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1997 Ford Ka Fuel System Diagnosis and Testing Guide

Fuel System - General Information - Fuel System Ka 1997 (09/1996-)
Diagnosis and Testing

Inspection and Verification

WARNING:
WARNING:Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable vapors are always present and can 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.
  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 filter
  • Fuel tank
  • Fuel line(s)
  • Fuel connector(s)
  • Fuel filler cap
  • Fuel tank filler pipe
  • Fuel tank ventilation hose
  • Gasket(s)
  • Seal(s)
  • Fuse(s)
  • Wiring harness
  • Electrical connector(s)
  • Fuel pump relay
  • Fuel pump
  • Inertia fuel shutoff switch (IFS)
  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 1.3L Endura E engine, REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls.Vehicles with 1.3L Duratec 8V engine. REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls.
*
IFS.
*
RESET the IFS if it has been activated. If the IFS has not been activated, REFER to WDS
*
Contaminated fuel.
*
INSTALL a new fuel filter. REFER to Section  310-01 Fuel Tank and Lines. DRAIN and RENEW the fuel.
REFER to Fuel Tank Draining - in this section.
Poor starting
*
Fuel charging and controls.
*
Vehicles with 1.3L Endura E engine, REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls.Vehicles with 1.3L Duratec 8V engine. REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls.
*
Contaminated fuel.
*
INSTALL a new fuel filter. REFER to Section  310-01 Fuel Tank and Lines. DRAIN and RENEW the fuel.
REFER to Fuel Tank Draining - in this section.
Engine starts but immediately stops
*
Fuel charging and controls.
*
Vehicles with 1.3L Endura E engine, REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls.Vehicles with 1.3L Duratec 8V engine. REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls.
Poor idling
*
Fuel charging and controls.
*
Vehicles with 1.3L Endura E engine, REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls.Vehicles with 1.3L Duratec 8V engine. REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls.
*
Contaminated fuel.
*
INSTALL a new fuel filter. REFER to Section  310-01 Fuel Tank and Lines. DRAIN and RENEW the fuel.
REFER to Fuel Tank Draining - in this section.
Engine lacks power
*
Fuel charging and controls.
*
Vehicles with 1.3L Endura E engine, REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls.Vehicles with 1.3L Duratec 8V engine. REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls.
*
Engine management system.
*
Vehicles with 1.3L Endura E engine, REFER to Section  303-14A Electronic Engine Controls / 303-14B Electronic Engine Controls.Vehicles with 1.3L Duratec 8V engine. REFER to Section  303-14A Electronic Engine Controls / 303-14B Electronic Engine Controls.
*
Fuel filter blocked.
*
INSTALL a new fuel filter. REFER to Section  310-01 Fuel Tank and Lines.
*
Contaminated fuel.
*
INSTALL a new fuel filter. REFER to Section  310-01 Fuel Tank and Lines. DRAIN and RENEW the fuel.
REFER to Fuel Tank Draining - in this section.
Engine misfire
*
Ignition system.
*
REFER to Section  303-07 Engine Ignition..
*
Fuel charging and controls.
*
Vehicles with 1.3L Endura E engine, REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls.Vehicles with 1.3L Duratec 8V engine. REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls.
Excessive fuel consumption
*
Fuel charging and controls.
*
Vehicles with 1.3L Endura E engine, REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls.Vehicles with 1.3L Duratec 8V engine. REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls.
*
Contaminated fuel.
*
INSTALL a new fuel filter. REFER to Section  310-01 Fuel Tank and Lines. DRAIN and RENEW the fuel.
REFER to Fuel Tank Draining - in this section.
Fuel filler nozzle shuts off prematurely.
*
Fuel tank ventilation pipe or hose blocked.
*
Fuel tank ventilation pipe or hose collapsed.
*
CHECK the fuel tank ventilation pipe or hose for obstruction or damage. INSTALL a new fuel tank ventilation pipe or hose.
*
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 or hose. REFER to Section  310-01 Fuel Tank and Lines.
*
Fuel gauge indication.
*
CHECK the fuel level in the fuel tank. CHECK the fuel gauge indication system. REFER to Section  413-01 Instrument Cluster.
*
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 leak is evident, INSTALL a new fuel tank filler pipe or hose. REFER to Section  310-01 Fuel Tank and Lines.
*
Fuel tank leaking.
*
CHECK the fuel tank for evidence of a fuel leak. If a leak is evident, INSTALL a new fuel tank. REFER to Section  310-01 Fuel Tank and Lines.
*
Fuel tank ventilation pipe or hose leaking.
*
CHECK the fuel tank ventilation pipe or hose for evidence of a fuel leak. If a leak is evident, INSTALL a new fuel tank ventilation pipe or hose.

General Procedures > < Catalytic Converter