Symptom | Possible Sources | Action |
Engine does not crank and glow plug indicator is flashing | * DTC detected. | * REFER to the WDS. |
Engine does not crank | * Starting system. | * REFER to: Starting System (303-06 Starting System, Diagnosis and Testing). |
Engine cranks but does not start and glow plug indicator is flashing | * DTC detected. | * REFER to the WDS. |
Engine cranks but does not start | * Fuel metering valve (CP1H fuel pump) open circuit causing fuel rail pressure to be less than 20 bar. | * REFER to the WDS |
* Low fuel tank fuel level. | * CHECK the fuel tank fuel level is greater than four liters. If the fuel tank fuel level is less then four liters, FILL with fuel. |
* Fuel filter blocked. | * INSTALL a new fuel filter. REFER to: Fuel Filter - 1.6L Duratorq-TDCi (DV) Diesel (310-01 Fuel Tank and Lines, Removal and Installation). |
* Fuel lines damaged or blocked. | * REFER to: Fuel System - 1.6L Duratorq-TDCi (DV) Diesel/2.0L Duratorq-TDCi (DW) Diesel (310-00 Fuel System - General Information, Diagnosis and Testing). |
* Air ingress into the fuel lines. | * REFER to: Fuel System - 1.6L Duratorq-TDCi (DV) Diesel/2.0L Duratorq-TDCi (DW) Diesel (310-00 Fuel System - General Information, Diagnosis and Testing). |
* Glow plugs. | * REFER to the WDS. |
* Incorrect valve timing. | * CHECK the valve timing. REFER to: Timing Belt (303-01D Engine - 1.6L Duratorq-TDCi (DV) Diesel, In-vehicle Repair). |
* Low cylinder compression. | * Check the cylinder compression. |
* Crankshaft position (CKP) sensor. | * REFER to the WDS. |
* Camshaft position (CMP) sensor. | * REFER to the WDS. |
* Engine coolant temperature (ECT) sensor. | * REFER to the WDS. |
* PCM. | * REFER to the WDS. |
* Fuel rail fuel pressure sensor. | * REFER to the WDS. |
* Fuel inlet metering valve. | * REFER to the WDS. |
* Fuel pump. | * REFER to the WDS. |
* Fuel injector(s). | * REFER to the WDS. |
Poor starting and glow plug indicator is flashing | * DTC detected. | * REFER to the WDS. |
Poor starting | * Low fuel tank fuel level. | * CHECK the fuel tank fuel level is greater than four liters. If the fuel tank fuel level is less then four liters, FILL with fuel. |
* Fuel filter blocked. | * INSTALL a new fuel filter. REFER to: Fuel Filter - 1.6L Duratorq-TDCi (DV) Diesel (310-01 Fuel Tank and Lines, Removal and Installation). |
* Air cleaner element blocked. | * INSTALL a new air cleaner element. |
* Glow plugs. | * REFER to the WDS. |
* 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 - 1.6L Duratorq-TDCi (DV) Diesel/2.0L Duratorq-TDCi (DW) Diesel (310-00 Fuel System - General Information, Diagnosis and Testing). |
* Fuel system restriction. | * REFER to: Fuel System - 1.6L Duratorq-TDCi (DV) Diesel/2.0L Duratorq-TDCi (DW) Diesel (310-00 Fuel System - General Information, Diagnosis and Testing). |
* Incorrect engine oil. | * INSTALL a new engine oil filter and engine oil. |
* Catalytic converter blocked. | * REMOVE and visually INSPECT the catalytic converter for damage. INSTALL a new catalytic converter as necessary. REFER to: Catalytic Converter - 1.6L Duratorq-TDCi (DV) Diesel (309-00 Exhaust System, Removal and Installation) / Catalytic Converter - 1.6L Duratorq-TDCi (DV) Diesel (110 PS), VIN Plate Emission Level Code: V (309-00 Exhaust System, Removal and Installation). |
* Low cylinder compression. | * Check the cylinder compression. |
* CKP sensor. | * REFER to the WDS. |
* ECT sensor. | * REFER to the WDS. |
* Fuel temperature sensor. | * REFER to the WDS. |
* Mass air flow (MAF) sensor. | * REFER to the WDS. |
* Manifold absolute pressure (MAP) sensor. | * REFER to the WDS. |
* Fuel injector(s). | * REFER to the WDS. |
* Fuel rail fuel pressure sensor. | * REFER to the WDS. |
* Fuel inlet metering valve. | * REFER to the WDS. |
* Fuel pump. | * REFER to the WDS. |
Engine starts but immediately stops and glow plug indicator is flashing | * DTC detected. | * REFER to the WDS. |
Engine starts but immediately stops | * Fuel metering valve (CP3.2 fuel pump) open circuit causing the fuel rail pressure to be greater than 1600 bar. | * REFER to the WDS. |
* Air cleaner element blocked. | * INSTALL a new air cleaner element. |
* Air ingress into the fuel lines. | * REFER to: Fuel System - 1.6L Duratorq-TDCi (DV) Diesel/2.0L Duratorq-TDCi (DW) Diesel (310-00 Fuel System - General Information, Diagnosis and Testing). |
* PCM relay. | * CARRY OUT the relay component test. REFER to Wiring Diagrams. |
* Dual mass flywheel. | * INSPECT the dual mass flywheel for damage. INSTALL a new dual mass flywheel as necessary. |
* CKP sensor. | * REFER to the WDS. |
* CMP sensor. | * REFER to the WDS. |
* ECT sensor. | * REFER to the WDS. |
* PCM. | * REFER to the WDS. |
* Fuel inlet metering valve. | * REFER to the WDS. |
Poor idling and glow plug indicator is flashing | * DTC detected. | * REFER to the 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 then 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: Fuel Filter - 1.6L Duratorq-TDCi (DV) Diesel (310-01 Fuel Tank and Lines, Removal and Installation). |
* 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: Fuel Tank Draining (310-00 Fuel System - General Information, General Procedures). INSTALL a new fuel filter. REFER to: Fuel Filter - 1.6L Duratorq-TDCi (DV) Diesel (310-01 Fuel Tank and Lines, Removal and Installation). INSTALL a new fuel pump, fuel injectors, fuel injection supply manifold, and high-pressure fuel supply lines. REFER to: Fuel Injectors - VIN Plate Emission Level Code: S (303-04H Fuel Charging and Controls - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation) / Fuel Injectors - VIN Plate Emission Level Code: K (303-04H Fuel Charging and Controls - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation) / Fuel Injection Supply Manifold - VIN Plate Emission Level Code: S (303-04H Fuel Charging and Controls - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation) / Fuel Injection Supply Manifold - VIN Plate Emission Level Code: K (303-04H Fuel Charging and Controls - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation) / Fuel Pump (303-04H Fuel Charging and Controls - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation). |
* Air ingress into the fuel lines. | * REFER to: Fuel System - 1.6L Duratorq-TDCi (DV) Diesel/2.0L Duratorq-TDCi (DW) Diesel (310-00 Fuel System - General Information, Diagnosis and Testing). |
* EGR valve incorrect operation. | * REFER to: Fuel System - 1.6L Duratorq-TDCi (DV) Diesel/2.0L Duratorq-TDCi (DW) Diesel (310-00 Fuel System - General Information, Diagnosis and Testing). |
* Dual mass flywheel. | * INSPECT the dual mass flywheel for damage. INSTALL a new dual mass flywheel as necessary. |
* Fuel injector(s). | * REFER to the WDS. |
* MAF sensor. | * REFER to the WDS. |
* MAP sensor. | * REFER to the WDS. |
* CKP sensor. | * REFER to the WDS. |
* Fuel rail fuel pressure sensor. | * REFER to the WDS. |
* Fuel inlet metering valve. | * REFER to the WDS. |
* Fuel pump. | * REFER to the WDS. |
Engine stumbling and glow plug indicator is flashing | * DTC detected. | * REFER to the WDS. |
Engine stumbling | * Low fuel level. | * CHECK the fuel tank level is greater than four liters. If the fuel tank level is less than four liters, FILL with fuel. |
* Dual mass flywheel. | * INSPECT the dual mass flywheel for damage. INSTALL a new dual mass flywheel as necessary. |
* Acceleration pedal position (APP) sensor. | * REFER to the WDS. |
* Fuel injector(s). | * REFER to the WDS. |
* Fuel rail fuel pressure sensor. | * REFER to the WDS. |
* Fuel pump. | * REFER to the WDS. |
Engine lacks power and glow plug indicator is flashing | * DTC detected. | * REFER to the WDS. |
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 fuel consumption. |
* Air cleaner element blocked. | * INSTALL a new air cleaner element as necessary. |
* Fuel filter blocked. | * INSTALL a new fuel filter. REFER to: Fuel Filter - 1.6L Duratorq-TDCi (DV) Diesel (310-01 Fuel Tank and Lines, Removal and Installation). |
* Kinked or restricted fuel lines. | * REFER to: Fuel System - 1.6L Duratorq-TDCi (DV) Diesel/2.0L Duratorq-TDCi (DW) Diesel (310-00 Fuel System - General Information, Diagnosis and Testing). |
* Air ingress into the fuel lines. | * REFER to: Fuel System - 1.6L Duratorq-TDCi (DV) Diesel/2.0L Duratorq-TDCi (DW) Diesel (310-00 Fuel System - General Information, Diagnosis and Testing). |
* Turbocharger. * Turbocharger vacuum diaphragm unit. | * INSPECT the vacuum line(s) for visible signs of damage or blockage. CLEAN, REPAIR or INSTALL new parts as necessary. REFER to: Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel (303-04F Fuel Charging and Controls - Turbocharger, Diagnosis and Testing) / Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel (110 PS) (303-04F Fuel Charging and Controls - Turbocharger, Diagnosis and Testing). |
* Incorrect valve timing. | * CHECK the valve timing. REFER to: Timing Belt (303-01E Engine - 2.0L Duratorq-TDCi (DW) Diesel, In-vehicle Repair). |
* 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 - 1.6L Duratorq-TDCi (DV) Diesel (309-00 Exhaust System, Removal and Installation) / Catalytic Converter - 1.6L Duratorq-TDCi (DV) Diesel (110 PS), VIN Plate Emission Level Code: V (309-00 Exhaust System, Removal and Installation). |
* EGR valve incorrect operation. | * REFER to: Engine Emission Control (303-08D Engine Emission Control - 2.0L Duratorq-TDCi (DW) Diesel, Diagnosis and Testing). |
* Charge air cooler blocked or cracked. * Charge air cooler pipes split or cracked. * Charge air cooler pipe 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 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: Fuel Tank Draining (310-00 Fuel System - General Information, General Procedures). INSTALL a new fuel filter. REFER to: Fuel Filter - 1.6L Duratorq-TDCi (DV) Diesel (310-01 Fuel Tank and Lines, Removal and Installation). INSTALL a new fuel pump, fuel injectors, fuel injection supply manifold, and high-pressure fuel supply lines. REFER to: Fuel Injectors - VIN Plate Emission Level Code: S (303-04H Fuel Charging and Controls - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation) / Fuel Injectors - VIN Plate Emission Level Code: K (303-04H Fuel Charging and Controls - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation) / Fuel Injection Supply Manifold - VIN Plate Emission Level Code: S (303-04H Fuel Charging and Controls - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation) / Fuel Injection Supply Manifold - VIN Plate Emission Level Code: K (303-04H Fuel Charging and Controls - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation) / Fuel Pump (303-04H Fuel Charging and Controls - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation). |
* Vehicle speed sensor (VSS). | * REFER to the WDS. |
* ECT sensor. | * REFER to the WDS. |
* MAF sensor. | * REFER to the WDS. |
* MAP sensor. | * REFER to the WDS. |
* APP sensor. | * REFER to the WDS. |
* Fuel injector(s). | * REFER to the WDS. |
* Fuel temperature sensor. | * REFER to the WDS. |
* Fuel rail fuel pressure sensor. | * REFER to the WDS. |
* Fuel inlet metering valve. | * REFER to the WDS. |
* Fuel pump. | * REFER to the WDS. |
Black smoke at idle and glow plug indicator is flashing | * DTC detected. | * REFER to the WDS. |
Black smoke at idle | * Air cleaner element blocked. | * INSTALL a new air cleaner element as necessary. |
* Glow plug system. | * REFER to the WDS. |
* Incorrect valve timing. | * CHECK the valve timing. REFER to: Timing Belt (303-01E Engine - 2.0L Duratorq-TDCi (DW) Diesel, In-vehicle Repair). |
* Catalytic converter blocked. | * REMOVE and visually INSPECT the catalytic converter for damage. INSTALL a new catalytic converter as necessary. REFER to: Catalytic Converter - 1.6L Duratorq-TDCi (DV) Diesel (309-00 Exhaust System, Removal and Installation) / Catalytic Converter - 1.6L Duratorq-TDCi (DV) Diesel (110 PS), VIN Plate Emission Level Code: V (309-00 Exhaust System, Removal and Installation). |
* ECT sensor. | * REFER to the WDS. |
* MAF sensor. | * REFER to the WDS. |
* MAP sensor. | * REFER to the WDS. |
* Fuel injector(s). | * REFER to the WDS. |
* Fuel rail fuel pressure sensor. | * REFER to the WDS. |
Excessive black smoke during acceleration and glow plug indicator is flashing | * DTC detected. | * REFER to the WDS. |
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 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: Fuel Tank Draining (310-00 Fuel System - General Information, General Procedures). INSTALL a new fuel filter. REFER to: Fuel Filter - 1.6L Duratorq-TDCi (DV) Diesel (310-01 Fuel Tank and Lines, Removal and Installation). INSTALL a new fuel pump, fuel injectors, fuel injection supply manifold, and high-pressure fuel supply lines. REFER to: Fuel Injectors - VIN Plate Emission Level Code: S (303-04H Fuel Charging and Controls - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation) / Fuel Injectors - VIN Plate Emission Level Code: K (303-04H Fuel Charging and Controls - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation) / Fuel Injection Supply Manifold - VIN Plate Emission Level Code: S (303-04H Fuel Charging and Controls - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation) / Fuel Injection Supply Manifold - VIN Plate Emission Level Code: K (303-04H Fuel Charging and Controls - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation) / Fuel Pump (303-04H Fuel Charging and Controls - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation). |
* EGR valve incorrect operation. | * REFER to: Exhaust Gas Recirculation (EGR) Valve (303-08D Engine Emission Control - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation). |
* Catalytic converter blocked. | * REMOVE and visually INSPECT the catalytic converter for damage. INSTALL a new catalytic converter as necessary. REFER to: Catalytic Converter - 1.6L Duratorq-TDCi (DV) Diesel (309-00 Exhaust System, Removal and Installation) / Catalytic Converter - 1.6L Duratorq-TDCi (DV) Diesel (110 PS), VIN Plate Emission Level Code: V (309-00 Exhaust System, Removal and Installation). |
* APP sensor. | * REFER to the WDS. |
* CKP sensor. | * REFER to the WDS. |
* Fuel injector(s). | * REFER to the WDS. |
* Fuel rail fuel pressure sensor. | * REFER to the WDS. |
Black smoke at cruising speeds and glow plug indicator is flashing | * DTC detected. | * REFER to the WDS. |
Black smoke at cruising speeds | * Air cleaner element blocked. | * INSTALL a new air cleaner element. |
* EGR valve incorrect operation. | * REFER to: Exhaust Gas Recirculation (EGR) Valve (303-08D Engine Emission Control - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation). |
* Turbocharger vacuum diaphragm unit. | * REFER to: Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel (303-04F Fuel Charging and Controls - Turbocharger, Diagnosis and Testing) / Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel (110 PS) (303-04F Fuel Charging and Controls - Turbocharger, Removal and Installation). |
* Catalytic converter blocked. | * REMOVE and visually INSPECT the catalytic converter for damage. INSTALL a new catalytic converter as necessary. REFER to: Catalytic Converter - 1.6L Duratorq-TDCi (DV) Diesel (309-00 Exhaust System, Removal and Installation) / Catalytic Converter - 1.6L Duratorq-TDCi (DV) Diesel (110 PS), VIN Plate Emission Level Code: V (309-00 Exhaust System, Removal and Installation). |
* ECT sensor. | * REFER to the WDS. |
* MAF sensor. | * REFER to the WDS. |
* MAP sensor. | * REFER to the WDS. |
* Fuel injector(s). | * REFER to the WDS. |
* Fuel rail fuel pressure sensor. | * REFER to the WDS. |
Blue smoke and glow plug indicator is flashing | * DTC detected. | * REFER to the 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 of a liter per 1000 km (600 miles). |
* 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: Fuel Tank Draining (310-00 Fuel System - General Information, General Procedures). INSTALL a new fuel filter. REFER to: Fuel Filter - 1.6L Duratorq-TDCi (DV) Diesel (310-01 Fuel Tank and Lines, Removal and Installation). INSTALL a new fuel pump, fuel injectors, fuel injection supply manifold, and high-pressure fuel supply lines. REFER to: Fuel Injectors - VIN Plate Emission Level Code: S (303-04H Fuel Charging and Controls - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation) / Fuel Injectors - VIN Plate Emission Level Code: K (303-04H Fuel Charging and Controls - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation) / Fuel Injection Supply Manifold - VIN Plate Emission Level Code: S (303-04H Fuel Charging and Controls - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation) / Fuel Injection Supply Manifold - VIN Plate Emission Level Code: K (303-04H Fuel Charging and Controls - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation) / Fuel Pump (303-04H Fuel Charging and Controls - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation). |
* 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. |
* 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 - 1.6L Duratorq-TDCi (DV) Diesel (303-04F Fuel Charging and Controls - Turbocharger, Diagnosis and Testing) / Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel (110 PS) (303-04F Fuel Charging and Controls - Turbocharger, Diagnosis and Testing). |
White smoke and glow plug indicator is flashing | * DTC detected. | * REFER to the WDS. |
White smoke | * Water in fuel. | * CHECK for signs of water in the diesel. * If contaminated fuel is found, DRAIN the complete fuel system. FLUSH the fuel system through with clean diesel. REFER to: Fuel Tank Draining (310-00 Fuel System - General Information, General Procedures). INSTALL a new fuel filter. REFER to: Fuel Filter - 1.6L Duratorq-TDCi (DV) Diesel (310-01 Fuel Tank and Lines, Removal and Installation). INSTALL a new fuel pump, fuel injectors, fuel injection supply manifold, and high-pressure fuel supply lines. REFER to: Fuel Injectors - VIN Plate Emission Level Code: S (303-04H Fuel Charging and Controls - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation) / Fuel Injectors - VIN Plate Emission Level Code: K (303-04H Fuel Charging and Controls - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation) / Fuel Injection Supply Manifold - VIN Plate Emission Level Code: S (303-04H Fuel Charging and Controls - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation) / Fuel Injection Supply Manifold - VIN Plate Emission Level Code: K (303-04H Fuel Charging and Controls - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation) / Fuel Pump (303-04H Fuel Charging and Controls - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation). |
* Fuel injector(s). | * REFER to the WDS. |
* EGR valve incorrect operation. | * REFER to: Exhaust Gas Recirculation (EGR) Valve (303-08D Engine Emission Control - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation). |
* Incorrect valve timing. | * CHECK the valve timing. REFER to: Timing Belt (303-01E Engine - 2.0L Duratorq-TDCi (DW) Diesel, In-vehicle Repair). |
* Coolant in the combustion chamber. | * CARRY OUT a cooling system pressure test. REFER to: Engine Cooling (303-03E Engine Cooling - 2.0L Duratorq-TDCi (DW) Diesel, Diagnosis and Testing). REMOVE the cylinder head. INSPECT the cylinder head, cylinder head gasket and cylinder bores for wear or damage. |
Engine misfire and glow plug indicator is flashing | * DTC detected. | * REFER to the WDS. |
Engine misfire | * Low fuel tank level. | * CHECK the fuel tank level is greater than four liters. If the fuel tank level is less than four liters, FILL with fuel. |
* 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: Fuel Tank Draining (310-00 Fuel System - General Information, General Procedures). INSTALL a new fuel filter. REFER to: Fuel Filter - 1.6L Duratorq-TDCi (DV) Diesel (310-01 Fuel Tank and Lines, Removal and Installation). INSTALL a new fuel pump, fuel injectors, fuel injection supply manifold, and high-pressure fuel supply lines. REFER to: Fuel Injectors - VIN Plate Emission Level Code: S (303-04H Fuel Charging and Controls - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation) / Fuel Injectors - VIN Plate Emission Level Code: K (303-04H Fuel Charging and Controls - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation) / Fuel Injection Supply Manifold - VIN Plate Emission Level Code: S (303-04H Fuel Charging and Controls - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation) / Fuel Injection Supply Manifold - VIN Plate Emission Level Code: K (303-04H Fuel Charging and Controls - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation) / Fuel Pump (303-04H Fuel Charging and Controls - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation). |
* Air ingress into the fuel lines. | * REFER to: Fuel System - 1.6L Duratorq-TDCi (DV) Diesel/2.0L Duratorq-TDCi (DW) Diesel (310-00 Fuel System - General Information, Diagnosis and Testing). |
* EGR valve incorrect operation. | * REFER to: Exhaust Gas Recirculation (EGR) Valve (303-08D Engine Emission Control - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation). |
* Low cylinder compression. | * Check cylinder compression. |
* Worn or damaged valve(s), tappet(s) or camshaft(s). | * REMOVE the cylinder head. INSPECT the cylinder head, valves, tappets and camshafts for signs of wear or damage. |
* Damaged cylinder head gasket. | * REMOVE the cylinder head. INSPECT the cylinder head gasket and cylinder bores for wear or damage. |
* Engine overheats. | * REFER to: Engine Cooling (303-03E Engine Cooling - 2.0L Duratorq-TDCi (DW) Diesel, Diagnosis and Testing). |
* ECT sensor. | * REFER to the WDS. |
* CKP sensor. | * REFER to the WDS. |
* CMP sensor. | * REFER to the WDS. |
* MAF sensor. | * REFER to the WDS. |
* MAP sensor. | * REFER to the WDS. |
* Fuel injector(s). | * REFER to the WDS. |
* Fuel rail fuel pressure sensor. | * REFER to the WDS. |
* Fuel pump. | * REFER to the WDS. |
Engine knock at idle and glow plug indicator is flashing | * DTC detected. | * REFER to the 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: Fuel Tank Draining (310-00 Fuel System - General Information, General Procedures). INSTALL a new fuel filter. REFER to: Fuel Filter - 1.6L Duratorq-TDCi (DV) Diesel (310-01 Fuel Tank and Lines, Removal and Installation). INSTALL a new fuel pump, fuel injectors, fuel injection supply manifold, and high-pressure fuel supply lines. REFER to: Fuel Injectors - VIN Plate Emission Level Code: S (303-04H Fuel Charging and Controls - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation) / Fuel Injectors - VIN Plate Emission Level Code: K (303-04H Fuel Charging and Controls - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation) / Fuel Injection Supply Manifold - VIN Plate Emission Level Code: S (303-04H Fuel Charging and Controls - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation) / Fuel Injection Supply Manifold - VIN Plate Emission Level Code: K (303-04H Fuel Charging and Controls - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation) / Fuel Pump (303-04H Fuel Charging and Controls - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation). |
* Dual mass flywheel. | * INSPECT the dual mass flywheel for damage. INSTALL a new dual mass flywheel as necessary. |
* Incorrect valve timing. | * CHECK the valve timing. REFER to: Timing Belt (303-01E Engine - 2.0L Duratorq-TDCi (DW) Diesel, In-vehicle Repair). |
* Excessive carbon build up. | * REMOVE the cylinder head. INSPECT the cylinder head and pistons for signs carbon build up. |
* Worn or damaged oil pump. * Major mechanical engine failure. | * REFER to: Engine (303-01C Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4), Diagnosis and Testing). |
* CKP sensor. | * REFER to the WDS. |
* Fuel injector(s). | * REFER to the WDS. |
Engine knock during acceleration and glow plug indicator is flashing | * DTC detected. | * REFER to the WDS. |
Engine knock during acceleration | * Fuel injector(s). | * REFER to the WDS. |
* Major mechanical engine failure. | * REFER to: Engine (303-01C Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4), Diagnosis and Testing). |
* Fuel inlet metering valve. | * REFER to the WDS. |
* Fuel pump. | * REFER to the WDS. |
Excessive fuel consumption and glow plug indicator is flashing | * DTC detected. | * REFER to the WDS. |
Excessive fuel consumption | * Brakes binding. | * CHECK the braking system. |
* 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. | * INSTALL a new fuel filter. REFER to: Fuel Filter - 1.6L Duratorq-TDCi (DV) Diesel (310-01 Fuel Tank and Lines, Removal and Installation). |
* Fuel system leak(s). | * CHECK the system for fuel leak(s). REPAIR or INSTALL new parts as necessary. |
* Dual mass flywheel. | * INSPECT the dual mass flywheel for damage. INSTALL a new dual mass flywheel as necessary. |
* Incorrect engine oil. | * INSTALL a new oil filter and engine oil. |
* Generator. | * REFER to the WDS. |
* EGR valve incorrect operation. | * REFER to: Exhaust Gas Recirculation (EGR) Valve (303-08D Engine Emission Control - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation). |
* Turbocharger vacuum diaphragm unit. | * REFER to: Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel (303-04F Fuel Charging and Controls - Turbocharger, Diagnosis and Testing) / Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel (110 PS) (303-04F Fuel Charging and Controls - Turbocharger, Diagnosis and Testing). |
* Air ingress into the fuel lines. | * REFER to: Fuel System - 1.6L Duratorq-TDCi (DV) Diesel/2.0L Duratorq-TDCi (DW) Diesel (310-00 Fuel System - General Information, Diagnosis and Testing). |
* Incorrect valve timing. | * CHECK the valve timing. REFER to: Timing Belt (303-01E Engine - 2.0L Duratorq-TDCi (DW) Diesel, In-vehicle Repair). |
* Turbocharger. | * REFER to: Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel (303-04F Fuel Charging and Controls - Turbocharger, Diagnosis and Testing) / Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel (110 PS) (303-04F Fuel Charging and Controls - Turbocharger, Diagnosis and Testing). |
* Slipping clutch. | * REFER to: Manual Transaxle and Clutch - 3-Door (308-00 Manual Transmission/Transaxle and Clutch - General Information, Diagnosis and Testing). |
* Low cylinder compression. | * Check cylinder compression. |
* ECT sensor. | * REFER to the WDS. |
* MAF sensor. | * REFER to the WDS. |
* MAP sensor. | * REFER to the WDS. |
* Fuel injector(s). | * REFER to the WDS. |
Engine cuts out during hard acceleration | * CMP sensor. | * REFER to the WDS. |
* CKP sensor. | * REFER to the WDS. |
* Fuel rail fuel pressure sensor. | * REFER to the WDS. |
* Fuel inlet metering valve. | * REFER to the WDS. |
* Fuel pump. | * REFER to the WDS. |