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Ford Fusion 1.6 16V TDCi Trend common faults.

2005–2012, MPV, diesel, 90 HP.

The fault list covers: HHJA, HHJB engine, IB5 transmission.

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2 fault write-ups. Both are important. No recall on the list.

If you know the year, pick it. Faults for other years drop out of the list.

Before you buy

Known faults

2 important faults

IB5 manual: worn synchros and differential bearings in the larger models

expensive

In the smaller models, the Fiesta, the Fusion and the B-Max, the IB5 holds up well, but in the larger Focus and especially the Mondeo it does less well: there the engine torque and the weight of the car put a heavier load on the same gearbox.

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The synchros and the gears can wear before 100,000 km, and around 150,000 km the differential bearings need replacing. On cars with the 1.8-litre engine the differential pinion pin often breaks when the wheels spin.

between 100,000 and 150,000 km

What to check

  • While rolling, change down into second and third: worn synchros grate here
  • At a steady speed, listen for noise: a worn differential bearing gives a droning sound
  • In a slow corner, listen for knocking from the gearbox
2 more steps in the write-up

Injector copper washer: the soot blocks the turbo's oil filter

expensive

The copper washers under the injectors start to leak at around 100 000 kilometres, and sooty gas gets from the combustion chamber into the engine bay. The soot first collects in the injector sleeve and makes the seal worse there, and then it gets into the engine oil.

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From there the path leads to the turbo. A fine gauze filter sits in the banjo bolt of the turbo's oil feed pipe, and the soot blocks it. Measured on such a car, the oil pressure at the turbo at idle was 0.8 bar, while the specified minimum is 2.3 bar; after the gauze was taken out it became 3.4 bar. With that much less oil the bearing of the turbo fails, and that typically happens above 130 000 kilometres.

The early signs are the smell of diesel in the cabin and black, oily deposits around the injectors on the engine cover.

The repair is not just the turbo, and that is the most important part of it. The oil feed pipe and its banjo bolts, the sump, the oil pick-up strainer, the oil filter housing and the oil cooler, the intercooler, the particulate filter with the exhaust and the vacuum pump of the brake system all have to be cleaned or replaced, and all the injector sleeves, seals and copper washers have to be replaced. If any of these is left out, the new turbo goes the same way.

above 100,000 km

What to check

  • Open the bonnet and look at the base of the injectors: a black, oily ring shows a leak
  • Look at the engine cover as well: the black, oily trace appears there too
  • Smell the cabin after a cold start: the smell of diesel points to the same thing
3 more steps in the write-up

Checklist

Ford Fusion 1.6 16V TDCi Trend

First what you would check on any car. Then the faults of this model.

Before you buy

Checklist

The printed sheet starts with what you would check on any car. What you tick stays on this device only.

On every car

Ask the owner

Faults of this model

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Engine and transmission

2 engines · 1 transmissions

HHJA · 1.6 TDCI

66 kW (90 HP) · diesel

IB5 · 5-speed manual

manual · 5 speed

Torque limit185 Nm
MakerFord/Getrag

We built the code from the model and the gear count. The factory sheet does not state it. More than one engine code is possible. The fault list shows the faults of each.

Variant data

What is in this version

Factory data

Trim
Trend
Body
MPV
Fuel
diesel
Transmission
manual
Engine size
1560 cc
Power
66 kW (90 HP)
Drive
FWD
Production
2005–2012

Factory service interval

The manufacturer specifies this for this version. Of the mileage and the time, the one that comes first is the one that counts.

  • Air filter

    • 60,000 km or 4 years

  • Cabin (pollen) filter

    • 30,000 km or 2 years

  • Brake fluid change

    • first: 3 years, then 2 years(first change at 3 years, then every two years)

  • Fuel filter, diesel

    • 60,000 km or 2 years
All Mk1.5 versions

Information, not an expert opinion

We write the descriptions, and we put the source next to them. A person reviews them before they go out. They are still information, not a technical expert opinion.

  • A fault on the list does not mean the car you are looking at has it.
  • A fault missing from the list does not mean the model is fault-free. Write-ups are made model by model. Not all of them are done.
  • You decide whether to buy. This is no substitute for an inspection. That needs a workshop and a history check.
Details in the terms