Ford Focus

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

Vehicles with 6-speed manual gearbox and 1.0/1.5/1.6 EcoBoost (Aug 2012–Jun 2016) were recalled due to faulty clutch pressure plates. In some cases a complete clutch replacement was required.

The PTU of the GKN all-wheel drive system has no active cooling. Above 150°C the system switches to FWD. TSB 5461 for oil leaks 2016–2017. An aftermarket cooling kit is strongly recommended for track use.

The GKN torque-vectoring rear differential (RDU) of the Focus RS Mk3 requires fresh specialist oil every 48,000 km. Neglecting this causes the clutch plate packs to overheat and the gears to wear prematurely.

Springs and shock absorbers are frequently flagged at inspection. The sportily tuned suspension of the MK3 wears chassis components more rapidly than its predecessor.

The Getrag six-speed shows synchromesh wear in 2nd and 3rd gear at higher mileages. A gearbox oil change with specialist fluid can delay early failure. Repair 1,500–3,000 EUR.

Rear wheel arch openings rust at the bumper transition edge. The roof above the rear doors can deform through body torsion. Boot water ingress through leaking spoiler fixings is widespread.

Launch control and drift mode put enormous strain on the clutch. Replacement including labour over 1,000 EUR. Clutch test: 5th gear, 50 km/h, full throttle — if revs rise without vehicle accelerating, the clutch is worn.

The standard 350×25mm one-piece discs on the Focus RS Mk3 overheat with aggressive driving and warp. Particularly after track days or hard mountain passes. Noticeable as pedal vibration under braking.