ModerateAffected: 2011-201880,000–150,000 miles

Ford Focus Mk3 1.6 TDCi 115bhp — Glow Plug Failure and White Smoke on Cold Start

Glow plug failure on the Focus Mk3 TDCi is a common higher-mileage issue. Failed plugs cause white smoke and rough running when cold, clearing quickly once the engine reaches temperature.

Severity

Moderate

DIY Difficulty

Moderate

Est. Cost

£100–£250

OBD Codes

P0671P0672P0673P0674

Component Diagram

Engine

Typical layout and location for the Engine assembly.

Reference Illustration

Symptoms

White smoke on startup in cold weather
Long cranking before the engine fires
Rough running for first 2-3 minutes
Glow plug warning light
P0671-P0674 codes

Root Cause

Glow plugs are wear items. The Focus 1.6 TDCi plugs are known to seize in the head at high mileage, making removal risky. Prevention is better than cure.

How To Fix

Test plugs with a multimeter — open circuit = failed plug
Soak in penetrating fluid for 24 hours before removal attempt
Never force a seized glow plug — extraction is specialist work
Replace all four at once — NGK or Bosch plugs recommended
Cost: £100-250 depending on plug removal difficulty

Estimated Repair Costs

Repair Option	Est. Cost (GBP)
DIY (parts only)	£40–£100
Independent Garage	£100–£250
Main Dealership	£160–£400

Other Faults on This Variant

DPF Blockage and Forced Regeneration Failure

Moderate

2011-201840,000–90,000 miles£200–£1000

DPF blockage is the most reported issue on the Focus Mk3 1.6 TDCi. City driving prevents regeneration, and the DPF warning light becomes a familiar sight for urban Focus diesel owners.

EGR Valve and Cooler Failure

Severe

2011-201860,000–120,000 miles£400–£700

The EGR valve and cooler on the Mk3 Focus 1.6 TDCi are known to fail together. EGR cooler failure can cause coolant to enter the intake — a more serious failure than a simple blocked valve.

Turbocharger Failure

Severe

2011-201890,000–160,000 miles£500–£1000

The turbocharger on the Focus Mk3 1.6 TDCi is vulnerable to bearing wear from oil sludge and extended service intervals. Failure typically presents as a sudden loss of power with a loud noise.

Disclaimer: Repair cost estimates are indicative and based on community data. Always get a quote from a qualified mechanic before proceeding with any repair.