Hi Guys 

Looking for some advice, 

My Focus Zetec Sport Diesel 2.0 TDCI  has had an issue for a few months where the engine malfunction service now light appears on the dash. This causes it to go into limp mode, it loses power, really struggles with acceleration and won't go above 3000rpm. If you turn it off for a minute and restart it the issue clears and it starts and drives fine. It is happening maybe once or twice a week.

FORSCAN is telling me it is code P2263 (signal above allowable range) which is something to do with the turbo. (I could only find this error code with the EML on the dash, no code was found when scanned whilst the car was running normally)

I have had it into Ford to run a diagnostic check, they have said they cant find anything wrong from visual inspection and no code found on their diagnostic kit, I have explained to them I have already found the code but seems they were not interested in looking further into the issue.  

They have checked the air filter, checked the boost pipes, checked the turbo actuator and reprogrammed the PCM. The issue is still there.

I'm surprised they did not suggest to change a part, something like the MAF sensor or boost pressure sensor. I have seen various posts where Ford cant find the issue and suggest replacing a part for the issue to continue and trying to replace a different part.

My friend is a mechanic and has suggested to change the MAF sensor and Boost pressure sensor and see if that solves the issue. He is happy to do this without charge but the parts direct from Ford are about £110 each.

I have already spent quite a few quid on this car, I'm reluctant to spend £200 plus on parts for it to still not work. Is their any way to pinpoint where this issue is coming from by using FORSCAN Live data, presumably checking for issues when the car goes into lip mode and the EML on the dash. If there is would you be kind enough to let me know what things I should be checking.

Are there any other things worth checking, I just hope it is not the turbo that is the problem.

Thanks

 

 

 

 

Where the fuse box is looking from the passenger side UK look straight ahead for this and is it making a strange sound like quack if so get a replacement that's what was wrong when I was getting that code. It's the boost solenoid. 

I had a not terribly dissimilar issue which turned out to be a problem with the wiring harness. You can monitor the live-data on forscan, and I agree this would be of use for your situation.

I would be live-monitoring the boost pressure reading (part of the MAP sensor, they are about £20 for replacements and a simple job to change yourself), and the MAP sensor voltage. Monitor these at idle and then go and replicate your fault conditions and see what happens.

 

 

Thanks for reply’s so far, something else interesting has happened this morning on my way to work. The engine malfunction service now light come on again and went into limp mode, reduced power etc.

turned off the car for a minute then turned it back on, started fine and then went back to normal. whilst driving I was flicking through my trip computer and reset my MPG as it was going up and down like a yo-yo. The MPG trip going up and down has been like this for some time now but it didn’t cause any issues.

After resetting the MPG it displayed 41.6MPG and did not budge from that number. Within 5 minutes the engine malfunction light come back on and back into limp mode. Stopped turned it off and drove normally again, 2 minutes later same again EMSN light on, limp mode but this time the actual engine warning light also appeared. Got to the train station turned off the car for a few minutes, turned it back on and the Engine light stayed on. I won’t know what this code is until I get home. 
is this possibly a faulty O2 sensor?

If it is the O2 sensor does this control fuel and air to the turbo, Could this be the reason why the P2263 Turbo issue has been coming on and off ?

4 hours ago, Orsm99 said:

I was flicking through my trip computer and reset my MPG as it was going up and down like a yo-yo. The MPG trip going up and down has been like this for some time now but it didn’t cause any issues.

After resetting the MPG it displayed 41.6MPG and did not budge from that number.

You probably just changed the setting from instantaneous MPG to average MPG.

11 hours ago, Orsm99 said:

Thanks for reply’s so far, something else interesting has happened this morning on my way to work. The engine malfunction service now light come on again and went into limp mode, reduced power etc.

turned off the car for a minute then turned it back on, started fine and then went back to normal. whilst driving I was flicking through my trip computer and reset my MPG as it was going up and down like a yo-yo. The MPG trip going up and down has been like this for some time now but it didn’t cause any issues.

After resetting the MPG it displayed 41.6MPG and did not budge from that number. Within 5 minutes the engine malfunction light come back on and back into limp mode. Stopped turned it off and drove normally again, 2 minutes later same again EMSN light on, limp mode but this time the actual engine warning light also appeared. Got to the train station turned off the car for a few minutes, turned it back on and the Engine light stayed on. I won’t know what this code is until I get home. 
is this possibly a faulty O2 sensor?

If it is the O2 sensor does this control fuel and air to the turbo, Could this be the reason why the P2263 Turbo issue has been coming on and off ?

I think these MPG readings are a bit pointless if you are having engine malfunction symptoms and limp mode etc.

The sensors all feed into the ECU, and then the ECU will calculate expected readings from other sensors based on the information it recieves and also give out instructions i.e to throttle based on the sensor readings it gets.

If you have a fault (sensor, wiring, etc) then of course that input reading to the ECU will often result in deranged other readings (either deranged 'expected' inputs from other sensors, or deranged outputs to actuator).

This is the reason why people have suggested that you get FORScan, because then you can start to see what is actually happening. How did you get on with this?

Hi 

Thanks for the reply.

I got FORSCAN several week ago, The code that comes up when the engine malfunction service now light appears with limp mode is P2263 which says its something to to with the turbo. Ford had it and could not find the fault code, I could only find that code when the Engine malfunction service now was on the dash. The checked a few things but I got the feeling they could not be bothered as there was no code even though I told them what code it was.

As I said the other day, the actual engine light come on with the engine malfunction service now, first time they have both come on but it was weird that the engine light come on after I reset the MPG - That was going bonkers, right upto 99.99mpg and all the way back down.

The code showing for engine light was 

P00BD - Mass or Air flow - Air flow too high

P0299 - Turbocharger underboost.

I reset the code when I got home a few days ago, the engine light went and has not come back, however the engine malfunction service now light come on yesterday 2 times with limp mode.

I am gonna test the live data for the MAF and see what that comes up as, it was showing between 8-9 at idle.

It is going into the garage tomorrow to check for boost leaks, my mate thinks it is either the boost pressure sensor or MAF sensor, now it shows these new codes for the MAF we are going to change the MAF sensor.

 

Sounds like a boost leak, you say that it is going into the garage tomorrow for testing, do you know what they are planning to do i.e smoke test etc?

 

Do you hear any hissing sounds or similar when the symptoms happen?

4 hours ago, ssmith93 said:

Sounds like a boost leak, you say that it is going into the garage tomorrow for testing, do you know what they are planning to do i.e smoke test etc?

 

Do you hear any hissing sounds or similar when the symptoms happen?

I am getting him to test for boost leak, clean the MAF Sensor, Clean the MAP sensor, Clean the Boost Pressure Sensor. Spray turbo cleaner in the turbo. The car is 10 years old and has done 83k miles, to my knowledge none of the sensors have ever been cleaned. I did a live data test and recorded the results, video is far to big to post but from what ive seen on google the MAF sensor should read "MAF's PID value should read anywhere from 2 to 7 grams/second (g/s) at idle and rise to between 15 to 25 g/s at 2500 rpm, depending on engine size"

MAF readings at idle its roughly 8.5 g/s, idle after 30 minutes 13.5 g/s

During the 30 minutes drive the MAF g/s goes as high as 160 g/s

 

 

How did it get on?

On 6/26/2024 at 8:46 PM, ssmith93 said:

How did it get on?

So it is has been in the garage whilst I am on holiday. Smoke test showed a split on the seem of the inlet manifold. My mechanic said it was opening when revved, he was ordering a new one. He has said there might be another issue that has caused this or its simply a manufacturing issue. He has said this would likely be the cause of the boost and MAF errors leading to the engine malfunction service now then limp mode. Today they said they have found another issue which might be the root cause, but its hard to say for sure. They are going to send the fuel injectors off for testing as two of them are giving a fault. 

Thats where we are at the minute.

Good that the smoke test found the problem. It sounds likely that the manifold is the cause of both of your issues. Would be odd to have two things break at once.

 

Keep us updated!

Right, an update, 

I am slowly losing the will to live with this car. There is not much I can do as I am currently on holiday and can't drive it until I get back home.

So The fuel injectors were all checked and cleaned by a specialist and they confirm they are all working perfectly.

The inlet manifold which had the split seam has been replaced and there seems to be no leaks. My mechanic took it for a drive after and said he was not 100% happy with how it was running, another mechanic also agreed it did not feel right. One of them took it to a friend who is a master ford tech and he said the MAF and MAP were not reading correctly and suggested to change them. Since being changed the mechanic said is drives so much better but as soon as you start it it throws an error on the dash and the code relates to a problem with the ECU. Apparently as soon as you start it it throws a code for the ECU, you can clear it and drives fine. Stop turn it off and turn it on again the warning light on the dash appears again with a code for the ECU. 

I am unsure what the code number is but I did ask if he reprogrammed the ECU because of the new MAF and MAP sensor and he said he did. The next thing to check would be the wiring harness or the actual ECU itself. But warned due to the age of the car things could start to get very expensive.

This seems to be a new issue since the MAF and MAP were replaced, I really cant be spending much more on this as its costing a fortune. Is there a simple thing that might of been missed, for example the ECU needs time to settle and be driven x amount of miles due to new MAF and MAP sensor.

 

Do you have ForScan, it would be far easier for us to help if you were able to read us the exact codes and provide the actual details of what the ECU is unhappy with.

Forscan is free, you just need the cable to use it which really isn't expensive at £25. It is a dealer-level diagnostic program which will allow you to tell us the exact faults you are getting, and you can run tests on the ECU specifically. You can also monitor the live data coming from these sensors which are giving you faults which may provide useful information if you are suspecting a wiring issue.

I don't know if you have read through my saga, it is a long read, however I was chasing strange faults around for a little while before I eventually recognised (with assistance of ForScan) that it was an electrical issue rather than an issue with the individual sensors themselves. Once I had narrowed it down to the ECU or the wiring harness, I tried replacing the ECU first as it is a simpler job, just unplug the old one plug in a replacement and code it to the car (Again - using ForScan!!!).

As mine turned out not to be the ECU, I actually have the spare ECU I bought to try out for sale so if you want one to try let me know (https://www.facebook.com/marketplace/item/862213919274295/). I can also explain how I coded it using ForScan.

So in my case as it wasn't the ECU, it turned out to be the wiring harness. I bought a replacement harness for £90 and replaced it myself, but of course you could get the garage to do it.

 

9 hours ago, Orsm99 said:

 Is there a simple thing that might of been missed, for example the ECU needs time to settle and be driven x amount of miles due to new MAF and MAP sensor.

 

You can reset the learned values for the MAF and MAP sensors using forscan, but I believe disconnecting the battery or driving for half hour might do it too.

15 minutes ago, ssmith93 said:

Do you have ForScan

Read the thread above 🙄

On 6/23/2024 at 9:52 AM, Orsm99 said:

I got FORSCAN several week ago, The code that comes up when the engine malfunction service now light appears with limp mode is P2263 which says its something to to with the turbo.

 

Apologies, I forgot where things were with this...

3 hours ago, ssmith93 said:

Do you have ForScan, it would be far easier for us to help if you were able to read us the exact codes and provide the actual details of what the ECU is unhappy with.

Forscan is free, you just need the cable to use it which really isn't expensive at £25. It is a dealer-level diagnostic program which will allow you to tell us the exact faults you are getting, and you can run tests on the ECU specifically. You can also monitor the live data coming from these sensors which are giving you faults which may provide useful information if you are suspecting a wiring issue.

I don't know if you have read through my saga, it is a long read, however I was chasing strange faults around for a little while before I eventually recognised (with assistance of ForScan) that it was an electrical issue rather than an issue with the individual sensors themselves. Once I had narrowed it down to the ECU or the wiring harness, I tried replacing the ECU first as it is a simpler job, just unplug the old one plug in a replacement and code it to the car (Again - using ForScan!!!).

As mine turned out not to be the ECU, I actually have the spare ECU I bought to try out for sale so if you want one to try let me know (https://www.facebook.com/marketplace/item/862213919274295/). I can also explain how I coded it using ForScan.

So in my case as it wasn't the ECU, it turned out to be the wiring harness. I bought a replacement harness for £90 and replaced it myself, but of course you could get the garage to do it.

 

You can reset the learned values for the MAF and MAP sensors using forscan, but I believe disconnecting the battery or driving for half hour might do it too.

Hi mate, 

Yeah I have forscan. Once I get back from holiday I will pick the car up and take it out for a drive, all the issues I have had seem to relate to issues with the turbo. As said above there was a split on the inlet manifold seam which possibly caused all these issues in the first place. There were also error codes showing issues with the MAF sensor, and an error for the boost. The car to me drove fine, it only goes wrong when the Engine malfunction light appears and goes into limp.

So it was strange to hear from the mechanic that it did not feel right once the in inlet manifold was changed. They are saying there is now a code being shown for the ECU but this has only happened since they did the work on the manifold and new sensors.

I might have to disconnect the battery myself for an hour and let it idle for 10 minutes just to satisfy myself. I would of hoped the mechanic would of done this. He did say he reprogrammed the ECU himself due to adding a new MAF and MAP sensor. 

If it still happens I might have to look at what the ECU is saying via forscan. 

Thanks for the info on your ECU, I will keep that in mind i I am still struggling.

These are the codes off the mechanic's scan tool. So far the car seems to drive completely fine according to the mechanic, as said above, all the issues seemed to go wrong above 70mph. engine malfunction, limp mode. That seems to now be fixed.

Replacing the inlet manifold (boost leak) replacing the MAF and MAP sensor and cleaning all the injectors seems to have cured the Turbo issue which was causing the limp mode.

Now a new code has appeared AFTER all the above work has been done, could it be a simple "re-programming error" Mechanic said he did reprogramme the ECU after new MAF and MAP.

P0606-00 ECU processor fault

P060-48- Internal control module main processor performance-Supervision software failure.

Im not back until Sunday so cant check with Forscan, Mechanic said he has cleared the codes but once you turn the car off and start it again they appear once more.

 

 

Interesting - and annoying.  It sounds like your ECU is playing up doesn't it from those codes.

Let us know how you get on Sunday.

Another update.

Picked the car up and it runs like an absolute piece of crap. It is actually worse now than earlier. What ever the garage have done it just seems to have made it worse, or as Sam suggested above it could possibly be the ECU or the wiring harness. When I took it out yesterday the Engine malfunction light come on, it was back in limp mode and had no power. The car just struggled to go and would hang around high revs before changing, I could hardly get it above 50mph. This is all new and different to the other issues above. This never happened before they did the work. Then it started to shake and shudder, bit like it was going to stall or stop. This then showed the engine light, both engine light and the management info light were both displayed.
As said above the limp mode and engine management light coming on happened around 70mph, before that the car was fine to drive. All the new stuff has happened after the work has been carried out.

So just to recapture the work that has been done on it. This work was to establish what was causing the original P2263 Code which was something to do with the turbo.

1 - New inlet manifold - Smoke test showed a leak on a seam.   
2 - Fuel injectors removed and taken to a specialist. Mechanic said fuel injector 1 and 4 were showing errors on his scan tool. (nothing ever showed on FORScan when I did my tests before car went into be fixed. They have been cleaned and apparently are all shown working on the test they performed.

New MAF sensor
New MAP sensor

They took the car to a supposed "master ford tech" who had a look, he said the MAF and MAP were not reading correctly, he suggested they be replaced.
Mechanic said both MAF and MAP sensors were programmed to ECU

Mechanic said after all this work done there was an engine management light being shown but can was driving fine.
Now I have picked it up it is clearly not working in the same way as before, when I dropped it off there were no issues apart from the P2263 code and another few to do with boost and MAF.
Now the car has shown so many DTC errors I don't know what to do. Garage said it's possibly the ECU/PCM or wiring harness but think they are saying this because that is what I told them as Ford wanted to take apart the wiring harness.
All the new errors point towards the same fuel injectors that were removed and cleaned, 1&4 on mechanic scan tool, same on mine, also the ECU error codes were not there before, There is still a P2263 turbo error code being shown. Is it possible the ECU/PCM needs properly reprogramming ? (New MAP and MAF Sensors and the fuel injectors being taken out and cleaned)?

I cant even give it a hard drive to reach 70mph to see if the P2263 code was sorted by replacing the inlet manifold and now MAF and MAP.

I have added the pics from Forscan which show the new ECU/PCM codes, new Fuel injector codes and also injector driver codes, also Turbo code.

I have disconnected the negative battery terminal and left it off for an hour, started it and did not touch the throttle pedal, left it for 15 minutes then took it out, still runs like crap.

I have taken a live data capture using forscan, selecting MAF, MAP, ECU and injector codes.
Its to big to upload, I am happy to share via email if someone wants to look. 

Any ideas chaps, I've had enough 😞

One other thing to note, I purchased a bottle of Wynns Turbo cleaner and put it in the tank before taking it to the garage thinking it was going to be in and out in a day. I added it and then drove 5 minutes to the garage where it sat for a few days. Is it possible these new codes are related to the bottle I added to the fuel, has it possibly dislodged a load of crap and is running around the fuel system and clogged the injector cylinders up ?  

The fact that you are getting random strange codes, poor performance, along with PCM specific codes reporting the PCM processor is not working all together makes me put my money on the PCM/ECU itself being the cause of your problems here. It is the common element of all of your faults, including giving self-reports of problems.

I don't think it is likely the wiring harness as this shouldn't cause PCM processor errors, just circuit range/performance faults.

A faulty PCM isn't a common issue, but it does happen and I think it is your issue here. The good news is that if this is the case, it's not that hard to fix yourself, and it also won't be expensive (<£150).

Given the PCM is a relatively simple thing to replace as well, I think it would be foolish not to try changing that as your next step. You need to get to it first to get the part number off your car before sourcing a replacement. If you post that on here then I can tell you if mine will fit or if you need a different one.

Then you simply need to change the old PCM for the replacement PCM (a very simple job to remove the two wiring plugs and then plug the new one in. The new PCM will need coding to your car, which you can do with FORScan that you already have now and I will happily talk you through it.

If you need help accessing the PCM or anything like that let us know and can help. The process is a 2 out of 5 star difficulty for a DIYer.

Hi Guys, I have now changed the PCM and it is now coded to the car, unfortunately I'm still getting DTC Code P2263 Turbocharger/supercharger "A" Boost system performance.

Strangely I have not received the other codes for a while.

I'm now thinking there is a possibility something has not been put back on the car correctly, (injectors) or something has been knocked like a hose or pipe when the inlet manifold was replaced. Or even a faulty MAP or MAF sensor which were replaced with new ones.

Just to recap, Inlet manifold replaced (smoke test showed a split seam) All injectors removed sent off for testing and cleaned and put back working, New MAP and MAF sensor.

Car is in limp mode straight away with engine malfunction service now coming on the dash within 10 seconds of driving, code P2263 - Car struggles to accelerate and as no guts. This did not happen before above work was carried out.

I know I can check live data with forscan, If I check the MAP and MAF what other things should I check that could be related to P2263.

Thanks 

 

Hi Guys,

So a new turbo boost solenoid did not work, a second hand PCM seems to have cured most the other faults but I am till having the P2263 error and engine malfunction service now with limp mode.

Could my DPF be causing all these issues?

A few days ago I had an error come up for P246B which states it cant perform a regen. I did the live testing with forscan this morning and it is showing my DPF at 138%, I presume this means my soot level is off the scale and blocked, the KPA fluctuates between 4.00-9.00 after a 5 minute drive. I have tried to do a forced regen with forscan and it only lasts 5 minutes at about 7% and then fails. I'm Pretty sure when doing the forced regen it is showing the P2263 engine Malfunction code when it hits and holds the revs on the first cycle. Also to note, I cant clear the DTC P246B. I also think my EGR vale reading on a live test is not right ?

Do I need the DPF cleaned and a new vaporiser , Is this what  causing the P2263 Turbo issues. Pic below of DFP, and EGR. 5 Minutes into a drive.

Thanks 🙂