Hi all - seem to have lost my log in credentials, so new account.

2009 1.8 Petrol focus had been fine but started it up the other day (loaded up with kids to see inlaws for xmas!) and all of the error lights came on and it then said engine malfunction. Turned it off and on again and seemed ok, but then 50 yards down the road all the lights came on again and it cut out. Got it back onto the drive. 

Have now run forscan and i'm getting a lot of error codes. Any ideas? Seems odd there are so many - wondering if some wiring has cracked in the cold weather or perhaps the battery is shot?

 

===PCM DTC P0231-63===
Code: P0231 - Fuel pump secondary circuit Low

Additional Fault Symptom:
 - Signal is Above Maximum Threshold

Status: 
 - DTC Present at Time of Request
 - Malfunction Indicator Lamp is Off for this DTC

Module: Powertrain Control Module

Diagnostic Trouble Code details

Fuel pump secondary circuit Low

The FP is commanded ON, but the secondary circuit monitor (returned over CAN) reports the pump is OFF.

This DTC may be caused by :

Open or grounded circuit.

Unserviceable FP.

===END PCM DTC P0231-63===

===PCM DTC P0571-63===
Code: P0571 - Brake Switch A Circuit

Additional Fault Symptom:
 - Signal is Above Maximum Threshold

Status: 
 - DTC Present at Time of Request
 - Malfunction Indicator Lamp is Off for this DTC

Module: Powertrain Control Module

Diagnostic Trouble Code details

Brake Switch A Circuit

Noise on the CAN derived signal is greater than the calibrated limit.

CAN message times out.

Fault status reported over CAN.

The number of BLS transitions with no BPP switch transitions exceeds the calibrated limit.

This DTC may be caused by :

Electrical Interference

CAN communication bus fault.

Faulty switch operation.

To clear this DTC, it is necessary to reset the KAM.

===END PCM DTC P0571-63===

===PCM DTC P1260-63===
Code: P1260 - THEFT Detected, Vehicle Immobilized.

Additional Fault Symptom:
 - Signal is Above Maximum Threshold

Status: 
 - DTC Present at Time of Request
 - Malfunction Indicator Lamp is Off for this DTC

Module: Powertrain Control Module

Diagnostic Trouble Code details

THEFT Detected, Vehicle Immobilized.

This DTC may be caused by :

Communications with the IC timing out.

An invalid response from the IC.

A disable message from the IC.

===END PCM DTC P1260-63===

===PCM DTC P2121-63===
Code: P2121 - Throttle/Pedal Position Sensor/Switch D Circuit Range/Performance

Additional Fault Symptom:
 - Signal is Above Maximum Threshold

Status: 
 - DTC Present at Time of Request
 - Malfunction Indicator Lamp is Off for this DTC

Module: Powertrain Control Module

Diagnostic Trouble Code details

Throttle/Pedal Position Sensor/Switch D Circuit Range/Performance

APPS1 fault.

The CAN message from the cluster is missing.

The PCM receives APPS1 signal over the CAN network.

This DTC may be caused by :

CAN communication bus fault.

Faulty APPS circuit.

Faulty APP Sensor

===END PCM DTC P2121-63===

===PCM DTC P2122-63===
Code: P2122 - TP Sensor/Switch D Circuit Low Input

Additional Fault Symptom:
 - Signal is Above Maximum Threshold

Status: 
 - DTC Present at Time of Request
 - Malfunction Indicator Lamp is Off for this DTC

Module: Powertrain Control Module

Diagnostic Trouble Code details

Throttle/Pedal Position Sensor/Switch D Circuit Low Input

APPS 1 input voltage is less than the calibrated limit.

Note: This DTC relates to the APPS.

This DTC may be caused by :

Open circuit in wiring or component

Signal shorted to ground or signal return.

Faulty Sensor

===END PCM DTC P2122-63===

===PCM DTC U1900-E3===
Code: U1900 - CAN communication bus fault

Additional Fault Symptom:
 - Signal is Above Maximum Threshold

Status: 
 - DTC Present at Time of Request
 - Malfunction Indicator Lamp is On for this DTC

Module: Powertrain Control Module

Diagnostic Trouble Code details

CAN Communication Bus Fault - Receive Error

Note:

DTCs that start with 'U' are faults which occur during module-to-module communication.

Modules should never be replaced based only on a 'U' code. These codes do not always indicate a problem, and can be caused by normal diagnostic functions, carried out on the vehicle.

===END PCM DTC U1900-E3===

===OBDII DTC U1900-C===
Code: U1900 - CAN communication bus fault

Status: 
 - Confirmed - malfunction is confirmed 

Module: On Board Diagnostic II

Diagnostic Trouble Code details

CAN Communication Bus Fault - Receive Error

Note:

DTCs that start with 'U' are faults which occur during module-to-module communication.

Modules should never be replaced based only on a 'U' code. These codes do not always indicate a problem, and can be caused by normal diagnostic functions, carried out on the vehicle.

===END OBDII DTC U1900-C===

===ABS DTC U2023-A0===
Code: U2023 - Vehicle Communication Network Fault

Status: 
 - Previously Set DTC - Not Present at Time of Request
 - Malfunction Indicator Lamp is On for this DTC

Module: Antilock braking system

Diagnostic Trouble Code details

Vehicle Communication Network Fault

CAN communication failure between the PCM and the ESP module.

This DTC may be caused by :

The ESP module has not received the correct message from other modules on the CAN communication data bus.

There may be other modules on the CAN communication data line that are not communicating and are timing out.

Short circuit on the CAN line.

Open circuit on the CAN line.

The ESP module has not received the correct message from other modules on the CAN communication data bus.

There is a time out between two modules on the CAN bus

There is Interference on the CAN bus

Perform these checks

Do not replace the ABS module based on this DTC alone. Make sure all the necessary checks have been carried out.

Check all connectors for continuity, corrosion, water ingress and any signs of visible damage.

Check that there are no CAN communication faults on the other modules.

Check the continuity of the CAN communication connections between the ABS and the PCM modules.

Check the wiring harness

Check the continuity of the CAN communication connections between the ABS module, other modules and the PCM.

Check the PCM for DTCs.

Note:

DTCs that start with 'U' are faults which occur during module-to-module communication.

Modules should never be replaced based only on a 'U' code. These codes do not always indicate a problem, and can be caused by normal diagnostic functions, carried out on the vehicle.

For further diagnostic information refer to the appropriate section of eTIS.

Additional Information

The ABS lamp should be illuminated.

The ESP lamp should be illuminated.

The ABS lamp should be illuminated.

There will be an ESP malfunction warning displayed on the driver information text panel.

===END ABS DTC U2023-A0===

===EPS DTC U1900-20===
Code: U1900 - Missing Message for Engine Speed

Status: 
 - Previously Set DTC - Not Present at Time of Request
 - Malfunction Indicator Lamp is Off for this DTC

Module: Electronic-Controlled Power Steering

Diagnostic Trouble Code details

CAN Communication Bus Fault (missing messages)

Possible causes are:

Missing Message for Engine Speed

Engine RPM Data Invalid

Vehicle Speed Data Invalid

Check CAN Wiring/CAN Network is functioning.

Note:

DTCs that start with 'U' are faults which occur during module-to-module communication.

Modules should never be replaced based only on a 'U' code. These codes do not always indicate a problem, and can be caused by normal diagnostic functions, carried out on the vehicle.

===END EPS DTC U1900-20===

===IC DTC U1900-20===
Code: U1900 - CAN communication bus fault

Status: 
 - Previously Set DTC - Not Present at Time of Request
 - Malfunction Indicator Lamp is Off for this DTC

Module: Instrument Cluster

Diagnostic Trouble Code details

CAN Communication Bus Fault - Receive Error

Note:

DTCs that start with 'U' are faults which occur during module-to-module communication.

Modules should never be replaced based only on a 'U' code. These codes do not always indicate a problem, and can be caused by normal diagnostic functions, carried out on the vehicle.

===END IC DTC U1900-20===

===IC DTC U2510-20===
Code: U2510 - CAN communication bus fault

Status: 
 - Previously Set DTC - Not Present at Time of Request
 - Malfunction Indicator Lamp is Off for this DTC

Module: Instrument Cluster

Diagnostic Trouble Code details

CAN communication bus fault

Possible causes :

The PCM must be configured for this vehicle before the system can be initialized

Modules should never be replaced based only on a 'U' code. These codes do not always indicate a problem, and can be caused by normal diagnostic functions, carried out on the vehicle.

===END IC DTC U2510-20===

===RCM DTC U0155-20===
Code: U0155 - Lost Communication With The Instrument Panel Cluster Control Module

Status: 
 - Previously Set DTC - Not Present at Time of Request
 - Malfunction Indicator Lamp is Off for this DTC

Module: Restraint Control Module

===END RCM DTC U0155-20===

===ACM DTC None===
Successful DTC reading, no error codes found

Module: Audio Control Module

===END ACM DTC None===

===GEM DTC None===
Successful DTC reading, no error codes found

Module: Generic Electronic Module

===END GEM DTC None===

Hi Ewan, now that you have that full list you need to use FORScan to clear them all, and then wait and see what comes back when you try and restart the car.

The number one suspect in this is a faulty Instrument Cluster. Give the top of the dashboard a thump with your hand just above the instrument cluster and see if things change.

The EML is being set because of a communication error on the Canbus but this more a case of the result of a fault rather than the cause. As said above I think you have the broken/poor quality solder joint problem on the instrument cluster.

Whilst it is likely to be the soldering on the instrument cluster it might not be.  This thread shows the similar problem on my brothers car.  Hopefully yours won’t need such drastic action as that car (rewiring the canbus) but the thread does give detail of where the various connectors are . 

 

Cool thanks both, i'll clear them tomorrow and try again. 

Is the dashboard a difficult fix? (I'm assuming thumping it isn't a long term fix!)

10 minutes ago, ewanjp said:

I'm assuming thumping it isn't a long term fix!

Thumping it isn't a fix at all, it's just a way of confirming the instrument cluster is the source of the problem. I agree with unofix, the number of canbus errors in your report means it's 99% certain that cracked solder joints on the main connector in the cluster are the cause. These errors will result in all manner of spurious codes being thrown up.

Whether you can fix it yourself depends greatly on how competent you are with a soldering iron. There are several companies that have been mentioned on here that will do the repair and test the cluster.

1 hour ago, ewanjp said:

(I'm assuming thumping it isn't a long term fix!)

It is to some on this forum 🤣

but no, it's not a fix. Unless you are extremely good, and have a very fine soldering iron, I would recommend sending it away for repair. Generally costs around £90 and has some form of warranty. Just use Google and search 'instrument cluster repairs'

There are YouTube videos showing how to dismantle the cluster and solder it.  It is fiddly, eg you have to prise the needles off the gauges and get them back in the right positions. The soldering is definitely not for a first timer. The terminals (I think 18) are very close together and it’s very easy to accidentally bridge them with the molten solder.  If there is an electronics repair place near you eg old skool tv repair man if any still exist you could perhaps dismantle yourself and just take the circuit board to him . It’s a 5 min job for anyone who has got the circuit board and solder kit on their bench in front of them. 

This is one video which gives you some idea of how fiddly it is for you to judge it against your skill level. If you ***** it up it’s a major problem as the cluster holds programming for you immobiliser chips in the keys. 

 

When I did one I put masking tape on the mark the exact position of the gauge needles so I could get them exact when putting back on

Agree totally with above, my son’s 2008 ST developed the cluster issue. 10 mins to remove the cluster, 10 mins to replace, £96 to the experts who gave a lifetime warranty.

p.s. He had to slap the dash many times to drive the car from Cornwall back to Essex.

Right cleared all the codes and then took it for a drive. Predictably now it's fine and did not get the engine malfunction thing - I guess that's possible with the cracked solder suggestion, esp if it's temp related. I'll try it again when its cold again.

I do have a good soldering iron and a little experience, but for 90 quid i'll get the warranty i think! I see if it comes up again first tho.

Cheeers for the advice!

Sod’s law says it will do it at the most inconvenient moment.  There’s nothing worse than an intermittent fault that you don’t know the pattern of when it will happen. 

Yep no doubt. It's the wife's car as well which will make it even more dramatic when it happens! I'll take the laptop out with me a few times and see if I can trigger it.