I'm sorry Hammy1962. The spelling is caused by the small key pad on my phone ! perhaps I should only reply when I have access to my PC. I agree with your comments, but I have to add that all the turbo's I have been involved in replacing have not failed. I must add that I insist on increased oil changes and that the strict guidelines to oil drainage is adhered too. Interestingly I have placed temp sensors on both turbo's and cylinder heads and in addition looked at oil contamination over a period with different diesel oils. Interestingly the temperature of the engine cylinder head and turbo run considerably higher in the Focus compared with the Fiesta 1.6TDCi, which isn't so notorious for turbo's and the P207 Oil and fuel testing with a well known American Fuel giant in the past has created an additional interest in engine failures. I would suggest that investigation into the types of fuel users are burning may well assist to find more answers. I often used to find that certain problems could often be regional, relating to Fuel.

Please please please point out the fundamental flaws !! I have actually experienced these first hand and have fixed many myself that have already had 3-4 turbots. From experience I can actually tell you which injector seal fails ! I too moved on 4 years ago and now train globally and trouble shoot for manufactures and some of the best engineers overlook the basics or lack the experience where its required too wrapped up in their own little word ! I also write TSB's Look at Concorde and the devastation caused by leaving wheel arches off the design ! I can assure you that 9/10 failures of turbo's on Focus 1.6tdci's are caused by no 3 injector seal leaking causing excess carboning of the oil, causing restriction in the oil feed to the turbo. It also blocks the oil pick up gauze. I even have pictures of injectors leaking and the effects to the oil and gallery's and pumps etc.

"Sorry, but I'm afraid you are getting your injector seals mixed up." Hammy2 is confused ! & shouldn't comment on what he doesn't understand ! The injectors are internal in the engine, under the cam cover so if the seals are leaking the gases burn the oil and convert it to carbon ! as I first explained and "Stumble on" has grasped !100% It been a known issue for some time and have seen a few myself. I have spent 35 years as a diagnostic tech , both training and trouble shooting for those that cant fix issues !

I have a TSB from Forte that shows you pictures and explains the cause of turbo failure ! Its not just about oil flush, it shows pictures of leaking injector seals causing excessive carbon in the engine casuing premature failure of replacement turbo's. If you post an e-mail address I will send you the TSB, I think you need to see it or ask forte for a copy ! There are no real tell tale signs of a leaking injector seal. Its a silent killer for the engine I have tried to post a link to a site where this in in major discussion but this site will not let me post a link ! There is about 10 pages on the subject of 4 turbo failures on 1.6 tdci focus with all the causes and action and photo's

It sounds to me like the dealer and the independent are not aware of the leaking injector issue ! causing the carbon to build in the engine ! The trouble with Garages is they are only as good as the guys that work in them ! there is no licence or code of conduct ! If you contact Forte lubricants they may help with a tech bulliten

the cause of the excessive carbon in the engine if the garage did remove and clean the sump originally is a leaking injector seal ! This is a known issue ! its normally number 3 injector on a focus 1.6tdci and it leaks carbon around the injector inside the cylinder head and the carbon then circulates around the engine causing the blockage. The original garage may of done the job properly but ford may of found carbon in the engine ! The rocker cover needs removing and inspection of the injectors to check for any carbon around the base of the in jectors. This is a serious and well known problem in the trade effecting the Focus. You would be best off taking some legal advice as the first garage have not done the job properly, ignorance isnt the answer ! Best get the original garage to put the car right or take them to court, little knowledge is more dangerous than no knowledge!