I have now owned my Ford Focus Sport 1.8 TDCI duratorq for 3 years and during that time have had several problems with it. All of which i have returned to Brooklyn dealership to be repaired (or at least they tried)
1. Fuel guage stopped working ( They replaced the sender unit)
2. Bellowing Black smoke from exhaust ( EGR changed)
returned again for black smoke and service technician suggested it was the diesel i was using. I had to laugh never the less i gave him the benifit of the doubt and changed fuel.
tried redex treatment and this seemed to help BUT.
warrenty expired end of Nov 06 and its now Xmas and i have been towed home twice.
RAC gent seemed to think the fuel filter was blocked. I changed the filter boxing day.
Car stops suddently and glow plug warning light on the dash flashes indicating there is a problem somewhere. swearing removed - DD. give it 30 mins and it starts again for a while then nothing. no amount of turning over starts the engine.
I have read reports of a TSB detailing problems of the nature i am having suggesting the fuel pump is to blame.
I have since returned the car to the dealership and they called to say that the problem lies in the fuel rail and it will cost in excess of £600 to get fixed. I suggested that i have had an ongoing issue with the vehicle and not prepared to pay for the repair and it should be covered by warranty as the fuel problems i have had in the past have never been fixed.
He offered 35% towards bill. i refused this and he is now getting in touch with Ford Motor Co Ltd to get there advise.
I have done the same writing a letter to
The Managing Director
Ford Motor Company
this is being posted recorded delivery tomorrow 28/12/06
Hopefully i will get some good news
I have a 2002 1.8 (115) TDCi Focus in zetec trim and experienced similar problems to yourself in that the glow plug light would start flashing, the car would go into limp home mode and then cut out altogether all in a matter of seconds. On occasions, it was difficult to start and when it did, it started with a real metallic sounding clatter, often cutting out again until it eventually started normally. Then on one occasion, it would not start at all despite the engine turning over - it would just not fire. Had to be towed by the RAC to the local Ford dealer.
Once plugged in to their diagnostic equipment, it threw up faults relating to the common rail fuel pressure sensor and the IMV valve which, as far as I understand it ,controls the fuel pressure to the common rail and hence the pressure sensor fault. The IMV valve was replaced at considerably less than £600, it was approx. £140 iirc. Had no problems in the 2 months since, touch wood! The car drives totally normally.
Don't know if this is of any help to you but the problem sounds similar. Hope you get it sorted soon.
Thanks for your advise, searching through the internet it seems that this is a common fault with both Focus and mondeo TDCI.
I am going back to the dealership tomorrow who still have my car and ask how they come to the conclusion that it is the fuel rail. i will ask if they found faults from the diagnostics with the IMV valve.
A 'poke and hope' approach does not work with these systems. You have to have someone who understands the system and has the correct diagnostic tools (and can use them properly). There are lots of possible faults with TDCI.
If your previous problems with the car are documented then Ford should complete the repair FOC. I believe it is possible for the tech to clase/blank the IMV valve so that the pump develops full pressure in the rail. They can then check pump performance and rail pressure sensor.
I owned a Focus TDCI Ghia, purchased from new and it was the best car I had ever owned for the first 18 months. The engine would intermittently refuse to start and if left for a short time then light up. The very disinterested and useless local Ford Garage could find no problems( is'nt this always the case?) and then I had no problems for over a year. The starting problem returned and then the engine began to cut out whist driving along. I took it to a diesel specialist who suggested I change the Camshaft timing sensor( about £12.00 at the time). I did this and it fixed the problem. I also had rusting on the hatchback during the first 3 years which was repainted but re-appeared after several months. For a car that cost £16000 retail it was not good enough. I sold my Ford and now purchase Japanese.
on the hatchback during the first 3 years which was repainted
but re-appeared after several months. >>
The chrome boot lid handle on Ghias cuts into the paint, this does not happen on models with black plastic handles, my dad has found this on his recently bought 2002 Ghia estate, the chrome handle really needs a rubber gasket or similar.
This is a known fault by Ford, and they will I believe do it under the bodywork warranty. When it is done they place a plasic film under the chrome to stop it happening again. Reason I know this - I am a Ford salesman and pretty much any used focus's with the chrome strip are affected. Occasionaly you get one which is lucky and hasnt gone but is very rare. It is worth noting though, that unless the paintwork record in the service book is all stamped up, Ford will through any paintwork warranty claims out the window.
Slight thread divert here. I was interested to see most Focus Ghia's rust near the chrome trim on the boot, as my 2000 'X' 1.8 Ghia model does not appear to have any such rust. Where should I look (or should it be obvious)?
Will be around the chrome strip, sometimes actually under it (by the number plate) and also at the two top corners. You will be lucky to have got away with it, could it have been repaired before you owned it?