Ford Workshop Service and Repair Manuals

Principles of Operation

The 2.0L DW10 engine uses a second generation Siemens common rail fuel injection system. The systems main components consist of a fuel pump, fuel rail, electrically operated fuel injectors, a fuel temperature sensor and a fuel rail pressure sensor.

Fuel Pump

The fuel pump consists of a transfer pump and a high-pressure fuel delivery pump. The transfer pump draws fuel from the fuel tank through the fuel filter and delivers the fuel to the three high-pressure fuel pump chambers through a fuel metering valve. The fuel metering valve controls the quantity of fuel that is allowed to enter the high-pressure fuel pump chambers. Excess fuel volume developed by the transfer pump is returned to the fuel tank. The fuel metering valve is controlled by the powertrain control module (PCM) using a pulse-width modulated signal. The high-pressure fuel pump outlet pressure is controlled by an electronic fuel control valve which is also controlled by the PCM.

Fuel Rail

The fuel rail function is to supply a reservoir of fuel to all four fuel injectors with no variations in fuel pressure for any one fuel injector. The fuel rail acts as a pulse damper eliminating surges in fuel pressure. Attached to the fuel rail is a FRP sensor, which monitors the fuel pressure at the fuel injectors. The FRP sensor develops a pressure conscious variable resistance which provides a controlled variable voltage signal to the PCM.

Fuel Injectors

The fuel injectors have a Piezoelectric actuator. The advantages of using Piezoelectric instead of traditional solenoid actuators are the reduction in reaction switching times and the lower switching currents. Both of which improve the control and therefore the efficiency of the fuel injector. During manufacture, the fuel injectors are graded according to their flow characteristics into one of three grades. The grade is printed on the top of the fuel injector and can be the number 4, 5, or 6. All four fuel injectors must be of a matching grade for any one engine application. The grade value is used by the PCM to adjust the fuel injector injection signal to achieve optimum efficiency. The fuel injectors are designed to allow a quantity of fuel to return to the fuel tank. The returned fuel is developed during the opening cycle of the fuel injector control valve. This returned fuel is used to lubricate the fuel injector moving components and is essential to the operation of the fuel injector. This lubricating fuel is returned to the fuel tank through the fuel injector fuel return line. Only by accurate measurement, at precise engine conditions, can the volumes of fuel from the fuel injector fuel return be used to diagnose concerns with the fuel charging control system.

Fuel Temperature Sensor

The fuel temperature sensor is fitted into the fuel pump to fuel tank fuel return line. The temperature sensor monitors the temperature of the fuel returning to the fuel tank from the fuel pump and the fuel injectors. The fuel temperature sensor housing acts as a venturi. The venturi assists with the fuel return from the fuel injectors by creating a pressure reduction in the fuel injector fuel return line.

Inspection and Verification

WARNING:REFER to: Diesel Fuel System Health and Safety Precautions (100-00 General Information, Description and Operation).

WARNING:This procedure involves fuel handling. Be prepared for fuel spillage at all times. Failure to follow this instruction may result in personal injury.

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 fit blanking plugs to any open orifices or lines.

NOTE:As well as carrying out its normal function the glow plug indicator also acts as an engine check lamp which will flash continuously when a hard diagnostic trouble code (DTC) is detected by the powertrain control module (PCM). Soft DTCs are also stored by the PCM but will only be known if the system is checked for DTCs using the WDS.

NOTE:If a DTC is detected, all DTCs must be cleared after the concern is rectified. Failure to clear all DTCs may cause driveability concerns.

NOTE:If the fuel level in the fuel tank drops below approximately four liters, rough running will occur. This is to signal to the driver that the vehicle requires refuelling in order to prevent the fuel system from running dry.

Visual Inspection Chart

Symptom Chart

Symptom	Possible Sources	Action
Engine does not crank and passive anti-theft system (PATS) LED is flashing	* PATS system fault detected.	* REFER to: Anti-Theft - Passive (419-01B Anti-Theft - Passive, Diagnosis and Testing).
Engine does not crank and glow plug indicator is flashing	* DTC detected.	* REFER to the WDS.
Engine does not crank	* Starting system.	* REFER to: Starting System (303-06D Starting System - 2.0L Duratorq-TDCi (DW) Diesel, Diagnosis and Testing).
Engine cranks but does not start and glow plug indicator is flashing	* DTC detected.	* REFER to the WDS.
Engine cranks but does not start	* Low fuel tank fuel level.	* CHECK the fuel tank fuel level is greater than four liters. If the fuel tank fuel level is less then four liters, FILL with fuel.
	* Fuel filter blocked.	* INSTALL a new fuel filter. REFER to: Fuel Filter (310-01D Fuel Tank and Lines - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation).
	* Fuel lines damaged or blocked.	* REFER to: Fuel System - 2.0L Duratorq-TDCi (DW) Diesel (310-00, Diagnosis and Testing).
	* Air ingress into the fuel lines.	* REFER to: Fuel System - 2.0L Duratorq-TDCi (DW) Diesel (310-00, Diagnosis and Testing).
	* Glow plugs.	* REFER to the WDS.
	* Incorrect valve timing.	* CHECK the valve timing. REFER to: Timing Belt (303-01E Engine - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation).
	* Low cylinder compression.	* REFER to: Engine (303-01F Engine - 2.2L Duratorq-TDCi (Puma) Diesel, Diagnosis and Testing).
	* Crankshaft position (CKP) sensor.	* REFER to the WDS.
	* Camshaft position (CMP) sensor.	* REFER to the WDS.
	* Engine coolant temperature (ECT) sensor.	* REFER to the WDS.
	* PCM.	* REFER to the WDS.
	* FRP sensor.	* REFER to the WDS.
	* Fuel pump fuel pressure regulator.	* REFER to the WDS.
	* Fuel pump.	* REFER to the WDS.
	* Fuel injector(s).	* REFER to the WDS.
Poor starting and glow plug indicator is flashing	* DTC detected.	* REFER to the WDS.
Poor starting	* Low fuel tank fuel level.	* CHECK the fuel tank fuel level is greater than four liters. If the fuel tank fuel level is less then four liters, FILL with fuel.
	* Fuel filter blocked.	* INSTALL a new fuel filter element. REFER to: Fuel Filter Element (310-01D Fuel Tank and Lines - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation).
	* Air cleaner element blocked.	* INSTALL a new air cleaner element.
	* Glow plugs.	* REFER to the WDS.
	* Fuel system leak.	* CHECK the system for fuel leak(s). REPAIR the system as necessary.
	* Air ingress into the fuel lines.	* REFER to: Fuel System - 2.0L Duratorq-TDCi (DW) Diesel (310-00, Diagnosis and Testing).
	* Fuel system restriction.	* REFER to: Fuel System - 2.0L Duratorq-TDCi (DW) Diesel (310-00, Diagnosis and Testing).
	* Incorrect engine oil.	* INSTALL a new engine oil filter and engine oil.
	* Catalytic converter blocked.	* REMOVE and visually INSPECT the catalytic converter for damage. INSTALL a new catalytic converter as necessary. REFER to: Catalytic Converter (309-00D Exhaust System - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation).
	* Low cylinder compression.	* REFER to: Engine (303-01F Engine - 2.2L Duratorq-TDCi (Puma) Diesel, Diagnosis and Testing).
	* CKP sensor.	* REFER to the WDS.
	* ECT sensor.	* REFER to the WDS.
	* Fuel temperature sensor.	* REFER to the WDS.
	* Mass air flow (MAF) sensor.	* REFER to the WDS.
	* Manifold absolute pressure (MAP) sensor.	* REFER to the WDS.
	* Fuel injector(s).	* REFER to the WDS.
	* FRP sensor.	* REFER to the WDS.
	* Fuel pump fuel pressure regulator.	* REFER to the WDS.
	* Fuel pump.	* REFER to the WDS.
	* Intake air shut-off throttle.	* CHECK the intake air sut-off throttle for obstructions and correct operation. * REFER to the WDS.
	* Intake air shut-off throttle vacuum control solenoid.	* CHECK the intake air shut-off throttle vacuum control solenoid vacuum lines for kinks or restrictions. * REFER to the WDS.
Engine starts but immediately stops and glow plug indicator is flashing	* DTC detected.	* REFER to the WDS.
Engine starts but immediately stops	* Air cleaner element blocked.	* INSTALL a new air cleaner element.
	* Air ingress into the fuel lines.	* REFER to: Fuel System - 2.0L Duratorq-TDCi (DW) Diesel (310-00, Diagnosis and Testing).
	* PCM relay.	* CARRY OUT a relay component test.
	* Dual mass flywheel.	* INSPECT the dual mass flywheel for damage. INSTALL a new dual mass flywheel as necessary.
	* CKP sensor.	* REFER to the WDS.
	* CMP sensor.	* REFER to the WDS.
	* ECT sensor.	* REFER to the WDS.
	* PCM.	* REFER to the WDS.
	* Fuel pump fuel pressure regulator.	* REFER to the WDS.
	* Intake air shut-off throttle.	* CHECK the intake air shut-off throttle for obstructions and correct operation. * REFER to the WDS.
	* Intake air shut-off throttle vacuum control solenoid.	* CHECK the intake air shut-off throttle vacuum control solenoid vacuum lines for kinks or restrictions. * REFER to the WDS.
Poor idling and glow plug indicator is flashing	* DTC detected.	* REFER to the WDS.
Poor idling	* Low fuel tank fuel level.	* CHECK the fuel tank fuel level is greater than four liters. If the fuel tank fuel level is less then four liters, FILL with fuel.
	* Air cleaner element blocked.	* INSTALL a new air cleaner element.
	* Fuel filter blocked.	* INSTALL a new fuel filter element. REFER to: Fuel Filter Element (310-01D Fuel Tank and Lines - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation).
	* Incorrect or contaminated fuel.	* CHECK for signs of contamination such as strange odors from the fuel tank. * CHECK for signs of water or gasoline in the diesel. * If contaminated fuel is found, DRAIN the complete fuel system. FLUSH the fuel system through with clean diesel. REFER to: Fuel Tank Draining (310-00 Fuel System - General Information, General Procedures). INSTALL a new fuel filter element. REFER to: Fuel Filter Element (310-01D Fuel Tank and Lines - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation). INSTALL a new fuel pump, fuel injectors, fuel rail, and high-pressure fuel supply lines. REFER to: Fuel Pump (303-04E Fuel Charging and Controls - 2.2L Duratorq-TDCi (DW) Diesel, Removal and Installation) / Fuel Injectors (303-04E Fuel Charging and Controls - 2.2L Duratorq-TDCi (DW) Diesel, Removal and Installation) / Fuel Rail (303-04E Fuel Charging and Controls - 2.2L Duratorq-TDCi (DW) Diesel, Removal and Installation).
	* Air ingress into the fuel lines.	* REFER to: Fuel System - 2.0L Duratorq-TDCi (DW) Diesel (310-00, Diagnosis and Testing).
	* EGR valve incorrect operation.	* REFER to: Engine Emission Control (303-08D Engine Emission Control - 2.0L Duratorq-TDCi (DW) Diesel, Diagnosis and Testing).
	* Dual mass flywheel.	* INSPECT the dual mass flywheel for damage. INSTALL a new dual mass flywheel as necessary.
	* Fuel injector(s).	* REFER to the WDS.
	* MAF sensor.	* REFER to the WDS.
	* MAP sensor.	* REFER to the WDS.
	* CKP sensor.	* REFER to the WDS.
	* FRP sensor.	* REFER to the WDS.
	* Fuel pump fuel pressure regulator.	* REFER to the WDS.
	* Fuel pump.	* REFER to the WDS.
	* Intake air shut-off throttle.	* CHECK the intake air shut-off throttle butterfly for obstructions and correct operation. * REFER to the WDS.
	* Intake air shut-off throttle vacuum control solenoid.	* CHECK the intake air shut-off throttle vacuum control solenoid vacuum lines for kinks or restrictions. * REFER to the WDS.
Engine stumbling and glow plug indicator is flashing	* DTC detected.	* REFER to the WDS.
Engine stumbling	* Low fuel level.	* CHECK the fuel tank level is greater than four litres. If the fuel tank level is less than four litres, FILL with fuel.
	* Dual mass flywheel.	* INSPECT the dual mass flywheel for damage. INSTALL a new dual mass flywheel as necessary.
	* Accelerator pedal position (APP) sensor.	* REFER to the WDS.
	* Fuel injector(s).	* REFER to the WDS.
	* FRP sensor.	* REFER to the WDS.
	* Fuel pump.	* REFER to the WDS.
Engine lacks power and glow plug indicator is flashing	* DTC detected.	* REFER to the WDS.
Engine lacks power	* Brakes binding.	* CHECK the braking system. REFER to: Brake System (206-00 Brake System - General Information, Diagnosis and Testing).
	* 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 as necessary.
	* Fuel filter blocked.	* INSTALL a new fuel filter element. REFER to: Fuel Filter Element (310-01D Fuel Tank and Lines - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation).
	* Kinked or restricted fuel lines.	* REFER to: Spring Lock Couplings (310-00 Fuel System - General Information, General Procedures).
	* Air ingress into the fuel lines.	* REFER to: Spring Lock Couplings (310-00 Fuel System - General Information, General Procedures).
	* Turbocharger. * Turbocharger vacuum diaphragm unit.	* INSPECT the vacuum line(s) for visible signs of damage or blockage. CLEAN, REPAIR or INSTALL new parts as necessary. REFER to: Turbocharger (303-04I Fuel Charging and Controls - Turbocharger - 2.2L Duratorq-TDCi (Puma) Diesel, Diagnosis and Testing).
	* Incorrect valve timing.	* CHECK the valve timing. REFER to: Timing Belt (303-01E Engine - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation).
	* Low cylinder compression.	* REFER to: Engine (303-01F Engine - 2.2L Duratorq-TDCi (Puma) Diesel, Diagnosis and Testing).
	* Catalytic converter blocked.	* REMOVE and visually INSPECT the catalytic converter for damage. INSTALL a new catalytic converter as necessary. REFER to: Catalytic Converter (309-00D Exhaust System - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation).
	* EGR valve incorrect operation.	* REFER to: Engine Emission Control (303-08D Engine Emission Control - 2.0L Duratorq-TDCi (DW) Diesel, Diagnosis and Testing).
	* Charge air cooler blocked or cracked. * Charge air cooler pipes split or cracked. * Charge air cooler pipe retaining clips missing or loose.	* INSPECT for visible signs of damage or blockage. 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. * CHECK for signs of water or gasoline in the diesel. * If contaminated fuel is found, DRAIN the complete fuel system. FLUSH the fuel system through with clean diesel. REFER to: Fuel Tank Draining (310-00 Fuel System - General Information, General Procedures). INSTALL a new fuel filter element. REFER to: Fuel Filter Element (310-01D Fuel Tank and Lines - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation). INSTALL a new fuel pump, fuel injectors, fuel rail, and high-pressure fuel supply lines. REFER to: Fuel Pump (303-04E Fuel Charging and Controls - 2.2L Duratorq-TDCi (DW) Diesel, Removal and Installation) / Fuel Injectors (303-04E Fuel Charging and Controls - 2.2L Duratorq-TDCi (DW) Diesel, Removal and Installation) / Fuel Rail (303-04E Fuel Charging and Controls - 2.2L Duratorq-TDCi (DW) Diesel, Removal and Installation).
	* Vehicle speed sensor (VSS).	* REFER to the WDS.
	* ECT sensor.	* REFER to the WDS.
	* MAF sensor.	* REFER to the WDS.
	* MAP sensor.	* REFER to the WDS.
	* APP sensor.	* REFER to the WDS.
	* Fuel injector(s).	* REFER to the WDS.
	* Fuel temperature sensor.	* REFER to the WDS.
	* FRP sensor.	* REFER to the WDS.
	* Fuel pump fuel pressure regulator.	* REFER to the WDS.
	* Fuel pump.	* REFER to the WDS.
	* Intake air shut-off throttle.	* CHECK the intake air shut-off throttle butterfly for obstructions and correct operation. * REFER to the WDS.
	* Intake air shut-off throttle vacuum control solenoid.	* CHECK the intake air shut-off throttle vacuum control solenoid vacuum lines for kinks or restrictions. * REFER to the WDS.
Black smoke at idle and glow plug indicator is flashing	* DTC detected.	* REFER to the WDS.
Black smoke at idle	* Air cleaner element blocked.	* INSTALL a new air cleaner element as necessary.
	* Glow plug system.	* REFER to the WDS.
	* Incorrect valve timing.	* CHECK the valve timing. REFER to: Timing Belt (303-01E Engine - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation).
	* Catalytic converter blocked.	* REMOVE and visually INSPECT the catalytic converter for damage. INSTALL a new catalytic converter as necessary. REFER to: Catalytic Converter (309-00D Exhaust System - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation).
	* ECT sensor.	* REFER to the WDS.
	* MAF sensor.	* REFER to the WDS.
	* MAP sensor.	* REFER to the WDS.
	* Fuel injector(s).	* REFER to the WDS.
	* FRP sensor.	* REFER to the WDS.
	* Intake air shut-off throttle.	* CHECK the intake air shut-off throttle butterfly for obstructions and correct operation. * REFER to the WDS.
	* Intake air shut-off throttle vacuum control solenoid.	* CHECK the intake air shut-off throttle vacuum control solenoid vacuum lines for kinks or restrictions. * REFER to the WDS.
Excessive black smoke during acceleration and glow plug indicator is flashing	* DTC detected.	* REFER to the WDS.
Excessive black smoke during acceleration	* Air cleaner element blocked.	* INSTALL a new air cleaner element as necessary.
	* Incorrect or contaminated fuel.	* CHECK for signs of contamination such as strange odors from the fuel tank. * CHECK for signs of water or gasoline in the diesel. * If contaminated fuel is found, DRAIN the complete fuel system. FLUSH the fuel system through with clean diesel. REFER to: Fuel Tank Draining (310-00 Fuel System - General Information, General Procedures). INSTALL a new fuel filter element. REFER to: Fuel Filter Element (310-01D Fuel Tank and Lines - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation). INSTALL a new fuel pump, fuel injectors, fuel rail, and high-pressure fuel supply lines. REFER to: Fuel Pump (303-04E Fuel Charging and Controls - 2.2L Duratorq-TDCi (DW) Diesel, Removal and Installation) / Fuel Injectors (303-04E Fuel Charging and Controls - 2.2L Duratorq-TDCi (DW) Diesel, Removal and Installation) / Fuel Rail (303-04E Fuel Charging and Controls - 2.2L Duratorq-TDCi (DW) Diesel, Removal and Installation).
	* EGR valve incorrect operation.	* REFER to: Engine Emission Control (303-08D Engine Emission Control - 2.0L Duratorq-TDCi (DW) Diesel, Diagnosis and Testing).
	* Catalytic converter blocked.	* REMOVE and visually INSPECT the catalytic converter for damage. INSTALL a new catalytic converter as necessary. REFER to: Catalytic Converter (309-00D Exhaust System - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation).
	* APP sensor.	* REFER to the WDS.
	* CKP sensor.	* REFER to the WDS.
	* Fuel injector(s).	* REFER to the WDS.
	* FRP sensor.	* REFER to the WDS.
	* Intake air shut-off throttle.	* CHECK the intake air shut-off throttle butterfly for obstructions and correct operation. * REFER to the WDS.
	* Intake air shut-off throttle vacuum control solenoid.	* CHECK the intake air shut-off throttle vacuum control solenoid vacuum lines for kinks or restrictions. * REFER to the WDS.
Black smoke at cruising speeds and glow plug indicator is flashing	* DTC detected.	* REFER to the WDS.
Black smoke at cruising speeds	* Air cleaner element blocked.	* INSTALL a new air cleaner element.
	* EGR valve incorrect operation.	* REFER to: Engine Emission Control (303-08D Engine Emission Control - 2.0L Duratorq-TDCi (DW) Diesel, Diagnosis and Testing).
	* Turbocharger vacuum diaphragm unit.	* REFER to: Turbocharger (303-04I Fuel Charging and Controls - Turbocharger - 2.2L Duratorq-TDCi (Puma) Diesel, Diagnosis and Testing).
	* Catalytic converter blocked.	* REMOVE and visually INSPECT the catalytic converter for damage. INSTALL a new catalytic converter as necessary. REFER to: Catalytic Converter (309-00D Exhaust System - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation).
	* ECT sensor.	* REFER to the WDS.
	* MAF sensor.	* REFER to the WDS.
	* MAP sensor.	* REFER to the WDS.
	* Fuel injector(s).	* REFER to the WDS.
	* FRP sensor.	* REFER to the WDS.
	* Intake air shut-off throttle.	* CHECK the intake air shut-off throttle butterfly for obstructions and correct operation. * REFER to the WDS.
	* Intake air shut-off throttle vacuum control solenoid.	* CHECK the intake air shut-off throttle vacuum control solenoid vacuum lines for kinks or restrictions. * REFER to the WDS.
Blue smoke and glow plug indicator is flashing	* DTC detected.	* REFER to the WDS.
Blue smoke	* Engine burning oil.	* CARRY OUT a controlled oil consumption test over 1000 km (600 miles). CONFIRM that the oil consumption is less than 0.1 of a liter per 1000 km (600 miles). REFER to: Engine (303-01F Engine - 2.2L Duratorq-TDCi (Puma) Diesel, Diagnosis and Testing).
	* Incorrect or contaminated fuel.	* CHECK for signs of contamination such as strange odors from the fuel tank. * CHECK for signs of water or gasoline in the diesel. * If contaminated fuel is found, DRAIN the complete fuel system. FLUSH the fuel system through with clean diesel. REFER to: Fuel Tank Draining (310-00 Fuel System - General Information, General Procedures). INSTALL a new fuel filter element. REFER to: Fuel Filter Element (310-01D Fuel Tank and Lines - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation). INSTALL a new fuel pump, fuel injectors, fuel rail, and high-pressure fuel supply lines. REFER to: Fuel Pump (303-04E Fuel Charging and Controls - 2.2L Duratorq-TDCi (DW) Diesel, Removal and Installation) / Fuel Injectors (303-04E Fuel Charging and Controls - 2.2L Duratorq-TDCi (DW) Diesel, Removal and Installation) / Fuel Rail (303-04E Fuel Charging and Controls - 2.2L Duratorq-TDCi (DW) Diesel, Removal and Installation).
	* Positive crankcase ventilation (PCV) system.	* INSPECT for visible signs of damage or blockage. CLEAN, REPAIR or INSTALL new parts as necessary.
	* Turbocharger oil return tube blocked or damaged.	* REFER to: Turbocharger (303-04I Fuel Charging and Controls - Turbocharger - 2.2L Duratorq-TDCi (Puma) Diesel, Diagnosis and Testing).
	* Worn or damaged valve guide(s), piston ring(s), cylinder bore(s), cylinder head or gasket.	* REMOVE the cylinder head. INSPECT the cylinder head, pistons and cylinder bores for signs of wear or damage.
White smoke and glow plug indicator is flashing	* DTC detected.	* REFER to the WDS.
White smoke	* Water in fuel.	* CHECK for signs of water in the diesel. * If contaminated fuel is found, DRAIN the complete fuel system. FLUSH the fuel system through with clean diesel. REFER to: Fuel Tank Draining (310-00 Fuel System - General Information, General Procedures). INSTALL a new fuel filter element. REFER to: Fuel Filter Element (310-01D Fuel Tank and Lines - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation). INSTALL a new fuel pump, fuel injectors, fuel rail, and high-pressure fuel supply lines. REFER to: Fuel Pump (303-04E Fuel Charging and Controls - 2.2L Duratorq-TDCi (DW) Diesel, Removal and Installation) / Fuel Injectors (303-04E Fuel Charging and Controls - 2.2L Duratorq-TDCi (DW) Diesel, Removal and Installation) / Fuel Rail (303-04E Fuel Charging and Controls - 2.2L Duratorq-TDCi (DW) Diesel, Removal and Installation).
	* Fuel injector(s).	* REFER to the WDS.
	* EGR valve incorrect operation.	* REFER to: Engine Emission Control (303-08D Engine Emission Control - 2.0L Duratorq-TDCi (DW) Diesel, Diagnosis and Testing).
	* Incorrect valve timing.	* CHECK the valve timing. REFER to: Timing Belt (303-01E Engine - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation).
	* Coolant in the combustion chamber.	* CARRY OUT a cooling system pressure test. REFER to: Engine Cooling (303-03E Engine Cooling - 2.2L Duratorq-TDCi (DW) Diesel, Diagnosis and Testing). REMOVE the cylinder head. INSPECT the cylinder head, cylinder head gasket and cylinder bores for wear or damage.
Engine misfire and glow plug indicator is flashing	* DTC detected.	* REFER to the WDS.
Engine misfire	* Low fuel tank level.	* CHECK the fuel tank level is greater than four liters. If the fuel tank level is less than four liters, FILL with fuel.
	* Incorrect or contaminated fuel.	* CHECK for signs of contamination such as strange odors from the fuel tank. * CHECK for signs of water or gasoline in the diesel. * If contaminated fuel is found, DRAIN the complete fuel system. FLUSH the fuel system through with clean diesel. REFER to: Fuel Tank Draining (310-00 Fuel System - General Information, General Procedures). INSTALL a new fuel filter element. REFER to: Fuel Filter Element (310-01D Fuel Tank and Lines - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation). INSTALL a new fuel pump, fuel injectors, fuel injection supply manifold, and high-pressure fuel supply lines. REFER to: Fuel Pump (303-04E Fuel Charging and Controls - 2.2L Duratorq-TDCi (DW) Diesel, Removal and Installation) / Fuel Injectors (303-04E Fuel Charging and Controls - 2.2L Duratorq-TDCi (DW) Diesel, Removal and Installation) / Fuel Rail (303-04E Fuel Charging and Controls - 2.2L Duratorq-TDCi (DW) Diesel, Removal and Installation).
	* Air ingress into the fuel lines.	* REFER to: Fuel System - 1.8L Duratorq-TDCi (Lynx) Diesel/2.0L Duratorq-TDCi (DW) Diesel (310-00 Fuel System - General Information, Diagnosis and Testing).
	* EGR valve incorrect operation.	* REFER to: Engine Emission Control (303-08D Engine Emission Control - 2.0L Duratorq-TDCi (DW) Diesel, Diagnosis and Testing).
	* Low cylinder compression.	* REFER to: Engine (303-01F Engine - 2.2L Duratorq-TDCi (Puma) Diesel, Diagnosis and Testing).
	* Engine overheats.	* REFER to: Engine Cooling (303-03E Engine Cooling - 2.2L Duratorq-TDCi (DW) Diesel, Diagnosis and Testing).
	* ECT sensor.	* REFER to the WDS.
	* CKP sensor.	* REFER to the WDS.
	* CMP sensor.	* REFER to the WDS.
	* MAF sensor.	* REFER to the WDS.
	* MAP sensor.	* REFER to the WDS.
	* Fuel injector(s).	* REFER to the WDS.
	* FRP sensor.	* REFER to the WDS.
	* Fuel pump.	* REFER to the WDS.
	* Intake air shut-off throttle.	* CHECK the intake air shut-off throttle butterfly for obstructions and correct operation. * REFER to the WDS.
	* Intake air shut-off throttle vacuum control solenoid.	* CHECK the intake air shut-off throttle vacuum control solenoid vacuum lines for kinks or restrictions. * REFER to the WDS.
	* Worn or damaged valve(s), tappet(s) or camshaft(s).	* REMOVE the cylinder head. INSPECT the cylinder head, valves, tappets and camshafts for signs of wear or damage.
	* Damaged cylinder head gasket.	* REMOVE the cylinder head. INSPECT the cylinder head gasket and cylinder bores for wear or damage.
Engine knock at idle and glow plug indicator is flashing	* DTC detected.	* REFER to the 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. * CHECK for signs of water or gasoline in the diesel. * If contaminated fuel is found, DRAIN the complete fuel system. FLUSH the fuel system through with clean diesel. REFER to: Fuel Tank Draining (310-00 Fuel System - General Information, General Procedures). INSTALL a new fuel filter element. REFER to: Fuel Filter Element (310-01D Fuel Tank and Lines - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation). INSTALL a new fuel pump, fuel injectors, fuel rail, and high-pressure fuel supply lines. REFER to: Fuel Pump (303-04E Fuel Charging and Controls - 2.2L Duratorq-TDCi (DW) Diesel, Removal and Installation) / Fuel Injectors (303-04E Fuel Charging and Controls - 2.2L Duratorq-TDCi (DW) Diesel, Removal and Installation) / Fuel Rail (303-04E Fuel Charging and Controls - 2.2L Duratorq-TDCi (DW) Diesel, Removal and Installation).
	* Dual mass flywheel.	* INSPECT the dual mass flywheel for damage. INSTALL a new dual mass flywheel as necessary.
	* Incorrect valve timing.	* CHECK the valve timing. REFER to: Timing Belt (303-01E Engine - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation).
	* Excessive carbon build up.	* REMOVE the cylinder head. INSPECT the cylinder head and pistons for signs carbon build up.
	* Worn or damaged oil pump. * Major mechanical engine failure.	* REFER to: Engine (303-01F Engine - 2.2L Duratorq-TDCi (Puma) Diesel, Diagnosis and Testing).
	* CKP sensor.	* REFER to the WDS.
	* Fuel injector(s).	* REFER to the WDS.
Engine knock during acceleration and glow plug indicator is flashing	* DTC detected.	* REFER to the WDS.
Engine knock during acceleration	* Fuel injector(s).	* REFER to the WDS.
	* Major mechanical engine failure.	* REFER to: Engine (303-01F Engine - 2.2L Duratorq-TDCi (Puma) Diesel, Diagnosis and Testing).
	* Fuel pump fuel pressure regulator.	* REFER to the WDS.
	* Fuel pump.	* REFER to the WDS.
Excessive fuel consumption and glow plug indicator is flashing	* DTC detected.	* REFER to the WDS.
Excessive fuel consumption	* Brakes binding.	* CHECK the braking system. REFER to: Brake System (206-00 Brake System - General Information, Diagnosis and Testing).
	* 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 element. REFER to: Fuel Filter Element (310-01D Fuel Tank and Lines - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation).
	* Fuel system leak(s).	* CHECK the system for fuel leak(s). REPAIR or INSTALL new parts as necessary.
	* Dual mass flywheel.	* INSPECT the dual mass flywheel for damage. INSTALL a new dual mass flywheel as necessary.
	* Incorrect engine oil.	* INSTALL a new oil filter and engine oil.
	* Generator.	* REFER to the WDS.
	* EGR valve incorrect operation.	* REFER to: Engine Emission Control (303-08D Engine Emission Control - 2.0L Duratorq-TDCi (DW) Diesel, Diagnosis and Testing).
	* Turbocharger vacuum diaphragm unit.	* REFER to: Turbocharger (303-04I Fuel Charging and Controls - Turbocharger - 2.2L Duratorq-TDCi (Puma) Diesel, Diagnosis and Testing).
	* Air ingress into the fuel lines.	* REFER to: Fuel System - 1.8L Duratorq-TDCi (Lynx) Diesel/2.0L Duratorq-TDCi (DW) Diesel (310-00 Fuel System - General Information, Diagnosis and Testing).
	* Incorrect valve timing.	* CHECK the valve timing. REFER to: Timing Belt (303-01E Engine - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation).
	* Turbocharger.	* REFER to: Turbocharger (303-04I Fuel Charging and Controls - Turbocharger - 2.2L Duratorq-TDCi (Puma) Diesel, Diagnosis and Testing).
	* Slipping clutch (If equipped).	* REFER to: Manual Transaxle and Clutch (308-00 Manual Transmission/Transaxle and Clutch - General Information, Diagnosis and Testing).
	* Low cylinder compression.	* REFER to: Engine (303-01F Engine - 2.2L Duratorq-TDCi (Puma) Diesel, Diagnosis and Testing).
	* ECT sensor.	* REFER to the WDS.
	* MAF sensor.	* REFER to the WDS.
	* MAP sensor.	* REFER to the WDS.
	* Fuel injector(s).	* REFER to the WDS.
	* Intake air shut-off throttle.	* CHECK the intake air shut-off throttle butterfly for obstructions and correct operation. * REFER to the WDS.
	* Intake air shut-off throttle vacuum control solenoid.	* CHECK the intake air shut-off throttle vacuum control solenoid vacuum lines for kinks or restrictions. * REFER to the WDS.
Engine cuts out during hard acceleration	* CMP sensor.	* REFER to the WDS.
	* CKP sensor.	* REFER to the WDS.
	* FRP sensor.	* REFER to the WDS.
	* Fuel pump fuel pressure regulator.	* REFER to the WDS.
	* Fuel pump.	* REFER to the WDS.