Hi folks,

I have a MK2.5 Focus, 1.6 TDCi from 2010. It's the pre-DPF model. It has developed recently an annoying fault, whereby when I am driving along regardless of speed or engine load. The centre screen pops up with 'Engine Malfunction!' when it does this the car makes the alarm noise like you would get if you left the door open, with the lights on. The engine then cuts outs from this point, and will not restart unless the key is turned off and on again. It will either restart from 2nd gear by bumping it while rolling, or from the key but the starter will take several revolutions to fire it up. Other times it starts perfectly fine without fault. This is an intermittent fault, and with Forscan I cannot find any stored DTC's bar an issue with the EGR valve sticking, which has been rectified and was an issue years before this problem occurred.

The only things I notice as of recent, is the power steering is a bit heavier than usual. And when the engine is stopped, there is a loud buzzing sound coming from the top left of the engine (it didn't do this before). Please see this YouTube link where I have captured the noise on video. Any ideas/help would be greatly appreciated!.

 

 

 

It should have a DPF in 2010.  The later coated DPF was fitted to both 90ps & 110ps models from 2009 onwards.

These have adjustable power steering weight.  Worth checking whether it's defaulted to 'normal' if it was set to 'comfort' before.  Can be accessed through the dash menu.  Also worth checking tyre pressures, as the steering felt heavy on mine when I had a slow puncture and didn't realise for several days.

Not sure what to suggest with the noise though.  It could be vacuum being sucked in through a tiny pinhole leak somewhere until the pressure equalises.  Or it might be a solenoid that's remaining energised.  Very odd that there are no fault codes.

There is a chance that this is the common dash cluster fault, but I'm not convinced without some more evidence...

No DTCs???

Must be a mechanical issue then, but it sounds like the common solder issue on the cluster, but you would be getting loads of "U" DTCs and "THEFT DETECTED"

45 minutes ago, DaveT70 said:

No DTCs???

Must be a mechanical issue then, but it sounds like the common solder issue on the cluster, but you would be getting loads of "U" DTCs and "THEFT DETECTED"

I did wonder if the cluster was at fault, especially since it has never been replaced since the car was built. Checking through ForScan the PATS value is '10' I am not sure if that 10 means there has been 10 initiations of PATS, or it's a service code. I do wonder if the cluster is losing connection with the ECU, and causing the immobiliser to kick in, since the car seems to lose fueling when this issue occurs, as I say no DTC's or limp mode, the engine just dies until you coast to a stop, or flick the key and bump it in second gear.

49 minutes ago, TomsFocus said:

It should have a DPF in 2010.  The later coated DPF was fitted to both 90ps & 110ps models from 2009 onwards.

These have adjustable power steering weight.  Worth checking whether it's defaulted to 'normal' if it was set to 'comfort' before.  Can be accessed through the dash menu.  Also worth checking tyre pressures, as the steering felt heavy on mine when I had a slow puncture and didn't realise for several days.

Not sure what to suggest with the noise though.  It could be vacuum being sucked in through a tiny pinhole leak somewhere until the pressure equalises.  Or it might be a solenoid that's remaining energised.  Very odd that there are no fault codes.

There is a chance that this is the common dash cluster fault, but I'm not convinced without some more evidence...

 

Thanks for your reply. Tyre pressures are good, I do think the steering issue is the missus exaggerating it feels fine to me. I made sure it was in 'comfort' as it has always been since we've owned it. The car definitely doesn't have a DPF fitted, I am fairly certain there's a few 10 plates floating around without DPF's, this car came from Ford main dealer as the first owner had it since new on finance, who is actually a family member. He confirms he's never had the DPF removed.

12 minutes ago, MikeyTDCI said:

The car definitely doesn't have a DPF fitted, I am fairly certain there's a few 10 plates floating around without DPF's, this car came from Ford main dealer as the first owner had it since new on finance, who is actually a family member. He confirms he's never had the DPF removed.

Is it a late registered 90ps version?  The 110ps version had a DPF from 2004!

Just now, TomsFocus said:

Is it a late registered 90ps version?  The 110ps version had a DPF from 2004!

Yeah it's a 90ps variant, but registered in December 2010.

2 minutes ago, MikeyTDCI said:

Yeah it's a 90ps variant, but registered in December 2010.

Ah ok, it was most likely built many months before it was registered in that case.

26 minutes ago, MikeyTDCI said:

I did wonder if the cluster was at fault, especially since it has never been replaced since the car was built. Checking through ForScan the PATS value is '10' I am not sure if that 10 means there has been 10 initiations of PATS, or it's a service code. I do wonder if the cluster is losing connection with the ECU, and causing the immobiliser to kick in, since the car seems to lose fueling when this issue occurs, as I say no DTC's or limp mode, the engine just dies until you coast to a stop, or flick the key and bump it in second gear.

Battery going down can cause multiple issues too, especially the steering one.

I still suspect cluster though, I'd be tempted to fetch it out and get it re-soldered, it's not that expensive

20 minutes ago, DaveT70 said:

Battery going down can cause multiple issues too, especially the steering one.

I still suspect cluster though, I'd be tempted to fetch it out and get it re-soldered, it's not that expensive

I've verified the alternator output with my multi meter, the onboard voltage output, and with Forscan. All are relatively within range of each other, measuring over 14v when running at high load. I also fitted a new battery a few months ago, which I've tested separately and is performing nominally. I am with other people suspecting a cluster fault, I might pull it out and fix it myself to see if that rectifies the issue.

39 minutes ago, TomsFocus said:

Ah ok, it was most likely built many months before it was registered in that case.

Makes sense, I think it was one of the few remaining in the show room at the time before the later registrations came in. It was bought new from a main dealer here in Suffolk, and stayed in the family since. This is why I am eager to keep it on the road, I just can't let go of it lol.

3 hours ago, MikeyTDCI said:

The centre screen pops up with 'Engine Malfunction!' when it does this the car makes the alarm noise like you would get if you left the door open, with the lights on

That''s the exact same symptom as we had with ours. It didn't seem to go into limp mode, though, although I was on local roads at the time so maybe didn't get to the speed where it would have limited. It didn't stop the engine or have any of the other symptoms you've described either but when the canbus signals are scrambled it does cause all manner of random odd effects. Cycling the ignition cleared the message and it behaved normally until the next time. Forscan found loads of spurious codes on ours, though, including canbus communication errors, so it's very odd that you haven't found any.

Anyway, if your cluster has never been resoldered it's definitely worth doing and it will, at least, eliminate one possible culprit. I did ours and it's been absolutely fine since.

16 hours ago, MikeyTDCI said:

I am with other people suspecting a cluster fault, I might pull it out and fix it myself to see if that rectifies the issue.

It's quite tricky to do yourself, you have to ensure the needles are back on correctly plus, if you do do it yourself, make sure you replace the solder with new, don't just reflow

So I have held off on the clocks. I managed to get a reading off of Forscan now. I've cleared all codes, took it for a spirited drive, and the engine malfunction light came on several times. Upon return home, and checking Forscan. I have one DTC code, which is consistent with the issues I am experiencing.

PCM DTC P0087-20 - Fuel Rail/System Pressure - Too low

I have ordered a new fuel filter, as the one on the car is the original. Any ideas for other causes?, I know the fuel rail pressure sensor can be a weak point, but I am not getting any DTC's for the sensor at all.

1 hour ago, MikeyTDCI said:

I know the fuel rail pressure sensor can be a weak point, but I am not getting any DTC's for the sensor at all.

 

1 hour ago, MikeyTDCI said:

PCM DTC P0087-20 - Fuel Rail/System Pressure - Too low

🤔

It may be an idea to say which interface lead you’re using for Forscan. Many incompatible ones about which cannot read both Can Busses.

I have replaced the fuel filter today, with a new one from Ford. No luck, same issue. Still getting PCM DTC P0087-20 - Fuel Rail/System Pressure - Too low in Forscan. Would it be worth replacing the fuel rail pressure sensor?.

You could change the sensor, but it's awkward to access on these.

I'm leaning more towards the regulator for this one though.  Even more awkward to access unfortunately.

You could take some live data on Forscan, graphing the desired pressure against measured pressure.  That will at least show whether the pressure is consistently low, or whether it's just 'glitching' randomly, or whether it's only unable to maintain pressure during high demand/engine load.

3 minutes ago, TomsFocus said:

You could change the sensor, but it's awkward to access on these.

I'm leaning more towards the regulator for this one though.  Even more awkward to access unfortunately.

You could take some live data on Forscan, graphing the desired pressure against measured pressure.  That will at least show whether the pressure is consistently low, or whether it's just 'glitching' randomly, or whether it's only unable to maintain pressure during high demand/engine load.

 

The only thing I forgot to do was clear the codes before test driving. Would I have needed to reclear the codes after fitting a new filter?, I am assuming it wouldn't make a difference.

Just now, MikeyTDCI said:

The only thing I forgot, was I didn't clear the codes before test driving. Would I have needed to reclear the codes after fitting a new filter?, I am assuming it wouldn't make a difference.

If the code hasn't been cleared since it was flagged, then yes it will remain until you manually clear it.

1 minute ago, TomsFocus said:

If the code hasn't been cleared since it was flagged, then yes it will remain until you manually clear it.

Where is the fuel pressure regulator?, I presume that's some sort of actuator. Might explain what the ominous noise is, which can be heard when ignition is in run position, or engine is turned off. It definitely didn't make this noise before all these issues started happening?.

8 minutes ago, MikeyTDCI said:

Where is the fuel pressure regulator?, I presume that's some sort of actuator. Might explain what the ominous noise is, which can be heard when ignition is in run position, or engine is turned off. It definitely didn't make this noise before all these issues started happening?.

The regulator is attached to the HP pump on these.  Yes, I'd forgotten about the noise, there is a solenoid in the FPR so that could cause an electrical whine.

19 minutes ago, TomsFocus said:

The regulator is attached to the HP pump on these.  Yes, I'd forgotten about the noise, there is a solenoid in the FPR so that could cause an electrical whine.

I'm going to try replacing the sensor, as it's the easiest thing to do at the moment. I don't want to fire up the parts cannon, but it's a cheap and easy thing to try.

May I just reiterate Forscan does require certain ebd327 interface lead otherwise it will miss dtcs in various modules. 
obdlink ex and vlinker are amongst those recommended by Forscan for use on Ford

 

I have added a screenshot of the live capture. When the ignition goes on, you can see the fuel pump rise. And then the RPM rise, when I crank. But the whole time there is no reported fuel pressure.

8 minutes ago, RL123 said:

May I just reiterate Forscan does require certain ebd327 interface lead otherwise it will miss dtcs in various modules. 
obdlink ex and vlinker are amongst those recommended by Forscan for use on Ford

 

Also, thanks for reiterating. It's the correct interface, I got it yonks ago on recommendation from the Forscan website. It wasn't working properly before, due to group policy on my laptop.