Car stall, jerks and shuts off with A/C on even at full tank

Tiny
ZARA PAWS
  • MEMBER
  • 2005 FORD FOCUS
  • 2.0L
  • 4 CYL
  • 2WD
  • MANUAL
  • 160,000 MILES
Hi, my car (hatchback) developed a stalling, jerking and sudden stop problem after installation of a catalytic converter and for five months running. I have changed the spark plugs, ignition coil, fuel relay, used nine fuel pumps, changed slow jet, changed air collector, used two fuel pump casings, inner and outer fuel filters and changed the brain box all to no avail. I have also washed my fuel tank from clogs. Diagnosis displayed error codes PO230, P1100 and P720. Please, what could be the possible element that reduces voltage to the pump thereby overheating it twenty to thirty minutes after working or when the A/C is turned on?
I took voltage readings for the battery, relay, inertia switch, alternator and fuel pump. When engine is idle, battery-12.48 volts and cranking-13.5 volts. When engine is idle, alternator-12.49 volts and cranking-13.77 volts. When engine is cranking, Inertia feed cable before switch-12.92 volts and after switch-12.84 volts. When engine is cranking, fuel pump-12.6 volts and during the stalling, jerking and sudden shut off situation, fuel pump-11.6 volts. The problem is intermittent. It occurs at odd times. Sometimes twenty times in a day, sometimes twice, three times, forty times, but it sure occurs. One cannot predict especially when the A/C is turned on. What are your thoughts on this please?
Friday, December 28th, 2018 AT 6:20 AM

2 Replies

Tiny
KEN L
  • MASTER CERTIFIED MECHANIC
  • 47,643 POSTS
The P0230 is telling us you have a fuel pump circuit issue. Here is the fuel pump and engine wiring diagrams and a guide to help you test the wires to see if there is high resistance or an open circuit. If you have not replaced the fuel pump relay I would start there.

https://www.2carpros.com/articles/how-to-check-an-electrical-relay-and-wiring-control-circuit

Check out the diagrams (below). Please let us know what you find.
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Sunday, December 30th, 2018 AT 12:15 PM
Tiny
BMDOUBLE
  • MECHANIC
  • 1,139 POSTS
These cars are notorious for having battery cable issues, and will set transmission codes as a result. Look at the cables at the battery terminals and see if the insulation is partially melted and also feel them while the engine is running with all of the accessories and headlights on, chances are they are going to be too hot to hold! If they are replace them. Fuel pumps were also no good in these cars.
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Sunday, December 30th, 2018 AT 10:06 PM

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