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General Procedures > < Fuel System

Focus 1999 (08.1998-12.2004)

Fuel System - General Information - Fuel System Focus 1999 (08/1998-12/2004)
Diagnosis and Testing

Special Tool(s)

Hand Vacuum/Pressure Pump

416-D001 (23-036A)

Inspection and Verification

  1. Verify the customer concern.
  1. Visually inspect for obvious signs of mechanical or electrical damage.

Visual Inspection Chart

Mechanical Electrical
  • Fuel level
  • Fuel filter
  • Fuel tank
  • Fuel line(s)
  • Fuel connector(s)
  • Fuel filler cap
  • Fuel tank filler pipe
  • Gasket(s)
  • Seal(s)
  • Inertia fuel shutoff switch (IFS)
  • Electrical connector(s)
  • Wiring harness
  1. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
  1. If the cause is not visually evident, verify the symptom and refer to WDS to diagnose the system (all except vehicles with diesel engine).
  1. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart (vehicles with diesel engine).

Symptom Chart

Symptom Chart

Symptom Possible Sources Action
Engine cranks but does not start
*
Fuel charging and controls.
*
REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls / 303-04D Fuel Charging and Controls - Turbocharger / 303-04E Fuel Charging and Controls / 303-04F Fuel Charging and Controls / 303-04K Fuel Charging and Controls / 303-04M Fuel Charging and Controls. – Vehicles with 75 PS or 90 PS diesel engine
*
REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls / 303-04D Fuel Charging and Controls - Turbocharger / 303-04E Fuel Charging and Controls / 303-04F Fuel Charging and Controls / 303-04K Fuel Charging and Controls / 303-04M Fuel Charging and Controls. – Vehicles with 115 PS diesel engine
*
Air ingress into the fuel lines.
*
GO to Pinpoint Test ??. – Vehicles with 75 PS or 90 PS diesel engine.
*
GO to Pinpoint Test ??. – Vehicles with 115 PS diesel engine.
Poor starting
*
Fuel charging and controls.
*
REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls / 303-04D Fuel Charging and Controls - Turbocharger / 303-04E Fuel Charging and Controls / 303-04F Fuel Charging and Controls / 303-04K Fuel Charging and Controls / 303-04M Fuel Charging and Controls. – Vehicles with 75 PS or 90 PS diesel engine
*
REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls / 303-04D Fuel Charging and Controls - Turbocharger / 303-04E Fuel Charging and Controls / 303-04F Fuel Charging and Controls / 303-04K Fuel Charging and Controls / 303-04M Fuel Charging and Controls. – Vehicles with 115 PS diesel engine
*
Air ingress into the fuel lines.
*
GO to Pinpoint Test ??. – Vehicles with 75 PS or 90 PS diesel engine.
*
GO to Pinpoint Test ??. – Vehicles with 115 PS diesel engine.
Engine starts but immediately stops
*
Fuel charging and controls.
*
REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls / 303-04D Fuel Charging and Controls - Turbocharger / 303-04E Fuel Charging and Controls / 303-04F Fuel Charging and Controls / 303-04K Fuel Charging and Controls / 303-04M Fuel Charging and Controls. – Vehicles with 75 PS or 90 PS diesel engine
*
REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls / 303-04D Fuel Charging and Controls - Turbocharger / 303-04E Fuel Charging and Controls / 303-04F Fuel Charging and Controls / 303-04K Fuel Charging and Controls / 303-04M Fuel Charging and Controls. – Vehicles with 115 PS diesel engine
*
Air ingress into the fuel lines.
*
GO to Pinpoint Test ??. – Vehicles with 75 PS or 90 PS diesel engine.
*
GO to Pinpoint Test ??. – Vehicles with 115 PS diesel engine.
Poor idling
*
Fuel charging and controls.
*
REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls / 303-04D Fuel Charging and Controls - Turbocharger / 303-04E Fuel Charging and Controls / 303-04F Fuel Charging and Controls / 303-04K Fuel Charging and Controls / 303-04M Fuel Charging and Controls. – Vehicles with 75 PS or 90 PS diesel engine
*
REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls / 303-04D Fuel Charging and Controls - Turbocharger / 303-04E Fuel Charging and Controls / 303-04F Fuel Charging and Controls / 303-04K Fuel Charging and Controls / 303-04M Fuel Charging and Controls. – Vehicles with 115 PS diesel engine
*
Air ingress into the fuel lines.
*
GO to Pinpoint Test ??. – Vehicles with 75 PS or 90 PS diesel engine.
*
GO to Pinpoint Test ??. – Vehicles with 115 PS diesel engine.
Engine lacks power
*
Fuel charging and controls.
*
REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls / 303-04D Fuel Charging and Controls - Turbocharger / 303-04E Fuel Charging and Controls / 303-04F Fuel Charging and Controls / 303-04K Fuel Charging and Controls / 303-04M Fuel Charging and Controls. – Vehicles with 75 PS or 90 PS diesel engine
*
REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls / 303-04D Fuel Charging and Controls - Turbocharger / 303-04E Fuel Charging and Controls / 303-04F Fuel Charging and Controls / 303-04K Fuel Charging and Controls / 303-04M Fuel Charging and Controls. – Vehicles with 115 PS diesel engine
*
Air ingress into the fuel lines.
*
GO to Pinpoint Test ??. – Vehicles with 75 PS or 90 PS diesel engine.
*
GO to Pinpoint Test ??. – Vehicles with 115 PS diesel engine.
Engine misfire
*
Fuel charging and controls.
*
REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls / 303-04D Fuel Charging and Controls - Turbocharger / 303-04E Fuel Charging and Controls / 303-04F Fuel Charging and Controls / 303-04K Fuel Charging and Controls / 303-04M Fuel Charging and Controls. – Vehicles with 75 PS or 90 PS diesel engine
*
REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls / 303-04D Fuel Charging and Controls - Turbocharger / 303-04E Fuel Charging and Controls / 303-04F Fuel Charging and Controls / 303-04K Fuel Charging and Controls / 303-04M Fuel Charging and Controls. – Vehicles with 115 PS diesel engine
*
Air ingress into the fuel lines.
*
GO to Pinpoint Test ??. – Vehicles with 75 PS or 90 PS diesel engine.
*
GO to Pinpoint Test ??. – Vehicles with 115 PS diesel engine.
Excessive fuel consumption
*
Fuel charging and controls.
*
REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls / 303-04D Fuel Charging and Controls - Turbocharger / 303-04E Fuel Charging and Controls / 303-04F Fuel Charging and Controls / 303-04K Fuel Charging and Controls / 303-04M Fuel Charging and Controls. – Vehicles with 75 PS or 90 PS diesel engine
*
REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls / 303-04D Fuel Charging and Controls - Turbocharger / 303-04E Fuel Charging and Controls / 303-04F Fuel Charging and Controls / 303-04K Fuel Charging and Controls / 303-04M Fuel Charging and Controls. – Vehicles with 115 PS diesel engine
*
Air ingress into the fuel lines.
*
GO to Pinpoint Test ??. – Vehicles with 75 PS or 90 PS diesel engine.
*
GO to Pinpoint Test ??. – Vehicles with 115 PS diesel engine.

Pinpoint Tests

PINPOINT TEST A : AIR INGRESS INTO THE FUEL LINES – VEHICLES WITH 75 PS OR 90 PS DIESEL ENGINE
WARNING:
WARNING:Do not smoke or carry lighted tobacco of any type when working on or near any fuel related components. Highly flammable mixtures are always present and may ignite. Failure to follow these instructions may result in personal injury.
WARNING:
WARNING:This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow these instructions may result in personal injury.
CAUTION:
CAUTION:The generator must be protected from contamination. Failure to follow this instruction may cause premature failure of the generator.
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
A1: INSPECT THE VALVE FOR LEAKAGE
1
Protect the generator with lint-free material to prevent contamination.

2
Inspect the valve in the fuel filter to fuel injection pump fuel supply line for signs of diesel leakage. If the valve base is wet this indicates O-ring seal damage.

Is the valve leaking fuel?
Yes
INSTALL a new fuel filter to fuel injection pump fuel supply line. Make sure the fuel filter to fuel injection pump fuel supply line valve is in the closed position (fully screwed in). TEST the system for normal operation.
No
GO to A2. .
A2: INSPECT THE FUEL FILTER RETURN LINE FOR LEAKAGE
1
Disconnect the fuel injection pump to fuel filter fuel return line from the fuel filter.

2
Inspect the fuel injection pump to fuel filter fuel return line on the fuel filter.

Are the O-ring seals or fuel return line damaged?
Yes
INSTALL a new fuel injection pump to fuel filter fuel return line. TEST the system for normal operation.
No
GO to A3. .
A3: CHECK WHERE AIR IS ENTERING THE SYSTEM
1
Protect the generator with lint-free material to prevent contamination.
2
Using a suitable piece of clear plastic pipe, manufacture a pipe that may be installed between the fuel injection pump and the fuel injection pump to fuel filter fuel return line.
3
Install the clear plastic pipe between the fuel injection pump and the fuel injection pump to fuel filter fuel return line.
4
Start the engine, wait a few minutes and then visually observe the clear plastic pipe for signs of air ingress.
5
Using a suitable clean engine oil, apply the oil to each of the fuel supply line and fuel return line connections, unions and joints in turn and observe the clear plastic pipe for visible signs of air after each oil application.

Did the amount of air in the clear plastic pipe decrease when any of the connectors, unions or joints were oiled?
Yes
INSTALL a new fuel line(s) in question. TEST the system for normal operation.
No
GO to A4. .
A4: CHECK FOR AIR INGRESS INTO FUEL SYSTEM
1
Protect the generator with lint-free material to prevent contamination.
2
Drain the fuel tank.
3
Fill the fuel tank with 10 liters of diesel.
4
Disconnect the fuel tank to fuel filter fuel supply line from the bulkhead connection.
5
Remove the fuel tank to fuel filter fuel supply line from the fuel filter.
6
Using a suitable piece of clear plastic pipe, manufacture and install a pipe between the fuel filter and the fuel tank to fuel filter bulkhead connection.
7
Remove the clear plastic pipe from between the fuel injection pump and the fuel injection pump to fuel filter fuel return line.

8
Using the special tool, prime the fuel pump until clear air-free fuel is seen entering the vacuum pump reservoir.
9
Remove the special tool and connect the fuel injection pump to fuel filter fuel return line.
10
Start the engine, wait a few minutes to clear remaining air from the fuel system. A small amount of air ingress into the fuel system is acceptable, however a continuous stream of air in the fuel system is not acceptable.
11
Leave the vehicle to stand overnight.

Are any signs of air present in the clear plastic pipe?
Yes
INSPECT the fuel tank level sensor and fuel tank connections for damage or leakage. INSTALL new parts as necessary.
No
INSTALL a new fuel filter. REFER to Section  310-01A Fuel Tank and Lines / 310-01B Fuel Tank and Lines / 310-01C Fuel Tank and Lines.

PINPOINT TEST B : AIR INGRESS INTO THE FUEL LINES – VEHICLES WITH 115 PS DIESEL ENGINE
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
B1: CHECK FOR AIR INGRESS INTO THE FUEL SYSTEM
WARNING:
WARNING:Do not smoke or carry lighted tobacco of any type when working on or near any fuel related components. Highly flammable mixtures are always present and may ignite. Failure to follow these instructions may result in personal injury.
WARNING:
WARNING:This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow this instruction may result in personal injury.
CAUTION:
CAUTION:The generator must be protected from contamination. Failure to follow this instruction may cause premature failure of the generator.
1
Protect the generator with lint-free material to prevent contamination.
2
Using a suitable piece of clear plastic pipe, manufacture a pipe that may be installed between the fuel pump and the fuel pump to fuel filter fuel return line.
3
Install the clear plastic pipe between the fuel pump and the fuel pump to fuel filter fuel return line.
4
Start the engine, wait a few minutes and then visually observe the clear plastic pipe for signs of air ingress.

Are any signs of air present in the clear plastic pipe?
Yes
GO to B2.
No
REMOVE the clear plastic pipe and CONNECT the fuel pump to fuel filter fuel return line. For additional diagnostics for Fuel Charging and Controls REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls / 303-04D Fuel Charging and Controls - Turbocharger / 303-04E Fuel Charging and Controls / 303-04F Fuel Charging and Controls / 303-04K Fuel Charging and Controls / 303-04M Fuel Charging and Controls.
B2: CHECK WHERE AIR IS ENTERING THE SYSTEM
1
Using suitable clean engine oil, apply the oil to each of the fuel supply line and fuel return line connections, unions and joints in turn and observe the clear plastic pipe for visible signs of air after each oil application.

Did the amount of air in the clear plastic pipe decrease when any of the connectors, unions or joints were oiled?
Yes
INSTALL a new fuel line(s) in question. Test the system for normal operation.
No
INSTALL a new fuel filter. REFER to Section  310-01A Fuel Tank and Lines / 310-01B Fuel Tank and Lines / 310-01C Fuel Tank and Lines.

General Procedures > < Fuel System