Ford Focus

The copper sealing washers at the injector seat fail under pressure and heat. Combustion gases blow past the injector and bake black, tar-like carbon onto the injector boss. Seized injectors require specialist tools for removal; the cylinder head sealing face can be damaged.

Symptoms: Black deposits around injectors, diesel smell, rough running, cylinder pressure loss

Turbocharger damage from oil starvation due to blocked oil supply passages, or from soot ingress via leaking injector seals. Repair costs are significant, as the sump and cooler must also be cleaned in addition to the turbo.

Symptoms: Whistling or grinding from the turbo area, severe power loss, oil entering the intake tract, blue exhaust smoke

The 1.8 TDCi high-pressure fuel pump typically fails between 150,000 and 220,000 km. Metal debris contaminates the fuel system and injectors, often requiring the entire common-rail system to be renewed.

Symptoms: Engine dies suddenly, glow plug light flashes, poor throttle response, engine will not restart, blue smoke trail

The dual-mass flywheel (DMF) is a known wear point on Duratorq diesels. Rattling and drivetrain vibrations appear from around 150,000–200,000 km. Repair is typically combined with a full clutch kit (approx. 1,200 €).

Symptoms: Metallic rattling when releasing the clutch, vibrations at idle, grinding noise when pulling away

The piezo common-rail injectors in the 1.8L TDCi (HJBA) tend to leak at their sealing cones from around 120,000 km. Fuel ingress cokes the injector and makes removal extremely difficult. A specialist puller tool and professional cleaning are required.

Symptoms: Diesel smell in the engine bay, rough idle, exhaust smell inside the cabin, engine management warning (P0200)

The rubber damper in the crankshaft pulley of the 1.8 TDCi wears from around 100,000 km and creates noise. Continued use risks the auxiliary belt being thrown off, putting the alternator and power steering out of action.

Symptoms: Ticking or slapping noise at idle from the auxiliary belt area, louder on cold start, vibration at standstill

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.