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General Procedures > < Fuel System - 75 PS-90 PS

Transit.Tourneo Connect 2002.5 (06.2002-)

Fuel System - General Information - Fuel System—Vehicles Built From: 08/2006 1.8L Duratorq-TDCi (Lynx) Diesel (75 PS/90 PS/110 PS) Transit/Tourneo Connect 2002.5 (06/2002-)
Diagnosis and Testing

Special Tool(s)

Hand Pressure Pump with Adapter Kit

310-110
General Equipment
Worldwide Diagnostic System (WDS)

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 level
  • Fuel leak(s)
  • Fuel line(s)
  • Fuel filler cap
  • Fuel filter
  • Fuel tank
  • Fuel tank ventilation hose
  • Fuel tank filler hose
  • 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.
*
REFER to: Fuel Charging and Controls - Vehicles Built From: 08/2006 75 PS/90 PS/110 PS (303-04B Fuel Charging and Controls - 1.8L Duratorq-TDCi (Lynx) Diesel/1.8L Duratorq-TDDi (Lynx) Diesel, Diagnosis and Testing).
*
Air ingress into the fuel lines.
*
GO to Pinpoint Test A.
*
Contaminated fuel.
*
DRAIN and REFILL the fuel system with fresh fuel. INSTALL a new fuel filter.
REFER to: Fuel Filter - 1.8L Duratorq-TDCi (Lynx) Diesel (310-01 Fuel Tank and Lines, Removal and Installation).
Poor starting
*
Fuel charging and controls.
*
REFER to: Fuel Charging and Controls - Vehicles Built From: 08/2006 75 PS/90 PS/110 PS (303-04B Fuel Charging and Controls - 1.8L Duratorq-TDCi (Lynx) Diesel/1.8L Duratorq-TDDi (Lynx) Diesel, Diagnosis and Testing).
*
Air ingress into the fuel lines.
*
GO to Pinpoint Test A.
*
Contaminated fuel.
*
DRAIN and REFILL the fuel system with fresh fuel. INSTALL a new fuel filter.
REFER to: Fuel Filter - 1.8L Duratorq-TDCi (Lynx) Diesel (310-01 Fuel Tank and Lines, Removal and Installation).
Engine starts but immediately stops
*
Fuel charging and controls.
*
REFER to: Fuel Charging and Controls - Vehicles Built From: 08/2006 75 PS/90 PS/110 PS (303-04B Fuel Charging and Controls - 1.8L Duratorq-TDCi (Lynx) Diesel/1.8L Duratorq-TDDi (Lynx) Diesel, Diagnosis and Testing).
*
Air ingress into the fuel lines.
*
GO to Pinpoint Test A.
Poor idling
*
Fuel charging and controls.
*
REFER to: Fuel Charging and Controls - Vehicles Built From: 08/2006 75 PS/90 PS/110 PS (303-04B Fuel Charging and Controls - 1.8L Duratorq-TDCi (Lynx) Diesel/1.8L Duratorq-TDDi (Lynx) Diesel, Diagnosis and Testing).
*
Air ingress into the fuel lines.
*
GO to Pinpoint Test A.
*
Contaminated fuel.
*
DRAIN and REFILL the fuel system with fresh fuel. INSTALL a new fuel filter.
REFER to: Fuel Filter - 1.8L Duratorq-TDCi (Lynx) Diesel (310-01 Fuel Tank and Lines, Removal and Installation).
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 as necessary.
*
GO to Pinpoint Test B.
*
Fuel filter blocked.
*
INSTALL a new fuel filter.
REFER to: Fuel Filter - 1.8L Duratorq-TDCi (Lynx) Diesel (310-01 Fuel Tank and Lines, Removal and Installation).
*
Fuel charging and controls.
*
REFER to: Fuel Charging and Controls - Vehicles Built From: 08/2006 75 PS/90 PS/110 PS (303-04B Fuel Charging and Controls - 1.8L Duratorq-TDCi (Lynx) Diesel/1.8L Duratorq-TDDi (Lynx) Diesel, Diagnosis and Testing).
*
Air ingress into the fuel lines.
*
GO to Pinpoint Test A.
*
Contaminated fuel.
*
DRAIN and REFILL the fuel system with fresh fuel. INSTALL a new fuel filter.
REFER to: Fuel Filter - 1.8L Duratorq-TDCi (Lynx) Diesel (310-01 Fuel Tank and Lines, Removal and Installation).
Engine misfire
*
Fuel charging and controls.
*
REFER to: Fuel Charging and Controls - Vehicles Built From: 08/2006 75 PS/90 PS/110 PS (303-04B Fuel Charging and Controls - 1.8L Duratorq-TDCi (Lynx) Diesel/1.8L Duratorq-TDDi (Lynx) Diesel, Diagnosis and Testing).
*
Air ingress into the fuel lines.
*
GO to Pinpoint Test A.
Excessive fuel consumption
*
Fuel charging and controls.
*
REFER to: Fuel Charging and Controls - Vehicles Built From: 08/2006 75 PS/90 PS/110 PS (303-04B Fuel Charging and Controls - 1.8L Duratorq-TDCi (Lynx) Diesel/1.8L Duratorq-TDDi (Lynx) Diesel, Diagnosis and Testing).
*
Air ingress into the fuel lines.
*
GO to Pinpoint Test A.
*
Contaminated fuel.
*
DRAIN and REFILL the fuel system with fresh fuel. INSTALL a new fuel filter.
REFER to: Fuel Filter - 1.8L Duratorq-TDCi (Lynx) Diesel (310-01 Fuel Tank and Lines, Removal and Installation).
Fuel filler nozzle shuts off prematurely
*
Fuel tank ventilation hose or pipe blocked.
*
Fuel tank ventilation hose or pipe collapsed.
*
CHECK the fuel tank ventilation hose for obstruction or damage. INSTALL a new fuel tank ventilation pipe as necessary.
*
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 as necessary.
*
Fuel gauge indication.
*
CHECK the fuel level in the fuel tank. CHECK the fuel indication system. For additional information,
REFER to: Instrument Cluster - Vehicles Built From: 08/2006 (413-01, Diagnosis and Testing).
*
Fuel filler nozzle at the fuel filling station not functioning correctly.
*
VERIFY the 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 fuel leak is evident, INSTALL a new fuel tank filler pipe or hose as necessary.
*
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 - 1.8L Duratorq-TDCi (Lynx) Diesel/1.8L Duratorq-TDDi (Lynx) Diesel (310-01 Fuel Tank and Lines, Removal and Installation).
*
Fuel tank ventilation pipe or hose leaking.
*
CHECK the fuel tank ventilation pipe and hose for evidence of a fuel leak. If a fuel leak is evident, INSTALL a new fuel tank ventilation pipe or hose as necessary.

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.
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 system components to prevent foreign material 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
Using a suitable piece of clear plastic pipe, manufacture and install a pipe between the fuel filter fuel supply line and the fuel filter.
3
Start the engine, wait a few minutes and 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
For additional diagnostics,
REFER to: Fuel Charging and Controls - Vehicles Built From: 08/2006 75 PS/90 PS/110 PS (303-04B Fuel Charging and Controls - 1.8L Duratorq-TDCi (Lynx) Diesel/1.8L Duratorq-TDDi (Lynx) 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 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 A3.
A3: 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 to fuel pump 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 to fuel pump fuel supply line and the fuel filter.
NOTE:
NOTE:Make sure that the engine is at normal operating temperature.
5
Start the engine, wait a few minutes and 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 or fuel tank to fuel filter supply pipe as necessary.
No
INSTALL a new fuel filter.
REFER to: Fuel Filter - 1.8L Duratorq-TDCi (Lynx) Diesel (310-01 Fuel Tank and Lines, Removal and Installation).

PINPOINT TEST B : FUEL FILTER FUEL SUPPLY LINE BLOCKAGE
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
B1: 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 material ingress to the components.
CAUTION:
CAUTION:The generator must be protected from contamination. Failure to follow this instruction may result in failure of the generator.

1
Disconnect the fuel filter fuel supply line quick release coupling.
REFER to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).

NOTE:
NOTE:Make sure that the hand pressure pump arrow indicating the direction of fuel flow is pointing towards the fuel filter.
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 at least 30 times.

4
Disconnect the fuel pump fuel return line quick release coupling.
REFER to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).

5
Using a suitable piece of clear plastic pipe, manufacture and install a pipe between the fuel pump fuel return line and the fuel return line union.
6
Observe the flow of fuel in the clear plastic pipe.

Does the fuel from the fuel tank flow freely with no restrictions?
Yes
GO to Pinpoint Test A.
No
REPAIR or INSTALL a new fuel filter fuel supply line as necessary.

General Procedures > < Fuel System - 75 PS-90 PS