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Fuel Charging and Controls - 1.8L Endura-DI (Lynx) Diesel > < Fuel Charging and Controls

Fiesta 1996 (08.1995-02.2002)

Fuel Charging and Controls - 1.8L Diesel - Fuel Charging and Controls—1.8L Endura-DE (Kent) Diesel Fiesta 1996 (08/1995-02/2002)
Diagnosis and Testing

Inspection and Verification

NOTE:
NOTE:If the engine idle speed drops below 450 RPM, the fuel shutoff solenoid valve will shutoff the fuel to the fuel injectors.
  1. Verify the customer concern.
  1. Visually inspect for obvious signs of mechanical or electrical damage.

Visual Inspection Chart

Mechanical Electrical
  • Fuel leaks
  • Fuel filter
  • Air cleaner element
  • Vacuum line(s)/vacuum connections
  • Hose(s)/hose connections
  • Pipe(s)/pipe connections
  • Contaminated fuel
  • High pressure fuel supply lines
  • Fuel injectors
  • Fuel injection pump
  • Fuse(s)
  • Relay(s)
  • Wiring harness
  • Electrical connector(s)
  • Passive anti-theft system (PATS) LED operation
  • PATS fuel shutoff module
  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 Symptom Chart.

Symptom Chart

Symptom Chart

Symptom Possible Sources Action
Engine does not turn over
*
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 fuse.
*
Ignition relay fuse.
*
CHECK the fuse. If fuse blown, INSTALL a new fuse. If the fuse blows again, REFER to WDS.
*
Starter inhibit relay.
*
Ignition relay.
*
CARRY OUT the Relay Component Test. REFER to the Wiring Diagrams.
*
Ignition switch.
*
REFER to Section  211-05 Steering Column Switches.
Engine turns over but does not start
*
The PATS fuel shutoff module and the PATS module are not matched.
*
REFER to Section  419-01A Anti-Theft - Active / 419-01B Anti-Theft - Passive.
*
Blocked fuel filter element.
*
INSTALL a new fuel filter. TEST the system for normal operation.
*
Air ingress into the fuel lines.
*
REFER to Section  310-00 Fuel System - General Information.
*
Damaged or blocked fuel lines.
*
REFER to Section  310-00 Fuel System - General Information.
*
Fuel injection pump timing.
*
Incorrect valve timing.
*
CHECK the fuel injection pump timing and valve timing. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01D Engine / 303-01E Engine.
*
PATS fuel shutoff module.
*
REFER to WDS.
*
Fuel injection pump.
*
Have the fuel injection pump checked by an appropriate fuel injection specialist agent. INSTALL a new fuel injection pump as required only after the specialist agent checks have been carried out.
Intermittent start (engine turns over)
*
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.
*
PATS fuel shutoff module.
*
REFER to WDS.
*
Fuel injection pump.
*
Have the fuel injection pump checked by an appropriate fuel injection specialist agent. INSTALL a new fuel injection pump as required only after the specialist agent checks have been carried out.
Intermittent crank (engine does not turn over)
*
PATS transceiver.
*
PATS transponder key.
*
PATS module.
*
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.
*
Ignition switch.
*
REFER to Section  211-05 Steering Column Switches.
*
Starter inhibit relay.
*
CARRY OUT the Relay Component Test. REFER to the Wiring Diagrams.
Poor starting
*
Fuel filter element blocked.
*
INSTALL a new fuel filter. TEST the system for normal operation.
*
Air cleaner element blocked.
*
INSTALL a new air cleaner element. TEST the system for normal operation.
*
Glow plug relay fuse.
*
CHECK the fuse. If fuse blown, INSTALL a new fuse. If the fuse blows again, REFER to WDS.
*
Glow plug relay.
*
CARRY OUT the Relay Component Test. REFER to the Wiring Diagrams.
*
Glow plugs.
*
REFER to WDS.
*
Fuel system leak.
*
CHECK the system for fuel leak(s). REPAIR the system as necessary.
*
Air ingress into the fuel lines.
*
REFER to Section  310-00 Fuel System - General Information.
*
Fuel injection pump timing.
*
CHECK the fuel injection pump timing. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01D Engine / 303-01E Engine.
*
Incorrect engine oil.
*
INSTALL a new engine oil filter and engine oil.
*
Fuel system restriction.
*
REFER to Section  310-00 Fuel System - General Information.
*
Fuel injector(s).
*
Have the fuel injectors checked by an appropriate fuel injection specialist agent. CLEAN or INSTALL a new set of injectors as required only after the specialist agent checks have been carried out.
*
Fuel injection pump fuel return valve.
*
INSTALL a suitable clear pipe to the fuel injection pump return line and place in a suitable container for 15 minutes. CHECK that no extra fuel has drained from the fuel injection pump.
Engine starts but immediately stops
*
Air cleaner element blocked.
*
INSTALL a new air cleaner element. TEST the system for normal operation.
*
Air ingress into the fuel lines.
*
REFER to Section  310-00 Fuel System - General Information.
*
Idle speed dropping below 450 RPM.
*
ADJUST the idle speed as necessary.
REFER to Idle Speed Adjustment in this section.
*
PATS fuel shutoff module.
*
REFER to WDS.
*
Fuel injection pump.
*
Have the fuel injection pump checked by an appropriate fuel injection specialist agent. INSTALL a new fuel injection pump as required only after the specialist agent checks have been carried out.
Poor idling
*
Air cleaner element blocked.
*
INSTALL a new air cleaner element. TEST the system for normal operation.
*
Fuel filter element blocked.
*
INSTALL a new fuel filter. TEST the system for normal operation.
*
Water in fuel.
*
CHECK the water-in-fuel warning lamp is not illuminated, if lamp is illuminated, DRAIN the water from the fuel filter.
*
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.
*
Fuel injection pump timing.
*
CHECK the fuel injection pump timing. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01D Engine / 303-01E Engine.
*
Fuel injector(s).
*
Fuel injection pump.
*
Have the fuel injection pump and fuel injectors checked by an appropriate fuel injection specialist agent. INSTALL a new fuel injection pump or fuel injector(s) as required only after the specialist agent checks have been carried out.
Engine stumbling
*
Fuel injector(s).
*
Fuel injection pump.
*
Have the fuel injection pump and fuel injectors checked by an appropriate fuel injection specialist agent. INSTALL a new fuel injection pump or fuel injector(s) as required only after the specialist agent checks have been carried out.
Engine lacks power
*
Air cleaner element blocked.
*
INSTALL a new air cleaner element. TEST the system for normal operation.
*
Fuel filter element blocked.
*
INSTALL a new fuel filter. TEST the system for normal operation.
*
Kinked or restricted fuel lines.
*
REFER to Section  310-00 Fuel System - General Information.
*
Air ingress into the fuel lines.
*
REFER to Section  310-00 Fuel System - General Information.
*
Fuel injection pump vacuum line.
*
CHECK the vacuum line and union(s) for signs of leakage. INSTALL new parts as necessary.
*
Fuel injection pump timing.
*
Valve timing.
*
CHECK the fuel injection pump timing and valve timing. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01D Engine / 303-01E Engine.
*
Turbocharger.
*
REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls / 303-04D Fuel Charging and Controls / 303-04E Fuel Charging and Controls - Turbocharger.
*
Charge air cooler blocked or cracked.
*
Charge air cooler pipes split or cracked.
*
INSPECT for visible signs of damage. REPAIR as necessary.
*
Incorrect or contaminated fuel.
*
CHECK for signs of contamination such as strange odors from the fuel tank.
*
Fuel injector(s).
*
Fuel injection pump.
*
Have the fuel injection pump and fuel injectors checked by an appropriate fuel injection specialist agent. INSTALL a new fuel injection pump or fuel injector(s) as required only after the specialist agent checks have been carried out.
Black smoke at idle
*
Air cleaner element blocked.
*
INSTALL a new air cleaner element. TEST the system for normal operation.
*
Fuel injection pump vacuum line.
*
CHECK the vacuum line and union(s) for signs of blockage. INSTALL new parts as necessary.
*
Fuel injection pump timing.
*
Incorrect valve timing.
*
CHECK the fuel injection pump timing and valve timing. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01D Engine / 303-01E Engine.
*
Fuel injector(s).
*
Fuel injection pump.
*
Have the fuel injection pump and fuel injectors checked by an appropriate fuel injection specialist agent. INSTALL a new fuel injection pump or fuel injector(s) as required only after the specialist agent checks have been carried out.
Excessive black smoke during acceleration
*
Fuel contamination.
*
CHECK for signs of contamination such as strange odors from the fuel tank.
*
Fuel injection pump vacuum line.
*
CHECK the vacuum line and union(s) for signs of blockage. INSTALL new parts as necessary.
*
Fuel injection pump timing.
*
CHECK the fuel injection pump timing. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01D Engine / 303-01E Engine.
*
Fuel injector(s).
*
Fuel injection pump.
*
Have the fuel injection pump and fuel injectors checked by an appropriate fuel injection specialist agent. INSTALL a new fuel injection pump or fuel injector(s) as required only after the specialist agent checks have been carried out.
Black smoke at cruising speeds
*
Air cleaner element restricted.
*
INSTALL a new air cleaner element. TEST the system for normal operation.
*
Fuel injection pump vacuum line.
*
CHECK the vacuum line and union(s) for signs of blockage. INSTALL new parts as necessary.
*
Fuel injector(s).
*
Fuel injection pump.
*
Have the fuel injection pump and fuel injectors checked by an appropriate fuel injection specialist agent. INSTALL a new fuel injection pump or fuel injector(s) as required only after the specialist agent checks have been carried out.
Blue smoke
*
Engine burning oil.
*
CARRY OUT a controlled oil consumption test over 1,000 km (625 miles)
*
Incorrect fuel.
*
CHECK for signs of contamination such as strange odors from the fuel tank.
*
Engine breather system.
*
CHECK engine breather pipes for signs of restriction or blockage.
*
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 / 303-01D Engine / 303-01E Engine.
*
Turbocharger oil seals leaking.
*
Turbocharger oil return pipe blocked or damaged.
*
REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls / 303-04D Fuel Charging and Controls / 303-04E Fuel Charging and Controls - Turbocharger.
White smoke
*
Water in fuel.
*
REFER to Section  310-00 Fuel System - General Information.
*
Retarded fuel injection pump timing.
*
Incorrect valve timing.
*
CHECK the fuel injection pump timing and valve timing. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01D Engine / 303-01E Engine.
*
Coolant in the combustion chamber.
*
REMOVE and inspect the cylinder head, gasket and bores for wear. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01D Engine / 303-01E Engine.
Engine misfire
*
Cracked or damaged high-pressure fuel supply lines.
*
CHECK the high-pressure fuel supply lines for signs of damage INSTALL new high - pressure fuel supply lines as necessary.
*
Water in Fuel.
*
REFER to Section  310-00 Fuel System - General Information.
*
Air ingress into the fuel lines.
*
REFER to Section  310-00 Fuel System - General Information.
*
Low cylinder compression.
*
REFER to Section  303-00 Engine System - General Information.
*
Worn or damaged valve(s), tappet(s) or camshaft(s).
*
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 / 303-01D Engine / 303-01E Engine.
*
Damaged cylinder head gasket.
*
REMOVE and inspect the cylinder gasket and bores for wear. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01D Engine / 303-01E Engine.
*
Engine operating temperature too high.
*
REFER to Section  303-03 Engine Cooling.
*
Fuel injection pump timing.
*
CHECK the fuel injection pump timing and valve timing. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01D Engine / 303-01E Engine.
*
Fuel injector(s).
*
Fuel injection pump.
*
Have the fuel injection pump and fuel injectors checked by an appropriate fuel injection specialist agent. INSTALL a new fuel injection pump or fuel injector(s) as required only after the specialist agent checks have been carried out.
Engine knock at idle
*
Low engine oil level.
*
CHECK the engine oil level. REFILL as necessary.
*
Petrol in the fuel tank.
*
CHECK for signs of contamination such as strange odors from the fuel tank.
*
Fuel injection pump vacuum line.
*
CHECK the vacuum line and union(s) for signs of blockage. INSTALL new parts as necessary.
*
Fuel injection pump timing.
*
Incorrect valve timing.
*
CHECK the fuel injection pump timing and valve timing. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01D Engine / 303-01E Engine.
*
Excessive carbon build up.
*
REMOVE the cylinder head and visually inspect for signs of carbon build up. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01D Engine / 303-01E Engine.
*
Fuel injector(s).
*
Fuel injection pump.
*
Have the fuel injection pump and fuel injectors checked by an appropriate fuel injection specialist agent. INSTALL a new fuel injection pump or fuel injector(s) as required only after the specialist agent checks have been carried out.
*
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 / 303-01D Engine / 303-01E Engine.
Engine knock during acceleration
*
Fuel injection pump vacuum line.
*
CHECK the vacuum line and union(s) for signs of blockage. INSTALL new parts as necessary.
*
Fuel injection pump timing.
*
CHECK the fuel injection pump timing. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01D Engine / 303-01E Engine.
*
Fuel injector(s).
*
Fuel injection pump.
*
Have the fuel injection pump and fuel injectors checked by an appropriate fuel injection specialist agent. INSTALL a new fuel injection pump or fuel injector(s) as required only after the specialist agent checks have been carried out.
*
Major mechanical engine failure.
*
REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01D Engine / 303-01E Engine.
Excessive fuel consumption
*
Brakes binding, vehicle overloaded, or excessive wind resistance (roof racks, towing etc).
*
CHECK the braking system. REFER to Section  206-00 Brake System - General Information.
*
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. TEST the system for normal operation.
*
Fuel system leaks.
*
CHECK the system for fuel leak(s). REPAIR the system as necessary.
*
Fuel injection pump vacuum line.
*
CHECK the vacuum line and union(s) for signs of blockage. INSTALL new parts as necessary.
*
Incorrect engine oil.
*
INSTALL a new oil filter and engine oil.
*
Low engine oil level.
*
CHECK the engine oil level. REFILL as necessary.
*
Clutch worn or slipping.
*
REFER to Section  308-01 Clutch.
*
Generator.
*
REFER to Section  414-00 Charging System - General Information.
*
Air ingress into the fuel lines.
*
REFER to Section  310-00 Fuel System - General Information.
*
Fuel injection pump timing.
*
Incorrect valve timing.
*
CHECK the fuel injection pump timing and valve timing. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01D Engine / 303-01E Engine.
*
Low cylinder compression.
*
REFER to Section  303-00 Engine System - General Information.
*
Fuel injector(s).
*
Fuel injection pump.
*
Have the fuel injection pump and fuel injectors checked by an appropriate fuel injection specialist agent. INSTALL a new fuel injection pump or fuel injector(s) as required only after the specialist agent checks have been carried out.

Fuel Charging and Controls - 1.8L Endura-DI (Lynx) Diesel > < Fuel Charging and Controls