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General Procedures > < Fuel Charging and Controls

Fusion 2002.75 (06.2002-)

Fuel Charging and Controls - 1.4L Duratorq-TDCi (DV) Diesel - Fuel Charging and Controls Fusion 2002.75 (06/2002-)
Diagnosis and Testing

Inspection and Verification

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. Failure to follow this instruction may result in personal injury.
CAUTION:
CAUTION:Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances. The fuel injection pump is a fully electronic and has no linkages or cables. Do not grease any of the fuel injection pump terminals or connectors. It is therefore essential that absolute cleanliness is observed when working with these components. Always fit blanking plugs to any open orifices or lines.
NOTE:
NOTE:As well as carrying out its normal function the glow plug lamp also acts as an engine check lamp which will flash continuously when a hard diagnostic trouble code (DTC) is detected by the powertrain control module (PCM). Soft DTCs are also stored by the PCM but will only be known if the system is checked for DTCs using WDS.
NOTE:
NOTE:If a DTC is detected, all DTCs must be cleared after the cause is repaired. Failure to clear all DTCs may cause driveability concerns.
NOTE:
NOTE:If the fuel level in the fuel tank drops below approximately 4 liters, rough running will occur. This is to signal to the driver that the vehicle requires refuelling in order to prevent the fuel system from running dry.
  1. Verify the customer concern.
  1. Visually inspect for obvious signs of mechanical or electrical damage.

Visual Inspection Chart

Mechanical Electrical
  • Fuel leak(s)
  • Fuel filter
  • Air cleaner element
  • Vacuum line(s)/vacuum connections
  • Hose(s)/hose connections
  • Pipe(s)/pipe connections
  • Contaminated fuel
  • High-pressure fuel supply line(s)
  • Fuel injectors
  • Fuel injection pump
  • Fuse(s)
  • Relay(s)
  • Wiring harness
  • Electrical connector(s)
  • Passive anti-theft system (PATS) LED operation
  • Sensor(s)
  • Glow plug indicator
  • Battery
  • Powertrain control module (PCM)
  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 retrieve the diagnostic trouble codes (DTCs).
  1. If no DTCs related to the concern are retrieved, proceed to the Symptom Chart below to continue diagnostics.

Symptom Chart

Symptom Chart

Symptom Possible Sources Action
Engine does not crank and glow plug indicator is flashing
*
DTC detected.
*
REFER to WDS.
Engine does not crank
*
Battery
*
CHECK the condition of the battery. REFER to WDS.
*
Starter motor.
*
Check the condition of the starting system. REFER to Section  303-06 Starting System.
*
PATS.
*
CHECK the PATS LED extinguishes within 3 seconds when the ignition is turned on. REFER to Section  419-01A Anti-Theft - Active / 419-01B Anti-Theft - Passive.
*
Starter inhibit relay.
*
Power relay.
*
CARRY OUT the Relay Component Test. REFER to the Wiring Diagrams.
*
Ignition switch.
*
REFER to Section  211-05 Steering Column Switches.
*
PCM.
*
REFER to WDS.
Engine cranks but does not start and glow plug indicator is flashing
*
DTC detected.
*
REFER to WDS.
Engine cranks but does not start
*
Inertia fuel shutoff (IFS) switch.
*
RESET the IFS switch.
*
Fuel filter blocked.
*
INSTALL a new fuel filter. REFER to Section  310-01 Fuel Tank and Lines.
*
Damaged or blocked fuel lines.
*
INSTALL new fuel lines as necessary.
*
Air ingress into the fuel lines.
*
REFER to Section  310-00 Fuel System - General Information.
*
Crankshaft position (CKP) sensor.
*
PCM.
*
REFER to WDS.
*
Incorrect valve timing.
*
CHECK the valve timing. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine.
*
PCM.
*
REFER to WDS.
*
Fuel injection pump.
*
REFER to WDS.
*
Fuel injection supply manifold.
*
REFER to WDS.
*
Low cylinder compression.
*
REFER to Section  303-00 Engine System - General Information.
Poor starting and glow plug indicator is flashing
*
DTC detected.
*
REFER to WDS.
Poor starting
*
Fuel filter blocked.
*
INSTALL a new fuel filter. REFER to Section  310-01 Fuel Tank and Lines.
*
Air ingress into the fuel lines.
*
REFER to Section  310-00 Fuel System - General Information.
*
Air cleaner element blocked.
*
INSTALL a new air cleaner element.
*
Glow plug relay.
*
CARRY OUT the Relay Component Test. REFER to Wiring Diagrams.
*
Glow plug(s).
*
REFER to WDS.
*
Fuel system leak(s).
*
CHECK the system for fuel leak(s). REPAIR the system as necessary.
*
CKP sensor.
*
Manifold absolute pressure (MAP) sensor.
*
REFER to WDS.
*
Incorrect engine oil.
*
INSTALL a new engine oil filter and designated engine oil.
*
Fuel injector(s).
*
REFER to WDS.
*
PCM.
*
REFER to WDS.
*
Fuel injection pump.
*
INSTALL a new fuel injection pump.
REFER to Fuel Injection Pump in this section.
*
Fuel injection supply manifold.
*
REFER to WDS.
Engine starts but immediately stops and glow plug indicator is flashing
*
DTC detected.
*
REFER to WDS.
Engine starts but immediately stops
*
Air cleaner element blocked.
*
INSTALL a new air cleaner element.
*
Air ingress into the fuel lines.
*
REFER to Section  310-00 Fuel System - General Information.
*
CKP sensor.
*
MAP sensor.
*
REFER to WDS.
*
PCM relay.
*
CARRY OUT the relay component test. REFER to Wiring Diagrams.
*
PCM.
*
REFER to WDS.
Poor idling and glow plug indicator is flashing
*
DTC detected.
*
REFER to WDS.
Poor idling
*
Low fuel tank fuel level.
*
CHECK the fuel tank fuel level is greater than four liters. If the fuel tank fuel level is less than four liters, FILL with fuel.
*
Air cleaner element blocked.
*
INSTALL a new air cleaner element.
*
Fuel filter blocked.
*
INSTALL a new fuel filter. REFER to Section  310-01 Fuel Tank and Lines.
*
Air ingress into the fuel lines.
*
REFER to Section  310-00 Fuel System - General Information.
*
Incorrect or contaminated fuel.
*
CHECK for signs of contamination such as strange odors from the fuel tank.
*
CHECK for signs of water or petrol in the diesel.
*
If contaminated fuel is found, DRAIN the complete fuel system. FLUSH the fuel system through with clean diesel. REFER to Section  310-00 Fuel System - General Information. INSTALL a new fuel filter. REFER to Section  310-01 Fuel Tank and Lines. INSTALL a new fuel injection pump, fuel injectors, fuel injection supply manifold and high-pressure fuel supply lines.
REFER to Fuel Injection Pump /
Fuel Injectors /
Fuel Injection Supply Manifold in this section.
*
CKP sensor.
*
MAP sensor.
*
REFER to WDS.
*
Fuel injector(s).
*
REFER to WDS.
*
PCM.
*
REFER to WDS.
*
Fuel injection supply manifold.
*
REFER to WDS.
*
Fuel injection pump.
*
REFER to WDS.
Engine stumbling and glow plug indicator is flashing
*
DTC detected.
*
REFER to WDS.
Engine stumbling
*
Low fuel tank fuel level.
*
CHECK the fuel tank fuel level is greater than four liters. If the fuel tank fuel level is less than four liters, FILL with fuel.
*
Accelerator pedal position (APP) sensor.
*
REFER to WDS.
*
Fuel injector(s).
*
REFER to WDS.
*
PCM.
*
REFER to WDS.
*
Fuel injection supply manifold.
*
REFER to WDS.
*
Fuel injection pump.
*
REFER to WDS.
Engine lacks power and glow plug indicator is flashing
*
DTC detected.
*
REFER to WDS.
Engine lacks power
*
Air cleaner element blocked.
*
INSTALL a new air cleaner element.
*
Fuel filter blocked.
*
INSTALL a new fuel filter. REFER to Section  310-01 Fuel Tank and Lines.
*
APP sensor.
*
MAP sensor.
*
REFER to WDS.
*
Air ingress into the fuel lines.
*
REFER to Section  310-00 Fuel System - General Information.
*
Catalytic converter blocked.
*
CHECK if the catalytic converter rattles if gently tapped. If noise is present, REMOVE and visually INSPECT the catalytic convertor for damage. INSTALL a new catalytic converter as necessary. REFER to Section  309-00 Exhaust System.
*
Exhaust gas recirculation (EGR) valve.
*
REFER to Section  303-08A Engine Emission Control / 303-08B Engine Emission Control / 303-08C Engine Emission Control.
*
Turbocharger.
*
REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls - Turbocharger / 303-04D Fuel Charging and Controls / 303-04E Fuel Charging and Controls - Turbocharger.
*
Incorrect valve timing.
*
CHECK the valve timing. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine.
*
Fuel injector(s).
*
REFER to WDS.
*
Incorrect or contaminated fuel.
*
CHECK for signs of contamination such as strange odors from the fuel tank.
*
CHECK for signs of water or petrol in the diesel.
*
If contaminated fuel is found, DRAIN the complete fuel system. FLUSH the fuel system through with clean diesel. REFER to Section  310-00 Fuel System - General Information. INSTALL a new fuel filter. REFER to Section  310-01 Fuel Tank and Lines. INSTALL a new fuel injection pump, fuel injectors, fuel injection supply manifold and high-pressure fuel supply lines.
REFER to Fuel Injection Pump /
Fuel Injectors /
Fuel Injection Supply Manifold in this section.
*
PCM.
*
REFER to WDS.
*
Fuel injection supply manifold.
*
REFER to WDS.
*
Fuel injection pump.
*
REFER to WDS.
Black smoke at idle and glow plug indicator is flashing
*
DTC detected.
*
REFER to WDS.
Black smoke at idle
*
Air cleaner element blocked.
*
INSTALL a new air cleaner element.
*
MAP sensor.
*
REFER to WDS.
*
Fuel injector(s).
*
REFER to WDS.
*
Incorrect valve timing.
*
CHECK the valve timing. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine.
*
PCM.
*
REFER to WDS.
*
Fuel injection supply manifold.
*
REFER to WDS.
*
Fuel injection pump.
*
REFER to WDS.
Excessive black smoke during acceleration and glow plug indicator is flashing
*
DTC detected.
*
REFER to WDS.
Excessive black smoke during acceleration
*
APP sensor.
*
CKP sensor.
*
REFER to WDS.
*
Incorrect or contaminated fuel.
*
CHECK for signs of contamination such as strange odors from the fuel tank.
*
CHECK for signs of water or petrol in the diesel.
*
If contaminated fuel is found, DRAIN the complete fuel system. FLUSH the fuel system through with clean diesel. REFER to Section  310-00 Fuel System - General Information. INSTALL a new fuel filter. REFER to Section  310-01 Fuel Tank and Lines. INSTALL a new fuel injection pump, fuel injectors, fuel injection supply manifold and high-pressure fuel supply lines.
REFER to Fuel Injection Pump /
Fuel Injectors /
Fuel Injection Supply Manifold in this section.
*
Fuel injector(s).
*
REFER to WDS.
*
PCM.
*
REFER to WDS.
*
Fuel injection supply manifold.
*
REFER to WDS.
Black smoke at cruising speeds and glow plug indicator is flashing
*
DTC detected.
*
REFER to WDS.
Black smoke at cruising speeds
*
Air cleaner element blocked.
*
INSTALL a new air cleaner element. REFER to Section  303-12 Intake Air Distribution and Filtering.
*
MAP sensor.
*
REFER to WDS.
*
Vacuum lines.
*
CHECK all vacuum lines are correctly installed and no signs of air leaks are present. REPAIR or INSTALL new vacuum line(s) as necessary.
*
EGR valve sticking open.
*
EGR vacuum switching valve.
*
REFER to WDS.
*
Turbocharger.
*
REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls - Turbocharger / 303-04D Fuel Charging and Controls / 303-04E Fuel Charging and Controls - Turbocharger.
*
Fuel injector(s).
*
REFER to WDS.
*
PCM.
*
REFER to WDS.
*
Fuel injection supply manifold.
*
REFER to WDS.
Blue smoke and glow plug indicator is flashing
*
DTC detected.
*
REFER to WDS.
Blue smoke
*
Engine burning oil.
*
CARRY OUT a controlled oil consumption test over 1000 km (600 miles). CONFIRM that the oil consumption is less than 0.1 liters per 1000 km (600 miles). REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine.
*
Incorrect or contaminated fuel.
*
CHECK for signs of contamination such as strange odors from the fuel tank.
*
CHECK for signs of water or petrol in the diesel.
*
If contaminated fuel is found, DRAIN the complete fuel system. FLUSH the fuel system through with clean diesel. REFER to Section  310-00 Fuel System - General Information. INSTALL a new fuel filter. REFER to Section  310-01 Fuel Tank and Lines. INSTALL a new fuel injection pump, fuel injectors, fuel injection supply manifold and high-pressure fuel supply lines.
REFER to Fuel Injection Pump /
Fuel Injectors /
Fuel Injection Supply Manifold in this section.
*
Worn or damaged valve guides, piston rings, cylinder bores, cylinder head or gasket.
*
REMOVE and inspect the cylinder head, pistons and cylinder bores for signs of wear. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine.
*
Positive crankcase ventilation (PCV) system.
*
CHECK the PCV pipes for signs of restriction or blockage. REPAIR as necessary.
*
Turbocharger oil seals leaking.
*
Turbocharger oil return tube blocked or damaged.
*
REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls - Turbocharger / 303-04D Fuel Charging and Controls / 303-04E Fuel Charging and Controls - Turbocharger.
White smoke and glow plug indicator is flashing
*
DTC detected.
*
REFER to WDS.
White smoke
*
Water in fuel.
*
DRAIN the fuel filter of water until clear fuel is present. If contaminated fuel is still found, DRAIN the complete fuel system. FLUSH the fuel system through with clean diesel. REFER to Section  310-00 Fuel System - General Information. INSTALL a new fuel filter. REFER to Section  310-01 Fuel Tank and Lines. INSTALL a new fuel injection pump, fuel injectors, fuel injection supply manifold and high-pressure fuel supply lines.
REFER to Fuel Injection Pump /
Fuel Injectors /
Fuel Injection Supply Manifold in this section.
*
Incorrect valve timing.
*
CHECK the valve timing. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine.
*
Coolant in the combustion chamber.
*
CARRY OUT a cooling system pressure test. REFER to Section  303-03A Engine Cooling / 303-03B Engine Cooling / 303-03C Engine Cooling. REMOVE and INSPECT the cylinder head, cylinder head gasket and cylinder bores for wear or damage. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine.
Engine misfire and glow plug indicator is flashing
*
DTC detected.
*
REFER to WDS.
Engine misfire
*
Low fuel tank fuel level.
*
CHECK the fuel tank fuel level is greater than four liters. If the fuel tank fuel level is less than four liters, FILL with fuel.
*
high-pressure fuel supply line(s).
*
CHECK the high-pressure fuel supply lines for signs of damage. INSTALL new high-pressure fuel supply lines as necessary.
*
Air ingress into the fuel lines.
*
REFER to Section  310-00 Fuel System - General Information.
*
Incorrect or contaminated fuel.
*
CHECK for signs of contamination such as strange odors from the fuel tank.
*
CHECK for signs of water or petrol in the diesel.
*
If contaminated fuel is found, DRAIN the complete fuel system. FLUSH the fuel system through with clean diesel. REFER to Section  310-00 Fuel System - General Information. INSTALL a new fuel filter. REFER to Section  310-01 Fuel Tank and Lines. INSTALL a new fuel injection pump, fuel injectors, fuel injection supply manifold and high-pressure fuel supply lines.
REFER to Fuel Injection Pump /
Fuel Injectors /
Fuel Injection Supply Manifold in this section.
*
Fuel injector(s).
*
REFER to WDS.
*
Low cylinder compression.
*
REFER to Section  303-00 Engine System - General Information.
*
Worn or damaged valve, camshaft followers or camshafts.
*
REMOVE the cylinder head and visually INSPECT for signs of wear or damage. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine.
*
Damaged cylinder head gasket.
*
REMOVE and INSPECT the cylinder head gasket and cylinder bores for wear or damage. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine.
*
Engine operating temperature too high.
*
REFER to Section  303-03A Engine Cooling / 303-03B Engine Cooling / 303-03C Engine Cooling.
*
PCM.
*
REFER to WDS.
*
Fuel injection supply manifold.
*
REFER to WDS.
*
Fuel injection pump.
*
REFER to WDS.
Engine knock at idle and glow plug indicator is flashing
*
DTC detected.
*
REFER to WDS.
Engine knock at idle
*
Low engine oil level.
*
CHECK the engine oil level. REFILL as necessary.
*
Incorrect or contaminated fuel.
*
CHECK for signs of contamination such as strange odors from the fuel tank.
*
CHECK for signs of water or petrol in the diesel.
*
If contaminated fuel is found, DRAIN the complete fuel system. FLUSH the fuel system through with clean diesel. REFER to Section  310-00 Fuel System - General Information. INSTALL a new fuel filter. REFER to Section  310-01 Fuel Tank and Lines. INSTALL a new fuel injection pump, fuel injectors, fuel injection supply manifold and high-pressure fuel supply lines.
REFER to Fuel Injection Pump /
Fuel Injectors /
Fuel Injection Supply Manifold in this section.
*
Incorrect valve timing.
*
CHECK the valve timing. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine.
*
CKP sensor.
*
REFER to WDS.
*
Excessive carbon build up.
*
REMOVE and INSPECT the cylinder head for signs of carbon build up. INSPECT the pistons for signs carbon build up. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine.
*
Fuel injector(s).
*
REFER to WDS.
*
PCM.
*
REFER to WDS.
*
Worn or damaged oil pump.
*
Worn or damaged timing chain or sprocket.
*
Major mechanical engine failure.
*
REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine.
Engine knock during acceleration and glow plug indicator is flashing
*
DTC detected.
*
REFER to WDS.
Engine knock during acceleration
*
Fuel injector(s).
*
REFER to WDS.
*
PCM.
*
REFER to WDS.
*
Major mechanical engine failure.
*
REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine.
*
Fuel injection pump.
*
REFER to WDS.
Excessive fuel consumption and glow plug indicator indicator is flashing
*
DTC detected.
*
REFER to WDS.
Excessive fuel consumption
*
Brakes binding.
*
CHECK the braking system. REFER to Section  206-00 Brake System - General Information.
*
Vehicle overloaded, or excessive wind resistance (roof racks, towing etc).
*
ADVISE the customer about the effects of overloading the vehicle and wind resistance on the fuel consumption.
*
Air cleaner element blocked.
*
INSTALL a new air cleaner element.
*
Fuel system leak(s).
*
CHECK the system for fuel leak(s). REPAIR the system as necessary.
*
MAP sensor.
*
REFER to WDS.
*
Incorrect engine oil.
*
INSTALL a new oil filter and designated engine oil.
*
Generator.
*
REFER to Section  414-00 Charging System - General Information.
*
EGR valve stuck open.
*
REFER to WDS.
*
Air ingress into the fuel lines.
*
REFER to Section  310-00 Fuel System - General Information.
*
Incorrect valve timing.
*
CHECK the valve timing. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine.
*
Turbocharger.
*
Turbocharger wastegate actutator.
*
REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls - Turbocharger / 303-04D Fuel Charging and Controls / 303-04E Fuel Charging and Controls - Turbocharger.
*
Low cylinder compression.
*
REFER to Section  303-00 Engine System - General Information.
*
Fuel injector(s).
*
REFER to WDS.
*
PCM.
*
REFER to WDS.

General Procedures > < Fuel Charging and Controls