05 1.6 Engine System Failure on 115PS - PhilFocus
Hi folks,

Have had intimitent what I would call "stutters" on my Focus occasionally during the 13 months I have had it. (one previous owner, bought at 2.5 year old, 25,000 on clock, now done 42,000). Power loss is similar to someone lightly dabbing the brake, hardly detectable to a passenger but detectable and annoying to the driver. Loss is not quite enought to visibly move the rev counter down.

Yesterday evening this stuttering was getting worse making me think it could be an ignition problem (was going to check plugs when I got home), then doing about 70mph just about to leave the M42 it came up with an "engine system failure" light on the dash and then when I pressed the acknowledge button on the end of the indicator wand it said it was in "Speed Limited Mode".

Engine then stalled setting off from lights at motorway island and after restarting appeared to return to normal. I have done around 35 miles in 3 seperate trips since this problem without the "Engine System Failure" warning re-occuring.

From what I have researched am I correct in thinking the "Engine System Failure" will have logged an error code somewhere on the system that connecting it to diagnostics will reveal.

Can anyone suggest what my be the root of this problem. I have heard it could be a speed senor, lambda senor, engine coolant senor or problem with ECU itself.

I also understand that a main dealer can charge £100 or more just to plug car into diagnostics machine without actually fixing problem.

What is my best plan of action?.

Can someone other and/or cheaper than a main dealer access the diagnostic codes ?.

Could any on these sensors be a likely cause and be replaced myself for less than the cost of £100 worth of diagnostics?

Strangely this problem appeared to disappear from the point the car had its first oil and filter change since I bought the car and then re-appeared coinciding with having it's second oil and filter change. Is this just fluke or could there be some logic to this?.

Thanks in advance for any help and advise.

Phil.

Top Reply

05 1.6 Engine System Failure on 115PS - mikey_k
PhilFocus

I have a 05 1.6 115PS Focus and experienced similiar problems with mine. The car went into 'Limp Mode' after displaying the 'Engine System failure' message on the dash after motorway drive.

Called out the RAC but they could not diagnose any faults so recommended that the car was checked out by Ford.

Ford diagnosed that the problem as a faulty throttle body and both this part and the wiring loom had to be replaced.

I bought the car in Aug 08 so I was lucky enough to have the throttle body and labour covered by the warranty- Wiring loom not so I had to pay for this as they advised that wiring was not covered!!

This happened in Jan this year and have not experienced any recurring problems since.

Hope this helps.


Mike


All Replies

05 1.6 Engine System Failure on 115PS - mikey_k
PhilFocus

I have a 05 1.6 115PS Focus and experienced similiar problems with mine. The car went into 'Limp Mode' after displaying the 'Engine System failure' message on the dash after motorway drive.

Called out the RAC but they could not diagnose any faults so recommended that the car was checked out by Ford.

Ford diagnosed that the problem as a faulty throttle body and both this part and the wiring loom had to be replaced.

I bought the car in Aug 08 so I was lucky enough to have the throttle body and labour covered by the warranty- Wiring loom not so I had to pay for this as they advised that wiring was not covered!!

This happened in Jan this year and have not experienced any recurring problems since.

Hope this helps.


Mike


05 1.6 Engine System Failure on 115PS - derek eastbourne
This sounds very similar to the problem I am currently experiencing with the same model Focus. I reported in this forum about flat spots earlier this month & had the local Ford dealer try to diagnose the problem with no success. I had already replaced the coil pack & plugs.The faults are not stored on fords in the same way as on some other makes e.g BMW.

All the dealer is able to suggest is that I take it in to them if the fault is actually on at the time & they will try to diagnose it. Although they are trying to be helpful it is not very satisfactory as fault is so intermittent. All this of course is costing money.

I will let you know if I have any success.
05 1.6 Engine System Failure on 115PS - Dougie2009
Got a 55 2.0 Focus 39k, but have exactly the same issue as yourself. Slight loss of power inconsistently, into Engine Systems Failure warning on two occasions in the past week, drives perfectly happily (mostly) having re-started. I've got it in for a full service tomorrow. I'll let you know the outcome.

Also, having done a few Google searches, it doesn't seem to be a specific issue to either of our models, and seem to be widespread across the range from what I can tell.
05 1.6 Engine System Failure on 115PS - Dougie2009
Ok. So I got my car serviced and had them look inot the engine systems fault messages, etc. They 'suspected' an internal fialure to the throttle body, which would cost £375 to replace. I havn't had it done, and touch wood, no a single blip since the service. There may be something in the oil change thing, whcih seems to be about the only thing they do on a £255 service. Here's hoping the situation doesn't re-materialise, but about 700 miles in, no problems so far.
05 1.6 Engine System Failure on 115PS - Woodspeed
I had a friend who asked me to look at his Focus as it "stuttered". I had a look b ut said take it to Ford. They said it needed this and that, but as it was due for a service he instructed a service only, and would look into the fault later - with fingers crossed.
Since the service (basically oil and filter, + sundries = Mars bars and Swarfega) all has been well.
I had the thought about sticking valves on these engines, and Ford changing the oil requirement to 5/30. Evidently the 5/30 is not a fully synthtic, so will degrade faster than a full synthetic. If it does it again before a service is required, it would be interesting to just change the oil and filter for a full synthetic 5/30 or 0/30 and see it fault improves.
Would also be interested to know if these engines are driven gently with the eye on consumption.
(I always drive my cars with an eye to making good progress) and never get these rough running problems. What I spend on fuel is more than saved by lack or parts required!
Just a thought!
05 1.6 Engine System Failure on 115PS - PhilFocus
LATEST UPDATE!!.

Have had car fail again several times and have borrowed a OBDII code scanner to plug into car when error has occured. I can now confirm that DTC code indicated is P2135. The generic code scanner describes this code as "Throttle / Pedal Position Sensor / Switch A/B Voltage Correlation". From what I can tell to Ford this code is a "Throttle body fault code" and indicates "Throttle position sensor ratio error".

From what I have researched this is an error on the Throttle body. It has two sensors (A and B) and if the position indicated by the two sensors differs more than a certain amount this error is triggered (as clearly boths sensors can't be right!) and then engine switches to reduced speed mode.

The relatively cheap code scanner I used can ONLY pick up this error while the ignition is still on following the error. If I Turn ignition off and rescan the code is no longer available. I have just had diagnostic run using a high-end professional scanner at a local garage and this comes up with the same P2135 code even after the car has been restarted.

Unfortunately the throttle body costs £210 (just for the part) and I just fear that if I have this replace it may not cure the issue if it is a loose/bad contact issue or wiring loom problem.

Can anyone else confirm that have had problems like this and they have been fixed by replacing throttle body alone?
05 1.6 Engine System Failure on 115PS - mislec
I have same problems for past 9 months. They replaced the throttle body but it did not help. Now we are looking into connector board, which costs around 650EUR. I am waiting for a temporary replacement part at my service but I do not believe this will solve the problem.
05 1.6 Engine System Failure on 115PS - durham525
My Focus is 57 reg and hence still under Ford warranty. Same symptoms as described by other contributors. To local Ford garage today, couldn't find the fault. They did tell me that for the car to record the fault the engine light has to come on (mine hasn't) and that cars memory deletes any recorded faults after 30 uses of the ignition. Told me that there was an upgrade to improve driveability and this had been done on my car. I'll keep you posted.
05 1.6 Engine System Failure on 115PS - paulbevington1965
well mine showed the amber engine fault on my dash display,and i must have turned the ignition on and off 100s of times before i got the fault code reader and plugged it into the computer socket under the dash.they must have meant that you have to wait until the onboard computer shows up a fault on the dash.ie a engine fault warning
05 1.6 Engine System Failure on 115PS - paulbevington1965
hi,my 55 plate ford focus was doing exactly the same thing when i took it onto the motorway! it kept showing the message ENGINE SYSTEM FAILURE, and SPEED LIMIT MODE APPLIED,or words to that nature on the dashboard display.it was also running unevenly around town and seemed short of power.it felt like it was misfiring as you accellerated.i bought myself a OBDII code scanner from ebay for 30 quid and plugged it into the socket in the car,just to the right of the steering wheel.after the scanner searched for a relevant fault code from the cars computer it came up with the error code p2135 same as your car.
i bought a new throttle body from my local ford dealer for 240 pounds and they fitted it for me on tuesday for 40 quid including VAT.
the car has been absolutely fine since and is running like new since i had the new throttle body fitted.hope this helps someone.nice to see there are customer forums,and decent mechanics sharing their experiences and knowledge on here.there are too many money making garages about,who are only interested in making as much money from you as they can!
WHY DONT FORD,OR OTHER DEALERS CHARGE A MINIMAL FEE OF 30 POUNDS OR SO TO DIAGNOSE THE FAULT ON THEIR COMPUTERS? INSTEAD OF THE 110 QUID MY LOCAL ONE ASKED FOR! ISNT IT ENOUGH THAT YOU BUT THE REPLACEMENT PARTS FROM THEM AND LET THEM DO THE WORK? DOESNT EXACTLY ENCOURAGE BRAND AND CUSTOMER LOYALTY DOES IT??
05 1.6 Engine System Failure on 115PS - Ravenger
When my C-Max came down with a similar fault I found that the dealers really don't have a clue when it comes to fixing electrical or sensor faults. The dealer had two attempts at fixing the problem - It broke down on my way back from the dealers after the first time! My dealer had to get a Ford master technician to help as they had no idea what was wrong. In the end checking over the wiring loom and its connections magically fixed the fault, so it might have been a dodgy connector.

Total cost came to over £200, for fault diagnosis and fitting of a £30 part that may not have needed replacing anyway, and of course there was the loss of the car for a week while they tried to fix it. They graciously didn't charge me for checking over the wiring loom as they'd failed to fix the car properly in the first place. Oh and the car was a week out of warranty too. I'm trying to get a goodwill payment from Ford at the moment.
05 1.6 Engine System Failure on 115PS - paulbevington1965
do they really not have any idea on how to diagnose a specific fault? and are other cars with eloctronic ignition and all these sensors everywhere just to get the engine running,prone to these never ending faults/problems? is it really a case of trial and error for the ford technicians?
05 1.6 Engine System Failure on 115PS - TurboD
I suspect that as mass produced cas , Ford are thrown togther, so that faults will occur in some and not others. The complex nature of the building means that the average grease monkey cannot possibly understand the electronics.
Are we asking too much of these people? Basically, cars are too cheap because they are made so badly, but economics dictates the price, not the time required to build a relaible motor.
That is why Fords are cheaper than Hondas. But , hey , my Mondy is fine and has been for 4 years now ( petrol) so I say keep them cheap and cheerful.
05 1.6 Engine System Failure on 115PS - bell boy
fortunately ford systems dont throw up codes like a child throwing teddies out of bed,did i mention vauxhalls?
anyway
the ford tech will use the codes as a guide but that is all they are
he can use his knowledge but every cars different
he cant just nail parts on to try and fix a problem because if it doesnt fix it then this component is now s/h and the next customer would demand new
so you see
modern cars are a pain
05 1.6 Engine System Failure on 115PS - Kamikaze Kal
I second that, I have been looking for this problem all over the net. i have bookmarked this site now as i feel i am going to keep having problems with the car.

The mechic i took it too had the same problem with another car, he 'fixed' it by ''resealing the throttle body''. this will stop leakage of extra air into the throttle system and hopefully stops it from throwing the dummy out of the pram and shutting down the engine.

I have 2 55 Plate Focuses, the other one has NEVER had this problem....

I will update after one month of testing.
05 1.6 Engine System Failure on 115PS - WorkshopTech
We have seen LOADS of focus with throttle body, throttle sensor and wiring and connect problems. Ford wiring is above only french cars and chryslers in the cheap and nasty league. The connector pins arent properly plated so if a bit of water gets into the connector they corrode. The throttle bodies are a bit cheap and often the mating surface is not machined flat so can leak air. remove and replace the gasket, with some jointing compound if necessary. Throttle pedal sensors also prone to early failure. Most ford dealers are pretty hopeless at anything other than oil filter and brake pad changes. Take the car to an independent repairer who is interested in your custom and should charge less than £110 for a simple code read.
05 1.6 Engine System Failure on 115PS - cheddar
While I agree with some of what you say WT, as an acknowledged VAG specialist your anti Ford stance is a little irritating.

The Focus is a great car and statistically more reliable than a Golf, Ford dealers have been excellent IME and the one time I have needed a code read it was done FOC along with an injector reprogramme as good will despite the car being out of warranty. BTW I understand that they normally charge 30mins labour for a code read which is a lot less than £110.
05 1.6 Engine System Failure on 115PS - WorkshopTech
I'm not anti-ford, we see loads and loads of focus, they are a popular car, Im jusyt telling it like it is. They drive nicely but let down by quality issues (poor paint, electrics etc).
dont know what you mean by statistically more reliable, but we have more awkward problems with focus than golfs. VAG cars tend to have a number of standard faults that are fairly easy to fix, but we get a lot of niggling and difficult to diagnose faults on the fords.
We currently are looking at an 06 mondeo with electical problems, all the pins in the connector to the door module are corroded so I'm trying to find a scrap loom I can chop the connector off and splice in. its things like this that cause a lot of hassle and take a lot of time to fix. Fords would be much better cars if they painted them better, used better rust protection and raised the standard of their electics.

Dont thing there is an standard labour time for code reading, most dealers seem to charge a set amount which varies randomly from one to another.

Edited by WorkshopTech on 06/01/2010 at 11:21

05 1.6 Engine System Failure on 115PS - cheddar
Look at Warranty Direct's index WT:

www.warrantydirect.co.uk/reliability_index.html

Try comparing the 97-04 Golf Mk IV with the 98-04 Focus Mk I, the Focus wins hands down, hey even the fuel system is more reliable.

Likewise a Ford v VW comparison is in Ford's favour.

This VW-and-Audi-are-relaible-because-they-are-VW-and-Audi myth has got to be debunked once and for all, they are great cars and there are many I would like, and my next car might even be one though they are simply not better than, say, a Ford per se.

--

One strange thing, WD have Suzuki as the top manufacturer though as I recall JD Power rated Suzuki last in the US (with VW second last as it happens), it may be because there are various Hyundais, Kias or similar badged as Suzuki in the US.
05 1.6 Engine System Failure on 115PS - WorkshopTech
WD, LOL! The less said about warranty companies the better (we have to deal with them sometimes - my advice: keep your money in the bank for a rainy day). The figures are utterly worthless.

I am not saying VAG cars are particularly reliable, my comments on this thread are concerning the ford.
05 1.6 Engine System Failure on 115PS - cheddar
My money does not go in the direction of a warranty company though why are their figures worthless, relevant like for like comparisons I would say.
05 1.6 Engine System Failure on 115PS - WorkshopTech
Just spent a few minutes looking at that WD link. Its not a reliability index at all, its "an index of cost of repair of claims on cars that we cover and are prepared to pay out on".
So when mr focus driver rings them and says 'my focus broke down because the connector pins are all corroded' they say 'sorry sir, wear and tear!'.
05 1.6 Engine System Failure on 115PS - cheddar
So when mr focus driver rings them and says 'my focus broke down because the connector pins are all corroded' they say 'sorry sir wear and tear!'.


Tosh, that doesnt really warrant comment, of course wiring would not be considered wear and tear as wouldnt VAG coil packs and ABS pumps.

Look at the VAG v Ford electrical system stats, Fords suffer less faults.

Of course wear and tear items such as clutch friction material, brake pads, bulbs etc would not feature.
05 1.6 Engine System Failure on 115PS - Kamikaze Kal

NEW Update

I have had the throttle body resealed, this at first seemed to fix the fault...for about 3 months.

About 3 Days ago the car started to display the classic P2135 symptoms.

I would admit it is not as bad as before, but it is b***** annoying.

have taken it back to garage who will check to see if the seal may have failed.

but will also check the inlet manifiolds.

a friend of mine has had this problem on his audi (dont know what the audi code might be)

he had the throttle body replaced and has had no problems.

i am thinking about replacing the throttle body if the car comes up with this problem after i fix it now.

Will keep updating.

BTW - I had a 1.3 Corolla 92 reg with 80k on clock (Cat C)..... all i ever had to do was replace the battery..... it could take the abuse and never fail..... God i miss that car.

05 1.6 Engine System Failure on 115PS - elaine77
I have a Ford Focus Zetec 1.6 TDCI '55 reg and I have had nothing but problems the whole two years I have owned it!

Granted I knew it had high mileage when I bought it (88k) but in the last two years I have had to replace the Alternator, the Timing Belt and just two days ago the Inlet Manifold.

Now, two days after paying £400 for the inlet manifold I have this "engine systems failure" error coming up and the car won't accelerate properly...

I'm scared to take it back to the garage just for them to charge me another £400! Could I possibly expect them to sort it without charging me ridiculous amounts on the basis that the error has only occured since they were messing about in my engine the other day for the Inlet Manifold?

To be honest I just need a new car but can't afford it right now and I need my car to do my job :-(

05 1.6 Engine System Failure on 115PS - Kamikaze Kal

I had a 1.6 Zetec 55PLT Focus with the same problem. after having the throttle body replaced for +£200 it had NO EFFECT.

The problem stayed the same. it was only when i fiddled with the wiring loom that connects the throttle body to the rest of the loom that i was able to replicate the problem at will.

Ii have since replaced the loom and its been over 20 months without a single stutter.

Changing the loom is really easy, the loom itself will cost you around £70 from the ford dealers.

DO NOT GET IT FROM ANYWHERE ELSE, DO NOT GET A CHEAP CHINESE LOOM.

05 1.6 Engine System Failure on 115PS - drogers

Saw the 'posting' by Woodspeed

Here we have some 50 people all with serious issues with their cars all along the same fault sequence, and most of them spending almost a grand to franchise delaers to sort out AND yet Woodspeed says we've all got it wrong ! all 50 of us are to blame for pootling along watching our MPG and if we blasted along like he does then our problems would be over............

05 1.6 Engine System Failure on 115PS - derek eastbourne
Having had diagnostics carried out by local ford dealear & nothing found & having replaced ignition pack & plugs I replaced ignition leads & problem solved. It has been seven months on & the car goes very well. Sometimes old fashoined remedies work.
05 1.6 Engine System Failure on 115PS - bbhaga

I have recently had the same problem and after searching the internet have found that this seems to be a regular occurance.

This appears to be related to the Accelorator Housing (Cost of replacing is around £375). Apparantly it can go into speed limit mode at any point.

Therefore I contacted VOSA to see if this should be classed as a recall, and they said if we experience such faults, we should complete the Vehicle Safety Defect Report (here's a link):

vosa.gov.uk/vosa/repository/vehicle%20safety%20defect%20report.doc

They will then investigate and see if it should be a recall.

They need specific information so that the can determine time and manufacture of parts, etc.

Basically, the more people who report the problem, the more likely they are to determine it as a recall.

05 1.6 Engine System Failure on 115PS - speedycar53

Haven't experienced "Engine System Failure" but hesitancy and random EML warnings which then go away has been a persistant problem on ours from purchase (ex demo car, 3 months old).

I cannot offer an answer but am glad you made this post and got some helpful replies. Surprised at how common the problem appears to be.

Our car has been a nightmare. In addition to the above, we have had new alternator (over-charging and causing instrument cluster to go haywire), new coil pack to rectify misfire and now face prospect of new catalytic converter and sensors at £1,500. Although symptoms of alternator were reported whilst in warranty but not diagnosed by the dealer until afterwards, Ford made every excuse in the book and refused to honour the warranty saying that we scored zero points on their customer loyalty scale - surprising since we have owned Fords for 40 years now. The unreliability is appaling and very disappointing for a less than 5 year old car. I don't think I will be buying Ford again.

05 1.6 Engine System Failure on 115PS - starfield

I have got a focus 1.8 petrol markII. This problem about the throttle body, is it limited to the focus 115 bhp or across the whole range?

It will be great that enybody experiencing this problem state the model they own

05 1.6 Engine System Failure on 115PS - Craig80

I've just bought a 55 plate Focus 1.6 Zetec [115].

I noticed a problem when going up hill that felt like I was lifting off accelerator and putting foot down again. A couple of days later I got a warning saying "Acceleration reduced". Turning off the engine seem to reset and it was OK few a few days until yesterday when I got "Engine systems failure". This was about 10 miles into a 100 mile drive. Again I pulled over and turned off the engine and no problems for rest of 90 miles.

This is just my luck, I used to own a Ford Mondeo and after a month engine management fuse kept blowing. No one, including Ford could fix the problem. I sent it to auction!

I'm takin the car back to Perrys as I did get a 12 month warranty. This post has helped, at least I know I'm not alone. I will keep this updated.

Craig

05 1.6 Engine System Failure on 115PS - Craig80

Update

Ford garage said it was the HT leads. They are Bosch and not genuine Ford parts. Does anyone know where I can buy genuine Ford HT leads online?

Thanks

05 1.6 Engine System Failure on 115PS - Craig80
Further update!

Replaced HT leads with Ford parts, £105 for leads and plugs. Problems is progressivly worse now, although "Acceleration reduced" does not come on.

All I have is a juddering focus, yellow warning light comes on now and then. Juddering comes and goes, seems ok one week and next it's bad!

Dare not to take it to local Ford garage, last time they forgot to put brake fluid cap back on and it was rolling about under bonet for a couple of miles until I pulled over to check what was rattling under bonet! Idiots!


Craig
05 1.6 Engine System Failure on 115PS - Kamikaze Kal

same here.

last ford ever!

05 1.6 Engine System Failure on 115PS - Ray Pink

Hi,

I drive a 2007 Ford Focus II Zetec climate 1.6 petrol 115PS and have owned the car from new. After driving the car for about 6 months i began experiencing this stuttering or powerloss which was very slight and intermittent. I took the car back to Ford as it was under warranty but they could find nothing wrong and suggested it might be dodgy fuel.

Over the next few months the stuttering became increasing worse but still Ford could find no issue. Then one day as the car began to stutter violently the Engine management light came on and i drove it straight to Ford. They hooked it up to the computer and the diagnoses was a faulty coil pack. They replaced the coil and for 3 months the car drove great but again the same stuttering started.

I have since had the coil pack changed 3 more times and each time it fixes this issue but just this week it has started all over again and unfortunately my warranty has just expired.

Can anyone please advise as to what might be causing the ignition coil packs to burn out or if they have had a similar problem and what was the permanent fix.

Many thanks in advance

Ray

05 1.6 Engine System Failure on 115PS - calv
had the same problem with my daughters car, tried new coil ( pattern part ) thinking it was breaking down - common fault, caused spiking of ecu and caused ecu to throw up several faults-lamba sensor, abs faults, which when checkout proved to be non existant, reverted to ford coil, still problem occured , eventually traced to air leaking into inlet manifold where the brake servo vacuum pipe connects, remade seal on pipe and secured it at variuos places along length with cable ties to minimise flexing and touch wood this has been running perfectly for last week

calv
05 1.6 Engine System Failure on 115PS - Aimz

I have a 1.6, 55 Focus Diesel. I intially had this engine system fault (red exclamation mark in - a technical term - a squiggly circle!) last september. The car loses power, and you can't get past 3000 rpm. They couldn't find a fault on the car, however having an oil and filter change seemed to resolve the problem.

I've now got this issue again and when i took it in this morning, they checked the ecu- no fault. The guy double checked which was the fault light and then told me that he had to use a different console for this fault light. Due to previously having a flat battery when i first got the car, the ECU retained all the system faults.... They have now cleared the unit and hopefully it should clear the problem. Waiting to see if the light comes on again and fingers crossed it won't be anything too bad. I'll update if the fault returns and what the outcome is.

Just a quick note - I initially phoned the ford dealers to get the diagnostics, and they were going to charge me £80 + Labour + VAT. Deciding this was a bit steep, took it to my normal garage, and they only charged me for the oil & filter change - bargain!.

Edited by Aimz on 24/08/2010 at 11:49

05 1.6 Engine System Failure on 115PS - Janspeed

My 57 plate 1.8 tdci Style had the same message today after about 10 miles on the M42. Reading this thread has been extremely interesting and helpful. My car entered into what can only be described as a limp mode with a loss of power. I got home, turned the ignition off, and back on again and the message vanished. I drove the car around the block, and it seemed to be back to normal.

My warranty expires at the end of January 2011, so I'm going to book my car into the nearest Ford dealership and report the problem. Reading this thread, the problem seems to be the throttle housing and just sealing it again,doesn't appear to solve the problem.

Thanks again for the above posts which have been most helpful.

Jan.

05 1.6 Engine System Failure on 115PS - memphuklf

Exactly same problem today. Have got an 05 focus zetec 1.6. 115ps. Car has been running fine without any problems for last 2 years and then all of sudden car felt a bit jerky today(Thought it was dirty petrol). All of a sudden engine warning light came on with message System Engine Failure and reduced acceleration.

Pulled up to side of road and restrted the engine and all warning lights dissappeared and car is running fine again. Gonna get it checked out on Monday and hoping its not gonna be a big thing. Worried about taking it out now till Monday incase it breaks down.

Edited by memphuklf on 25/03/2011 at 18:21

05 1.6 Engine System Failure on 115PS - Niall_Saunders

I am having the same problem on my '55 Ford Focus 2.0 TDCi Ghia Estate (136PS).

When it forst happened, I called the AA and they said that there were so many OBDii codes coming up that they couldn't figure out WHAT was the problem - but checked battery, alternator, etc, to no avail.

They towed it off to Arnold Clark's (where I am 'friendly' with the Service Manager) and he ran a very quick check for me, and suggested that I would need a new instrument cluster.

However, he told me that, if you 'thump' the top of the dash, it is likely that the fault will be eliminated - albeit temporarily. He did this, and I have driven the car for about thirty miles with no problems.

But the car failed on the way home tonight.

Rather than giving up and calling the AA out again, I tried driving at the reduced speed, whilst whacking the top of the dash. It occasionally recovered (and I managed 20 miles home driving in this manner!!!)

But, basically, Ford have ripped you (us) off - there is a bad connection "to do with" the instrument cluster (already a problem well enough documented to have made it all the way on to BBC TV's "Watchdog" Consumer Rights programme - and Ford have agreed to replace affected clusters as the reduced price of UK GB £99).

However, go into a Ford dealership, and the (May 2011) quoted price for a replacement instrument cluster is £600 - and they claim that the Ford £99 offer "doesn't apply, because that was only for pre 2003-registered vehicles".

I am now going to try and rip out my instrument cluster and see what the 'intermittent connection' problem might be. If I am successful, I'll re-post.

Cheers,

Niall (Aberdeen, UK)

05 1.6 Engine System Failure on 115PS - JOhn_W

No-one else seems to have mentioned that this could be down to a crack in the turbo intercooler pipe ref http://www.honestjohn.co.uk/carbycar/ford/focus-ii-2004/?section=bad.

This was certainly the case with my 1.6 TDCI. It's easy to check visually - this pipe is the wide metal pipe right in front of you when you open the bonnet. The crack develops low down to the right-hand side, near the join to the bracket.

My local garage charged me £30+VAT to take the pipe off and weld it.

05 1.6 Engine System Failure on 115PS - SSM

Hi Niall,

I am having the same problem you had, i.e the car goes into limp mode and if i tap the dashboard or more recently the speedo cluster the car goes back to normal.

So basically, I wanted to know if the problem was solved by replacing the instrument cluster please?

Any help would be really appreciated.

Thank you

Sukh

05 1.6 Engine System Failure on 115PS - FordRover

I have had this problem on my Automatic Ford Focus "06" plate for the last few weeks, again seem to experience loss of power particularly at low speeds, was 150+ miles away from home when the car shuddered and the Engine System Failure message was displayed. restarting the engine it seem fine and I drove the miles home on the M1.

The car seems to struggle below speeds of 40 MPH and appears to happen when the car changes gear making me suspect its the gearbox.

My friend who is a mechanic had the car a week ago and could not find the problem, but changed leads and plugs which has made no difference.

Seems the problem reading the thread could be anything from a simple oil change to a £250 part.

Any suggestions as need my car to be reliable

05 1.6 Engine System Failure on 115PS - oobuc5

yes dont buy ford cars ,buy japanese ,as they are made to be reliable.

05 1.6 Engine System Failure on 115PS - shorty1804
Hi All,

Edited by shorty1804 on 29/01/2012 at 13:56

05 1.6 Engine System Failure on 115PS - shorty1804
Hi All
05 1.6 Engine System Failure on 115PS - Ronners

My mrs has a 57 plate Focus 1.6 tdci and on the 2nd jan this year the engine systems fault light came on with the reduced acceleration sign also. We took it to a garage (not fords) and they said it was showing so many things they couldnt tell what was causing it so put all the lights out and said to come back if the warning light came back on which it did. They had it on diagnostics and came up with the throttle pedal so did that but the engine systems fault and reduced acceleration still showed, so after they rang fords they put another unit on that went with the throttle pedal and it still didnt cure the fault so they took the car to fords and fords put it on their diagnostics and tweaked it and all the lights went out problem solved....or so we thought.

After driving the car home from the garage (and having paid £500-00 the light came back on so took it to another garage and they said it is a common fault with the focus diesel (and most diesels) as there is a filter with the diesel cars that get blocked if they dont go on long runs once in a while and advised us to take it on the motorway and run it in 3rd gear for around 20 to 25 miles in high revs which usually burns away the blockage but if it didnt to fetch it back. Took it out and gave it a blast in 3rd gear high revs but when i got back the light was still on but after leaving it for a day we used it again and the light hasn't been back on since which was a month ago and now not sure if we actually needed the other parts fitting....hope this helps someone

05 1.6 Engine System Failure on 115PS - Collos25

Whatever you have been told is very much stretching the truth to say the least what on earth have you paid £500 for.

I would suggest common with most these engines the EGR is dirty 20min job to remove clean and replace.

05 1.6 Engine System Failure on 115PS - focussed

Have a look at this website, very handy for help with diagnosis of electronic problems, and they sell remanufactured electronic units.

http://www.bba-reman.com/HintsAndTipsNavigator.aspx.

05 1.6 Engine System Failure on 115PS - Collos25

Its a none shaming web site but I wouldn't touch them with a barge pole.

05 1.6 Engine System Failure on 115PS - AshDon91

I have an 05 Ford Focus 1.6 model too, and have it about 4 months now, and i have had nothing but trouble with it! I curse the car everyday i drivve it. When i bought it first i absolutely loved it....for about a month! Then started the trouble......

first thing was the handbrake light coming now and again and there was nothing wrong with the brakes at all, i knew ford had a rep for dodgy wiring so i let it go... then the orange engine light came on and this shuddering started almost like i was in too high a gear for the speed i was doing, but this wasnt the case...

I changed the coilpack, had a full service done on it, spark plugs and leads replaced, all filters replaced, timimg belt done....the works.....and to no avail! Im at the end of my tether with this car, its set me back almost 500 euro and with no results....

I almost dont want to spend any more on this care, im losing faith..... I've had 2 ford focus's before this and both were reliable cars, never had much trouble (apart from the coil packs but thats a given with ford), loved them, but this one has put me off buying another one completely!

05 1.6 Engine System Failure on 115PS - drogers

had same throttle body problem on my 1.8 petrol this week

Ford dealer replaced throttle body assy for £384

same fault happened again

right now today 31/7/12 they are looking at wiring l;oom and replacing part tomorrow - they tell if that doesnt fix it then I will need a new PCM unit at around £1000

Has anyone heard of the PCM being spiked by this problem>

I personally do not beleiev the PCM is an issue as it drove between the first time it failed and the nextimes 9twice more) all in a week, so how can it be PCM ?????

£1000 is a loto to gamble onfixing a problem

05 1.6 Engine System Failure on 115PS - drogers

This problem affects 1.6/1.8.2.0 petrol cars

I had throttle body assy 1537636 and PCM Module 1712930 fitted

Car seemingly runs OK mind you it will take a few months to trust it again

Seeing all the threads on this problem surely FORD need to get their act in order and address this problem, the loss of power when going into limp mode easily can could cause a rear end shunt

Has anyone rung FORD up ? Do FORD care ?

Be nice to know they were interested in the poor s*ds who paid 14K for these cars and are now paying 1 or 2K more to fix them

Do KIA have any problems what are KIAs like to own cost wise................

05 1.6 Engine System Failure on 115PS - drogers

This problem affects 1.6/1.8.2.0 petrol cars

I had throttle body assy 1537636 and PCM Module 1712930 fitted

Car seemingly runs OK mind you it will take a few months to trust it again

Seeing all the threads on this problem surely FORD need to get their act in order and address this problem, the loss of power when going into limp mode easily can could cause a rear end shunt

Has anyone rung FORD up ? Do FORD care ?

Be nice to know they were interested in the poor s*ds who paid 14K for these cars and are now paying 1 or 2K more to fix them

Do KIA have any problems what are KIAs like to own cost wise................

05 1.6 Engine System Failure on 115PS - CKerr001

Hi,

It might be too late in the day for this reply, but I have the same engine, year and model, the problems you talk about happened to me in Sept 2012.

The fix: Two cabbelt sprokets, one coil (Error codes were also pointing to this)

The error logged pointed to the cambelt sensors. However, after some digging and Ford Forums/Tech assistance etc it was found to be a more serious and costly repair.

Fault: The car would jerk about whilst driving, lose power and shudder, stall and rev up and down. The warning light you note also came on for me and stayed on.

Whilst these parts were off the car I had the Cambelt kit changed, water pump and oil changed, made sence as the side was already off the car.

Milage: 60k.

Cost £300 excluding extras.

The car hasn't had this problem since, all is well. So far!

Hope that helps you out. :)

05 1.6 Engine System Failure on 115PS - Ace-of-Jase

I have a 2003 1.6 Lx Focus suffering what soudns like exactly the same problems and issues as have been reported here.

The juddering started last week and the EMS light came on last night. I previously had a similar issue on a Skoda Octavia VRS and shortly after the EMS light came on there the car threw its cambelt on the M1 in the fast lane with hardly any warning.

Im utterly paranoid about driving my car due to this issue as I need my car for work and the earliest I could book my car in to have the Cambelt and waterpump changed with a courtesy car (which I need as I need my car) is 19th (next Tuesday).

My mileage is 70800 and Im hoping the cambelt change should resolve this.

I need to cover a fair few miles between now and Tuesday....about 600. Should I? Any further advice?

Jase

Edited by Ace-of-Jase on 14/02/2013 at 15:15

05 1.6 Engine System Failure on 115PS - reecewheeler
I have a Ford Focus 1.6 TDCI 57. I am
New to diesel and i dont know whether this normal or a problem. My car stutters in 4th gear going up hill, but its not lacking power. It feels like the turbo is engaging then turning off. Is this the same problem you are talking about?
05 1.6 Engine System Failure on 115PS - Simohere

I had the same problem. The mechanic garages could not find the reason. They said it is electricity related issue. I banged on the dash a few times and I realised the lights/engine fault messages come on/off so I knew it was the cluster. I took the cluster to one of the guys who said they can fix online near Portsmouth. They found the problem with the cluster and fixed it. The car has been running perfectly fine for a month now. I have ford focus 2006 automatic.

If you have the same issue call one of the guys who are saying they can fix the cluster (you can find them on ebay) and discuss the issue with them. They know what they are doing and they will let you know if it is likely to be related to the cluster or not.

 

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