After more search on the internet, my husband found a technical service bulletin article #04-5-6 describing the procedure for installing a new design fuel delivery module in the 2001-2002 Ford Focus. The car was built in the wayne assembly plant, the location of the fuel pumps that fail. Ford said my was not covered under the program because it was built in Aug. The pump is the same one described in the Ford extended coverage program03n01 dated 2003 and supplements 1 & 2 dated January 2004. I am the original owner of a 2001 Ford Focus purchased in mooresville nc the VIN is #. The only explanation that I can see for these unpredictable failures is a defect in the fuel delivery system. This indicates that it is not a problem with the quality or quantity of fuel in the tank. Each time a stall has happened, the car has worked fine the next day, without any addition of fuel. In between these stallouts, usually exactly one year apart, the engine has started and run smoothly, with no indication of problems. This year, I stopped trying to restart after 4 unsuccessful efforts. Those 3 incidents also required a new 15 amp fuse for the fuel pump, perhaps because of the repeated unsuccessful efforts to restart the car after it stalled. However, each one charged about $150 labor. None of them were able to look at it right away, and by the time they looked at it the next day, they could not find the problem. Locations were different, so it was always a different shop. Similar, but not identical, stalls occurred on March 16, 2009, Maand March 17, 2010. This car has done this every year now for the past 3 years. They charged $150 for the diagnostic labor. Ford ran many tests, including electrical and mechanical, took it out for 3 – 4 test drives and could not find a problem. ) I had the car towed to a Ford dealer, but they were not able to look at it till the next morning, at which time the car started fine. (later I learned that an identical scenario is described in Ford dealer letter 03n01, in which Ford agrees to replace fuel delivery modules for 20 models, but not 2002. It was potentially a dangerous situation, but luckily I was able to roll the car back downhill to a safer location. I restarted the engine a couple times, but it stalled out again after a few seconds. On March 17, 2011, my 2002 Ford Focus suddenly stalled out as I was accelerating uphill, turning right on a ramp to enter a busy highway. I hope this is the end of the "replacing parts" routine but am not optimistic due to other complaints I have read concerning this problem. The dealership has called to say they think it is the fuel pump and want to replace it with a "genuine Ford part," as opposed to aftermarket part my regular mechanic probably used. Nine "stalls" later I made it home an "improvement" over being stranded at the post office or the mall but certainly not acceptable. Also, I was able to put the car in drive by keeping one foot on the gas while the other foot was on the brake and continue moving until braking for a stop sign/traffic signal, at which point it would stall.
The latest time this has happened, after the fuel pump driver was replaced, I was able to do four errands before the stalling occurred. Has happened three times in past two weeks: brought it to local Ford dealership to see if they can diagnose the problem. Replaced fuel filter, fuel pump, oxygen sensors (twice), fuel pump driver by regular mechanic. Usually starts after waiting 45 minutes/amount of time it takes tow truck to arrive (towed 5x, 1 time was able to drive after 45 minutes). The car will start but immediately stall after taking foot off the gas. Situation usually happens in the afternoon after doing just a couple of local, short distance errands. Having an ongoing stalling problem starting on 5/20/11. The failure mileage was approximately 110,000. The manufacturer was informed of failure and a case was filed. The vehicle was diagnosed and the contact was informed that the fuel pump needed to be replaced. The vehicle was taken to rich Ford located at 8601 lomas blvd ne, albuquerque, nm 87112, and the motor mount, clutch release bearing, release cylinder bearing, purge valve were replaced however, the failure recurred.
The vehicle was taken to an independent mechanic where the fuel pump was replaced. Several unknown warning lights were temporarily illuminated. The vehicle resumed normal operation after the vehicle was turned off and restarted.
The contact stated that the battery warning light was illuminated. The contact stated that while driving at various speeds, the vehicle failed to accelerate. The contact stated that the vehicle was repaired under NHTSA campaign number: 18v735000 (fuel system, gasoline) however the failure recurred.
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