About the Engine
The second-generation Ford Focus (Mk2 and facelift Mk2.5) with the 1.6 TDCi engine is an excellent car for everyday use. The engine was co-developed with the PSA group (the same DV6 block used in the Peugeot) and comes in 90 and 109 HP versions. It is reliable and economical, but it has a few well-known weak points that we see regularly in the workshop.
Typical Faults
1. Dual-Mass Flywheel (DMF)
Symptom: Vibration at idle, knocking when starting and shutting off the engine, juddering at low RPMs.
The dual-mass flywheel is the number one fault on the Focus 1.6 TDCi. The engine produces quite a bit of vibration for its size, and the DMF absorbs it all until it wears out. It typically lasts 150,000-180,000 km, but city driving and frequent gear changes shorten its life. Replacement runs 400-600 KM for the part plus labor, and you should always replace the clutch kit at the same time.
2. EGR Valve
Symptom: Power loss, rough running, black smoke, check engine light.
The EGR valve gets clogged with carbon, especially on cars that only do short trips. On the Focus, access to the EGR is relatively good, so cleaning or replacement is more straightforward than on some other models. Cleaning buys you another 20,000-30,000 km, but eventually you need a new valve.
3. DPF Filter
Symptom: Warning on the instrument cluster, power loss, car enters limp mode.
A familiar story for all modern diesel owners. The Focus has an additional issue: failed regeneration cycles dilute the engine oil with diesel, because fuel is injected into the cylinders during regeneration but does not burn completely. Check the oil level regularly. If it is above maximum, change the oil immediately.
4. Injector Seals - "Black Death"
Symptom: Hissing sound from the engine, black oily deposits around the injectors, smell of exhaust gases.
This is a well-known problem that mechanics call "black death." The copper injector washers leak, and exhaust gases under pressure create black deposits around the injector bores. If left untreated, the deposits harden to the point where the injectors cannot be removed without specialist tools. Replacing the copper washers is cheap, but cleaning out baked-on deposits is expensive and time-consuming. Act as soon as you notice the first signs.
5. Thermostat Stuck Open
Symptom: Engine never reaches operating temperature, heater blows lukewarm, increased fuel consumption.
The thermostat gets stuck in the open position and coolant circulates through the radiator constantly. The engine runs at 60-70 degrees instead of 90. Besides weak cabin heating, this means the DPF cannot regenerate properly because it needs high exhaust temperatures. So one cheap fault (the thermostat costs 20-30 KM) can trigger an expensive DPF problem.
6. Rear Trailing Arm Bushings
Symptom: Knocking from the rear over bumps, instability in corners, uneven rear tire wear.
The rear trailing arm bushings are a notorious weak point on the Focus Mk2. On our roads they last 60,000-80,000 km. Replacement requires a press because the bushings are pressed into the mount. Many workshops replace the complete mount with new bushings already fitted, which is faster and more reliable.
7. Power Steering Pump
Symptom: Heavy steering, whining from the engine bay, steering fluid leak.
The electro-hydraulic power steering pump is an expensive part that can fail, especially on older examples. First it starts whining, then leaking, then it gives up entirely. A new pump costs 300-500 KM, and used ones are cheaper but risky. Check the power steering fluid level regularly.
8. Clutch Slave Cylinder
Symptom: Clutch pedal feels soft, pedal drops to the floor, difficulty changing gears.
The slave cylinder sits inside the gearbox on this model, which means replacing it requires removing the gearbox. The part itself is cheap, but the labor is not. That is why it should always be replaced together with the clutch and flywheel, so the gearbox does not have to come out twice.
Tips for Owners
- When replacing the DMF, always do the clutch and slave cylinder at the same time
- Replace the thermostat preventively at 100,000 km - a cheap part prevents expensive problems
- Do not ignore black deposits around the injectors - act immediately
- Check the oil level every 1,000 km, especially if you drive short trips
- Once a week, drive at least 30 minutes on the open road for DPF regeneration