CriticalCommonEngine

Ford Focus: Head gasket failure from wrong factory gasket - coolant loss and white smoke (Focus RS, 2.3 EcoBoost)

Head gasket failure from wrong factory gasket - coolant loss and white smoke (Focus RS, 2.3 EcoBoost) is a common engine fault on the Ford Focus on the 2016–2017 cars, and we rate it critical. Putting it right costs $3,500 to $8,000 at New Zealand independent workshop rates. Below is what goes wrong, the symptoms to notice on a test drive, where to look, and what to ask the seller before you hand over any money. It is one of 37 documented faults on the Ford Focus.

Vehicle: Ford Focus
Only on: RS
Engine: 2.3L
Years: 2016–2017
Fuel: petrol
System: Engine

This page covers the Ford Focus as a model. Some faults only affect particular engines or build years — enter a plate below to narrow the list to one car.

All Ford Focus faults37 documented faults on this model

What you are looking at

What goes wrong

Mk3 Focus RS models built between August 2015 and July 2017 left the factory with a 2.3 Mustang head gasket that does not suit the RS cylinder head - it has an extra hole and a coolant path that lets coolant stagnate, damaging the head. The result is coolant consumption, white exhaust smoke and eventually misfires. Ford ran a free repair program replacing the gasket and, where needed, the cylinder head itself, regardless of warranty - but that program required the car to be presented, and imported or later-sold cars may never have had it. Out of program, this is a head-off job with possible head replacement.

What you would notice

White exhaust smoke, especially at start-up
Coolant level drops with no external leak
Misfire or rough running once the damage progresses

How to check it

Where to look. Cylinder head gasket, 2.3-litre EcoBoost engine

Cold start it yourself and watch the exhaust: persistent white smoke after the first minute is the symptom, not brief condensation steam. Check the coolant expansion tank level and look for any oily film inside the tank. Ask specifically whether the head gasket recall/service program was performed and demand the dealer invoice - on an RS this single sheet of paper is worth thousands. If a workshop inspection is possible: a combustion-gas test of the coolant and a cooling-system pressure test will show an active leak; a bore inspection is warranted if any misfire history exists.

Parts involved: Head gasket.

What it costs to put right

$3,500 to $8,000 at New Zealand independent workshop rates. That is for this job on its own, not for the car.

An estimate, in NZD, for the repair as normally carried out. What a specific car costs depends on which part has failed and what it damaged on the way — treat this as the floor for a negotiation, not a quote.

Ask the seller

“Was the head gasket replaced under Ford's program? Show me the invoice.”
“Does it use coolant between services?”
“Has the cylinder head ever been replaced or machined?”

Now check the Ford Focus you are actually looking at

Everything above is true of the model, and it is free. What it does not tell you is whether THIS car has been looked after: its odometer history and whether the reading has ever gone backwards, whether there is still money owing on it, whether it has been reported stolen, how many owners it has had and what it is really worth today. That comes from the official records for that plate. Enter the plate for the free details, or get the full history and a market valuation from $13.49.

Not sure what you would be paying for? See what a full KickTyres check includes.

Where this comes from

The failure described above is documented in the sources below. The inspection instructions and the cost estimate are KickTyres’ own interpretation of them.

CarThrottle 'Here's How Ford Is Fixing The Head Gasket Issue On The Focus RS'
FocusRS.org 'I'm getting my head gasket fixed' megathread

Ford Focus buyer questions

Is head gasket failure from wrong factory gasket - coolant loss and white smoke (focus rs, 2.3 ecoboost) serious on a Ford Focus?

We rate it critical and common on the Ford Focus. Mk3 Focus RS models built between August 2015 and July 2017 left the factory with a 2.3 Mustang head gasket that does not suit the RS cylinder head - it has an extra hole and a coolant path that lets coolant stagnate, damaging the head. The result is coolant consumption, white exhaust smoke and eventually misfires. Ford ran a free repair program replacing the gasket and, where needed, the cylinder head itself, regardless of warranty - but that program required the car to be presented, and imported or later-sold cars may never have had it. Out of program, this is a head-off job with possible head replacement.

How much does it cost to fix on a Ford Focus?

$3,500 to $8,000 at New Zealand independent workshop rates. That figure is for this job on its own. A car showing the symptoms on this page is usually worth either walking away from or negotiating down by at least the repair figure.

Which Ford Focus years are affected?

Our research records this fault on the 2016–2017 Ford Focus. Build dates move around, especially on imported cars, so treat the range as the years to look hardest at rather than a guarantee either way. The official records tell you the exact build and first registration date for the car in front of you.