Diagnostics and checks (1.8 l diesel) (Power unit / Fuel supply / Ford Focus 1 1998-2004)

Inspection and verification

WARNING: Do not smoke or walk with a lit cigarette or any type of open flame while working on or near fuel related components. In such situations, there are always highly flammable mixtures that can ignite. Failure to follow these instructions may result in injury.

WARNING: This procedure is related to fuel handling. Always be prepared for splashing fuel. Failure to follow these instructions may result in injury.

CAUTION: Diesel fuel injection equipment is manufactured to very precise tolerances and very close clearances. The high pressure fuel pump is fully electronic and has no levers or cables. Do not lubricate the terminals and contacts of the high pressure fuel pump. Therefore, it is especially important to observe absolute cleanliness when working with these elements. Always insert plugs into any open holes or lines.

NOTE: In addition to performing its normal function, the glow plug warning light also functions as a check engine light, which flashes continuously when the powertrain control module (PCM) registers a serious diagnostic trouble code (DTC). Minor DTCs are also stored in the PCM memory, but are only displayed when a system check for DTCs is performed using WDS.

NOTE: If DTCs are found after the causes have been corrected, they should be cleared. If not all DTCs are cleared, this may cause problems with the overall drivability of the vehicle.

NOTE: If the fuel level in the fuel tank drops below 4 liters (approximately), the engine will run rough. This is a signal to the driver that the car needs refueling to prevent the fuel system from working «dry».

1. Check the customer's complaint.

2. Visually inspect for obvious signs of mechanical and electrical problems.

Visual Inspection Table

Mechanical factors

Electrical Factors

– Leakage (And) fuel

- Fuel filter

– Air filter element

– Fuel supply lines

– Vacuum line (And) / vacuum line connections

- Hose (And) / hose connections

– Piping/piping connections

– Fuel contamination

– High pressure fuel supply lines

- Fuel burner (And)

– High pressure fuel pump

- Fuse (And)

– Relay

– wiring harness

– Electrical plug (s)

– LED operation (LED) passive anti-theft system (PATS)

– Sensor (And)

– Work of a control lamp of candles of heating

– Battery

– Powertrain control module (PCM)

3. If an obvious cause of the problem you identified or described by the client is found, eliminate it before proceeding to further actions (if possible).

4. If the cause is not visually obvious, check the symptom and refer to WDS to retrieve DTCs (DTC).

5. If no problem DTCs are found, refer to the Symptom Table below to continue diagnosis.

Symptom table

State	Possible Causes	Action
• The engine does not turn over and the control lamp of the glow plugs is on	•DTC registered.	•CHECK if the glow plug warning light comes on when the engine is started and then goes out and stays off. If the glow plug warning light starts flashing, REFER to WDS.
•Engine does not crank	•Battery	•CHECK the condition of the battery. REFER to WDS.
	•PATS	•CHECK if the PATS LED goes out within 3 seconds after the ignition is turned on. See Section 419-01A / 419-01B for more information.
	• Fused fuse for starter interlock relay. •Starter relay.	•CHECK the fuse. If the fuse is blown, INSTALL a new fuse. If the fuse has blown again, REFER to WDS.
	• The relay of blocking of a starter. • Electrical ground circuit of the starter inhibit relay. • Inclusion of the power relay of a starter. •Power relay.	•PERFORM Relay Test. REFER to Wiring Diagrams.
	•Ignition switch	• For more information, see Section 211-05.
	•Powertrain control module (PCM).	• INSPECTION instrument panel. If the instrument panel does not illuminate, INSTALL a new PCM. If the instrument panel is OK, CONFER TO WDS.
• Engine cranks but does not start and the glow plug warning light is on.	•DTC registered.	•CHECK if the glow plug warning light comes on when the engine is started and then goes out and stays off. If the glow plug warning light starts flashing, REFER to WDS.
•Engine cranks but does not start	• The high pressure fuel pump control module and the PCM do not match.	• REFER to WDS.
	• Shtekerny socket of the block of management of the fuel pump of a high pressure.	• CHECK correct installation of the locking element of the plug connector of the high pressure fuel pump control unit. Shake the plug and make sure the plug is installed correctly.
	• High pressure fuel pump relay.	•PERFORM Relay Test. REFER to wiring diagrams.
	•Inertial fuel cut-off switch (IFS)	• RESET the IFS switch.
	• Clogged fuel filter.	•Install a new fuel filter. See Section 310-01A for more information.
	• Damage or blockage of fuel lines.	• INSTALL new fuel lines if necessary.
	• Penetration of air into fuel lines.	• For more information, see Section 310-00A.
	• Crankshaft position sensor (CKP)	• REFER to WDS.
	• Incorrect valve timing.	• Check valve timing. See Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E for more information.
	•PCM.	• REFER to WDS.
	•High pressure fuel pump	• REFER to WDS.
• Poor start and glow plug warning light on	•DTC registered.	• REFER to WDS.
•Bad start	• Clogged fuel filter.	•Install a new fuel filter. See Section 310-01A for more information.
	• Penetration of air into fuel lines.	• For more information, see Section 310-00A.
	•Clogged air filter element.	• CHECK the air filter element for clogging or obstruction. REMOVE and visually INSPECT the air filter element for obstruction. INSTALL a new air filter element if necessary. See Section 303-12 for more information.
	• Fuse for glow plug relay.	•CHECK the fuse If the fuse is blown, INSTALL a new fuse. If the fuse has blown again, REFER to WDS.
	• Relay for glow plugs.	•PERFORM Relay Test. REFER to wiring diagrams.
	•Candle (And) heating	• Refer to Section 303-07A / 303-07B / 303-07C / 303-07D for more information.
	• High pressure fuel pump relay fuse.	•CHECK the fuse. If the fuse is blown, INSTALL a new fuse. If the fuse has blown again, REFER to WDS.
	• High pressure fuel pump relay.	•PERFORM Relay Test. REFER to wiring diagrams.
	•Leakage (And) in the fuel system	•CHECK the system for fuel leaks. REPAIR the system if necessary.
	• Penetration of air into fuel lines.	• For more information, see Section 310-00A.
	• Injection distribution of the high pressure fuel pump.	• REFER to WDS.
	• CKP sensor.	• REFER to WDS.
	• Cylinder head temperature sensor (SNT)	• REFER to WDS.
	• Air intake temperature sensor (IAT).	• REFER to WDS.
	•Manifold absolute pressure sensor (MAP)	• REFER to WDS.
	• Wrong type of engine oil.	• INSTALL a new oil filter and fill with 5W/30 engine oil.
	• Incorrect power steering fluid.	• Drain the power steering fluid from the power steering system and refill the system with the correct fluid. See Section 211-00 for more information.
	•Fuel burner (And)	• INSTALL a new set of high pressure fuel lines and fuel injectors. For more information refer to Fuel Injectors available in this section.
	• Shtekerny socket of the block of management of the fuel pump of a high pressure.	• CHECK correct installation of the locking element of the plug connector of the high pressure fuel pump control unit. Shake the plug and make sure the plug is installed correctly.
	•High pressure fuel pump	• REFER to WDS.
• Engine starts but stops immediately and glow plug warning light flashes	•DTC registered.	• REFER to WDS.
•Engine starts but stops immediately	•Clogged air filter element.	• CHECK the air filter element for blockage or obstruction. REMOVE and visually INSPECT the air filter element for obstruction. INSTALL a new air filter element if necessary. See Section 303-12 for more information.
	• Penetration of air into fuel lines.	• For more information, see Section 310-00A.
	• CKP sensor.	• REFER to WDS.
	•CHT sensor.	• REFER to WDS.
	•IAT sensor.	• REFER to WDS.
	• MAP sensor.	• REFER to WDS.
	• PCM relay.	•PERFORM Relay Test. REFER to wiring diagrams.
	•PCM.	• REFER to WDS.
	•High pressure fuel pump	• REFER to WDS.
• Poor engine idling and glow plug warning light on	•DTC registered.	• REFER to WDS.
•Poor idling performance	•Low fuel level in the fuel tank.	•CHECK if the fuel level in the fuel tank is more than four liters. If the fuel level in the fuel tank is less than four liters, REFILL fuel.
	•Clogged air filter element.	• CHECK the air filter element for blockage or obstruction. REMOVE and visually INSPECT the air filter element for obstruction. INSTALL a new air filter element if necessary. See Section 303-12 for more information.
	• Clogged fuel filter.	•Install a new fuel filter. See Section 310-01A for more information.
	• Penetration of air into fuel lines.	• For more information, see Section 310-00A.
	• Wrong type or contamination of fuel.	•CHECK for signs of contamination such as strange odors from the fuel tank. •CHECK for signs of water or gasoline in diesel fuel • If fuel contamination is found, Drain the entire fuel system. FLUSH the entire fuel system with clean diesel fuel and INSTALL a new fuel filter. See Section 310-00A for more information. AND For more information, refer to Section 310-01A. INSTALL a new high pressure fuel pump, fuel injectors and high pressure fuel feed lines. For more information, refer to High Pressure Fuel Pump, Fuel Injectors available in this section.
	• CKP sensor.	• REFER to WDS.
	•CHT sensor.	• REFER to WDS.
	•IAT sensor.	• REFER to WDS.
	• MAP sensor.	• REFER to WDS.
	•Fuel burner (And)	• INSTALL a new set of fuel injectors and high pressure fuel feed lines. For more information refer to Fuel Injectors available in this section.
	•High pressure fuel pump	• REFER to WDS.
•Jerking when the engine is running and the control lamp of the glow plugs is on	•DTC registered.	• REFER to WDS.
•Jerking when the engine is running	•Low fuel level.	•CHECK if the fuel level in the fuel tank is more than four liters. If the fuel level in the fuel tank is less than four liters, REFILL fuel.
	• Penetration of air into fuel lines.	• For more information, see Section 310-00A.
	• Accelerator pedal position sensor (APP).	• REFER to WDS.
	•Fuel burner (And)	• INSTALL a new set of fuel injectors and high pressure fuel feed lines. For more information refer to Fuel Injectors available in this section.
	•High pressure fuel pump	• REFER to WDS.
•Loss of engine power and glow plug warning light on	•DTC registered.	• REFER to WDS.
•Loss of engine power	• Sticking brakes.	•CHECK the brake system. See Section 206-00 for more information.
	•Vehicle overloaded or increased aerodynamic drag (roof racks, towing, etc).	• TELL the customer about the impact of vehicle overload and aerodynamic drag on fuel consumption.
	•Clogged air filter element.	• CHECK the air filter element for blockage or obstruction. REMOVE and visually INSPECT the air filter element for obstruction. INSTALL a new air filter element if necessary. See Section 303-12 for more information.
	• Charge air cooler clogged or cracked. • The charge air cooler piping is cracked (in the presence of). • Charge air cooler clamps are cracked or missing (in the presence of).	• INSPECT for visible signs of damage or obstruction. CLEAN, REPAIR or INSTALL new elements as necessary.
	• Clogged fuel filter.	•Install a new fuel filter. See Section 310-01A for more information.
	•APP sensor.	• REFER to WDS.
	•CHT sensor.	• REFER to WDS.
	• MAP sensor.	• REFER to WDS.
	• Penetration of air into fuel lines.	• For more information, see Section 310-00A.
	• Clogged catalytic converter.	• CHECK if the catalytic converter rattles when tapped gently. If noise is present, REMOVE and visually INSPECT the catalytic converter for damage. INSTALL a new catalytic converter if necessary. See Section 309-00 for more information.
	• Exhaust gas recirculation valve (EGR)	• Refer to Section 303-08A / 303-08B for more information.
	•Turbocharger	• For more information, refer to Section 303-04A / 303-04B / 303-04C / 303-04D / 303-04E / 303-04F / 303-04G.
	• Incorrect valve timing.	• CHECK the valve timing. See Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E for more information.
	•Fuel burner (And)	• INSTALL a new set of fuel injectors and high pressure fuel feed lines. For more information refer to Fuel Injectors available in this section.
	• Wrong type or contamination of fuel.	•CHECK for signs of contamination such as strange odors from the fuel tank. •CHECK for signs of water or gasoline in diesel fuel. • If fuel contamination is found, empty the fuel system. FLUSH the fuel system with clean diesel fuel and INSTALL a new fuel filter. See Section 310-00A for more information. and See Section 310-01A for more information. INSTALL a new high pressure fuel pump, fuel injectors and high pressure fuel feed lines. For more information, refer to High Pressure Fuel Pump, Fuel Injectors available in this section.
	•High pressure fuel pump	• REFER to WDS.
• Black smoke at idle and glow plug warning light on	•DTC registered.	• REFER to WDS.
• Black smoke when the engine is idling	•Clogged air filter element.	• CHECK the air filter element for blockage or obstruction. REMOVE and visually INSPECT the air filter element for obstruction. INSTALL a new air filter element if necessary. See Section 303-12 for more information.
	•CHT sensor.	• REFER to WDS.
	•IAT sensor.	• REFER to WDS.
	• MAP sensor.	• REFER to WDS.
	•Fuel burner (And)	• INSTALL a new set of fuel injectors and high pressure fuel feed lines. For more information refer to Fuel Injectors available in this section.
	• Incorrect valve timing.	• CHECK the valve timing. See Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E for more information.
	•High pressure fuel pump	• REFER to WDS.
•Excessive black smoke on acceleration and glow plug warning light on	•DTC registered.	• REFER to WDS.
•Increased black smoke on acceleration	•APP sensor.	• REFER to WDS.
	• CKP sensor.	• REFER to WDS.
	• Wrong type or contamination of fuel.	•CHECK for signs of contamination such as strange odors from the fuel tank. •CHECK for signs of water or gasoline in diesel fuel • If fuel contamination is found, Drain the entire fuel system. FLUSH the fuel system with clean diesel fuel and INSTALL a new fuel filter. See Section 310-00A for more information. and See Section 310-01A for more information. INSTALL a new high pressure fuel pump, fuel injectors and high pressure fuel feed lines. For more information, refer to High Pressure Fuel Pump, Fuel Injectors available in this section.
	•Fuel burner (And)	• INSTALL a new set of fuel injectors and high pressure fuel feed lines. For more information refer to Fuel Injectors available in this section.
	•High pressure fuel pump	• REFER to WDS.
•Black smoke when cruising and glow plug warning light on	•DTC registered.	• REFER to WDS.
•Black smoke when driving at "cruising" speed	•Clogged air filter element.	• CHECK the air filter element for blockage or obstruction. REMOVE and visually INSPECT the air filter element for obstruction. INSTALL a new air filter element if necessary. See Section 303-12 for more information.
	•CHT sensor.	• REFER to WDS.
	•IAT sensor.	• REFER to WDS.
	• MAP sensor.	• REFER to WDS.
	• Vacuum lines.	• CHECK for proper installation of all vacuum lines and for signs of air leakage/blockage. REPAIR or, if necessary, INSTALL a new vacuum line (And).
	• EGR valve stuck open. • Vacuum EGR switching valve.	• REFER to WDS. CHECK the EGR valve by lifting it off the seat with the vacuum pump connected to the vacuum line; release the vacuum. If the valve does not stick, a metallic clang should be heard.
	•Turbocharger	• For more information, refer to Section 303-04A / 303-04B / 303-04C / 303-04D / 303-04E / 303-04F / 303-04G.
	•Fuel burner (And)	• INSTALL a new set of fuel injectors and high pressure fuel feed lines. For more information refer to Fuel Injectors available in this section.
	•High pressure fuel pump	• REFER to WDS.
• Blue smoke and glow plug warning light on	•DTC registered.	• REFER to WDS.
•Blue smoke	• Combustion of oil in the engine.	•PERFORM a 1000 km controlled oil flow test (600 miles). MAKE SURE that the oil consumption is less than 1 liter per 1000 km (600 miles).
	• Wrong type or contamination of fuel.	•CHECK for signs of contamination such as strange odors from the fuel tank. •CHECK for signs of water or gasoline in diesel fuel. • If fuel contamination is found, Drain the entire fuel system. FLUSH the fuel system with clean diesel fuel and INSTALL a new fuel filter. See Section 310-00A for more information. and See Section 310-01A for more information. INSTALL a new high pressure fuel pump, fuel injectors and high pressure fuel feed lines. For more information, refer to High Pressure Fuel Pump, Fuel Injectors available in this section.
	• Worn or damaged valve guides, piston rings, cylinders, cylinder head or gasket.	• REMOVE and inspect the cylinder head, pistons and cylinders for signs of wear. See Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E for more information.
	• Engine ventilation system.	• INSPECT engine breather lines for signs of constriction or blockage. Make any necessary repairs.
	• Leakage of turbocharger oil seals. •Clogged or damaged turbocharger oil return line.	• For more information, refer to Section 303-04A / 303-04B / 303-04C / 303-04D / 303-04E / 303-04F / 303-04G.
•White smoke and glow plug warning light on	•DTC registered.	• REFER to WDS.
•White smoke	•Water in fuel.	• DRAIN water from the fuel filter, clean fuel should remain. If there is still contaminated fuel, EMPTY the entire fuel system. FLUSH the fuel system with clean diesel fuel and INSTALL a new fuel filter. See Section 310-00A for more information. and See Section 310-01A for more information. INSTALL a new high pressure fuel pump, fuel injectors and high pressure fuel feed lines. For more information, refer to High Pressure Fuel Pump, Fuel Injectors available in this section.
	• Incorrect valve timing.	• Check valve timing. See Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E for more information.
	• Coolant in the combustion chamber.	• PERFORM a leak test on the cooling system. See Section 303-03 for more information. REMOVE and INSPECT cylinder head, cylinder head gasket and cylinders for wear or damage.
•Misfire and glow plug warning light on	•DTC registered.	• REFER to WDS.
•Misfire	•Low fuel level in the fuel tank.	•CHECK if the fuel level in the fuel tank is more than four liters. If the fuel level in the fuel tank is less than four liters, REFILL fuel.
	• Cracking or damage to high pressure fuel supply lines.	• CHECK the high pressure fuel supply lines for signs of damage. INSTALL a new fuel supply line if necessary (s) high pressure.
	• Penetration of air into fuel lines.	• For more information, see Section 310-00A.
	Wrong type or contamination of fuel.	•CHECK for signs of contamination such as strange odors from the fuel tank. •CHECK for signs of water or gasoline in diesel fuel • If fuel contamination is found, Drain the entire fuel system. FLUSH the fuel system with clean diesel fuel and INSTALL a new fuel filter. See Section 310-00A for more information. and See Section 310-01A for more information. INSTALL a new high pressure fuel pump, fuel injectors and high pressure fuel feed lines. For more information, refer to High Pressure Fuel Pump, Fuel Injectors available in this section.
	•CHT sensor.	• REFER to WDS.
	•Fuel burner (And)	• INSTALL a new set of fuel injectors and high pressure fuel feed lines. For more information refer to Fuel Injectors available in this section.
	•Low compression in the cylinders.	• For more information, see Section 303-00.
	• Worn or damaged valves, valve lifters or camshafts.	• REMOVE the cylinder head. Visually INSPECT it for signs of wear or damage. See Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E for more information.
	• Damage to the cylinder head gasket.	• REMOVE and INSPECT the cylinder head gasket and cylinders for wear or damage. See Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E for more information.
	• Engine operating temperature too high.	• For more information, see Section 303-03.
	•High pressure fuel pump	• REFER to WDS.
• Engine knock at idle and glow plug warning light on	•DTC registered.	• REFER to WDS.
•Engine knocking when idling	•Low engine oil level.	•Check the engine oil level. REFILL engine oil if necessary.
	• Wrong type or contamination of fuel.	•CHECK for signs of contamination such as strange odors from the fuel tank. •CHECK for signs of water or gasoline in diesel fuel • If fuel contamination is found, Drain the entire fuel system. FLUSH the fuel system with clean diesel fuel and INSTALL a new fuel filter. See Section 310-00A for more information. and See Section 310-01A for more information. INSTALL a new high pressure fuel pump, fuel injectors and high pressure fuel feed lines. For more information, refer to High Pressure Fuel Pump, Fuel Injectors available in this section.
	• Incorrect valve timing.	• CHECK the valve timing. See Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E for more information.
	• CKP sensor.	• REFER to WDS.
	•Excessive carbon deposits.	• REMOVE and INSPECT the cylinder head for signs of carbon deposits. INSPECT pistons for signs of carbon deposits. See Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E for more information.
	•Fuel burner (And)	• INSTALL a new set of fuel injectors and high pressure fuel feed lines. For more information refer to Fuel Injectors available in this section.
	•High pressure fuel pump	• REFER to WDS.
	• Worn or damaged oil pump. • Worn or damaged timing chain or sprocket. • Serious engine failure of a mechanical nature.	• Refer to Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E for more information.
•Engine knocking on acceleration and glow plug warning light on	•DTC registered.	• REFER to WDS.
• Engine knock on acceleration	•Fuel burner (And)	• INSTALL a new set of fuel injectors and high pressure fuel feed lines. For more information refer to Fuel Injectors available in this section.
	• Serious engine failure of a mechanical nature.	• Refer to Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E for more information.
	•High pressure fuel pump	• REFER to WDS.
•Increased fuel consumption and glow plug warning light on	•DTC registered.	• REFER to WDS.
•Increased fuel consumption	• Sticking brakes.	•CHECK the brake system. See Section 206-00 for more information.
	•Vehicle overloaded or increased aerodynamic drag (roof racks, towing, etc).	• TELL the customer about the impact of vehicle overload and aerodynamic drag on fuel consumption.
	•Clogged air filter element.	• CHECK the air filter element for blockage or obstruction. REMOVE and visually INSPECT the air filter element for obstruction. INSTALL a new air filter element if necessary. See Section 303-12 for more information.
	•Leakage (And) in the fuel system	•CHECK the system for leaks (ek) fuel. REPAIR the system if necessary.
	•CHT sensor. • MAP sensor.	• REFER to WDS.
	• Wrong type of engine oil.	• INSTALL a new oil filter and fill with 5W/30 engine oil.
	• Worn or slipping clutch.	• INSPECT the clutch disc. See Section 308-00 for more information.
	•Generator.	• For more information, see Section 414-00.
	• EGR valve stuck open.	• REFER to WDS. CHECK the EGR valve by lifting it off the seat with the vacuum pump connected to the vacuum line; release the vacuum. If the valve does not stick, a metallic clang should be heard.
	• Penetration of air into fuel lines.	• For more information, see Section 310-00A.
	• Incorrect valve timing.	• CHECK the valve timing. See Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E for more information.
	•Turbocharger •Turbine compressor bypass valve actuator.	• For more information, refer to Section 303-04A / 303-04B / 303-04C / 303-04D / 303-04E / 303-04F / 303-04G.
	•Low compression in the cylinders.	• For more information, see Section 303-00.
	•Fuel burner (And)	• INSTALL a new set of fuel injectors and high pressure fuel feed lines. For more information refer to Fuel Injectors available in this section.
	•High pressure fuel pump	• REFER to WDS.

Diagnostics and checks (1.8 l diesel)

Inspection and verification

Visual Inspection Table

Symptom table

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