Hello

I have a fault with my Fusion 2005 TDCI. 

The car fails to crank when the ignition is turned on. Initially, all the dashboard lights came on, and then the immobiliser light flashed rapidly, then slowly. I disconnected the negative battery terminal for 10 minutes to see if this might reset the immobiliser. This didn't work. I then removed the battery to check it was fully charged (12.6V). It was and I replaced it. After replacing it, there are now no lights on the dash (except for the flashing immobiliser light) when the ignition is turned on. 

Any ideas what the problem might be?

Thanks.

Sounds like the standard instrument cluster solder problem.

As a quick check, give the top of the dashboard a good couple of thumps with your hand just above the instrument cluster and see if there is any change to the situation.

10 minutes ago, unofix said:

Sounds like the standard instrument cluster solder problem.

As a quick check, give the top of the dashboard a good couple of thumps with your hand just above the instrument cluster and see if there is any change to the situation.

Thanks for the quick response.

No didn't help sadly, still just the immobiliser light. I should say, when the ignition is on, all lights, fans and wipers are working. I've also checked the fuse box (nothing blown) and relays ( can hear it clicking on when I turn the key). 

It still could be the solder problem, but to try and confirm it you need to use FORScan and see what the DTC's are.

1 minute ago, unofix said:

It still could be the solder problem, but to try and confirm it you need to use FORScan and see what the DTC's are.

Right, okay is there a guide to downloading and using it that you could recommend ?

FORScan:

On 4/7/2024 at 8:59 PM, unofix said:

FORScan (for use with Windows Laptop) : https://forscan.org/download.html

It's what many Ford owners use including some Ford technicians.

• vLinker FS, cable for laptop: https://www.amazon.co.uk/Vgate-vLinker-Adapter-FORScan-MS-CAN/dp/B0952P4MLP

OR

• OBDLINK EX, cable for laptop: https://www.amazon.co.uk/OBDLINK-EX-FORScan-OBD-Adapter/dp/B081VQVD3F/ref=sr_1_5

For diagnostic use only:

• vLinker FD, for android phone: https://www.amazon.co.uk/Vgate-Bluetooth-vLinker-Scanner-Diagnostic/dp/B08H82WC8L
• vLinker FD+, for iPhone: https://www.amazon.co.uk/Vgate-Bluetooth-vLinker-Scanner-Diagnostic/dp/B08H8JHWP2

 

31 minutes ago, unofix said:

FORScan:

 

Right, I'll get this ordered and give it a try next week

Hello, here is the readout from FORScan and the list of DTCs attached as a text file

Ford Fusion DTC scan 1.txt

Looks like you have two problems.

1. The car battery is now flat and needs a good solid 12 hour charge or more.
2. The engine bay wiring harness is damaged or a connector is corroded/broken.

Do you have a decent battery charger ? Get the battery on charge.

Do you have a digital multimeter ?

Thanks for looking over it.

1. No i don't have a charger, I can get one tonight or tomorrow.

2. I do have a digital multimeter 

Maypole charger.

https://www.ebay.co.uk/itm/323961816093

6 minutes ago, Stevob12348 said:

2. I do have a digital multimeter 

Charge the battery first.

Use FORScan to clear all the DTC's

Many of them will not be true and are probably a result of low battery voltage. Have a good look about the wiring harness especially underneath the battery tray, and also the PCM (ECU) plug.

Okay, I'll order the charger you recommend and get back to you when I've charged the battery and gone over hte harness. Thanks for all the help!

Hello,

Battery has been fully charged and DTCs cleared. I am now getting the following DTCs. I will start to look over the wiring harness.

Ford Fusion DTC scan 2.txt

That is quiet a worrying set of DTC's.

I'd start at the PCM and open up the plug. Check for corroded, broken wires.

Ah, could that mean the PCM has been damaged? I'll have a look tomorrow and see what I can find.

Hello 

A quick update on this. In short, it turns out it was the dashboard instrument cluster that was/is to blame and is currently unrepairable. A fuse had blown for the dashboard and that is why I wasn't seeing any ignition lights after reconnecting the battery. Had an auto-electrician out to confirm that it was the instrument cluster, all the DTCs relating to the PCM disappeared once the fuse was replaced. 

I sent the instrument cluster off to ECU testing in nottingham for repair. It was a software error rather than wiring problem and it could not be repaired. They suggested that they could do a code swap with another cluster. I bought one second hand (same part number etc), unfortunely, the software error was cloned across and they were unable to sucessfully carry out a code swap. I've asked for the original cluster to be returned. According to ECU testing, the only way will be to get another unit and completely reprogramme it (VIN relearn?).