, sills and wheel arches rust heavily, especially at the junctions between the wing and the bumper. The tailgate rusts under the roof spoiler when water ingresses.
Wheel bearing failures frequently noted in inspection reports, especially from 2010 model year. Track rods and suspension components wear above average. Control arm bushes and lower arms fail prematurely.
Plastic thermostat housings are prone to cracking and coolant loss. Coolant temperature can become unstable; in the worst case the engine overheats.
The brake pressure sensor in the ABS block corrodes and cannot be replaced individually — the entire ABS unit must be swapped. Primarily affects vehicles up to model year 2007.
Up to model year 2007, water accumulates at the junction between the rear bumper and wheel arch, leading to rust. Ford had to carry out multiple repaints. Check carefully before buying.
Ford does not supply an individual wheel bearing — only the complete hub (approximately 290 EUR). Lower RevoKnuckle needle bearings can seize. Press-fitting requires specialist tools. High front tyre wear accelerates deterioration.
Wheel arch edges are almost universally affected without cavity wax treatment. Water penetrates through rear light seals and spoiler fixings into the boot floor, which then corrodes from the inside.
ABS cables chafe on suspension components, ranging from a simple warning light to complete ABS failure. Cable repair is needed, not just a sensor swap.
Heated windscreen filaments fail due to corrosion at cable connections. Instrument cluster shows failures from cold solder joints on the PCB.
The boot draws in water through a leaking tailgate or failed seals. The spare wheel well fills with water, the floor covering rots, and electronics are at risk.
Already due after approximately 25,000 km with spirited use. Front axle 400–500 EUR for discs and pads, rear axle 180–220 EUR. Track day use drastically shortens the intervals.