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General Procedures > < Fuel Charging and Controls

Mondeo 1997 (08.1996-09.2000)

Fuel Charging and Controls - 1.8L Diesel - Fuel Charging and Controls Mondeo 1997 (08/1996-09/2000)
Diagnosis and Testing

Principles of Operation

The fuel injection timing demand is regulated by the powertrain control module (PCM). It receives information from various sensors on the engine and fuel injection system and continuously adjusts the timing of the fuel injection pump.

The idle speed is also regulated by the PCM through a control motor which compensates for loads applied to the engine. The idle speed control motor also assists with the cold starting by raising the idle speed when the engine is cold. If the idle speed control cable is disconnected idle speed will be reduced.

Inspection and Verification

  1. Verify the customer concern.
  1. Visually inspect for obvious signs of mechanical or electrical damage.

Visual Inspection Chart

Mechanical Electrical
  • Fuel leaks
  • Fuel filter
  • Air cleaner element
  • Vacuum line(s)/vacuum connections
  • Hose(s)/hose connections
  • Tube(s)/tube connections
  • Contaminated fuel
  • High-pressure fuel supply line(s)
  • Fuel injectors
  • Fuel injection pump
  • Tire pressures
  • Fuse(s)
  • Relay(s)
  • Wiring harness
  • Electrical connector(s)
  • Passive anti-theft system (PATS) indicator
  • Sensor(s)
  • Glow plug indicator
  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 Symptom Chart.

Symptom Chart

Symptom Chart

Symptom Possible Sources Action
Engine does not crank and PATS LED indicator is flashing
*
PATS.
*
REFER to Section  419-01A Anti-Theft - Active / 419-01B Anti-Theft - Passive.
Engine does not crank
*
Starter inhibit relay.
*
Power relay.
*
CARRY OUT the Relay Component Test. REFER to the Wiring Diagrams.
*
Ignition switch.
*
REFER to Section  303-06 Starting System.
*
PCM.
*
REFER to WDS.
Engine cranks but does not start
*
Inertia fuel shutoff (IFS) switch.
*
RESET the IFS switch.
*
Fuel filter blocked.
*
INSTALL a new fuel filter. REFER to Section  310-01A Fuel Tank and Lines / 310-01B Fuel Tank and Lines.
*
Incorrect or contaminated fuel.
*
CHECK for signs of contamination such as strange odors from the fuel tank. CLEAN or INSTALL new parts as necessary.
*
Air ingress into the fuel lines.
*
REFER to Section  310-00A Fuel System - General Information / 310-00B Fuel System - General Information.
*
Fuel lines damaged or blocked.
*
REFER to Section  310-00A Fuel System - General Information / 310-00B Fuel System - General Information.
*
Crankshaft position (CKP) sensor.
*
Fuel injection pump timing.
*
REFER to WDS.
*
Incorrect valve timing.
*
CHECK the valve timing. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01D Engine.
*
Fuel injection pump.
*
PCM.
*
REFER to WDS.
Poor starting
*
Fuel filter blocked.
*
INSTALL a new fuel filter. REFER to Section  310-01A Fuel Tank and Lines / 310-01B Fuel Tank and Lines.
*
Glow plug relay.
*
CARRY OUT the Relay Component Test. REFER to the Wiring Diagrams.
*
Glow plugs.
*
REFER to Section  303-07A Engine Ignition / 303-07B Engine Ignition.
*
Fuel system leak.
*
CHECK the system for fuel leak(s). REPAIR the system as necessary.
*
Air ingress into the fuel lines.
*
REFER to Section  310-00A Fuel System - General Information / 310-00B Fuel System - General Information.
*
Fuel injection pump timing.
*
REFER to WDS.
*
Incorrect engine oil.
*
INSTALL a new engine oil filter and engine oil. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01D Engine.
*
Incorrect or contaminated fuel.
*
CHECK for signs of contamination such as strange odors from the fuel tank. CLEAN or INSTALL new parts as necessary.
*
Fuel system restriction.
*
REFER to Section  310-00A Fuel System - General Information / 310-00B Fuel System - General Information.
*
Cylinder head temperature (CHT) sensor.
*
Manifold absolute pressure (MAP) sensor.
*
REFER to WDS.
*
Fuel injector(s).
*
Have the fuel injectors checked by an appropriate fuel injection specialist agent. CLEAN the fuel injectors or INSTALL a new set of injectors as required only after the specialist agent checks have been carried out.
Engine starts but immediately stops
*
Air ingress into the fuel lines.
*
REFER to Section  310-00A Fuel System - General Information / 310-00B Fuel System - General Information.
*
Glow plugs.
*
REFER to Section  303-07A Engine Ignition / 303-07B Engine Ignition.
*
Idle speed incorrectly set.
*
REFER to Idle Speed Adjustment in this section.
*
PCM relay.
*
CARRY OUT the Relay Component Test. REFER to the Wiring Diagrams.
*
CKP sensor.
*
REFER to WDS.
*
PCM.
*
REFER to WDS.
Poor idling
*
Idle speed incorrectly set.
*
REFER to Idle Speed Adjustment in this section.
*
Fuel filter blocked.
*
INSTALL a new fuel filter. REFER to Section  310-01A Fuel Tank and Lines / 310-01B Fuel Tank and Lines.
*
Water in fuel.
*
REFER to Section  310-00A Fuel System - General Information / 310-00B Fuel System - General Information.
*
MAP sensor.
*
CKP sensor.
*
REFER to WDS.
*
Air ingress into the fuel lines.
*
REFER to Section  310-00A Fuel System - General Information / 310-00B Fuel System - General Information.
*
Fuel injector(s).
*
Have the fuel injectors checked by an appropriate fuel injection specialist agent. CLEAN the fuel injectors or INSTALL a new set of injectors as required only after the specialist agent checks have been carried out.
*
Incorrect or contaminated fuel.
*
CHECK for signs of contamination such as strange odors from the fuel tank. CLEAN or INSTALL new parts as necessary.
*
Fuel injection pump timing.
*
Fuel injection pump.
*
REFER to WDS.
Engine stumbling
*
Acceleration pedal position (APP) sensor.
*
Clutch pedal position (CPP) sensor.
*
REFER to WDS.
*
Incorrect or contaminated fuel.
*
CHECK for signs of contamination such as strange odors from the fuel tank. CLEAN or INSTALL new parts as necessary.
*
Air ingress into the fuel lines.
*
REFER to Section  310-00A Fuel System - General Information / 310-00B Fuel System - General Information.
*
Catalytic converter blocked.
*
CHECK if the catalytic converter rattles if gently hit. If noise is present, REMOVE and visually INSPECT the catalytic converter for damage. INSTALL a new catalytic converter as necessary. REFER to Section  309-00 Exhaust System.
*
Fuel injector(s).
*
Have the fuel injectors checked by an appropriate fuel injection specialist agent. CLEAN the fuel injectors or INSTALL a new set of injectors as required only after the specialist agent checks have been carried out.
*
Fuel injection pump timing.
*
Fuel injection pump.
*
REFER to WDS.
Engine lacks power
*
Air cleaner element blocked.
*
INSTALL a new air cleaner element.
*
Fuel filter blocked.
*
INSTALL a new fuel filter. REFER to Section  310-01A Fuel Tank and Lines / 310-01B Fuel Tank and Lines.
*
Kinked or restricted fuel lines
*
REFER to Section  310-00A Fuel System - General Information / 310-00B Fuel System - General Information.
*
Air ingress into the fuel lines.
*
REFER to Section  310-00A Fuel System - General Information / 310-00B Fuel System - General Information.
*
APP sensor.
*
MAP sensor.
*
CHT sensor.
*
REFER to WDS.
*
Low cylinder compression.
*
REFER to Section  303-00 Engine System - General Information.
*
Turbocharger wastegate control valve.
*
Turbocharger to fuel injection pump pressure line.
*
REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls / 303-04D Fuel Charging and Controls - Turbocharger / 303-04E Fuel Charging and Controls.
*
Fuel injection pump timing.
*
REFER to WDS.
*
Incorrect valve timing.
*
CHECK the valve timing. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01D Engine.
*
Turbocharger.
*
REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls / 303-04D Fuel Charging and Controls - Turbocharger / 303-04E Fuel Charging and Controls.
*
EGR valve sticking open.
*
EGR vacuum regulating valve.
*
REFER to WDS.
*
Throttle cable incorrectly set.
*
ADJUST the throttle cable
*
Fuel injector(s).
*
Have the fuel injectors checked by an appropriate fuel injection specialist agent. CLEAN the fuel injectors or INSTALL a new set of injectors as required only after the specialist agent checks have been carried out.
*
Catalytic converter blocked.
*
CHECK if the catalytic converter rattles if gently hit. If noise is present, REMOVE and visually INSPECT the catalytic converter for damage. INSTALL a new catalytic converter as necessary. REFER to Section  309-00 Exhaust System.
*
Charge air cooler blocked.
*
Charge air cooler leaking.
*
Charge air cooler pipes split or cracked.
*
INSPECT for visible signs of damage. 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. CLEAN or INSTALL new parts as necessary.
*
Fuel injection pump
*
REFER to WDS.
Black smoke at idle
*
Fuel injection pump timing.
*
CHT sensor.
*
MAP sensor.
*
REFER to WDS.
*
EGR valve sticking open.
*
EGR vacuum regulating valve.
*
REFER to WDS.
*
Incorrect valve timing.
*
CHECK the valve timing. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01D Engine.
*
Fuel injector(s).
*
Have the fuel injectors checked by an appropriate fuel injection specialist agent. CLEAN the fuel injectors or INSTALL a new set of injectors as required only after the specialist agent checks have been carried out.
*
Fuel injection pump.
*
REFER to WDS.
Excessive black smoke during acceleration
*
APP sensor.
*
CKP sensor.
*
REFER to WDS.
*
Fuel contamination.
*
CHECK for signs of contamination such as strange odors from the fuel tank. CLEAN or INSTALL new parts as necessary.
*
Air cleaner element blocked.
*
INSTALL a new air cleaner element.
*
EGR valve sticking open.
*
EGR vacuum regulating valve.
*
REFER to WDS.
*
Low cylinder compression.
*
REFER to Section  303-00 Engine System - General Information.
*
Soot build up in exhaust system.
*
Road test the vehicle at high engine RPM until the exhaust smoke has cleared.
*
ADVISE the customer about the effects of low RPM driving, it will restrict the exhaust system.
*
Charge air cooler blocked.
*
Charge air cooler leaking.
*
Charge air cooler pipes split or cracked.
*
INSPECT for visible signs of damage. CLEAN, REPAIR or INSTALL new parts as necessary.
*
Turbocharger.
*
REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls / 303-04D Fuel Charging and Controls - Turbocharger / 303-04E Fuel Charging and Controls.
*
Fuel injector(s).
*
Have the fuel injectors checked by an appropriate fuel injection specialist agent. CLEAN the fuel injectors or INSTALL a new set of injectors as required only after the specialist agent checks have been carried out.
*
Fuel injection pump timing.
*
Fuel injection pump.
*
REFER to WDS.
Black smoke at cruising speeds
*
Air cleaner element blocked.
*
INSTALL a new air cleaner element.
*
MAP sensor.
*
REFER to WDS.
*
Vacuum lines.
*
CHECK all vacuum lines are installed and no signs of air leaks are present. REPAIR or INSTALL new vacuum line(s) as necessary.
*
EGR valve sticking open.
*
EGR vacuum regulating valve.
*
REFER to WDS.
*
Turbocharger.
*
REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls / 303-04D Fuel Charging and Controls - Turbocharger / 303-04E Fuel Charging and Controls.
*
Fuel injector(s).
*
Have the fuel injectors checked by an appropriate fuel injection specialist agent. CLEAN the fuel injectors or INSTALL a new set of injectors as required only after the specialist agent checks have been carried out.
*
Fuel injection pump.
*
REFER to WDS.
Blue smoke
*
Engine burning oil.
*
CARRY OUT a controlled oil consumption test over 600 miles (1000 km). CONFIRM that the oil consumption is less than one liter per 600 miles (1000 km). REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01D Engine.
*
Turbocharger.
*
REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls / 303-04D Fuel Charging and Controls - Turbocharger / 303-04E Fuel Charging and Controls.
*
Incorrect or contaminated fuel.
*
CHECK for signs of contamination such as strange odors from the fuel tank. CLEAN or INSTALL new parts as necessary.
*
Worn or damaged valve guides, piston rings, cylinder bores, cylinder head or gasket.
*
REMOVE the cylinder head. INSPECT the cylinder head, pistons and cylinder bores for signs of wear. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01D Engine.
*
Positive crankcase ventilation (PCV) system.
*
CHECK the PCV pipes for signs of restriction or blockage.
*
Turbocharger oil return pipe blocked or damaged.
*
REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls / 303-04D Fuel Charging and Controls - Turbocharger / 303-04E Fuel Charging and Controls.
White smoke
*
Water in fuel.
*
REFER to Section  310-00A Fuel System - General Information / 310-00B Fuel System - General Information.
*
Petrol in the fuel tank.
*
CHECK for signs of contamination such as strange odors from the fuel tank. CLEAN or INSTALL new parts as necessary.
*
Retarded fuel injection pump timing.
*
REFER to WDS.
*
Incorrect valve timing.
*
CHECK the valve timing. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01D Engine.
*
Coolant in the combustion chamber.
*
CARRY OUT a cooling system pressure test. REFER to Section  303-03 Engine Cooling. REMOVE the cylinder head. INSPECT the cylinder head, cylinder head gasket and cylinder bores for wear or damage. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01D Engine.
*
EGR valve sticking open.
*
EGR vacuum regulating valve.
*
REFER to WDS.
*
Fuel injector(s).
*
Have the fuel injectors checked by an appropriate fuel injection specialist agent. CLEAN the fuel injectors or INSTALL a new set of injectors as required only after the specialist agent checks have been carried out.
*
Low cylinder compression.
*
REFER to Section  303-00 Engine System - General Information.
Engine misfire
*
Cracked or damaged high-pressure fuel supply lines.
*
CHECK the high-pressure fuel supply lines for signs of damage. INSTALL new high-pressure fuel supply lines as necessary.
*
Water in fuel.
*
REFER to Section  310-00A Fuel System - General Information / 310-00B Fuel System - General Information.
*
Air ingress into the fuel lines.
*
REFER to Section  310-00A Fuel System - General Information / 310-00B Fuel System - General Information.
*
CHT sensor.
*
REFER to WDS.
*
Fuel injector(s).
*
Injector seals.
*
Have the fuel injectors checked by an appropriate fuel injection specialist agent. CLEAN the fuel injectors or INSTALL a new set of injectors as required only after the specialist agent checks have been carried out.
*
Low cylinder compression.
*
REFER to Section  303-00 Engine System - General Information.
*
Worn or damaged valve(s), tappets or camshaft(s).
*
REMOVE the cylinder head. INSPECT the cylinder head, valves, tappets and camshafts for signs of wear or damage. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01D Engine.
*
Damaged cylinder head gasket.
*
REMOVE the cylinder head. INSPECT the cylinder head, cylinder head gasket and cylinder block gasket surface for wear or damage. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01D Engine.
*
Engine operating temperature too high.
*
REFER to Section  303-03 Engine Cooling.
*
Fuel injection pump timing.
*
Fuel injection pump.
*
REFER to 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.
*
Incorrect valve timing.
*
REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01D Engine.
*
Fuel injection pump timing.
*
CKP sensor.
*
REFER to WDS.
*
Excessive carbon build up.
*
REMOVE the cylinder head. INSPECT the cylinder head and the pistons for signs of carbon build up. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01D Engine.
*
Fuel injector(s).
*
Have the fuel injectors checked by an appropriate fuel injection specialist agent. CLEAN the fuel injectors or INSTALL a new set of injectors as required only after the specialist agent checks have been carried out.
*
CHT sensor.
*
REFER to WDS.
*
Worn or damaged oil pump.
*
Worn or damaged timing chain or sprocket.
*
Major mechanical engine failure.
*
REFER to Section  301-01C .
Engine knock during acceleration
*
Fuel injection pump timing.
*
REFER to WDS.
*
CHT sensor.
*
REFER to WDS.
*
Fuel injector(s).
*
Have the fuel injectors checked by an appropriate fuel injection specialist agent. CLEAN the fuel injectors or INSTALL a new set of injectors as required only after the specialist agent checks have been carried out.
*
Major mechanical engine failure.
*
REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01D Engine.
*
Fuel injection pump.
*
REFER to WDS.
Excessive fuel consumption
*
Brakes binding.
*
CHECK the braking system. REFER to Section  206-00 Brake System - General Information.
*
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 Section  310-01A Fuel Tank and Lines / 310-01B Fuel Tank and Lines.
*
Fuel system leaks.
*
CHECK the system for fuel leak(s). REPAIR the system as necessary.
*
CHT sensor.
*
MAP sensor.
*
REFER to WDS.
*
Incorrect engine oil.
*
INSTALL a new oil filter and engine oil. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01D Engine.
*
Generator.
*
REFER to Section  414-00 Charging System - General Information.
*
EGR valve sticking open.
*
EGR vacuum regulating valve.
*
REFER to WDS.
*
Turbocharger wastegate control valve.
*
REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls / 303-04D Fuel Charging and Controls - Turbocharger / 303-04E Fuel Charging and Controls.
*
Air ingress into the fuel lines.
*
REFER to Section  310-00A Fuel System - General Information / 310-00B Fuel System - General Information.
*
Fuel injection pump timing.
*
REFER to WDS.
*
Incorrect valve timing.
*
CHECK the valve timing. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01D Engine.
*
Turbocharger.
*
REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls / 303-04D Fuel Charging and Controls - Turbocharger / 303-04E Fuel Charging and Controls.
*
Low cylinder compression.
*
REFER to Section  303-00 Engine System - General Information.
*
Fuel injector(s).
*
Have the fuel injectors checked by an appropriate fuel injection specialist agent. CLEAN the fuel injectors or INSTALL a new set of injectors as required only after the specialist agent checks have been carried out.
*
Fuel injection pump.
*
REFER to WDS.
*
Soot build up in exhaust system.
*
ADVISE the customer about the effects of low RPM driving, it will restrict the exhaust system.

General Procedures > < Fuel Charging and Controls