So I have started one
It may prove usefull
5/6/03 Occasional failure or erratic operation of the windshield wipers
Windshield wipers occasionally operate erratically or not at all, the probable cause is electrical or mechanical damage at the park position inside the windshield wiper motor. To rectify this concern, install a revised windshield wiper motor and adjust the position of the windshield wiper arms.
3/26/03 Wind noise from the sliding door, water entering over the sliding door seal, adjustment of the gaps at the sliding door
Wind noise from the sliding door and/or water entering over the sliding door seal, the probable cause is incorrect adjustment of the sliding door. Adjusting the gaps and also the distance the door stands proud / is inset at the top and bottom.
2/12/10 Accessory drive belt noise, failure of the charging system; Flat battery
Accessory drive belt noise, failure of the charging system or a flat battery the probable cause is an generator decoupler shaft failure.
To rectify this concern, the generator decoupler shaft should be renewed. It is NOT required to install a new generator.
If the generator decoupler shaft is not cause of this concern, refer to the diagnostic and testing
8/26/11 Grinding noise from the front end during straight-ahead driving and when cornering; Installation of a new halfshaft bearing
Grinding noise from the front end during straight-ahead driving and when cornering, the probable cause is a defective halfshaft bearing.
To rectify this concern, the intermediate shaft should be removed and a new halfshaft bearing and halfshaft bearing retainer installed.
When holding the halfshaft bearing retainer and rotating the bearing, a rough feel should clearly be felt. With the vehicle raised, turn the halfshaft via the wheel and listen for grinding noise or rough running of the halfshaft bearing for this purpose.
7/8/05 Grinding noise from the front end during straight-ahead driving and when cornering; Installation of a new halfshaft bearing
Grinding noise from the front end during straight-ahead driving and when cornering, the probable cause is a defective intermediate shaft center bearing. To rectify this concern, the intermediate shaft must be removed and a new intermediate shaft center bearing and center bearing retainer must be installed.
When holding the intermediate shaft center bearing retainer and rotating the bearing, a rough feel should clearly be felt. With the vehicle raised, turn the halfshaft via the wheel and listen for grinding noise or rough running of the intermediate shaft center bearing for this purpose.
11/30/05 Transmission noise or knocking, scratching noise from behind the engine rear mount
Transmission noise or knocking, scratching noise (knocking, scratching noise from behind the engine rear mount, occurs especially with the engine at operation temperature after abrupt gear changes, acceleration in 2nd gear or during rapid acceleration in 1st or reverse gear), the probable cause is an insufficient clamping force of the engine support insulator to subframe bolt owing to tolerances being exceeded. Failure of the rubber insulator will allow the normal acceptable Noise, Vibration and Harshness (NVH) levels to be transmitted to the subframe and body structure. The noise cannot be reproduced with the vehicle stationary or when raised on a vehicle lift. Please make sure the engine support insulator is inspected before any parts are renewed.
To rectify this concern, the engine support insulator has to be removed, inspected and if there are witness marks on the isolator due to contact a new engine support insulator and a new engine support insulator to subframe bolt should be installed. If there are no marks indicating contact, install the original engine support insulator and continue the diagnosis.
11/30/09 Waterleaks at the upper windshield
Waterleaks from the upper windshield area with heated windshield, one probable cause is insufficient application of windshield adhesive during production.
To rectify this concern, windshield adhesive should be applied into the gap at the windshield. It is NOT required to install a new windshield.
To enable a smooth adhesive application the grey flat nozzle needs to be reworked.
9/3/09 Inoperative or unintended blower motor operation
Blower motor is inoperative or operates independently of the position of the blower speed control switch, the probable cause is contact between the blower speed control switch wiring and the instrument panel bracket. This may affect one or more of the single wires causing the blower motor to not operate properly.
To rectify this concern, the damaged single wires should be repaired, re-routed and fixed with a cable tie ensuring sufficient distance away from the instrument panel bracket.
3/25/09 Growl noise and excessive vibration in the passenger compartment, clearly noticeable between 2600 and 3000 rpm
Growling noises and excessive vibration in passenger compartment, clearly noticeable between 2600 and 3000 rpm, the probable cause is the engine vibration being transmitted into the vehicle body through low pressure side rubber refrigerant hose (between the A/C compressor and A/C accumulator).
To rectify the concern, a damper mass should be attached onto the refrigerant hose specified location
7/4/07 Sliding door lock cannot be locked or unlocked via the central locking
Sliding door lock cannot be locked or unlocked using the central locking (with the vehicle key or with the remote control), the probable cause is a damaged sliding door lock assembly or poor sliding door alignment. To rectify the concern, the central locking and the door ajar switch should be checked and, if necessary, door alignment should be corrected or a new sliding door lock assembly and a new wiring harness to the actuator motor should be installed.
10/18/04 The sliding door lock cannot be locked or unlocked via the central locking
Sliding door lock cannot be locked or unlocked using the central locking (with the vehicle key or with the remote control), the probable cause is a damaged sliding door lock assembly or poor sliding door alignment. To rectify the concern, the central locking and the door ajar switch should be checked and, if necessary, door alignment should be corrected or a new sliding door lock assembly and a new wiring harness to the actuator motor should be installed
7/2/07 Rear doors cannot be locked or unlocked via the central locking; Rear door lock is inoperative and/or mechanism is seized
Rear doors cannot be locked or unlocked via the central locking or the rear cargo door lock is inoperative and/or mechanism is seized, the probable cause is a bent release lever or jammed door handle reinforcement.
6/29/07 Engine does not start; Starter motor does not crank
Engine does not start or the starter motor does not crank, the probable cause is a damaged circuit wire on 14K733 wiring harness under certain circumstances in the vicinity of connector C120 attached to battery tray.
To rectify this concern, the affected wiring harness has to be checked and a damaged wiring/insulation has to be repaired as required. To prevent further touch condition the installation position of connector C120 has to be attached to the battery tray using a cable tie.
6/5/09 No Start, poor driveability, black smoke and high fuel consumption
No start, poor driveability, black smoke, high fuel consumption, and other potential root causes have been eliminated (fuel quality, Exhaust Gas Recirculation (EGR), fuel line blockages, etc), the injectors may need to be investigated.
9/1/05 Engine undershooting to a stop, lack of power resulting in reduced top speed, hesitation or failure to start
Engine undershooting to a stop, lack of power resulting in reduced top speed or failure to start, one of the the probable causes is cam plate failure in the Bosch VP30 fuel injection pump, caused by contamination of the fuel system. To rectify this concern, a new fuel injection pump, fuel injectors and high pressure fuel supply lines should be installed, the fuel system thoroughly cleaned and a fuel additive should be used.
Failures will occur due to: Water in fuel. The capacity of the water trap in the fuel filter is around 100ml. Should a poor fuel quality supply be used or service intervals missed, the water trap will become inadequate. The water in the fuel will cause corrosion inside the fuel injection pump and lack of lubrication, which will lead to damage of the highly loaded cam plate and cam plate rollers. Petrol in the fuel. The cam plate and cam plate rollers being the highest loaded components in the fuel system need good lubrication, hence if petrol is in the fuel, wear of all components needing lubrication will occur. Failure of the cam plate can also lead to failure of the fuel injection pump front seal. This will allow diesel fuel to enter the sump and potentially cause catastrophic engine damage.
4/26/07 Oil leakage from the clutch master cylinder; Clutch does not function when clutch pedal is depressed or clutch pedal stays depressed when clutch pedal is released
Oil leakage to the driver footwell and that the clutch does not function when clutch pedal is depressed or the clutch pedal stays depressed when the clutch pedal is released, the probable cause is the clutch master cylinder piston surface being damaged due to the dust and dirt ingress.
To rectify this concern, a new clutch master cylinder and a rubber protective boot should be installed to prevent dust and dirt ingress.
1/31/07 Brakes binding when the brake pedal is not being depressed
Slight braking is occurring when the brake pedal is not being depressed and/or rattling noise from the brake pedal bracket is occurring when the brake pedal is being depressed, the probable cause is incorrect position of the retractor mechanism. Misalignment of the retractor mechanism hole and the body aperture causes the brake pedal to bind. To rectify this concern, the brake pedal retractor should be removed and the hole in the retractor mechanism reworked to a larger diameter leaving no less than 3 mm of material. a squeak or rattling noise is occurring from the brake pedal box when the clutch pedal is depressed or during cornering when the clutch pedal is not depressed, the probable cause is the clutch pedal return spring retainer being fractured. To rectify this concern, a new clutch pedal return spring and retainer should be installed.
4/22/03 Brakes binding
Slight braking is occurring when the brake pedal is not being depressed, the probable cause is incorrect position of the retractor mechanism. Misalignment of the retractor mechanism hole and the body aperture causes the brake pedal to bind. To rectify this concern, the retractor mechanism should be removed and the hole in the retractor mechanism reworked to a larger diameter leaving no less than 3 mm of material.
10/2/06 Noises and/or vibration from the front suspension
Noises and/or vibration coming from the front suspension the probable causes are
cupping on tires, halfshaft problems, front wheel bearings and wheel hub retaining nut failures.
4/22/03 Knocking noise from the rear under braking
Knocking noise coming from the rear under braking, the probable cause is a tolerance mismatch between the wheel spindle and the back plate. To rectify this concern, the wheel spindle should be reworked by chamfering the sides.
6/11/07 Knocking noise from the rear when braking
Knocking noise coming from the rear when braking, the probable cause is a tolerance mismatch between the wheel spindle and the brake back plate. To rectify this concern, for vehicles built up to 20.04.2007 first drive the vehicle at maximum 15 mph in first gear for 250 meters with handbrake applied 3 notches, wait for 15 minutes and carry out a road test to verify. If the concern still exists, then interchange the left hand and right hand brake drum and perform parking brake cable adjustment and carry out a road test to verify. If the concern still exists, then rework the wheel spindle by chamfering the sides and install new brake back plates. Perform parking brake cable adjustment again and carry out a road test to verify.
For vehicles built after 20.04.2007, first drive the vehicle at maximum 15 mph (20km/h) for 50 meters forward direction with handbrake applied in 3 notches and before releasing the handbrake lever, drive backwards under the same condition. Wait for 15 minutes and carry out a road test to verify.
9/6/07 Condensation dripping into the front footwell
Dampness in the front footwell the probable cause is incorrect manufacturing tolerances in the joints of the climate control housing components. This allows condensation to escape from the bottom corner of the climate control housing when the air conditioning (A/C) is operating.
To rectify this concern the climate control housing should be removed and sealing strip applied to the gaps in the climate control housing joint area.
Before carrying out the procedure detailed in this bulletin eliminate all other possible causes for water entry into the front footwell (e.g. water entry after passing through a car wash, during very heavy rain or because of a blocked A/C overflow hose on the bulkhead in the engine compartment). Additionally the A/C system should be tested.
9/14/07 Water ingress in the front footwell/interior and in the loadspace
Isolated instances of the following causes of possible water ingress points in the front footwell/interior have been identified:
A. Water ingress via the drain bore in the water trap or via the windshield (left-hand vehicle side):
Cause: Insufficient or intermittent sealer applied in production between the fender apron panel outer reinforcement and the A-pillar/water trap may lead to water entering into the front footwell. To rectify: Seal the affected areas with sealer. Installing a new windshield and a new windshield glass weatherstrip is not necessary. Cause: Water may enter into the front footwell between the windshield and the windshield frame because of insufficient or intermittent sealer applied in production. To rectify: Seal the affected areas with sealer. B. Water ingress via the fender apron panel outer reinforcement (right-hand vehicle side):
Cause: Water can enter the front footwell between the fender apron panel outer reinforcement and the grommet because of insufficient or intermittent sealer applied in production. To rectify: Seal the affected areas with sealer. C. Water ingress via the pollen filter housing:
Cause: Water can enter the front footwell via an excessively large gap between the pollen filter housing and the cowl panel grille as well as certain body joints. To rectify: Seal the affected areas with sealer. D. Water ingress via the liftgate/rear door weatherstrips:
Cause: The adjustment of the right-hand door check arm, a hardened blanking plug on the D-pillar, an incomplete seal at the liftgate hinges or an inadequately-installed door weatherstrip can result in water ingress in the rear section of the loadspace. To rectify: Adjust the door stop, install a new cover plug, correct the position of the rubber seal on the rear door. E. Water ingress via the C-pillar in the area of the sliding door:
Cause: Water can enter the interior between individual body parts of the sliding door guide because of insufficient or intermittent sealer applied in production. To rectify: Seal the body parts of the sliding door guide from the interior using additional sealer. F. Water ingress via the roof rack blanking plugs and the ventilation flaps:
Cause: Water can enter the interior via a deformed blanking plug bore, missing or damaged roof rack blanking plug seals or via the ventilation flaps in the rear section of the vehicle roof. To rectify: Remove the blanking plugs and install new roof rack blanking plug seals. Install new ventilation flaps. G. Water ingress via the sliding door:
Cause: Water can enter the interior via a damaged watershield and an inadequate seal at the upper sliding door guide. To rectify: Install a new watershield and seal the upper sliding door guide with additional sealer. H. Water ingress via the rear side windows:
Cause: Water can enter the interior via an incorrectly-installed rear quarter window glass weatherstrip. To rectify: Correct the installation position of the rear quarter window glass weatherstrip and seal with additional sealer. I. Water ingress via the rear door central high mounted stoplamp:
Cause: The stoplamp opening on the rear cargo door outer sheet metal is out of tolerances causing insufficient seal area.
8/8/06 Increased coolant temperature and oil residue in the cooling system in combination with leaks in the engine oil cooler
Increased coolant temperature leaks at the engine oil cooler oil residue in the cooling system coolant expansion tank the probable cause is an internal leak in the engine oil cooler.
To rectify the leaks at the engine oil cooler a modified oil cooler and oil filter housing should be installed.
To rectify the oil residues in the cooling system, the cooling system should be drained, the coolant thermostat should be removed, the cooling system should be flushed and new coolant hoses and coolant expansion tank installed.
3/27/06 Replacement of the accessory drive belt tensioner bracket or the idler pulley
Because of damage to the threaded hole during the re-tightening process, the pulley located on the tensioner bracket (Part Number: F1351134) should NOT be removed. The pulley is NOT a serviceable part and does not have a part number.
The accessory drive belt pulley retaining bolt must NOT be unscrewed/re-tightened. The tensioner bracket MUST be replaced as a COMPLETE unit. Because of damage to the threaded hole during the re-tightening process, the retaining bolt may become loose and cause total loss of the Accessory Drive hence the tensioner bracket MUST be replaced as a COMPLETE unit. Removing and installing the pulley may cause damage resulting in failure.
1/30/06 Anti-lock braking system (ABS) warning lamp illuminating in the instrument cluster
ABS warning lamp is illuminating on the instrument cluster, the probable cause is a touch condition between the ABS module wiring and the transmission shifter mass, resulting in a damaged ABS module wiring. To rectify this concern, the ABS module wiring has to be checked and a damaged wiring/insulation has to be repaired as required. To prevent further touch condition the ABS module wiring has to be attached to the brake tube using two cable ties, creating a minimum clearance of 20 mm between the ABS module wiring and the transmission shifter mass (reverse gear engaged).
1/16/06 Poor gear shiftability, difficult changing gear or transmission jumping out of gear
Difficulties in changing gear or a transmission jumping out of gear, the probable cause is contact between the power steering hoses and the transmission external controls. The power steering lines are loose/saggy and stick with the transmission shifter mechanism.
Before performing any repair work on the inner selector mechanism or the gear shift cables and before the adjustment of the gearshift cables is checked, the routing of the power steering lines has to be changed.
10/13/05 Unable to engage gear, disengaged gearshift cable from the shift lever
Unable to engage a gear, the probable cause is a disengaged gearshift cable. To rectify this concern, a new gearshift cable retainer and a new spring must be installed.
11/4/05 Noise from the fuel tank area and damaged fuel tank support straps
Excessive noise from the fuel tank area issue with possible damage to the fuel tank support strap, the probable cause is insufficient grip of the fuel tank straps, creating a clearance between fuel tank and vehicle body.
To rectify this concern, new fuel tank noise, vibration and harshness (NVH) pads and/or new fuel tank support strap should be installed.
4/21/05 Speedometer fluctuating; engine difficult to start; loss of power; radio losing volume
Following concerns: Speedometer fluctuating Engine difficult to start or running rough Loss of power when descending long inclines, clutch is depressed or under braking Radio losing volume the probable cause is the powertrain control module (PCM) error detection system incorrectly diagnosing the vehicle speed sensor (VSS) signal. This leads to the vehicle displaying a diagnostic trouble code (DTC) showing the VSS as defective. To rectify this concern, the VSS should be correctly diagnosed as defective prior to installing a new one.
8/17/05 Poor power; delayed accelerator response and/or rough idle, engine hard or impossible to start
Poor performance Delayed throttle response Rough idle or hard to start and WDS checks reveal that either diagnostic trouble code (DTC) P0340 or P0335 is set, the probable root cause is a loss of signal from the CMP sensor. To rectify the concern, a new CMP sensor and electrical connector should be installed as required.
Due to various changes to the CMP sub-system throughout the listed products program cycles, it is necessary to make sure that the wiring loom side electrical connector is compatible with the CMP sensor in the event of a new CMP sensor being installed.
3/9/10 Delayed reaction of fuel gauge on the instrument cluster after fuel tank refilling
fuel gauge is delaying to respond after fuel refillling, the probable cause is a software failure of the instrument cluster.
To rectify this concern, the instrument cluster should be reprogrammed with updated software.
3/11/11 Water ingress into the interior; Windnoise from the front door; Upper front door weatherstrip loose or comes adrift on the A-pillar sheet metal
Water ingress into the interior, windnoise from the front door or that the upper front door weatherstrip becomes loose or comes adrift on the A-pillar sheet metal, the probable cause is poor installation of the weatherstrip in conjunction with minor adhesion of the adhesive strip.
To rectify this concern, the affected upper front door weatherstrip should be renewed. To improve the adhesion primer should be applied to the installation area.
4/3/03 Production changeover from tin plated to gold plated connector pins on the fuel temperature sensor on the high pressure pump; installing a new high pressure pump
Since 24.10.2002 there has been a change in production from tin plated to gold plated connector pins on the fuel temperature sensor on the high pressure pump for Focus and Transit Connect with 1.8L DuraTorq-TDCi engine (90/100/115PS), with common rail fuel injection system.
Since 24.10.2002 only the high pressure pump together with a partial wiring harness with gold plated connector pins has been installed. Making a connection between tin plated connector pins and gold plated pins in the wiring harness socket is NOT permitted.
If a new high pressure pump or partial wiring harness of the high pressure pump must be installed, make sure that both components either have only tin plated or only gold plated connector pins.
The high pressure pumps can be identified by the colour of the fuel temperature sensor.Fuel temperature sensor (green) - tin plated connector pinsFuel temperature sensor (blue) - gold plated connector pins.
