Ford Workshop Service and Repair Manuals > Transit 2000.5 (01.2000-05.2006) > Mechanical Repairs | 3 Powertrain | 303 Engine | 303-04F Fuel Charging and Controls - 2.0L Duratorq-TDCi (Puma) Diesel | Description and Operation | Diagnosis and Testing

General Procedures > < Fuel Charging and Controls

Fuel Charging and Controls - 2.0L Duratorq-TDCi (Puma) Diesel - Fuel Charging and Controls

Transit 2000.5 (01/2000-05/2006)

Diagnosis and Testing

Special Tool(s)

	Diagnostic Tool, Common Rail Fuel Injection 310-129
	Hand Pressure Pump with Adapter Kit 310-110
	Test Hose for 310-025 310-025-18
	Test Hose for 310-025 310-025-19A

General Equipment

Ford approved diagnostic tool

Pneumatic vacuum gun

Magnet

Transparent container

Principles of Operation

System overview

The common rail fuel system shown is known as the two box system comprising of a separate injector driver module (IDM) and powertrain control module (PCM). Later versions of this system combined the IDM and PCM into one unit known simply as the PCM.

Item

Part Number

Description

High-pressure fuel injector fuel supply line

High-pressure fuel supply line

Fuel pump fuel return line

Fuel pump fuel supply line

Fuel injector fuel return line

Fuel filter to fuel tank fuel return line

To meet the increasing demands for lower exhaust emissions, greater economy, improved driving characteristic's, lower noise output and increased power output from modern diesel engines, the vehicle requires a fuel supply system which can deliver small fuel droplets at high speed with refined control. The common rail fuel injection system has been introduced to the diesel engine to meet these demands.

The Delphi system fitted to the 2.0L and 2.4L diesel engines fulfills this role by using controlled high-pressure fuel delivery to individually electronically controlled injectors.

Fuel pump fuel supply

Item

Part Number

Description

Fuel pump fuel return line connection

Fuel tank fuel supply line connection

Fuel pump fuel supply line connection

Filter element

Filter drain screw

Bimetallic fuel return sensor

Fuel return bypass valve

The fuel system on this vehicle is designed to prevent the fuel tank and fuel injection system being run dry. When the fuel tank level reaches a preset limit, after the low fuel indicator has been illuminated, the engine will be made to run rough to indicate that the fuel level in the fuel tank is very low. To protect the fuel injection components if this warning is ignored, the IDM/PCM will terminate the fuel injection process and the engine will stop.

The fuel filter element in the common rail fuel system is designed to extract far smaller particles from the fuel supply than conventional fuel filters.

To aid with the rapid warm up of the fuel supply to the fuel pump, the fuel filter is fitted with a temperature conscious fuel return bypass valve.

At temperatures below 50°C, the bypass valve is fully open and the majority of the returned fuel is circulated through the fuel filter and back to the fuel pump.

When the fuel temperature in the fuel filter has reached a temperature above 50°C, the fuel return bypass valve closes and the returned fuel is delivered back to the fuel tank.

The return fuel cannot be allowed to continue to circulate through the fuel filter after 50°C as the temperatures produced by compressing the fuel to such high pressures would cause the fuel to overheat. When the fuel is returned to the fuel tank, the fuel line which transfers the fuel along the underbody, cools the fuel sufficiently to prevent overheat concerns.

High-pressure fuel pump

High-pressure fuel pump cam ring

High-pressure pump low pressure fuel inlet channel

Fuel temperature sensor

Fuel return line venturi

Fuel metering valve

High-pressure fuel outlet union

High-pressure fuel pump fuel outlet channel

High-pressure fuel pump chamber

Fuel is drawn from the fuel tank through the fuel filter by means of a transfer pump. The transfer pump is built into the high-pressure pump and driven by the high-pressure pump input shaft.

Fuel from the transfer pump is passed through the high-pressure pump low pressure fuel inlet channel into the high-pressure fuel pump chamber.

In the high-pressure pump low pressure fuel inlet channel is situated a fuel metering valve. The fuel metering valve is controlled by the IDM/PCM. A fuel pressure sensor input signal is used by the IDM/PCM to calculate the position required by the fuel metering valve to achieve the desired fuel rail pressure. The fuel metering valve reduces the cross sectional area of the high-pressure pump low pressure fuel inlet channel and so decreases the quantity of fuel allowed to reach the high-pressure fuel pump chamber.

Located in the rear of the fuel pump is a fuel temperature sensor which monitors the fuel transfer pump fuel delivery temperature. The sensor information is used by the IDM/PCM to adjust the fuel metering valve to compensate for cold fuel charge values.

If the fuel temperature sensor or its related circuits become shorted to ground, the engine will shut down and not restart.

If the fuel temperature sensor or its related circuits become open circuit, the engine management system will default to a value of 39°C and cold start characteristics will be impaired.

Fuel pump high-pressure fuel development

High-pressure fuel pump cam ring

Fuel pump piston roller and shoe

High-pressure fuel pump chamber

Fuel outlet valve

Fuel pump piston

CAUTION:The high pressure fuel pump relies on the fuel in the pump for lubrication. The fuel pump input shaft should not be allowed to rotate above hand cranking speed unless the air has been bled from the fuel pump fuel supply lines and fuel is present in the fuel transfer pump. Failure to follow this instruction may result in damage to the components of the high-pressure fuel pump.

Fuel enters the high-pressure fuel pump chamber through a fuel inlet valve. The inlet valve will only allow fuel to enter the fuel pump chamber, if the fuel pressure in the chamber is lower than the pressure in the high-pressure pump low pressure fuel inlet channel.

Fuel entering the high-pressure fuel pump chamber, forces the fuel pump piston's outwards and holds the fuel pump piston roller and shoe against the high-pressure fuel pump cam ring.

The high-pressure fuel pump fuel outlet valve will remain closed until the fuel pressure inside the high-pressure fuel pump chamber exceeds the pressure in the fuel rail.

High-pressure fuel pump cam ring

Fuel pump piston roller and shoe

High-pressure fuel pump chamber

Fuel outlet valve

High-pressure fuel to high-pressure fuel outlet union

Fuel pump piston

As the high-pressure fuel pump cam ring rotates, the fuel pump roller, shoe and piston is forced by the cam lobe inwards compressing the fuel held in the high-pressure fuel pump chamber.

The fuel pressure in the high-pressure fuel pump chamber rises above the fuel pressure developed by the transfer pump and the fuel inlet valve is closed.

As the fuel in the high-pressure fuel pump chamber exceeds the pressure of the fuel in the fuel rail, the fuel outlet valve opens and high-pressure fuel is delivered to the fuel rail.

Fuel from the high-pressure fuel pump chamber will enter the fuel rail until the fuel pump pistons have reached the maximum delivery movement. At this point the fuel pressure in the high-pressure fuel pump chamber drops to below the pressure of the fuel in the fuel rail and the fuel outlet valve is closed.

For each full rotation of the fuel pump cam ring, the fuel pump pistons go through four compression cycles.

Item

Part Number

Description

High-pressure fuel outlet union

High-pressure fuel pump fuel outlet channel

Pressure release ball valve

Calibrated pressure release spring

As a safety precaution, built into the fuel pump body is a high-pressure fuel relief valve. If the fuel pump fuel pressure exceeds the maximum permissible value, the fuel relief valve will open and vent the excess fuel pressure into the fuel pump inner chamber.

Fuel pump fuel flow and control

Item

Part Number

Description

Low pressure fuel control valve

Calibrated fuel pump fuel return bore

High-pressure pump low pressure fuel inlet channel

Fuel injector fuel return

Fuel pump to fuel filter fuel return

High-pressure fuel pump fuel outlet channel

Fuel feed to fuel transfer pump

Under normal demand conditions, fuel is delivered to the high-pressure fuel pump chamber unrestricted where it is compressed and delivered to the fuel rail.

A small proportion of fuel is diverted through the calibrated fuel pump fuel return bore. This returned fuel is used to lubricate and cool the high-pressure pump. As the fuel exits through the fuel return line venturi, the accelerated flow across the injector return line orifice creates a partial vacuum in the fuel injector return line. This partial vacuum assists with the scavenging of fuel injector fuel return fuel.

Item

Part Number

Description

Low pressure fuel control valve

Calibrated fuel pump fuel return bore

High-pressure pump low pressure fuel inlet channel

Fuel injector fuel return

Fuel pump to fuel filter fuel return

High-pressure fuel pump fuel outlet channel

Fuel feed to fuel transfer pump

When the engine is off demand (decelerating), the fuel shut-off valve restricts the high-pressure pump fuel supply. As the pressure in the high-pressure pump low pressure fuel inlet channel increases, the low pressure fuel control valve opens and recirculates low pressure fuel through the fuel transfer pump.

Fuel rail

Fuel pump high-pressure fuel line connection

Fuel injector high-pressure fuel line connections

The fuel rail function, is to supply a reservoir of fuel at a constant controlled pressure to all four fuel injectors.

The action of the fuel injectors opening and closing causes changes in pressure to the fuel behind the fuel injector. The fuel rail acts as an accumulator, minimizing this affect.

The volume of fuel held by the fuel rail cannot be to large as this will cause a increase in pressurization time and a corresponding increase in engine start time.

The four fuel injector high-pressure fuel lines attached to the fuel rail are of equal length. This is to eliminate any variation in delivery pressure at the fuel injectors.

Fitted into the fuel rail is the fuel pressure sensor. The fuel pressure sensor monitors the current fuel pressure available at the fuel injectors. The fuel pressure sensor is a non serviceable component. Due to the tapered thread construction of the fuel rail union, a fuel tight seal capable of withstanding the high fuel pressures cannot be guaranteed. So the fuel rail and fuel pressure sensor must be renewed as one component.

If the fuel pressure sensor does not see a minimum preset value during cranking, the IDM/PCM will not allow the fuel injectors to inject and the engine will not start.

If the fuel pressure sensor signal to the IDM/PCM is lost or the value indicated does not match the expected value for the given engine condition, the fuel metering valve will default to the closed position and will not allow the development of the high-pressure fuel supply.

Fuel injector

Item

Part Number

Description

Control chamber fuel inlet choke

Solenoid valve

Injection control valve spring

Injection control valve

Injection control valve fuel return bore

Injector needle upper control chamber fuel outlet choke

Injector needle upper chamber

Injector needle high-pressure fuel outlet

Injector needle

Injector needle lower chamber

Injector needle lower chamber fuel inlet choke

Injector needle upper chamber fuel inlet choke

The fuel injector consists of two main sections.

Electrically operated solenoid control valve.
Mechanically operated fuel injection valve.

The solenoid control valve has a switching time of approximately 0.3 milliseconds. This short switching time is achieved by keeping the moving components and the distances required to function to a minimum. The design of the fuel injector chambers means that at no time does the solenoid control valve work against any major forces other than that of the solenoid valve spring.

The fuel injector needle works on a combination of hydraulic and spring control.

All injectors are calibrated to take into account manufacturing tolerances. These calibrations are indicated on the exterior of the injector by a code. The code is used by the IDM/PCM to adjust the duration of the injection cycle.

If the codes for the individual injector's are incorrectly matched to the codes stored in the IDM/PCM, the engine may exhibit rough idle, increased combustion noise and black smoke emissions.

Fuel injector working state closed

Injection control valve

Injector needle upper chamber

Injector needle control spring

Injector needle

Injector needle lower chamber

High-pressure fuel feed

With the solenoid valve de-energised, the injection control valve is held in the closed position by the injection control valve spring. Fuel pressure above and below the injection control valve is slightly above atmospheric pressure during engine run conditions.

Fuel pressure in the injector needle upper chamber and injector needle lower chamber is equal to the high-pressure fuel feed pressure. The injector needle is held in the closed position by the injector needle control spring.

Fuel injector working state opening

Fuel injector fuel return bore

Injection control valve

Injector needle upper control chamber fuel outlet choke

Injector needle upper chamber

Injector needle upper chamber fuel inlet choke

Control chamber fuel inlet choke

The fuel injection process starts with a voltage being applied to the solenoid valve with a pull-in current of 12 amperes.

The solenoid valve moves the injection control valve against the pressure of the injection control valve spring.

The injection control valve releases the high fuel pressure from the injector needle upper chamber and vents the excess pressure out through the fuel injector fuel return bore. The fuel pressure does not drop instantly but is slowed down by the injector needle upper control chamber fuel outlet choke.

High-pressure fuel entering the injector needle upper chamber and the injection control valve chambers is restricted by the very small diameters of the injector needle upper chamber fuel inlet choke and the control chamber inlet choke.

Fuel injector working state injecting

Fuel injector fuel return bore

Injector needle upper chamber

Injector needle

Injector needle lower chamber

Injector needle upper chamber fuel inlet choke

Control chamber fuel inlet choke

During the injection state of the process, the current applied to the solenoid valve is reduced to 6 amperes. This value is sufficient to maintain the injection control valve in the open position.

As the fuel pressure in the injector needle upper chamber decays, the fuel pressure in the injector needle lower chamber forces the injector needle open against the injector needle control spring. Fuel is injected into the engine combustion chamber.

Fuel will continue to be injected as long as the fuel pressure in the injector needle lower chamber is higher than the combined force of the fuel pressure in the injector needle upper chamber and the injector needle control spring.

Fuel injector working state closing

Injection control valve

Injector needle upper chamber

Injector needle control spring

Injector needle

Injector needle lower chamber

High-pressure fuel feed

When the fuel injection process has reached the desired injection duration, the solenoid valve is de-energised.

The injection control valve spring closes the injection control valve and the fuel pressure in the injector needle upper chamber rises to equal the pressure of the injector needle lower chamber. As the pressures equalize, the injector needle spring closes the injector needle so preventing fuel injection.

To prevent a sudden increase in the pressure in the injector needle lower chamber as the injector needle closes, the fuel entering the chamber is restricted by the injector needle lower chamber fuel inlet choke.

Fuel injector fuel return

The fuel injector fuel return is required to make the fuel injectors function.

The amount of return fuel developed during the normal functioning of a fuel injector indicates the condition of that injector. By measurement and comparison of fuel injector fuel return quantities, diagnosis of the fuel injectors is possible.

Inspection and Verification

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:This procedure involves fuel handling. Be prepared for fuel spillage at all times. Failure to follow this instruction may result in personal injury.

CAUTION: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.

NOTE:As well as carrying out its normal function the glow plug indicator 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 the Ford approved diagnostic tool.

NOTE:If a DTC is detected, all DTCs must be cleared after the concern is repaired. Failure to clear all DTCs may cause driveability concerns.

NOTE:If the fuel level in the fuel tank drops below approximately four litres, 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.

Verify the customer concern.

Visually inspect for obvious signs of mechanical or electrical damage.

Visual Inspection Chart

Mechanical	Electrical
Fuel leak(s)	Starter inhibit relay fuse
Fuel filter	Power relay fuse
Air cleaner element	Glow plug relay fuse
Vacuum line(s)/vacuum connections	Relay(s)
Hose(s)/hose connections	Wiring harness
Tube(s)/tube connections	Electrical connector(s)
Contaminated fuel	Passive anti-theft system (PATS) LED operation
Fuel supply line(s)	Sensor(s)
Fuel return line(s)	Glow plug indicator
High-pressure fuel supply line(s)	Injector driver module (IDM). (If equipped)
Fuel injectors	PCM
Fuel injection supply manifold
Fuel pump

If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.

NOTE:A PCM calibration update should only be carried out if it is applicable to the symptoms exhibited by the vehicle.

If the cause is not visually evident, verify the symptom and refer to the Ford approved diagnostic tool. Check for the availability of an applicable PCM calibration update. Continue with the Ford approved diagnostic tool and retrieve the DTCs.

If DTCs related to the concern are retrieved, proceed to the Symptom Chart below to continue diagnostics.

Symptom Chart

Symptom Possible Sources Action

Engine does not crank and glow plug indicator is flashing
*

DTC detected.

*

REFER to the Ford approved diagnostic tool.

Engine does not crank
*

PATS.

*

CHECK the PATS LED extinguishes within 3 seconds when the ignition is turned on.
REFER to: Anti-Theft - Passive - Vehicles With: Central Junction Box (CJB) (419-01B Anti-Theft - Passive, Diagnosis and Testing).

*

Starting system.

*

REFER to: Starting System - Vehicles With: Central Junction Box (CJB) (303-06 Starting System, Diagnosis and Testing).

*

Ignition switch.

*

REFER to the Wiring Diagrams.

*

PCM.

*

REFER to the Ford approved diagnostic tool.

Engine cranks but does not start and glow plug indicator is flashing
*

DTC detected.

*

RETRIEVE the DTCs using the Ford approved diagnostic tool. INVESTIGATE and RESOLVE all stored DTCs. If the concern persists, vehicles without IDM, GO to Pinpoint Test D. Vehicles with IDM, GO to Pinpoint Test E.

Engine cranks but does not start
*

Low fuel tank fuel level.

*

CHECK the fuel tank fuel level is greater than four litres. If the fuel tank fuel level is less then four litres, FILL with fuel.

*

Inertia fuel shut off (IFS) switch.

*

RESET the IFS switch.

*

Fuel pump.

*

Vehicles without IDM, GO to Pinpoint Test D. Vehicles with IDM, GO to Pinpoint Test E.

*

Fuel injectors.

*

Vehicles without IDM, GO to Pinpoint Test D. Vehicles with IDM, GO to Pinpoint Test E.

*

Incorrect or contaminated fuel.

*

CHECK for signs of contamination such as strange odours from the fuel tank.

*

CHECK for signs of water or petrol in the diesel.

*

If contaminated fuel is found, vehicles without IDM, GO to Pinpoint Test D. Vehicles with IDM, GO to Pinpoint Test E.

*

Fuel filter blocked.

*

GO to Pinpoint Test C.

*

Fuel lines damaged or blocked.

*

GO to Pinpoint Test C.

*

Air ingress into the fuel lines.

*

REFER to: Fuel System (310-00A Fuel System - General Information, Diagnosis and Testing).

*

Glow plug relay.

*

REFER to the Ford approved diagnostic tool.

*

IDM relay (if equipped).

*

CARRY OUT the Relay Component Test. REFER to the Wiring Diagrams.

*

Glow plugs.

*

REFER to the Ford approved diagnostic tool.

*

Crankshaft position (CKP) sensor.

*

REFER to Ford approved diagnostic tool.

*

Camshaft position (CMP) sensor.

*

REFER to the Ford approved diagnostic tool.

*

Cylinder head temperature (CHT) sensor.

*

REFER to the Ford approved diagnostic tool.

*

PCM.

*

REFER to the Ford approved diagnostic tool.

*

Fuel rail fuel pressure sensor.

*

REFER to the Ford approved diagnostic tool.

*

Fuel inlet metering valve.

*

REFER to the Ford approved diagnostic tool.

*

Incorrect valve timing.

*

CHECK the valve timing.

*

Low cylinder compression.

*

TEST the cylinder compression.

Poor starting and glow plug indicator is flashing
*

DTC detected.

*

RETRIEVE the DTCs using the Ford approved diagnostic tool. INVESTIGATE and RESOLVE all stored DTCs. If the concern persists, vehicles without IDM, GO to Pinpoint Test D. Vehicles with IDM, GO to Pinpoint Test E.

Poor starting
*

Low fuel tank fuel level.

*

CHECK the fuel tank fuel level is greater than four litres. If the fuel tank fuel level is less then four litres, FILL with fuel.

*

Fuel filter blocked.

*

GO to Pinpoint Test C.

*

Air cleaner element blocked.

*

INSTALL a new air cleaner element.

*

Glow plug relay.

*

REFER to the Ford approved diagnostic tool.

*

Glow plugs.

*

REFER to the Ford approved diagnostic tool.

*

Fuel system leak.

*

CHECK the system for fuel leak(s). REPAIR the system as necessary.

*

Air ingress into the fuel lines.

*

REFER to: Fuel System (310-00A Fuel System - General Information, Diagnosis and Testing).

*

Fuel system restriction.

*

GO to Pinpoint Test C.

*

Fuel pump.

*

GO to Pinpoint Test C.

*

Fuel injector(s).

*

Vehicles without IDM, GO to Pinpoint Test A. Vehicles with IDM, GO to Pinpoint Test B.

*

Incorrect engine oil.

*

INSTALL a new engine oil filter and engine oil.

*

Incorrect power steering fluid.

*

DRAIN and REFILL the power steering system with the correct fluid.
REFER to: Power Steering System Filling (211-00 Steering System - General Information, General Procedures).

*

CKP sensor.

*

REFER to the Ford approved diagnostic tool.

*

CHT sensor.

*

REFER to the Ford approved diagnostic tool.

*

Fuel temperature sensor.

*

REFER to the Ford approved diagnostic tool.

*

Temperature and manifold absolute pressure (T-MAP) sensor.

*

REFER to the Ford approved diagnostic tool.

*

IDM (if equipped).

*

REFER to the Ford approved diagnostic tool.

*

Fuel rail fuel pressure sensor.

*

REFER to the Ford approved diagnostic tool.

*

Fuel inlet metering valve.

*

REFER to the Ford approved diagnostic tool.

*

Catalytic converter blocked.

*

REMOVE and visually INSPECT the catalytic converter as necessary.
REFER to: Catalytic Converter - 2.0L Duratorq-Di (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.0L Duratorq-TDDi (Puma) Diesel/2.4L Duratorq-Di (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Diesel (309-00 Exhaust System, Removal and Installation).

*

Low cylinder compression.

*

TEST the cylinder compression.

Engine starts but immediately stops and glow plug indicator is flashing
*

DTC detected.

*

REFER to the Ford approved diagnostic tool.

Engine starts but immediately stops
*

Air cleaner element blocked.

*

INSTALL a new air cleaner element.

*

Air ingress into the fuel lines.

*

REFER to: Fuel System (310-00A Fuel System - General Information, Diagnosis and Testing).

*

PCM relay.

*

CARRY OUT the relay component test. REFER to Wiring Diagrams.

*

IDM relay (if equipped).

*

CARRY OUT the relay component test. REFER to Wiring Diagrams.

*

CKP sensor.

*

REFER to the Ford approved diagnostic tool.

*

CMP sensor.

*

REFER to the Ford approved diagnostic tool.

*

CHT sensor.

*

REFER to the Ford approved diagnostic tool.

*

PCM.

*

REFER to the Ford approved diagnostic tool.

*

IDM (if equipped).

*

REFER to the Ford approved diagnostic tool.

*

Fuel inlet metering valve.

*

REFER to the Ford approved diagnostic tool.

*

Dual mass flywheel.

*

Visually INSPECT the dual mass flywheel for damage. INSTALL new parts as necessary.

Poor idling and glow plug indicator is flashing
*

DTC detected.

*

RETRIEVE the DTCs using the Ford approved diagnostic tool. INVESTIGATE and RESOLVE all stored DTCs. If the concern persists, vehicles without IDM, GO to Pinpoint Test D. Vehicles with IDM, GO to Pinpoint Test E.

Poor idling
*

Low fuel tank fuel level.

*

CHECK the fuel tank fuel level is greater than four litres. If the fuel tank fuel level is less then four litres, FILL with fuel.

*

Air cleaner element blocked.

*

INSTALL a new air cleaner element.

*

Fuel filter blocked.

*

GO to Pinpoint Test C.

*

Fuel injector(s).

*

Vehicles without IDM, GO to Pinpoint Test A. Vehicles with IDM, GO to Pinpoint Test B.

*

Incorrect or contaminated fuel.

*

CHECK for signs of contamination such as strange odours from the fuel tank.

*

CHECK for signs of water or petrol in the diesel.

*

If contaminated fuel is found, vehicles without IDM, GO to Pinpoint Test D. Vehicles with IDM, GO to Pinpoint Test E.

*

Air ingress into the fuel lines.

*

REFER to: Fuel System (310-00A Fuel System - General Information, Diagnosis and Testing).

*

EGR valve sticking open.

*

EGR vacuum regulator valve.

*

REFER to: Engine Emission Control (303-08 Engine Emission Control, Diagnosis and Testing).

*

IDM (if equipped).

*

REFER to the Ford approved diagnostic tool.

*

T-MAP sensor.

*

REFER to the Ford approved diagnostic tool.

*

CKP sensor.

*

REFER to the Ford approved diagnostic tool.

*

(KS).

*

REFER to the Ford approved diagnostic tool.

*

Fuel rail fuel pressure sensor.

*

REFER to the Ford approved diagnostic tool.

*

Fuel inlet metering valve.

*

REFER to the Ford approved diagnostic tool.

*

Fuel pump.

*

GO to Pinpoint Test C.

*

Dual mass flywheel.

*

Visually INSPECT the dual mass flywheel for damage. INSTALL new parts as necessary.

Engine stumbling and glow plug indicator is flashing
*

DTC detected.

*

REFER to the Ford approved diagnostic tool.

Engine stumbling
*

Low fuel level.

*

CHECK the fuel tank level is greater than four litres. If the fuel tank level is less than four litres, FILL with fuel.

*

Acceleration pedal position (APP) sensor.

*

REFER to the Ford approved diagnostic tool.

*

Fuel injector(s).

*

Vehicles without IDM, GO to Pinpoint Test A. Vehicles with IDM, GO to Pinpoint Test B.

*

Fuel pump.

*

GO to Pinpoint Test C.

*

IDM (if equipped).

*

REFER to the Ford approved diagnostic tool.

*

Fuel injection supply manifold fuel pressure sensor.

*

REFER to the Ford approved diagnostic tool.

*

Dual mass flywheel.

*

Visually INSPECT the dual mass flywheel for damage. INSTALL new parts as necessary.

Engine lacks power and glow plug indicator is flashing
*

DTC detected.

*

REFER to the Ford approved diagnostic tool.

Engine lacks power
*

Brakes binding.

*

CHECK the braking system.
REFER to: Brake System (206-00 Brake System - General Information, Diagnosis and Testing).

*

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 performance.

*

Air cleaner element blocked.

*

INSTALL a new air cleaner element as necessary.

*

Fuel filter blocked.

*

GO to Pinpoint Test C.

*

Kinked or restricted fuel lines.

*

GO to Pinpoint Test C.

*

Fuel pump.

*

GO to Pinpoint Test C.

*

Fuel injector(s).

*

Vehicles without IDM, GO to Pinpoint Test A. Vehicles with IDM, GO to Pinpoint Test B.

*

Air ingress into the fuel lines.

*

REFER to: Fuel System (310-00A Fuel System - General Information, Diagnosis and Testing).

*

Turbocharger.

*

Turbocharger vacuum control.

*

Turbocharger vacuum diaphragm unit.

*

Vane adjustment solenoid valve.

*

INSPECT the vacuum line(s) for visible signs of damage or blockage. CLEAN, REPAIR or INSTALL new parts as necessary.
REFER to: Turbocharger - 2.4L Duratorq-Di (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Diesel (303-04D Fuel Charging and Controls - Turbocharger, Removal and Installation) /
Turbocharger - 2.0L Duratorq-Di (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.0L Duratorq-TDDi (Puma) Diesel (303-04D Fuel Charging and Controls - Turbocharger, Removal and Installation).

*

EGR valve sticking open.

*

EGR vacuum regulator valve.

*

REFER to: Engine Emission Control (303-08 Engine Emission Control, Diagnosis and Testing).

*

Charge air cooler blocked or cracked.

*

Charge air cooler pipes split or cracked.

*

Charge air cooler retaining clips missing or loose.

*

INSPECT for visible signs of damage or blockage. CLEAN, REPAIR or INSTALL new parts as necessary.

*

Incorrect or contaminated fuel.

*

CHECK for signs of contamination such as strange odours from the fuel tank.

*

CHECK for signs of water or petrol in the diesel.

*

If contaminated fuel is found, vehicles without IDM, GO to Pinpoint Test D. Vehicles with IDM, GO to Pinpoint Test E.

*

Vehicle speed sensor (VSS).

*

REFER to the Ford approved diagnostic tool.

*

CHT sensor.

*

REFER to the Ford approved diagnostic tool.

*

T-MAP sensor.

*

REFER to the Ford approved diagnostic tool.

*

APP sensor.

*

REFER to the Ford approved diagnostic tool.

*

IDM (if equipped).

*

REFER to the Ford approved diagnostic tool.

*

Fuel temperature sensor.

*

REFER to the Ford approved diagnostic tool.

*

Fuel rail fuel pressure sensor.

*

REFER to the Ford approved diagnostic tool.

*

Fuel inlet metering valve.

*

REFER to the Ford approved diagnostic tool.

*

Incorrect valve timing.

*

CHECK the valve timing.

*

Low cylinder compression.

*

CHECK the cylinder compression

*

Catalytic converter blocked.

*

REMOVE and visually INSPECT the catalytic converter for damage. INSTALL a new catalytic converter as necessary.
REFER to: Catalytic Converter - 2.0L Duratorq-Di (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.0L Duratorq-TDDi (Puma) Diesel/2.4L Duratorq-Di (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Diesel (309-00 Exhaust System, Removal and Installation).

Black smoke at idle and glow plug indicator is flashing
*

DTC detected.

*

REFER to the Ford approved diagnostic tool.

Black smoke at idle
*

Air cleaner element blocked.

*

INSTALL a new air cleaner element as necessary.

*

Glow plug relay.

*

REFER to the Ford approved diagnostic tool.

*

Fuel injector(s).

*

Vehicles without IDM, GO to Pinpoint Test A. Vehicles with IDM, GO to Pinpoint Test B.

*

Turbocharger vacuum control.

*

Vane adjustment solenoid valve.

*

INSPECT for visible signs of damage or blockage. CLEAN, REPAIR or INSTALL new parts as necessary.
REFER to: Turbocharger - 2.0L Duratorq-Di (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.0L Duratorq-TDDi (Puma) Diesel (303-04D Fuel Charging and Controls - Turbocharger, Removal and Installation) /
Turbocharger - 2.4L Duratorq-Di (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Diesel (303-04D Fuel Charging and Controls - Turbocharger, Removal and Installation).

*

CHT sensor.

*

REFER to the Ford approved diagnostic tool.

*

T-MAP sensor.

*

REFER to the Ford approved diagnostic tool.

*

IDM (if equipped).

*

REFER to the Ford approved diagnostic tool.

*

Fuel rail fuel pressure sensor.

*

REFER to the Ford approved diagnostic tool.

*

Incorrect valve timing.

*

CHECK the valve timing.

*

Catalytic converter blocked.

*

REMOVE and visually INSPECT the catalytic converter for damage. INSTALL a new catalytic converter as necessary.
REFER to: Catalytic Converter - 2.0L Duratorq-Di (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.0L Duratorq-TDDi (Puma) Diesel/2.4L Duratorq-Di (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Diesel (309-00 Exhaust System, Removal and Installation).

Excessive black smoke during acceleration and glow plug indicator is flashing
*

DTC detected.

*

REFER to the Ford approved diagnostic tool.

Excessive black smoke during acceleration
*

Air cleaner element blocked.

*

INSTALL a new air cleaner element as necessary.

*

Incorrect or contaminated fuel.

*

CHECK for signs of contamination such as strange odours from the fuel tank.

*

CHECK for signs of water or petrol in the diesel.

*

If contaminated fuel is found, vehicles without IDM, GO to Pinpoint Test D. Vehicles with IDM, GO to Pinpoint Test E.

*

EGR valve sticking open.

*

EGR vacuum regulator valve.

*

REFER to: Engine Emission Control (303-08 Engine Emission Control, Diagnosis and Testing).

*

Fuel injector(s).

*

Vehicles without IDM, GO to Pinpoint Test A. Vehicles with IDM, GO to Pinpoint Test B.

*

APP sensor.

*

REFER to the Ford approved diagnostic tool.

*

CKP sensor.

*

REFER to the Ford approved diagnostic tool.

*

KS.

*

REFER to the Ford approved diagnostic tool.

*

IDM (if equipped).

*

REFER to the Ford approved diagnostic tool.

*

Fuel rail fuel pressure sensor.

*

REFER to the Ford approved diagnostic tool.

*

Catalytic converter blocked.

*

REMOVE and visually INSPECT the catalytic converter for damage. INSTALL a new catalytic converter as necessary.
REFER to: Catalytic Converter - 2.0L Duratorq-Di (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.0L Duratorq-TDDi (Puma) Diesel/2.4L Duratorq-Di (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Diesel (309-00 Exhaust System, Removal and Installation).

Black smoke at cruising speeds and glow plug indicator is flashing
*

DTC detected.

*

REFER to the Ford approved diagnostic tool.

Black smoke at cruising speeds
*

Air cleaner element blocked.

*

INSTALL a new air cleaner element.

*

EGR valve sticking open.

*

EGR vacuum regulator valve.

*

REFER to: Engine Emission Control (303-08 Engine Emission Control, Diagnosis and Testing).

*

Turbocharger vacuum diaphragm unit.

*

Vane adjustment solenoid valve.

*

REFER to: Turbocharger (303-04D Fuel Charging and Controls - Turbocharger, Diagnosis and Testing).

*

CHT sensor.

*

REFER to the Ford approved diagnostic tool.

*

T-MAP sensor.

*

REFER to the Ford approved diagnostic tool.

*

Fuel injector(s).

*

Vehicles without IDM, GO to Pinpoint Test A. Vehicles with IDM, GO to Pinpoint Test B.

*

IDM (if equipped).

*

REFER to the Ford approved diagnostic tool.

*

Fuel injection supply manifold fuel pressure sensor.

*

REFER to the Ford approved diagnostic tool.

*

Catalytic converter blocked.

*

REMOVE and visually INSPECT the catalytic converter for damage. INSTALL a new catalytic converter as necessary.
REFER to: Catalytic Converter - 2.0L Duratorq-Di (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.0L Duratorq-TDDi (Puma) Diesel/2.4L Duratorq-Di (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Diesel (309-00 Exhaust System, Removal and Installation).

Blue smoke and glow plug indicator is flashing
*

DTC detected.

*

REFER to the Ford approved diagnostic tool.

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 litre per 1000 km (600 miles).

*

Incorrect or contaminated fuel.

*

CHECK for signs of contamination such as strange odours from the fuel tank.

*

CHECK for signs of water or petrol in the diesel.

*

If contaminated fuel is found, vehicles without IDM, GO to Pinpoint Test D. Vehicles with IDM, GO to Pinpoint Test E.

*

Positive crankcase ventilation (PCV) system.

*

INSPECT for visible signs of damage or blockage. CLEAN, REPAIR or INSTALL new parts as necessary.

*

Turbocharger oil return tube blocked or damaged.

*

REFER to: Turbocharger (303-04D Fuel Charging and Controls - Turbocharger, Diagnosis and Testing).

*

Worn or damaged valve guide(s), piston ring(s), cylinder bore(s), cylinder head or gasket.

*

REMOVE the cylinder head. INSPECT the cylinder head, pistons and cylinder bores for signs of wear or damage.
REFER to: Cylinder Head (303-01B Engine - 2.0L Duratorq-Di (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.0L Duratorq-TDDi (Puma) Diesel, In-vehicle Repair).

White smoke and glow plug indicator is flashing
*

DTC detected.

*

REFER to the Ford approved diagnostic tool.

White smoke
*

Incorrect or contaminated fuel.

*

CHECK for signs of contamination such as strange odours from the fuel tank.

*

CHECK for signs of water or petrol in the diesel.

*

If contaminated fuel is found, vehicles without IDM, GO to Pinpoint Test D. Vehicles with IDM, GO to Pinpoint Test E.

*

KS.

*

REFER to the Ford approved diagnostic tool.

*

Fuel injector(s).

*

Vehicles without IDM, GO to Pinpoint Test A. Vehicles with IDM, GO to Pinpoint Test B.

*

EGR valve sticking open.

*

EGR vacuum regulator valve.

*

REFER to: Engine Emission Control (303-08 Engine Emission Control, Diagnosis and Testing).

*

Incorrect valve timing.

*

CHECK the valve timing.

*

Coolant in the combustion chamber.

*

CARRY OUT a cooling system pressure test.
REFER to: Engine Cooling (303-03 Engine Cooling, Diagnosis and Testing).
REMOVE the cylinder head. INSPECT the cylinder head, cylinder head gasket and cylinder bores for wear or damage.
REFER to: Cylinder Head (303-01B Engine - 2.0L Duratorq-Di (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.0L Duratorq-TDDi (Puma) Diesel, In-vehicle Repair).

Engine misfire and glow plug indicator is flashing
*

DTC detected.

*

REFER to the Ford approved diagnostic tool.

Engine misfire
*

Low fuel tank level.

*

CHECK the fuel tank level is greater than four litres. If the fuel tank level is less than four litres, FILL with fuel.

*

Incorrect or contaminated fuel.

*

CHECK for signs of contamination such as strange odours from the fuel tank.

*

CHECK for signs of water or petrol in the diesel.

*

If contaminated fuel is found, vehicles without IDM, GO to Pinpoint Test D. Vehicles with IDM, GO to Pinpoint Test E.

*

Air ingress into the fuel lines.

*

REFER to: Fuel System (310-00A Fuel System - General Information, Diagnosis and Testing).

*

Fuel pump.

*

GO to Pinpoint Test C.

*

Fuel injector(s).

*

Vehicles without IDM, GO to Pinpoint Test A. Vehicles with IDM, GO to Pinpoint Test B.

*

EGR valve sticking open.

*

EGR vacuum regulator valve.

*

REFER to: Engine Emission Control (303-08 Engine Emission Control, Diagnosis and Testing).

*

Engine operating temperature too high.

*

REFER to: Engine Cooling (303-03 Engine Cooling, Diagnosis and Testing).

*

CHT sensor.

*

REFER to the Ford approved diagnostic tool.

*

CKP sensor.

*

REFER to the Ford approved diagnostic tool.

*

CMP sensor.

*

REFER to the Ford approved diagnostic tool.

*

T-MAP sensor.

*

REFER to the Ford approved diagnostic tool.

*

KS.

*

REFER to the Ford approved diagnostic tool.

*

IDM (if equipped).

*

REFER to the Ford approved diagnostic tool.

*

Fuel injection supply manifold fuel pressure sensor.

*

REFER to the Ford approved diagnostic tool.

*

Low cylinder compression.

*

CHECK the cylinder compression.

*

Worn or damaged valve(s), tappet(s), camshaft(s) or cylinder head gasket.

*

REMOVE the cylinder head. INSPECT the cylinder head, valves, tappets and camshafts for signs of wear or damage.
REFER to: Cylinder Head (303-01B Engine - 2.0L Duratorq-Di (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.0L Duratorq-TDDi (Puma) Diesel, In-vehicle Repair).

Engine knock at idle and glow plug indicator is flashing
*

DTC detected.

*

REFER to the Ford approved diagnostic tool.

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 odours from the fuel tank.

*

CHECK for signs of water or petrol in the diesel.

*

If contaminated fuel is found, vehicles without IDM, GO to Pinpoint Test D. Vehicles with IDM, GO to Pinpoint Test E.

*

KS.

*

REFER to the Ford approved diagnostic tool.

*

Fuel injector(s).

*

Vehicles without IDM, GO to Pinpoint Test A. Vehicles with IDM, GO to Pinpoint Test B.

*

CKP sensor.

*

REFER to the Ford approved diagnostic tool.

*

IDM (if equipped).

*

REFER to the Ford approved diagnostic tool.

*

Incorrect valve timing.

*

CHECK the valve timing.

*

Excessive carbon build up.

*

REMOVE the cylinder head. INSPECT the cylinder head and pistons for signs carbon build up.
REFER to: Cylinder Head (303-01B Engine - 2.0L Duratorq-Di (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.0L Duratorq-TDDi (Puma) Diesel, In-vehicle Repair).

*

Worn or damaged oil pump.

*

Worn or damaged timing chain or sprocket.

*

Major mechanical engine failure.

*

INSPECT the engine components.

*

Dual mass flywheel.

*

Visually INSPECT the dual mass flywheel for damage. INSTALL new parts as necessary.

Engine knock during acceleration and glow plug indicator is flashing
*

DTC detected.

*

REFER to the Ford approved diagnostic tool.

Engine knock during acceleration
*

KS.

*

REFER to the Ford approved diagnostic tool.

*

Fuel injector(s).

*

Vehicles without IDM, GO to Pinpoint Test A. Vehicles with IDM, GO to Pinpoint Test B.

*

IDM (if equipped).

*

REFER to the Ford approved diagnostic tool.

*

Fuel inlet metering valve.

*

REFER to the Ford approved diagnostic tool.

*

Fuel pump.

*

GO to Pinpoint Test C.

*

Major mechanical engine failure.

*

REFER to: Engine (303-01B Engine - 2.0L Duratorq-Di (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.0L Duratorq-TDDi (Puma) Diesel, Diagnosis and Testing).

Excessive fuel consumption and glow plug indicator is flashing
*

DTC detected.

*

REFER to the Ford approved diagnostic tool.

NOTE:Before proceeding with any of the actions in relation to the possible sources for excessive fuel consumption, a fuel consumption test must be carried out using the Ford approved diagnostic tool.

Excessive fuel consumption
*

Brakes binding.

*

CHECK the braking system.
REFER to: Brake System (206-00 Brake System - General Information, Diagnosis and Testing).

*

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 filter blocked.

*

GO to Pinpoint Test C.

*

Fuel system leak(s).

*

CHECK the system for fuel leak(s). REPAIR or INSTALL new parts as necessary.

*

Incorrect engine oil.

*

INSTALL a new oil filter and engine oil.

*

Generator.

*

REFER to: Charging System - 2.0L Duratorq-Di (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.0L Duratorq-TDDi (Puma) Diesel/2.4L Duratorq-Di (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Diesel (414-00 Charging System - General Information, Diagnosis and Testing).

*

EGR valve sticking open.

*

EGR vacuum regulator valve.

*

REFER to: Engine Emission Control (303-08 Engine Emission Control, Diagnosis and Testing).

*

Turbocharger vacuum diaphragm unit.

*

REFER to: Turbocharger - 2.0L Duratorq-Di (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.0L Duratorq-TDDi (Puma) Diesel (303-04D Fuel Charging and Controls - Turbocharger, Removal and Installation) / Turbocharger - 2.4L Duratorq-Di (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Diesel (303-04D Fuel Charging and Controls - Turbocharger, Removal and Installation).

*

Air ingress into the fuel lines.

*

REFER to: Fuel System (310-00A Fuel System - General Information, Diagnosis and Testing).

*

CHT sensor.

*

REFER to the Ford approved diagnostic tool.

*

T-MAP sensor.

*

REFER to the Ford approved diagnostic tool.

*

Fuel injector(s).

*

Vehicles without IDM, GO to Pinpoint Test A. Vehicles with IDM, GO to Pinpoint Test B.

*

IDM (if equipped).

*

REFER to the Ford approved diagnostic tool.

*

Turbocharger.

*

REFER to: Turbocharger (303-04D Fuel Charging and Controls - Turbocharger, Diagnosis and Testing).

*

Incorrect valve timing.

*

CHECK the valve timing.

*

Slipping clutch.

*

REFER to: Manual Transmission and Clutch - Vehicles With: MT-75 (308-00 Manual Transmission/Transaxle and Clutch - General Information, Diagnosis and Testing).

*

Low cylinder compression.

*

CHECK the cylinder compression.

*

Dual mass flywheel.

*

Visually INSPECT the dual mass flywheel for damage. INSTALL new parts as necessary.

Engine cuts out during hard acceleration
*

CMP sensor.

*

REFER to the Ford approved diagnostic tool.

*

CKP sensor.

*

REFER to the Ford approved diagnostic tool.

*

Fuel rail fuel pressure sensor.

*

REFER to the Ford approved diagnostic tool.

*

Fuel inlet metering valve.

*

REFER to the Ford approved diagnostic tool.

*

Fuel pump.

*

GO to Pinpoint Test C.