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 high-pressure pump on the 1.8 TDCi frequently fails between 150,000 and 220,000 km. Metal wear particles contaminate the fuel system and injectors, often requiring the entire common-rail system to be renewed.

Symptoms: Engine cuts out suddenly, flashing glow plug light, poor throttle response, engine will not restart, blue smoke

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 common-rail injectors of the 1.8L TDCi tend to leak at the copper seal from 130,000 km. Exhaust gases entering the engine oil promote sludge formation and turbocharger damage. All four injectors should be resealed simultaneously.

Symptoms: Diesel smell in the engine bay, exhaust fumes smell inside the cabin, increased fuel consumption, power loss

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

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

Sills and rear wheel arches rust from the inside out. Vehicles from approximately 150,000 km often have widespread corrosion. Always check with a magnet before buying.

Door lower edges and tailgate frequently show early rust spots, particularly at seal contact areas. Water collects in the folds and attacks the metal.

Water enters through a faulty windscreen seal on the passenger side. The pollen filter box can overflow and the passenger footwell carpet becomes wet. Risk of mould.

Rear brake callipers or drum brakes tend to seize, especially after extended periods standing. Brake discs and pads wear unevenly.