Hello. Thanks for looking at this.

We have a 2011 Focus Sport 1.6 TDCI it's not the new model it's the 2009-2011 one. Sometimes when we try to start the engine a red triangle shows up on the dash saying 'Engine Malfunction' and it will not allow us to start the engine. The thing is sometimes it shows up and sometimes it does not. When the error is not coming up you can start the engine and it drives perfectly - but every time you want to start the engine it's like a lottery - you need to try again and again by taking the key out and put it back in again. Most of the times it's fine but sometimes as it happens you may end up spending quite a few minutes until will allow you to start the engine. I've noticed that especially after a long drive you have a better chance to get the error when you stop and try to start the engine again.

Local Ford garage had the car check, it comes up with some vague communication error codes and they can't figure out what's wrong with it. They even had the ECU removed tested and it's fine, they still have the car but they really don't know what's wrong with it.

Any idea what can be wrong? Anyone else had this problem ?

Thank you, this is my first post so please forgive me if I posted in the wrong place.

My guess is that you have the classic MK2/MK2.5 instrument cluster problem. The MK2/MK2.5 instrument cluster is known to have poor quality soldering connections on the circuit board of the instrument cluster. During time the soldering connections become cracked (caused by vibrations) which results in a bad connection on the circuit board or no connection at all. This problem can result in various DTC codes which many times are related to communication problems between the instrument cluster and the PCM. Depending on which connection is bad this problem can cause various very strange symptoms. Because the MK2/MK2.5 instrument cluster is a part of the PATS immobilizer system a bad connection of the circuit board can also immobilize the vehicle.

In early stages of this problem the symptoms occur intermittently. Usually the problem can be confirmed by wiggling the connector. Most times this solves the problem temporarily or makes it worse.

Thank you for your reply Wilco.

Do you know if there are any tests to make sure that's the actual problem ?

I see there are lots of companies that can fix instrument clusters is it worth using one of them or maybe I am better off with a new one ?

Thanks

A new instrument cluster will cost a fortune so repair would be the best option.

If you are handy with a soldering iron you could try to repair the cluster yourself. Until now I repaired over 20 Focus MK2/MK2.5 instrument clusters myself with only a decent soldering iron ans soldering skills. My experience is that most times the problems are caused by bad soldering connections of the large connector to the circuit board. In most cases resoldering these connection solves the problem. It is definitely worth to try.