Ford Focus

Injectors on the 2.0 TDCi family show measurable wear from around 150,000 km. Leaking copper sealing washers allow combustion gases to escape ('Black Death'). Replacing one injector soon necessitates replacing all, as wear state is similar across the set.

Symptoms: Rough running, diesel knock, black soot deposits around injectors, power loss

At higher mileages the high-pressure fuel pump wears internally and leaves metal swarf in the fuel filter. Particles can damage injectors. The pump can fail suddenly at motorway speed.

Symptoms: Gold-coloured metal particles in the diesel filter housing, engine enters limp mode or dies under full load, difficult cold start.

Ford specifies 200,000 km or 10 years as the change interval (automatic: 100,000 km). Belt documented with 15 cm of missing teeth at just 99,000 km. Belt snap destroys rocker arms and the camshaft.

Symptoms: No warning sign on belt snap — sudden engine stop on the motorway, loud hammering from the engine.

The diesel particulate filter blocks up in frequent short-trip use when regeneration temperature is not reached. Fuel enters the engine oil and measurably dilutes it. Oil level check every 5,000 km recommended.

Symptoms: Engine management light, power reduction, elevated oil level, regular motorway runs required

The dual-mass flywheel wears over time. Verified failure documented at 270,000 km (Mondeo estate), total cost approx. £1,050 including clutch and labour. With normal use trouble-free operation beyond 200,000 km is possible.

Symptoms: Metallic rattle on gear changes, vibration at idle, shudder on take-up

From 75,000–100,000 km, poorly maintained examples develop axial play in the turbocharger shaft. The oil feed line to the turbo can coke up, leading to oil starvation.

Symptoms: Whistling or metallic rattle on acceleration, power loss, blue smoke.

Despite full galvanising, sills and wheel arches rust heavily, especially at the junctions between the wing and the bumper. The tailgate rusts under the roof spoiler when water ingresses.

Wheel bearing failures frequently noted in inspection reports, especially from 2010 model year. Track rods and suspension components wear above average. Control arm bushes and lower arms fail prematurely.

Plastic thermostat housings are prone to cracking and coolant loss. Coolant temperature can become unstable; in the worst case the engine overheats.

The brake pressure sensor in the ABS block corrodes and cannot be replaced individually — the entire ABS unit must be swapped. Primarily affects vehicles up to model year 2007.

Up to model year 2007, water accumulates at the junction between the rear bumper and wheel arch, leading to rust. Ford had to carry out multiple repaints. Check carefully before buying.

Ford does not supply an individual wheel bearing — only the complete hub (approximately 290 EUR). Lower RevoKnuckle needle bearings can seize. Press-fitting requires specialist tools. High front tyre wear accelerates deterioration.

Wheel arch edges are almost universally affected without cavity wax treatment. Water penetrates through rear light seals and spoiler fixings into the boot floor, which then corrodes from the inside.

ABS cables chafe on suspension components, ranging from a simple warning light to complete ABS failure. Cable repair is needed, not just a sensor swap.