What's Bad
Criticised for "unstable body structure" in 2001 NCAP test, despite four star score. Still seems to lack space for oddments inside cockpit.
Reports of poor 35mpg economy from stop-gap 2.0 litre 115bhp TDDI engine. 2.0 TDDI diesel engine also prone to flat spots and surging.
On early LX and Zetecs the bottom of the seat is not very friendly to the coccyx. Also uncomfortable for heavier drivers because the plastic pins holding the moulded padding in place can actually protrude through to the seat face. Later models much improved.
Possible security issue in that access can be gained via passenger door when car is locked and immobilised.
Petrol models rated fewest breakdowns but poor for problems and faults in 2003 Which survey.
What to Watch Out For
Two reports of timing chain tensioner rattles on 2001MY 2.0 litre petrol engines, fixed under warranty.
Several Complaints of wind noise from front and rear door seals.
TDCI 130bhp engine may suffer from starting problems and uneven idling, may misfire between 1,800 and 2,000rpm, may sometimes cut out and may not be particularly economical with 42.5 mpg fairly typical. Partially cured by a an ECU software download, but head and injectors have also been modified on later cars.
Also reports of the TDCI smoking and of high oil consumption, which may be turbo oil seals.
Reports of failures of fuel tank lifter pumps leading to fuel delivery problems in 2.0 petrol models.
Reports of out of true alloy wheels.
Check inside edges of the bottoms of all doors of 2000 - 2003 cars for paint lifting and corrosion because the wax sealing between the door frame and skin can fail.
Check for corroded rear brake pipes where they pass over the fuel tank (an MOT failure point).
Check rear suspension bushes which can become loose in the attachment points (an MOT failure point) and used to require a new subframe costing £300 - £500 to replace. Ford now has a procedure that removes the need for a new subframe involving a new type of bush, a special tool (part number is 205-047-07) and Loctite 270 superglue (part number 1128-392). Unfortunately the tool and glue have been in short supply. The solution will not work if the subframe has corroded around the attachment points.
Look for rust around chrome number plate light cover on Ghia estates.
An engine rattle from 4 - 5 year old 2.0i engines might indicate wearing of the shaft of the injection air inlet manifold flaps . 2000 - 2001 2.0 litre petrol engiens can develop an inlet injection manifold problem that eventually results with parts being ingested by the engine.
Diff problem starting to crop up on TDCI 130 6-speeds at around 3 years old, so any vibrations just before the warranty ends, make sure you notify the supplying garage in writing.
Undertray of ST very difficult to remove to get to engine supm plug, then very difficult to put back. 16 fasteners and a two man job.
Reports of problems with camshaft position sensors of TDCI 130s. Spate of clutch and dual-mass flywheel failures on 2003 built 2004 model year TDCIs. Starting problems with diesel may be due to impending clutch failure. 13/10/07 Voluntary Recall letter to owners of TDDIs and TDCIs to replace faulty dual mass flywheels.
Reports of 2nd gear band breaking up in 4-speed autobox, contaminating the ATF and requiring the box to be rebuilt. These boxes tend to have a life of 60k - 90k.
JATCO advises owners of later 5-speed autoboxes not to carry out AUTOMATIC transmission fluid changes hemselves because it's difficult to ensure the correct amount is added (the gearbox needs to be run to a specific temperature - This requires diagnostic equipment) and probably they will use the wrong oil, e.g. Land Rover Discovery ATF is different from a Land Rover Freelander, and Jaguar X-Type (Jatco) uses different ATF to a Land Rover Freelander (Jatco).
ST models can suffer from drooping rear bumper/valence mouldings (
www.stdrivers.co.uk
Rear tracking is adjustable for toe in / toe out, but cannot be set with some types of alloy wheel because they do not have continuous rims and confuse the laser. Too much toe in will make the steering very light. Too much toe out will lead to severe tyre inner shoulder wear.
TDCI injectors seem to be very fuel sensitive. Many have needed to be replaced after 3-4 years and circa 60,000 miles. Report of turbo oil-seal failure in 2.2 TDCi turbo caused engine to run on its sump oil and self-destruct. Bill for replacement engine, turbo, catalytic converter, exceeded £7,000.
Flexible front brake hoses vulnerable to chafing when not secured properly, and this can cause total brake failure if ruptured.
One reader's catalogue of failures from his 1.8SCi: "Coolant leaks, water leaks, alloy wheel paint flaking around the valves, the Sat-Nav/Air/CD control has a tendency to freeze but worst of all the fuel consumption is very bad. Less than 30 mpg, where my previous 2001 1.8 Zetec gave me 35mpg." Seems to have a problem with the air con pipe at the front of the engine. Fix is new type of pipe £227 all in.
Recalls
29-12-2000: 2,500 2001 model year Mondeos recalled to have side airbag trigger electronics replaced. (Source Daily Mirror 29-12-2000.)16-7-2001: Warning sent out to owners about correct operation of handbrake: press brake pedal firmly; while brake pedal pressed, pull handbrake lever up to its fullest extent keeping finger off the ratchet button. Always park an automatic in 'P'. 21-8-2001: 5,595 2001 model year Mondeos built October 2000 to July 2001 fitted with cruise control recalled because water ingress can corrode the electrics leading to failure to switch off. 20-4-2002: 60,000 Mondeos built January to November 2001 recalled for parking brake ratchet to be adjusted. 10-7-2002: Battery cable may chafe on automatic transmission valve cover plate. 8,888 Mondeos affected. (Some recall notices not received until March 2003.) TSB No.63/2002 31.10.2002 Model: Mondeo 2001 with 2.0L DuraTorq-TDCi engine built from 10.2001 (build code 1K), Focus with 1.8L DuraTorq-TDCi engine built from 05.2001 (build code 1B. Engine running erratically or does not start. Common cause is that the fuel pump is unable to deliver the required fuel rail pressure due to wear of the cam, rollers and shoes. The damage is caused by insufficient bedding of the rollers during early life. This also creates metallic particles which can enter the high pressure fuel system and lead to injector failure. To rectify this concern, a revised fuel pump, new injectors and associated parts should be installed. If this concern is present, it will generally be indicated by a flashing glow plug indicator showing that a fault has been detected. This bulletin supersedes TSB 63/2002 dated 08.08.2002, which should either be destroyed or clearly marked to show it is no longer valid (e.g. with a line across the page). Additions have been made to the Parts Required and Labour Times. The Service Instruction has been ammended. 3/2/2003: Power steering pressure hose may chafe on engine inlet manifold, ultimately resulting in oil leak and loss of assistance to steering. Fit latest production level, revised routing PAS pressure hose. TECHNICAL SERVICE BULLETIN No.37/2003
Car and Light/Medium Commercial 31.03.2003 Section: 303-04E
Model: Mondeo 2001 (Engine: 2.0L DuraTorq-TDCi)
Markets: All. Subject: Engine cuts out. Summary: Should a customer express concern that the engine is cutting out, the probable cause is a failed connection of the fuel pressure sensor electrical connector. To rectify this concern, a modified fuel pressure sensor electrical connector should be installed. Note: To carry out the service instruction, it will be necessary to splice the new fuel pressure sensor electrical connector into the engine wiring harness. 4-8-2003: recall of 72,682 Mondeo IIs to modify parking brake lever mechanism with improved leverage.
13/10/07 Voluntary Recall letter to owners of TDDIs and TDCIs to replace faulty dual mass flywheels.
