Plastc In Engine of Ford Transit Connect

[Thomastursh]

Hi Everyone, I hope someone here can help me.

I have a Ford Transit Connect 2015 Model with VIN Number WF0SXXWPGSEA10765, It is a 1.6 Diesel, with a T1GA Engine.

I was driving and had the temperature guage fluctuating until I had white smoke in my rear view mirror.

The vehicle was still able to drive however it was now boiling and so had to be towed.

Upon opening the motor we discovered that one piston (#3) had melted and deformed, the pistons were replaced, however we found deposits of melted plastic in the engine, and through the galleries leading to the cam shaft, CAM was worn howerver the cranks mains & big ends were intact.

We have rebuilt the engine but cannot figure out where the melted plastic came from.

Visited FORD in Johannesburg and they have never come across this problem.

My guess is there is a piece of plastic that goes under the oil pump ( see images attached) that is meant to channel oil to the top of the engine, as we are cranking the motor and not getting oil at the top of the motor, all the galleries were checked and cleaned out and the block and head were said to be fine.

Would anybody have come across this problem, or may know where / what could have melted in the engine, I also do not think this is a random occurance as I came across 2 other garages that reported having a simillar problem and they could not figure out where the plastic came from.

I also visited Ford and they showed me an engine they had done a warranty replacement on and under the oil pump there was no pipe, however the hole that is covered by the oil pump is threaded yet nothing threaded is sitting in there, that is my only basis for saying the plastic piece sits there, however I have not seen anything that suggests the plastic could have come from anywhere else.

I would really appreciate any and all assistance regarding this issue would hate to scrap a whole motor over a piece of plastic

[metalworker0]

Don't know much about the 1.6 ...does it have a wet belt?

1. Had the wet belt degraded .and delaminated..ford have been having trouble with this happening...it could have happened in the past if the belts ok now .........and someone did not do a through job of cleaning the engine....after it had failed

2. The plastic has to make its way through the oil strainer and the oil filter to end up in the galleries.
Another idea is that its come from inside of the oil filter ..there from manufacture of the oil filter.

3. What's that gouge ...around the "oilway" that you have circled ..was that there ..or did you or the garage do it . those o-rings will not seal on that gouged surface ...if someone else has damaged it in the past ...they may have put some sort of plastic bonda / filler type substance in the gouge that is no longer there and is now in the galleries.

Does the manufacturing date on the oil pump (a circle with a number and days of month around the outside of it say 16 ...if so its been apart and had a new pump.

all the best.mark

[Thomastursh]

Hi Mark

Thank you for yur prompt response.

The timing belt is external (dry).

I like the idea of the plastic coming from the oil filter, however the oil filter was intact.

The gouge is from where they had to remove the chuck of plastic that was stuck at that entrance, the block has since been polished and cleaned (photos were taken before).

I would agree with some filler having been used before if I had not come across two other motors with the same plastic residue inside, this is definitely from some part of the motor.

It is scary to continue, not knowing where the plastic came from as the motor could fail once more, open to more ideas.

Many thanks.

[metalworker0]

The other failure point is the oil cooler assembly and mount for the oil filter

These are all the versions of that 1.6 engine you have

1.6L Duratorq DI SOHC (95PS) (+)"Africa" "Transit/Tourneo Connect 2013- (CHC)"
1.6L Duratorq CR TC (75PS) - DV6 (+)"Africa" "Transit/Tourneo Connect 2013- (CHC)"
1.6L Duratorq CR TC (115PS) - DV6 (+)"Africa" "Transit/Tourneo Connect 2013- (CHC)"

note ..."Africa" - meaning the engine in the connect as 1.6 form was only available there ...which means help here is going to be limited -

But it is a 1.6 and in many others cars that are covered in other forums for focus , mondeo , fiesta...which may share considerably more knowledge than this forum can

As you can see, hard to know what you've got ...i know you gave the VIN ..but the web sites i search for info on ..are now stopping me putting the VIN into them without paying x amount of money and becoming member .

So is it dohc or sohc that would be a start .it would help somewhat ...well it would help others here ..who want to help you.

I suggest you look at a lot of Alen Howatts videos ,....he does a lot with this engine since its in his Mondeo taxis in one form or another

it is, i believe a Peugeot designed engine and is also in Citroen's and Peugeot's

He covers mostly everything that goes wrong with them

There maybe one vIdeo amongst his that covers your problem, he does cover oil cooler mount failures and brake vacuum pump failures ..id say focus on them ..as they are plastic

https://www.youtube.com/@alan4x/videos

all the best.mark

[Thomastursh]

Hi Mark,

Thank you very much I have been going through the Youtube videos to no avail, could not find a way to also reach him directly save for commenting on a video.

The engine is the SOHC.

I am still scared to put the motor back in until I am sure where the plastic came from.

Been scouring the other platforms, and no joy from them either.

[metalworker0]

Hi Mark,

Thank you very much I have been going through the Youtube videos to no avail, could not find a way to also reach him directly save for commenting on a video.

The engine is the SOHC.

I am still scared to put the motor back in until I am sure where the plastic came from.

Been scouring the other platforms, and no joy from them either.

Think i may be mistaken about alan and these engines, his are 2l dohc french designed engines with chain driven cams ....well when say chain driven it is belt driven with a short chain on the inside, there so many different designs of ford engines these days, its mind boggling .

Alan ..if he knows your answer has / did have a live stream every wednesday at 8pm

if asking questions you have to have the question ready to paste in the moment he opens the live stream, wait any more than 30 mins and it will never get answered .

all the best.mark

[metalworker0]

found on the net + all OTHER cars this engine is fitted in .

DLD-416
The DLD-416 (or DV6) is a 1.6 L (1560 cc/95 cu in) version used by Ford, Volvo, PSA, BMW and Mazda.

Applications include:

2007–present Suzuki SX4 1.6 DDiS, 90 PS (89 hp/66 kW) and 159 ft·lbf (215 N·m)
2007–present MINI Cooper D 1.6 110 PS (108 hp/80 kW) and 177 ft·lbf (240 N·m)
2007–present Citroën C4 Picasso 1.6 HDi, 110 PS (108 hp/80 kW) and 177 ft·lbf (240 N·m)
2006–present Citroën Berlingo 1.6 HDi, 75–90 PS (74–89 hp/55–66 kW) and 127–159 ft·lbf (172–215 N·m)
2005–present Citroën C3 1.6 HDi, 90 PS (89 hp/66 kW) and 159 ft·lbf (215 N·m)
2004–present Citroën C4 1.6 HDi, 90–109 PS (89–108 hp/66–80 kW) and 159–177 ft·lbf (215–240 N·m)
2004–present Citroën C5 1.6 HDi, 109 PS (108 hp/80 kW) and 177 ft·lbf (240 N·m)
2004–present Citroën Xsara Picasso 1.6 HDi, 109 PS (108 hp/80 kW) and 177 ft·lbf (240 N·m)
2005–present Ford Fiesta 1.6 TDCi, 90 PS (89 hp/66 kW) and 159 ft·lbf (215 N·m)
2005–present Ford Fusion (European) 1.6 TDCi, 90 PS (89 hp/66 kW) and 159 ft·lbf (215 N·m)
2004–present Ford Focus 1.6 TDCi 90, 90 PS (89 hp/66 kW) and 159 ft·lbf (215 N·m)
2004–present Ford Focus 1.6 TDCi 110, 109 PS (108 hp/80 kW) and 177 ft·lbf (240 N·m)
2004–present Ford Focus C-MAX 1.6 TDCi 90, 90 PS (89 hp/66 kW) and 159 ft·lbf (215 N·m)
2003–present Ford Focus C-MAX 1.6 TDCi 110, 109 PS (108 hp/80 kW) and 177 ft·lbf (240 N·m)
2003–present Peugeot 206 1.6 HDi, 109 PS (108 hp/80 kW) and 177 ft·lbf (240 N·m)
–2008 Peugeot 307 1.6 HDi, 90–109 PS (89–108 hp/66–80 kW) and 159–177 ft·lbf (215–240 N·m)
2003–present Peugeot 407 1.6 HDi, 109 PS (108 hp/80 kW) and 177 ft·lbf (240 N·m)
2003–present Mazda 3 1.6 CiTD, 109 PS (108 hp/80 kW) and 177 ft·lbf (240 N·m)
2004–present Volvo S40 1.6D, 109 PS (108 hp/80 kW) and 177 ft·lbf (240 N·m)
2004–present Volvo V50 1.6D, 109 PS (108 hp/80 kW) and 177 ft·lbf (240 N·m)

[metalworker0]

Another thing to check

In the oil feed pipe to the turbo is a tiny filter / strainer, that is housed in the banjo bolt which is screwed into the block

it is common, lots of rumours, unconfirmed - This filter / strainer can deteriorate over time and fall to pieces, i suppose it could be possible for it to fall down the gallery and into the main gallery .

the bolt looks like this with the filter installed into it . they call it a restrictor ..i call it a strainer. ..pic is part of ebay advert for 1.6 tdci turbo oil feed pipe kit

all the best.mark