Ford Workshop Service and Repair Manuals

The main operational difference between the CP1H fuel pump and the CP3.2 fuel pump is:

• If the CP1H fuel pump fuel metering valve or fuel metering valve wiring fails, the fuel metering valve will default to the closed position causing the fuel rail pressure to be less than 20 bar.
• If the CP3.2 fuel pump fuel metering valve or fuel metering valve wiring fails, the fuel metering valve will default to the open position causing the fuel rail pressure to be greater than 1600 bar.

The visual differences between the CP1H fuel pump and the CP3.2 fuel pump are:

• The CP1H fuel pump fuel metering valve has a radial connector.
• The CP3.2 fuel pump fuel metering valve has a axial connector.
• The CP1H fuel pump has 3 cylinder heads.
• The CP3.2 fuel pump does not have cylinder heads.

NOTE:Fuel pump shown is for component identification only and is not vehicle specific.

The fuel pump is made up of a fuel transfer pump and a high-pressure fuel delivery pump.

The fuel transfer pump works using two meshed gears. One gear is driven by the fuel pump input shaft. The fuel is carried between the teeth of the gears and the fuel transfer pump casing. The amount of fuel the fuel transfer pump can deliver to the high-pressure fuel pump chambers is dependent on engine speed. But at the minimum transfer rate, a larger than required quantity of fuel is available. Excess fuel from the fuel transfer pump is returned to the fuel tank through the fuel return line manifold.

The amount of fuel allowed to enter the high-pressure fuel pump chambers from the fuel transfer pump is controlled by the fuel metering valve. Controlling the fuel volume input to the high-pressure pump chambers, directly controls the fuel pressure output from the high-pressure pump. The developed high-pressure fuel supply is monitored by the fuel pressure sensor mounted on the fuel rail. The PCM uses the signal from the fuel pressure sensor to calculate the flow rate through the fuel metering valve.

During the development of high-pressure fuel supply, large amounts of heat are generated. The excess fuel returned to the fuel tank assists with the cooling and lubrication of the high-pressure fuel pump components.

Fuel Pump High-Pressure Fuel Development

The high-pressure fuel pump is driven by the engine camshaft through the fuel pump input shaft. The input shaft rotates an eccentric lobe within the eccentric ring. The eccentric ring is forced against the high-pressure pistons to produce the high pressure fuel supply.

During each revolution of the fuel pump input shaft, all three high-pressure fuel pump chambers will deliver pressurized fuel to the fuel rail.

During the high-pressure fuel development stage, fuel in the high-pressure fuel pump chamber is compressed by the high-pressure piston until the pressure in the fuel pump high-pressure chamber exceeds the fuel pressure in the fuel rail. At this point the high-pressure fuel outlet valve opens and allows fuel to be delivered to the fuel rail. As the high-pressure piston reaches the end of its compression stroke, the fuel pressure in the fuel rail and the fuel pump chamber equalize.

As the eccentric ring rotates, the high-pressure piston will retract from the high-pressure chamber under the force of the high-pressure piston return spring. The fuel pressure in the fuel rail will become greater than the fuel pressure in the high-pressure chamber. This will make the high-pressure fuel outlet valve close, so maintaining the fuel pressure in the fuel rail.

When the fuel pressure in the high-pressure chamber drops below the fuel pressure developed by the fuel transfer pump, the high-pressure chamber fuel intake valve will open and allow fuel to be delivered from the fuel transfer pump to the high-pressure chamber. The fuel transfer pump will continue to deliver fuel to the high-pressure chamber until the high-pressure fuel development stage has started and the developing fuel pressure in the high-pressure chamber exceeds the fuel pressure of the transfer pump at which point the high-pressure chamber fuel intake valve will close.

Fuel Rail

The function of the fuel rail is to supply a reservoir of fuel to all four fuel injectors with no variations in fuel pressure for any one fuel injector. The fuel rail acts as a pulse damper eliminating surges in fuel pressure. Attached to one end of the fuel rail is a fuel pressure sensor. The fuel pressure sensor monitors the fuel pressure at the fuel injectors. The fuel pressure sensor develops a pressure conscious variable resistance which provides a controlled variable voltage signal to the PCM.

Fuel Injectors

Individual fuel injectors are measured for flow characteristics and assigned a calibration code which is printed on the head of the fuel injector. The calibration code is used by the PCM to adjust the fuel injector injection signal to achieve optimum efficiency. The fuel injectors are designed to allow a quantity of fuel to return to the fuel system. The returned fuel is developed during the opening cycle of the fuel injector control valve. This returned fuel is used to lubricate the fuel injector moving components and is essential to the operation of the fuel injector. This lubricating fuel is returned to the fuel tank through the fuel injector fuel return line. Only by accurate measurement, at precise engine conditions, can the volumes of fuel from the fuel injector fuel return be used to diagnose concerns with the fuel charging control system.

Fuel Return Line Venturi and Temperature Sensor

The fuel temperature sensor is fitted into the fuel pump to fuel tank fuel return line. The fuel temperature sensor also acts as a fuel by-pass valve. When the fuel temperature is below a preset value, the low pressure fuel from the fuel pump is returned to the fuel pump and not the fuel tank. This assists in the rapid warm up of the fuel supply and prevents sludging in the fuel system at low temperatures. The fuel temperature sensor housing acts as a venturi. The venturi assists with the fuel return from the fuel injectors by creating a pressure reduction in the fuel injector fuel return line.

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 WDS.

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

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

Visual Inspection Chart

Symptom Chart

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 (303-06A 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/1.8L Duratorq-TDCi (Lynx) 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/1.8L Duratorq-TDCi (Lynx) 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 (303-01E 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/1.8L Duratorq-TDCi (Lynx) 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/1.8L Duratorq-TDCi (Lynx) 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 (309-00A Exhaust System, Removal and Installation) / Catalytic Converter - 1.6L Duratorq-TDCi (DV) Diesel (110 PS), VIN Plate Emission Level Code: V (309-00A 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/1.8L Duratorq-TDCi (Lynx) 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/1.8L Duratorq-TDCi (Lynx) 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/1.8L Duratorq-TDCi (Lynx) 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/1.8L Duratorq-TDCi (Lynx) 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/1.8L Duratorq-TDCi (Lynx) 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 (309-00A Exhaust System, Removal and Installation) / Catalytic Converter - 1.6L Duratorq-TDCi (DV) Diesel (110 PS), VIN Plate Emission Level Code: V (309-00A 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 (309-00A Exhaust System, Removal and Installation) / Catalytic Converter - 1.6L Duratorq-TDCi (DV) Diesel (110 PS), VIN Plate Emission Level Code: V (309-00A 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 (309-00A Exhaust System, Removal and Installation) / Catalytic Converter - 1.6L Duratorq-TDCi (DV) Diesel (110 PS), VIN Plate Emission Level Code: V (309-00A 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 (309-00A Exhaust System, Removal and Installation) / Catalytic Converter - 1.6L Duratorq-TDCi (DV) Diesel (110 PS), VIN Plate Emission Level Code: V (309-00A 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/1.8L Duratorq-TDCi (Lynx) 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/1.8L Duratorq-TDCi (Lynx) 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.