Hi! I have Mondeo 2.0 TDCi 140ps, year 2011. For almost A year, for some reason it goes intermittently into limp mode, ALWAYS gives DTC P062E regarding to Injector bank 2 driver perfomance issue, power loss or ground issue, also power supply/regulator circuit inside ECU.

Symptoms have occured at 99% of the cases when it's been wet weather and roads, raining hard or car has stayed for example overnight in humid weather. And 100% when accelerating.

When engine turned off and then back on, limp mode goes away... sometimes for the next 2000km... but usually lets me drive about 20m, then limp mode again and needed to restart engine 5-15 times before it settles and works like a charm. Though sometimes even 20 restarts haven't solved the problem. Best way to clear the issue has been idling the engine in park for 15min. Something gets to dry a little, because symptoms only when wet??

Has anyone had this kind of situation? What could be possible causes? Bad Injector? Wiring harness issue, but where? Faulty ECU circuit or software? Ford mechanic and also one independent car electrician have been tried to figure this out, no success. 

Ps. Somewhere between march 2011 and december last year the PCM module cover box was opened and it had been totally available for all mud, snow, dirt and water splashes. I've owned the since june 2014, we noticed open cover box last december. 

Pps. Sorry if my english is bad, i'm from Finland. Decided to ask from UK cause nobody in finnish Ford Club can help.

3 hours ago, Mutti82 said:

PCM module cover box was opened and it had been totally available for all mud, snow, dirt and water splashes.

Looks to me like you may have answered the question. That PCM needs to come out, be given a good clean with alcohol (Isopropyl Alcohol is usually used for electronics) & a soft bristled brush. Then inspected under good light with a magnifying glass. And the connectors checked for corrosion.

Water residues & corrosion are hygroscopic, and become conductive when damp. Diesel injectors need quite high voltage (up to 100v), so the drivers will be especially sensitive.

 

Ok. Is possible that all the water etc could affected also inside pcm-module or should have stayed outside and only the pins got wet? If also inside, can I (and is it wise to) open it myself and clean it or should be taken to some ecu-specialist?

And does someone know where would I get pinout diagram Ford PCM BG91-12A650 (made by Delphi)? Could check more accurate those pins which are for Injectors...

18 hours ago, Mutti82 said:

can I (and is it wise to) open it myself

Usually these PCMs have a cover which is help in place by a security bolt that is headless (sheared off in fitting), and has to be drilled or ground out. It requires some care, but once done, the unit should be removed quite easily.

Ford Etis will have the pinout info, but that is not available to casual users without paying a license fee. The wiring colour codes should help in tracing the injector wiring.

If at all uncertain, and you can find someone to do it for a sensible fee, that would be a good option.

 

Right, the wiring colour codes is the best way to find out correct pins. If the wiring is ok, then options are faulty PCM or faulty Injector from bank 2 (though it would be weird if symptoms come only when wet weather). Because if some sensor (MAF, MAP, FRP, CPS, BAP...) is faulty, SHOULD give at least some DTC? Now only P062E...

4 hours ago, Mutti82 said:

if some sensor (MAF, MAP, FRP, CPS, BAP...) is faulty, SHOULD give at least some DTC? Now only P062E

There is hardly ever a 100% guarantee!

Sensors that fail out of range (short circuit / open circuit) will usually give a specific DTC. In-range errors are harder, and false indications are frequent. For instance the engine compares the MAF with computed readings that use the MAP, and faulty (but in range) MAP errors may generate MAF DTCs.

P062E is "Fuel Injector Driver Circuit Performance Bank 2"

The term "driver circuit" does strongly hint the fault is electrical, in the wiring or driver in the pcm. And so is specific to the injector circuit. And "performance" suggests it is not short or open circuit, but an intermediate electrical failure.

The correlation with damp is significant: The injector coil and connector would heat up quickly with the engine running, so should only malfunction on a cold start. The pcm is in a location where it can be kept cool, in the Focus it is in the air intake system. So while moving, and drawing a good flow of air, the pcm will stay cool & prone to damp. When stopped with a hot engine, it may warm up and dry out. That is why I put the pcm as suspect number 1.

But, like I say, there is no 100% guarantee!

 

Guess what everyone? I'm so damn glad that I joined this U.K Ford Club, never had answers this wide and good in finnish forums. So conclusion: I measure Injector bank 2 wiring just in case first, then concentrate on pcm. Clear pins from it with contact spray once more. And if still same symptoms come, take pcm to electrician. Just to know, could it be just driver software failure and recoding could cure it? Or is it more likely electric circuit hardware failure?

injector bank 2 , seems strange, bank 2 normaly refers to bank of cyls in a v formation, ie v6, v8 etc. in a 4cyl its bank 1 only.

connector 3 , pins l1, m1 injector 4 circuit yellow/orange blue.

pins l2 m2 3 violet/grey green/ violet

pins l3 m3 2 grey/yellow blue /orange

pins l4 m4 1 green/blue yellow /blue

24 minutes ago, iantt said:

injector bank 2 , seems strange, bank 2 normaly refers to bank of cyls in a v formation, ie v6, v8 etc. in a 4cyl its bank 1 only.

Actually I found some while ago a diesel engine injector diagram where 4 injectors have been divided in 2 circuits (at least I understood that so)... marked in diagram as C1 and C2...

Or the there is seriously something wrong inside PCM if giving DTC from bank 2 what there even isn't. :D

 

1 minute ago, iantt said:

connector 3 , pins l1, m1 injector 4 circuit yellow/orange blue.

pins l2 m2 3 violet/grey green/ violet

pins l3 m3 2 grey/yellow blue /orange

pins l4 m4 1 green/blue yellow /blue

thanks! :)

c1 and c2 refer to the connectors

1 minute ago, iantt said:

c1 and c2 refer to the connectors

Ok.

trying to find the connector diagrams and colours, normally theres grey black and brown. the connectors should show the relevant numbers , ie l2 m2

Just now, iantt said:

trying to find the connector diagrams and colours, normally theres grey black and brown. the connectors should show the relevant numbers , ie l2 m2

Tried to find right one for three days but didn't find even non-coloured ones... somehow those diagrams seems to be well protected secrets. But those pins for each injector, those are specifically for pcm I mentioned? BG91-12A650-XX (where X varies... is there differences between different end letter combinations? Just thinking that if my pcm is ruined and beyond recoding, going to buy used ecm and flash it... brand new pcm is bit high priced...)

And bit stupid question, just to be sure... l stands for line, but m is... "vertical direction" in particular line? Again, I'm finnish... ;)

those pins are relevant regardless of pcm numbers regarding 2.0 tdci various outputs from march 2008 onwards, manual transmission. i assume manual unless you say otherwise.

1 minute ago, iantt said:

those pins are relevant regardless of pcm numbers regarding 2.0 tdci various outputs from march 2008 onwards, manual transmission. i assume manual unless you say otherwise.

Well... I have PowerShift automatic...

ha ha, will recheck later

same locations, basically you have 3 connector plugs on to pcm, the one that is relevant to injector wiring is the larger one. theres  one smaller one(24 pins) , then 2 larger ones. (48 pins)its the last larger one in a row.

if you look at the connector you should see letters and numbers at each pin from what i remember. starts at "a" and finishes at "m" then each row is numbered 1-4.

the injector wiring is the larger of the pins ( 8 of them )

still cant find a diagram of the connector for you to see . it will be obvious when you look though. 

with the dtc your getting, it does look like pcm internal problem or water ingress/corrosion on connectors

 

googled a pcm connector so you see what im refering to.not the one for your car but you get the idea

Fine. Now I got that. :) But hey, I've been in contact to Ford customer care in case if my pcm is internally ruined and needs to be replaced. They told me that my car is engine code UFBA and should have currently PCM named AU71-12A650-AA (made by Delphi), and that replacement would be 

AG91-12A650-ABA
AG91-12A650-ACA
AG91-12A650-ADA
AG91-12A650-ADE
AG91-12A650-ADF
AG91-12A650-ADG
AG91-12A650-AEA
AG91-12A650-AFA
AG91-12A650-AGA
AG91-12A650-AHA
AG91-12A650-XA
AG91-12A650-YA
AG91-12A650-ZA

I didn't find any of those "end letters" to be sold as used. Are those pcm how interchangeable? Because for example nearest model I found one is from Ebay with ending -AGF, stripped from 2010 2.0 TDCi 103kW estate automatic, engine code UFBA (same as I have), compatibility windows of item shows it would fit to my car, price £313 = approx 360€.
Searching by Mondeo 2007-2015 stripped pcm found also many from Finland, but all starts with something else than AG91.

- BG91-12A650-FJD stripped from Mondeo year 2012 with exactly same engine and transmission estate, price 250€.
- BG91-12A650-FJF stripped from Mondeo year 2014 estate with same engine and transmission, engine code UFBB, price 400€
- 8G91-12A650-RB stripped from Mondeo year 2010 estate with same engine but manual transmission, engine code LPBA, price 250€

Are those BG91 compatible also cause stripped from cars only bit different manufacturing year? Or should try to find AG91 either exactly same ending what Ford customer care told OR some other ending too? Want to do this right in one time, too expensive to buy a pcm which therefore doesn't even work in my vehicle.

EDIT: Just getting funnier... got access to ETIS, it shows my vehicle has BG91-12A650-SF module installed, not what Ford customer care told. Need to open that cover box in first place so that can figure this out. Though if it is what ETIS said, finding replacement PCM just got pretty much easier. And cheaper. Found exactly same item code PCM from U.k and only costs 175€ + shipping 25€. :D  

On 29.8.2016 at 4:23 PM, iantt said:

injector bank 2 , seems strange, bank 2 normaly refers to bank of cyls in a v formation, ie v6, v8 etc. in a 4cyl its bank 1 only.

Coming back to this subject, I found document regarding Vauxhall Astra J where DTC P062E is opened as Injector High Control Circuit Group 2 Malfunction and Group 2 explained to be injectors #3 and #4 (and DTC P062D for Group 1 = #1 and #2). So I'm thinking that could ForScan expression for that DTC be wrong when talking of Bank 2, not Group 2...? And therefore my vehicle still could have intermittently faulting injector (#3 or #4) cause at least in Astra ecm will disable all injectors in circuit where it notices fault. And we all know that especially Mondeo MK3 and MK4 has had severe issues with Delphi injectors failing even with low mileage. Link to Astra document below...

http://workshop-manuals.com/vauxhall/astra-j/engine/engine_control_and_fuel_system_1.3l_diesel/other_information/dtc_p062d_or_p062e/ 

On 8/27/2016 at 9:26 PM, Mutti82 said:

Hi! I have Mondeo 2.0 TDCi 140ps, year 2011. For almost A year, for some reason it goes intermittently into limp mode, ALWAYS gives DTC P062E regarding to Injector bank 2 driver perfomance issue, power loss or ground issue, also power supply/regulator circuit inside ECU.

Symptoms have occured at 99% of the cases when it's been wet weather and roads, raining hard or car has stayed for example overnight in humid weather. And 100% when accelerating.

When engine turned off and then back on, limp mode goes away... sometimes for the next 2000km... but usually lets me drive about 20m, then limp mode again and needed to restart engine 5-15 times before it settles and works like a charm. Though sometimes even 20 restarts haven't solved the problem. Best way to clear the issue has been idling the engine in park for 15min. Something gets to dry a little, because symptoms only when wet??

Has anyone had this kind of situation? What could be possible causes? Bad Injector? Wiring harness issue, but where? Faulty ECU circuit or software? Ford mechanic and also one independent car electrician have been tried to figure this out, no success. 

Ps. Somewhere between march 2011 and december last year the PCM module cover box was opened and it had been totally available for all mud, snow, dirt and water splashes. I've owned the since june 2014, we noticed open cover box last december. 

Pps. Sorry if my english is bad, i'm from Finland. Decided to ask from UK cause nobody in finnish Ford Club can help.

Did you find a solution for this problem??:)