Turbo Ford: problems by model and engine

Documented faults, from most to least important

Severity × frequency. Below each one, the Ford models it appears in.

- High severityFrequency: Very frequent1.6 HDiTurbo failure through lack of lubrication (carbon deposits and union filter)On the 16-valve 1.6 HDi/TDCi engines (2004-2011) the turbo can seize because carbon deposits from the oil clog the mesh filter in the union that feeds it. It is a serious, repeat fault: if only the turbo is replaced without cleaning the circuit, it fails again.Repair (garage): €700–€1,050
In C-Max I, Fiesta VII and Focus II
- High severityFrequency: Common2.0 HDiVariable-geometry turbo failures (actuator, sensors and clogging)On the 107/110 hp and, above all, 136-140 hp 2.0 HDi, the variable-geometry turbo fails relatively often: sometimes it is the whole turbo, but often it is the actuator, sensors or hoses, with loss of power and limp mode.
In C-Max II and Focus III
- High severityFrequency: Occasional1.6 EcoBoostPremature turbocharger failureThere are documented cases of premature turbocharger failure: in a Ford Mondeo the turbo housing cracked at 47,000 km along with a coolant leak, and in a Ford S-Max the turbo failed at 60,000 km without the warranty covering it.
In C-Max II, Focus III, Galaxy II, Kuga II, Mondeo IV and S-Max I
- High severityFrequency: Occasional1.3 MultijetSeized variable-geometry turboOn versions with a variable-geometry turbo, the vanes can seize through soot build-up, especially on cars used in town for short journeys. The engine loses power gradually and may give off black smoke when accelerating.Repair (garage): €450–€700
In Ka II
- High severityFrequency: Occasional2.2 HDiTurbo faults, somewhat more frequent on the sequential twin-turbo versionsThe 2.2 HDi comes in single-turbo versions (128-156 hp) and twin-turbo versions with two turbochargers in sequence (170 hp and up). Fiches-auto does not consider it a chronic problem, but it does record a significant number of turbo cases across all power outputs, somewhat higher on the twin-turbos.
In Mondeo IV
- Medium severityFrequency: Common1.8 TDCiCracked boost hoses and turbo wearThe boost air hoses on Ford diesels of this era, including the 1.8 TDCi, crack over time and cause a loss of power; the turbo itself can end up damaged if this is not detected in time.Appears at around 35,000 km
In C-Max I, Focus I, Focus II, Galaxy II, Mondeo III and Mondeo IV and 2 more models
- Medium severityFrequency: Occasional1.4 HDiPremature turbo wear from poor lubricationThe BorgWarner KP35 turbo of the 8-valve version can wear out early when the oil degrades and forms carbon deposits, reducing its lubrication. It is a minority but recurring fault: it appears in just over 9% of the reports collected for the 68 hp version.
In Fiesta V, Fiesta VII and Fusion
- Low severityFrequency: OccasionalVolvo 5 cilindros gasolinaFaulty turbo boost control solenoidThe solenoid that regulates turbo boost pressure can fail on turbocharged five-cylinder Volvos and the Focus ST; the symptom is a noticeable loss of power and, on the ST, a boost gauge helps to detect it.
In Focus II, Kuga I, Mondeo IV and S-Max I

By Ford model

Open yours to see only the faults that affect it, by engine and by year.

Engines and gearboxes involved

Frequently asked questions

What faults with the turbo do Ford cars have?

In 16 models from Ford there are 8 documented faults with the turbo. The most important: turbo failure through lack of lubrication (carbon deposits and union filter), variable-geometry turbo failures (actuator, sensors and clogging) and premature turbocharger failure. Each fault has its own page with the affected years and versions, the symptoms and the repair cost.

Which Ford models have the most problems with the turbo?

Ford Mondeo IV (4 faults), Ford Focus II (3 faults), Ford S-Max I (3 faults) and Ford C-Max I (2 faults).

Which Ford engines have faults with the turbo?

1.3 Multijet (1 fault), 1.4 HDi (1 fault), 1.6 EcoBoost (1 fault), 1.6 HDi (1 fault) and 1.8 TDCi (1 fault).