The passenger version of Ford's successful Transit Custom platform, the Tourneo Custom seats eight or nine in a spacious cabin on commercial-grade underpinnings. Widely used as a shuttle, taxi, and family bus across Europe, it pairs the practicality of a panel van with proper windows, seating, and passenger comfort. The 2.2 TDCi Duratorq diesel was available from 2012 to 2016 in 100, 125, and 155 PS outputs before the 2.0 EcoBlue took over.· more· less
Turbo actuator is a known weak pointDPF issues on short-trip use
Buy if: You need a durable multi-seat vehicle for regular mixed or long-distance driving and can verify the turbo actuator and injectors are in good condition.
Avoid if: You mostly drive short urban trips, which accelerate DPF and EGR problems, or want the refinement of a purpose-built MPV.
Price & maintenance
Used price
€15,000
median asking price, typically 180,000 km
Typical range€12,200 – €17,700
Kilometres drivenAll
Maintenance cost
€800 – €1,550/year
at 15,000 km/year
Fixed costsservice, tyres, brakes€500 – €850 /yr
Risk bufferunplanned repairs€300 – €700 /yr
Price estimates are based on German asking prices. Prices and costs vary by vehicle condition and location.
Ownership costs
Maintenance assumes 15,000 km a year. Price estimates are based on German asking prices. Prices and costs vary by vehicle condition and location.
Used price
€15,000
Typically €12,200 – €17,700, at around 180,000 km.
Electronic actuator seizes from carbon buildup or electrical failure, causing limp mode · more· less
The Hella electronic turbo actuator (part G41752406 / 6NW009206) is widely regarded as one of the most commonly failed components on the 2.2 TDCi Transit/Tourneo range. It controls the variable-geometry turbo vanes and fails due to carbon buildup on the vanes or internal electrical faults. Symptoms include a flashing glow plug warning light, limp mode with severely reduced power, intermittent power loss that initially clears after a restart, and fault codes P132A/P132B. Ford does not sell the actuator separately, so a dealer will quote for a complete turbocharger replacement at €1,500-2,500. However, specialist remanufacturers can repair just the actuator unit for €150-250, often with a lifetime warranty. If the turbo internals are also damaged from prolonged running with a seized actuator, full turbo replacement becomes necessary. Most affected between 80,000 and 150,000 km.
DPF clogging and fuel vaporizer failure
€300 - 1,5002 of 7
Short-trip driving prevents regeneration, and the DPF fuel vaporizer often fails first · more· less
The 2.2 TDCi's DPF relies on a fuel vaporizer to inject diesel into the exhaust stream, raising temperatures to 600-650 degrees for soot burn-off. This vaporizer is a common failure point: when it fails, the DPF cannot regenerate and fills with soot. Symptoms include frequent DPF warning lights, aborted regeneration cycles, and eventually limp mode. The vaporizer itself costs €200-400 to replace. However, if misdiagnosed and the DPF is allowed to become completely blocked, the filter may need professional cleaning (€300-500) or replacement (€800-1,500). Vehicles used predominantly for short urban trips are most affected because the exhaust never reaches regeneration temperature. Regular motorway driving of 20+ minutes significantly reduces this risk.
Fuel injector failure
€400 - 1,5003 of 7
Injectors develop leaks, clog, or fail electronically, typically after 100,000 km · more· less
Injector failure is a well-documented issue on the 2.2 TDCi, particularly on higher-mileage examples. Continental's application catalogue lists the Continental/VDO injector A2C59517051 for the 74, 92, and 114 kW 2.2 TDCi Transit Custom applications and their DRF, CYF, and CVF engine codes. Symptoms include rough idling, knocking on cold start, excessive black or white smoke, poor fuel economy, and diesel smell in the cabin. A single injector costs €175-300 for the part, but labor is significant because each replacement injector must be coded to the ECU using Ford IDS/FDRS diagnostic software. When one injector fails, others often follow within 20,000-30,000 km, so some specialists recommend replacing all four at once (€1,000-1,500 including labor). Clean fuel and regular fuel filter changes help extend injector life.
EGR valve carbon buildup
€200 - 5004 of 7
Exhaust gas recirculation valve clogs with carbon, causing rough running and hesitation · more· less
The EGR valve on the 2.2 TDCi accumulates carbon deposits over time, restricting gas flow and causing rough idling, hesitation under acceleration, and increased emissions. Short-trip driving accelerates buildup because the engine rarely reaches sustained high temperatures. Cleaning the EGR valve costs around €100-200 and provides temporary relief, but the problem typically recurs within 20,000-30,000 km. Replacement with a new valve costs €250-500 including labor. If carbon loading progresses to the turbo vanes or DPF, combined repair costs can be significantly higher. Regular extended highway driving and using quality diesel fuel help reduce carbon accumulation.
Gearbox synchromesh wear (1st/2nd gear)
€300 - 1,5005 of 7
Synchroniser wear causes the gearbox to pop out of 1st or 2nd gear under load · more· less
A known issue on 2013-2017 Transit Custom and Tourneo Custom models is the gearbox dropping out of first or second gear into neutral, particularly under load or when decelerating. The fault lies with the synchroniser rings on these gears. Ford supplies an output shaft synchroniser (part number 1852724) that requires specialist installation. It makes repairing the gearbox possible instead of replacing it, but the gearbox still has to be removed and refitted, so the job is a specialist transmission repair rather than a quick in-car fix, from around €300-500. If the damage is more extensive or the synchroniser repair is not viable, a second-hand gearbox can be sourced for €200-400 plus fitting (€400-600 labor). A new gearbox from Ford runs into thousands. Vehicles used heavily in stop-start traffic or for towing are most susceptible.
Dual mass flywheel and clutch wear
€700 - 1,2006 of 7
Premature DMF and clutch wear from frequent stop-start urban driving · more· less
The dual mass flywheel and clutch assembly wears faster than average on Tourneo Customs used for urban shuttle or taxi duty, where frequent stop-start driving puts heavy demand on the drivetrain. Symptoms include vibration at idle, clutch judder, rattling from the bellhousing area, and eventually clutch slippage. A complete DMF and clutch kit replacement typically costs €700-1,200 depending on whether OEM or aftermarket parts are used. Some owners opt for a solid flywheel conversion, which eliminates the DMF failure mode but may increase drivetrain vibration. Typically occurs between 120,000 and 200,000 km depending on driving pattern.
Timing chain stretch
€800 - 1,5007 of 7
Chain stretches at very high mileage, causing rattle on cold start and rough running · more· less
The 2.2 TDCi Duratorq uses a timing chain rather than a belt, designed to last the engine's lifetime. However, chains can stretch over time, particularly if oil changes are neglected or low-quality oil is used. Symptoms include a metallic rattle on cold start that fades after a few seconds, rough idle, and in advanced cases, misfiring. Do not treat a rattling chain as harmless: documented cases where the chain jumped on this engine have ended with bent valves and major engine repair, so investigate the noise rather than waiting. Chain, guides, tensioner, and sprocket replacement costs €800-1,500. This issue is uncommon before 200,000 km with proper oil maintenance and is primarily a concern for very high-mileage examples.
Durable commercial platform with known turbo and emissions weak points
The 2.2 TDCi Duratorq is fundamentally robust and many examples exceed 300,000 km with proper maintenance. However, the electronic turbo actuator is a well-documented weak point, and the DPF system needs regular highway driving to stay healthy. The gearbox synchromesh on 1st and 2nd gear can wear on heavily used examples. Most issues are well-understood and parts are widely available. Avoid vehicles that have been used exclusively for short urban trips, and verify service history carefully.
Service history
Complete Ford dealer or specialist records are essential. There is no single universal interval: Ford's Irish Tourneo Custom 2.2 schedule specifies two years or 50,000 km, while other markets are shorter, so check the schedule that applies to this vehicle by country, build date, and VIN, then verify the oil changes against it.
Tires
Check tread depth, age (date codes), and ensure commercial C-rated tires are fitted. Uneven wear may indicate suspension problems.
Cold start
Start the engine completely cold. Listen for timing chain rattle in the first 10-30 seconds and turbo whine.
Test drive
Drive for at least 30 minutes including highway speeds to allow full engine warm-up and potential DPF regeneration.
Specific for this vehicle
Watch for turbo actuator symptoms during test drive
Drive firmly and watch for flashing glow plug light, sudden power loss, or limp mode. Try several hard accelerations from low speed.
Check DPF warning light and regeneration behavior
Ask the owner about DPF warning light frequency. Vehicles that only do short trips are high risk. Check for the DPF light during the test drive.
Test 1st and 2nd gear engagement under load
Accelerate in 1st gear, then lift the throttle and check if the gear pops out to neutral. Repeat in 2nd gear, especially on inclines.
+ 4 more checksShow less
Listen for injector knock on cold start
On first cold start, listen for uneven knocking or rattling that persists beyond 30 seconds. Rough cold idle suggests injector problems.
Check for EGR-related rough idle
At operating temperature, idle should be smooth. Hesitation, rough running, or hunting idle points to EGR carbon buildup.
Verify brake pedal clip recall completed
The retaining clip on the brake pedal pin could fail, causing the pedal to separate. Campaign R/2013/028 covers vehicles built between 28 September 2012 and 6 February 2013 and is VIN-specific, so contact Ford with the VIN to confirm whether this vehicle is affected and whether the work was done.
Inspect underbody for corrosion
Check floor panels, sills, and rear wheel arches. Commercial vehicles often accumulate road salt damage. Look for bubbling paint or surface rust.
Recalls and Technical Service Bulletins
Brake pedal retaining clip failure (R/2013/028, vehicles built 28 September 2012 to 6 February 2013, VIN-specific)Critical - verify completed
Only one recall applies to this early 2.2 TDCi build window. Campaign R/2013/028 covers the brake pedal retaining clip and is limited to vehicles built between 28 September 2012 and 6 February 2013; it is applied by VIN, so not every vehicle from that period is included. Contact a Ford dealer with the VIN to confirm whether this vehicle is affected and whether the work was carried out.
Warranty Status
Factory warranty (2 years)Expired on all 2.2 TDCi models
Extended warrantyAvailable through Ford and third-party providers
All Tourneo Custom 2.2 TDCi models (2012-2016) are well outside their original 2-year factory warranty. Extended warranties from third-party providers may still be available for lower-mileage examples but are uncommon for vehicles of this age.
Sources: Research draws on model-specific owner forums and owner communities, recall information from official authorities, German automotive press, and multiple workshop cost references cross-checked against each other.
This report is for informational purposes only and does not constitute professional advice. Estimates may be inaccurate. Always have a qualified specialist inspect the vehicle before purchase. We accept no liability for decisions made based on this information.
