Known Issues And Faults

***Ford known fixes*** 
Subject/Concern: Ticking noise from B-pillar when driving / cornering on rough roads 
Model: 
Focus C-MAX 2003.75 (06/2003–) Build Date: 01.06.2003 Onwards 
Build Code: 3Y Onwards 
Focus 2004.75 (07/2004–) - only 5-door and wagon Build Date: 07/2004 Onwards 
Build Code: 4D Onwards 
Markets: All 
Section: 501-25G 
Summary 

Should a customer express concern that there is ticking noise from the B-pillar, in the area of the opening for the front safety belt, when driving / cornering on rough roads, the probable cause is the sheet metal sticking between the B-pillar panel spot welding points. The noise is generated by the sheet metal breaking away from the spot welds between the panel. 

In general this noise can only be heard/recognised on the driver or the passenger side. 

To rectify this concern, the dip-primer between the B-pillar spot panel welding points should be "cracked" with the use of the weaker plastic side of the wheel brace (part of the vehicle tools). To prevent further sticking of the sheet metals between the B-pillar panel spot welding points, multi-function spray should be applied to the reworked areas. 

CAUTION: Make sure that only the weaker plastic side of the wheel brace is used. The use of any metal object may cause damage to the paint surface (especially when slipping down). 


Parts Required 
Description Finis Code Quantity 
Multi-function spray (200 ml) 1 321 554 1 
Labor Time 
Operation Description Operation No. Time 
B-Pillar Trim Panel - Remove And Install (Upper) 43 614 0 - 
B-Pillar Trim Panel - Remove And Install (Lower) 43 617 1 - 
Cracking The Dip-Primer Between The B-Pillar Panel Spot Welding Points (One Side) - additional 0,2 hours 
Repair/Claim Coding 
Causal Part: 00012 RH; 00013 LH 
ACES Condition Code: 41 
OASIS 702100, 702300 

Service Instruction 
See Summary. 

1. Remove the wheel brace which is located under the spare wheel in the luggage compartment. 

2. Remove the B-Pillar trim panel (lower and upper). For additional information, refer to Focus 2004.75 / Focus C-MAX 2003.75 Workshop Manual Section 501-05. 

1. Rear door opening weatherstrip 
2. Front scuff plate trim panel 
3. Front door opening weatherstrip 
4. B-pillar upper trim panel retaining screws cover 
5. B-pillar upper trim panel retaining screws 
6. Front safety belt lower anchor 
7. Upper B-pillar trim panel 
8. Lower B-pillar trim panel retaining clips 
9. Lower B-pillar trim panel 
10. Lower B-pillar trim panel retaining clips 

3. CAUTION: Only use the weaker plastic side of the wheel brace. 
Crack the dip-primer between the B-pillar panels at the rear door opening. 

Move the weaker plastic side of the wheel brace (part of the vehicle tools) into the gaps between the sheet panel. 
• NOTE: There could be areas at the B-pillar were no sticking of the sheet metal exists and accordingly no audible "cracking" noise can be heard. In these areas no further action is required. 

Carefully push the tool, by hand, into the gap until an audible "cracking" noise can be heard. 
Repeat this for all other gaps on both sides (middle/outer panel and middle/inner panel) between the lock striker and the front safety belt fixing point. 

4. Repeat the previous step for the same areas of the B-pillar at the front door opening. 

5. Unroll the safety belt fully from the front safety belt retractor. 
Fix the safety belt to the head restraint. 
Cover the safety belt retractor with a clean cloth to avoid any contamination. 

6. CAUTION: Do not contaminate the safety belt. 
Apply multi-function spray (see Parts Required): 
Into the opened gaps between the sheet panel of the B-pillar. 
• NOTE: Direction of spraying. 

Spray the multi-function spray in the direction of the arrows into the marked holes. 

7. To install all other components, reverse the removal procedure. 

E58153 Battery Discharging 

Subject/Concern: Power loss; engine difficult to start or does not start (fault code P0380 is set); battery discharged 
Model: 
Focus C-MAX 2003.75 (06/2003–) Engine: 1.6L Duratorq-TDCi (DV) Diesel 
Engine: 2.0L Duratorq-TDCi (DW) Diesel 
Focus 2004.75 (07/2004–) Engine: 1.6L Duratorq-TDCi (DV) Diesel 
Engine: 2.0L Duratorq-TDCi (DW) Diesel 
Markets: All 
Section: 303-07 
Summary 

Should a customer express concern regarding power loss or that the engine is difficult to start or does not start at all or that the battery becomes discharged and if fault code P0380 is set, the probable cause is a damaged glow plug relay due to water ingress via the ground cable in the wiring harness to the glow plug relay. To rectify the concern, a new glow plug relay and a modified wiring harness from the engine compartment fuse box to the glow plug relay should be installed. 

Parts Required 
Description Finis Code Quantity 
Glow plug relay 1 252 609 1 
Glow plug relay repair wiring harness 1 363 580 1 
Solder/crimp connectors locally procured - 
Cable ties locally procured - 
Labor Time 
Operation Description Operation No. Time 
WDS Vehicle Connection/Communication 29 099 0 - 
Stored Fault Codes - Read Out - additional 0.1 hours 
Headlamp Assembly - Remove And Install (One Side) 32 115 1 - 
Engine Undershield - Remove and Install 21 130 4 - 
Glow Plug Relay And Glow Plug Relay Wiring Harness - Renew - additional 0.8 hours 
Repair/Claim Coding 
Causal Part: Finis Code for glow plug relay 
ACES Condition Code: 49 
OASIS 203000, 203100, 603300, 607000, 614000 

Service Information 
Glow plug relay repair wiring harness 


19145 - FOCUS / C-MAX 2.0 TDCI - DTC P0002/P0089 SOME FOCUS AND C-MAX 2.0 TDCI PRODUCED UNTIL JAN 2006 MAY EXHIBIT THE MIL ILLUMINATED AND VARIOUS DRIVEABILITY CONCERNS WITH DTC P0002 (FUEL VOLUME REGULATOR CONTROL CIRCUIT RANGE/PERFORMANCE) AND/OR DTC P0089 (FUEL PRESSURE REGULATOR PERFORMANCE)PRESENT. TO RECTIFY, REPROGRAM THE PCM WITH THE APPROPRIATE NEW CALIBRATION AVAILABLE IN SERVICE FROM WDS CD B42 ONWARDS (REVISED CALIBRATION'S ARE:3M51-12A650-AD; 3M51-12A650-NG; 3M5A- 12A650-HT; 4M51-12A650-ZG; 5M51-12A650-MD; 6M51-12A650-TD; 6M51-12A650-UD; 6M51-12A650-HC) 
EFFECTIVE DATE: 27/03/2006 

19013 - NEW FOCUS/C-MAX 2.0 TDCI - DTC P1412/P0490/P1335 
CONTINUING OF SSM 18859. DO NOT REPLACE THE EGR COOLER UNLESS THERE IS DIRECT EVIDENCE OF COOLER FAILURE, EVEN IF THE DEPOSITS ON THE EGR VALVE LEADS TO SUCH A CONCLUSION. A NEW DESIGNED EGR VALVE TO OVERCOME THIS LEVEL OF DEPOSITS WILL BE AVAILABLE SOON AND YOU'LL BE INFORMED WITH A SEPERATE OASIS MESSAGE. PLEASE BE ALSO REMINDED THAT THE USE OF BIO DIESEL FOR ALL FORD DIESEL ENGINES (MORE THAN 5% WHICH ARE BASICALLY PART OF DIESEL FUEL) IS NOT ALLOWED AND WILL INVALIDATE WARRANTY. IT CAN LEAD TO THIS KIND OF FAILURE ON THE EGR VALVE. 
EFFECTIVE DATE: 23/01/2006 

18859 - NEW FOCUS/C-MAX 2.0 TDCI - DTC P1412/P0490/P1335 
SOME NEW FOCUS/C-MAX 2.0L TDCI MAY EXHIBIT POOR START; ROUGH IDLE OR LOSS OF POWER WITH DTC: P1412 (EGR FROZEN); P0490 (EGR CONTROL CIRCUIT HIGH) OR P1335 (EGR POSITION SENSOR MIN/MAX STOP PERFORMANCE) PRESENT. IF SO REPROGRAM THE PCM WITH THE APPROPRIATE NEW CALIBRATION AVAILABLE IN SERVICE FROM WDS CD B39A ONWARDS (REVISED PCM PART NO.: 3M51-12A650-AC; 3M51-12A650-NF; 3M51- 12A650-HS; 4M51-12A650-ZF; 5M51-12A650-MC) AND FOLLOWING ALL THE ON SCREEN INSTRUCTION INCLUDING RESETTING THE EGR VALVE. IF ANY CODES ARE STILL PRESENT AFTER ROAD TEST FOLLOW THE DIAGNOSTIC PROCEDURES FOR THAT CODE. SHOULD A REPLACEMENT EGR VALVE STILL BE REQUIRED THE NEW VALVE MUST STILL BE RESET TO THE PCM USING WDS. THIS FUNCTION IS FOUND IN TOOLBOX, POWERTRAIN, SERVICE FUNCTIONS, COMPONENT/PARAMETER RESET. 
EFFECTIVE DATE: 03/10/2005 

18502 - NEW FOCUS / C-MAX TDCI - DTC P0089 OR P0002 
IF DURING A WDS DIAGNOSIS ON A NEW FOCUS OR FOCUS C-MAX WITH TDCI - DIESEL ENGINE, THE DTC'S: P0089 (PCV/VCV CONTROL AT MINIMUM OR MAXIMUM VALUE) OR P0002 (VCV OUTSIDE ADAPTIVE RANGE, FUEL FLOW IS LOW) IS SET, PRIOR TO MAKING ANY HARDWARE CHANGE ON THE ENGINE SUCH AS FUEL PUMP, VERIFY THAT THE FUEL LINES ARE CLEAR AND FREE FROM BLOCKAGES/KINKS FROM THE DDM IN THE FUEL TANK, RIGHT THROUGH TO THE FUEL PUMP INLET ON THE ENGINE.A FEW CASES WERE REPORTED WHERE, DUE TO CUSTOMER MISS-USE, THE PLASTIC INSERT IN THE UPPER FILLER NECK GOT DAMAGED. A DAMAGED PLASTIC INSERT CAN BE EASILY DETECTED BY VISUALLY INSPECTING THE INSIDE OF THE FILLER NECK WHEN THE FILLER CAP IS REMOVED. VISUAL SIGNS ARE A DEFORMED METAL FLAP OR CRACKS IN THE PLASTIC MATERIAL. 
EFFECTIVE DATE: 23/03/2005 

18429 - NEW FOCUS / C-MAX 2.0 TDCI - DTC P0089 OR P0002 
IF DURING A WDS DIAGNOSIS ON A NEW FOCUS OR FOCUS C-MAX EQUIPPED WITH 2.0 TDCI, THE DTC'S : P0089 (PCV/VCV CONTROL AT MINIMUM OR MAXIMUM VALUE) OR P0002 (VCV OUTSIDE ADAPTIVE RANGE, FUEL FLOW IS LOW) IS SET, PRIOR TO MAKING ANY HARDWARE CHANGE ON THE ENGINE SUCH AS FUEL PUMP, VERIFY THAT THE FUEL LINES ARE CLEAR AND FREE FROM BLOCKAGES/KINKS FROM THE DDM IN THE FUEL TANK, RIGHT THROUGHTO THE FUEL PUMP INLET ON THE ENGINE. 
EFFECTIVE DATE: 22/02/2005 

17898 - FOCUS C-MAX - CLUSTER WARNING LIGHTS ON. 
FOCUS C-MAX ALL EXCEPT 1.6 PETROL ENGINE - ALL INSTRUMENT CLUSTER WARNING LIGHTS ERRATIC READING AND ENGINE LOSS OF POWER/NO START. THIS CAN BE CAUSED BY AN INTERRUPTION OF THE CAN BUS VIA THE ELECTRO- HYDRAULIC POWER ASSISTED STEERING (EHPAS) UNIT. TO VERIFY, PLEASE DISCONNECT THE WIRING CONNECTOR OF THE EHPAS UNIT AND CHECK WHETHER ALL SYMPTOMS ARE STILL PRESENT. IF THE CONCERN CANNOT BE REPRODUCED WITH THE EHPAS UNIT DISCONNECTED, THEN CONTACT THE EHPAS PRE-APPROVAL HELPDESK FOR ASSISTANCE BEFORE REPLACING ANY PARTS 
EFFECTIVE DATE: 29/06/2004 

TECHNICAL SERVICE BULLETINS : 
017/2005 FOCUS C-MAX 2003.75 AND FOCUS 2004.75 WITH 1.6/2.0L DURATORQ-TDCI (DV) DIESEL: POWER LOSS; ENGINE DIFFICULT TO START OR DOES NOT START (DTC P0380 STORED); ENGINE UNDERSHOOTS TO ASTOP; BATTERY DISCHARGED 
EFFECTIVE DATE: 16/03/2005 
____________________________________ 

607400 - DRIVEABILITY STALLS/QUITS AT IDLE 
SPECIAL SERVICE MESSAGES : 
18715 - C-MAX 1.8 DURATEC 120 / 125PS - POOR PULL AWAY 
SOME FOCUS C-MAX EQUIPPED WITH 1.8 DURATEC HE 120 AND 125 PS, MAY EXHIBIT POOR PULL AWAY WHEN THE AIR CONDITIONING IS ON AND THE AMBIENT TEMPERATURE IS ABOVE 20�C. TO RECTIFY THIS, REPROGRAMM THE PCM WITH THE LATEST LEVEL CALIBRATION WHICH IS ON WDS CD38 ONWARDS. PCM PART NO.: 5M51-12A650-RC FOR 125 PS AND 3M51-12A650-GF FOR 120 PS ) 
EFFECTIVE DATE: 06/07/2005 

SSM 19168 EFFECTIVE DATE: 18/04/2006 
FOCUS AND C-MAX - INTERMITTENT ELECTRICAL CONCERNS 
SOME FOCUS AND C-MAX MAY EXHIBIT INTERMITTET ELECTRICAL CONCERNS, FOR EXAMPLE, 
WIPER PARKED IN MIDDLE POSITION; CLUSTER WARNING LIGHTS ON; RADIO INTERFERENCE OR ENGINE WON'T CRANK. 
BEFORE STARTING A DIAGNOSIS WITH WDS OR EXCHANGING ANY HARDWARE IT IS ESSENTIAL TO ENSURE 
SECURE B+ CONNECTIONS (3 OF): 1) NUT M6 (1-OF), FIXING OF B+ CLAMP TO BATTERY POLE: 5,4NM +/- 0.8. 2) NUT M8 (2-OF), 
FIXING OF B+ CABLES TO BATTERY CLAMP: 15NM +/- 2.3-. 

TSB 7/2006 
Subject/Concern: Hesitations; Poor or no start; Deteriorated fuel economy; Diagnostic trouble codes (DTC) P1412, P0490 and P1335 stored 
Model: Focus C-MAX 2003.75 (06/2003�) Build Date: 14.02.2004-01.03.2006 
Build Code: 4R-6S 
Assembly Plant: Saarlouis 
Engine: 2.0L Duratorq-TDCi (DW) Diesel 
Focus 2004.75 (07/2004�) Build Date: Up to 01.03.2006 
Build Code: Up to 6S 
Assembly Plant: Saarlouis 
Assembly Plant: Valencia 
Engine: 2.0L Duratorq-TDCi (DW) Diesel 
Markets: All 
Section: 303-08 
Summary 

Should a customer express concern about one of the following: 

* hesitations, 
* poor or no start, 
* deteriorated fuel economy, 
and upon investigation diagnostic trouble codes (DTC) P1412, P0490 and P1335 are stored in the powertrain control module (PCM), the probable cause is a sticky exhaust gas recirculation (EGR) valve. 

To rectify this concern, a new EGR valve with a stronger EGR valve motor and revised PCM calibration should be installed. 

� NOTE: Use CD-42 or a later version. 

TSB 5/2006 
Subject/Concern: Inaccurate fuel gauge and inaccurate trip computer (if equipped) 

SSM 19013 EFFECTIVE DATE: 23/01/2006 
NEW FOCUS/C-MAX 2.0 TDCI - DTC P1412/P0490/P1335 
CONTINUING OF SSM 18859. DO NOT REPLACE THE EGR COOLER UNLESS THERE IS DIRECT EVIDENCE OF COOLER FAILURE, EVEN IF THE DEPOSITS ON THE EGR VALVE LEADS TO SUCH A CONCLUSION. A NEW DESIGNED EGR VALVE TO OVERCOME THIS LEVEL OF DEPOSITS WILL BE AVAILABLE SOON AND YOU'LL BE INFORMED WITH A SEPERATE OASIS MESSAGE. PLEASE BE ALSO REMINDED THAT THE USE OF BIO DIESEL FOR ALL FORD DIESEL ENGINES (MORE THAN 5% WHICH ARE BASICALLY PART OF DIESEL FUEL) IS NOT ALLOWED AND WILL INVALIDATE WARRANTY. IT CAN LEAD TO THIS KIND OF FAILURE ON THE EGR VALVE. 

SSM 18859 EFFECTIVE DATE: 03/10/2005 
NEW FOCUS/C-MAX 2.0 TDCI - DTC P1412/P0490/P1335 
SOME NEW FOCUS/C-MAX 2.0L TDCI MAY EXHIBIT POOR START; ROUGH IDLE OR LOSS OF POWER WITH DTC: P1412 (EGR FROZEN); P0490 (EGR CONTROL CIRCUIT HIGH) OR P1335 (EGR POSITION SENSOR MIN/MAX STOP PERFORMANCE) PRESENT. IF SO REPROGRAM THE PCM WITH THE APPROPRIATE NEW CALIBRATION AVAILABLE IN SERVICE FROM WDS CD B39A ONWARDS (REVISED PCM PART NO.: 3M51-12A650-AC; 3M51-12A650-NF; 3M51- 12A650-HS; 4M51-12A650-ZF; 5M51-12A650-MC) AND FOLLOWING ALL THE ON SCREEN INSTRUCTION INCLUDING RESETTING THE EGR VALVE. IF ANY CODES ARE STILL PRESENT AFTER ROAD TEST FOLLOW THE DIAGNOSTIC PROCEDURES FOR THAT CODE. SHOULD A REPLACEMENT EGR VALVE STILL BE REQUIRED THE NEW VALVE MUST STILL BE RESET TO THE PCM USING WDS. THIS FUNCTION IS FOUND IN TOOLBOX, POWERTRAIN, SERVICE FUNCTIONS, COMPONENT/PARAMETER RESET. 

SSM 5310 
FOCUS AND C-MAX 1.6 TDCI - LOSS OF POWER 
SOME NEW FOCUS OR C-MAX EQUIPPED WITH 1.6 TDCI BUILT BETWEEN JUNE 2003 AND JAN 
2005, MAY EXHIBIT THE FOLLOWING DRIVEABILITY ISSUES: 
1.MIL ON DTC P0404/P1412 (EGR) REDUCED POWER. 2. MIL ON DTC P0234 TURBO 
OVERBOOST REDUCED POWER. 3. MIL ON DTC P0238 TURBO BOOST SENSOR VOLTAGE UPPER 
LIMIT REDUCED POWER. 4. RUN DOWN ROUGHNESS. ALSO REDUCES OIL BACKFLOW IN AIR 
INTAKE SYSTEM IN COMBINATION WITH SSM 18120. 5. MIL ON DTC P0116 ECT REDUCED 
POWER.IN CASE OF THESE CONCERNS, A REVISED PCM CALIBRATION IS NEEDS TO BE 
INSTALLED. THIS NEW LEVEL CALIBRATION WILL BECOME AVAILABLE ON WDS CD B41. 
REVISED PCM NO: 3M51-12A650-MH; 4M51-12A650-NF;-KG 

TSB 40/2005 
* Loss of power,* Engine does not start, 
* Engine undershooting to a stop with immediate restarting possible, 
* "POWER STEERING FAILURE" displayed on the instrument cluster, 
Focus C-MAX 2003.75 (06/2003�) Build Date: 23.06.2003-03.01.2005 
Build Code: 3Y-5J 
Engine: 1.6L Duratorq-TDCi (DV) Diesel 
Engine: 2.0L Duratorq-TDCi (DW) Diesel 
Transmission/Transaxle: CFT23 
Transmission/Transaxle: MTX-75 
one probable cause is a damaged wiring harness in the area of the manual/automatic transaxle 

TSB 11/2006 
Clock in Radio resets after engine crank 
Should a customer express concern that the displayed time and date in the audio unit or the instrument cluster reverts 
back to always the same values after engine start, the probable cause is a voltage drop during the cranking process of 
the engine. This could lead to a reset of the instrument cluster. 

To rectify this concern a voltage buffer module should be installed to the production wiring harness for the instrument cluster 

SSM 18579 EFFECTIVE DATE: 26/04/2005 
CLOCK IN RADIO LOOSES TIME 
SOME NEW FOCUS AND C-MAX VEHICLES MAY HAVE A RADIO UNIT WITH THE CLOCK DISPLAY RUNNING SLOW, A FEW SECONDS PER DAY COULD BE LOST. 
TO RECTIFY THIS UPDATE THE INSTRUMENT CLUSTER WITH REVISED SOFTWARE WHICH IS AVAILABLE WITH WDS CD37 ONWARDS. 
ID THE VEHICLE AS NORMAL; CHOOSE INSTRUMENT CLUSTER UNDER "BODY" IN THE GUIDED DIAGNOSTIC TAB MENU; 
SELECT CLOCK TIME FROM THE DIAGNOSTIC MENU AND PRESS THE BLUE TICK; FOLLOW THE ON SCREEN COMMANDS UNTIL THE PROCEDURE IS COMPLETE, 
THEN EXIT THE GUIDED DIAGNOSTIC. 

SSM 17927 
Desc: When the ignition is switched on, occasionally a Low Fuel Warning is shown. 
Fix: Updated Cluster firmware. 

SSM 7608 
Desc: When the ignition is switched on, a yellow warning with 'Limited EPB function!' is shown. 
Fix: Firmware update 

SSM 18122 
Desc: Noticeable flat spot in first gear around 1700rpm (TDCi engines) when pulling away from standstill. 
Fix: ECU Firmware update 

TSB 13/2005 
Desc: Leak from Turbocharger outlet pipe (1.6 TDCi) Oil pipe unseated during assembly. 
Fix: A revised turbocharger outlet pipe is installed Applies to models up-to 31/07/2004 Code 4D 

TSB 05/2005 
Desc: Light application of the brakes when reversing causes a loud squeel. 
Fix: Replacement Brake Pads. (Under Warranty) 

TSB 41/2004 
Desc: The time randomly changes on the radio clock. 
Fix: Updated Instrument Cluster firmware (current version 4.24 shown as ROM Level 0424 in TEST mode Later versions include the fixes) 

SSM 18356 EFFECTIVE DATE: 22/12/2004 
RADIO (SONY/5000/6000) INCORRECT CLOCK DISPLAY 
SOME NEW FOCUS AND C-MAX EQUIPPED WITH RADIO: 5000/6000/SONY MAY EXHIBIT THE RADIO DISPLAY SHOWING DIFFERENT CLOCK VALUES AFTER 
E.G. CRANK, DURING DRIVING. TO RECTIFY 1.DISCONNECT BATTERY FOR AT MINIMUM 5 SEC. TO INITIALIZE A CLUSTER RESET ( CLOCK DRIVER ). 
AFTERWARDS SET CLOCK AND DATE TO THE ACTUAL TIME. 2. ON C-MAX BUILT UNTIL 08.06.04 (4K) PLEASE WORK ACCORDING TO TSB 41/04. 
ALL VEHICLES BUILT AFTER HAVE ALREADY THE LATEST LEVEL SOFTWARE AND IT IS NOT RECOMMENDED TO REFLASH THESE VEHICLES AGAIN. 
IF THE ISSUE STILL OCCURS NO FURTHER REPAIR WILL IMPROVE THE SITUATION. THIS IS CURRENTLY UNDER INVESTIGATION. 

TSB 45/2004 
Desc: Ocassionally HID headlamp fails to ignite. 
Fix: Uprated Earthing Cable

 
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