ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

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General Procedures > < Fuel System - 1.8L Duratec-HE (MI4)-1.8L Duratec-SCi (MI4)-2.0L Duratec-HE (MI4)-2.5L Duratec-VE (VE6)-3.0L Duratec-SE (VE6)-3.0

Mondeo 2001 (10.2000-02.2007)

Fuel System - General Information - Fuel System—2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel Mondeo 2001 (10/2000-02/2007)
Diagnosis and Testing

Special Tool(s)

Hand Vacuum/Pressure Pump

416-D001 (23-036A)

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 connector(s)
  • Gasket(s)
  • Seal(s)
  • Fuel line(s)
  • Fuel filter
  • Fuel tank
  • Fuel tank filler pipe
  • Fuel filler cap
  • Electrical connector(s)
  • Wiring harness
  • Inertia fuel shutoff (IFS) switch
  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.
*
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 / 303-04E Fuel Charging and Controls / 303-04F Fuel Charging and Controls - Turbocharger.
*
Air ingress into the fuel lines.
*
GO to Pinpoint Test ??. .
Poor starting
*
Fuel charging and controls.
*
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 / 303-04E Fuel Charging and Controls / 303-04F Fuel Charging and Controls - Turbocharger.
*
Air ingress into the fuel lines.
*
GO to Pinpoint Test ??. .
Engine starts but immediately stops
*
Fuel charging and controls.
*
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 / 303-04E Fuel Charging and Controls / 303-04F Fuel Charging and Controls - Turbocharger.
*
Air ingress into the fuel lines.
*
GO to Pinpoint Test ??. .
Poor idling
*
Fuel charging and controls.
*
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 / 303-04E Fuel Charging and Controls / 303-04F Fuel Charging and Controls - Turbocharger.
*
Air ingress into the fuel lines.
*
GO to Pinpoint Test ??. .
Engine lacks power
*
Fuel charging and controls.
*
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 / 303-04E Fuel Charging and Controls / 303-04F Fuel Charging and Controls - Turbocharger.
*
Air ingress into the fuel lines.
*
GO to Pinpoint Test ??. .
Engine misfire
*
Fuel charging and controls.
*
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 / 303-04E Fuel Charging and Controls / 303-04F Fuel Charging and Controls - Turbocharger.
*
Air ingress into the fuel lines.
*
GO to Pinpoint Test ??. .
Excessive fuel consumption
*
Fuel charging and controls.
*
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 / 303-04E Fuel Charging and Controls / 303-04F Fuel Charging and Controls - Turbocharger.
*
Air ingress into the fuel lines.
*
GO to Pinpoint Test ??. .

Pinpoint Tests

PINPOINT TEST A : AIR INGRESS INTO THE FUEL LINES
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.
1
Using a suitable piece of clear plastic pipe, manufacture and install a pipe between the fuel injection pump and the fuel injection pump to fuel filter fuel return line.
2
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
GO to A2. .
No
REMOVE the clear plastic pipe and connect the fuel injection pump to fuel filter fuel return line. For additional diagnostics for Fuel Charging and Controls 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 / 303-04E Fuel Charging and Controls / 303-04F Fuel Charging and Controls - Turbocharger.
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 pipe decrease when any of the connectors, unions or joints were oiled?
Yes
INSTALL a new fuel line(s) in question. Test the system for normal operation.
No
REMOVE the clear plastic pipe from between the fuel injection pump and the fuel injection pump to fuel filter fuel return line. GO to A3.
A3: CHECK THE FUEL LEVEL SENSOR FOR AIR INGRESS
1
Drain the fuel tank.
REFER to Fuel Tank Draining in this section.
2
Fill the fuel tank with 10 liters of diesel.
3
Disconnect the fuel tank to fuel filter fuel supply line from the bulkhead connection.
4
Remove the fuel tank to fuel filter fuel supply line from the fuel filter.
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 bulkhead connection.
6
Remove the clear plastic pipe from between the fuel injection pump and the fuel injection pump to fuel filter fuel return line.

7
Using the special tool, prime the fuel pump until clean air-free fuel is seen entering the vacuum pump reservoir.
8
Remove the special tool and connect the fuel injection pump to fuel filter fuel return line.
NOTE:
NOTE:Make sure the engine is at normal operating temperature.
9
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 Section  310-01 Fuel Tank and Lines.
No
INSTALL a new fuel filter. REFER to Section  310-01 Fuel Tank and Lines.

General Procedures > < Fuel System - 1.8L Duratec-HE (MI4)-1.8L Duratec-SCi (MI4)-2.0L Duratec-HE (MI4)-2.5L Duratec-VE (VE6)-3.0L Duratec-SE (VE6)-3.0