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Ford Transit Custom: 2.2 TDCi injector wear and EGR valve failure

2.2 TDCi injector wear and EGR valve failure is a common engine fault on the Ford Transit Custom on the 2013–2016 cars, and we rate it major. Putting it right costs $700 to $3,500 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 7 documented faults on the Ford Transit Custom.

Vehicle
Ford Transit Custom
Engine
2.2L
Years
2013–2016
Fuel
diesel
System
Engine

This page covers the Ford Transit Custom 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 Transit Custom faults7 documented faults on this model

What you are looking at

A single common-rail diesel fuel injector photographed against a plain background.Example of the part — not this vehicle

A common-rail diesel injector. Contamination damages the nozzle at the tip.

Panoha · CC BY-SA 3.0 · Wikimedia Commons

What goes wrong

Pre-2017 Customs use the 2.2 Duratorq (timing chain, no wet belt) whose known weak points are injectors — rough running, smoke, hard starts, and seizure into the head if neglected — and EGR valves that gum up with soot, causing limp mode and poor running. Both are well documented on the Mk7-era engine this carries over. Fuel filter history matters; contaminated or stretched-interval fuel systems kill injectors early.

What you would notice

  • Knocky, uneven idle or misfire
  • Black smoke under load
  • Hard starting
  • Limp mode with EGR fault codes

How to check it

Where to look. Injectors under the top engine cover; EGR valve on the exhaust side of the engine

  1. Cold-start it and listen for uneven, nailing combustion.

  2. Check for tarry deposits around the injectors under the engine cover.

  3. Ask about fuel filter intervals and scan for EGR codes; a recently cleaned or replaced EGR with an invoice is a good sign.

Parts involved: EGR valve, Fuel injector.

What it costs to put right

$700 to $3,500 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

  • “Have injectors or the EGR valve been replaced?”
  • “How often has the fuel filter been changed?”

Now check the Ford Transit Custom 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 published sources — owner forums, technical service bulletins, recall notices and workshop write-ups — held in our fault database. The inspection instructions and the cost estimate are KickTyres’ own interpretation of them, and it is a starting point for an inspection rather than a manufacturer statement.

Ford Transit Custom buyer questions

Is 2.2 tdci injector wear and egr valve failure serious on a Ford Transit Custom?

We rate it major and common on the Ford Transit Custom. Pre-2017 Customs use the 2.2 Duratorq (timing chain, no wet belt) whose known weak points are injectors — rough running, smoke, hard starts, and seizure into the head if neglected — and EGR valves that gum up with soot, causing limp mode and poor running. Both are well documented on the Mk7-era engine this carries over. Fuel filter history matters; contaminated or stretched-interval fuel systems kill injectors early.

How much does it cost to fix on a Ford Transit Custom?

$700 to $3,500 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 Transit Custom years are affected?

Our research records this fault on the 2013–2016 Ford Transit Custom. 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.

How do I check for it before I buy?

Cold-start it and listen for uneven, nailing combustion. Check for tarry deposits around the injectors under the engine cover. Ask about fuel filter intervals and scan for EGR codes; a recently cleaned or replaced EGR with an invoice is a good sign. Look here: Injectors under the top engine cover; EGR valve on the exhaust side of the engine