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Diagnosis and Testing|Removal and Installation > < Fuel Charging and Controls
Fuel Charging and Controls - 2.0L Duratorq-Di (Puma) Diesel/2.0L Duratorq-TDDi (Puma) Diesel - Fuel Charging and Controls Transit 2000.5 (01/2000-05/2006)
Diagnosis and Testing

Inspection and Verification

NOTE:
NOTE:As well as carrying out its normal function the glow plug lamp 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 WDS.
NOTE:
NOTE:If a DTC is detected, all DTCs must be cleared after the concern is repaired. Failure to clear all DTCs may cause driveability concerns.
NOTE:
NOTE:If the fuel level in the fuel tank drops below approximately 4 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.

Verify the power output of the vehicle:

  • Vehicles with a 75 PS engine have no charge air cooler or EGR cooler fitted.
  • Vehicles with a 100PS engine have a charge air cooler and EGR cooler fitted.
  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 minder
  • Air filter minder
  • Vacuum line(s)/vacuum connections
  • Hose(s)/hose connections
  • Pipe(s)/pipe connections
  • Contaminated fuel
  • Fuel delivery pipes
  • Fuel injectors
  • Fuel injection pump
  • Fuse(s)
  • Relay(s)
  • Wiring harness
  • Electrical connector(s)
  • Passive anti-theft system (PATS) LED operation
  • Sensor(s)
  • Glow plug lamp operation
  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 turn over and glow plug lamp is illuminated
*
DTC detected.
*
CHECK the glow plug lamp illuminates when starting the engine and then goes out and stays out. If the glow plug lamp starts flashing, REFER to WDS.
Engine does not turn over
*
PATS.
*
CHECK the PATS LED extinguishes within 3 seconds when the ignition is turned on. REFER to Section  419-01A Anti-Theft - Active / 419-01B Anti-Theft - Passive.
*
Starter inhibit relay fuse.
*
Relay start ground fuse.
*
Power relay start enable fuse.
*
Power relay ignition fuse.
*
CHECK the fuse. If the fuse is blown, INSTALL a new fuse. If the fuse blows again, REFER to WDS.
*
Starter inhibit relay.
*
Relay start ground.
*
Power relay start enable.
*
Power relay.
*
CARRY OUT the Relay Component Test. REFER to the Wiring Diagrams.
*
Ignition switch.
*
*
PCM.
*
REFER to WDS.
Engine turns over but does not start and glow plug lamp is illuminated
*
DTC detected.
*
CHECK the glow plug lamp illuminates when starting the engine and then goes out and stays out. If the glow plug lamp starts flashing, REFER to WDS.
Engine turns over but does not start
*
The fuel injection pump control unit and the PCM are not matched.
*
*
Fuel injection pump control unit electrical connector.
*
CHECK the fuel injection pump control unit electrical connector locking tang is correctly installed.
*
Inertia fuel shutoff (IFS) switch .
*
RESET the IFS switch.
*
Fuel injection pump relay fuse.
*
CHECK the fuse. If fuse blown, INSTALL a new fuse. If the fuse blows again, REFER to WDS.
*
Fuel injection pump relay.
*
CARRY OUT the Relay Component Test. REFER to the Wiring Diagrams.
*
Blocked fuel filter element.
*
CARRY OUT the Fuel Filter Element Component Test. REFER to Section  310-00A Fuel System - General Information / 310-00B Fuel System - General Information.
*
Air ingress into the fuel lines.
*
*
Damaged or blocked fuel lines.
*
*
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.
*
Fuel injection pump.
*
PCM.
*
REFER to WDS.
Intermittent start (engine turns over) and glow plug lamp is illuminated
*
DTC detected.
*
CHECK the glow plug lamp illuminates when starting the engine and then goes out and stays out. If the glow plug lamp starts flashing, REFER to WDS.
Intermittent start (engine turns over)
*
PATS.
*
CHECK the PATS LED extinguishes within 3 seconds when the ignition is turned on. REFER to Section  419-01A Anti-Theft - Active / 419-01B Anti-Theft - Passive.
*
Fuel injection pump control unit electrical connector.
*
CHECK the fuel injection pump control unit electrical connector locking tang is correctly installed.
*
CKP sensor.
*
REFER to WDS.
*
Fuel injection pump fuse.
*
CHECK the fuse. If the fuse is blown, INSTALL a new fuse. If the fuse blows again, REFER to WDS.
*
Fuel injection pump relay.
*
CARRY OUT the Relay Component Test. REFER to the Wiring Diagrams.
*
Fuel injection pump.
*
PCM.
*
REFER to WDS.
Intermittent crank (engine does not turn over) and glow plug lamp is illuminated
*
DTC detected.
*
CHECK the glow plug lamp illuminates when starting the engine and then goes out and stays out. If the glow plug lamp starts flashing, REFER to WDS.
Intermittent crank (engine does not turn over)
*
PATS transceiver.
*
PATS transponder key.
*
CHECK the PATS LED extinguishes within 3 seconds when the ignition is turned on. REFER to Section  419-01A Anti-Theft - Active / 419-01B Anti-Theft - Passive.
*
Ignition switch.
*
*
Starter enable relay.
*
CARRY OUT the Relay Component Test. REFER to the Wiring Diagrams.
*
PCM.
*
REFER to WDS.
Poor starting and glow plug lamp is illuminated
*
DTC detected.
*
CHECK the glow plug lamp illuminates when starting the engine and then goes out and stays out. If the glow plug lamp starts flashing, REFER to WDS.
Poor starting
*
Fuel filter element blocked.
*
CARRY OUT the Fuel Filter Element Component Test. REFER to Section  310-00A Fuel System - General Information / 310-00B Fuel System - General Information.
*
Air cleaner element blocked.
*
CARRY OUT the Air Cleaner Element Component Test. REFER to Section  303-12 Intake Air Distribution and Filtering.
*
Glow plug relay fuse.
*
CHECK the fuse. If fuse blown, INSTALL a new fuse. If the fuse blows again, REFER to WDS.
*
Glow plug relay.
*
CARRY OUT the Relay Component Test. REFER to the Wiring Diagrams.
*
Glow plugs.
*
*
Fuel system leak.
*
CHECK the system for fuel leak(s). REPAIR the system as necessary.
*
Air ingress into the fuel lines.
*
*
Fuel injection pump timing.
*
REFER to WDS.
*
Incorrect engine oil.
*
INSTALL a new engine oil filter and 5W/30 engine oil.
*
Fuel system restriction.
*
*
CHT sensor.
*
Temperature and manifold absolute pressure (T-MAP) sensor.
*
REFER to WDS.
*
Fuel injector(s).
*
Have the fuel injectors checked by an appropriate fuel injection specialist agent. CLEAN or INSTALL a new set of injectors as required only after the specialist agent checks have been carried out.
*
Fuel injection pump fuel return valve.
*
INSTALL a suitable clear pipe to the fuel injection pump return line and place in a suitable container for 15 minutes. CHECK that no extra fuel has drained from the fuel injection pump.
Engine starts but immediately stops and glow plug lamp is illuminated
*
DTC detected.
*
CHECK the glow plug lamp illuminates when starting the engine and then goes out and stays out. If the glow plug lamp starts flashing, REFER to WDS.
Engine starts but immediately stops
*
Air cleaner element blocked.
*
CARRY OUT the Air Cleaner Element Component Test. REFER to Section  303-12 Intake Air Distribution and Filtering.
*
Air ingress into the fuel lines.
*
*
PCM relay.
*
CARRY OUT the Relay Component Test. REFER to the Wiring Diagrams.
*
CKP sensor.
*
REFER to WDS.
*
Fuel injection pump control unit.
*
PCM.
*
REFER to WDS.
Poor idling and glow plug lamp is illuminated
*
DTC detected.
*
CHECK the glow plug lamp illuminates when starting the engine and then goes out and stays out. If the glow plug lamp starts flashing, REFER to WDS.
Poor idling
*
Low fuel tank level.
*
CHECK the fuel tank level is greater than 4 liters. If fuel tank level is less than 4 liters, FILL with fuel.
*
Air cleaner element blocked.
*
CARRY OUT the Air Cleaner Element Component Test. REFER to Section  303-12 Intake Air Distribution and Filtering.
*
Fuel filter element blocked.
*
CARRY OUT the Fuel Filter Element Component test. REFER to Section  310-00A Fuel System - General Information / 310-00B Fuel System - General Information.
*
Water in fuel.
*
CHECK the water-in-fuel warning lamp is not illuminated, if the lamp is illuminated, DRAIN the water from the fuel filter.
*
T-MAP sensor.
*
CKP sensor.
*
REFER to WDS.
*
Air ingress into the fuel lines.
*
*
Fuel injector(s).
*
Have the fuel injectors checked by an appropriate fuel injection specialist agent. CLEAN 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.
*
Fuel injection pump timing.
*
Fuel injection pump.
*
REFER to WDS.
Engine stumbling and glow plug lamp is illuminated
*
DTC detected.
*
CHECK the glow plug lamp illuminates when starting the engine and then goes out and stays out. If the glow plug lamp starts flashing, REFER to WDS.
Engine stumbling
*
Low fuel level.
*
CHECK the fuel tank level is greater than 4 liters. If the fuel tank level is less than 4 liters, FILL with fuel.
*
Accelerator pedal position (APP) sensor.
*
REFER to WDS.
*
Fuel injector(s).
*
Have the fuel injectors checked by an appropriate fuel injection specialist agent. CLEAN 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.
Engine lacks power and glow plug lamp is illuminated
*
DTC detected.
*
CHECK the glow plug lamp illuminates when starting the engine and then goes out and stays out. If the glow plug lamp starts flashing, REFER to WDS.
Engine lacks power
*
Air cleaner element blocked.
*
CARRY OUT the Air Cleaner Element Component Test. REFER to Section  303-12 Intake Air Distribution and Filtering.
*
Fuel filter element blocked.
*
CARRY OUT the Fuel Element Component Test. REFER to Section  310-00A Fuel System - General Information / 310-00B Fuel System - General Information.
*
Kinked or restricted fuel lines
*
*
Air ingress into the fuel lines.
*
*
APP sensor.
*
T-MAP sensor.
*
CHT sensor.
*
REFER to WDS.
*
Exhaust gas recirculation (EGR) valve.
*
*
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.
*
Turbocharger.
*
*
Fuel injector(s).
*
Have the fuel injectors checked by an appropriate fuel injection specialist agent. CLEAN 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 convertor for damage. INSTALL a new catalytic converter as necessary. REFER to Section  309-00 Exhaust System.
*
Charge air cooler blocked or cracked.
*
Charge air cooler pipes split or cracked.
*
INSPECT for visible signs of damage. REPAIR as necessary.
*
Incorrect or contaminated fuel.
*
CHECK for signs of contamination such as strange odors from the fuel tank.
*
Fuel injection pump
*
REFER to WDS.
Black smoke at idle and glow plug lamp is illuminated
*
DTC detected.
*
CHECK the glow plug lamp illuminates when starting the engine and then goes out and stays out. If the glow plug lamp starts flashing, REFER to WDS.
Black smoke at idle
*
Air cleaner element blocked.
*
CARRY OUT the Air Cleaner Element Component Test. REFER to Section  303-12 Intake Air Distribution and Filtering.
*
Fuel injection pump timing.
*
CHT sensor.
*
T-MAP sensor.
*
REFER to WDS.
*
Incorrect valve timing.
*
CHECK the valve timing. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine.
*
Fuel injector(s).
*
Have the fuel injectors checked by an appropriate fuel injection specialist agent. CLEAN 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 and glow plug lamp is illuminated
*
DTC detected.
*
CHECK the glow plug lamp illuminates when starting the engine and then goes out and stays out. If the glow plug lamp starts flashing, 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.
*
Fuel injector(s).
*
Have the fuel injectors checked by an appropriate fuel injection specialist agent. CLEAN or INSTALL a new set of injectors as required only after the specialist agent checks have been carried out.
*
Fuel injection pump timing piston.
*
Fuel injection pump.
*
REFER to WDS.
Black smoke at cruising speeds and glow plug lamp is illuminated
*
DTC detected.
*
CHECK the glow plug lamp illuminates when starting the engine and then goes out and stays out. If the glow plug lamp starts flashing, REFER to WDS.
Black smoke at cruising speeds
*
Air cleaner element restricted.
*
CARRY OUT the Air Cleaner Element Component Test. REFER to Section  303-12 Intake Air Distribution and Filtering.
*
T-MAP sensor.
*
REFER to WDS.
*
Vacuum lines.
*
CHECK all vacuum lines are installed and no signs of air leaks are present. REPAIR as necessary.
*
EGR valve sticking open.
*
EGR vacuum switching valve.
*
DISCONNECT the vacuum line from the EGR vacuum switching valve lower vacuum line and start the engine. Using a hand vacuum/pressure pump, CHECK that a vacuum is present. RECONNECT the vacuum line and DISCONNECT the vacuum line to the EGR valve. CHECK that a vacuum is present. If no vacuum is present, INSTALL a new EGR vacuum switching valve. If vacuum is present, APPLY a vacuum to the EGR valve and CHECK that it holds a vacuum. If EGR valve does not hold a vacuum, INSTALL a new EGR valve. If EGR valve holds vacuum, REFER to WDS.
*
Fuel injector(s).
*
Have the fuel injectors checked by an appropriate fuel injection specialist agent. CLEAN 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 and glow plug lamp is illuminated
*
DTC detected.
*
CHECK the glow plug lamp illuminates when starting the engine and then goes out and stays out. If the glow plug lamp starts flashing, REFER to 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 litres per 1000 km (600 miles). REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine.
*
Incorrect fuel.
*
CHECK for signs of contamination such as strange odors from the fuel tank.
*
Worn or damaged valve guides, piston rings, cylinder bores, cylinder head or gasket.
*
REMOVE and inspect the cylinder head, pistons and cylinder bores for signs of wear. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine.
*
Engine breather system.
*
CHECK engine breather pipes for signs of restriction or blockage.
*
Turbocharger oil seals leaking.
*
Turbocharger oil return pipe blocked or damaged.
*
White smoke and glow plug lamp is illuminated
*
DTC detected.
*
CHECK the glow plug lamp illuminates when starting the engine and then goes out and stays out. If the glow plug lamp starts flashing, REFER to WDS.
White smoke
*
Water in fuel.
*
*
Retarded fuel injection pump timing.
*
REFER to WDS.
*
Incorrect valve timing.
*
*
Coolant in the combustion chamber.
*
REMOVE and inspect the cylinder head, gasket and bores for wear. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine.
Engine misfire and glow plug lamp is illuminated
*
DTC detected.
*
CHECK the glow plug lamp illuminates when starting the engine and then goes out and stays out. If the glow plug lamp starts flashing, REFER to WDS.
Engine misfire
*
Low fuel tank level.
*
CHECK the fuel tank level is greater than 4 liters. If fuel tank level is less than 4 liters, FILL with fuel.
*
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.
*
*
Air ingress into the fuel lines.
*
*
CHT sensor.
*
REFER to WDS.
*
Fuel injector(s).
*
Injector seals.
*
Have the fuel injectors checked by an appropriate fuel injection specialist agent. CLEAN or INSTALL a new set of injectors as required only after the specialist agent checks have been carried out.
*
Low cylinder compression.
*
*
Worn or damaged valve, tappets or camshafts.
*
REMOVE the cylinder head and visually INSPECT for signs of wear or damage. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine.
*
Damaged cylinder head gasket.
*
REMOVE and inspect the cylinder gasket and bores for wear. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine.
*
Engine operating temperature too high.
*
REFER to Section  303-03 Engine Cooling.
*
Fuel injection pump timing piston stuck in full advance.
*
Fuel injection pump.
*
REFER to WDS.
Engine knock at idle and glow plug lamp is illuminated
*
DTC detected.
*
CHECK the glow plug lamp illuminates when starting the engine and then goes out and stays out. If the glow plug lamp starts flashing, REFER to WDS.
Engine knock at idle
*
Low engine oil level.
*
CHECK the engine oil level. REFILL as necessary.
*
Petrol in the fuel tank.
*
CHECK for signs of contamination such as strange odors from the fuel tank.
*
Incorrect valve timing.
*
*
Fuel injection pump timing.
*
CKP sensor.
*
REFER to WDS.
*
Excessive carbon build up.
*
REMOVE the cylinder head and visually inspect for signs of carbon build up. REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine.
*
Fuel injector(s).
*
Have the fuel injectors checked by an appropriate fuel injection specialist agent. CLEAN or INSTALL a new set of injectors as required only after the specialist agent checks have been carried out.
*
Fuel injection pump timing piston stuck in full advance.
*
REFER to WDS.
*
Worn or damaged oil pump.
*
Worn or damaged timing chain or sprocket.
*
Major mechanical engine failure.
*
Engine knock during acceleration and glow plug lamp is illuminated
*
DTC detected.
*
CHECK the glow plug lamp illuminates when starting the engine and then goes out and stays out. If the glow plug lamp starts flashing, REFER to WDS.
Engine knock during acceleration
*
Fuel injection pump timing.
*
REFER to WDS.
*
Fuel injectors.
*
Have the fuel injectors checked by an appropriate fuel injection specialist agent. CLEAN or INSTALL a new set of injectors as required only after the specialist agent checks have been carried out.
*
Major mechanical engine failure.
*
*
Fuel injection pump timing piston.
*
Fuel injection pump.
*
REFER to WDS.
Excessive fuel consumption and glow plug lamp is illuminated
*
DTC detected.
*
CHECK the glow plug lamp illuminates when starting the engine and then goes out and stays out. If the glow plug lamp starts flashing, REFER to WDS.
Excessive fuel consumption
*
Brakes binding, vehicle overloaded, or excessive wind resistance (roof racks, towing etc).
*
CHECK the braking system. REFER to Section  206-00 Brake System - General Information.
*
ADVISE the customer about the effects of overloading the vehicle and wind resistance on the fuel consumption.
*
Air cleaner element blocked.
*
CARRY OUT the Air Cleaner Element Component Test. REFER to Section  303-12 Intake Air Distribution and Filtering.
*
Fuel filter element blocked.
*
CARRY OUT the Fuel Filter Element Component Test. REFER to Section  310-00A Fuel System - General Information / 310-00B Fuel System - General Information.
*
Fuel system leaks.
*
CHECK the system for fuel leak(s). REPAIR the system as necessary.
*
CHT sensor.
*
T-MAP sensor.
*
REFER to WDS.
*
Incorrect engine oil.
*
INSTALL a new oil filter and 5W/30 engine oil.
*
Low engine oil level.
*
CHECK the engine oil level. REFILL as necessary.
*
Clutch worn or slipping.
*
*
Generator.
*
*
EGR valve stuck open.
*
DISCONNECT the vacuum line from the EGR vacuum switching valve lower vacuum line and start the engine. Using a hand vacuum/pressure pump, CHECK that a vacuum is present. RECONNECT the vacuum line and DISCONNECT the vacuum line to the EGR valve. CHECK that a vacuum is present. If no vacuum is present, INSTALL a new EGR vacuum switching valve. If vacuum is present, APPLY a vacuum to the EGR valve and CHECK that it holds a vacuum. If EGR valve does not hold a vacuum, INSTALL a new EGR valve. If EGR valve holds vacuum, REFER to WDS.
*
Air ingress into the fuel lines.
*
*
Fuel injection pump timing.
*
REFER to WDS.
*
Incorrect valve timing.
*
*
Turbocharger.
*
Turbocharger wastegate actutator.
*
*
Low cylinder compression.
*
*
Fuel injector(s).
*
Have the fuel injectors checked by an appropriate fuel injection specialist agent. CLEAN 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.

Diagnosis and Testing|Removal and Installation > < Fuel Charging and Controls