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Mondeo 1 and 2 (1993-2000) Mondeo 2 (1997-2000) Mondeo 3 (2000-2007) Mondeo 4 (2007-2014) Mondeo 1 (1993-1996)

Diesel injection system faults (Mondeo 3)

            0

Cause
Action and elimination
A. The engine starts poorly or does not start at all.
  1. The fuel tank is empty.
  2. The fuel tank ventilation is blocked.
  3. Defective temperature switch or cold start device.
  4. Defect in the glow system.
  5. Air in the fuel system.
  6. No fuel supply. Check: Open the injection tubes on the injectors and check if small amounts of fuel appear.
  7. The injection lines were incorrectly laid after dismantling.
  8. Defect in the injector(s).
  9. The start of the electric pump feed is incorrect.
  10. Defect in the electric pump.
  11. The compression pressure is low.
  1. Fill it up.
  2. Slowly open the tank cap (watch for hissing noises). Clean the plug and vent.
  3. Check the temperature switch, replace if necessary.
  4. Check voltage, check glow plugs for functionality, replace defective parts.
  5. Ventilate the system using the starter until fuel comes out of 1 nozzle.
  6. Check for kinks, clogs or leaks in the fuel lines. Clean or replace the fuel filter. In winter, replace the salted filter and fill with winter fuel.
  7. Check the connections: on the top left of the pump distributor housing is cylinder 1, on the bottom left is cylinder 3, on the bottom right is cylinder 4, on the top right is cylinder 2.
  8. Check and repair, replace if necessary.
  9. The pump needs to be adjusted. Check the start of the feed.
  10. Install the replacement pump.
  11. Check the compression pressure.
B. A hot engine has a poor or rough idle.
  1. Idle speed is set incorrectly.
  2. The fuel hose between the filter and the pump is disconnected.
  3. .Defect in the low pressure hoses of the EGR device.
  4. The rear pump mount is disconnected or broken.
  5. See A2, 7 – 9.
  1. Check and adjust.
  2. Tighten the connections and replace the seals if necessary.
  3. Check and replace if necessary.
  4. Secure or replace.
B. Incorrect idle speed at operating temperature.
  1. See A7, 10.
  2. See B1.
 —
D. Heavy black, white or blue smoke from the exhaust system.
  1. The engine is not at operating temperature.
  2. Extreme driving style.
  3. The air filter is closed.
  4. The fuel filter is dirty.
  5. The maximum speed is not set correctly.
  6. The filter in the EGR control valve is clogged.
  7. The injectors are dripping.
  8. The injector needle is hanging or torn off.
  9. Injection pressure is low.
  10. Incorrect nozzle design.
  11. See A10.
  1. Warm up.
  2. Switch off high gears, shift in time.
  3. Blow out the element or replace it.
  4. Replace.
  5. Please adjust.
  6. Clean or replace.
  7. Check and replace if necessary.
  8. Check and replace if necessary
  9. Check and adjust if necessary
  10. Replace.
D. Poor power, low top speed.
  1. The throttle response is incorrect.
  2. Maximum rotation speed is not reached.
  3. High pressure fuel lines are bent at the connection points.
  4. High pressure fuel lines are incorrectly installed.
  5. The injectors are not adjusted correctly.
  6. See A7, 8, 10.
  7. See D3, 4, 6 - 10.
  1. Adjust the system.
  2. Check the speed controller, adjust if necessary.
  3. Remove the pipes and check.
  4. Repair or replace.
  5. Check the pipelines (need to be coordinated with the electric pump).
  6. Adjust the injection pressure.
E. High fuel consumption.
  1. The engine has not yet been developed.
  2. The fuel system is leaking.
  3. The drain pipe is clogged.
  4. The idle speed or maximum speed is high.
  5. See D4, 6 - 10.
  1. Follow the driving instructions and then measure again.
  2. Starting from the tank, perform a visual inspection of all supply lines; check for leaks and tighten all hoses, hose connections, fuel filter and pump under the engine hood.
  3. Blow compressed air from the tank towards the nozzles step by step.
  4. Check and adjust if necessary.
G. The engine misfires while driving (faulty ignition).
  1. The injectors are loose or defective
  2. The cylinder head gasket is blown (check if there is engine oil in cold water or if gas bubbles rise in the coolant when the engine is running).
  3. The valve clearance is small: the valve is burnt out.
  1. Clean or replace.
  2. Check and replace.
  3. Conduct compression pressure measurement or pressure loss test. Check valve clearance, replace valve if necessary, grind others.
Z. The engine does not stop.
The PCU unit is defective, the contacts are corroded. Check the unit and contacts.

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• Replacing components (EFI) of the electronic fuel injection system Ford Taurus 1 and 2 (1986-1994)
• Diagnostics of faults of the injection system of a diesel engine Ford Scorpio 2 (1994-1998)
• Fuel system (diesel) Ford Transit 2 (1986-2000, diesel)
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