B-MAX 2012 – Fuel Charging and Controls – 1.4L Duratec-16V (66kW/90PS) – Fuel Charging and Controls – Visual Inspection Chart

Fuel Charging and Controls - 1.4L Duratec-16V (66kW/90PS) - Fuel Charging and ControlsB-MAX 2012.75 (01/2012-)
Diagnosis and Testing

Ford diagnostic equipment

Inspection and Verification

Visual Inspection Chart

MechanicalElectrical
  • Fuel leak(s)
  • Vacuum line(s)
  • Gasket(s)
  • Seal(s)
  • Fuel injector(s)
  • Throttle body
  • Fuel rail
  • Fuel supply line
  • Wiring harness
  • Electrical connector(s)
  • Throttle body
  • Fuel injector(s)
  • Crankshaft position (CKP) sensor
  • Camshaft position (CMP) sensor(s)
  • Engine coolant temperature (ECT) sensor
  • Knock sensor(s) (KS)
  • Wheel speed sensor
  • Powertrain control module (PCM)

Symptom Chart

SymptomPossible SourcesAction
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: Passive Anti-Theft System (PATS) (419-01B Passive Anti-Theft System (PATS), Diagnosis and Testing).
*
Starting system.
*

REFER to: Starting System (303-06B Starting System - 1.4L Duratec-16V (66kW/90PS), Diagnosis and Testing).
*
Ignition switch.
*
REFER to the Wiring Diagrams.
*
Powertrain control module (PCM).
*
Carry out a full engine diagnosis using the guided diagnostic menu in the Ford diagnostic equipment.
Engine cranks but does not start
*
Low fuel system pressure.
*
Check the fuel system pressure.
REFER to: Fuel System Pressure Check (310-00B Fuel System - General Information - 1.4L Duratec-16V (66kW/90PS), General Procedures).
*
Fuel lines damaged or blocked.
*
INSPECT the fuel lines. INSTALL new components as necessary. TEST the system for normal operation.
*
Fuel pump and sender unit.
*

REFER to: Fuel System (310-00B Fuel System - General Information - 1.4L Duratec-16V (66kW/90PS), Diagnosis and Testing).
*
CKP sensor.
*
Carry out a full engine diagnosis using the guided diagnostic menu in the Ford diagnostic equipment.
*
CMP sensor(s).
*
Carry out a full engine diagnosis using the guided diagnostic menu in the Ford diagnostic equipment.
*
PCM.
*
Carry out a full engine diagnosis using the guided diagnostic menu in the Ford diagnostic equipment.
*
Fuel injectors.
*
INSPECT the fuel injectors. CLEAN the fuel injectors or INSTALL a new set of fuel injectors as required only after the checks have been carried out.
REFER to: Fuel Rail (303-04B Fuel Charging and Controls - 1.4L Duratec-16V (66kW/90PS), Removal and Installation).
*
Incorrect valve timing.
*
CHECK the valve timing.
REFER to: Timing Belt (303-01B Engine - 1.4L Duratec-16V (66kW/90PS), Removal and Installation).
*
Low cylinder compression.
*
TEST the cylinder compression.
REFER to: Engine (303-01B Engine - 1.4L Duratec-16V (66kW/90PS), Diagnosis and Testing).
Poor starting
*
Low fuel system pressure.
*
Check the fuel system pressure.
REFER to: Fuel System Pressure Check (310-00B Fuel System - General Information - 1.4L Duratec-16V (66kW/90PS), General Procedures).
*
Fuel system leak.
*
CHECK the system for fuel leak(s). REPAIR the system as necessary.
*
Fuel system restriction.
*
INSPECT the fuel system. INSTALL new components as necessary. TEST the system for normal operation.
*
Air cleaner element blocked.
*
INSTALL a new air cleaner element.
*
Incorrect engine oil.
*
INSTALL a new engine oil filter and engine oil.
*
CKP sensor.
*
Carry out a full engine diagnosis using the guided diagnostic menu in the Ford diagnostic equipment.
*
ECT sensor.
*
Carry out a full engine diagnosis using the guided diagnostic menu in the Ford diagnostic equipment.
*
Fuel injector(s).
*
INSPECT the fuel injectors. CLEAN the fuel injectors or INSTALL a new set of fuel injectors as required only after the checks have been carried out.
REFER to: Fuel Rail (303-04B Fuel Charging and Controls - 1.4L Duratec-16V (66kW/90PS), Removal and Installation).
*
Catalytic converter blocked.
*
REMOVE and visually INSPECT the catalytic converter as necessary.
REFER to: Catalytic Converter (309-00B Exhaust System - 1.4L Duratec-16V (66kW/90PS), Removal and Installation).
*
Low cylinder compression.
*
TEST the engine cylinder compression.
REFER to: Engine (303-01B Engine - 1.4L Duratec-16V (66kW/90PS), Diagnosis and Testing).
Engine starts but immediately stops
*
Air cleaner element blocked.
*
INSTALL a new air cleaner element.
*
CKP sensor.
*
Carry out a full engine diagnosis using the guided diagnostic menu in the Ford diagnostic equipment.
*
CMP sensor(s).
*
Carry out a full engine diagnosis using the guided diagnostic menu in the Ford diagnostic equipment.
*
PCM.
*
Carry out a full engine diagnosis using the guided diagnostic menu in the Ford diagnostic equipment.
*
Low fuel system pressure.
*
Check the fuel system pressure.
REFER to: Fuel System Pressure Check (310-00B Fuel System - General Information - 1.4L Duratec-16V (66kW/90PS), General Procedures).
*
Fuel system restriction.
*
INSPECT the fuel system. INSTALL new components as necessary. TEST the system for normal operation.
Poor idling
*
Air cleaner element blocked.
*
INSTALL a new air cleaner element.
*
Incorrect or contaminated fuel.
*
CHECK for signs of contamination such as strange odors from the fuel tank.
*
If contaminated fuel is found, DRAIN the complete fuel system. FLUSH the fuel system through with clean gasoline.
*
INSPECT the fuel injectors. CLEAN the fuel injectors or INSTALL a new set of fuel injectors as required only after the checks have been carried out.
*
INSTALL a new fuel rail.
REFER to: Fuel Rail (303-04B Fuel Charging and Controls - 1.4L Duratec-16V (66kW/90PS), Removal and Installation).
*
Low fuel system pressure.
*
Check the fuel system pressure.
REFER to: Fuel System Pressure Check (310-00B Fuel System - General Information - 1.4L Duratec-16V (66kW/90PS), General Procedures).
*
Fuel injectors.
*
INSPECT the fuel injectors. CLEAN the fuel injectors or INSTALL a new set of fuel injectors as required only after the checks have been carried out.
REFER to: Fuel Rail (303-04B Fuel Charging and Controls - 1.4L Duratec-16V (66kW/90PS), Removal and Installation).
*
CKP sensor.
*
Carry out a full engine diagnosis using the guided diagnostic menu in the Ford diagnostic equipment.
*
KS.
*
Carry out a full engine diagnosis using the guided diagnostic menu in the Ford diagnostic equipment.
Engine stumbling
*
Engine ignition.
*
Carry out an ignition system diagnosis using the Ford diagnostic equipment.
*
Fuel injectors.
*
INSPECT the fuel injectors. CLEAN the fuel injectors or INSTALL a new set of fuel injectors as required only after the checks have been carried out.
REFER to: Fuel Rail (303-04B Fuel Charging and Controls - 1.4L Duratec-16V (66kW/90PS), Removal and Installation).
*
Low fuel system pressure.
*
Check the fuel system pressure.
REFER to: Fuel System Pressure Check (310-00B Fuel System - General Information - 1.4L Duratec-16V (66kW/90PS), General Procedures).
Engine lacks power
*
Engine ignition.
*
Carry out an ignition system diagnosis using the Ford diagnostic equipment.
*
Brakes binding.
*
CHECK the braking system.
REFER to: Anti-Lock Brake System (ABS) and Stability Control (206-09 Anti-Lock Brake System (ABS) and Stability Control, 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.
*
Air cleaner element blocked.
*
INSTALL a new air cleaner element as necessary.
*
Low fuel system pressure.
*
Check the fuel system pressure.
REFER to: Fuel System Pressure Check (310-00B Fuel System - General Information - 1.4L Duratec-16V (66kW/90PS), General Procedures).
*
Kinked or restricted fuel lines.
*
INSPECT the fuel lines. INSTALL new components as necessary. TEST the system for normal operation.
*
Incorrect or contaminated fuel.
*
CHECK for signs of contamination such as strange odors from the fuel tank.
*
If contaminated fuel is found, DRAIN the complete fuel system. FLUSH the fuel system through with clean gasoline.
*
INSPECT the fuel injectors. CLEAN the fuel injectors or INSTALL a new set of fuel injectors as required only after the checks have been carried out.
*
INSTALL a new fuel rail.
REFER to: Fuel Rail (303-04B Fuel Charging and Controls - 1.4L Duratec-16V (66kW/90PS), Removal and Installation).
*
Wheel speed sensor.
*
Carry out a full engine diagnosis using the guided diagnostic menu in the Ford diagnostic equipment.
*
ECT sensor.
*
Carry out a full engine diagnosis using the guided diagnostic menu in the Ford diagnostic equipment.
*
Fuel injectors.
*
INSPECT the fuel injectors. CLEAN the fuel injectors or INSTALL a new set of fuel injectors as required only after the checks have been carried out.
REFER to: Fuel Rail (303-04B Fuel Charging and Controls - 1.4L Duratec-16V (66kW/90PS), Removal and Installation).
*
Incorrect valve timing.
*
CHECK the valve timing.
REFER to: Timing Belt (303-01B Engine - 1.4L Duratec-16V (66kW/90PS), Removal and Installation).
*
Low cylinder compression.
*
CHECK the cylinder compression.
REFER to: Engine (303-01B Engine - 1.4L Duratec-16V (66kW/90PS), Diagnosis and Testing).
*
Catalytic converter blocked.
*
REMOVE and visually INSPECT the catalytic converter for damage. INSTALL a new catalytic converter as necessary.
REFER to: Catalytic Converter (309-00B Exhaust System - 1.4L Duratec-16V (66kW/90PS), Removal and Installation).
Black smoke at idle
*
Air cleaner element blocked.
*
INSTALL a new air cleaner element as necessary.
*
Fuel injectors.
*
INSPECT the fuel injectors. CLEAN the fuel injectors or INSTALL a new set of fuel injectors as required only after the checks have been carried out.
REFER to: Fuel Rail (303-04B Fuel Charging and Controls - 1.4L Duratec-16V (66kW/90PS), Removal and Installation).
*
ECT sensor.
*
Carry out a full engine diagnosis using the guided diagnostic menu in the Ford diagnostic equipment.
*
Catalytic converter blocked.
*
REMOVE and visually INSPECT the catalytic converter for damage. INSTALL a new catalytic converter as necessary.
REFER to: Catalytic Converter (309-00B Exhaust System - 1.4L Duratec-16V (66kW/90PS), Removal and Installation).
*
Incorrect valve timing.
*
CHECK the valve timing.
REFER to: Timing Belt (303-01B Engine - 1.4L Duratec-16V (66kW/90PS), Removal and Installation).
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 odors from the fuel tank.
*
If contaminated fuel is found, DRAIN the complete fuel system. FLUSH the fuel system through with clean gasoline.
*
INSPECT the fuel injectors. CLEAN the fuel injectors or INSTALL a new set of fuel injectors as required only after the checks have been carried out.
*
INSTALL a new fuel rail.
REFER to: Fuel Rail (303-04B Fuel Charging and Controls - 1.4L Duratec-16V (66kW/90PS), Removal and Installation).
*
CKP sensor.
*
Carry out a full engine diagnosis using the guided diagnostic menu in the Ford diagnostic equipment.
*
KS.
*
Carry out a full engine diagnosis using the guided diagnostic menu in the Ford diagnostic equipment.
*
Fuel injectors.
*
INSPECT the fuel injectors. CLEAN the fuel injectors or INSTALL a new set of fuel injectors as required only after the checks have been carried out.
REFER to: Fuel Rail (303-04B Fuel Charging and Controls - 1.4L Duratec-16V (66kW/90PS), Removal and Installation).
*
Catalytic converter blocked.
*
REMOVE and visually INSPECT the catalytic converter for damage. INSTALL a new catalytic converter as necessary.
REFER to: Catalytic Converter (309-00B Exhaust System - 1.4L Duratec-16V (66kW/90PS), Removal and Installation).
Black smoke at cruising speeds
*
Air cleaner element blocked.
*
INSTALL a new air cleaner element.
*
ECT sensor.
*
Carry out a full engine diagnosis using the guided diagnostic menu in the Ford diagnostic equipment.
*
Fuel injectors.
*
INSPECT the fuel injectors. CLEAN the fuel injectors or INSTALL a new set of fuel injectors as required only after the checks have been carried out.
REFER to: Fuel Rail (303-04B Fuel Charging and Controls - 1.4L Duratec-16V (66kW/90PS), Removal and Installation).
*
Catalytic converter blocked.
*
REMOVE and visually INSPECT the catalytic converter for damage. INSTALL a new catalytic converter as necessary.
REFER to: Catalytic Converter (309-00B Exhaust System - 1.4L Duratec-16V (66kW/90PS), Removal and Installation).
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 odors from the fuel tank.
*
If contaminated fuel is found, DRAIN the complete fuel system. FLUSH the fuel system through with clean gasoline.
*
INSPECT the fuel injectors. CLEAN the fuel injectors or INSTALL a new set of fuel injectors as required only after the checks have been carried out.
*
INSTALL a new fuel rail.
REFER to: Fuel Rail (303-04B Fuel Charging and Controls - 1.4L Duratec-16V (66kW/90PS), Removal and Installation).
*
Positive crankcase ventilation (PCV) system.
*
INSPECT for visible signs of damage or blockage. CLEAN, REPAIR or INSTALL new parts as necessary.
*
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 - 1.4L Duratec-16V (66kW/90PS), Removal and Installation).
White smoke
*
Incorrect or contaminated fuel.
*
CHECK for signs of contamination such as strange odors from the fuel tank.
*
If contaminated fuel is found, DRAIN the complete fuel system. FLUSH the fuel system through with clean gasoline.
*
INSPECT the fuel injectors. CLEAN the fuel injectors or INSTALL a new set of fuel injectors as required only after the checks have been carried out.
*
INSTALL a new fuel rail.
REFER to: Fuel Rail (303-04B Fuel Charging and Controls - 1.4L Duratec-16V (66kW/90PS), Removal and Installation).
*
Coolant in the combustion chamber.
*
CARRY OUT a cooling system pressure test.
REFER to: Engine Cooling (303-03B Engine Cooling - 1.4L Duratec-16V (66kW/90PS), 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 - 1.4L Duratec-16V (66kW/90PS), Removal and Installation).
Engine misfire
*
Engine ignition.
*
Carry out an ignition system diagnosis using the Ford diagnostic equipment.
*
Incorrect or contaminated fuel.
*
CHECK for signs of contamination such as strange odors from the fuel tank.
*
If contaminated fuel is found, DRAIN the complete fuel system. FLUSH the fuel system through with clean gasoline.
*
INSPECT the fuel injectors. CLEAN the fuel injectors or INSTALL a new set of fuel injectors as required only after the checks have been carried out.
*
INSTALL a new fuel rail.
REFER to: Fuel Rail (303-04B Fuel Charging and Controls - 1.4L Duratec-16V (66kW/90PS), Removal and Installation).
*
Low fuel system pressure.
*
Check the fuel system pressure.
REFER to: Fuel System Pressure Check (310-00B Fuel System - General Information - 1.4L Duratec-16V (66kW/90PS), General Procedures).
*
Engine operating temperature too high.
*

REFER to: Engine Cooling (303-03B Engine Cooling - 1.4L Duratec-16V (66kW/90PS), Diagnosis and Testing).
*
ECT sensor.
*
Carry out a full engine diagnosis using the guided diagnostic menu in the Ford diagnostic equipment.
*
CKP sensor.
*
Carry out a full engine diagnosis using the guided diagnostic menu in the Ford diagnostic equipment.
*
CMP sensor(s).
*
Carry out a full engine diagnosis using the guided diagnostic menu in the Ford diagnostic equipment.
*
KS.
*
Carry out a full engine diagnosis using the guided diagnostic menu in the Ford diagnostic equipment.
*
Fuel injectors.
*
INSPECT the fuel injectors. CLEAN the fuel injectors or INSTALL a new set of fuel injectors as required only after the checks have been carried out.
REFER to: Fuel Rail (303-04B Fuel Charging and Controls - 1.4L Duratec-16V (66kW/90PS), Removal and Installation).
*
Low cylinder compression.
*
CHECK the engine compression.
REFER to: Engine (303-01B Engine - 1.4L Duratec-16V (66kW/90PS), Diagnosis and Testing).
*
Worn or damaged valve(s), tappet(s) or camshaft(s).
*
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 - 1.4L Duratec-16V (66kW/90PS), Removal and Installation).
*
Damaged cylinder head gasket.
*
REMOVE the cylinder head. INSPECT the cylinder head gasket and cylinder bores for wear or damage.
REFER to: Cylinder Head (303-01B Engine - 1.4L Duratec-16V (66kW/90PS), Removal and Installation).
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 odors from the fuel tank.
*
If contaminated fuel is found, DRAIN the complete fuel system. FLUSH the fuel system through with clean gasoline.
*
INSPECT the fuel injectors. CLEAN the fuel injectors or INSTALL a new set of fuel injectors as required only after the checks have been carried out.
*
INSTALL a new fuel rail.
REFER to: Fuel Rail (303-04B Fuel Charging and Controls - 1.4L Duratec-16V (66kW/90PS), Removal and Installation).
*
KS.
*
Carry out a full engine diagnosis using the guided diagnostic menu in the Ford diagnostic equipment.
*
CKP sensor.
*
Carry out a full engine diagnosis using the guided diagnostic menu in the Ford diagnostic equipment.
*
Fuel injector(s).
*
INSPECT the fuel injectors. CLEAN the fuel injectors or INSTALL a new set of fuel injectors as required only after the checks have been carried out.
REFER to: Fuel Rail (303-04B Fuel Charging and Controls - 1.4L Duratec-16V (66kW/90PS), Removal and Installation).
*
Incorrect valve timing.
*
CHECK the valve timing.
REFER to: Timing Belt (303-01B Engine - 1.4L Duratec-16V (66kW/90PS), Removal and Installation).
*
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 - 1.4L Duratec-16V (66kW/90PS), Removal and Installation).
*
Worn or damaged oil pump.
*
Worn or damaged timing chain or sprocket.
*
Major mechanical engine failure.
*
INSPECT the engine components.
Engine knock during acceleration
*
KS.
*
Carry out a full engine diagnosis using the guided diagnostic menu in the Ford diagnostic equipment.
*
Fuel injectors.
*
INSPECT the fuel injectors. CLEAN the fuel injectors or INSTALL a new set of fuel injectors as required only after the checks have been carried out.
REFER to: Fuel Rail (303-04B Fuel Charging and Controls - 1.4L Duratec-16V (66kW/90PS), Removal and Installation).
*
Major mechanical engine failure.
*
INSPECT the engine components.

NOTE: Before proceeding with any of the actions in relation to the possible sources for excessive fuel consumption, a fuel consumption test located in the toolbox menu of the Ford diagnostic equipment must be carried out.

Excessive fuel consumption
*
Brakes binding.
*
CHECK the braking system.
REFER to: Anti-Lock Brake System (ABS) and Stability Control (206-09 Anti-Lock Brake System (ABS) and Stability Control, 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.
*
Air cleaner element blocked.
*
INSTALL a new air cleaner element.
*
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 the Ford diagnostic equipment.
*
Slipping clutch (if equipped).
*

REFER to: Clutch (308-01 Clutch - Vehicles With: 5-Speed Manual Transmission - B5/IB5, Diagnosis and Testing).
*
ECT sensor.
*
Carry out a full engine diagnosis using the guided diagnostic menu in the Ford diagnostic equipment.
*
Fuel injectors.
*
INSPECT the fuel injectors. CLEAN the fuel injectors or INSTALL a new set of fuel injectors as required only after the checks have been carried out.
REFER to: Fuel Rail (303-04B Fuel Charging and Controls - 1.4L Duratec-16V (66kW/90PS), Removal and Installation).
*
PCM calibration.
*
Using the Ford diagnostic equipment, CHECK for the availability of a calibration update.
*
Incorrect valve timing.
*
CHECK the valve timing.
REFER to: Timing Belt (303-01B Engine - 1.4L Duratec-16V (66kW/90PS), Removal and Installation).
*
Low cylinder compression.
*
CHECK the engine compression.
REFER to: Engine (303-01B Engine - 1.4L Duratec-16V (66kW/90PS), Diagnosis and Testing).
Engine cuts out during hard acceleration
*
CMP sensor(s).
*
Carry out a full engine diagnosis using the guided diagnostic menu in the Ford diagnostic equipment.
*
CKP sensor.
*
Carry out a full engine diagnosis using the guided diagnostic menu in the Ford diagnostic equipment.
*
Low fuel system pressure.
*
Check the fuel system pressure.
REFER to: Fuel System Pressure Check (310-00B Fuel System - General Information - 1.4L Duratec-16V (66kW/90PS), General Procedures).

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