Intermittent warning messages are displayed on the instrument cluster,

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1 1 of 11 21/03/ :49 TECHNICAL SERVICE BULLETIN Ford Motor Company reissue No.19/ April 2011 All rights reserved. This bulletin represents technical service information only. Without exception all gratis repairs and replacements are subject to the individual warranty and policy procedures of the supervisory Ford Company. The illustrations, technical information, data and descriptive text in this issue, to the best of our knowledge, were correct at the time of publication. This reissue replaces all previous versions. Please destroy all previous versions. Only refer to the electronic version of this TSB in FordEtis. The Labor Time section has been updated. Subject/Concern: Engine sometimes difficult to start; Intermittent warning messages displayed on the instrument cluster; Malfunction Indicator Lamp (MIL) illuminated; Various Diagnostic Trouble Codes DTCs (Lost Communication) stored in the Powertrain Control Module (PCM) or in the Body Control Module (BCM) Model: Mondeo (02/ /2014) Build Date: Build Code: AT-AG Assembly Plant: Genk S-MAX/Galaxy (03/ /2014) Build Date: Build Code: AT-AG Assembly Plant: Genk Markets: All Section: Summary Should a customer express concern that the engine sometimes is difficult to start, Intermittent warning messages are displayed on the instrument cluster, the Malfunction Indicator Lamp (MIL) is illuminated and various DTCs - Lost Communication - are stored either in the Powertrain Control Module (PCM) or in the Body Control Module (BCM), the probable cause is one or more damaged CAN bus wiring harness splices in the passenger compartment wiring harness and/or the instrument cluster wiring harness. The CAN bus wiring harness splices have been introduced in production to 0.13 mm² single wires since 04/2010, sometimes isolated by tape or special heat shrink tubing. For example the following various DTCs (Lost Communication) may be stored: U0167 LOST COMMUNICATION WITH VEHICLE IMMOBILIZER CONTROL MODULE U0129 LOST COMMUNICATION WITH BRAKE SYSTEM CONTROL MODULE U0100 LOST COMMUNICATION WITH ECM/PCM U0121 LOST COMMUNICATION WITH ANTI-LOCK BRAKE SYSTEM (ABS) CONTROL MODULE U0140 LOST COMMUNICATION WITH BODY CONTROL MODULE U0126 LOST COMMUNICATION WITH STEERING ANGLE SENSOR MODULE U0123 LOST COMMUNICATION WITH YAW RATE SENSOR MODULE To rectify this concern the BCM should be updated to the latest level. If the concern still occurs ALL located CAN bus wiring harness splices should be repaired. This bulletin details the repair procedure for the CAN bus wiring harness splices.

2 2 of 11 21/03/ :49 For markets where FordEtis IDS is used, refer to WB 45/2009 for the policy on using FordEtis IDS for warranty repairs. If FordEtis IDS is used to diagnose a customer's concern(s), select the appropriate customer symptom(s), follow any diagnostic, repair and post repair procedures presented, and ensure the completed diagnostic session file is transmitted to Ford. Failure to follow this process may affect any associated warranty claim submission. For markets where FordEtis IDS is not available, rectify this concern by following the attached service repair instruction. Parts Required Description Finis Code Quantity Cable tie Locally procured - Tape Locally procured - Labor Time Operation Description Operation No. / Time Passenger Compartment CAN Bus Wiring Harness Splice: IDS - Vehicle Connection/Communication Body Control Module (BCM) - Programming IDS - Read/Delete DTCs (Not in conjunction with Symptom Based Diagnostic) CAN Bus Wiring Harness Splice (2 off) - Repair (Includes: Front Seat - Remove And Install) additional D19 Instrument Panel CAN Bus Wiring Harness Splice: Audio Unit - Remove And Install Floor Console - Remove And Install CAN Bus Wiring Harness Splice (2 off) - Repair (Includes: Floor Console And Audio System - Remove And Install additional D19 IDS - Read/Delete DTCs (Not in conjunction with Symptom Based Diagnostic) Repair/Claim Coding Causal Part: ACES Condition Code: 28 General equipment / Material Supplier Hot air gun commercially available Solder/heat shrink connector end-to-end; Ø max. 3.3 mm Please contact your local supplier. Solder/heat shrink connector; Ø max. 2.7 mm Production Action Revised wiring harnesses have been installed in production in Genk plant since (build code AG). Service Information The following CAN bus wiring harness splices are located in the passenger compartment wiring harness and the instrument panel wiring harness. Overview of the CAN bus wiring harness splices NOTE: Depending on the model the CAN Bus wiring harness splice could be located in the area of the floor console or behind the audio unit.

3 3 of 11 21/03/ :49 Item Description 1 CAN bus wiring splice on the passenger compartment wiring harness (right-hand side) (Mondeo and S-MAX/Galaxy ) 2 CAN bus wiring splice on the passenger compartment wiring harness (left-hand side) (Mondeo and S-MAX/Galaxy ) 3 CAN bus wiring splice on the instrument panel wiring harness in the area of the floor console (Mondeo only) 4 CAN bus wiring splice on the instrument panel wiring harness in the area of the audio system (S-MAX/Galaxy only) Service Instruction For markets where FordEtis IDS is used, refer to WB 45/2009 for the policy on using FordEtis IDS for warranty repairs. If FordEtis IDS is used to diagnose a customer's concern(s), select the appropriate customer symptom(s), follow any diagnostic, repair and post repair procedures presented, and ensure the completed diagnostic session file is transmitted to Ford. NOTE: Failure to follow this process may affect any associated warranty claim submission. For markets where FordEtis IDS is not available, rectify this concern by following the attached service repair instruction. IDS - Body Control Module (BCM) - Programming 1. NOTE: Before commencing module configuration or programming, connect the vehicle battery to a suitable external power supply in order to maintain a constant battery voltage throughout the procedure. For detailed information refer to TSB 62/2007. Connect IDS standard portable diagnostic unit to the vehicle and establish communication

4 4 of 11 21/03/ :49 2. (VID the vehicle). Confirm the vehicle details are correct. Go to next step. Reprogram the BCM using IDS. Select the <Toolbox> tab at the top of the screen. Select <Module Programming> and then press the tick. Select <Module Reprogramming> and then <BCM>. Press the tick. Follow the further instructions from IDS standard and confirm. 3. Clear any stored DTCs related to this concern. 4. Verify the customers concern. Start the engine and switch on various consumer loads (Air conditioning system; Audio unit; Heated front windshield; etc.) Switch off the engine and check for stored DTCs. If various DTCs (Lost Communication) are stored, go to <Passenger compartment CAN Bus wiring harness splice - Repair>. If no DTCs are stored, no further action is required. If other DTCs are stored, perform opportune analysis. Passenger compartment CAN Bus wiring harness splice - Repair NOTE: LHD vehicle shown, RHD vehicles similar Remove the passenger seat. For additional information, refer to Mondeo ; S-MAX/Galaxy Workshop Manual Section Remove the scuff trim panel on both sides. Partially lift the floor covering. 3. Partially remove the insulation and locate the CAN bus wiring harness splice on the right-hand side. Remove the tape and cut off any damaged part of the splice.

5 5 of 11 21/03/ :49 4. NOTE: Use solder/heat shrink connector end-to-end Ø max. 3.3 mm only (see General equipment / material). To prevent further damage, the solder/heat shrink connector should be installed on ALL located CAN bus wiring harness splices. Repair the CAN bus wiring harness splice. If required remove the insulation at the cable ends. Insert the twisted ends of the wires into the solder/heat shrink connector. CAUTION: Do NOT damage any surrounding wiring. Using a hot air gun, heat the internal solder joint and the heat shrink sleeving. Insulate the repair area using tape (see Parts Required). 5. Partially remove the insulation and locate the CAN bus wiring harness splice on the left-hand side. Remove the tape and cut off any damaged part of the splice.

6 6 of 11 21/03/ :49 6. NOTE: Use solder/heat shrink connector end-to-end Ø max. 3.3 mm only (see General equipment / material). To prevent further damage, the solder/heat shrink connector should be installed on ALL located CAN bus wiring harness splices. Repair the CAN bus wiring harness splice. If required remove the insulation at the cable ends. Insert the twisted ends of the wires into the solder/heat shrink connector. CAUTION: Do NOT damage any surrounding wiring. Using a hot air gun, heat the internal solder joint and the heat shrink sleeving. Insulate the repair area using tape (see Parts Required). 7. Verify the customers concern. Start the engine and switch on various consumer loads (Air conditioning system; Audio unit; Heated front windshield; etc.) Switch off the engine and check for stored DTCs. If various DTCs (Lost Communication) are stored, go to <Instrument panel CAN Bus wiring harness splice - Repair>. If no DTCs are stored, no further action is required.

7 7 of 11 21/03/ :49 If other DTCs are stored, perform opportune analysis. Instrument panel CAN Bus wiring harness splice - Repair All vehicles NOTE: LHD vehicle shown, RHD vehicles similar. NOTE: Depending on the model the CAN Bus wiring harness splice could be located in the area of the floor console or behind the audio unit. 1. Remove the floor console. For additional information, refer to Mondeo Workshop Manual Section Partially disconnect several electrical connectors and detach the wiring harness. 3. Remove the audio unit. For additional information, refer to Mondeo ; S-MAX/Galaxy Workshop Manual Section Remove the ashtray. 5. NOTE: Vehicles with electronic automatic temperature control (EATC). Remove the audio unit support bracket.

8 8 of 11 21/03/ :49 6. NOTE: Vehicles with manual temperature control. Remove the audio unit support bracket. Mondeo only 7. NOTE: To get access to the CAN bus wiring harness splice, partially disconnect several electrical connectors and detach the wiring harness. Partially remove the insulation and locate the CAN bus wiring harness splice. 1. CAN bus wiring harness splice isolated by special heat shrink tubing. 2. Damaged CAN bus wiring harness splice. Remove the insulation at the cable ends.

9 9 of 11 21/03/ :49 8. NOTE: Use solder/heat shrink connector Ø max. 2.7 mm only (see General equipment / material). To prevent further damage, the solder/heat shrink connector should be installed on ALL located CAN bus wiring harness splices. Repair the CAN bus wiring harness splice. 1. CAN bus wiring harness splice isolated by special heat shrink tubing. Insert the twisted ends of the wires into the solder/heat shrink connector. CAUTION: Do NOT damage any surrounding wiring. 2. Using a hot air gun, heat the internal solder joint and the heat shrink sleeving. Insulate the repair area using tape (see Parts Required). Repeat the step for the remaining CAN bus wiring harness splice. S-MAX/Galaxy only 9. NOTE: To get access to the CAN bus wiring harness splice, partially disconnect several electrical connectors and detach the wiring harness. Partially remove the insulation and locate the CAN bus wiring harness splice. CAN bus wiring harness splice. Remove the insulation at the cable ends.

10 10 of 11 21/03/ : NOTE: Use solder/heat shrink connector end-to-end Ø max. 3.3 mm only (see General equipment / material). To prevent further damage, the solder/heat shrink connector should be installed on ALL located CAN bus wiring harness splices. Repair the CAN bus wiring harness splice. 1. Second CAN bus wiring harness splice. Insert the twisted ends of the wires into the solder/heat shrink connector. CAUTION: Do NOT damage any surrounding wiring. 2. Using a hot air gun, heat the internal solder joint and the heat shrink sleeving. Insulate the repair area using tape (see Parts Required). Repeat the step for the remaining CAN bus wiring harness splice. 11. Install all components in reverse order. 12. Clear any stored DTCs. All vehicles

11 11 of 11 21/03/ : Disconnect IDS standard portable diagnostic unit.

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