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

General Equipment
Ford diagnostic equipment

Inspection and Verification

  1. Verify the customer concern.

  1. Visually inspect for obvious signs of mechanical or electrical damage.

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)

  1. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.

  1. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart.

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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