Ford Workshop Service and Repair Manuals

Principles of Operation

Ethanol equipped vehicles

Ethanol, is derived from cellulose waste. A large proportion of Ethanol is distilled from corn, wheat and sugar cane crops. The product that is to be used in this vehicle is called Ethanol E85. E85 is a mixture of 15% gasoline and 85% Ethanol. Ethanol is a clear liquid and when fully burnt the combustion gasses remaining are Carbon Dioxide and water. This makes the use of Ethanol a good environmental proposition. One drawback with pure Ethanol is that it is corrosive to certain rubber and plastic materials.

The introduction of Ethanol E85 has required some major internal changes to the fuel supply and delivery system. Some earlier vehicles used an Ethanol mixture called Ethanol E15. This fuel was made up of 15% Ethanol and 85% gasoline. At this mixture ratio, no changes to the fuel charging or delivery system where required, as no degradation would occur with the cylinder head valves or material content of the components, although some performance loss would be noticeable.

The components used by vehicles running Ethanol appear to be the same in construction as those that use unleaded fuel only. The changes are mainly to do with the materials used and increases in fuel flow rates.

Ethanol has a much higher octane rating than standard fuel which means that the ignition and fuel injection calibrations for a vehicle that is capable of using Ethanol E85 must be adapted suitably.

Fuel injectors

To maintain the same or similar power output to that of the unleaded fuel vehicle, the fuel injectors have been replaced with high flow fuel injectors.

Fuel composition monitoring

The quantity of Ethanol E85 in relation to the quantity of unleaded fuel contained in the fuel tank at any one time is not monitored at the fuel tank. The Ethanol percentage volume can only decrease from its maximum 85% (pure Ethanol E85), to zero (100% unleaded fuel).

The fuel charging system compensates for the changes in fuel composition using the signal received by the power train control module (PCM) from the HO2s. The PCM adapts the fueling and ignition calibrations to suit the current fuel tank content composition.

Fuel supply

The fuel supply for all petrol fueled variants is equipped with a return-less fuel system. This means that the fuel delivery pressure at the fuel injectors, is monitored and controlled by the fuel tank module. This control is achived by switching the fuel pump on and off.

The fuel pump module for both the Ethanol E85 variant vehicle and the unleaded fueled vehicle are very similar. Visualy the only difference is the fuel pump electrical connections which on the Ethanol E85 variant is sealed. This is not the only differance, both fuel pump modules have different fuel level sensor resistor card values.

Cold start

To overcome the problems relating to cold start inherent with Ethanol E85 vehicles (temperatures down to -29 degrees centigrade), a block heater has been installed into the engine coolant system.

The block heater is located to the rear of the engine under the exhaust manifold. The block heater is fitted with a dedicated harness which terminates at an external plug connector fitted into the radiator grill.

The block heater can be connected to an external power supply, which will pre-heat the engine coolant contained within the cylinder block. The heated coolant will radiate heat to the fuel rail, which will warm the contained fuel. Sufficient warmed fuel is stored in the fuel rail to allow the engine to start and continue running correctly, until the engine combustion generates sufficient heat to maintain correct operating conditions.

Fuel rail

The fuel rail on Ethanol E85 vehicles is the same as non Ethanol E85 variants. The fuel rail function is to supply a reservoir of fuel at equal pressure for all four fuel injectors.

Throttle body

The throttle body on Ethanol E85 vehicles is the same as non Ethanol E85 variants. This is a fully electronic controlled and monitored component. The PCM adapts to the wear characteristics of the throttle plate. If a new throttle body is installed, it is necessary to teach the values of the new throttle body to the PCM. If installing a new throttle body, follow the initialization procedure.
REFER to: Throttle Body (303-04 Fuel Charging and Controls - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4), Removal and Installation).

Intake manifold

The intake manifold for both Ethanol E85 and standard unleaded fueled vehicles is the same construction.

Built into the intake manifold, are the IMRC throttle plates and IMT swirl plates.

Under low demand throttle conditions, the air charge is delivered to the cylinder head intake ports through the primary air intake chambers. The clean flow of the air charge is disturbed by the IMT swirl plates to assist in the mixing of the air fuel mixture at the fuel injectors.

During high demand throttle conditions, the IMRC throttle plates are opened and the air charge is allowed to use both primary and secondary intake chambers. This means a higher volume of air charge can be accommodated by the intake manifold. During this high demand throttle condition, the IMT swirl plates are fully open so as not to restrict the air charge flow.

Inspection and Verification

Visual Inspection Chart

Symptom Chart

Symptom Chart

Symptom	Possible Sources	Action
Engine does not crank	* PATS.	* CHECK the PATS LED extinguishes within 3 seconds when the ignition is turned on. REFER to: Anti-Theft - Passive (419-01B, Diagnosis and Testing).
	* Starting system.	* REFER to: Starting System (303-06A Starting System, Diagnosis and Testing).
	* Ignition switch.	* REFER to the Wiring Diagrams.
	* Powertrain control module (PCM).	* Carry out a full engine diagnosis using the guided diagnostic menu in WDS.
Engine cranks but does not start	* Inertia fuel shutoff (IFS) switch.	* RESET the IFS switch.
	* Low fuel system pressure.	* Check the fuel system pressure. REFER to: Fuel System Pressure Check - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) (310-00 Fuel System - General Information, General Procedures).
	* Fuel lines damaged or blocked.	* INSPECT the fuel lines. INSTALL new components as necessary. TEST the system for normal operation.
	* Fuel filter blocked.	* INSTALL a new fuel filter.
	* Fuel pump module.	* REFER to: Fuel System - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma)/1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) (310-00 Fuel System - General Information, Diagnosis and Testing).
	* Crankshaft position (CKP) sensor.	* Carry out a full engine diagnosis using the guided diagnostic menu in WDS.
	* Camshaft position (CMP) sensor.	* Carry out a full engine diagnosis using the guided diagnostic menu in WDS.
	* PCM.	* Carry out a full engine diagnosis using the guided diagnostic menu in WDS.
	* Fuel rail fuel pressure sensor.	* Carry out a full engine diagnosis using the guided diagnostic menu in WDS.
	* Fuel injectors.	* INSPECT the fuel injectors. CLEAN the fuel injectors or INSTALL a new set of injectors as required only after the checks have been carried out.
	* Incorrect valve timing.	* CHECK the valve timing.
	* Low cylinder compression.	* TEST the cylinder compression.
Poor starting	* Low fuel system pressure.	* Check the fuel system pressure. REFER to: Fuel System Pressure Check - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) (310-00 Fuel System - General Information, General Procedures).
	* Fuel system leak.	* CHECK the system for fuel leak(s). REPAIR the system as necessary.
	* Fuel system restriction.	* INSPECT the fuel system. INSTALL new components as necessary. TEST the system for normal operation.
	* Fuel filter blocked.	* INSTALL a new fuel filter.
	* Air cleaner element blocked.	* INSTALL a new air cleaner element.
	* 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 Flushing - Vehicles With: Electro-Hydraulic Power Steering (EHPS) (211-00, General Procedures).
	* CKP sensor.	* Carry out a full engine diagnosis using the guided diagnostic menu in WDS.
	* Engine coolant temperature (ECT) sensor.	* Carry out a full engine diagnosis using the guided diagnostic menu in WDS.
	* Fuel injector(s).	* INSPECT the fuel injectors. CLEAN the fuel injectors or INSTALL a new set of injectors as required only after the checks have been carried out.
	* Fuel rail fuel pressure sensor.	* Carry out a full engine diagnosis using the guided diagnostic menu in WDS.
	* Catalytic converter blocked.	* REMOVE and visually INSPECT the catalytic converter as necessary. REFER to: Catalytic Converter - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) (309-00A Exhaust System, Removal and Installation).
	* Low cylinder compression.	* TEST the engine cylinder compression.
Engine starts but immediately stops	* Air cleaner element blocked.	* INSTALL a new air cleaner element.
	* CKP sensor.	* Carry out a full engine diagnosis using the guided diagnostic menu in WDS.
	* CMP sensor.	* Carry out a full engine diagnosis using the guided diagnostic menu in WDS.
	* PCM.	* Carry out a full engine diagnosis using the guided diagnostic menu in WDS.
	* Low fuel system pressure.	* Check the fuel system pressure. REFER to: Fuel System Pressure Check - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) (310-00 Fuel System - General Information, General Procedures).
	* Fuel system restriction.	* INSPECT the fuel system. INSTALL new components as necessary. TEST the system for normal operation.
	* Fuel filter blocked.	* INSTALL a new fuel filter.
Poor idling	* Air cleaner element blocked.	* INSTALL a new air cleaner element.
	* Incorrect or contaminated fuel.	* CHECK for signs of contamination such as strange odors from the fuel tank. * If contaminated fuel is found, DRAIN the complete fuel system. FLUSH the fuel system through with clean gasoline. REFER to: Fuel Tank Draining (310-00 Fuel System - General Information, General Procedures). INSTALL a new fuel filter. * INSPECT the fuel injectors. CLEAN the fuel injectors or INSTALL a new set of injectors as required only after the checks have been carried out. * INSTALL a new fuel rail. REFER to: Fuel Injection Supply Manifold (303-04C, Removal and Installation).
	* Low fuel system pressure.	* Check the fuel system pressure. REFER to: Fuel System Pressure Check - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) (310-00 Fuel System - General Information, General Procedures).
	* Fuel filter blocked.	* INSTALL a new fuel filter.
	* EGR valve sticking open.	* REFER to: Engine Emission Control (303-08 Engine Emission Control - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4), Diagnosis and Testing).
	* Fuel injectors.	* INSPECT the fuel injectors. CLEAN the fuel injectors or INSTALL a new set of injectors as required only after the checks have been carried out.
	* CKP sensor.	* Carry out a full engine diagnosis using the guided diagnostic menu in WDS.
	* Knock sensor (KS).	* Carry out a full engine diagnosis using the guided diagnostic menu in WDS.
	* Fuel injection supply manifold fuel pressure sensor.	* Carry out a full engine diagnosis using the guided diagnostic menu in WDS.
Engine stumbling	* Engine ignition.	* REFER to: Engine Ignition (303-07 Engine Ignition - 2.5L Duratec-RS (VI5)/2.5L Duratec-ST (VI5), Diagnosis and Testing).
	* Fuel injectors.	* INSPECT the fuel injectors. CLEAN the fuel injectors or INSTALL a new set of injectors as required only after the checks have been carried out.
	* Low fuel system pressure.	* Check the fuel system pressure. REFER to: Fuel System Pressure Check - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) (310-00 Fuel System - General Information, General Procedures).
	* Fuel rail fuel pressure sensor.	* Carry out a full engine diagnosis using the guided diagnostic menu in WDS.
	* EGR valve sticking open.	* REFER to: Engine Emission Control (303-08 Engine Emission Control - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4), Diagnosis and Testing).
Engine lacks power	* Engine ignition.	* REFER to: Engine Ignition (303-07 Engine Ignition - 2.5L Duratec-RS (VI5)/2.5L Duratec-ST (VI5), Diagnosis and Testing).
	* 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.
	* Low fuel system pressure.	* Check the fuel system pressure. REFER to: Fuel System Pressure Check - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) (310-00 Fuel System - General Information, General Procedures).
	* Kinked or restricted fuel lines.	* INSPECT the fuel lines. INSTALL new components as necessary. TEST the system for normal operation.
	* Incorrect or contaminated fuel.	* CHECK for signs of contamination such as strange odors from the fuel tank. * If contaminated fuel is found, DRAIN the complete fuel system. FLUSH the fuel system through with clean gasoline. REFER to: Fuel Tank Draining (310-00 Fuel System - General Information, General Procedures). INSTALL a new fuel filter. * INSPECT the fuel injectors. CLEAN the fuel injectors or INSTALL a new set of injectors as required only after the checks have been carried out. * INSTALL a new rail. REFER to: Fuel Injection Supply Manifold (303-04C, Removal and Installation).
	* Fuel filter blocked.	* INSTALL a new fuel filter.
	* EGR valve sticking open.	* REFER to: Engine Emission Control (303-08 Engine Emission Control - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4), Diagnosis and Testing).
	* Vehicle speed sensor (VSS).	* Carry out a full engine diagnosis using the guided diagnostic menu in WDS.
	* ECT sensor.	* Carry out a full engine diagnosis using the guided diagnostic menu in WDS.
	* Fuel injectors.	* INSPECT the fuel injectors. CLEAN the fuel injectors or INSTALL a new set of injectors as required only after the checks have been carried out.
	* Fuel rail fuel pressure sensor.	* Carry out a full engine diagnosis using the guided diagnostic menu in WDS.
	* 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 - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) (309-00A Exhaust System, Removal and Installation).
Black smoke at idle	* Air cleaner element blocked.	* INSTALL a new air cleaner element as necessary.
	* Fuel injectors.	* INSPECT the fuel injectors. CLEAN the fuel injectors or INSTALL a new set of injectors as required only after the checks have been carried out.
	* ECT sensor.	* Carry out a full engine diagnosis using the guided diagnostic menu in WDS.
	* Fuel rail fuel pressure sensor.	* Carry out a full engine diagnosis using the guided diagnostic menu in WDS.
	* Catalytic converter blocked.	* REMOVE and visually INSPECT the catalytic converter for damage. INSTALL a new catalytic converter as necessary. REFER to: Catalytic Converter - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) (309-00A Exhaust System, Removal and Installation).
	* Incorrect valve timing.	* CHECK the valve timing.
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. * If contaminated fuel is found, DRAIN the complete fuel system. FLUSH the fuel system through with clean gasoline. REFER to: Fuel Tank Draining (310-00 Fuel System - General Information, General Procedures). INSTALL a new fuel filter. * INSPECT the fuel injectors. CLEAN the fuel injectors or INSTALL a new set of injectors as required only after the checks have been carried out. * INSTALL a new fuel rail. REFER to: Fuel Injection Supply Manifold (303-04C, Removal and Installation).
	* EGR valve sticking open.	* REFER to: Engine Emission Control (303-08 Engine Emission Control - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4), Diagnosis and Testing).
	* CKP sensor.	* Carry out a full engine diagnosis using the guided diagnostic menu in WDS.
	* KS.	* Carry out a full engine diagnosis using the guided diagnostic menu in WDS.
	* Fuel injectors.	* INSPECT the fuel injectors. CLEAN the fuel injectors or INSTALL a new set of injectors as required only after the checks have been carried out.
	* Fuel rail fuel pressure sensor.	* Carry out a full engine diagnosis using the guided diagnostic menu in WDS.
	* Catalytic converter blocked.	* REMOVE and visually INSPECT the catalytic converter for damage. INSTALL a new catalytic converter as necessary. REFER to: Catalytic Converter - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) (309-00A Exhaust System, Removal and Installation).
Black smoke at cruising speeds	* Air cleaner element blocked.	* INSTALL a new air cleaner element.
	* EGR valve sticking open.	* REFER to: Engine Emission Control (303-08 Engine Emission Control - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4), Diagnosis and Testing).
	* ECT sensor.	* Carry out a full engine diagnosis using the guided diagnostic menu in WDS.
	* Fuel injectors.	* INSPECT the fuel injectors. CLEAN the fuel injectors or INSTALL a new set of injectors as required only after the checks have been carried out.
	* Fuel rail fuel pressure sensor.	* Carry out a full engine diagnosis using the guided diagnostic menu in WDS.
	* Catalytic converter blocked.	* REMOVE and visually INSPECT the catalytic converter for damage. INSTALL a new catalytic converter as necessary. REFER to: Catalytic Converter - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) (309-00A Exhaust System, Removal and Installation).
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 odors from the fuel tank. * If contaminated fuel is found, DRAIN the complete fuel system. FLUSH the fuel system through with clean gasoline. REFER to: Fuel Tank Draining (310-00 Fuel System - General Information, General Procedures). INSTALL a new fuel filter. * INSPECT the fuel injectors. CLEAN the fuel injectors or INSTALL a new set of injectors as required only after the checks have been carried out. * INSTALL a new fuel rail. REFER to: Fuel Injection Supply Manifold (303-04C, Removal and Installation).
	* Positive crankcase ventilation (PCV) system.	* INSPECT for visible signs of damage or blockage. CLEAN, REPAIR or INSTALL new parts as necessary.
	* 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 (303-01F Engine - 1.8L Duratorq-TDCi (Lynx) Diesel, In-vehicle Repair).
White smoke	* Incorrect or contaminated fuel.	* CHECK for signs of contamination such as strange odors from the fuel tank. * If contaminated fuel is found, DRAIN the complete fuel system. FLUSH the fuel system through with clean gasoline. REFER to: Fuel Tank Draining (310-00 Fuel System - General Information, General Procedures). INSTALL a new fuel filter. * INSPECT the fuel injectors. CLEAN the fuel injectors or INSTALL a new set of injectors as required only after the checks have been carried out. * INSTALL a new fuel injection supply manifold. REFER to: Fuel Injection Supply Manifold (303-04C, Removal and Installation).
	* Coolant in the combustion chamber.	* CARRY OUT a cooling system pressure test. REFER to: Engine Cooling (303-03 Engine Cooling - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4), 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 (303-01F Engine - 1.8L Duratorq-TDCi (Lynx) Diesel, In-vehicle Repair).
Engine misfire	* Engine ignition.	* REFER to: Engine Ignition (303-07 Engine Ignition - 2.5L Duratec-RS (VI5)/2.5L Duratec-ST (VI5), Diagnosis and Testing).
	* Incorrect or contaminated fuel.	* CHECK for signs of contamination such as strange odors from the fuel tank. * If contaminated fuel is found, DRAIN the complete fuel system. FLUSH the fuel system through with clean gasoline. REFER to: Fuel Tank Draining (310-00 Fuel System - General Information, General Procedures). INSTALL a new fuel filter. * INSPECT the fuel injectors. CLEAN the fuel injectors or INSTALL a new set of injectors as required only after the checks have been carried out. * INSTALL a new fuel rail. REFER to: Fuel Injection Supply Manifold (303-04C, Removal and Installation).
	* Low fuel system pressure.	* Check the fuel system pressure. REFER to: Fuel System Pressure Check - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) (310-00 Fuel System - General Information, General Procedures).
	* EGR valve sticking open.	* REFER to: Engine Emission Control (303-08 Engine Emission Control - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4), Diagnosis and Testing).
	* Engine operating temperature too high.	* REFER to: Engine Cooling (303-03 Engine Cooling - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4), Diagnosis and Testing).
	* ECT sensor.	* Carry out a full engine diagnosis using the guided diagnostic menu in WDS.
	* CKP sensor.	* Carry out a full engine diagnosis using the guided diagnostic menu in WDS.
	* CMP sensor.	* Carry out a full engine diagnosis using the guided diagnostic menu in WDS.
	* KS.	* Carry out a full engine diagnosis using the guided diagnostic menu in WDS.
	* Fuel injectors.	* INSPECT the fuel injectors. CLEAN the fuel injectors or INSTALL a new set of injectors as required only after the checks have been carried out.
	* Fuel rail fuel pressure sensor.	* Carry out a full engine diagnosis using the guided diagnostic menu in WDS.
	* Low cylinder compression.	* CHECK the engine 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. REFER to: Cylinder Head (303-01F Engine - 1.8L Duratorq-TDCi (Lynx) Diesel, In-vehicle Repair).
	* Damaged cylinder head gasket.	* REMOVE the cylinder head. INSPECT the cylinder head gasket and cylinder bores for wear or damage. REFER to: Cylinder Head (303-01F Engine - 1.8L Duratorq-TDCi (Lynx) Diesel, In-vehicle Repair).
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. * If contaminated fuel is found, DRAIN the complete fuel system. FLUSH the fuel system through with clean gasoline. REFER to: Fuel Tank Draining (310-00 Fuel System - General Information, General Procedures). INSTALL a new fuel filter. * INSPECT the fuel injectors. CLEAN the fuel injectors or INSTALL a new set of injectors as required only after the checks have been carried out. * INSTALL a new fuel rail. REFER to: Fuel Injection Supply Manifold (303-04C, Removal and Installation).
	* KS.	* Carry out a full engine diagnosis using the guided diagnostic menu in WDS.
	* CKP sensor.	* Carry out a full engine diagnosis using the guided diagnostic menu in WDS.
	* Fuel injector(s).	* INSPECT the fuel injectors. CLEAN the fuel injectors or INSTALL a new set of injectors as required only after the checks have been carried out.
	* 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 (303-01F Engine - 1.8L Duratorq-TDCi (Lynx) Diesel, In-vehicle Repair).
	* Worn or damaged oil pump. * Worn or damaged timing chain or sprocket. * Major mechanical engine failure.	* INSPECT the engine components.
Engine knock during acceleration	* KS.	* Carry out a full engine diagnosis using the guided diagnostic menu in WDS.
	* Fuel injectors.	* INSPECT the fuel injectors. CLEAN the fuel injectors or INSTALL a new set of injectors as required only after the checks have been carried out.
	* Major mechanical engine failure.	* REFER to: Engine (303-01 Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4), Diagnosis and Testing).
NOTE:Before proceeding with any of the actions in relation to the possible sources for excessive fuel consumption, a fuel consumption test located in the toolbox menu of WDS must be performed. 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 system leak(s).	* CHECK the system for fuel leak(s). REPAIR or INSTALL new parts as necessary.
	* Fuel filter blocked.	* INSTALL a new fuel filter.
	* Incorrect engine oil.	* INSTALL a new oil filter and engine oil.
	* Generator.	* REFER to WDS.
	* EGR valve sticking open.	* REFER to: Engine Emission Control (303-08 Engine Emission Control - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4), 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).
	* ECT sensor.	* Carry out a full engine diagnosis using the guided diagnostic menu in WDS.
	* Fuel injectors.	* INSPECT the fuel injectors. CLEAN the fuel injectors or INSTALL a new set of injectors as required only after the checks have been carried out.
	* PCM calibration.	* Using WDS, CHECK for the availability of a calibration update.
	* Incorrect valve timing.	* CHECK the valve timing.
	* Low cylinder compression.	* CHECK the engine compression.
Engine cuts out during hard acceleration	* CMP sensor.	* Carry out a full engine diagnosis using the guided diagnostic menu in WDS.
	* CKP sensor.	* Carry out a full engine diagnosis using the guided diagnostic menu in WDS.
	* Fuel rail fuel pressure sensor.	* Carry out a full engine diagnosis using the guided diagnostic menu in WDS.
	* Low fuel system pressure.	* Check the fuel system pressure. REFER to: Fuel System Pressure Check - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) (310-00 Fuel System - General Information, General Procedures).