1 hour ago, Tdci-Peter said:

The full list of DTCs you gave was informative, in that most were directly connected to CAN bus problems. If the only DTCs now regularly appearing are related to the TCM, then it may be the TCM module is faulty. I guess the two messages on the dash are, or are connected to U2023 (CAN failure PCM to ESP), and P0790 (TCM switch malfunction).

But.. If more CAN related DTCs are appearing inside the system (even if not show on the dash), then none of the individual DTCs can really be believed. Failure of any one module on the HS CAN bus can corrupt messages on the whole bus.
 

DTCs you gave were:

U2023-A0-ABS - Vehicle communication network fault, CAN communication failure between PCM and ESP module.

U1900-IC - CAN communication bus fault - receive error

U1900-EPS - CAN communication bus fault (missing messages)

P700-A1-PCM - transmission control system malfunction

P790-TCM - Normal/performance switch circuit malfunction

U0101-A1-PCM - lost communication with TCM

U0001-PCM - High speed CAN communication bus 

 

The PCM could be faulty, it could still be the IC, or TCM or EHPAS etc. There are self test routines in most of the modules, which can be initiated by Forscan, and I presume by IDS. But I do not have the vehicle specific knowledge to pinpoint a likely suspect. I would repeat the CAN bus resistance tests from time to time, the fault seems to have originally been temperature dependent, and may still be intermittent. Faults have a knack of hiding away as soon as a DMM or 'scope goes anywhere near them, I know to my cost!.

Just a thought, how are the earth connections from battery to body & to engine. I do not know what the car is, if diesel, the glowplugs put a lot of current down the engine earth cable, as does the stater & alternator on all cars. Poor earths can corrupt the high speed data links. Measuring the voltage drops on these links under heavy electrical load (all lights, fan, de-misters, etc), with engine running, is the best test.

If all fails, perhaps a local auto-electrician or specialist may be able to help. I do not think the average garage will do, they may just change expensive modules on a semi-random basis at your cost till it works!

Peter.

 

Hey Peter,

It's a Focus 1.6tdci. Earth connections were checked. Battery was replaced with a new one to do the test. Smart charging gave good voltage on tests.

A think that a thing or two can be worth of mentioning is that:

- during the autumn I noticed that when the doors of the car got locked they automatically unlocked after a min or so. After a few days it was back to normal!

- during winter with temps -10 deg, the cooling fan started from time to time even with the engine was cold and it's temp 60-70 C! This too, got back to normal by itself!

Does this tell something?

8 hours ago, ff2007 said:

Hey Peter,

It's a Focus 1.6tdci. Earth connections were checked. Battery was replaced with a new one to do the test. Smart charging gave good voltage on tests.

A think that a thing or two can be worth of mentioning is that:

- during the autumn I noticed that when the doors of the car got locked they automatically unlocked after a min or so. After a few days it was back to normal!

- during winter with temps -10 deg, the cooling fan started from time to time even with the engine was cold and it's temp 60-70 C! This too, got back to normal by itself!

Does this tell something?

Hmmmm,

This may help, or it may be a red herring, but:

The A/C on/off switch goes to the PJB (Passenger Fuse Box). The A/C solenoid and the cooling fan are controlled directly by the PCM. The PJB does not seem to be on the HS-CAN bus, but it is on the MS-CAN BUS. The PCM is on the HS-CAN bus, but not the MS-CAN bus.

Thus the only link from the PJB to the PCM is via the IC, which definitely has both CAN busses. So the IC tells the PCM when the A/C is on, and that will trigger the cooling fan, regardless of engine temp. So a dodgy IC can turn the cooling fan on.

The Door modules are on the MS-CAN bus, so can possibly be controlled by the IC.

And the problem was temperature dependent at the start?

The common link in all this is the IC. But if you spend a fortune changing the IC and it is not the problem, please do not blame me! I would recommend more tests, maybe by a more knowledgeable person than me first!

Peter.

 

12 hours ago, Tdci-Peter said:

Hmmmm,

This may help, or it may be a red herring, but:

The A/C on/off switch goes to the PJB (Passenger Fuse Box). The A/C solenoid and the cooling fan are controlled directly by the PCM. The PJB does not seem to be on the HS-CAN bus, but it is on the MS-CAN BUS. The PCM is on the HS-CAN bus, but not the MS-CAN bus.

Thus the only link from the PJB to the PCM is via the IC, which definitely has both CAN busses. So the IC tells the PCM when the A/C is on, and that will trigger the cooling fan, regardless of engine temp. So a dodgy IC can turn the cooling fan on.

The Door modules are on the MS-CAN bus, so can possibly be controlled by the IC.

And the problem was temperature dependent at the start?

The common link in all this is the IC. But if you spend a fortune changing the IC and it is not the problem, please do not blame me! I would recommend more tests, maybe by a more knowledgeable person than me first!

Peter.

 

ABS pump replaced, reprogrammed, it's still the same!

This became a very complex issue! Not sure what to check now!

I think suspect no 1 is the IC. But it does not look as simple as the fault I had, if it can affect both CAN buses.

Try this search string in Google:

ford focus instrument cluster test

You should find a self test mode accessed via the trip reset button, & people offering a repair & test service with a warranty.

There is also a self test function that can be started via the diagnostic connector using IDS or Forscan.

About all I can think of at present.

Peter.

Hello Peter,

Looking forward to do more measurements on network at the connectors for modules DLC-IC-PCM.

 

FF2007 Asked:

Do you think these measurements will tell what is the problem?

http://workshop-manuals.com/ford/focus_2004.75_07.2004/mechanical_repairs/4_electrical/418_electrical_distribution/418-00_module_communications_network/description_and_operation/diagnosis_and_testing/communications_network/

see sections: "faulty communication between the modules for ms can, and hs can".

Answer:

The manual details a long, slow & quite difficult series of tests. It requires access to many connectors, on all electronic modules, some not easy to get to. With difficult to locate problems, any procedure may yield a clue or result, but I am not overly optimistic here.

The critical tests in AD8 & AE8 are the CAN bus resistance tests (60 ohms line to line) that have been done already. Always worth doing again, things can change.

The Network tests pre-suppose that communication can NOT be established to the furthest module from the DLC (Diagnostic Connector), That is the GEM (in the PJB or fuse box) for the MS-CAN, and the PCM (Or ECM or ECU) for the HS-CAN. Intermediate modules are disconnected, one by one, until communication can be established, then the last one removed is the faulty one.

In this case, there is no permanent failure of comms.  IDS can talk to the PCM, and presumably the GEM, and read DTCs & status from all the modules. I assume it would flag an error if any module failed to respond.

Most of the rest of the tests consist of buzzing through individual cables to check for continuity of less than 2 ohms. A good idea, but very time consuming. It would be worth testing from the DLC to GEM (AD19 & AD20) as this tests almost the full length of the MS CAN bus, and DLC to PCM (AE15 to AE22, The options are for different variants of PCM). This tests almost full length of the HS CAN bus. In conjunction with the 60ohm tests above, this provides quite good coverage.

In this case, the TCM is also a suspect, worth checking that connector fully, if it can be accessed.

TO make sense of some of the references, you will need the Wiring diagram (Full Schematic), on a topic by Preee, look for

Ford Focus Full Wiring Schematics Mk2/2.5 And Mk3

Good luck.

3 hours ago, Tdci-Peter said:

FF2007 Asked:

Do you think these measurements will tell what is the problem?

http://workshop-manuals.com/ford/focus_2004.75_07.2004/mechanical_repairs/4_electrical/418_electrical_distribution/418-00_module_communications_network/description_and_operation/diagnosis_and_testing/communications_network/

see sections: "faulty communication between the modules for ms can, and hs can".

Answer:

The manual details a long, slow & quite difficult series of tests. It requires access to many connectors, on all electronic modules, some not easy to get to. With difficult to locate problems, any procedure may yield a clue or result, but I am not overly optimistic here.

The critical tests in AD8 & AE8 are the CAN bus resistance tests (60 ohms line to line) that have been done already. Always worth doing again, things can change.

The Network tests pre-suppose that communication can NOT be established to the furthest module from the DLC (Diagnostic Connector), That is the GEM (in the PJB or fuse box) for the MS-CAN, and the PCM (Or ECM or ECU) for the HS-CAN. Intermediate modules are disconnected, one by one, until communication can be established, then the last one removed is the faulty one.

In this case, there is no permanent failure of comms.  IDS can talk to the PCM, and presumably the GEM, and read DTCs & status from all the modules. I assume it would flag an error if any module failed to respond.

Most of the rest of the tests consist of buzzing through individual cables to check for continuity of less than 2 ohms. A good idea, but very time consuming. It would be worth testing from the DLC to GEM (AD19 & AD20) as this tests almost the full length of the MS CAN bus, and DLC to PCM (AE15 to AE22, The options are for different variants of PCM). This tests almost full length of the HS CAN bus. In conjunction with the 60ohm tests above, this provides quite good coverage.

In this case, the TCM is also a suspect, worth checking that connector fully, if it can be accessed.

TO make sense of some of the references, you will need the Wiring diagram (Full Schematic), on a topic by Preee, look for

Ford Focus Full Wiring Schematics Mk2/2.5 And Mk3

Good luck.

Hey Peter,

Does these two DTCs say PCM is faulty?

U0101 - "PCM lost communication with TCM"

U2023 - "CAN communication failure between the PCM and the ESP module. The ESP module has NOT received the correct message from other modules on the CAN communication data bus. There may be other modules on the CAN communication data line that are not communicating and are timing out" -

To summarize: TCM and ESP have lost communication with the PCM. Since ESP module was replaced and it didn't make any difference. I am suspecting PCM is faulty?

Forscan always says a module should never be replaced on the basis of a U DTC alone. They can be caused by the acts of connecting & using diagnostic equipment, or by other, faulty, modules on the bus. I would not recommend replacing the most expensive module in the car on that basis.

Peter.

the only WA of checking all the modules properly is to take it to ford since a cluster will give lots of random faults

Update: car got repaired! Some (not all) mechanics/electricians don't tell exactly what the problem was not sure why (it's not that we're going to compete on their business). He said problem was with the TCM and also in the electrical installation (nothing specific or detailed)!

Then I found the lens plastic of IC has a line of broken glass and told him that it wasn't there when I brought the car! He said that he did not touch or work at the IC!!!

Car to be taken today and paid for the repair.

On 5/26/2016 at 8:51 PM, Tdci-Peter said:

Forscan always says a module should never be replaced on the basis of a U DTC alone. They can be caused by the acts of connecting & using diagnostic equipment, or by other, faulty, modules on the bus. I would not recommend replacing the most expensive module in the car on that basis.

Peter.

Q: Is this IC lens only replaceable? Anyone know where to find such part?

haven't seen just s lens usually complete unit if its broken the cluster was removed tcm isn't in the cluster so IDE ask for more info incase it is the cluster and you're being fobbed off till the warranty runs out

7 hours ago, artscot79 said:

haven't seen just s lens usually complete unit if its broken the cluster was removed tcm isn't in the cluster so IDE ask for more info incase it is the cluster and you're being fobbed off till the warranty runs out

Hi there,

No issue with the transmission and esp anymore not sure what he has really done BUT today it rained and I found that windshield wiper blades do not work at low speeds, it only works at highest speed!!! (Opening a new thread on this now)

Called the guy who repaired the car and he said that this wiper thing has nothing to do with what they worked on. 

Cheers!

 

 

 

On 20/05/2016 at 10:17 AM, simcor said:

I beg to differ artscot I have just looked at a colleagues car as it had engine malfunction and transmission error. Lots of can bus errors and vehicle speed sensor and pats immobilised.

Cleared all codes and still showing malfunction.

Eventually cleared all codes and error gone.

When a cluster is faulty it causes issues on the can network whether it be interference or no communication so should log plenty of error codes. 

When I messed with my c90 connector I had the same type of issue and lots of can error codes.

Once a module is not communicating with others it causes all sorts of issues.

Found out yesterday my colleague had to have her car taken to a Ford dealer in the end, new cluster and VSS at a whopping £900 ouch, so I was correct in my diagnosis on it. Fortunately for her the AA warranty have paid the first £500 but it still cost her £400.

All she said was "you were right" when I asked what about she told me all about it, not a nice feeling to be right though.

I had the same symptoms as Simon describes, it was IC fault, but the repair cost £0.00, plus quite a lot of aggro.

Did it myself, the actual repair was a 10 minute job. A main Fraud Stealer will always go for the quick & expensive option.

Details of repair are somewhere up in this long thread.

On Thursday, June 09, 2016 at 1:12 PM, Tdci-Peter said:

I had the same symptoms as Simon describes, it was IC fault, but the repair cost £0.00, plus quite a lot of aggro.

Did it myself, the actual repair was a 10 minute job. A main Fraud Stealer will always go for the quick & expensive option.

Details of repair are somewhere up in this long thread.

Hi Peter,

It's been sometime now, car works fine, however tonight I found out the leds on IC only work when ignition is on! They dont light up from the parking light switch! 

Did not check anything like fuses yet. Could it be a fuse thing?

 

Cheers!

See your other topic on this!

I'll got a ford focus 2003 model if I replace a second hand odometer is there any issue