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Fuel System - 1.25L Duratec-16V (Sigma)-1.3L Duratec-8V (Rocam)-1.4L Duratec-16V (Sigma)-1.6L Duratec-16V (Sigma)-2.0L Duratec-H > < 309-00 Exhaust System|Specifications

Fusion 2002.75 (06.2002-)

  • Mechanical Repairs
  • 3 Powertrain
  • 310 Fuel System
  • 310-00 Fuel System - General Information
  • Diagnosis and Testing
  • Fuel System - 1.4L Duratorq-TDCi (DV) Diesel-1.6L Duratorq-TDCi (DV) Diesel

Fuel System - General Information - Fuel System—1.4L Duratorq-TDCi (DV) Diesel/1.6L Duratorq-TDCi (DV) Diesel Fusion 2002.75 (06/2002-)
Diagnosis and Testing

Special Tool(s)

Hand Pressure Pump with Adapter Kit

310-110

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 filter
  • Fuel filler cap
  • Fuel tank
  • Fuel tank ventilation pipe
  • Fuel tank filler pipe
  • 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 Possible Sources Action
Engine cranks but does not start
*
Fuel charging and controls.
*
Vehicles with 1.4L Duratorq-TDCi (DV) Diesel engine.
REFER to: Fuel Charging and Controls (303-04B Fuel Charging and Controls - 1.4L Duratorq-TDCi (DV) Diesel, Diagnosis and Testing).
*
Vehicles with 1.6L Duratorq-TDCi (DV) Diesel engine.
REFER to: Fuel Charging and Controls (303-04D Fuel Charging and Controls - 1.6L Duratorq-TDCi (DV) Diesel, Diagnosis and Testing).
*
Air ingress into the fuel lines.
*
Vehicles with 1.4L Duratorq-TDCi (DV) Diesel engine. GO to Pinpoint Test A.
*
Vehicles with 1.6L Duratorq-TDCi (DV) Diesel engine. GO to Pinpoint Test B.
*
Contaminated fuel.
*
INSTALL a new fuel filter.
REFER to: Fuel Filter - 1.4L Duratorq-TDCi (DV) Diesel (310-01 Fuel Tank and Lines, Removal and Installation) /
Fuel Filter - 1.6L Duratorq-TDCi (DV) Diesel (310-01 Fuel Tank and Lines, Removal and Installation).
DRAIN and RENEW the fuel.
REFER to: Fuel Tank Draining (310-00 Fuel System - General Information, General Procedures).
Poor starting
*
Fuel charging and controls.
*
Vehicles with 1.4L Duratorq-TDCi (DV) Diesel engine.
REFER to: Fuel Charging and Controls (303-04B Fuel Charging and Controls - 1.4L Duratorq-TDCi (DV) Diesel, Diagnosis and Testing).
*
Vehicles with 1.6L Duratorq-TDCi (DV) Diesel engine.
REFER to: Fuel Charging and Controls (303-04D Fuel Charging and Controls - 1.6L Duratorq-TDCi (DV) Diesel, Diagnosis and Testing).
*
Air ingress into the fuel lines.
*
Vehicles with 1.4L Duratorq-TDCi (DV) Diesel engine. GO to Pinpoint Test A.
*
Vehicles with 1.6L Duratorq-TDCi (DV) Diesel engine. GO to Pinpoint Test B.
*
Contaminated fuel.
*
INSTALL a new fuel filter.
REFER to: Fuel Filter - 1.4L Duratorq-TDCi (DV) Diesel (310-01 Fuel Tank and Lines, Removal and Installation) /
Fuel Filter - 1.6L Duratorq-TDCi (DV) Diesel (310-01 Fuel Tank and Lines, Removal and Installation).
DRAIN and RENEW the fuel.
REFER to: Fuel Tank Draining (310-00 Fuel System - General Information, General Procedures).
Engine starts but immediately stops
*
Fuel charging and controls.
*
Vehicles with 1.4L Duratorq-TDCi (DV) Diesel engine.
REFER to: Fuel Charging and Controls (303-04B Fuel Charging and Controls - 1.4L Duratorq-TDCi (DV) Diesel, Diagnosis and Testing).
*
Vehicles with 1.6L Duratorq-TDCi (DV) Diesel engine.
REFER to: Fuel Charging and Controls (303-04D Fuel Charging and Controls - 1.6L Duratorq-TDCi (DV) Diesel, Diagnosis and Testing).
*
Air ingress into the fuel lines.
*
Vehicles with 1.4L Duratorq-TDCi (DV) Diesel engine. GO to Pinpoint Test A.
*
Vehicles with 1.6L Duratorq-TDCi (DV) Diesel engine. GO to Pinpoint Test B.
Poor idling
*
Fuel charging and controls.
*
Vehicles with 1.4L Duratorq-TDCi (DV) Diesel engine.
REFER to: Fuel Charging and Controls (303-04B Fuel Charging and Controls - 1.4L Duratorq-TDCi (DV) Diesel, Diagnosis and Testing).
*
Vehicles with 1.6L Duratorq-TDCi (DV) Diesel engine.
REFER to: Fuel Charging and Controls (303-04D Fuel Charging and Controls - 1.6L Duratorq-TDCi (DV) Diesel, Diagnosis and Testing).
*
Air ingress into the fuel lines.
*
Vehicles with 1.4L Duratorq-TDCi (DV) Diesel engine. GO to Pinpoint Test A.
*
Vehicles with 1.6L Duratorq-TDCi (DV) Diesel engine. GO to Pinpoint Test B.
*
Contaminated fuel.
*
INSTALL a new fuel filter.
REFER to: Fuel Filter - 1.4L Duratorq-TDCi (DV) Diesel (310-01 Fuel Tank and Lines, Removal and Installation) /
Fuel Filter - 1.6L Duratorq-TDCi (DV) Diesel (310-01 Fuel Tank and Lines, Removal and Installation).
DRAIN and RENEW the fuel.
REFER to: Fuel Tank Draining (310-00 Fuel System - General Information, General Procedures).
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.
*
CHECK the fuel supply line for blockage. Vehicles with 1.6L Duratorq-TDCi (DV) Diesel engine. GO to Pinpoint Test C.
*
Fuel filter blocked.
*
INSTALL a new fuel filter.
REFER to: Fuel Filter - 1.4L Duratorq-TDCi (DV) Diesel (310-01 Fuel Tank and Lines, Removal and Installation) /
Fuel Filter - 1.6L Duratorq-TDCi (DV) Diesel (310-01 Fuel Tank and Lines, Removal and Installation).
*
Fuel charging and controls.
*
Vehicles with 1.4L Duratorq-TDCi (DV) Diesel engine.
REFER to: Fuel Charging and Controls (303-04B Fuel Charging and Controls - 1.4L Duratorq-TDCi (DV) Diesel, Diagnosis and Testing).
*
Vehicles with 1.6L Duratorq-TDCi (DV) Diesel engine.
REFER to: Fuel Charging and Controls (303-04D Fuel Charging and Controls - 1.6L Duratorq-TDCi (DV) Diesel, Diagnosis and Testing).
*
Air ingress into the fuel lines.
*
Vehicles with 1.4L Duratorq-TDCi (DV) Diesel engine. GO to Pinpoint Test A.
*
Vehicles with 1.6L Duratorq-TDCi (DV) Diesel engine. GO to Pinpoint Test B.
*
Contaminated fuel.
*
INSTALL a new fuel filter.
REFER to: Fuel Filter - 1.4L Duratorq-TDCi (DV) Diesel (310-01 Fuel Tank and Lines, Removal and Installation) /
Fuel Filter - 1.6L Duratorq-TDCi (DV) Diesel (310-01 Fuel Tank and Lines, Removal and Installation).
DRAIN and RENEW the fuel.
REFER to: Fuel Tank Draining (310-00 Fuel System - General Information, General Procedures).
Engine misfire
*
Fuel charging and controls.
*
Vehicles with 1.4L Duratorq-TDCi (DV) Diesel engine.
REFER to: Fuel Charging and Controls (303-04B Fuel Charging and Controls - 1.4L Duratorq-TDCi (DV) Diesel, Diagnosis and Testing).
*
Vehicles with 1.6L Duratorq-TDCi (DV) Diesel engine.
REFER to: Fuel Charging and Controls (303-04D Fuel Charging and Controls - 1.6L Duratorq-TDCi (DV) Diesel, Diagnosis and Testing).
*
Air ingress into the fuel lines.
*
Vehicles with 1.4L Duratorq-TDCi (DV) Diesel engine. GO to Pinpoint Test A.
*
Vehicles with 1.6L Duratorq-TDCi (DV) Diesel engine. GO to Pinpoint Test B.
Excessive fuel consumption
*
Fuel charging and controls.
*
Vehicles with 1.4L Duratorq-TDCi (DV) Diesel engine.
REFER to: Fuel Charging and Controls (303-04B Fuel Charging and Controls - 1.4L Duratorq-TDCi (DV) Diesel, Diagnosis and Testing).
*
Vehicles with 1.6L Duratorq-TDCi (DV) Diesel engine.
REFER to: Fuel Charging and Controls (303-04D Fuel Charging and Controls - 1.6L Duratorq-TDCi (DV) Diesel, Diagnosis and Testing).
*
Air ingress into the fuel lines.
*
Vehicles with 1.4L Duratorq-TDCi (DV) Diesel engine. GO to Pinpoint Test A.
*
Vehicles with 1.6L Duratorq-TDCi (DV) Diesel engine. GO to Pinpoint Test B.
*
Contaminated fuel.
*
INSTALL a new fuel filter.
REFER to: Fuel Filter - 1.4L Duratorq-TDCi (DV) Diesel (310-01 Fuel Tank and Lines, Removal and Installation) /
Fuel Filter - 1.6L Duratorq-TDCi (DV) Diesel (310-01 Fuel Tank and Lines, Removal and Installation).
DRAIN and RENEW the fuel.
REFER to: Fuel Tank Draining (310-00 Fuel System - General Information, General Procedures).
Fuel filler nozzle shuts off prematurely
*
Fuel tank ventilation pipe blocked.
*
Fuel tank ventilation pipe collapsed.
*
CHECK the fuel tank ventilation pipe for obstruction or damage. INSTALL a new fuel tank ventilation pipe.
*
Fuel tank filler pipe blocked.
*
Fuel tank filler pipe collapsed.
*
CHECK the fuel tank filler pipe for obstruction or damage. INSTALL a new fuel tank filler pipe.
REFER to: Fuel Tank Filler Pipe (310-01 Fuel Tank and Lines, Removal and Installation).
*
Fuel gauge indication.
*
CHECK the fuel level in the fuel tank. CHECK the fuel indication system.
REFER to: Instrument Cluster - Vehicles Built Up To: 10/2005 (413-01 Instrument Cluster, 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 leaking.
*
CHECK the fuel tank filler pipe for evidence of a fuel leak. If a fuel leak is evident, INSTALL a new fuel tank filler pipe.
REFER to: Fuel Tank Filler Pipe (310-01 Fuel Tank and Lines, 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.
REFER to: Fuel Tank (310-01 Fuel Tank and Lines, Removal and Installation).
*
Fuel tank ventilation pipe leaking.
*
CHECK the fuel tank ventilation pipe for evidence of a fuel leak. If a fuel leak is evident, INSTALL a new fuel tank ventilation pipe.

Pinpoint Tests

PINPOINT TEST A : ENGINE CRANKS BUT DOES NOT START - VEHICLES WITH 1.4L DURATORQ-TDCI (DV) DIESEL ENGINE
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 these instructions 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.
CAUTION:
CAUTION:Always carry out the cleaning process before carrying out any repairs to the fuel injection system components. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
A1: CHECK FOR AIR INGRESS INTO THE FUEL SYSTEM
1
Remove the air cleaner.
REFER to: Air Cleaner - 1.4L Duratorq-TDCi (DV) Diesel (303-12 Intake Air Distribution and Filtering, Removal and Installation).

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

Are there any signs of air present in the fuel return line?
Yes
GO to A2.
No
For additional diagnostics for Fuel Charging and Controls.
REFER to: Fuel Charging and Controls (303-04B Fuel Charging and Controls - 1.4L Duratorq-TDCi (DV) Diesel, 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 fuel return line decrease when any of the connectors, unions or joints were oiled?
Yes
INSTALL a new fuel line(s) as necessary. Test the system for normal operation.
No
For additional diagnostics for Fuel Charging and Controls.
REFER to: Fuel Charging and Controls (303-04B Fuel Charging and Controls - 1.4L Duratorq-TDCi (DV) Diesel, Diagnosis and Testing).

PINPOINT TEST B : ENGINE CRANKS BUT DOES NOT START - VEHICLES WITH 1.6L DURATORQ-TDCI (DV) 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 these instructions 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.
CAUTION:
CAUTION:Always carry out the cleaning process before carrying out any repairs to the fuel injection system components. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
1
Remove the air cleaner.
REFER to: Air Cleaner - 1.6L Duratorq-TDCi (DV) Diesel (303-12 Intake Air Distribution and Filtering, Removal and Installation).

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
GO to B2.
No
For additional diagnostics go to Fuel Charging and Controls,
REFER to: Fuel Charging and Controls (303-04D Fuel Charging and Controls - 1.6L Duratorq-TDCi (DV) Diesel, 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
GO to B3.
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 filter fuel supply line quick release coupling.
REFER to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).

4
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.
5
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 Level Sensor (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 - 1.6L Duratorq-TDCi (DV) Diesel (310-01 Fuel Tank and Lines, Removal and Installation).

PINPOINT TEST C : ENGINE LACKS POWER - VEHICLES WITH 1.6L DURATORQ-TDCI (DV) DIESEL ENGINE
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
C1: 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
Disconnect the fuel filter fuel supply line quick release coupling.
REFER to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).

2
Install the special tool between the fuel filter fuel supply line quick release coupling and the fuel filter union.
3
Operate the hand pressure pump.

4
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 B.
No
REPAIR or INSTALL a new fuel filter fuel supply line.

  • Mechanical Repairs
  • 3 Powertrain
  • 310 Fuel System
  • 310-00 Fuel System - General Information
  • Diagnosis and Testing
  • Fuel System - 1.4L Duratorq-TDCi (DV) Diesel-1.6L Duratorq-TDCi (DV) Diesel

Fuel System - 1.25L Duratec-16V (Sigma)-1.3L Duratec-8V (Rocam)-1.4L Duratec-16V (Sigma)-1.6L Duratec-16V (Sigma)-2.0L Duratec-H > < 309-00 Exhaust System|Specifications