Ford Focus 1.6 TDCi Zetec

By Lesley Harris

October 2005

Ever experienced deja vu? We have, with our Ford Focus 1.6 TDCi Zetec, which, as reported in issue 867, has suffered a recurring problem. The fuel indicator appeared to be faulty, insisting the tank still had diesel in it when in fact it was virtually empty. We returned the car to Ford, which diagnosed a defective gauge and trip computer, and replaced both. However, no sooner was the car back on the road than the problem arose again.

Deputy art editor Eileen Pegden was at the wheel when, heading back down the M1 after a weekend away, the Focus started to cough and splutter and the engine warning light flickered on. According to the fuel gauge, the tank was nearly a quarter full, which should have been more than enough for the journey. The RAC was called, and while no problem could be found, with the help of a can of diesel Eileen was back on her way.< /p>

As the car was due for its 12,000-mile service, I took it to Dagenham Motors in Byfleet, Surrey, to check out this frustrating fault. The standard service was carried out effectively, costing ΂£175, and I told the dealer that the fuel gauge had already been re-calibrated in an attempt to rectify the problem.

On further inspection, the garage found that the offending part was the fuel tank sender unit. Its replacement would require the removal of the tank and the diesel inside, along with the fitting of a new credit card-sized sensor. The component was ordered and the car booked in to have the work completed the following week.

I took the Focus back to Dagenham Motors on the appointed day. But on my return, all the technicians had done was re-calibrate the fuel gauge - even though they'd been told this had already been carried out and a new sensor had been ordered!

The dealer kept the car overnight to re-fit the sender unit, but a phone call the following afternoon revealed another setback. In removing the fuel tank to get to the unit inside, staff had found a hairline crack on the pump house casing - so our Ford stayed in the workshop for its third day.

Eventually, it was ready for collection and, touch wood, has behaved itself ever since. I have even deliberately run the car low on fuel with no hint of a cough or splutter - so hopefully we won't encounter any more trouble. However, as a result of the problems, few people in the office wholly trust its reliability - and the inept service we received from the dealership has done nothing to increase our confidence in the Focus.

Second opinion

Having successfully completed a 600-mile trip to Wales recently, the Focus is back to full fitness. It was as much at home on the M4 as negotiating Pembrokeshire's coastal roads. Despite being crammed full of surfing gear, it returned an average of 55mpg - way up on what we have been achieving in and around London.
Sam Hardy, motoring writer

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