i have an 08 1.6tdci and an 09 1.4tdci fusions  both have been having intermittent door ajar warnings and central locking failing to lock and double clicking.

the door sensor is inside the door lock assembly and cannot easily be removed and replaced as you may have an explosion of springs and small parts.

i read about someone bypassing the sensor by joining 2 wires, i think that was a focus,  to get at the lock you need to remove the outer door card, 1, remove the mirror control inner panel using a wide trim tool from the front, i did it from the back and broke a retainer pillar (which i hot glued back on) the wire connector needs a thin screwdriver to release the locking tab. 2, remove the window switch panel around the inner door handle and release the connector. 3, 2 screws in door handle.    4, 1 screw inner door unlock / open lever and unclip the flexy cable,  5, use trim remover to pop the push studs on doorcard and lift up off the window ledge.

there is an inner panel with a load of 10mm bolts and you cannot remove that fully without taking the window out, i removed most of the 10mm bolts leaving the hinge side fitted then wedged the panel out at the lock end, initially i drilled a large hole in the recessed triangular bit of the plastic inner panel, this wasnt enough access to remove the lock assy connector so i cut through from the hole to the bolt positions see inner panel pic with blue lines.

theres a red slider locking tab but i still had to use a small screwdriver to remove connector.  YOU WILL NOT NEED TO REMOVE CONNECTOR.

with ignition on i tested all pins and found 2 that put the door ajar light out but the central locking wouldnt work, i have a manual and checked the diagram, the sensor is a single wire to negative, all the wires are black but the one you need is no8, or 4th one on left bank from bottom / furthest from you, use 1ft of wire scotchlocked to that wire and a ring connector to one of the 10mm bolts, see the pic of the wire connector with blue marks.

i only did the drivers side so the nearside front still occasionally plays up but just takes an extra close, with the ignition on you will see if it,s the drivers or passenger playing up, you can also set the central locking to only open drivers door, on the dash computor along with other settings you may not know about.

my 09 has folding mirrors so when they fold, i know it,s locked properly.

the only downside which doesnt bother me is the interior light doesnt come on when door open.

this is yet another manufacturer rip off, anything that is unreliable or a design flaw, they charge 3 times it,s worth to replace, £250-300 for a lock assy and a 2nd hand unit could already have the problem. 

pictures are not in order. i have also posted glow plug and egr repairs which are more common probs on the fusion / fiesta tdci,s

 

If you do this, and only open the driver's door, does it auto lock after a while ?

hi, i,ve just done 3 test,s. each 5 mins duration and there was no auto locking, 

1, door unlocked key out of ignition.

2 door unlocked ignition on engine off.

3 door unlocked engine running.

if i,m  watching or working on engine with key in ignition i always open a window just in case.

Just now, stevads61 said:

hi, i,ve just done 3 test,s. each 5 mins duration and there was no auto locking, 

1, door unlocked key out of ignition.

2 door unlocked ignition on engine off.

3 door unlocked engine running.

if i,m  watching or working on engine with key in ignition i always open a window just in case.

this is on an 09 fusion.