These engines have mehanical tappets that should be checked every 37,500 miles and reshimmed as necessary. It a strait forward job for any garage with the correct Ford tool and a pile of shims. Without the tool and pile of shims it can be a nightmare.

The noise goes when the engine warm because the tollerences close up but even when cold there should really be no rattle.

People get very confused over the Ford "Zetec" engine, Ford made it very confusing.

The original Zetec "E" was introduced in the Escort/Orion in the early 90's in 1600 and 1800 cc versions. This was then used in the Mondeo in 1600, 1800 and 2 litre versions. Some Fiestas (RS1800 I think) from this period also used this engine in 1800 cc version. This engine used a cast iron block and had hydraulic tappets and was commonly referred to as the "Silvertop" (cast alloy cam cover).

In about 1998 Ford modified the engine with a different block, sump and fitted solid tappets. It was used in 1800 and 2 litre versions in the late Mk2 Mondeo until 2000 and in the Mk 1 Focus until 2004. It was commonly referred to the "Blacktop" (black plastic cam cover.

What you have in your Focus is a totally unrelated engine that Ford originally called the "Zetec SE" (now refered to as the Sigma engine). It was designed in partnership with Yamaha and has no common parts with the above engines. It is all alloy costruction for starters and much smaller physically. Originally fitted to the Fiesta from about 1996 in 1250 and 1400 versions (later 1600 as well), it was used in the Focus Mk 1 and 2 in 1400 and 1600 versions, and the Puma had a special 1700 cc version. All engines have been fitted with solid tappets.

No doubt I have missed some cars that have used the above engines.

As for where to get the work done unless you have a particularly good Ford independant with all the special tools I would first have a word with your local Ford dealer and get them to have a listen, it may not be the tappets.

As for cost, how long is a piece of string.

Hi

I had a 2004 ford focus 1.6 (100) purchased it with 25,000 and part ex'd it with 105,000 full service history for another focus, the oil was changed every 4000 miles by me using 5w 30 oil.

The engine always had rattley tappets worse when cold but still present when hot especially on overun. I understood the noise was due to the fact the valve clearances are shimmed rather than hydraulic and nothing to worry about. The motor had a bit of piston slap as well when cold for the last couple of years aswell again nothing to worry about if it fades when warmed up.

The car and engine were very reliable and tough it never let me down in 7 years. I really wouldn't worry and just enjoy the car.

PS

My wifes 2007 ford fiesta 1.25 zetec se is also the same along with the piston slap thats done 45,000.

Thanks very much for your informative post and it does give me some confidence. I just worry about leaving it unchecked with potential cam lobe wear etc. I want at least 4+ years from this relatively low mileage engine. I do about 12k a year mileage. Just wondering whether it's worth spending the money on getting it shimmed.

Edited by K21000 on 26/12/2013 at 18:29