Diesel injection system malfunctions (General information / Help with malfunctions / Ford Mondeo 3 2000-2007)

Cause	Action and elimination
A. The engine starts poorly or does not start at all.
The fuel tank is empty. Fuel tank vent blocked. Defective temperature switch or cold start device. Defect in the heating system. Air in the fuel system. Lack of fuel supply. Check: open the injection pipes on the injectors and check if small amounts of fuel appear. After dismantling, the injection lines have not been laid correctly. Defect in the nozzle (Oh). Start of delivery of the electric pump is incorrect. Defect in the electric pump. Compression pressure is low.	Refuel. Slowly open the tank cap (pay attention to hissing noises). Clean the plug and ventilation. Check temperature switch, replace if necessary. Check voltage, check glow plugs for function, replace defective parts. Ventilate the system with the starter until fuel comes out at 1 nozzle. Check for broken, clogged or leaking fuel lines. Clean fuel filter or replace. In winter, replace salted filter and fill with winter fuel. Check the connections: cylinder 1 on the top left of the pump distributor housing, cylinder 3 on the bottom left, cylinder 4 on the bottom right, cylinder 2 on the top right. Check and repair, replace if necessary. The pump needs to be adjusted. Check the start of the feed. Mount the replacement pump. Check compression pressure.
B. A warm engine has poor or «sawing» idling.
Idle speed set incorrectly. Fuel hose between filter and pump is disconnected. .Defect in the low pressure hoses of the EGR device. Rear pump mount is loose or broken. See A2, 7 - 9.	Check and adjust. Tighten connections, replace seals if necessary. Check, replace if necessary. Fix or replace.
B. Incorrect idle speed at operating temperature.
See A7, 10. See B1.	—
D. Heavy black and white or blue smoke from the exhaust system.
The engine is not at operating temperature. Extreme driving style. The air filter is closed. The fuel filter is dirty. The maximum speed is incorrectly set. The filter in the EGR control valve is clogged. The nozzles are stuck. Nozzle needle hanging or broken off. Injection pressure is low. Wrong nozzle design. See A10.	Warm up. Turn off high gears, switch in a timely manner. Purge element or replace. Replace. Adjust. Clean or replace. Check, replace if necessary. Check, replace if necessary Check and adjust if necessary Replace.
D. Poor power, low top speed.
Throttle thrust gives incorrect impulses. The maximum speed is not reached. The high pressure fuel lines are bent at the joints. High pressure fuel lines incorrectly installed. The injectors are incorrectly adjusted. See A7, 8, 10. See D3, 4, 6 - 10.	Adjust the system. Check the speed controller, install if necessary. Remove piping and check. Repair or replace. Check pipelines (must be coordinated with the electric pump). Adjust injection pressure.
E. High fuel consumption.
The engine has not yet been developed. The fuel system is leaking. The drain pipe is clogged. Idle speed or maximum speed is high. See D4, 6 - 10.	Follow the driving instructions and then measure again. Carry out, starting from the tank, a visual inspection of all supply pipelines; check for leaks and seal all hoses, hose connections, fuel filter and pump under the engine hood. Blow compressed air from the tank towards the nozzles step by step. Check, adjust if necessary.
G. The engine misfires while driving (faulty ignition).
Injectors are loose or defective Burnt cylinder head gasket (check if there is engine oil in cold water or if gas bubbles rise in the coolant when the engine is running). Valve clearance too small: valve burnt out.	Clean or replace. Check and replace. Perform compression pressure measurement or pressure loss test. Check valve clearance, replace valve if necessary, grind others.
3. The engine does not stop.
The PCU is defective, the contacts are corroded.	Check block and contacts.

Diesel injection system malfunctions

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