1.8 TDCI Focus stalling when diesel gets low

Atomic Pineapple

I bought a 2010 1.8 TDCI Focus a while ago and it was running fine up until two weeks ago, previously I was using Topaz diesel but in the last two weeks I filled up with Apple Green diesel both times.

Both times I used Apple Green diesel the car started "chugging" on me with a loss of power so severe I had to pull in, the first time I just turned off the engine, waited about 3 minutes turned it on again and the car ran fine until I got to a station and filled up. The car was just above the mark where the low fuel indicator comes on.

The car has run 100% until the same thing happened me again this evening, again the fuel gauge was just above the low fuel indicator mark and the car started "chugging" this time I pulled in straight away before a severe loss of power occurred. This time the engine cut out on me when I pulled in and when I went to start it again it wouldn't start, the engine struggled as I turned the key, it was as if it was choking, not getting any fuel.

It eventually started again after about 10 minutes at the side of the road and several tries to start it. I made it to a station and this time filled up with Topaz diesel and the car is again running fine.

So I'm wondering is it just a coincidence that both times I filled up with Apple Green that this happened? And what might be the root causes of it? It was recently serviced but the fuel filter wasn't changed, could it be it is getting blocked? Would the tank be prone to gunk in the bottom of it thus causing the fuel to be blocked when the tank gets low? Could it just be that it doesn't like the Apple Green diesel?

George Dalton

Change the fuel filter, the 1.8TDCI is very sensitive to any contamination of the fuel filter.

Frankie Lee

You are right about avoiding Applegreen too.

Atomic Pineapple

George Dalton wrote: »

Change the fuel filter, the 1.8TDCI is very sensitive to any contamination of the fuel filter.

Thanks, further research suggest the same that they need to be changed at a much higher interval than Ford suggests to avoid issues and that even if they are assembled incorrectly they can cause issues. Most people say they get a warning light on the dash though and this hasn't happened me. I will get it changed anyway.

Frankie Lee wrote: »

You are right about avoiding Applegreen too.

I just thought it was a strange coincidence that it ran fine right down to 20/30 km to empty on the trip computer when running on Topaz and then both fills of Apple Green and it happened both times, weird but will give Apple Green a miss for awhile just to see.

Atomic Pineapple

Sorry to bump this but I went ahead and changed the fuel filter on the car a while back but the issue is still there, it seems to have got slightly worse too, it used to lose power and stall when the trip computer showed under 100km to empty. Now it is doing it when under 200km to empty but still well above 100 km to empty. This morning it occurred with 164 km to empty on the computer.

The power goes first, so this morning I was in 5th gear traveling at 120km/h and I felt a lull, from here the power slowly falls away and the car won't rev up to give me any power, I pull in, some white smoke comes from the exhaust and then after sitting idle for about 15 - 20 seconds the car dies.

When trying to start the car engine the engine struggles badly and the whole thing starts to vibrate pretty violently the longer I keep the key turned trying to start it. After the third attempt it eventually started.

I was quite some distance from a diesel pump so decided to drive it on anyway and see what happen, the car ran fine for about 30 km but again the exact same thing happened, exact same scenario, drove it on again about 20 km to a diesel pump and it was fine the whole way, filled up and now it will be fine as long as I keep the diesel above the 200 km to empty level.

So since the fuel filter hasn't helped I was wondering if anyone has any other ideas what it might be? It's due a service in Ford in two weeks and I'd like to maybe have an idea of something to ask them to look at.

Bpmull

its funny because I have a focus 1.6tdci and I cant drive it much under 1/4 of a tank. It runs 100 percent until it gets to 1/4 of a tank. then the more under 1/4 tank it drops it starts to get hard to start. And twice it just cut out no advance warning one of the times it wouldnt restart I had to change to fuel filter and it eventually started.

The second time it was idleing in a car park and cut out. I eventually got it restarted was about a miles from a petrol station. It was the longest mile ever the car stalled 5 times going to the petrol station. I got to the petrol station filled it up it started first time and i drove it a further 50km no issues. that was almost 3 months ago. Ive had no issue since but ive always kept it above 1/4tank. The most logical fault that was suggested is a damaged cracked fuel sender pipe and once the crack is covered in diesel it is ok once the level drops it starts to suck in air.

I know there different engine but i thought it was worth putting down. Ive spent so much on my car that im just not bothered to start throwing money at this problem its easier just to keep mine topped up with diesel. its a pure pain but its the cheapest time. I dont know if the problem will get worse or what only time will tell.

MarkR

I had a similar problem with an avens is diesel. Was a problem with the fuel pump assembly iirc. You sure the gauge is accurate?

Walshey96

My Dad had the same problem with Apple Green. Stay well clear from now on..

visual

Sounds like a pump could be going bad and struggling when the tank is getting low.

Hateart

Sludge in diesel tank is problem, you bought unfortunately some washed diesel somewhere , keep it topped up and change the diesel filter , you will get rid of the sludge through driving. Applegreen do appear to have a common theme beginning to surface .
If car no better you need take out the fuel gauge sender in the tank and clean the filter on the feed pipe to the engine. You can try blowing some air into the feed pipe after the filter with a garage hose tho clear any blockage in the pipe or tank filter, a few seconds will do. Remember to open the filler cap.

owen247

does this video look familiar:
http://www.youtube.com/watch?v=K1UN5e8_hIk

I am currently experiencing problems with a 2009 1.8d focus I just bought... but it happens on full tank too. I'm concerned now it may have had dodgey fuel in the past... but haven't a clue how to tell let alone prove it. - it's currently back with the garage I got it in.

I also posted in this thread, which is dedicated to that engine type. wish I'd seen it before... :-(

http://www.boards.ie/vbulletin/showpost.php?p=85932465&postcount=40

Plug

It's drawing in air I reckon. Try locate source of leak with clear pipe. Could be cracked pipes on the sender unit in tank.