Symptom | Possible Sources | Action |
Engine does not crank and glow plug indicator is flashing | * DTC detected. | * REFER to the Ford approved diagnostic tool. |
Engine does not crank | * Passive anti-theft system (PATS). | * CHECK the PATS LED extinguishes within 3 seconds when the ignition is turned on. REFER to: Anti-Theft - Active (419-01A Anti-Theft - Active, Diagnosis and Testing). |
* Starting system. | * REFER to: Starting System (303-06 Starting System, Diagnosis and Testing). |
* Ignition switch. | * REFER to the Wiring Diagrams. |
* PCM. | * REFER to the Ford approved diagnostic tool. |
* Engine locked. | * REFER to: Engine (303-00 Engine System - General Information, Diagnosis and Testing). |
* Accessories locked. | * REFER to: Accessory Drive (303-05 Accessory Drive, Diagnosis and Testing). |
Engine cranks but does not start and glow plug indicator is flashing | * DTC detected. | * REFER to the Ford approved diagnostic tool. |
Engine cranks but does not start | * Battery | * REFER to: Battery (414-01 Battery, Mounting and Cables, Diagnosis and Testing). |
* 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. |
* Inertia fuel shutoff (IFS) switch. | * RESET the IFS switch. |
* Fuel pump. | * REFER to the Ford approved diagnostic tool. |
* Fuel injectors. | * REFER to the Ford approved diagnostic tool. |
* Fuel filter blocked. | * |
* Fuel lines damaged or blocked. | * |
* Air ingress into the fuel lines. | * REFER to: Fuel System (310-00 Fuel System - General Information, Diagnosis and Testing). |
* Glow plug relay. | * REFER to the Ford approved diagnostic tool. |
* Glow plugs. | * REFER to the Ford approved diagnostic tool. |
* Crankshaft position (CKP) sensor. | * REFER to the Ford approved diagnostic tool. |
* Camshaft position (CMP) sensor. | * REFER to the Ford approved diagnostic tool. |
* Cylinder head temperature (CHT) sensor. | * REFER to the Ford approved diagnostic tool. |
* FRP sensor. | * REFER to the Ford approved diagnostic tool. |
* Fuel intake metering valve. | * REFER to the Ford approved diagnostic tool. |
* Incorrect valve timing. | * CHECK the valve timing. |
* Low cylinder compression. | * TEST the cylinder compression. |
* PCM. | * REFER to the Ford approved diagnostic tool. |
* Incorrect or contaminated fuel. | * CHECK for signs of contamination such as strange odours from the fuel tank. * CHECK for signs of water or petrol in the diesel. * If contaminated fuel is found, DRAIN the complete fuel system. FLUSH the fuel system through with clean diesel. INSTALL a new fuel filter element. REFER to: Fuel Filter Element - Diesel (310-01 Fuel Tank and Lines, Removal and Installation). INSTALL a new fuel pump, fuel injectors, fuel rail, and high-pressure fuel supply lines. REFER to: Fuel Pump (303-04C Fuel Charging and Controls - 2.4L Duratorq-TDCi (Puma) Diesel, Removal and Installation) / Fuel Injectors (303-04C Fuel Charging and Controls - 2.4L Duratorq-TDCi (Puma) Diesel, Removal and Installation) / Fuel Rail (303-04C Fuel Charging and Controls - 2.4L Duratorq-TDCi (Puma) Diesel, Removal and Installation). |
* Incorrect pilot learn. * Incorrect pump learn. | * REFER to the Ford approved diagnostic tool. |
* Accessories load. | * REFER to: Accessory Drive (303-05 Accessory Drive, Diagnosis and Testing). |
* Air intake blocked. | * REFER to: Intake Air Distribution and Filtering (303-12 Intake Air Distribution and Filtering, Diagnosis and Testing). |
Poor starting and glow plug indicator is flashing | * DTC detected. | * REFER to the Ford approved diagnostic tool. |
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. |
* Incorrect or contaminated fuel. | * CHECK for signs of contamination such as strange odours from the fuel tank. * CHECK for signs of water or petrol in the diesel. * If contaminated fuel is found, DRAIN the complete fuel system. FLUSH the fuel system through with clean diesel. INSTALL a new fuel filter element. REFER to: Fuel Filter Element - Diesel (310-01 Fuel Tank and Lines, Removal and Installation). INSTALL a new fuel pump, fuel injectors, fuel rail, and high-pressure fuel supply lines. REFER to: Fuel Pump (303-04C Fuel Charging and Controls - 2.4L Duratorq-TDCi (Puma) Diesel, Removal and Installation) / Fuel Injectors (303-04C Fuel Charging and Controls - 2.4L Duratorq-TDCi (Puma) Diesel, Removal and Installation) / Fuel Rail (303-04C Fuel Charging and Controls - 2.4L Duratorq-TDCi (Puma) Diesel, Removal and Installation). |
* Fuel filter blocked. | * |
* Air cleaner element blocked. | * INSTALL a new air cleaner element. |
* Glow plug relay. | * REFER to the Ford approved diagnostic tool. |
* Glow plugs. | * REFER to the Ford approved diagnostic tool. |
* 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 (310-00 Fuel System - General Information, Diagnosis and Testing). |
* Fuel system restriction. | * |
* Fuel pump. | * |
* Fuel injector(s). | * REFER to the Ford approved diagnostic tool. |
* Accessories load. | * REFER to: Accessory Drive (303-05 Accessory Drive, Diagnosis and Testing). |
* Incorrect engine oil. | * INSTALL a new engine oil filter and engine oil. CARRY OUT the oil reset procedure. REFER to the Service interval indicator lamp section within the Owner's Guide. |
* Incorrect power steering fluid. | * DRAIN and REFILL the power steering system with the correct fluid. REFER to: Power Steering System Flushing - 2.2L Duratorq-TDCi (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Diesel (211-00 Steering System - General Information, General Procedures) / Power Steering System Filling (211-00 Steering System - General Information, General Procedures) / Power Steering System Bleeding (211-00 Steering System - General Information, General Procedures). |
* CKP sensor. | * REFER to the Ford approved diagnostic tool. |
* CHT sensor. | * REFER to the Ford approved diagnostic tool. |
* Manifold absolute pressure and temperature (MAPT) sensor. | * REFER to the Ford approved diagnostic tool. |
* FRP sensor. | * REFER to the Ford approved diagnostic tool. |
* Fuel intake metering valve. | * REFER to the Ford approved diagnostic tool. |
* Catalytic converter blocked. | * REMOVE and visually INSPECT the catalytic converter as necessary. REFER to: Catalytic Converter - 2.2L Duratorq-TDCi (Puma) Diesel (309-00 Exhaust System, Removal and Installation). |
* Low cylinder compression. | * TEST the cylinder compression. |
Engine starts but immediately stops and glow plug indicator is flashing | * DTC detected. | * REFER to the Ford approved diagnostic tool. |
Engine starts but immediately stops | * Incorrect or contaminated fuel. | * CHECK for signs of contamination such as strange odours from the fuel tank. * CHECK for signs of water or petrol in the diesel. * If contaminated fuel is found, DRAIN the complete fuel system. FLUSH the fuel system through with clean diesel. INSTALL a new fuel filter element. REFER to: Fuel Filter Element - Diesel (310-01 Fuel Tank and Lines, Removal and Installation). INSTALL a new fuel pump, fuel injectors, fuel rail, and high-pressure fuel supply lines. REFER to: Fuel Pump (303-04C Fuel Charging and Controls - 2.4L Duratorq-TDCi (Puma) Diesel, Removal and Installation) / Fuel Injectors (303-04C Fuel Charging and Controls - 2.4L Duratorq-TDCi (Puma) Diesel, Removal and Installation) / Fuel Rail (303-04C Fuel Charging and Controls - 2.4L Duratorq-TDCi (Puma) Diesel, Removal and Installation). |
* Air cleaner element blocked. | * INSTALL a new air cleaner element. |
* Air ingress into the fuel lines. | * REFER to: Fuel System (310-00 Fuel System - General Information, Diagnosis and Testing). |
* PCM relay. | * CARRY OUT the relay component test. REFER to Wiring Diagrams. |
* Accessories load. | * REFER to: Accessory Drive (303-05 Accessory Drive, Diagnosis and Testing). |
* CKP sensor. | * REFER to the Ford approved diagnostic tool. |
* CMP sensor. | * REFER to the Ford approved diagnostic tool. |
* CHT sensor. | * REFER to the Ford approved diagnostic tool. |
* Fuel intake metering valve. | * REFER to the Ford approved diagnostic tool. |
* PCM. | * REFER to the Ford approved diagnostic tool. |
* Dual mass flywheel. | * Visually INSPECT the dual mass flywheel for damage. INSTALL new parts as necessary. |
Poor idling and glow plug indicator is flashing | * DTC detected. | * REFER to the Ford approved diagnostic tool. |
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. |
* Accessories load. | * REFER to: Accessory Drive (303-05 Accessory Drive, Diagnosis and Testing). |
* Fuel filter blocked. | * |
* Fuel injector(s). | * REFER to the Ford approved diagnostic tool. |
* Incorrect or contaminated fuel. | * CHECK for signs of contamination such as strange odours from the fuel tank. * CHECK for signs of water or petrol in the diesel. * If contaminated fuel is found, DRAIN the complete fuel system. FLUSH the fuel system through with clean diesel. INSTALL a new fuel filter element. REFER to: Fuel Filter Element - Diesel (310-01 Fuel Tank and Lines, Removal and Installation). INSTALL a new fuel pump, fuel injectors, fuel rail, and high-pressure fuel supply lines. REFER to: Fuel Pump (303-04B Fuel Charging and Controls - 2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation) / Fuel Injectors (303-04B Fuel Charging and Controls - 2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation) / Fuel Rail (303-04B Fuel Charging and Controls - 2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation). |
* Air ingress into the fuel lines. | * REFER to: Fuel System (310-00 Fuel System - General Information, Diagnosis and Testing). |
* EGR valve sticking open. | * REFER to: Engine Emission Control (303-08 Engine Emission Control, Diagnosis and Testing). |
* MAPT sensor. | * REFER to the Ford approved diagnostic tool. |
* CKP sensor. | * REFER to the Ford approved diagnostic tool. |
* FRP sensor. | * REFER to the Ford approved diagnostic tool. |
* Fuel intake metering valve. | * REFER to the Ford approved diagnostic tool. |
* Fuel pump. | * |
* Dual mass flywheel. | * Visually INSPECT the dual mass flywheel for damage. INSTALL new parts as necessary. |
Engine stumbling and glow plug indicator is flashing | * DTC detected. | * REFER to the Ford approved diagnostic tool. |
Engine stumbling | * Low fuel 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 odours from the fuel tank. * CHECK for signs of water or petrol in the diesel. * If contaminated fuel is found, DRAIN the complete fuel system. FLUSH the fuel system through with clean diesel. INSTALL a new fuel filter element. REFER to: Fuel Filter Element - Diesel (310-01 Fuel Tank and Lines, Removal and Installation). INSTALL a new fuel pump, fuel injectors, fuel rail, and high-pressure fuel supply lines. REFER to: Fuel Pump (303-04C Fuel Charging and Controls - 2.4L Duratorq-TDCi (Puma) Diesel, Removal and Installation) / Fuel Injectors (303-04C Fuel Charging and Controls - 2.4L Duratorq-TDCi (Puma) Diesel, Removal and Installation) / Fuel Rail (303-04C Fuel Charging and Controls - 2.4L Duratorq-TDCi (Puma) Diesel, Removal and Installation). |
* Accelerator pedal position (APP) sensor. | * REFER to the Ford approved diagnostic tool. |
* Fuel injector(s). | * REFER to the Ford approved diagnostic tool. |
* Fuel pump. | * |
* FRP sensor. | * REFER to the Ford approved diagnostic tool. |
* CKP sensor. | * REFER to the Ford approved diagnostic tool. |
* CMP sensor. | * REFER to the Ford approved diagnostic tool. |
* Dual mass flywheel. | * Visually INSPECT the dual mass flywheel for damage. INSTALL new parts as necessary. |
Engine lacks power and glow plug indicator is flashing | * DTC detected. | * REFER to the Ford approved diagnostic tool. |
Engine lacks power | * Low fuel level. | * CHECK the fuel tank level is greater than four liters. If the fuel tank level is less than four liters, FILL with fuel. |
* Fuel system leak(s). | * Carry out a Fuel System Leak Test using the Ford approved diagnostic tool menu options: ToolBox/Powertrain/Service Functions. REFER to the Ford approved diagnostic tool. |
* 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 performance. |
* Accessories load. | * REFER to: Accessory Drive (303-05 Accessory Drive, Diagnosis and Testing). |
* Air cleaner element blocked. | * INSTALL a new air cleaner element as necessary. |
* Fuel filter blocked. | * |
* Kinked or restricted fuel lines. | * |
* Fuel pump. | * |
* Fuel injector(s). | * REFER to the Ford approved diagnostic tool. |
* Air ingress into the fuel lines. | * REFER to: Fuel System (310-00 Fuel System - General Information, Diagnosis and Testing). |
* Turbocharger. * Turbocharger vacuum control. * Turbocharger vacuum diaphragm unit. * Vane adjustment solenoid valve. | * INSPECT the vacuum line(s) for visible signs of damage or blockage. CLEAN, REPAIR or INSTALL new parts as necessary. REFER to: Turbocharger (303-04E Fuel Charging and Controls - Turbocharger, Diagnosis and Testing). |
* EGR valve sticking open. | * REFER to: Engine Emission Control (303-08 Engine Emission Control, Diagnosis and Testing). |
* Charge air cooler blocked or cracked. * Charge air cooler pipes split or cracked. * Charge air cooler 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 odours from the fuel tank. * CHECK for signs of water or petrol in the diesel. * If contaminated fuel is found, DRAIN the complete fuel system. FLUSH the fuel system through with clean diesel. INSTALL a new fuel filter element. REFER to: Fuel Filter Element - Diesel (310-01 Fuel Tank and Lines, Removal and Installation). INSTALL a new fuel pump, fuel injectors, fuel rail, and high-pressure fuel supply lines. REFER to: Fuel Pump (303-04B Fuel Charging and Controls - 2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation) / Fuel Injectors (303-04B Fuel Charging and Controls - 2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation) / Fuel Rail (303-04B Fuel Charging and Controls - 2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation). |
* Vehicle speed sensor (VSS). | * REFER to the Ford approved diagnostic tool. |
* CHT sensor. | * REFER to the Ford approved diagnostic tool. |
* MAPT sensor. | * REFER to the Ford approved diagnostic tool. |
* MAF sensor. | * REFER to the Ford approved diagnostic tool. |
* APP sensor. | * REFER to the Ford approved diagnostic tool. |
* CKP sensor. | * REFER to the Ford approved diagnostic tool. |
* Fuel pressure relief valve. | * REFER to the Ford approved diagnostic tool. |
* FRP sensor. | * REFER to the Ford approved diagnostic tool. |
* Fuel intake metering valve. | * REFER to the Ford approved diagnostic tool. |
* Incorrect valve timing. | * CHECK the valve timing. |
* Low cylinder compression. | * CHECK the cylinder compression |
* Catalytic converter blocked. | * REMOVE and visually INSPECT the catalytic converter for damage. INSTALL a new catalytic converter as necessary. REFER to: Catalytic Converter - 2.2L Duratorq-TDCi (Puma) Diesel (309-00 Exhaust System, Removal and Installation). |
* Wiring harness/connector. | * REFER to the Ford approved diagnostic tool. |
* PCM. | * REFER to: Electronic Engine Controls (303-14 Electronic Engine Controls, Diagnosis and Testing). |
Black smoke at idle and glow plug indicator is flashing | * DTC detected. | * REFER to the Ford approved diagnostic tool. |
Black smoke at idle | * Incorrect or contaminated fuel. | * CHECK for signs of contamination such as strange odours from the fuel tank. * CHECK for signs of water or petrol in the diesel. * If contaminated fuel is found, DRAIN the complete fuel system. FLUSH the fuel system through with clean diesel. INSTALL a new fuel filter element. REFER to: Fuel Filter Element - Diesel (310-01 Fuel Tank and Lines, Removal and Installation). INSTALL a new fuel pump, fuel injectors, fuel rail, and high-pressure fuel supply lines. REFER to: Fuel Pump (303-04B Fuel Charging and Controls - 2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation) / Fuel Injectors (303-04B Fuel Charging and Controls - 2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation) / Fuel Rail (303-04B Fuel Charging and Controls - 2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation). |
* Air cleaner element blocked. | * INSTALL a new air cleaner element as necessary. |
* Glow plug relay. | * REFER to the Ford approved diagnostic tool. |
* Fuel injector(s). | * REFER to the Ford approved diagnostic tool. |
* Turbocharger vacuum control. * Vane adjustment solenoid valve. | * INSPECT for visible signs of damage or blockage. CLEAN, REPAIR or INSTALL new parts as necessary. REFER to: Turbocharger (303-04E Fuel Charging and Controls - Turbocharger, Diagnosis and Testing). |
* Incorrect pilot learn. * Incorrect pump learn. | * REFER to the Ford approved diagnostic tool. |
* Incorrect engine timing. | * REFER to the Ford approved diagnostic tool. |
* Fuel pressure relief valve. | * REFER to the Ford approved diagnostic tool. |
* CHT sensor. | * REFER to the Ford approved diagnostic tool. |
* CKP sensor. | * REFER to the Ford approved diagnostic tool. |
* MAPT sensor. | * REFER to the Ford approved diagnostic tool. |
* FRP sensor. | * REFER to the Ford approved diagnostic tool. |
* Incorrect valve timing. | * CHECK the valve timing. |
* Catalytic converter blocked. | * REMOVE and visually INSPECT the catalytic converter for damage. INSTALL a new catalytic converter as necessary. REFER to: Catalytic Converter - 2.2L Duratorq-TDCi (Puma) Diesel (309-00 Exhaust System, Removal and Installation). |
* Wiring harness/connector. | * REFER to the Ford approved diagnostic tool. |
* PCM. | * REFER to: Electronic Engine Controls (303-14 Electronic Engine Controls, Diagnosis and Testing). |
Excessive black smoke during acceleration and glow plug indicator is flashing | * DTC detected. | * REFER to the Ford approved diagnostic tool. |
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 odours from the fuel tank. * CHECK for signs of water or petrol in the diesel. * If contaminated fuel is found, DRAIN the complete fuel system. FLUSH the fuel system through with clean diesel. INSTALL a new fuel filter element. REFER to: Fuel Filter Element - Diesel (310-01 Fuel Tank and Lines, Removal and Installation). INSTALL a new fuel pump, fuel injectors, fuel rail, and high-pressure fuel supply lines. REFER to: Fuel Pump (303-04B Fuel Charging and Controls - 2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation) / Fuel Injectors (303-04B Fuel Charging and Controls - 2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation) / Fuel Rail (303-04B Fuel Charging and Controls - 2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation). |
* EGR valve sticking open. | * REFER to: Engine Emission Control (303-08 Engine Emission Control, Diagnosis and Testing). |
* Incorrect pilot learn. * Incorrect pump learn. | * REFER to the Ford approved diagnostic tool. |
* Fuel injector(s). | * REFER to the Ford approved diagnostic tool. |
* APP sensor. | * REFER to the Ford approved diagnostic tool. |
* CKP sensor. | * REFER to the Ford approved diagnostic tool. |
* Fuel pressure relief valve. | * REFER to the Ford approved diagnostic tool. |
* FRP sensor. | * REFER to the Ford approved diagnostic tool. |
* Catalytic converter blocked. | * REMOVE and visually INSPECT the catalytic converter for damage. INSTALL a new catalytic converter as necessary. REFER to: Catalytic Converter - 2.2L Duratorq-TDCi (Puma) Diesel (309-00 Exhaust System, Removal and Installation). |
* Wiring harness/connector. | * REFER to the Ford approved diagnostic tool. |
* PCM. | * REFER to: Electronic Engine Controls (303-14 Electronic Engine Controls, Diagnosis and Testing). |
Black smoke at cruising speeds and glow plug indicator is flashing | * DTC detected. | * REFER to the Ford approved diagnostic tool. |
Black smoke at cruising speeds | * Incorrect or contaminated fuel. | * CHECK for signs of contamination such as strange odours from the fuel tank. * CHECK for signs of water or petrol in the diesel. * If contaminated fuel is found, DRAIN the complete fuel system. FLUSH the fuel system through with clean diesel. INSTALL a new fuel filter element. REFER to: Fuel Filter Element - Diesel (310-01 Fuel Tank and Lines, Removal and Installation). INSTALL a new fuel pump, fuel injectors, fuel rail, and high-pressure fuel supply lines. REFER to: Fuel Pump (303-04C Fuel Charging and Controls - 2.4L Duratorq-TDCi (Puma) Diesel, Removal and Installation) / Fuel Injectors (303-04C Fuel Charging and Controls - 2.4L Duratorq-TDCi (Puma) Diesel, Removal and Installation) / Fuel Rail (303-04C Fuel Charging and Controls - 2.4L Duratorq-TDCi (Puma) Diesel, Removal and Installation). |
* Air cleaner element blocked. | * INSTALL a new air cleaner element. |
* EGR valve sticking open. | * REFER to: Engine Emission Control (303-08 Engine Emission Control, Diagnosis and Testing). |
* Incorrect pilot learn. * Incorrect pump learn. | * REFER to the Ford approved diagnostic tool. |
* Fuel pressure relief valve. | * REFER to the Ford approved diagnostic tool. |
* Turbocharger vacuum diaphragm unit. * Vane adjustment solenoid valve. | * REFER to: Turbocharger (303-04E Fuel Charging and Controls - Turbocharger, Diagnosis and Testing). |
* Incorrect engine timing. | * REFER to the Ford approved diagnostic tool. |
* CHT sensor. | * REFER to the Ford approved diagnostic tool. |
* MAPT sensor. | * REFER to the Ford approved diagnostic tool. |
* Fuel injector(s). | * REFER to the Ford approved diagnostic tool. |
* FRP sensor. | * REFER to the Ford approved diagnostic tool. |
* Catalytic converter blocked. | * REMOVE and visually INSPECT the catalytic converter for damage. INSTALL a new catalytic converter as necessary. REFER to: Catalytic Converter - 2.2L Duratorq-TDCi (Puma) Diesel (309-00 Exhaust System, Removal and Installation). |
* Wiring harness/connector. | * REFER to the Ford approved diagnostic tool. |
* PCM. | * REFER to: Electronic Engine Controls (303-14 Electronic Engine Controls, Diagnosis and Testing). |
Blue smoke and glow plug indicator is flashing | * DTC detected. | * REFER to the Ford approved diagnostic tool. |
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 litre per 1000 km (600 miles). |
* Incorrect or contaminated fuel. | * CHECK for signs of contamination such as strange odours from the fuel tank. * CHECK for signs of water or petrol in the diesel. * If contaminated fuel is found, DRAIN the complete fuel system. FLUSH the fuel system through with clean diesel. INSTALL a new fuel filter element. REFER to: Fuel Filter Element - Diesel (310-01 Fuel Tank and Lines, Removal and Installation). INSTALL a new fuel pump, fuel injectors, fuel rail, and high-pressure fuel supply lines. REFER to: Fuel Pump (303-04B Fuel Charging and Controls - 2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation) / Fuel Injectors (303-04B Fuel Charging and Controls - 2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation) / Fuel Rail (303-04B Fuel Charging and Controls - 2.2L Duratorq-TDCi (Puma) 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 (303-04E Fuel Charging and Controls - Turbocharger, 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. REFER to: Cylinder Head (303-01B Engine - 2.2L Duratorq-TDCi (Puma) Diesel, In-vehicle Repair). |
White smoke and glow plug indicator is flashing | * DTC detected. | * REFER to the Ford approved diagnostic tool. |
White smoke | * Incorrect or contaminated fuel. | * CHECK for signs of contamination such as strange odours from the fuel tank. * CHECK for signs of water or petrol in the diesel. * If contaminated fuel is found, DRAIN the complete fuel system. FLUSH the fuel system through with clean diesel. INSTALL a new fuel filter element. REFER to: Fuel Filter Element - Diesel (310-01 Fuel Tank and Lines, Removal and Installation). INSTALL a new fuel pump, fuel injectors, fuel rail, and high-pressure fuel supply lines. REFER to: Fuel Pump (303-04B Fuel Charging and Controls - 2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation) / Fuel Injectors (303-04B Fuel Charging and Controls - 2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation) / Fuel Rail (303-04B Fuel Charging and Controls - 2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation). |
* Incorrect pilot learn. * Incorrect pump learn. | * REFER to the Ford approved diagnostic tool. |
* Fuel pressure relief valve. | * REFER to the Ford approved diagnostic tool. |
* Incorrect engine timing. | * REFER to the Ford approved diagnostic tool. |
* Fuel injector(s). | * REFER to the Ford approved diagnostic tool. |
* EGR valve sticking open. | * REFER to: Engine Emission Control (303-08 Engine Emission Control, Diagnosis and Testing). |
* Incorrect valve timing. | * CHECK the valve timing. |
* Coolant in the combustion chamber. | * CARRY OUT a cooling system pressure test. REFER to: Engine Cooling - 2.2L Duratorq-TDCi (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Diesel (303-03 Engine Cooling, Diagnosis and Testing). REMOVE the cylinder head. INSPECT the cylinder head, cylinder head gasket and cylinder bores for wear or damage. REFER to: Cylinder Head (303-01B Engine - 2.2L Duratorq-TDCi (Puma) Diesel, In-vehicle Repair). |
* Wiring harness/connector. | * REFER to the Ford approved diagnostic tool. |
* PCM. | * REFER to: Electronic Engine Controls (303-14 Electronic Engine Controls, Diagnosis and Testing). |
Engine misfire and glow plug indicator is flashing | * DTC detected. | * REFER to the Ford approved diagnostic tool. |
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 odours from the fuel tank. * CHECK for signs of water or petrol in the diesel. * If contaminated fuel is found, DRAIN the complete fuel system. FLUSH the fuel system through with clean diesel. INSTALL a new fuel filter element. REFER to: Fuel Filter Element - Diesel (310-01 Fuel Tank and Lines, Removal and Installation). INSTALL a new fuel pump, fuel injectors, fuel rail, and high-pressure fuel supply lines. REFER to: Fuel Pump (303-04B Fuel Charging and Controls - 2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation) / Fuel Injectors (303-04B Fuel Charging and Controls - 2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation) / Fuel Rail (303-04B Fuel Charging and Controls - 2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation). |
* Incorrect pilot learn. * Incorrect pump learn. | * REFER to the Ford approved diagnostic tool. |
* Fuel pressure relief valve. | * REFER to the Ford approved diagnostic tool. |
* Incorrect engine timing. | * REFER to the Ford approved diagnostic tool. |
* Air ingress into the fuel lines. | * REFER to: Fuel System (310-00 Fuel System - General Information, Diagnosis and Testing). |
* Fuel pump. | * |
* Fuel injector(s). | * REFER to the Ford approved diagnostic tool. |
* EGR valve sticking open. | * REFER to: Engine Emission Control (303-08 Engine Emission Control, Diagnosis and Testing). |
* Engine operating temperature too high. | * REFER to: Engine Cooling - 2.2L Duratorq-TDCi (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Diesel (303-03 Engine Cooling, Diagnosis and Testing). |
* CHT sensor. | * REFER to the Ford approved diagnostic tool. |
* CKP sensor. | * REFER to the Ford approved diagnostic tool. |
* CMP sensor. | * REFER to the Ford approved diagnostic tool. |
* MAPT sensor. | * REFER to the Ford approved diagnostic tool. |
* FRP sensor. | * REFER to the Ford approved diagnostic tool. |
* Low cylinder compression. | * CHECK the cylinder compression. |
* Worn or damaged valve(s), tappet(s), camshaft(s) or cylinder head gasket. | * REMOVE the cylinder head. INSPECT the cylinder head, valves, tappets and camshafts for signs of wear or damage. REFER to: Cylinder Head (303-01B Engine - 2.2L Duratorq-TDCi (Puma) Diesel, In-vehicle Repair). |
* Wiring harness/connector. | * REFER to the Ford approved diagnostic tool. |
* PCM. | * REFER to: Electronic Engine Controls (303-14 Electronic Engine Controls, Diagnosis and Testing). |
Engine knock at idle and glow plug indicator is flashing | * DTC detected. | * REFER to the Ford approved diagnostic tool. |
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 odours from the fuel tank. * CHECK for signs of water or petrol in the diesel. * If contaminated fuel is found, DRAIN the complete fuel system. FLUSH the fuel system through with clean diesel. INSTALL a new fuel filter element. REFER to: Fuel Filter Element - Diesel (310-01 Fuel Tank and Lines, Removal and Installation). INSTALL a new fuel pump, fuel injectors, fuel rail, and high-pressure fuel supply lines. REFER to: Fuel Pump (303-04B Fuel Charging and Controls - 2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation) / Fuel Injectors (303-04B Fuel Charging and Controls - 2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation) / Fuel Rail (303-04B Fuel Charging and Controls - 2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation). |
* Incorrect pilot learn. * Incorrect pump learn. | * REFER to the Ford approved diagnostic tool. |
* Incorrect engine timing. | * REFER to the Ford approved diagnostic tool. |
* Fuel injector(s). | * REFER to the Ford approved diagnostic tool. |
* CKP sensor. | * REFER to the Ford approved diagnostic tool. |
* Incorrect valve timing. | * CHECK the valve timing. |
* Excessive carbon build up. | * REMOVE the cylinder head. INSPECT the cylinder head and pistons for signs carbon build up. REFER to: Cylinder Head (303-01B Engine - 2.2L Duratorq-TDCi (Puma) Diesel, In-vehicle Repair). |
* Worn or damaged oil pump. * Worn or damaged timing chain or sprocket. * Major mechanical engine failure. | * INSPECT the engine components. |
* Dual mass flywheel. | * Visually INSPECT the dual mass flywheel for damage. INSTALL new parts as necessary. |
* Wiring harness/connector. | * REFER to the Ford approved diagnostic tool. |
* PCM. | * REFER to: Electronic Engine Controls (303-14 Electronic Engine Controls, Diagnosis and Testing). |
Engine knock during acceleration and glow plug indicator is flashing | * DTC detected. | * REFER to the Ford approved diagnostic tool. |
Engine knock during acceleration | * Incorrect pilot learn. * Incorrect pump learn. | * REFER to the Ford approved diagnostic tool. |
* Incorrect engine timing. | * REFER to the Ford approved diagnostic tool. |
* Fuel injector(s). | * REFER to the Ford approved diagnostic tool. |
* Fuel intake metering valve. | * REFER to the Ford approved diagnostic tool. |
* Fuel pump. | * |
* Major mechanical engine failure. | * REFER to: Engine (303-01C Engine - 2.4L Duratorq-TDCi (Puma) Diesel, Diagnosis and Testing). |
* Wiring harness/connector. | * REFER to the Ford approved diagnostic tool. |
* PCM. | * REFER to: Electronic Engine Controls (303-14 Electronic Engine Controls, Diagnosis and Testing). |
Excessive fuel consumption and glow plug indicator is flashing | * DTC detected. | * REFER to the Ford approved diagnostic tool. |
NOTE:Before proceeding with any of the actions in relation to the possible sources for excessive fuel consumption, a fuel consumption test must be carried out using the Ford approved diagnostic tool. 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. |
* Incorrect or contaminated fuel. | * CHECK for signs of contamination such as strange odours from the fuel tank. * CHECK for signs of water or petrol in the diesel. * If contaminated fuel is found, DRAIN the complete fuel system. FLUSH the fuel system through with clean diesel. INSTALL a new fuel filter element. REFER to: Fuel Filter Element - Diesel (310-01 Fuel Tank and Lines, Removal and Installation). INSTALL a new fuel pump, fuel injectors, fuel rail, and high-pressure fuel supply lines. REFER to: Fuel Pump (303-04C Fuel Charging and Controls - 2.4L Duratorq-TDCi (Puma) Diesel, Removal and Installation) / Fuel Injectors (303-04C Fuel Charging and Controls - 2.4L Duratorq-TDCi (Puma) Diesel, Removal and Installation) / Fuel Rail (303-04C Fuel Charging and Controls - 2.4L Duratorq-TDCi (Puma) Diesel, Removal and Installation). |
* Air cleaner element blocked. | * INSTALL a new air cleaner element. |
* Fuel filter blocked. | * |
* Incorrect pilot learn. * Incorrect pump learn. | * REFER to the Ford approved diagnostic tool. |
* Incorrect engine timing. | * REFER to the Ford approved diagnostic tool. |
* Fuel system leak(s). | * CHECK the system for fuel leak(s). REPAIR or INSTALL new parts as necessary. |
* Incorrect engine oil. | * INSTALL a new oil filter and engine oil. |
* Generator. | * REFER to: Generator (414-02 Generator and Regulator, Diagnosis and Testing). |
* EGR valve sticking open. | * REFER to: Engine Emission Control (303-08 Engine Emission Control, Diagnosis and Testing). |
* Turbocharger vacuum diaphragm unit. | * REFER to: Turbocharger (303-04E Fuel Charging and Controls - Turbocharger, Diagnosis and Testing). |
* Air ingress into the fuel lines. | * REFER to: Fuel System (310-00 Fuel System - General Information, Diagnosis and Testing). |
* Fuel pressure relief valve. | * REFER to the Ford approved diagnostic tool. |
* CHT sensor. | * REFER to the Ford approved diagnostic tool. |
* MAPT sensor. | * REFER to the Ford approved diagnostic tool. |
* Fuel injector(s). | * REFER to the Ford approved diagnostic tool. |
* Turbocharger. | * REFER to: Turbocharger (303-04E Fuel Charging and Controls - Turbocharger, Diagnosis and Testing). |
* Incorrect valve timing. | * CHECK the valve timing. |
* Slipping clutch. | * REFER to: Manual Transmission and Clutch - Vehicles With: MT-75 (308-00 Manual Transmission/Transaxle and Clutch - General Information, Diagnosis and Testing) / Manual Transaxle and Clutch - Vehicles With: VXT-75 (308-00 Manual Transmission/Transaxle and Clutch - General Information, Diagnosis and Testing) / Manual Transmission and Clutch - Vehicles With: MT82 (308-00 Manual Transmission/Transaxle and Clutch - General Information, Diagnosis and Testing). |
* Low cylinder compression. | * CHECK the cylinder compression. |
* Dual mass flywheel. | * Visually INSPECT the dual mass flywheel for damage. INSTALL new parts as necessary. |
* Wiring harness/connector. | * REFER to the Ford approved diagnostic tool. |
* PCM. | * REFER to: Electronic Engine Controls (303-14 Electronic Engine Controls, Diagnosis and Testing). |
Engine cuts out during hard acceleration | * CMP sensor. | * REFER to the Ford approved diagnostic tool. |
* CKP sensor. | * REFER to the Ford approved diagnostic tool. |
* Incorrect pilot learn. * Incorrect pump learn. | * REFER to the Ford approved diagnostic tool. |
* FRP sensor. | * REFER to the Ford approved diagnostic tool. |
* Fuel pressure relief valve. | * REFER to the Ford approved diagnostic tool. |
* Fuel intake metering valve. | * REFER to the Ford approved diagnostic tool. |
* Fuel pump. | * |