Toyota
Ford Kuga
 Service Manual
Fuel Charging and Controls-2.5L Duratec (147kW/200PS) - VI5 » Fuel Charging and Controls
Symptom Chart

Symptom Possible Sources Action
Engine does not crank PATS. CHECK the PATS LED extinguishes within 3 seconds when the ignition is turned on.

REFER to: Anti-Theft - Passive (419-01 Anti-Theft - Passive, Diagnosis and Testing).
Starting system. REFER to: Starting System (303-06 Starting System - 2.5L Duratec (147kW/200PS) - VI5, Diagnosis and Testing).
Ignition switch. REFER to theWiring 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 Inertia fuel shutoff (IFS) switch RESET the IFS switch.
Low fuel system pressure. Check the fuel system pressure.
Fuel lines damaged or blocked INSPECT the fuel lines.

INSTALL new components as necessary. TEST the system for normal operation.
Fuel filter blocked. INSTALL a new fuel filter.
Fuel pump and sender unit. REFER to: Fuel Pump and Sender Unit - 2.5L Duratec (147kW/200PS) - VI5 (310-01 Fuel Tank and Lines, Removal and Installation).
Crankshaft position (CKP) sensor. Carry out a full engine diagnosis using the guided diagnostic menu in the Ford diagnostic equipment.
Camshaft position (CMP) sensor. 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 rail fuel pressure 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 injectors as required only after the checks have been carried out.

REFER to: Fuel Injectors (303- 04 Fuel Charging and Controls - 2.5L Duratec (147kW/200PS) - VI5, Removal and Installation).
Incorrect valve timing. CHECK the valve timing.

REFER to: Timing Belt (303-01 Engine - 2.5L Duratec (147kW/200PS) - VI5, Removal and Installation).
Low cylinder compression. TEST the cylinder compression.

REFER to: Engine (303-00 Engine System - General Information, Diagnosis and Testing).
Poor starting Low fuel system pressure Check the fuel system pressure.
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.
Fuel filter blocked. INSTALL a new fuel filter.
Air cleaner element blocked. INSTALL a new air cleaner element.
Incorrect engine oil. INSTALL a new engine oil filter and engine oil.
Incorrect power steering fluid. DRAIN and REFILL the power steering system with the correct fluid.

REFER to: Power Steering System Filling (211-00 Steering System - General Information, General Procedures).
CKP sensor. Carry out a full engine diagnosis using the guided diagnostic menu in the Ford diagnostic equipment.
Engine coolant temperature (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 injectors as required only after the checks have been carried out.

REFER to: Fuel Injectors (303- 04 Fuel Charging and Controls - 2.5L Duratec (147kW/200PS) - VI5, Removal and Installation).
Fuel rail fuel pressure 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 as necessary.

REFER to: Catalytic Converter (309-00 Exhaust System - 2.5L Duratec (147kW/200PS) - VI5, Removal and Installation).
Low cylinder compression. TEST the engine cylinder compression.

REFER to: Engine (303-00 Engine System - General Information, 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. 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.
Fuel system restriction. INSPECT the fuel system.

INSTALL new components as necessary. TEST the system for normal operation.
Fuel filter blocked. INSTALL a new fuel filter.
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.

REFER to: Fuel Tank Draining (310-00 Fuel System - General Information, General Procedures).

INSTALL a new fuel filter.

INSPECT the fuel injectors.

CLEAN the fuel injectors or INSTALL a new set of injectors as required only after the checks have been carried out.

REFER to: Fuel Injectors (303- 04 Fuel Charging and Controls - 2.5L Duratec (147kW/200PS) - VI5, Removal and Installation).

INSTALL a new fuel rail.

REFER to: Fuel Rail (303-04 Fuel Charging and Controls - 2.5L Duratec (147kW/200PS) - VI5, Removal and Installation).
Low fuel system pressure. Check the fuel system pressure.
Fuel filter blocked. INSTALL a new fuel filter.
Fuel injectors. INSPECT the fuel injectors.

CLEAN the fuel injectors or INSTALL a new set of injectors as required only after the checks have been carried out.

REFER to: Fuel Injectors (303- 04 Fuel Charging and Controls - 2.5L Duratec (147kW/200PS) - VI5, Removal and Installation).
CKP sensor. Carry out a full engine diagnosis using the guided diagnostic menu in the Ford diagnostic equipment.
Knock sensor (KS). Carry out a full engine diagnosis using the guided diagnostic menu in the Ford diagnostic equipment.
Fuel injection supply manifold fuel pressure sensor. Carry out a full engine diagnosis using the guided diagnostic menu in the Ford diagnostic equipment.
Engine stumbling

Engine lacks power

 Engine ignition. REFER to: Engine Ignition (303-07 Engine Ignition - 2.5L Duratec (147kW/200PS) - VI5, Diagnosis and Testing).
Fuel injectors. INSPECT the fuel injectors.

CLEAN the fuel injectors or INSTALL a new set of injectors as required only after the checks have been carried out.

REFER to: Fuel Injectors (303- 04 Fuel Charging and Controls - 2.5L Duratec (147kW/200PS) - VI5, Removal and Installation).
Low fuel system pressure. Check the fuel system pressure.
Fuel rail fuel pressure sensor Carry out a full engine diagnosis using the guided diagnostic menu in the Ford diagnostic equipment.
Engine ignition. REFER to: Engine Ignition (303-07 Engine Ignition - 2.5L Duratec (147kW/200PS) - VI5, Diagnosis and Testing).
Brakes binding. CHECK the braking system.

REFER to: Brake System (206- 00 Brake System - General Information, 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.
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.

    REFER to: Fuel Tank Draining (310-00 Fuel System - General Information, General Procedures).

    INSTALL a new fuel filter.

  • INSPECT the fuel injectors.

    CLEAN the fuel injectors or INSTALL a new set of injectors as required only after the checks have been carried out.

  • INSTALL a new fuel rail.

    REFER to: Fuel Rail (303-04 Fuel Charging and Controls - 2.5L Duratec (147kW/200PS) - VI5, Removal and Installation).
Fuel filter blocked. INSTALL a new fuel filter.
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 injectors as required only after the checks have been carried out.

REFER to: Fuel Injectors (303- 04 Fuel Charging and Controls - 2.5L Duratec (147kW/200PS) - VI5, Removal and Installation).
Fuel rail fuel pressure sensor Carry out a full engine diagnosis using the guided diagnostic menu in the Ford diagnostic equipment.
Incorrect valve timing. CHECK the valve timing.

REFER to: Timing Belt (303-01 Engine - 2.5L Duratec (147kW/200PS) - VI5, Removal and Installation).
Low cylinder compression. CHECK the cylinder compression.

REFER to: Engine (303-00 Engine System - General Information, 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 (309-00 Exhaust System - 2.5L Duratec (147kW/200PS) - VI5, 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 injectors as required only after the checks have been carried out.

REFER to: Fuel Injectors (303- 04 Fuel Charging and Controls - 2.5L Duratec (147kW/200PS) - VI5, Removal and Installation).
ECT sensor. Carry out a full engine diagnosis using the guided diagnostic menu in the Ford diagnostic equipment.
Fuel rail fuel pressure 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 (309-00 Exhaust System - 2.5L Duratec (147kW/200PS) - VI5, Removal and Installation).
Incorrect valve timing. CHECK the valve timing.

REFER to: Timing Belt (303-01 Engine - 2.5L Duratec (147kW/200PS) - VI5, Removal and Installation).
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.

    REFER to: Fuel Tank Draining (310-00 Fuel System - General Information, General Procedures).

    INSTALL a new fuel filter.

  • INSPECT the fuel injectors.

    CLEAN the fuel injectors or INSTALL a new set of injectors as required only after the checks have been carried out.

  • INSTALL a new fuel rail.

    REFER to: Fuel Rail (303-04 Fuel Charging and Controls - 2.5L Duratec (147kW/200PS) - VI5, 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 injectors as required only after the checks have been carried out.

REFER to: Fuel Injectors (303- 04 Fuel Charging and Controls - 2.5L Duratec (147kW/200PS) - VI5, Removal and Installation).
Fuel rail fuel pressure 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 (309-00 Exhaust System - 2.5L Duratec (147kW/200PS) - VI5, Removal and Installation).
Black smoke at cruising speeds Air cleaner element blocked. INSTALL a new air cleaner element.
Fuel injectors. Carry out a full engine diagnosis using the guided diagnostic menu in the Ford diagnostic equipment.
Fuel rail fuel pressure sensor. INSPECT the fuel injectors.

CLEAN the fuel injectors or INSTALL a new set of injectors as required only after the checks have been carried out.

REFER to: Fuel Injectors (303- 04 Fuel Charging and Controls - 2.5L Duratec (147kW/200PS) - VI5, Removal and Installation).
Fuel rail fuel pressure 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 (309-00 Exhaust System - 2.5L Duratec (147kW/200PS) - VI5, 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.

    REFER to: Fuel Tank Draining (310-00 Fuel System - General Information, General Procedures).

    INSTALL a new fuel filter.

  • INSPECT the fuel injectors.

    CLEAN the fuel injectors or INSTALL a new set of injectors as required only after the checks have been carried out.

    REFER to: Fuel Injectors (303- 04 Fuel Charging and Controls - 2.5L Duratec (147kW/200PS) - VI5, Removal and Installation).

  • INSTALL a new fuel rail.

    REFER to: Fuel Rail (303-04 Fuel Charging and Controls - 2.5L Duratec (147kW/200PS) - VI5, 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- 01 Engine - 2.5L Duratec (147kW/200PS) - VI5, 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.

    REFER to: Fuel Tank Draining (310-00 Fuel System - General Information, General Procedures).

    INSTALL a new fuel filter.

  • INSPECT the fuel injectors.

    CLEAN the fuel injectors or INSTALL a new set of injectors as required only after the checks have been carried out.

    REFER to: Fuel Injectors (303- 04 Fuel Charging and Controls - 2.5L Duratec (147kW/200PS) - VI5, Removal and Installation).

  • INSTALL a new fuel rail.

    REFER to: Fuel Rail (303-04 Fuel Charging and Controls - 2.5L Duratec (147kW/200PS) - VI5, Removal and Installation).
Coolant in the combustion chamber.
  • CARRY OUT a cooling system pressure test.

    REFER to: Engine Cooling (303-03 Engine Cooling, Diagnosis and Testing).

  • INSPECT the cylinder head, cylinder head gasket and cylinder bores for wear or damage.

    REFER to: Cylinder Head (303- 01 Engine - 2.5L Duratec (147kW/200PS) - VI5, Removal and Installation).
Engine misfire Engine ignition. REFER to: Engine Ignition (303-07 Engine Ignition - 2.5L Duratec (147kW/200PS) - VI5, Diagnosis and Testing).
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.

    REFER to: Fuel Tank Draining (310-00 Fuel System - General Information, General Procedures).

    INSTALL a new fuel filter.

  • INSPECT the fuel injectors.

    CLEAN the fuel injectors or INSTALL a new set of injectors as required only after the checks have been carried out.

    - INSTALL a new fuel rail.

  • REFER to: Fuel Rail (303-04 Fuel Charging and Controls - 2.5L Duratec (147kW/200PS) - VI5, Removal and Installation).
Low fuel system pressure. Check the fuel system pressure.
Engine operating temperature too high. REFER to: Engine Cooling (303-03 Engine Cooling, 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. 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 injectors as required only after the checks have been carried out.

REFER to: Fuel Injectors (303- 04 Fuel Charging and Controls - 2.5L Duratec (147kW/200PS) - VI5, Removal and Installation).
Fuel rail fuel pressure sensor. Carry out a full engine diagnosis using the guided diagnostic menu in the Ford diagnostic equipment.
Low cylinder compression. CHECK the engine compression.

REFER to: Engine (303-00 Engine System - General Information, 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- 01 Engine - 2.5L Duratec (147kW/200PS) - VI5, 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- 01 Engine - 2.5L Duratec (147kW/200PS) - VI5, 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.

    REFER to: Fuel Tank Draining (310-00 Fuel System - General Information, General Procedures).

    INSTALL a new fuel filter.

  • INSPECT the fuel injectors.

    CLEAN the fuel injectors or INSTALL a new set of injectors as required only after the checks have been carried out.

    REFER to: Fuel Injectors (303- 04 Fuel Charging and Controls - 2.5L Duratec (147kW/200PS) - VI5, Removal and Installation).

  • INSTALL a new fuel rail.

    REFER to: Fuel Rail (303-04 Fuel Charging and Controls - 2.5L Duratec (147kW/200PS) - VI5, 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 injectors as required only after the checks have been carried out.

REFER to: Fuel Injectors (303- 04 Fuel Charging and Controls - 2.5L Duratec (147kW/200PS) - VI5, Removal and Installation).
Incorrect valve timing. CHECK the valve timing.

REFER to: Timing Belt (303-01 Engine - 2.5L Duratec (147kW/200PS) - VI5, 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- 01 Engine - 2.5L Duratec (147kW/200PS) - VI5, 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 accelera- - KS.

tion

 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 injectors as required only after the checks have been carried out.

REFER to: Fuel Injectors (303- 04 Fuel Charging and Controls - 2.5L Duratec (147kW/200PS) - VI5, Removal and Installation).
Major mechanical engine failure. REFER to: Engine (303-00 Engine System - General Information, Diagnosis and Testing).
Excessive fuel consumption Brakes binding. CHECK the braking system.

REFER to: Brake System (206- 00 Brake System - General Information, 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.
Fuel filter blocked. INSTALL a new fuel filter.
Incorrect engine oil. INSTALL a new oil filter and engine oil.
Generator. REFER to the Ford diagnostic equipment.
Slipping clutch.  
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 injectors as required only after the checks have been carried out.

REFER to: Fuel Injectors (303- 04 Fuel Charging and Controls - 2.5L Duratec (147kW/200PS) - VI5, 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 (303-01 Engine - 2.5L Duratec (147kW/200PS) - VI5, Removal and Installation).
Low cylinder compression. CHECK the engine compression.

REFER to: Engine (303-00 Engine System - General Information, Diagnosis and Testing).
Engine cuts out during hard acceleration CMP 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.
Fuel rail fuel pressure 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.

    More about «Fuel Charging and Controls»:

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    Symptom Chart

    Ford Kuga Service Manual / Fuel Charging and Controls-2.5L Duratec (147kW/200PS) - VI5 / Fuel Charging and Controls / Symptom Chart

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