Ford Focus Engine Problems

I'd say you're looking at two different problems here, neither one of which involves the actual fuel tank (which is, indeed, 55 litres). The first problem is more likely to be the calibration of your fuel gauge that is out. If the gauge isn't reading accurately, it will tell you the tank is emptier (or fuller) than it really is. Your car is actually doing what most fuel gauges do, which is to be a bit pessimistic, suggesting there's not as much fuel still in the tank as there really is. You could have the gauge recalibrated, or simply know that even when the needle is at empty, you've still got a buffer zone of fuel remaining.

The fuel consumption, meanwhile, is another issue and it's true to say that 20 litres for 140km of driving is too thirsty. A basic tune up might help, starting with fuel filters, air cleaners and spark plugs. But don't ignore things like correct tyres pressures and whether there's a roof rack fitted; these things will affect fuel economy more than you might imagine. And never under-estimate the affect driving style has on fuel use. A driver who smashes the throttle from every green light will soon start using more fuel every kilometre.

The short answer is no. Ford changed from a range of normally-aspirated engines in late 2016, to a newer, turbocharged 1.5-litre engine for the 2016 model year.

In theory, any engine can be made to fit any car, but there's no chance of this swap being an easy or inexpensive one. You'd also have to change the transmission to suit the newer engine and then there are the thousands of modifications to things like heater cores, radiators, engine mounts, steering and suspension components, exhaust systems and anything else that could be in the wrong place to suit the newer engine. And that's before we get to the different computers the newer engine will have to run it properly. You'd probably also need to have this conversion signed off by an engineer to ensure its legality and safety, too.

The simple solution (particularly ion a relatively inexpensive car like a second-hand Focus) is to simply buy the version you want in the first place.

Just for starters, the ZX4 is a four-door sedan, while the ZX3 body is the three-door hatchback. At the very least, that will mean differences in the wiring loom as regards door-courtesy and boot/tailgate lights. Cars will have different wiring looms depending on their transmission, too, so even if the engine is the same in both cars, the loom might not be.

Then there's the more basic question of whether they're actually the same model of Ford Focus. Ford Australia switched to the all-new second-gen Focus in April 2005, and if your 2005 Focus is that newer version, the wiring will not be compatible with the 2001 model. But even if they're from the same generation of Focus, swapping a wiring loom from one car to another involves many, many hours of work.

Ford replaced the Mark 1 Focus with the Mark 2 in June 2005, so interchangeability would depend on the build date of the 2005 Focus you have. While the Mark 1 and Mark 2 Focus both offered a two-litre four-cylinder engine (among others) the two engines were from different engine families. The earlier car used a member of the Zetec family, while the Mark 2 Focus two litre was from the Duratec family.

So, unless both Focuses are Mark 2 cars, there's very little chance of sharing things like intake manifolds, even if the spark plugs and ignition systems could be swapped between Mark 1 and Mark 2 cars.

Don't be so sure your car isn't covered by Ford's factory warranty. If it was delivered brand-new (as opposed to built) after May 1 of that year, it's subject to a five-year/unlimited kilometre warranty, so would still be covered. However, if it was delivered before that date, the warranty would have been three years or 100,000km which has now run out. Even so, given the kilometres and the service record, I think you'd be a good case to have Ford come to the party with some help on the repairs on a pro-rata basis.

From what you've told me, I'm guessing you've only dealt with Ford at the dealership level. Go over their heads and talk directly with Ford HQ's customer service department. A quote for $3500 just to examine the car is, on the surface of it, absurd and should be treated with suspicion. Any competent mechanic should be able to diagnose what's going on and whether or not the engine needs to be replaced. My advice here would be to have the car inspected by your state motoring club (the RACV in Victoria) which can give a cost-effective and independent report on the car's condition (and won't cost anything like $3500). This is also excellent legal and evidential back-up if the case does progress to VCAT.

On the face of it, 62,000km is not a reasonable lifespan for a fully serviced engine and the manufacturer should shoulder at least some of the cost of putting it right. Your last resort should be to contact the ACCC and talk to that body regarding your rights under Australia Consumer Law which covers goods (including cars) that are not built to a reasonable level of quality or are unfit for service. A failed engine at such mileage may well fall into that category.

The Ford Focus wasn’t released into Australia until late 2002, so it’s very unlikely you have a 2001 model unless it’s been privately imported. At which point, all bets are off in this regard as different markets had different models which may or may not be swappable.

But if the two cars are the same model of Focus and aren’t either side of an upgrade, facelift or model change AND provided they used the same engine from the factory (1.8 litre or 2.0 litre) then you should be able to repower one with the other’s engine. The problems would start if one was a 1.8 and the other a 2.0 when you might find that wiring looms, computer software, sensors and even engine mounts might differ from each other, making the swap much harder than it should be. Don’t forget to inform your insurance company and your local registration authorities of the change of engine number.

Your question is a bit confusing Geniel, because the Ford Focus wasn’t released in Australia until September 2002. Which is to say, there wouldn’t be any 2000 model-year Focus engines lying around waiting to be fitted to another Focus. However, the original Focus was launched in Europe in 1998 and that car was broadly the same structurally as the version sold right up to 2005 in Australia.

The catch, of course, is that the Focus was sold with both a 1.8 and a 2.0-litre engine here, so you’d need to make sure that you were trying to fit exactly the same engine in exactly the same specification to ensure that everything from the fuel lines to the wiring loom and the cooling system to the gearbox matched up and fitted properly.

If, by some chance, you’ve found an imported Focus engine, be very wary of fitting that as it may not have the appropriate pollution equipment fitted to be legally registered in Australia. And don’t forget, whenever you swap an engine you need to inform the registration authorities and your insurance company of the new engine number.

The 1.6-litre engine has a timing belt, the larger 2.0-litre engines also offered in the Focus have timing chains.

The claimed average for your car is 6.7 L/100 km. It would be higher if it were driven around town – 9.4 L/100 km – but a less – 5.2 L/100 km – if only driven in the country. But remember that these so-called claimed figures are a guide only and not necessarily what you might get from your car.

If you have a non-turbo Focus model I'd suggest looking to trade it in on a turbocharged ST or RS model Focus. These models can be easily upgraded to be made much faster, however before you modify your car you should talk to an engineering signatory in your local state to ascertain if the modifications are legal.