Cameron,
I also experienced a fume problem in my 04 1.6 TDCi. The garage who located the problem discovered that the fault to be combustion blow past (in my engine) number two injector, which was removed cleaned and reset. After 3000 miles all still OK. Perhaps this could also be your problem.
Best of luck!

ELJ

 

I have the same smell, mine too is an injector problem, the seal has eroded on one of the four, its going in soon to be fixed but I've been assured that is the cause, start there, bonnet up with engine running, you'll hear if its one of them, located at the rear in the centre, Check for diesel on the engine, like spray spots on and around the injectors.
All the best

 

If the injectors are leaking under pressure don't get your fingers too close as the fuel could be pushed through the skin because of the presure

 

Many thanks, its going into the garage today and will post the outcome
cheers
Cameron

 

Hi

Cmax been in to garage and sure enough seal on no 4 injector was gone, cost for strip down and replacement of £1 washer = £208+VAT heyho!

thanks for your help

Cameron

 

zzz! what a price, I thought mine was expensive at £122.00 inc.VAT. Another example why NOT to use Ford. I have to be honest and say I thought VW were expensive when I had my previous car, a Golf but I never got treated, or 'ripped off' the way I read of examples with Ford Dealership and Service. Enough said!

ELJ