Ford Mondeo and Kuga diesel engines won’t start due to faulty engine ECU

Mondeo and Kuga ECU fault

This engine ECU fitted to Ford Mondeo (Mk IV) and Ford Kuga (Mk II) diesel engines is a common failing module that will prevent cranking and start of the engine. When the ECU completely fails you will find that the engine management system fails to achieve communications with your diagnostic equipment. Instead there will be loss of communication fault codes from other electronic modules on the vehicle.

Symptoms often begin intermittently with limp mode being activated, the vehicle cutting out and then being unable to restart. At this stage the Mondeo/Kuga ECU may store fault codes relating to sensor voltage references and ECM/PCM power relay de-energised performance. The message ‘Engine Malfunction’ may appear on the dash along with the illumination of the engine management warning light.

This ECU failure not only affects Ford Mondeo and Kuga diesel models but also: C-Max, Focus, Galaxy and S-Max.

As market leaders in remanufacture services, our in-house R&D team have identified that these Delphi DCM3.5 engine ECUs all suffer from manufacturing defects and have developed a solution to get you back on the road as quickly as possible. Before this solution was available main dealerships and specialists would purchase new from manufacturer. However, the defect has not yet been worked-out by the manufacturer, meaning that even new ECUs are predisposed to fail.

We can now rebuild your Ford Mondeo/Kuga diesel engine ECU within 3-5 working days and return it back to you without the need for programming at a fraction of the cost of new.


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Common Failure symptoms:

  • Will not crank
  • Not running / none start
  • No communication to ECU
  • Cutting out
  • Limp mode
  • Engine management light (EML) illuminated
  • ‘Engine Malfunction’ message on dash

(These fault symptoms can be intermittent or permanent)


Common fault codes:

  • U0100 – Lost Communication With PCM
  • U0401 – Invalid Data From PCM
  • P06A6 – Sensor Reference Voltage A Malfunction
  • P06A7 – Sensor Reference Voltage B Malfunction
  • P06A8 – Sensor Reference Voltage C Malfunction
  • P0606 – PCM Processor Fault
  • P060C – Internal Control Module Main Processor Performance
  • P0194 – Fuel Pressure Sensor Intermittent
  • P068A – ECM/PCM Power Relay De-Energised – Too Early


Affected Vehicles:

  • Mondeo (Mk IV) 2007-2015
  • Kuga (Mk II) 2010-2015
  • C-Max (Mk II) 2010-2015
  • Focus (Mk III) 2011-2015
  • Galaxy (Mk III) 2010-2015
  • S-Max (Facelift) 2010-2015

Click here for more information on Galaxy and S-Max or Focus and C-Max


(Can’t find your part number? Check our full engine ECU catalogue for Mondeo or Kuga)

Test and rebuild:

Using our bespoke HIL (Hardware In-the-Loop) test rigs each Mondeo/Kuga engine ECU is tested beyond operating parameters both before and after the rebuild. This ensures that the ECU will meet, and even exceed, OEM standards. Using components that are higher rated than standard, we know that a rebuilt ECU will outlast the vehicle.



This ECU is programmed to the vehicle, all coding information is retained during test and rebuild so that when you receive your ECU back from us, it’s just plug and play.



Franchise dealerships and specialists across the globe benefit from our services. Our work defect rate is lower than 0.49% on all rebuilds, because of this, and our strict quality control guidelines, we can confidently provide an unlimited mile Lifetime Warranty.



Lifetime unlimited mileage*


How do I get my unit rebuilt?

To pay for the rebuild select your part number above and then click: Get yours rebuilt

Print the payment/booking confirmation email.

Package the Mondeo/Kuga ECU inside a sturdy box with plenty of packaging material (make sure you include your confirmation email in the box).

Send us your package by tracked courier (the shipping instructions are on the confirmation email).

Once received we will test, rebuild and return your engine ECU with an unlimited mileage lifetime warranty. (if your unit turns out not to be faulty then we will refund your payment less a small testing fee and return shipping)


What if I don’t want to pay up front?

This is not a problem, if you prefer this option then follow the following steps:

Fill in and submit this test form.

Print the booking confirmation email.

Package the engine management ECU inside a sturdy box with plenty of packaging material (make sure you include your confirmation email in the box).

Send us your package by tracked courier (the shipping instructions are on the confirmation email).

Once received, we will test your Mondeo/Kuga ECU and call you to advise on the outcome of testing, if your ECU is faulty and you choose to go ahead with the rebuild then we will take payment over the phone using a debit/credit card.

We will then rebuild your engine ECU and return it to you with an unlimited mileage warranty.

If you require further information regarding this Ford Mondeo/Kuga engine ECU then please contact us.

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Comments on "Ford Mondeo and Kuga diesel engines won’t start due to faulty engine ECU"
robert baran says: 30/7/2020 6:10:51 PM
Hello, Smax 1.6 EcoBoost. Unable to start the engine. What's the cost of rebuilding ecu please ?
ECU Admin says: 31/7/2020 3:50:58 PM
Hi Robert, this is a very common failure for S-Max also. Please select your part number on the following page for prices and shipping information:
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