Ford Tourneo Custom FAC — Problems & Common Faults
Weaknesses, engine ratings and buying advice
The Tourneo Custom (FAC/V362, 2012 to 2023) is essentially a Transit Custom with seats instead of a cargo bay — correspondingly robust, but with correspondingly van-typical weak points. Until 2016 a 2.2-liter TDCi from the PSA cooperation was fitted with 100 to 155 hp, after which Ford's own 2.0-liter TDCi/EcoBlue took over with 105 to 185 hp, from 2019/2022 partly with 48-volt mild-hybrid assistance. From mid-2020 a 1.0-liter EcoBoost plug-in hybrid was added, where the three-cylinder petrol engine works purely as a generator while the front wheels are driven electrically — technically interesting but rare in numbers. The biggest weakness across the whole production run is rust: sills, floor pan, frame sections and brake lines corrode noticeably earlier than on comparable passenger cars on high-mileage and commercial-use examples, especially near the coast or with frequent road-salt exposure. When buying used, check underneath and inspect the brake lines. Electrically, the sliding door actuators and central locking recur as weak points, along with the headlight leveling control; on early build years up to around 2014 the alternator is also a known issue. On the chassis side, the high vehicle weight and frequent loading wear out anti-roll bar links, tie-rod ends and driveshaft boots earlier, the parking brake often bites unevenly and the rarely used rear brakes tend to seize with rust. On the gearbox side, manual-transmission vans wear the dual-mass flywheel and clutch noticeably from stop-and-go driving and trailer loads, while the six-speed 6F55 torque-converter automatic occasionally shows a brief RPM flare under part throttle — often a software issue around the torque converter lockup clutch. On the plug-in hybrid, watch for a recall covering faulty high-voltage battery cell connectors that can, in the worst case, cause a short circuit and fire; checking the recall history via the VIN is essential when buying a PHEV example. For reliability, the 2.0-liter EcoBlue with 130 or 170 hp from the facelift era from 2018 is a solid compromise of power and economy, while the early 2.2-liter diesel is mechanically simpler but thirstier. A complete service history, especially regular oil changes with the correct specification, is essential on all diesel variants for turbocharger and timing chain longevity. Anyone looking at a Tourneo Custom as a camper conversion base or high-mileage family bus should specifically check for fresh oil traces around the turbocharger, listen for unusual behavior from the automatic transmission during steady-state driving, and inspect the condition of the rear brakes. A test drive of several kilometers with a warm engine reveals 6F55 automatic quirks more reliably than a short drive from standstill. Anyone covering mostly short trips also benefits from asking about the EGR valve and particulate filter service history, since both components see above-average stress in predominantly urban driving.
185 PS
Tourneo Custom 320 2.0 EcoBlue mHEV · Diesel
The powerhouse diesel
Fun to Drive!105–185 PS
2.0L EcoBlue Diesel
12 weaknesses
Stay Away!Generations
Engine Overview
The Ford Tourneo Custom FAC is available with 10 engine variants — from 100 to 185 hp.
Modern common-rail diesel with quiet, refined combustion and strong pull from low revs. A timing chain saves belt changes. The DPF and AdBlue need enough long-distance use and level checks. NOx sensors can throw faults over time. Efficient and durable as long as servicing and oil quality are right.
- !! Continental Injector Coating Defect (2019) from 50,000 km
Continental injectors with a faulty internal coating (vehicles built Feb–Sep 2019). The coating delaminates and blocks the injector. Ford service action: free injector replacement (Ford TSB-20-2335). Affected vehicles: Transit, Ranger, Focus, Mondeo, S-Max, Galaxy, Edge.
Symptoms: Hesitation, poor idle, power reduction, increased fuel consumption, limp mode - !! DPF Clogging from Injector Soot Ingestion from 80,000 km
Faulty injectors generate excessive soot that prematurely clogs the DPF. On the high-output variant (190 hp), soot also blocks the low-pressure filter of the dual EGR system. Repair requires simultaneous replacement of injectors AND DPF (TSB-20-2335). Replacing the DPF alone does not resolve the issue long-term.
Symptoms: Fault codes P2002, P02EC, P02FA, check engine light, power reduction - !! VGT Actuator Failure from 140,000 km
The variable turbine geometry actuator on the bi-turbo system fails electrically or mechanically. Often only the electric motor is faulty, but Ford supplies only the complete turbocharger.
Symptoms: Sudden power loss, limp mode, fault codes P0299 or P0045 in ECU.
+ 9 more engine weaknesses + vehicle weaknesses
The 2.2-liter diesel with common-rail injection and turbocharging comes from a cooperation with a French partner and is regarded as a robust, torquey commercial-vehicle engine with solid reserves even under sustained load. With inadequate maintenance the EGR valve tends to coke up, causing power loss and rough running, while the diesel particulate filter clogs under mostly short-trip use and forces limp-home mode. The timing chain can stretch if service intervals are overrun, noticeable as rattling on cold start. The turbocharger and high-pressure pump are sensitive to contaminated or incorrectly specified engine oil, so regular oil changes with the correct approval are essential for longevity.
- !! Turbo damage from oil starvation/contamination from 120,000 km
Under heavy use and neglected oil changes, the turbocharger sustains damage from around 120,000 km, often triggered by contaminated or degraded engine oil.
Symptoms: Whistling under acceleration, blue smoke from the exhaust, power loss under load. - !! Timing chain stretches with overrun service intervals from 120,000 km
If oil change and service intervals are overrun, the timing chain can stretch from around 120,000 km and, in the worst case, snap.
Symptoms: Timing chain rattle on cold start, engine damage from a broken chain in extreme cases. - !! EGR valve coking up
With frequent short trips and low engine temperatures, the EGR valve increasingly cokes up, causing it to stick or fail to close properly.
Symptoms: Engine warning light, power loss, increased fuel consumption, rough idle.
+ 2 more engine weaknesses + vehicle weaknesses
Modern common-rail diesel with quiet, refined combustion and strong pull from low revs. A timing chain saves belt changes. The DPF and AdBlue need enough long-distance use and level checks. NOx sensors can throw faults over time. Efficient and durable as long as servicing and oil quality are right.
- !! Continental Injector Coating Defect (2019) from 50,000 km
Continental injectors with a faulty internal coating (vehicles built Feb–Sep 2019). The coating delaminates and blocks the injector. Ford service action: free injector replacement (Ford TSB-20-2335). Affected vehicles: Transit, Ranger, Focus, Mondeo, S-Max, Galaxy, Edge.
Symptoms: Hesitation, poor idle, power reduction, increased fuel consumption, limp mode - !! DPF Clogging from Injector Soot Ingestion from 80,000 km
Faulty injectors generate excessive soot that prematurely clogs the DPF. On the high-output variant (190 hp), soot also blocks the low-pressure filter of the dual EGR system. Repair requires simultaneous replacement of injectors AND DPF (TSB-20-2335). Replacing the DPF alone does not resolve the issue long-term.
Symptoms: Fault codes P2002, P02EC, P02FA, check engine light, power reduction - !! VGT Actuator Failure from 140,000 km
The variable turbine geometry actuator on the bi-turbo system fails electrically or mechanically. Often only the electric motor is faulty, but Ford supplies only the complete turbocharger.
Symptoms: Sudden power loss, limp mode, fault codes P0299 or P0045 in ECU.
+ 9 more engine weaknesses + vehicle weaknesses
Modern common-rail diesel with quiet, refined combustion and strong pull from low revs. A timing chain saves belt changes. The DPF and AdBlue need enough long-distance use and level checks. NOx sensors can throw faults over time. Efficient and durable as long as servicing and oil quality are right.
- !! Continental Injector Coating Defect (2019) from 50,000 km
Continental injectors with a faulty internal coating (vehicles built Feb–Sep 2019). The coating delaminates and blocks the injector. Ford service action: free injector replacement (Ford TSB-20-2335). Affected vehicles: Transit, Ranger, Focus, Mondeo, S-Max, Galaxy, Edge.
Symptoms: Hesitation, poor idle, power reduction, increased fuel consumption, limp mode - !! DPF Clogging from Injector Soot Ingestion from 80,000 km
Faulty injectors generate excessive soot that prematurely clogs the DPF. On the high-output variant (190 hp), soot also blocks the low-pressure filter of the dual EGR system. Repair requires simultaneous replacement of injectors AND DPF (TSB-20-2335). Replacing the DPF alone does not resolve the issue long-term.
Symptoms: Fault codes P2002, P02EC, P02FA, check engine light, power reduction - !! VGT Actuator Failure from 140,000 km
The variable turbine geometry actuator on the bi-turbo system fails electrically or mechanically. Often only the electric motor is faulty, but Ford supplies only the complete turbocharger.
Symptoms: Sudden power loss, limp mode, fault codes P0299 or P0045 in ECU.
+ 9 more engine weaknesses + vehicle weaknesses
In this drivetrain the three-cylinder turbo petrol engine works purely as a generator and has no mechanical connection to the driven wheels — propulsion is electric in every driving situation, while the combustion engine supplies power as needed. This series architecture reduces mechanical wear on the combustion side itself, but shifts the reliability question more toward the power electronics and the high-voltage battery. That is exactly where a recall struck: faulty cell connectors inside the high-voltage battery could trigger an internal short circuit, which in the worst case led to loss of drive or a vehicle fire, so affected vehicles underwent a full battery replacement campaign. For a used purchase of this drivetrain, checking the recall history via the VIN is therefore particularly important.
- !! Recall: faulty high-voltage battery cell connectors
Faulty connections between the high-voltage battery's cells can trigger an internal short circuit, leading to loss of drive and, in the worst case, a vehicle fire. Ford replaces the entire high-voltage battery on affected vehicles.
Vehicle Weaknesses
| Weakness | Cost | |
|---|---|---|
| Rust on sills, floor pan and frame High-mileage and commercial-use vans show corrosion on sills, floor pan and frame sections, plus corroded brake lines. Coastal regions and frequent road-salt exposure are the main drivers. Symptoms: Visible rust on sills and underbody, brake lines flagged during inspection, paint bubbling around wheel arches. | Low |
Alternatives
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Known Problems and Issues +
A total of 32 weaknesses have been documented for the Ford Tourneo Custom FAC (2012–2023) — 18 engine-related and 14 vehicle-related. 2 problem engines: EcoBlue-2.0-Custom (2.0L EcoBlue), EcoBoost-1.0-PHEV-Custom (1.0L EcoBoost PHEV (Range Extender)). Typical issues affect Rust, Electronics, Brakes, Suspension.
Tourneo Custom (TDCi-2.2-Custom, 2012–2016) — Be Careful: Turbo damage from oil starvation/contamination, Timing chain stretches with overrun service intervals, EGR valve coking up. Power: 101 PS.
Tourneo Custom (TDCi-2.2-Custom, 2012–2016) — Be Careful: Turbo damage from oil starvation/contamination, Timing chain stretches with overrun service intervals, EGR valve coking up. Power: 125 PS.
Tourneo Custom (TDCi-2.2-Custom, 2012–2016) — Be Careful: Turbo damage from oil starvation/contamination, Timing chain stretches with overrun service intervals, EGR valve coking up. Power: 155 PS.
Tourneo Custom (EcoBlue-2.0-Custom, 2016–2023) — Stay Away!: Continental Injector Coating Defect (2019), DPF Clogging from Injector Soot Ingestion, VGT Actuator Failure. Power: 105–107 PS.
Tourneo Custom (EcoBlue-2.0-Custom, 2016–2023) — Stay Away!: Continental Injector Coating Defect (2019), DPF Clogging from Injector Soot Ingestion, VGT Actuator Failure. Power: 131 PS.
Tourneo Custom (EcoBlue-2.0-Custom, 2016–2023) — Stay Away!: Continental Injector Coating Defect (2019), DPF Clogging from Injector Soot Ingestion, VGT Actuator Failure. Power: 170 PS.
Tourneo Custom (EcoBoost-1.0-PHEV-Custom, 2020–2023) — Stay Away!: Recall: faulty high-voltage battery cell connectors. Power: 126 PS.
Tourneo Custom (EcoBlue-2.0-Custom, 2019–2023) — Stay Away!: Continental Injector Coating Defect (2019), DPF Clogging from Injector Soot Ingestion, VGT Actuator Failure. Power: 185 PS.
Tourneo Custom (EcoBlue-2.0-Custom, 2022–2023) — Stay Away!: Continental Injector Coating Defect (2019), DPF Clogging from Injector Soot Ingestion, VGT Actuator Failure. Power: 150 PS.
What to watch out for with the Ford Tourneo Custom? See the detailed listing of all engine and vehicle weaknesses in the sections above.
Frequently Asked Questions
What problems and weaknesses does the Ford Tourneo Custom FAC have? +
What should I look for when buying a used Ford Tourneo Custom FAC? +
Which engine is recommended? +
Which Ford Tourneo Custom FAC engine is the most fun? +
Is the Ford Tourneo Custom FAC worth buying used? +
What horsepower variants are available for the Ford Tourneo Custom FAC? +
Last updated: February 2026 · All information without guarantee