Symptom | Possible Sources | Action |
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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).
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* Starting system. | *
REFER to: Starting System (303-06B Starting System - 1.4L Duratec-16V (66kW/90PS), Diagnosis and Testing).
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* 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).
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* 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).
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* 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).
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* Incorrect valve timing. | * CHECK the valve timing. REFER to: Timing Belt (303-01B Engine - 1.4L Duratec-16V (66kW/90PS), Removal and Installation).
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* Low cylinder compression. | * TEST the cylinder compression. REFER to: Engine (303-01B Engine - 1.4L Duratec-16V (66kW/90PS), Diagnosis and Testing).
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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).
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* 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).
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* 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).
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* Low cylinder compression. | * TEST the engine cylinder compression. REFER to: Engine (303-01B Engine - 1.4L Duratec-16V (66kW/90PS), Diagnosis and Testing).
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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).
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* 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).
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* 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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* 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).
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* 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).
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* 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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Engine lacks power | * Engine ignition. | * Carry out an ignition system diagnosis using the Ford diagnostic equipment. |
* Brakes binding. | * |
* 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).
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* 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).
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* 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).
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* Incorrect valve timing. | * CHECK the valve timing. REFER to: Timing Belt (303-01B Engine - 1.4L Duratec-16V (66kW/90PS), Removal and Installation).
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* Low cylinder compression. | * CHECK the cylinder compression. REFER to: Engine (303-01B Engine - 1.4L Duratec-16V (66kW/90PS), Diagnosis and Testing).
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* 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).
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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).
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* 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).
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* Incorrect valve timing. | * CHECK the valve timing. REFER to: Timing Belt (303-01B Engine - 1.4L Duratec-16V (66kW/90PS), Removal and Installation).
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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).
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* 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).
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* 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).
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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).
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* 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).
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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).
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* 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).
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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).
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* 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).
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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).
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* 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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* Engine operating temperature too high. | *
REFER to: Engine Cooling (303-03B Engine Cooling - 1.4L Duratec-16V (66kW/90PS), Diagnosis and Testing).
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* 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).
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* Low cylinder compression. | * CHECK the engine compression. REFER to: Engine (303-01B Engine - 1.4L Duratec-16V (66kW/90PS), Diagnosis and Testing).
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* 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).
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* 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).
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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).
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* 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).
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* Incorrect valve timing. | * CHECK the valve timing. REFER to: Timing Belt (303-01B Engine - 1.4L Duratec-16V (66kW/90PS), Removal and Installation).
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* 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).
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* 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).
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* 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. | * |
* 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).
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* 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).
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* 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).
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* Low cylinder compression. | * CHECK the engine compression. REFER to: Engine (303-01B Engine - 1.4L Duratec-16V (66kW/90PS), Diagnosis and Testing).
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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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