CriticalAffected: 2004-201160,000–110,000 miles

Ford Focus Mk2 1.8 TDCi — Alternator Smart Charge Failure

Ford's 'Smart Charge' alternators on the Mk2 Focus fail regularly, often taking the battery with them.

Severity

Critical

DIY Difficulty

Moderate

Est. Cost

£20–£350

OBD Codes

P1632P0620

Component Diagram

Electrics

Typical layout and location for the Electrics assembly.

Reference Illustration

Symptoms

Battery warning light
Dashboard acting crazily (lights flashing, dials dropping to zero)
Car stalls while driving

Root Cause

The internal voltage regulator fails. Sometimes the 3-pin Smart Charge plug wiring breaks near the alternator.

How To Fix

Check the 3-pin wiring plug first. If broken, repair wiring (£20). If alternator is dead, replace with a high-quality OEM unit (Denso). Cost: £200-350

Estimated Repair Costs

Repair Option	Est. Cost (GBP)
DIY (parts only)	£8–£140
Independent Garage	£20–£350
Main Dealership	£32–£560

Other Faults on This Variant

Electric Window Regulator Cable Failure

Minor

2004-201150,000–120,000 miles£100–£200

The cables inside the electric window regulator mechanism fray and snap, causing the window glass to drop into the door frame.

Engine Thermostat Sticking Open

Minor

2004-201160,000–120,000 miles£100–£250

The engine coolant thermostat fails in the 'open' position. The engine never reaches its optimal operating temperature, killing fuel economy.

Starter Motor Solenoid / Brush Wear

Severe

2004-201170,000–130,000 miles£150–£350

The starter motor wears out internally. This is particularly common on vehicles equipped with Stop/Start systems.

Disclaimer: Repair cost estimates are indicative and based on community data. Always get a quote from a qualified mechanic before proceeding with any repair.