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

Inspection and verification

WARNING: Do not smoke or carry a lighted cigarette or open flame of any kind when working on or near fuel-related components. Highly flammable mixtures are always present in such situations and may ignite. Failure to follow these instructions may result in injury.

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

CAUTION: Diesel fuel injection equipment is manufactured to very precise tolerances and very small clearances. The high pressure fuel pump is completely electronic and has no levers or cables. Do not lubricate the terminals or contacts of the high pressure fuel pump. It is therefore especially important to maintain absolute cleanliness when working on these components. Always plug any open ports or lines.

NOTE: In addition to its normal function, the glow plug indicator lamp also functions as a check engine light that will flash continuously when the powertrain control module (PCM) records a serious diagnostic trouble code (DTC). Less serious DTCs are also stored in the PCM's memory, but will only illuminate when the WDS DTC system check is performed.

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 overall vehicle drivability.

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 vehicle requires refueling to prevent the fuel system from running dry.

1. Check the customer complaint.

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

Visual inspection table

Mechanical factors

Electrical factors

– Fuel leak(s)

- Fuel filter

– Air filter element

– Fuel supply lines

– Vacuum line(s)/vacuum line connections

– Hose(s)/hose connections

– Pipelines/pipeline connections

– Fuel contamination

– High pressure fuel supply lines

– Fuel injector(s)

– High pressure fuel pump

– Fuse(s)

- Relay

- Wiring harness

– Electrical plug(s)

– Operation of the Passive Anti-Theft System (PATS) LED

– Sensor(s)

– Operation of the glow plug indicator lamp

- Battery

– Powertrain Control Module (PCM)

3. If an obvious cause for the problem you have identified or the customer has described is found, correct it (if possible) before proceeding with further actions.

4. If the cause is not visually obvious, check the symptom of the malfunction and refer to WDS to retrieve diagnostic trouble codes (DTCs).

5. If no problem related DTCs are found, proceed to the Symptom Table below to continue diagnostics.

Table of signs of malfunction

State	Possible Causes	Action
•The engine does not turn over and the glow plug indicator light is on	•DTC has been registered.	•CHECK if the glow plug indicator light comes on when the engine is started and then goes out and remains off. If the glow plug indicator light starts to flash, CONSULT WDS.
•The engine does not turn over	•Battery	•CHECK battery condition. CONTACT WDS.
	•PATS	•CHECK if the PATS LED goes out within 3 seconds after the ignition is turned on. For additional information, refer to Section 419-01A / 419-01B.
	•Starter interlock relay fuse. •Starter relay.	* CHECK the fuse box. If the fuse is blown, INSTALL a new fuse. If the fuse blows again, CONTACT the WDS.
	•Starter lock relay. •Starter interlock relay grounding circuit. •Turning on the starter power relay. •Power relay.	•PERFORM Relay Test. REFER to Wiring Diagrams.
	•Ignition switch	•For additional information, see Section 211-05.
	•Powertrain Control Module (PCM).	•INSPECT the instrument cluster. If the instrument cluster does not illuminate, INSTALL a new PCM. If the instrument cluster is OK, REFER to WDS.
•The engine cranks but does not start and the glow plug indicator light is on.	•DTC has been registered.	•CHECK if the glow plug indicator light comes on when the engine is started and then goes out and remains off. If the glow plug indicator light starts to flash, CONSULT WDS.
•The engine turns over but does not start	•The high pressure fuel pump control unit and PCM do not match.	•CONSULT WDS.
	•Plug connector of the high-pressure fuel pump control unit.	•CHECK that the locking element of the high-pressure fuel pump control unit plug connector is installed correctly. Rock the plug connector and make sure that the plug connector is installed correctly.
	•High pressure fuel pump relay.	•PERFORM Relay Test. REFER to wiring diagrams.
	•Inertial Fuel Shutoff Switch (IFS)	•READIT the IFS switch.
	•Clogged fuel filter.	•Install a new fuel filter. Refer to Section 310-01A for additional information.
	•Damaged or blocked fuel lines.	•INSTALL new fuel lines if necessary.
	•Air penetration into fuel lines.	•For additional information, refer to Section 310-00A.
	•Crankshaft Position Sensor (CKP)	•CONSULT WDS.
	•Incorrect valve timing.	•Check the valve timing. For additional information, refer to Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E.
	•PCM.	•CONSULT WDS.
	•High pressure fuel pump	•CONSULT WDS.
•Poor starting and glow plug indicator light is on	•DTC has been registered.	•CONSULT WDS.
•Poor start	•Clogged fuel filter.	•Install a new fuel filter. Refer to Section 310-01A for additional information.
	•Air penetration into fuel lines.	•For additional information, refer to Section 310-00A.
	•Clogging of the air filter element.	•CHECK the air cleaner element for clogging or restriction. REMOVE and visually INSPECT the air cleaner element for clogging. INSTALL a new air cleaner element if necessary. Refer to Section 303-12 for additional information.
	•Glow plug relay fuse.	* CHECK THE fuse box If the fuse box is burned out, INSTALL a new fuse box. If the fuse blows again, CONTACT the WDS.
	•Glow plug relay.	•PERFORM Relay Test. REFER to wiring diagrams.
	•Glow plug(s)	•For additional information, refer to Section 303-07A / 303-07B / 303-07C / 303-07D.
	•Fuse for high pressure fuel pump relay.	* CHECK the fuse box. If the fuse is blown, INSTALL a new fuse. If the fuse blows again, CONTACT the WDS.
	•High pressure fuel pump relay.	•PERFORM Relay Test. REFER to wiring diagrams.
	• Leak(s) in the fuel system	•CHECK the system for fuel leaks. REPAIR the system if necessary.
	•Air penetration into fuel lines.	•For additional information, refer to Section 310-00A.
	•Distribution of injection of high-pressure fuel pump.	•CONSULT WDS.
	•CKP sensor.	•CONSULT WDS.
	•Cylinder head temperature sensor (CHT)	•CONSULT WDS.
	•Intake Air Temperature (IAT) sensor.	•CONSULT WDS.
	•Manifold Absolute Pressure (MAP) Sensor	•CONSULT 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 system fluid and refill the system with the correct fluid. Refer to Section 211-00 for additional information.
	•Fuel injector(s)	•INSTALL a new set of high pressure fuel lines and fuel injectors. For additional information, refer to Fuel Injectors in this section.
	•Plug connector of the high-pressure fuel pump control unit.	•CHECK that the locking element of the high-pressure fuel pump control unit plug connector is installed correctly. Rock the plug connector and make sure that the plug connector is installed correctly.
	•High pressure fuel pump	•CONSULT WDS.
•The engine starts but immediately stops and the glow plug indicator light flashes	•DTC has been registered.	•CONSULT WDS.
•The engine starts but stops immediately	•Clogging of the air filter element.	•CHECK the air cleaner element for blockage or obstruction. REMOVE and visually INSPECT the air cleaner element for obstruction. INSTALL a new air cleaner element if necessary. Refer to Section 303-12 for additional information.
	•Air penetration into fuel lines.	•For additional information, refer to Section 310-00A.
	•CKP sensor.	•CONSULT WDS.
	•CHT sensor.	•CONSULT WDS.
	•IAT sensor.	•CONSULT WDS.
	•MAP sensor.	•CONSULT WDS.
	•PCM relay.	•PERFORM Relay Test. REFER to wiring diagrams.
	•PCM.	•CONSULT WDS.
	•High pressure fuel pump	•CONSULT WDS.
•Poor engine performance at idle and glow plug indicator light on	•DTC has been registered.	•CONSULT WDS.
•Poor idle 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, ADD fuel.
	•Clogging of the air filter element.	•CHECK the air cleaner element for blockage or obstruction. REMOVE and visually INSPECT the air cleaner element for obstruction. INSTALL a new air cleaner element if necessary. Refer to Section 303-12 for additional information.
	•Clogged fuel filter.	•Install a new fuel filter. Refer to Section 310-01A for additional information.
	•Air penetration into fuel lines.	•For additional information, refer to Section 310-00A.
	•Incorrect type or contamination of fuel.	•CHECK for signs of contamination such as strange odors coming 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. Refer to Section 310-00A for additional information. And Refer to Section 310-01A for additional information. INSTALL a new high-pressure fuel pump, fuel injectors, and high-pressure fuel supply lines. Refer to High-Pressure Fuel Pump, Fuel Injectors in this section for additional information.
	•CKP sensor.	•CONSULT WDS.
	•CHT sensor.	•CONSULT WDS.
	•IAT sensor.	•CONSULT WDS.
	•MAP sensor.	•CONSULT WDS.
	•Fuel injector(s)	•INSTALL a new set of fuel injectors and high pressure fuel supply lines. For additional information, refer to Fuel Injectors in this section.
	•High pressure fuel pump	•CONSULT WDS.
• Jerking when the engine is running and the glow plug indicator light is on	•DTC has been registered.	•CONSULT 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, ADD fuel.
	•Air penetration into fuel lines.	•For additional information, refer to Section 310-00A.
	•Accelerator pedal position sensor (APP).	•CONSULT WDS.
	•Fuel injector(s)	•INSTALL a new set of fuel injectors and high pressure fuel supply lines. For additional information, refer to Fuel Injectors in this section.
	•High pressure fuel pump	•CONSULT WDS.
•Loss of engine power and glow plug indicator light on	•DTC has been registered.	•CONSULT WDS.
•Loss of engine power	•Brake drag.	•CHECK the brake system. Refer to Section 206-00 for additional information.
	•The vehicle is overloaded or has increased aerodynamic drag (roof racks, towing, etc.).	•TELL the customer about the impact of vehicle loading and aerodynamic drag on fuel consumption.
	•Clogging of the air filter element.	•CHECK the air cleaner element for blockage or obstruction. REMOVE and visually INSPECT the air cleaner element for obstruction. INSTALL a new air cleaner element if necessary. Refer to Section 303-12 for additional information.
	•The charge air cooler is clogged or cracked. •The charge air cooler line has cracks (if any). •Charge air cooler clamps are cracked or missing (if equipped).	•INSPECT for visible signs of damage or clogging CLEAN, REPAIR or INSTALL new components if necessary.
	•Clogged fuel filter.	•Install a new fuel filter. Refer to Section 310-01A for additional information.
	•APP sensor.	•CONSULT WDS.
	•CHT sensor.	•CONSULT WDS.
	•MAP sensor.	•CONSULT WDS.
	•Air penetration into fuel lines.	•For additional information, refer to Section 310-00A.
	•Clogging of the catalytic converter.	•CHECK if the catalytic converter rattles when gently tapping it. If noise is present, REMOVE and visually INSPECTE the catalytic converter for damage. INSTALL a new catalytic converter if necessary. Refer to Section 309-00 for additional information.
	•Exhaust Gas Recirculation (EGR) Valve	•For additional information, refer to Section 303-08A / 303-08B.
	•Turbocharger	•For additional information, refer to Section 303-04A / 303-04B / 303-04C / 303-04D / 303-04E / 303-04F / 303-04G.
	•Incorrect valve timing.	•CHECK valve timing. For additional information, refer to Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E.
	•Fuel injector(s)	•INSTALL a new set of fuel injectors and high pressure fuel supply lines. For additional information, refer to Fuel Injectors in this section.
	•Incorrect type or contamination of fuel.	•CHECK for signs of contamination such as strange odors coming from the fuel tank. •CHECK for signs of water or gasoline in diesel fuel. •If fuel contamination is found, drain the fuel system. FLUSH the fuel system with clean diesel fuel and INSTALL a new fuel filter. Refer to Section 310-00A for additional information. and Refer to Section 310-01A for additional information. INSTALL a new high-pressure fuel pump, fuel injectors, and high-pressure fuel supply lines. Refer to High-Pressure Fuel Pump, Fuel Injectors in this section for additional information.
	•High pressure fuel pump	•CONSULT WDS.
•Black smoke when idling and glow plug indicator light is on	•DTC has been registered.	•CONSULT WDS.
•Black smoke when the engine is idling	•Clogging of the air filter element.	•CHECK the air cleaner element for blockage or obstruction. REMOVE and visually INSPECT the air cleaner element for obstruction. INSTALL a new air cleaner element if necessary. Refer to Section 303-12 for additional information.
	•CHT sensor.	•CONSULT WDS.
	•IAT sensor.	•CONSULT WDS.
	•MAP sensor.	•CONSULT WDS.
	•Fuel injector(s)	•INSTALL a new set of fuel injectors and high pressure fuel supply lines. For additional information, refer to Fuel Injectors in this section.
	•Incorrect valve timing.	•CHECK valve timing. For additional information, refer to Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E.
	•High pressure fuel pump	•CONSULT WDS.
• Excessive black smoke when accelerating and glow plug indicator light is on	•DTC has been registered.	•CONSULT WDS.
•Increased amount of black smoke when accelerating	•APP sensor.	•CONSULT WDS.
	•CKP sensor.	•CONSULT WDS.
	•Incorrect type or contamination of fuel.	•CHECK for signs of contamination such as strange odors coming 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. Refer to Section 310-00A for additional information. and Refer to Section 310-01A for additional information. INSTALL a new high-pressure fuel pump, fuel injectors, and high-pressure fuel supply lines. Refer to High-Pressure Fuel Pump, Fuel Injectors in this section for additional information.
	•Fuel injector(s)	•INSTALL a new set of fuel injectors and high pressure fuel supply lines. For additional information, refer to Fuel Injectors in this section.
	•High pressure fuel pump	•CONSULT WDS.
•Black smoke when driving at cruising speed and glow plug indicator light is on	•DTC has been registered.	•CONSULT WDS.
•Black smoke when driving at cruising speed	•Clogging of the air filter element.	•CHECK the air cleaner element for blockage or obstruction. REMOVE and visually INSPECT the air cleaner element for obstruction. INSTALL a new air cleaner element if necessary. Refer to Section 303-12 for additional information.
	•CHT sensor.	•CONSULT WDS.
	•IAT sensor.	•CONSULT WDS.
	•MAP sensor.	•CONSULT WDS.
	•Vacuum lines.	•CHECK all vacuum lines for proper installation and signs of air leaks/clogging. REPAIR or INSTALL new vacuum line(s) if necessary.
	•EGR valve stuck in the open position. •EGR vacuum switching valve.	•REFER to WDS. CHECK the EGR valve by lifting it off the seat with a vacuum pump connected to the vacuum line; release the vacuum. If the valve is not sticking, a metallic clanking sound should be heard.
	•Turbocharger	•For additional information, refer to Section 303-04A / 303-04B / 303-04C / 303-04D / 303-04E / 303-04F / 303-04G.
	•Fuel injector(s)	•INSTALL a new set of fuel injectors and high pressure fuel supply lines. For additional information, refer to Fuel Injectors in this section.
	•High pressure fuel pump	•CONSULT WDS.
•Blue smoke and glow plug indicator light is on	•DTC has been registered.	•CONSULT WDS.
•Blue smoke	•Oil combustion in the engine.	•PERFORM a 1000 km (600 mile) controlled oil consumption test. ENSURE that oil consumption is less than 1 L per 1000 km (600 miles).
	•Incorrect type or contamination of fuel.	•CHECK for signs of contamination such as strange odors coming 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. Refer to Section 310-00A for additional information. and Refer to Section 310-01A for additional information. INSTALL a new high-pressure fuel pump, fuel injectors, and high-pressure fuel supply lines. Refer to High-Pressure Fuel Pump, Fuel Injectors in this section for additional information.
	•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. For additional information, refer to Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E.
	•Engine ventilation system.	•CHECK engine breather lines for signs of restriction or blockage. Repair as necessary.
	• Leaking turbocharger oil seals. •Clogging or damage to the turbocharger return oil line.	•For additional information, refer to Section 303-04A / 303-04B / 303-04C / 303-04D / 303-04E / 303-04F / 303-04G.
•White smoke and glow plug indicator light is on	•DTC has been registered.	•CONSULT WDS.
•White smoke	•Water in fuel.	•DRAIN the fuel filter to remove any water, leaving clean fuel. If contaminated fuel still remains, DRAIN the entire fuel system. FLUSH the fuel system with clean diesel fuel and INSTALL a new fuel filter. Refer to Section 310-00A for additional information. and Refer to Section 310-01A for additional information. INSTALL a new high-pressure fuel pump, fuel injectors, and high-pressure fuel supply lines. Refer to High-Pressure Fuel Pump, Fuel Injectors in this section for additional information.
	•Incorrect valve timing.	•Check the valve timing. For additional information, refer to Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E.
	•Coolant in the combustion chamber.	•PERFORM a cooling system leak test. Refer to Section 303-03 for additional information. REMOVE and INSPECT the cylinder head, head gasket, and cylinders for wear or damage.
•Misfiring and glow plug indicator light on	•DTC has been registered.	•CONSULT WDS.
•Misfires	•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, ADD fuel.
	•Cracking or damage to high-pressure fuel supply lines.	•CHECK the high pressure fuel supply lines for signs of damage. INSTALL new high pressure fuel supply line(s) if necessary.
	•Air penetration into fuel lines.	•For additional information, refer to Section 310-00A.
	Incorrect type or contamination of fuel.	•CHECK for signs of contamination such as strange odors coming 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. Refer to Section 310-00A for additional information. and Refer to Section 310-01A for additional information. INSTALL a new high-pressure fuel pump, fuel injectors, and high-pressure fuel supply lines. Refer to High-Pressure Fuel Pump, Fuel Injectors in this section for additional information.
	•CHT sensor.	•CONSULT WDS.
	•Fuel injector(s)	•INSTALL a new set of fuel injectors and high pressure fuel supply lines. For additional information, refer to Fuel Injectors in this section.
	•Low compression in cylinders.	•For additional 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. For additional information, refer to Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E.
	•Damaged cylinder head gasket.	•REMOVE and INSPECT the cylinder head gasket and cylinders for wear or damage. For additional information, refer to Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E.
	•Engine operating temperature too high.	•For additional information, see Section 303-03.
	•High pressure fuel pump	•CONSULT WDS.
•Engine detonation at idle and glow plug indicator light on	•DTC has been registered.	•CONSULT WDS.
•Engine detonation when idling	•Low engine oil level.	•Check engine oil level. FILL with engine oil if necessary.
	•Incorrect type or contamination of fuel.	•CHECK for signs of contamination such as strange odors coming 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. Refer to Section 310-00A for additional information. and Refer to Section 310-01A for additional information. INSTALL a new high-pressure fuel pump, fuel injectors, and high-pressure fuel supply lines. Refer to High-Pressure Fuel Pump, Fuel Injectors in this section for additional information.
	•Incorrect valve timing.	•CHECK valve timing. For additional information, refer to Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E.
	•CKP sensor.	•CONSULT WDS.
	•Excessive carbon deposits.	•REMOVE and INSPECT the cylinder head for signs of carbon deposits. INSPECT the pistons for signs of carbon deposits. Refer to Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E for additional information.
	•Fuel injector(s)	•INSTALL a new set of fuel injectors and high pressure fuel supply lines. For additional information, refer to Fuel Injectors in this section.
	•High pressure fuel pump	•CONSULT WDS.
	•Worn or damaged oil pump. •Worn or damaged timing chain or sprocket. • Serious mechanical engine failure.	•For additional information, refer to Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E.
•Engine detonation during acceleration and glow plug indicator light is on	•DTC has been registered.	•CONSULT WDS.
•Engine detonation during acceleration	•Fuel injector(s)	•INSTALL a new set of fuel injectors and high pressure fuel supply lines. For additional information, refer to Fuel Injectors in this section.
	• Serious mechanical engine failure.	•For additional information, refer to Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E.
	•High pressure fuel pump	•CONSULT WDS.
•Increased fuel consumption and glow plug indicator light is on	•DTC has been registered.	•CONSULT WDS.
•Increased fuel consumption	•Brake drag.	•CHECK the brake system. Refer to Section 206-00 for additional information.
	•The vehicle is overloaded or has increased aerodynamic drag (roof racks, towing, etc.).	•TELL the customer about the impact of vehicle loading and aerodynamic drag on fuel consumption.
	•Clogging of the air filter element.	•CHECK the air cleaner element for blockage or obstruction. REMOVE and visually INSPECT the air cleaner element for obstruction. INSTALL a new air cleaner element if necessary. Refer to Section 303-12 for additional information.
	• Leak(s) in the fuel system	•CHECK the system for fuel leak(s). REPAIR the system if necessary.
	•CHT sensor. •MAP sensor.	•CONSULT 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. Refer to Section 308-00 for additional information.
	•Generator.	•For additional information, refer to Section 414-00.
	•EGR valve stuck in the open position.	•REFER to WDS. CHECK the EGR valve by lifting it off the seat with a vacuum pump connected to the vacuum line; release the vacuum. If the valve is not sticking, a metallic clanking sound should be heard.
	•Air penetration into fuel lines.	•For additional information, refer to Section 310-00A.
	•Incorrect valve timing.	•CHECK valve timing. For additional information, refer to Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E.
	•Turbocharger •Turbine bypass valve actuator for turbocharger.	•For additional information, refer to Section 303-04A / 303-04B / 303-04C / 303-04D / 303-04E / 303-04F / 303-04G.
	•Low compression in cylinders.	•For additional information, see Section 303-00.
	•Fuel injector(s)	•INSTALL a new set of fuel injectors and high pressure fuel supply lines. For additional information, refer to Fuel Injectors in this section.
	•High pressure fuel pump	•CONSULT WDS.

Diagnostics and checks (1.8 l diesel)

Inspection and verification

Visual inspection table

Table of signs of malfunction

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