Diesel · 2002–2012
Enter your VIN and mileage and get a plan built for your exact engine and gearbox.
All about the Ford FusionAll about the 1.4 HDi / TDCi (DV4) engine
The 1.4 HDi / TDCi (DV4) engine was fitted to the Ford Fusion (2002–2012). In the EU that is 17.5 % of all new cars of this generation.
Versions: 1.4.
The most expensive known risk is injector or high-pressure pump faults: hard starting, smoke: it usually appears at 100,000–250,000 km and costs €300–1,300 to fix.
✓ The faults of this engine were checked against sources (10/2026). Each item has at least two independent sources or an official recall or parts-maker technical note.
Signs: Hard or no starting (often when warm), uneven running, smoke, injector or fuel-pressure fault codes
Fix: Read the injector corrections and do a return-flow test; replace the faulty injectors or the pump control valve / pump; change the fuel filter on time and avoid running the tank empty
Signs: Diesel or exhaust smell in the cabin, puffing or ticking near the injectors, soot deposits around them
Fix: Fit new injector washers and clamp bolts and clean the seats; repair early so the injectors do not seize in the head
Signs: Whistling, loss of power, blue or grey smoke, oil in the intake pipes
Fix: Replace or recondition the turbo, and check the oil feed and return pipes and the oil level; keep oil changes on time
Signs: Rattle or knock at idle from the belt side, wobbling pulley, auxiliary belt slips or jumps off
Fix: Replace the crankshaft pulley with a quality part and fit a new auxiliary belt; a loose belt can damage the timing belt
Signs: Power loss or limp mode, jerking, black smoke, EGR fault codes; mostly with city driving
Fix: Clean or replace the EGR valve; on older engines also check the vacuum solenoid and hoses
Signs: Oil level drops between services, oily intake, sometimes blue smoke
Fix: Check the turbo first, then replace the valve cover with the built-in breather membrane; a compression test shows if the rings are worn
Signs: Bubbling paint
Fix: Rust repair
Signs: Intermittent no-start
Fix: Replace the switch
Signs: Slipping, high bite point
Fix: Replace clutch kit
Signs: Won't select a gear, 'gearbox fault', jerky shifts
Fix: Repair or replace the actuator; clutch re-learn
Signs: Slipping, harsh engagement
Fix: Replace clutch + re-learn
Signs: Harsh 2–3 shift, slipping
Fix: Fluid change, solenoid repair
Typical routine maintenance cost for 100,000 km: €2,400–5,450. Sum of the services and wear parts in the plan above (about 15,000 km a year, independent workshop), without faults.
Intervals and typical prices for the Ford Fusion with the 1.4 HDi / TDCi (DV4) engine. The app gives the exact plan for your mileage.
| Item | Interval | Typical price |
|---|---|---|
| Engine oil + oil filterEngine | every 15,000 km or every 12 months | €70–150 |
| Cabin (pollen) filterClimate | every 15,000 km or every 12 months | €15–40 |
| Brake fluidBrakes | every 24 months | €50–95 |
| A/C service (regas + desiccant)Climate | every 24 months | €70–150 |
| Air filterEngine | every 30,000 km or every 24 months | €15–45 |
| Fuel filterFuel | every 30,000 km or every 24 months | €40–110 |
| Glow plugsEngine | every 100,000 km | €120–300 |
| Auxiliary (serpentine) beltEngine | every 120,000 km | €70–180 |
| Timing belt kit + water pumpEngine | every 140,000 km or every 120 months | €450–900 |
| Coolant replacementCooling | every 150,000 km or every 96 months | €70–150 |
| Manual gearbox oilTransmission | every 150,000 km | €60–130 |
| Front brake padsBrakes | usually at 30,000–60,000 km | €60–150 |
| Front brake discs + padsBrakes | usually at 60,000–120,000 km | €150–320 |
| Rear brake padsBrakes | usually at 50,000–90,000 km | €50–130 |
| Tyres (set of 4)Wheels | usually at 40,000–60,000 km | €320–700 |
| Wiper bladesBody | checked at service | €20–50 |
| 12V batteryElectrical | checked at service | €100–220 |
| Version | Share | Years | CO₂ | Fuel use |
|---|---|---|---|---|
| 1.4 Diesel1,399 cm³ | 16.5 % | 2010–2012 | — | — |
Source: European Environment Agency (EEA), monitoring of CO₂ emissions from new passenger cars, CC BY 4.0. CO₂ and fuel use are official type-approval values (WLTP from 2021), not real-world consumption.
Recalls the manufacturer published in the United Kingdom for this model (5). The same recalls usually apply across Europe. Ask an authorised dealer to check by VIN whether your car is affected and whether the work has been done.
The faults with the highest risk: turbocharger wear or failure (100,000–250,000 km, €500–1,200); injector or high-pressure pump faults: hard starting, smoke (100,000–250,000 km, €300–1,300); EGR valve sooting or sticking (80,000–200,000 km, €100–450); crankshaft pulley (damper) rubber breaks up (70,000–160,000 km, €100–300).
Belt · 140,000 km / every 120 mo.
5W-30 / 5W-40 · PSA B71 2290 / B71 2296 · ~3.75 L · every 15,000 km.
1.4 / 1.6 Duratec / Ti-VCT (Ford Sigma)1.5 / 1.6 HDi / TDCi / e-HDi (DV6, 8v / 16v)
Ford Fiesta VI (Mk6/Mk7) 2008–2017Peugeot 208 I 2012–2019Peugeot 207 2006–2014Peugeot 206 1998–2012Citroën C3 II 2009–2016
Main sources for the faults of this engine:
Faults, intervals and prices are indicative and collected from public sources and owner experience; always rely on the service book and a qualified workshop. Test statistics: DVSA – Anonymised MOT tests and results, Open Government Licence v3.0. Dutch tests: RDW Open Data (CC0). Engine versions: EEA, monitoring of CO₂ emissions from new passenger cars (CC BY 4.0, DG CLIMA). Owner complaints: NHTSA ODI (public domain). Recalls: DVSA Vehicle Safety Branch Recalls Database, OGL v3.0. Brand and model names are trademarks of their owners and are used only to describe the vehicles. How we check the data →
Updated 29/10/2026