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Fuel System - Vehicles Built From: 08-2006 1.8L Duratorq-TDCi (Lynx) Diesel (75 PS-90 PS-110 PS) > < Exhaust Flexible Pipe - 1.8L Duratorq-TDDi (Lynx) Diesel, Vehicles With: One-Piece Catalytic Converter and Exhaust Flexible Pipe

Transit.Tourneo Connect 2002.5 (06.2002-)

Fuel System - General Information - Fuel System—75 PS/90 PS Transit/Tourneo Connect 2002.5 (06/2002-)
Diagnosis and Testing

Special Tool(s)

Hand Vacuum/Pressure Pump

416-D001 (23-036A)

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.
WARNING:
WARNING:Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always fit blanking plugs to any open orifices or lines.
  1. Verify the customer concern.
  1. Visually inspect for obvious signs of mechanical or electrical damage.

Visual Inspection Chart

Mechanical Electrical
  • Fuel level
  • Fuel leak(s)
  • Fuel line(s)
  • Fuel filler cap
  • Fuel filter
  • Fuel tank
  • Fuel tank ventilation hose
  • Fuel tank filler hose
  • Fuse(s)
  • Relay(s)
  • Wiring harness
  • Electrical connector(s)
  • Inertia fuel shutoff (IFS) switch - all except vehicles with diesel engine
  • Fuel level sensor - vehicles with diesel engine
  • Fuel pump module - all except vehicles with diesel engine
  • Engine
  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 the Symptom Chart.

Symptom Chart

Symptom Chart

Symptom Possible Sources Action
Engine cranks but does not start - vehicles with diesel engine
*
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 - Turbocharger.
*
Air ingress into the fuel lines.
*
GO to Pinpoint Test A. .
*
Contaminated fuel.
*
INSTALL a new fuel filter. DRAIN and RENEW the fuel.
REFER to Fuel Tank Draining in this section.
Engine cranks but does not start - all except vehicles with diesel engine
*
Fuel charging and controls.
*
REFER to WDS.
*
IFS switch.
*
REFER to WDS.
*
Contaminated fuel.
*
INSTALL a new fuel filter. DRAIN and RENEW the fuel.
REFER to Fuel Tank Draining in this section.
Poor starting - vehicles with diesel engine
*
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 - Turbocharger.
*
Air ingress into the fuel lines.
*
GO to Pinpoint Test A. .
*
Contaminated fuel.
*
INSTALL a new fuel filter. DRAIN and RENEW the fuel.
REFER to Fuel Tank Draining in this section.
Poor starting - all except vehicles with diesel engine
*
Fuel charging and controls.
*
REFER to WDS.
*
Contaminated fuel.
*
INSTALL a new fuel filter. DRAIN and RENEW the fuel.
REFER to Fuel Tank Draining in this section.
Engine starts but immediately stops - vehicles with diesel engine
*
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 - Turbocharger.
*
Air ingress into the fuel lines.
*
GO to Pinpoint Test A. .
Engine starts but immediately stops - all except vehicles with diesel engine
*
Fuel charging and controls.
*
REFER to WDS.
Poor idling - vehicles with diesel engine
*
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 - Turbocharger.
*
Air ingress into the fuel lines.
*
GO to Pinpoint Test A. .
*
Contaminated fuel.
*
INSTALL a new fuel filter. DRAIN and RENEW the fuel.
REFER to Fuel Tank Draining in this section.
Poor idling - all except vehicles with diesel engine
*
Fuel charging and controls.
*
REFER to WDS.
*
Contaminated fuel.
*
INSTALL a new fuel filter. DRAIN and RENEW the fuel.
REFER to Fuel Tank Draining in this section.
Engine lacks power - vehicles with diesel engine
*
Fuel tank to fuel filter supply line blocked.
*
CHECK the fuel supply lines for damage. INSTALL a new fuel filter supply line.
*
CHECK the fuel supply line for blockage. Using the special tool, APPLY a vacuum to the fuel filter supply line at the fuel filter inlet. If fuel does not draw easily from the fuel tank, REPAIR the fuel filter supply line as necessary.
*
Fuel filter blocked.
*
INSTALL a new fuel filter. REFER to Section  310-01A Fuel Tank and Lines.
*
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 - Turbocharger.
*
Air ingress into the fuel lines.
*
GO to Pinpoint Test A. .
*
Contaminated fuel.
*
INSTALL a new fuel filter. DRAIN and RENEW the fuel.
REFER to Fuel Tank Draining in this section.
Engine lacks power - all except vehicles with diesel engine
*
Ignition system.
*
REFER to Section  303-07A Engine Ignition / 303-07B Glow Plug System.
*
Fuel filter blocked.
*
INSTALL a new fuel filter. REFER to Section  310-01A Fuel Tank and Lines.
*
Fuel charging and controls.
*
REFER to WDS.
*
Contaminated fuel.
*
INSTALL a new fuel filter. DRAIN and RENEW the fuel.
REFER to Fuel Tank Draining in this section.
Engine misfire - vehicles with diesel engine
*
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 - Turbocharger.
*
Air ingress into the fuel lines.
*
GO to Pinpoint Test A. .
Engine misfire - all except vehicles with diesel engine
*
Ignition system.
*
REFER to Section  303-07A Engine Ignition / 303-07B Glow Plug System.
*
Fuel charging and controls.
*
REFER to WDS.
Excessive fuel consumption - vehicles with diesel engine
*
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 - Turbocharger.
*
Air ingress into the fuel lines.
*
GO to Pinpoint Test A. .
*
Contaminated fuel.
*
INSTALL a new fuel filter. DRAIN and RENEW the fuel.
REFER to Fuel Tank Draining in this section.
Excessive fuel consumption - all except vehicles with diesel engine
*
Fuel charging and controls.
*
REFER to WDS.
*
Contaminated fuel.
*
INSTALL a new fuel filter. DRAIN and RENEW the fuel.
REFER to Fuel Tank Draining in this section.
Fuel filler nozzle shuts off prematurely
*
Fuel tank ventilation hose or pipe blocked.
*
Fuel tank ventilation hose or pipe collapsed.
*
CHECK the fuel tank ventilation hose for obstruction or damage. INSTALL a new fuel tank ventilation pipe. for additional information, REFER to Section  310-01A Fuel Tank and Lines.
*
Fuel tank filler pipe or hose blocked.
*
Fuel tank filler pipe or hose collapsed.
*
CHECK the fuel tank filler pipe or hose for obstruction or damage. INSTALL a new fuel tank filler pipe. for additional information, REFER to Section  310-01A Fuel Tank and Lines.
*
Fuel gauge indication.
*
CHECK the fuel level in the fuel tank. CHECK the fuel indication system. For additional information, REFER to Section  413-01 Instrument Cluster.
*
Fuel filler nozzle at fuel filling station not functioning correctly.
*
VERIFY condition by using a known good fuel filler nozzle.
Fuel loss after nozzle shutoff or during refilling
*
Fuel tank filler pipe or hose leaking.
*
CHECK the fuel tank filler pipe and hose for evidence of a fuel leak. If a fuel leak is evident, INSTALL a new fuel tank filler pipe and hose. For additional information, REFER to Section  310-01A Fuel Tank and Lines.
*
Fuel tank leaking.
*
CHECK the fuel tank for evidence of a fuel leak. If a fuel leak is evident, INSTALL a new fuel tank. For additional information, REFER to Section  310-01A Fuel Tank and Lines.
*
Fuel tank ventilation pipe or hose leaking.
*
CHECK the fuel tank ventilation pipe and hose for evidence of a fuel leak. If a fuel leak is evident, INSTALL a new fuel tank ventilation pipe and hose. For additional information, REFER to Section  310-01A Fuel Tank and Lines.

Pinpoint Tests

PINPOINT TEST A : AIR INGRESS INTO THE FUEL LINES
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
A1: 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
Using a suitable piece of clear plastic pipe, manufacture and install a pipe between the fuel injection pump and the fuel injection pump to fuel filter fuel return line.
2
Start the engine, wait a few minutes and then observe the clear plastic pipe for signs of air ingress.

Are any signs of air present in the clear plastic pipe?
Yes
GO to A2. .
No
REMOVE the clear plastic pipe and connect the fuel injection 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 - Turbocharger.
A2: 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 pipe(s) as necessary. Test the system for normal operation.
No
REMOVE the clear plastic pipe from between the fuel injection pump and the fuel injection pump to fuel filter fuel return line.GO to A3. .
A3: CHECK THE FUEL LEVEL SENSOR FOR AIR INGRESS
1
Drain the fuel tank.
REFER to Fuel Tank Draining in this section.
2
Fill the fuel tank with 10 liters of diesel.
3
Disconnect the fuel tank to fuel filter fuel supply line from the fuel filter.

4
Using a suitable piece of clear plastic pipe, manufacture and install a pipe between the fuel filter and the fuel tank to fuel filter supply line.

5
Using the special tool, prime the fuel pump until clean air-free fuel is seen entering the vacuum pump reservoir.
6
Remove the special tool and connect the fuel injection pump to fuel filter fuel return line.
NOTE:
NOTE:Make sure the engine is at normal operating temperature.
7
Start the engine, wait a few minutes and then observe the clear plastic pipe for signs of air ingress.

Are any signs of air present in the clear plastic pipe?
Yes
INSTALL a new fuel level sensor or fuel tank to fuel filter supply pipe as necessary. REFER to Section  310-01A Fuel Tank and Lines.
No
INSTALL a new fuel filter. REFER to Section  310-01A Fuel Tank and Lines.

Fuel System - Vehicles Built From: 08-2006 1.8L Duratorq-TDCi (Lynx) Diesel (75 PS-90 PS-110 PS) > < Exhaust Flexible Pipe - 1.8L Duratorq-TDDi (Lynx) Diesel, Vehicles With: One-Piece Catalytic Converter and Exhaust Flexible Pipe