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E58153 Battery Discharging
Subject/Concern: Power loss; engine difficult to start or does not start (fault code P0380 is set); battery discharged
Model:
Focus C-MAX 2003.75 (06/2003–) Engine: 1.6L Duratorq-TDCi (DV) Diesel
Engine: 2.0L Duratorq-TDCi (DW) Diesel
Focus 2004.75 (07/2004–) Engine: 1.6L Duratorq-TDCi (DV) Diesel
Engine: 2.0L Duratorq-TDCi (DW) Diesel
Markets: All
Section: 303-07
Summary
Should a customer express concern regarding power loss or that the engine is difficult to start or does not start at all or that the battery becomes discharged and if fault code P0380 is set, the probable cause is a damaged glow plug relay due to water ingress via the ground cable in the wiring harness to the glow plug relay. To rectify the concern, a new glow plug relay and a modified wiring harness from the engine compartment fuse box to the glow plug relay should be installed.
Parts Required
Description Finis Code Quantity
Glow plug relay 1 252 609 1
Glow plug relay repair wiring harness 1 363 580 1
Solder/crimp connectors locally procured -
Cable ties locally procured -
Labor Time
Operation Description Operation No. Time
WDS Vehicle Connection/Communication 29 099 0 -
Stored Fault Codes - Read Out - additional 0.1 hours
Headlamp Assembly - Remove And Install (One Side) 32 115 1 -
Engine Undershield - Remove and Install 21 130 4 -
Glow Plug Relay And Glow Plug Relay Wiring Harness - Renew - additional 0.8 hours
Repair/Claim Coding
Causal Part: Finis Code for glow plug relay
ACES Condition Code: 49
OASIS 203000, 203100, 603300, 607000, 614000
Service Information
Glow plug relay repair wiring harness
19145 - FOCUS / C-MAX 2.0 TDCI - DTC P0002/P0089 SOME FOCUS AND C-MAX 2.0 TDCI PRODUCED UNTIL JAN 2006 MAY EXHIBIT THE MIL ILLUMINATED AND VARIOUS DRIVEABILITY CONCERNS WITH DTC P0002 (FUEL VOLUME REGULATOR CONTROL CIRCUIT RANGE/PERFORMANCE) AND/OR DTC P0089 (FUEL PRESSURE REGULATOR PERFORMANCE)PRESENT. TO RECTIFY, REPROGRAM THE PCM WITH THE APPROPRIATE NEW CALIBRATION AVAILABLE IN SERVICE FROM WDS CD B42 ONWARDS (REVISED CALIBRATION'S ARE:3M51-12A650-AD; 3M51-12A650-NG; 3M5A- 12A650-HT; 4M51-12A650-ZG; 5M51-12A650-MD; 6M51-12A650-TD; 6M51-12A650-UD; 6M51-12A650-HC)
EFFECTIVE DATE: 27/03/2006
19013 - NEW FOCUS/C-MAX 2.0 TDCI - DTC P1412/P0490/P1335
CONTINUING OF SSM 18859. DO NOT REPLACE THE EGR COOLER UNLESS THERE IS DIRECT EVIDENCE OF COOLER FAILURE, EVEN IF THE DEPOSITS ON THE EGR VALVE LEADS TO SUCH A CONCLUSION. A NEW DESIGNED EGR VALVE TO OVERCOME THIS LEVEL OF DEPOSITS WILL BE AVAILABLE SOON AND YOU'LL BE INFORMED WITH A SEPERATE OASIS MESSAGE. PLEASE BE ALSO REMINDED THAT THE USE OF BIO DIESEL FOR ALL FORD DIESEL ENGINES (MORE THAN 5% WHICH ARE BASICALLY PART OF DIESEL FUEL) IS NOT ALLOWED AND WILL INVALIDATE WARRANTY. IT CAN LEAD TO THIS KIND OF FAILURE ON THE EGR VALVE.
EFFECTIVE DATE: 23/01/2006
18859 - NEW FOCUS/C-MAX 2.0 TDCI - DTC P1412/P0490/P1335
SOME NEW FOCUS/C-MAX 2.0L TDCI MAY EXHIBIT POOR START; ROUGH IDLE OR LOSS OF POWER WITH DTC: P1412 (EGR FROZEN); P0490 (EGR CONTROL CIRCUIT HIGH) OR P1335 (EGR POSITION SENSOR MIN/MAX STOP PERFORMANCE) PRESENT. IF SO REPROGRAM THE PCM WITH THE APPROPRIATE NEW CALIBRATION AVAILABLE IN SERVICE FROM WDS CD B39A ONWARDS (REVISED PCM PART NO.: 3M51-12A650-AC; 3M51-12A650-NF; 3M51- 12A650-HS; 4M51-12A650-ZF; 5M51-12A650-MC) AND FOLLOWING ALL THE ON SCREEN INSTRUCTION INCLUDING RESETTING THE EGR VALVE. IF ANY CODES ARE STILL PRESENT AFTER ROAD TEST FOLLOW THE DIAGNOSTIC PROCEDURES FOR THAT CODE. SHOULD A REPLACEMENT EGR VALVE STILL BE REQUIRED THE NEW VALVE MUST STILL BE RESET TO THE PCM USING WDS. THIS FUNCTION IS FOUND IN TOOLBOX, POWERTRAIN, SERVICE FUNCTIONS, COMPONENT/PARAMETER RESET.
EFFECTIVE DATE: 03/10/2005
18502 - NEW FOCUS / C-MAX TDCI - DTC P0089 OR P0002
IF DURING A WDS DIAGNOSIS ON A NEW FOCUS OR FOCUS C-MAX WITH TDCI - DIESEL ENGINE, THE DTC'S: P0089 (PCV/VCV CONTROL AT MINIMUM OR MAXIMUM VALUE) OR P0002 (VCV OUTSIDE ADAPTIVE RANGE, FUEL FLOW IS LOW) IS SET, PRIOR TO MAKING ANY HARDWARE CHANGE ON THE ENGINE SUCH AS FUEL PUMP, VERIFY THAT THE FUEL LINES ARE CLEAR AND FREE FROM BLOCKAGES/KINKS FROM THE DDM IN THE FUEL TANK, RIGHT THROUGH TO THE FUEL PUMP INLET ON THE ENGINE.A FEW CASES WERE REPORTED WHERE, DUE TO CUSTOMER MISS-USE, THE PLASTIC INSERT IN THE UPPER FILLER NECK GOT DAMAGED. A DAMAGED PLASTIC INSERT CAN BE EASILY DETECTED BY VISUALLY INSPECTING THE INSIDE OF THE FILLER NECK WHEN THE FILLER CAP IS REMOVED. VISUAL SIGNS ARE A DEFORMED METAL FLAP OR CRACKS IN THE PLASTIC MATERIAL.
EFFECTIVE DATE: 23/03/2005
18429 - NEW FOCUS / C-MAX 2.0 TDCI - DTC P0089 OR P0002
IF DURING A WDS DIAGNOSIS ON A NEW FOCUS OR FOCUS C-MAX EQUIPPED WITH 2.0 TDCI, THE DTC'S : P0089 (PCV/VCV CONTROL AT MINIMUM OR MAXIMUM VALUE) OR P0002 (VCV OUTSIDE ADAPTIVE RANGE, FUEL FLOW IS LOW) IS SET, PRIOR TO MAKING ANY HARDWARE CHANGE ON THE ENGINE SUCH AS FUEL PUMP, VERIFY THAT THE FUEL LINES ARE CLEAR AND FREE FROM BLOCKAGES/KINKS FROM THE DDM IN THE FUEL TANK, RIGHT THROUGHTO THE FUEL PUMP INLET ON THE ENGINE.
EFFECTIVE DATE: 22/02/2005
17898 - FOCUS C-MAX - CLUSTER WARNING LIGHTS ON.
FOCUS C-MAX ALL EXCEPT 1.6 PETROL ENGINE - ALL INSTRUMENT CLUSTER WARNING LIGHTS ERRATIC READING AND ENGINE LOSS OF POWER/NO START. THIS CAN BE CAUSED BY AN INTERRUPTION OF THE CAN BUS VIA THE ELECTRO- HYDRAULIC POWER ASSISTED STEERING (EHPAS) UNIT. TO VERIFY, PLEASE DISCONNECT THE WIRING CONNECTOR OF THE EHPAS UNIT AND CHECK WHETHER ALL SYMPTOMS ARE STILL PRESENT. IF THE CONCERN CANNOT BE REPRODUCED WITH THE EHPAS UNIT DISCONNECTED, THEN CONTACT THE EHPAS PRE-APPROVAL HELPDESK FOR ASSISTANCE BEFORE REPLACING ANY PARTS
EFFECTIVE DATE: 29/06/2004
TECHNICAL SERVICE BULLETINS :
017/2005 FOCUS C-MAX 2003.75 AND FOCUS 2004.75 WITH 1.6/2.0L DURATORQ-TDCI (DV) DIESEL: POWER LOSS; ENGINE DIFFICULT TO START OR DOES NOT START (DTC P0380 STORED); ENGINE UNDERSHOOTS TO ASTOP; BATTERY DISCHARGED
EFFECTIVE DATE: 16/03/2005
____________________________________
607400 - DRIVEABILITY STALLS/QUITS AT IDLE
SPECIAL SERVICE MESSAGES :
18715 - C-MAX 1.8 DURATEC 120 / 125PS - POOR PULL AWAY
SOME FOCUS C-MAX EQUIPPED WITH 1.8 DURATEC HE 120 AND 125 PS, MAY EXHIBIT POOR PULL AWAY WHEN THE AIR CONDITIONING IS ON AND THE AMBIENT TEMPERATURE IS ABOVE 20�C. TO RECTIFY THIS, REPROGRAMM THE PCM WITH THE LATEST LEVEL CALIBRATION WHICH IS ON WDS CD38 ONWARDS. PCM PART NO.: 5M51-12A650-RC FOR 125 PS AND 3M51-12A650-GF FOR 120 PS )
EFFECTIVE DATE: 06/07/2005
SSM 19168 EFFECTIVE DATE: 18/04/2006
FOCUS AND C-MAX - INTERMITTENT ELECTRICAL CONCERNS
SOME FOCUS AND C-MAX MAY EXHIBIT INTERMITTET ELECTRICAL CONCERNS, FOR EXAMPLE,
WIPER PARKED IN MIDDLE POSITION; CLUSTER WARNING LIGHTS ON; RADIO INTERFERENCE OR ENGINE WON'T CRANK.
BEFORE STARTING A DIAGNOSIS WITH WDS OR EXCHANGING ANY HARDWARE IT IS ESSENTIAL TO ENSURE
SECURE B+ CONNECTIONS (3 OF): 1) NUT M6 (1-OF), FIXING OF B+ CLAMP TO BATTERY POLE: 5,4NM +/- 0.8. 2) NUT M8 (2-OF),
FIXING OF B+ CABLES TO BATTERY CLAMP: 15NM +/- 2.3-.
TSB 7/2006
Subject/Concern: Hesitations; Poor or no start; Deteriorated fuel economy; Diagnostic trouble codes (DTC) P1412, P0490 and P1335 stored
Model: Focus C-MAX 2003.75 (06/2003�) Build Date: 14.02.2004-01.03.2006
Build Code: 4R-6S
Assembly Plant: Saarlouis
Engine: 2.0L Duratorq-TDCi (DW) Diesel
Focus 2004.75 (07/2004�) Build Date: Up to 01.03.2006
Build Code: Up to 6S
Assembly Plant: Saarlouis
Assembly Plant: Valencia
Engine: 2.0L Duratorq-TDCi (DW) Diesel
Markets: All
Section: 303-08
Summary
Should a customer express concern about one of the following:
* hesitations,
* poor or no start,
* deteriorated fuel economy,
and upon investigation diagnostic trouble codes (DTC) P1412, P0490 and P1335 are stored in the powertrain control module (PCM), the probable cause is a sticky exhaust gas recirculation (EGR) valve.
To rectify this concern, a new EGR valve with a stronger EGR valve motor and revised PCM calibration should be installed.
� NOTE: Use CD-42 or a later version.
TSB 5/2006
Subject/Concern: Inaccurate fuel gauge and inaccurate trip computer (if equipped)
SSM 19013 EFFECTIVE DATE: 23/01/2006
NEW FOCUS/C-MAX 2.0 TDCI - DTC P1412/P0490/P1335
CONTINUING OF SSM 18859. DO NOT REPLACE THE EGR COOLER UNLESS THERE IS DIRECT EVIDENCE OF COOLER FAILURE, EVEN IF THE DEPOSITS ON THE EGR VALVE LEADS TO SUCH A CONCLUSION. A NEW DESIGNED EGR VALVE TO OVERCOME THIS LEVEL OF DEPOSITS WILL BE AVAILABLE SOON AND YOU'LL BE INFORMED WITH A SEPERATE OASIS MESSAGE. PLEASE BE ALSO REMINDED THAT THE USE OF BIO DIESEL FOR ALL FORD DIESEL ENGINES (MORE THAN 5% WHICH ARE BASICALLY PART OF DIESEL FUEL) IS NOT ALLOWED AND WILL INVALIDATE WARRANTY. IT CAN LEAD TO THIS KIND OF FAILURE ON THE EGR VALVE.
SSM 18859 EFFECTIVE DATE: 03/10/2005
NEW FOCUS/C-MAX 2.0 TDCI - DTC P1412/P0490/P1335
SOME NEW FOCUS/C-MAX 2.0L TDCI MAY EXHIBIT POOR START; ROUGH IDLE OR LOSS OF POWER WITH DTC: P1412 (EGR FROZEN); P0490 (EGR CONTROL CIRCUIT HIGH) OR P1335 (EGR POSITION SENSOR MIN/MAX STOP PERFORMANCE) PRESENT. IF SO REPROGRAM THE PCM WITH THE APPROPRIATE NEW CALIBRATION AVAILABLE IN SERVICE FROM WDS CD B39A ONWARDS (REVISED PCM PART NO.: 3M51-12A650-AC; 3M51-12A650-NF; 3M51- 12A650-HS; 4M51-12A650-ZF; 5M51-12A650-MC) AND FOLLOWING ALL THE ON SCREEN INSTRUCTION INCLUDING RESETTING THE EGR VALVE. IF ANY CODES ARE STILL PRESENT AFTER ROAD TEST FOLLOW THE DIAGNOSTIC PROCEDURES FOR THAT CODE. SHOULD A REPLACEMENT EGR VALVE STILL BE REQUIRED THE NEW VALVE MUST STILL BE RESET TO THE PCM USING WDS. THIS FUNCTION IS FOUND IN TOOLBOX, POWERTRAIN, SERVICE FUNCTIONS, COMPONENT/PARAMETER RESET.
SSM 5310
FOCUS AND C-MAX 1.6 TDCI - LOSS OF POWER
SOME NEW FOCUS OR C-MAX EQUIPPED WITH 1.6 TDCI BUILT BETWEEN JUNE 2003 AND JAN
2005, MAY EXHIBIT THE FOLLOWING DRIVEABILITY ISSUES:
1.MIL ON DTC P0404/P1412 (EGR) REDUCED POWER. 2. MIL ON DTC P0234 TURBO
OVERBOOST REDUCED POWER. 3. MIL ON DTC P0238 TURBO BOOST SENSOR VOLTAGE UPPER
LIMIT REDUCED POWER. 4. RUN DOWN ROUGHNESS. ALSO REDUCES OIL BACKFLOW IN AIR
INTAKE SYSTEM IN COMBINATION WITH SSM 18120. 5. MIL ON DTC P0116 ECT REDUCED
POWER.IN CASE OF THESE CONCERNS, A REVISED PCM CALIBRATION IS NEEDS TO BE
INSTALLED. THIS NEW LEVEL CALIBRATION WILL BECOME AVAILABLE ON WDS CD B41.
REVISED PCM NO: 3M51-12A650-MH; 4M51-12A650-NF;-KG
TSB 40/2005
* Loss of power,* Engine does not start,
* Engine undershooting to a stop with immediate restarting possible,
* "POWER STEERING FAILURE" displayed on the instrument cluster,
Focus C-MAX 2003.75 (06/2003�) Build Date: 23.06.2003-03.01.2005
Build Code: 3Y-5J
Engine: 1.6L Duratorq-TDCi (DV) Diesel
Engine: 2.0L Duratorq-TDCi (DW) Diesel
Transmission/Transaxle: CFT23
Transmission/Transaxle: MTX-75
one probable cause is a damaged wiring harness in the area of the manual/automatic transaxle
TSB 11/2006
Clock in Radio resets after engine crank
Should a customer express concern that the displayed time and date in the audio unit or the instrument cluster reverts
back to always the same values after engine start, the probable cause is a voltage drop during the cranking process of
the engine. This could lead to a reset of the instrument cluster.
To rectify this concern a voltage buffer module should be installed to the production wiring harness for the instrument cluster
SSM 18579 EFFECTIVE DATE: 26/04/2005
CLOCK IN RADIO LOOSES TIME
SOME NEW FOCUS AND C-MAX VEHICLES MAY HAVE A RADIO UNIT WITH THE CLOCK DISPLAY RUNNING SLOW, A FEW SECONDS PER DAY COULD BE LOST.
TO RECTIFY THIS UPDATE THE INSTRUMENT CLUSTER WITH REVISED SOFTWARE WHICH IS AVAILABLE WITH WDS CD37 ONWARDS.
ID THE VEHICLE AS NORMAL; CHOOSE INSTRUMENT CLUSTER UNDER "BODY" IN THE GUIDED DIAGNOSTIC TAB MENU;
SELECT CLOCK TIME FROM THE DIAGNOSTIC MENU AND PRESS THE BLUE TICK; FOLLOW THE ON SCREEN COMMANDS UNTIL THE PROCEDURE IS COMPLETE,
THEN EXIT THE GUIDED DIAGNOSTIC.
SSM 17927
Desc: When the ignition is switched on, occasionally a Low Fuel Warning is shown.
Fix: Updated Cluster firmware.
SSM 7608
Desc: When the ignition is switched on, a yellow warning with 'Limited EPB function!' is shown.
Fix: Firmware update
SSM 18122
Desc: Noticeable flat spot in first gear around 1700rpm (TDCi engines) when pulling away from standstill.
Fix: ECU Firmware update
TSB 13/2005
Desc: Leak from Turbocharger outlet pipe (1.6 TDCi) Oil pipe unseated during assembly.
Fix: A revised turbocharger outlet pipe is installed Applies to models up-to 31/07/2004 Code 4D
TSB 05/2005
Desc: Light application of the brakes when reversing causes a loud squeel.
Fix: Replacement Brake Pads. (Under Warranty)
TSB 41/2004
Desc: The time randomly changes on the radio clock.
Fix: Updated Instrument Cluster firmware (current version 4.24 shown as ROM Level 0424 in TEST mode Later versions include the fixes)
SSM 18356 EFFECTIVE DATE: 22/12/2004
RADIO (SONY/5000/6000) INCORRECT CLOCK DISPLAY
SOME NEW FOCUS AND C-MAX EQUIPPED WITH RADIO: 5000/6000/SONY MAY EXHIBIT THE RADIO DISPLAY SHOWING DIFFERENT CLOCK VALUES AFTER
E.G. CRANK, DURING DRIVING. TO RECTIFY 1.DISCONNECT BATTERY FOR AT MINIMUM 5 SEC. TO INITIALIZE A CLUSTER RESET ( CLOCK DRIVER ).
AFTERWARDS SET CLOCK AND DATE TO THE ACTUAL TIME. 2. ON C-MAX BUILT UNTIL 08.06.04 (4K) PLEASE WORK ACCORDING TO TSB 41/04.
ALL VEHICLES BUILT AFTER HAVE ALREADY THE LATEST LEVEL SOFTWARE AND IT IS NOT RECOMMENDED TO REFLASH THESE VEHICLES AGAIN.
IF THE ISSUE STILL OCCURS NO FURTHER REPAIR WILL IMPROVE THE SITUATION. THIS IS CURRENTLY UNDER INVESTIGATION.
TSB 45/2004
Desc: Ocassionally HID headlamp fails to ignite.
Fix: Uprated Earthing Cable
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