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Fuel System - General Information - Fuel System—1.6L Duratorq-TDCi (DV) Diesel/1.8L Duratorq-TDCi (Lynx) Diesel/2.0L Duratorq-TDCi (DW) Diesel Focus 2004.75 (07/2004-)
Diagnosis and Testing

Special Tool(s)

Hand Pressure Pump with Adapter Kit

310-110

General Equipment
Worldwide Diagnostic System (WDS)

Principles of Operation

Fuel additive system overview

To reach the latest Stage IV emissions legislation, diesel vehicles require a system to clean the exhaust gases before they exit the exhaust system.

This is achieved by trapping or filtering the soot particulates produced during engine combustion. A diesel particulate filter is located in the exhaust system, downstream from the catalytic converter. The soot particulates coated with fuel additive, are stored in the diesel particulate filter until they reach a pre-defined level. At this point a process known as regeneration occurs.

Regeneration requires the exhaust gasses to be increased to approximately 500°C, much higher than typically obtained during general driving. The powertrain control module (PCM) uses control of the fuel and air systems to achieve this.

Regeneration is initiated at between 300-1000 km (186-621 miles) or earlier if the engine management system dictates.

The distance is dependent on the soot accumulation, which varies with the differing drive styles.

The remaining ash particles (which is a result of the regeneration of the soot particles and fuel additive) cannot be burnt and are collected in the diesel particulate filter. The diesel particulate filter is serviced every 120,000 km (74,000 miles) or earlier depending on vehicle drive cycles. For additional information,
REFER to: Exhaust System (309-00, Description and Operation).

The PCM will choose the optimum time to regenerate. Under normal operating conditions the regeneration process occurs when the PCM calculates that the diesel particulate filter requires regeneration and that a number of predetermined vehicle conditions are met (i.e. coolant temp, vehicle speed & load).

The PCM will then initiate the regeneration process by the following:

  • closing the exhaust gas recirculation (EGR)
  • increase the engine load
  • regulation of the intake temperature and pressure through the intake air shutoff throttle
  • additional fuel injections (post main fuel injection)

All these changes to engine behavior will increase the exhaust gas temperature. The increase in temperature will allow the soot particles and fuel additive in the diesel particulate filter to burn.

A calculated amount of fuel additive is injected into the normal fuel tank through a fuel additive injector located in the fuel tank, every time the fuel tank is refilled. The calculated quantity of fuel additive injected, is achieved by the fuel additive system module communicating on the central area network (CAN) bus circuit to the following components:

  • fuel tank filler pipe cover switch and magnet
  • PCM
  • instrument cluster (fuel level)

The fuel additive system module calculates the required amount of fuel additive to be injected into the fuel tank and activates the integral dosing pump.

Some components have been modified or work in conjunction with the diesel particulate filter and fuel additive system to meet the emissions level such as:

  • intake air distribution system
  • EGR system

Vehicles with 1.6L Duratorq-TDCi (DV) diesel engine

 
Item
Part Number
Description
1
-
Exhaust gas temperature sensor
2
-
Catalytic converter
3
-
Pressure differential sensor
4
-
PCM
5
-
Fuel additive system module
6
-
Instrument cluster
7
-
Fuel filler door switch
8
-
Fuel filler door switch magnet
9
-
Fuel additive tank
10
-
Dosing pump
11
-
Fuel additive injector
12
-
Fuel tank
13
-
Diesel particulate filter

Vehicles with 2.0L Duratorq-TDCi (DW) diesel engine

 
Item
Part Number
Description
1
-
Catalytic converter exhaust gas temperature sensor
2
-
Exhaust gas temperature sensor
3
-
Diesel particulate filter
4
-
Diesel particulate filter pressure sampling ports
5
-
Instrument cluster
6
-
Fuel additive system module
7
-
Fuel filler door switch
8
-
Fuel filler door switch magnet
9
-
Fuel additive tank
10
-
Dosing pump
11
-
Fuel additive injector
12
-
Fuel tank
13
-
PCM
14
-
Pressure differential sensor

Diesel particulate filter

The diesel particulate filter element is a honeycomb structure in which the walls of the structure are made of porous silicon carbide (composition of carbon with metal). The individual ducts are sealed at one end of the element and offset at the other.

 
Item
Part Number
Description
1
-
Diesel particulate filter
2
-
Exhaust gas flow
3
-
Sealed ducts
4
-
Porous walls
5
-
Filtered soot particles and fuel additive

As the exhaust gases with the soot particles and fuel additive are filtered/forced through the porous walls (due to the offset sealed ducts), the soot particles and additive are stuck to the walls of the element. This process occurs until a large build up of soot particles and fuel additive attached to the porous walls increase the exhaust gas pressure before the diesel particulate filter, which is monitored by the pressure differential sensor for diagnostic purposes.

The regular regeneration of soot particulates stored in the diesel particulate filter leads to a build up of stored ash (by-product of the regeneration process). This build up reduces the usable volume within the diesel particulate filter which soot is stored between regenerations, thus shortening the regeneration interval (as calculated by the PCM). For this reason the diesel particulate filter must be changed at the scheduled service interval.

On vehicles with 1.6L Duratorq-TDCi (DV) diesel engine, the diesel particulate filter and catalytic converter are serviced as a complete unit, whereas on vehicles with 2.0L Duratorq-TDCi (DW) diesel engine , the diesel particulate filter is a separate component installed after the catalytic converter and is serviced as a separate unit.

Exhaust gas temperature sensor

The exhaust gas temperature sensor measures the temperature of the exhaust gases as they pass through the diesel particulate filter. The temperature of the exhaust gases must be approximately 500°C for the soot particles and fuel additive to be regenerated.

The exhaust gas temperature sensor will send exhaust gas temperature data back to the PCM. This will enable the PCM to calculate the thermal energy produced and allow it to verify whether a regeneration event has been either partially or completely successful.

Pressure differential sensor

The pressure differential sensor main function is to assist the diagnosis of the diesel particulate filter. It determines if the diesel particulate filter is in one of the following states:

  • partially blocked
  • completely blocked
  • missing

The pressure differential sensor is connected to the diesel particulate filter by two pipes for monitoring the pre and post pressures of the diesel particulate filter. The pressure differential sensor converts the measurements taken from the two pipes into voltage, which is then sent to the PCM as part of the decision of whether to apply the regeneration process or not.

Intake air shutoff throttle - vehicles with 1.6L Duratorq-TDCi (DV) diesel engine

 
Item
Part Number
Description
1
-
Intake air shutoff throttle outlet
2
-
Charge air cooler bypass inlet
3
-
Charge air cooler bypass inlet valve stepper motor
4
-
Intake manifold air intake valve stepper motor
5
-
Intake air shutoff throttle inlet
6
-
Manifold absolute pressure (MAP) sensor
7
-
Charge air temperature sensor

The engine is equipped with an intake air shutoff throttle, which acts as a charge air cooler bypass while the diesel particulate filter is being regenerated.

The intake air shutoff throttle redirects the air from the turbocharger outlet pipe to the intake manifold by closing the intake manifold air intake valve, using a stepper motor. This uncooled (warm) air is measured by the charge air temperature sensor during the regeneration process.

The introduction of the intake air shutoff throttle means the air mass directed through the charge air cooler is reduced throughout the regeneration of the diesel particulate filter and at the same time, the warm or uncooled air to the intake manifold increases, to allow for high temperature combustion, which burns the soot particles and fuel additive efficiently.

The volumetric efficiency of the engine is reduced due to the redirection of the air flow, while at the same time the intake air temperature is kept constant, to prevent fluctuation in exhaust gas temperatures during regeneration.

The intake air temperature is monitored by the charge air temperature sensor in the intake air shutoff throttle housing. If the air temperature reduces, the PCM will correct the intake air shutoff throttle to allow the temperature of the intake air to increase and remain constant.

Intake air shutoff throttle - Vehicles with 2.0L Duratorq-TDCi (DW) diesel engine

 
Item
Part Number
Description
1
-
MAP sensor
2
-
Charge air cooler bypass inlet valve vacuum control
3
-
Charge air temperature sensor
4
-
Intake manifold air intake valve vacuum control

The intake air shutoff throttle equipped to vehicles with 2.0L Duratorq-TDCi (DW) diesel engine has the same operation as the intake air shutoff throttle on the 1.6L Duratorq-TDCi (DV) diesel engine, but with a difference in valve operation. These are controlled by vacuum operated valves instead of stepper motor controlled valves. The vacuum operated valves using remote control solenoids are controlled by the PCM, which open and close the valves during the regeneration process.

Fuel additive

The fuel additive uses a metallic catalyst consisting of cerium and iron. This allows the soot particles to be burnt off (regeneration) at a lower temperature.

When the fuel mixture (with the fuel additive) burns in the engine combustion chamber, cerium oxide (fuel additive) particles bind with the soot particles, which are then filtered by the diesel particulate filter and become embedded within the diesel particulate filter element.

The regeneration can accelerate the oxidation process considerably. due to the larger numbers of contact points between the cerium oxide particles or fuel additive and soot particles.

Fuel additive tank

 
Item
Part Number
Description
1
-
Fuel additive tank to fuel tank line
2
-
Overflow (filling)
3
-
Fuel additive tank filler pipe
4
-
Fuel additive tank
5
-
Dosing pump
6
-
Fuel additive tank vent

The fuel additive tank is located to the rear of the fuel tank and is secured to the rear subframe.

The fuel additive tank has an integral dosing pump built into the side of the fuel tank and can only be serviced as a complete unit.
REFER to: Fuel Additive Tank (310-01, Removal and Installation).

The fuel additive tank has the capacity of 1.8 liters and a total driving distance to empty of 60,000 km (37,000 miles) and must then be refilled.
REFER to: Fuel Additive System Filling and Bleeding (310-00, General Procedures).
After the refill of the fuel additive tank, the fuel additive system module must be reset by using either WDS, or manually with the fuel filler door providing no diagnostic trouble code(s) (DTC)s are present.
REFER to: Fuel Additive System Service Reset Procedure Without Using Diagnostic Tool (310-00, General Procedures).

Fuel additive injector

 
Item
Part Number
Description
1
-
Fuel additive injector

The fuel additive injector is an integral part of the vehicle fuel tank and is connected to the fuel additive tank with a short length of fuel pipe. The fuel additive injector cannot be removed from the fuel tank and must be serviced as a complete unit.
REFER to: Fuel Tank - 1.6L Duratorq-TDCi (DV) Diesel/2.0L Duratorq-TDCi (DW) Diesel, Vehicles With: Fuel Additive Tank (310-01, Removal and Installation).

The fuel additive injector is a one-way valve that opens to allow the calculated fuel additive to be injected into the fuel tank. The one-way valve opens due to the fuel additive pressure created by the dosing valve in the fuel additive tank. The one-way valve closes once the pressure has dropped after the calculated amount of fuel additive is injected into the fuel tank.

Fuel additive system module

 
Item
Part Number
Description
1
-
Fuel additive system module

The fuel additive system module is located under the rear seat cushion.

The main purpose of the fuel additive system module is to calculate the required amount of fuel additive and control the time of injection into the fuel tank. It also stores DTC(s) for the fuel additive system.

In addition to the already mentioned operation of the fuel additive system module, the instrument cluster will receive a command from the fuel additive system module to illuminate the malfunction indicator lamp (MIL) or the powertrain warning indicator if there are concerns with the additive system or if the fuel additive tank requires refilling.

 
Item
Part Number
Description
1
-
Powertrain warning indicator
2
-
MIL

The fuel additive system module also counts the amount of fuel tank refills and fuel additive injections that have occurred and sends the information to the PCM.

The fuel additive system module must be reset after the fuel additive tank has been refilled or DTC(s) have been retrieved by connecting to WDS through the data link connector (DLC).

The following information shows the components connected to the fuel additive system module, that assist in the calculation and metering of the quantity of fuel additive added.

 
Item
Part Number
Description
1
-
Instrument cluster
2
-
PCM
3
-
Fuel additive system module
4
-
Fuel filler door switch
5
-
Fuel additive tank
6
-
Dosing pump
7
-
Fuel level signal
8
-
Engine speed signal
9
-
Vehicle speed signal
10
-
Fuel tank filler pipe cover switch open/close signal
11
-
Fuel additive low level signal
12
-
Fuel additive calculated injection signal
13
-
Regeneration and DTC signal
14
-
Instrument cluster warning lamp(s) illumination signal

The fuel additive system module communicates with the PCM and instrument cluster by using the high-speed CAN bus circuit. The other components connected to the system are standard wiring harnesses.

Fuel filler door switch and switch magnet

 
Item
Part Number
Description
1
-
Fuel filler door switch

 
Item
Part Number
Description
1
-
Fuel filler door switch magnet

The fuel filler door switch works in conjunction with the fuel filler door switch magnet to indicate to the fuel additive system module that the fuel tank is being refilled.

The fuel filler door switch is closed contact when the fuel filler door is opened. A signal is sent to the fuel additive system module to indicate that the fuel tank is being refilled.

The fuel additive system module goes into sleep mode while the fuel tank is being refilled. Once the refill has been completed, the fuel filler door is closed and the fuel filler door switch is open contact, which cancels the fuel additive system module sleep mode.

When the ignition key is turned to position II, the current fuel tank level is registered by the PCM and compared with the previous level (before the fuel tanks was refilled). The difference between the two measurements is then calculated. The information is then added to the fuel additive tank refill calculations for the correct quantity of fuel additive to be injected.

Dosing pump

 
Item
Part Number
Description
1
-
Fuel additive to fuel tank supply line connector
2
-
Dosing pump
3
-
Piezo sensor

The dosing pump has a main function of supplying the correct calculated quantity of fuel additive to the fuel tank. This is achieved by signals sent from the fuel additive system module to the dosing pump, regarding the pump operation duration.

The dosing pump has a piezo sensor for the following functions:

  • The piezo sensor calculates the viscosity of the fuel additive which maybe affected by the ambient air temperature and transfers the value(s) to the fuel additive system module.
  • The piezo sensor measures the fuel additive level in the fuel additive tank only at very low level and transfers that information to the fuel additive system module.

The fuel additive system module can calculate the inputs of the piezo sensor and determine the precise quantity of fuel additive to be injected into the fuel tank.

Concerns with the diesel particulate filter and fuel additive system

Due to the nature of the diesel particulate filter and the fuel additive system, some unusual vehicle behavior may be induced if the vehicle is driven on short or stop/start journeys. The diesel particulate filter needs to have higher temperature exhaust gases than the normal operating temperature to assist the regeneration process. Short journeys have the opposite effect. The soot particulates and fuel additive build up in the diesel particulate filter element becomes excessive and blocks the diesel particulate filter. Typical symptoms exhibited for this are as follows:

  • Lack of power
  • Poor engine performance
  • MIL or powertrain warning indicator will illuminate.

Inspection and Verification

WARNING:
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:
WARNING:This procedure involves fuel handling. Be prepared for fuel spillage at all times. Failure to follow this instruction may result in personal injury.
WARNING:
WARNING: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.
CAUTION:
CAUTION:Always carry out the cleaning process before carrying out any repairs to the fuel injection system components to prevent foreign matter ingress to the components.
  1. Verify the customer concern.
  1. Visually inspect for obvious signs of mechanical or electrical damage.

Visual Inspection Chart

Mechanical Electrical
  • Fuel level
  • Fuel leak(s)
  • Fuel line(s)
  • Fuel filler cap
  • Fuel filter
  • Fuel tank
  • Fuel tank ventilation hose
  • Fuel tank filler hose
  • Wiring harness
  • Electrical connector(s)
  • Fuel level sensor
  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 the Symptom Chart.

Symptom Chart

Symptom Chart

Symptom Possible Sources Action
Engine cranks but does not start
*
Fuel charging and controls.
*
Vehicles with 1.6L Duratorq-TDCi (DV) diesel engine.
REFER to: Fuel Charging and Controls (303-04D, Diagnosis and Testing).
Vehicles with 1.8L Duratorq-TDCi (Kent) diesel engine.
REFER to: Fuel Charging and Controls - 1.8L Duratorq-TDCi (Kent) Diesel (303-04G, Diagnosis and Testing).
Vehicles with 2.0L Duratorq-TDCi (DW) diesel engine.
REFER to: Fuel Charging and Controls (303-04E, Diagnosis and Testing).
*
Air ingress into the fuel lines.
*
Vehicles with 1.6L Duratorq-TDCi (DV) diesel engine. GO to Pinpoint Test A. Vehicles with 1.8L Duratorq-TDCi (Kent) diesel engine. GO to Pinpoint Test B. Vehicles with 2.0L Duratorq-TDCi (DW) diesel engine. GO to Pinpoint Test C.
*
Contaminated fuel.
*
INSTALL a new fuel filter.
REFER to: Fuel Filter - 1.6L Duratorq-TDCi (DV) Diesel (310-01, Removal and Installation) /
Fuel Filter - 1.8L Duratorq-TDCi (Kent) Diesel, Vehicles Without: Water-in-Fuel Sensor (310-01, Removal and Installation) /
Fuel Filter - 2.0L Duratorq-TDCi (DW) Diesel, Vehicles With: Water-in-Fuel Sensor (310-01, Removal and Installation).
or
REFER to: Fuel Filter - 2.0L Duratorq-TDCi (DW) Diesel, Vehicles Without: Water-in-Fuel Sensor (310-01, Removal and Installation).
DRAIN and INSTALL new fuel.
REFER to: Fuel Tank - 1.6L Duratorq-TDCi (DV) Diesel/2.0L Duratorq-TDCi (DW) Diesel, Vehicles With: Fuel Additive Tank (310-01, Removal and Installation).
or
REFER to: Fuel Tank - 1.6L Duratorq-TDCi (DV) Diesel/2.0L Duratorq-TDCi (DW) Diesel, Vehicles Without: Fuel Additive Tank (310-01, Removal and Installation).
Poor starting
*
Fuel charging and controls.
*
Vehicles with 1.6L Duratorq-TDCi (DV) diesel engine.
REFER to: Fuel Charging and Controls (303-04D, Diagnosis and Testing).
Vehicles with 1.8L Duratorq-TDCi (Kent) diesel engine.
REFER to: Fuel Charging and Controls - 1.8L Duratorq-TDCi (Kent) Diesel (303-04G, Diagnosis and Testing).
Vehicles with 2.0L Duratorq-TDCi (DW) diesel engine.
REFER to: Fuel Charging and Controls (303-04E, Diagnosis and Testing).
*
Air ingress into the fuel lines.
*
Vehicles with 1.6L Duratorq-TDCi (DV) diesel engine. GO to Pinpoint Test A. Vehicles with 1.8L Duratorq-TDCi (Kent) diesel engine. GO to Pinpoint Test B. Vehicles with 2.0L Duratorq-TDCi (DW) diesel engine. GO to Pinpoint Test C.
*
Contaminated fuel.
*
INSTALL a new fuel filter.
REFER to: Fuel Filter - 1.6L Duratorq-TDCi (DV) Diesel (310-01, Removal and Installation) /
Fuel Filter - 1.8L Duratorq-TDCi (Kent) Diesel, Vehicles Without: Water-in-Fuel Sensor (310-01, Removal and Installation) /
Fuel Filter - 2.0L Duratorq-TDCi (DW) Diesel, Vehicles With: Water-in-Fuel Sensor (310-01, Removal and Installation).
or
REFER to: Fuel Filter - 2.0L Duratorq-TDCi (DW) Diesel, Vehicles Without: Water-in-Fuel Sensor (310-01, Removal and Installation).
DRAIN and INSTALL new fuel.
REFER to: Fuel Tank - 1.6L Duratorq-TDCi (DV) Diesel/2.0L Duratorq-TDCi (DW) Diesel, Vehicles With: Fuel Additive Tank (310-01, Removal and Installation).
or
REFER to: Fuel Tank - 1.6L Duratorq-TDCi (DV) Diesel/2.0L Duratorq-TDCi (DW) Diesel, Vehicles Without: Fuel Additive Tank (310-01, Removal and Installation).
Engine starts but immediately stops
*
Fuel charging and controls.
*
Vehicles with 1.6L Duratorq-TDCi (DV) diesel engine.
REFER to: Fuel Charging and Controls (303-04D, Diagnosis and Testing).
Vehicles with 1.8L Duratorq-TDCi (Kent) diesel engine.
REFER to: Fuel Charging and Controls - 1.8L Duratorq-TDCi (Kent) Diesel (303-04G, Diagnosis and Testing).
Vehicles with 2.0L Duratorq-TDCi (DW) diesel engine.
REFER to: Fuel Charging and Controls (303-04E, Diagnosis and Testing).
*
Air ingress into the fuel lines.
*
Vehicles with 1.6L Duratorq-TDCi (DV) diesel engine. GO to Pinpoint Test A. Vehicles with 1.8L Duratorq-TDCi (Kent) diesel engine. GO to Pinpoint Test B. Vehicles with 2.0L Duratorq-TDCi (DW) diesel engine. GO to Pinpoint Test C.
Poor idling
*
Fuel charging and controls.
*
Vehicles with 1.6L Duratorq-TDCi (DV) diesel engine.
REFER to: Fuel Charging and Controls (303-04D, Diagnosis and Testing).
Vehicles with 1.8L Duratorq-TDCi (Kent) diesel engine.
REFER to: Fuel Charging and Controls - 1.8L Duratorq-TDCi (Kent) Diesel (303-04G, Diagnosis and Testing).
Vehicles with 2.0L Duratorq-TDCi (DW) diesel engine.
REFER to: Fuel Charging and Controls (303-04E, Diagnosis and Testing).
*
Air ingress into the fuel lines.
*
Vehicles with 1.6L Duratorq-TDCi (DV) diesel engine. GO to Pinpoint Test A. Vehicles with 1.8L Duratorq-TDCi (Kent) diesel engine. GO to Pinpoint Test B. Vehicles with 2.0L Duratorq-TDCi (DW) diesel engine. GO to Pinpoint Test C.
*
Contaminated fuel.
*
INSTALL a new fuel filter.
REFER to: Fuel Filter - 1.6L Duratorq-TDCi (DV) Diesel (310-01, Removal and Installation) /
Fuel Filter - 1.8L Duratorq-TDCi (Kent) Diesel, Vehicles Without: Water-in-Fuel Sensor (310-01, Removal and Installation) /
Fuel Filter - 2.0L Duratorq-TDCi (DW) Diesel, Vehicles With: Water-in-Fuel Sensor (310-01, Removal and Installation).
or
REFER to: Fuel Filter - 2.0L Duratorq-TDCi (DW) Diesel, Vehicles Without: Water-in-Fuel Sensor (310-01, Removal and Installation).
DRAIN and INSTALL new fuel.
REFER to: Fuel Tank - 1.6L Duratorq-TDCi (DV) Diesel/2.0L Duratorq-TDCi (DW) Diesel, Vehicles With: Fuel Additive Tank (310-01, Removal and Installation).
or
REFER to: Fuel Tank - 1.6L Duratorq-TDCi (DV) Diesel/2.0L Duratorq-TDCi (DW) Diesel, Vehicles Without: Fuel Additive Tank (310-01, Removal and Installation).
Engine lacks power
*
Fuel tank to fuel filter fuel supply line blocked.
*
CHECK the fuel supply lines for damage. INSTALL a new fuel filter fuel supply line.
REFER to: Fuel Supply Line - 1.6L Duratorq-TDCi (DV) Diesel/2.0L Duratorq-TDCi (DW) Diesel (310-01, Removal and Installation).
*
CHECK the fuel supply line for blockage. Vehicles with 1.6L Duratorq-TDCi (DV) diesel engine. GO to Pinpoint Test D. Vehicles with 1.8L Duratorq-TDCi (Kent) diesel engine. GO to Pinpoint Test E. Vehicles with 2.0L Duratorq-TDCi (DW) diesel engine. GO to Pinpoint Test F.
*
Fuel filter blocked.
*
INSTALL a new fuel filter.
REFER to: Fuel Filter - 1.6L Duratorq-TDCi (DV) Diesel (310-01, Removal and Installation) /
Fuel Filter - 1.8L Duratorq-TDCi (Kent) Diesel, Vehicles Without: Water-in-Fuel Sensor (310-01, Removal and Installation) /
Fuel Filter - 2.0L Duratorq-TDCi (DW) Diesel, Vehicles With: Water-in-Fuel Sensor (310-01, Removal and Installation).
or
REFER to: Fuel Filter - 2.0L Duratorq-TDCi (DW) Diesel, Vehicles Without: Water-in-Fuel Sensor (310-01, Removal and Installation).
*
Fuel charging and controls.
*
Vehicles with 1.6L Duratorq-TDCi (DV) diesel engine.
REFER to: Fuel Charging and Controls (303-04D, Diagnosis and Testing).
Vehicles with 1.8L Duratorq-TDCi (Kent) diesel engine.
REFER to: Fuel Charging and Controls - 1.8L Duratorq-TDCi (Kent) Diesel (303-04G, Diagnosis and Testing).
Vehicles with 2.0L Duratorq-TDCi (DW) diesel engine.
REFER to: Fuel Charging and Controls (303-04E, Diagnosis and Testing).
*
Air ingress into the fuel lines.
*
Vehicles with 1.6L Duratorq-TDCi (DV) diesel engine. GO to Pinpoint Test A. Vehicles with 1.8L Duratorq-TDCi (Kent) diesel engine. GO to Pinpoint Test B. Vehicles with 2.0L Duratorq-TDCi (DW) diesel engine. GO to Pinpoint Test C.
*
Contaminated fuel.
*
INSTALL a new fuel filter.
REFER to: Fuel Filter - 1.6L Duratorq-TDCi (DV) Diesel (310-01, Removal and Installation) /
Fuel Filter - 1.8L Duratorq-TDCi (Kent) Diesel, Vehicles Without: Water-in-Fuel Sensor (310-01, Removal and Installation) /
Fuel Filter - 2.0L Duratorq-TDCi (DW) Diesel, Vehicles With: Water-in-Fuel Sensor (310-01, Removal and Installation).
or
REFER to: Fuel Filter - 2.0L Duratorq-TDCi (DW) Diesel, Vehicles Without: Water-in-Fuel Sensor (310-01, Removal and Installation).
DRAIN and INSTALL new fuel.
REFER to: Fuel Tank - 1.6L Duratorq-TDCi (DV) Diesel/2.0L Duratorq-TDCi (DW) Diesel, Vehicles With: Fuel Additive Tank (310-01, Removal and Installation).
or
REFER to: Fuel Tank - 1.6L Duratorq-TDCi (DV) Diesel/2.0L Duratorq-TDCi (DW) Diesel, Vehicles Without: Fuel Additive Tank (310-01, Removal and Installation).
Engine misfire
*
Fuel charging and controls.
*
Vehicles with 1.6L Duratorq-TDCi (DV) diesel engine.
REFER to: Fuel Charging and Controls (303-04D, Diagnosis and Testing).
Vehicles with 1.8L Duratorq-TDCi (Kent) diesel engine.
REFER to: Fuel Charging and Controls - 1.8L Duratorq-TDCi (Kent) Diesel (303-04G, Diagnosis and Testing).
Vehicles with 2.0L Duratorq-TDCi (DW) diesel engine.
REFER to: Fuel Charging and Controls (303-04E, Diagnosis and Testing).
*
Air ingress into the fuel lines.
*
Vehicles with 1.6L Duratorq-TDCi (DV) diesel engine. GO to Pinpoint Test A. Vehicles with 1.8L Duratorq-TDCi (Kent) diesel engine. GO to Pinpoint Test B. Vehicles with 2.0L Duratorq-TDCi (DW) diesel engine. GO to Pinpoint Test C.
Excessive fuel consumption
*
Fuel charging and controls.
*
Vehicles with 1.6L Duratorq-TDCi (DV) diesel engine.
REFER to: Fuel Charging and Controls (303-04D, Diagnosis and Testing).
Vehicles with 1.8L Duratorq-TDCi (Kent) diesel engine.
REFER to: Fuel Charging and Controls - 1.8L Duratorq-TDCi (Kent) Diesel (303-04G, Diagnosis and Testing).
Vehicles with 2.0L Duratorq-TDCi (DW) diesel engine.
REFER to: Fuel Charging and Controls (303-04E, Diagnosis and Testing).
*
Air ingress into the fuel lines.
*
Vehicles with 1.6L Duratorq-TDCi (DV) diesel engine. GO to Pinpoint Test A. Vehicles with 1.8L Duratorq-TDCi (Kent) diesel engine. GO to Pinpoint Test B. Vehicles with 2.0L Duratorq-TDCi (DW) diesel engine. GO to Pinpoint Test C.
*
Contaminated fuel.
*
INSTALL a new fuel filter.
REFER to: Fuel Filter - 1.6L Duratorq-TDCi (DV) Diesel (310-01, Removal and Installation) /
Fuel Filter - 1.8L Duratorq-TDCi (Kent) Diesel, Vehicles Without: Water-in-Fuel Sensor (310-01, Removal and Installation) /
Fuel Filter - 2.0L Duratorq-TDCi (DW) Diesel, Vehicles With: Water-in-Fuel Sensor (310-01, Removal and Installation).
or
REFER to: Fuel Filter - 2.0L Duratorq-TDCi (DW) Diesel, Vehicles Without: Water-in-Fuel Sensor (310-01, Removal and Installation).
DRAIN and INSTALL new fuel.
REFER to: Fuel Tank - 1.6L Duratorq-TDCi (DV) Diesel/2.0L Duratorq-TDCi (DW) Diesel, Vehicles With: Fuel Additive Tank (310-01, Removal and Installation).
or
REFER to: Fuel Tank - 1.6L Duratorq-TDCi (DV) Diesel/2.0L Duratorq-TDCi (DW) Diesel, Vehicles Without: Fuel Additive Tank (310-01, Removal and Installation).
Fuel filler nozzle shuts off prematurely
*
Fuel tank ventilation hose or pipe blocked.
*
Fuel tank ventilation hose or pipe collapsed.
*
CHECK the fuel tank ventilation hose for obstruction or damage. INSTALL a new fuel tank ventilation pipe. for additional information,
REFER to: Fuel Tank Filler Pipe (310-01, Removal and Installation).
*
Fuel tank filler pipe or hose blocked.
*
Fuel tank filler pipe or hose collapsed.
*
CHECK the fuel tank filler pipe or hose for obstruction or damage. INSTALL a new fuel tank filler pipe. for additional information,
REFER to: Fuel Tank Filler Pipe (310-01, Removal and Installation).
*
Fuel gauge indication.
*
CHECK the fuel level in the fuel tank. CHECK the fuel indication system. For additional information,
REFER to: Instrument Cluster (413-01, Diagnosis and Testing).
*
Fuel filler nozzle at fuel filling station not functioning correctly.
*
VERIFY condition by using a known good fuel filler nozzle.
Fuel loss after nozzle shutoff or during refilling
*
Fuel tank filler pipe or hose leaking.
*
CHECK the fuel tank filler pipe and hose for evidence of a fuel leak. If a fuel leak is evident, INSTALL a new fuel tank filler pipe and hose. For additional information,
REFER to: Fuel Tank Filler Pipe (310-01, Removal and Installation).
*
Fuel tank leaking.
*
CHECK the fuel tank for evidence of a fuel leak. If a fuel leak is evident, INSTALL a new fuel tank. For additional information,
REFER to: Fuel Tank - 1.6L Duratorq-TDCi (DV) Diesel/2.0L Duratorq-TDCi (DW) Diesel, Vehicles With: Fuel Additive Tank (310-01, Removal and Installation).
or
REFER to: Fuel Tank - 1.6L Duratorq-TDCi (DV) Diesel/2.0L Duratorq-TDCi (DW) Diesel, Vehicles Without: Fuel Additive Tank (310-01, Removal and Installation).
*
Fuel tank ventilation pipe or hose leaking.
*
CHECK the fuel tank ventilation pipe and hose for evidence of a fuel leak. If a fuel leak is evident, INSTALL a new fuel tank ventilation pipe and hose. For additional information,
REFER to: Fuel Tank Filler Pipe (310-01, Removal and Installation).

Pinpoint Tests

PINPOINT TEST A : AIR INGRESS INTO THE FUEL LINES - VEHICLES WITH 1.6L DURATORQ-TDCI (DV) DIESEL ENGINE

TEST CONDITIONS DETAILS/RESULTS/ACTIONS
A1: CHECK FOR AIR INGRESS INTO THE FUEL SYSTEM
WARNING:
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:
WARNING:This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow this instruction may result in personal injury.
CAUTION:
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 install blanking plugs to any open orifices or lines.
CAUTION:
CAUTION:Always carry out the cleaning process before carrying out any repairs to the fuel injection system components to prevent foreign matter ingress to the components.

1
Remove the engine cover.

2
Start the engine, wait a few minutes and then observe the clear plastic fuel pipe in the fuel pump fuel return line for signs of air ingress.

Are any signs of air present in the clear plastic fuel pipe?
Yes
No
For additional diagnostics go to Fuel Charging and Controls,
REFER to: Fuel Charging and Controls (303-04D, Diagnosis and Testing).
A2: CHECK WHERE AIR IS ENTERING THE SYSTEM
1
Using suitable clean engine oil, apply the oil to each of the fuel supply line and fuel return line connections, unions and joints in turn and observe the clear plastic pipe for visible signs of air after each oil application.

Did the amount of air in the clear plastic fuel pipe decrease when any of the connectors, unions or joints were oiled?
Yes
INSTALL a new fuel pipe(s) as necessary. Test the system for normal operation.
No
A3: CHECK THE FUEL LEVEL SENSOR FOR AIR INGRESS
1
Drain the fuel tank.
REFER to: Fuel Tank Draining (310-00, General Procedures).
2
Fill the fuel tank with 10 liters of diesel.

3
Remove the fuel filter crash shield.
  • Disconnect water in fuel electrical connector (if equipped).
  • Disconnect the vacuum pump vacuum supply line quick release coupling.
    REFER to: Quick Release Coupling (310-00, General Procedures).
  • Detach the vacuum pump vacuum supply line clip from the fuel filter crash shield.
  • Remove the fuel filter crash shield retaining bolts.

4
Disconnect the fuel filter fuel supply line quick release coupling.
REFER to: Quick Release Coupling (310-00, General Procedures).

5
Using a suitable piece of clear plastic pipe, manufacture and install a pipe between the fuel filter and the fuel tank to fuel filter supply line.
NOTE:
NOTE:Make sure the engine is at normal operating temperature.
6
Start the engine, wait a few minutes and then observe the clear plastic pipe for signs of air ingress.

Are any signs of air present in the clear plastic pipe?
Yes
INSTALL a new fuel level sensor
REFER to: Fuel Pump Module (310-01 Fuel Tank and Lines, Removal and Installation).
or fuel tank to fuel filter supply pipe as necessary.
REFER to: Fuel Supply Line - 1.6L Duratorq-TDCi (DV) Diesel/2.0L Duratorq-TDCi (DW) Diesel (310-01, Removal and Installation).
No
INSTALL a new fuel filter.
REFER to: Fuel Filter - 1.6L Duratorq-TDCi (DV) Diesel (310-01, Removal and Installation).

PINPOINT TEST B : AIR INGRESS INTO THE FUEL LINES - VEHICLES WITH 1.8L DURATORQ-TDCI (KENT) DIESEL ENGINE

TEST CONDITIONS DETAILS/RESULTS/ACTIONS
B1: CHECK FOR AIR INGRESS INTO THE FUEL SYSTEM
WARNING:
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:
WARNING:This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow this instruction may result in personal injury.
CAUTION:
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 install blanking plugs to any open orifices or lines.
CAUTION:
CAUTION:Always carry out the cleaning process before carrying out any repairs to the fuel injection system components to prevent foreign material ingress to the components.

1
Note the location of the engine cover retaining clips.

CAUTION:
CAUTION:Care must be taken when releasing the fourth retaining clip and maneuvering the engine cover past the manifold absolute pressure (MAP) sensor. Failure to follow this instruction may result in damage to the MAP sensor.
NOTE:
NOTE:Remove the engine cover in the sequence shown.
2
Remove the engine cover.

3
Remove the fuel filter crash protection top shield.

4
Disconnect the fuel filter fuel supply line.
REFER to: Quick Release Coupling (310-00, General Procedures).

5
Using a suitable piece of clear plastic pipe, manufacture and install a pipe between the fuel filter fuel supply line and fuel filter.
6
Start the engine, wait a few minutes and then observe the clear plastic fuel pipe between the fuel filter fuel supply line and fuel filter for signs of air ingress.

Are any signs of air present in the clear plastic pipe?
Yes
No
For additional diagnostics,
REFER to: Fuel Charging and Controls - 1.8L Duratorq-TDCi (Kent) Diesel (303-04G, Diagnosis and Testing).
B2: CHECK WHERE AIR IS ENTERING THE SYSTEM
1
Using suitable clean engine oil, apply the oil to each of the fuel supply line and fuel return line connections, unions and joints in turn and observe the clear plastic pipe for visible signs of air after each oil application.

Did the amount of air in the clear plastic fuel pipe decrease when any of the connectors, unions or joints were oiled?
Yes
INSTALL a new fuel pipe(s) as necessary. Test the system for normal operation.
No
B3: CHECK THE FUEL LEVEL SENSOR FOR AIR INGRESS
1
Drain the fuel tank.
REFER to: Fuel Tank Draining (310-00 Fuel System - General Information, General Procedures).
2
Fill the fuel tank with 10 liters of diesel.

3
Disconnect the fuel pump fuel supply line quick release coupling.
REFER to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).
  • Detach the fuel line line from the retaining clip.

4
Using a suitable piece of clear plastic pipe, manufacture and install a pipe between the fuel filter to fuel pump fuel supply line.
NOTE:
NOTE:Make sure the engine is at normal operating temperature.
5
Start the engine, wait a few minutes and observe the clear plastic pipe for signs of air ingress.

Are any signs of air present in the clear plastic pipe?
Yes
INSTALL a new fuel level sensor.
REFER to: Fuel Pump Module (310-01 Fuel Tank and Lines, Removal and Installation).
or fuel tank to fuel filter supply pipe as necessary.
No
INSTALL a new fuel filter.
REFER to: Fuel Filter - 1.8L Duratorq-TDCi (Kent) Diesel, Vehicles Without: Water-in-Fuel Sensor (310-01, Removal and Installation).

PINPOINT TEST C : AIR INGRESS INTO THE FUEL LINES - VEHICLES WITH 2.0L DURATORQ-TDCI (DW) DIESEL ENGINE

TEST CONDITIONS DETAILS/RESULTS/ACTIONS
C1: CHECK FOR AIR INGRESS INTO THE FUEL SYSTEM
WARNING:
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:
WARNING:This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow this instruction may result in personal injury.
CAUTION:
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 install blanking plugs to any open orifices or lines.
CAUTION:
CAUTION:Always carry out the cleaning process before carrying out any repairs to the fuel injection system components to prevent foreign matter ingress to the components.
CAUTION:
CAUTION:The generator must be protected from contamination. Failure to follow this instruction may cause premature failure of the generator.

1
Remove the engine cover.

2
Start the engine, wait a few minutes and then observe the clear plastic fuel pipe in the fuel pump fuel return line for signs of air ingress.

Are any signs of air present in the clear plastic fuel pipe?
Yes
No
For additional diagnostics for Fuel Charging and Controls,
REFER to: Fuel Charging and Controls (303-04E, Diagnosis and Testing).
C2: CHECK WHERE AIR IS ENTERING THE SYSTEM
1
Using suitable clean engine oil, apply the oil to each of the fuel supply line and fuel return line connections, unions and joints in turn and observe the clear plastic pipe for visible signs of air after each oil application.

Did the amount of air in the clear plastic pipe decrease when any of the connectors, unions or joints were oiled?
Yes
INSTALL a new fuel pipe(s) as necessary. Test the system for normal operation.
No
C3: CHECK THE FUEL LEVEL SENSOR FOR AIR INGRESS
1
Drain the fuel tank.
REFER to: Fuel Tank Draining (310-00, General Procedures).
2
Fill the fuel tank with 10 liters of diesel.
3
Protect the generator with lint-free material to prevent contamination.

4
Disconnect the fuel filter fuel supply line quick release coupling.
REFER to: Quick Release Coupling (310-00, General Procedures).

5
Using a suitable piece of clear plastic pipe, manufacture and install a pipe between the fuel filter and the fuel tank to fuel filter supply line.
6
Remove the lint-free material.
NOTE:
NOTE:Make sure the engine is at normal operating temperature.
7
Start the engine, wait a few minutes and then observe the clear plastic pipe for signs of air ingress.

Are any signs of air present in the clear plastic pipe?
Yes
INSTALL a new fuel level sensor.
REFER to: Fuel Pump Module (310-01, Removal and Installation).
or fuel tank to fuel filter supply pipe as necessary.
REFER to: Fuel Supply Line - 1.6L Duratorq-TDCi (DV) Diesel/2.0L Duratorq-TDCi (DW) Diesel (310-01, Removal and Installation).
No
INSTALL a new fuel filter.
REFER to: Fuel Filter - 2.0L Duratorq-TDCi (DW) Diesel, Vehicles With: Water-in-Fuel Sensor (310-01, Removal and Installation).
or
REFER to: Fuel Filter - 2.0L Duratorq-TDCi (DW) Diesel, Vehicles Without: Water-in-Fuel Sensor (310-01, Removal and Installation).

PINPOINT TEST D : FUEL FILTER FUEL SUPPLY LINE BLOCKAGE - VEHICLES WITH 1.6L DURATORQ-TDCI (DV) DIESEL ENGINE

TEST CONDITIONS DETAILS/RESULTS/ACTIONS
D1: CHECK THE FUEL FILTER FUEL SUPPLY LINE FOR BLOCKAGE
WARNING:
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:
WARNING:This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow this instruction may result in personal injury.
CAUTION:
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 install blanking plugs to any open orifices or lines.
CAUTION:
CAUTION:Always carry out the cleaning process before carrying out any repairs to the fuel injection system components to prevent foreign matter ingress to the components.

1
Remove the fuel filter crash shield.
  • Disconnect water in fuel electrical connector (if equipped).
  • Disconnect the vacuum pump vacuum supply line quick release coupling.
    REFER to: Quick Release Coupling (310-00, General Procedures).
  • Detach the vacuum pump vacuum supply line clip from the fuel filter crash shield.
  • Remove the fuel filter crash shield retaining bolts.

2
Disconnect the fuel filter fuel supply line quick release coupling.
REFER to: Quick Release Coupling (310-00, General Procedures).

3
Install the special tool between the fuel filter fuel supply line quick release coupling and the fuel filter union.
4
Operate the hand pressure pump.

5
Observe the flow of fuel in the clear plastic fuel pipe in the fuel pump fuel return line.

Does the fuel from the fuel tank flow freely with no restrictions?
Yes
GO to Pinpoint Test C.
No
REPAIR or INSTALL a new fuel filter fuel supply line.
REFER to: Fuel Supply Line - 1.6L Duratorq-TDCi (DV) Diesel/2.0L Duratorq-TDCi (DW) Diesel (310-01, Removal and Installation).

PINPOINT TEST E : FUEL FILTER FUEL SUPPLY LINE BLOCKAGE - VEHICLES WITH 1.8L DURATORQ-TDCI (KENT) DIESEL ENGINE

TEST CONDITIONS DETAILS/RESULTS/ACTIONS
E1: CHECK THE FUEL FILTER FUEL SUPPLY LINE FOR BLOCKAGE
WARNING:
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:
WARNING:This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow this instruction may result in personal injury.
CAUTION:
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 install blanking plugs to any open orifices or lines.
CAUTION:
CAUTION:Always carry out the cleaning process before carrying out any repairs to the fuel injection system components to prevent foreign material ingress to the components.
CAUTION:
CAUTION:The generator must be protected from contamination. Failure to follow this instruction may cause premature failure of the generator.

1
Note the location of the engine cover retaining clips.

CAUTION:
CAUTION:Care must be taken when releasing the fourth retaining clip and maneuvering the engine cover past the manifold absolute pressure (MAP) sensor. Failure to follow this instruction may result in damage to the MAP sensor.
NOTE:
NOTE:Remove the engine cover in the sequence shown.
2
Remove the engine cover.

3
Remove the fuel filter crash protection top shield.

4
Disconnect the fuel filter fuel supply line quick release coupling.
REFER to: Quick Release Coupling (310-00, General Procedures).

NOTE:
NOTE:Make sure that the hand pressure pump arrow indicating the direction of fuel flow is pointing towards the fuel filter.
5
Install the special tool between the fuel filter fuel supply line quick release coupling and the fuel filter union.

6
Operate the hand pressure pump at least 30 times.

7
Disconnect the fuel pump fuel return line quick release coupling.
REFER to: Quick Release Coupling (310-00, General Procedures).
  • Detach the fuel return line from the retaining clips.

8
Using a suitable piece of clear plastic pipe, manufacture and install a pipe between the fuel pump fuel return line and fuel return line union.
9
Observe the flow of fuel in the clear plastic pipe.

Does the fuel from the fuel tank flow freely with no restrictions?
Yes
GO to Pinpoint Test B.
No
REPAIR or INSTALL a new fuel filter fuel supply line.

PINPOINT TEST F : FUEL FILTER FUEL SUPPLY LINE BLOCKAGE - VEHICLES WITH 2.0L DURATORQ-TDCI (DW) DIESEL ENGINE

TEST CONDITIONS DETAILS/RESULTS/ACTIONS
F1: CHECK THE FUEL FILTER FUEL SUPPLY LINE FOR BLOCKAGE
WARNING:
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:
WARNING:This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow this instruction may result in personal injury.
CAUTION:
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 install blanking plugs to any open orifices or lines.
CAUTION:
CAUTION:Always carry out the cleaning process before carrying out any repairs to the fuel injection system components to prevent foreign matter ingress to the components.
CAUTION:
CAUTION:The generator must be protected from contamination. Failure to follow this instruction may cause premature failure of the generator.
1
Protect the generator with lint-free material to prevent contamination.

2
Disconnect the fuel filter fuel supply line quick release coupling.
REFER to: Quick Release Coupling (310-00, General Procedures).

3
Install the special tool between the fuel filter fuel supply line quick release coupling and the fuel filter union.
4
Operate the hand pressure pump.

5
Observe the flow of fuel in the clear plastic fuel line in the fuel pump fuel return line.

Does the fuel from the fuel tank flow freely with no restrictions?
Yes
GO to Pinpoint Test C.
No
REPAIR or INSTALL a new fuel filter fuel supply line.
REFER to: Fuel Supply Line - 1.6L Duratorq-TDCi (DV) Diesel/2.0L Duratorq-TDCi (DW) Diesel (310-01, Removal and Installation).

Mechanical Repairs > 3 Powertrain > 310 Fuel System > 310-00 Fuel System - General Information > Diagnosis and Testing > Fuel System - 1.6L Duratorq-TDCi (DV) Diesel-1.8L Duratorq-TDCi (Lynx) Diesel-2.0L Duratorq-TDCi (DW) Diesel

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