NO.6 CRANKS NORMALLY BUT WILL NOT START [YF (2.0L Zetec)]


6	CRANKS NORMALLY BUT WILL NOT START
DESCRIPTION	• The starter cranks the engine at normal speed but the engine will not run. • Refer to symptom troubleshooting "No.5 Engine stalls" if this symptom appears after engine stall. • Fuel is in tank. • Battery is in normal condition.
POSSIBLE CAUSE	• No battery power supply to PCM • Air leakage from intake-air system • Open PCM GND or vehicle body GND • Improper operation of IAC valve • EGR valve malfunction • No signal from CKP sensor due to sensor, related wire or incorrect installation • No signal from CMP sensor due to sensor, related wire or incorrect installation • Low engine compression • Engine overheating • Vacuum leakage • Erratic signal to ignition coil • Improper air/fuel mixture ratio control • Poor fuel quality • PCV valve malfunction • Restriction in intake-air system • Restriction in exhaust system • Disconnected electrical connector • Open or short circuit in fuel pump body and related wiring harness • Inadequate fuel pressure • Inertia fuel shutoff (IFS) switch malfunction • Fuel pump mechanical malfunction • Fuel leakage from injector • Fuel injector is clogged. • Purge valve malfunction • Spark plug malfunction • Ignition coil malfunction • Improper valve timing • Immobilizer system and/or circuit malfunction (if equipped) • Immobilizer system operating properly. (Ignition key is not registered) • Pressure regulator malfunction Warning The following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read the following warnings before performing any fuel system-related procedures: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE SERVICE PRECAUTION" and "AFTER SERVICE PRECAUTION" described in this manual. (See BEFORE SERVICE PRECAUTION [YF (2.0L Zetec)].) (See AFTER SERVICE PRECAUTION [YF (2.0L Zetec)].) Caution • Disconnecting/connecting quick release connectors without cleaning them may possibly cause damage to the fuel pipe or quick release connector. Always clean the quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material.


STEP	INSPECTION	RESULTS	ACTION
1	Note • The following test should be performed for vehicles with the immobilizer system. Go to Step 8 for vehicles without the immobilizer system. Connect the WDS or equivalent to the DLC-2. Do any of the following conditions appear? • The engine is not completely started. • DTC P1260 is displayed.	Yes	Both conditions appear: Go to Step 3.
1		No	Either or other condition appears: Go to the next step.
2	Does the engine stall approx. 2 s after the engine is started?	Yes	Go to the next step.
2		No	Immobilizer system is normal. Go to Step 10.
3	Is the coil connector securely connected to the coil?	Yes	Go to the next step.
3	Is the coil connector securely connected to the coil?	No	Connect the coil connector securely. Return to Step 2.
4	Does the security light illuminate?	Yes	Go to the next step.
4	Does the security light illuminate?	No	Inspect the instrument cluster and wiring harness.
5	Connect the WDS or equivalent to the DLC-2 and retrieve DTC. Are any of the following DTCs displayed? DTC B1213, B1600, B1601, B1602, B1681	Yes	Go to the appropriate DTC inspection. (See DTC TABLE [YF (2.0L Zetec)].)
5		No	Go to the next step.
6	Inspect the following wiring harnesses and connectors: • Between coil terminal 3 and terminal 19 • Between coil terminal 4 and terminal 53 Is there any malfunction?	Yes	Repair or replace the wiring harness and connector.
6		No	Go to the next step.
7	Verify the following: • Vacuum connection • External fuel shut off or accessory (such as kill switch, alarm) • Fuel quality: proper octane, contamination, winter/summer blend • No air leakage from intake-air system • Intake-air system restriction (such as air cleaner element, fresh air duct) • Proper sealing of intake manifold and components attached to intake manifold: EGR valve, IAC valve • Ignition wiring • Electrical connections • Fuses • Smooth operation of throttle valve Are all items normal?	Yes	Go to the next step.
7		No	Service if necessary. Repeat Step 7.
8	Connect the WDS or equivalent to the DLC-2. Retrieve any continuous memory and KOEO DTCs using the WDS or equivalent. Are any DTCs displayed?	Yes	DTC is displayed: Go to the appropriate DTC inspection. (See DTC TABLE [YF (2.0L Zetec)].) Communication error message is displayed: Inspect for the following: • Open circuit in wiring harness between main relay terminal 87 and PCM terminal 71, 97 • Open circuit in wiring harness between main relay terminal 86 and GND • Main relay is stuck open. • Open or poor GND circuit (PCM terminal 24, 51, 76, 77 or 103) • Poor connection of vehicle body GND
8		No	No DTC is displayed: Go to the next step.
9	Does the engine start with the throttle valve closed?	Yes	Go to Step 29.
9	Does the engine start with the throttle valve closed?	No	Go to the next step.
10	Will the engine start and run smoothly at part throttle?	Yes	Inspect the IAC valve and wiring harness.
10	Will the engine start and run smoothly at part throttle?	No	Go to the next step.
11	Connect the WDS or equivalent to the DLC-2. Access the RPM PID. Does the RPM PID indicate the engine speed when cranking the engine?	Yes	Go to the next step.
11		No	Inspect for the following: • Open or short circuit in CKP sensor • Open or short circuit between CKP sensor terminal 1 and PCM terminal 22 • Open or short circuit between CKP sensor terminal 2 and PCM terminal 21 • Open or short circuit in CKP sensor wiring harnesses If the CKP sensor and wiring harness are normal, go to the next step.
12	Visually inspect the CKP sensor and crankshaft pulley teeth. Are the CKP sensor and crankshaft pulley teeth normal?	Yes	Go to the next step.
12		No	Replace the malfunctioning part.
13	Measure the gap between the CKP sensor and crankshaft pulley teeth. Specification 0.5-1.9 mm {0.020-0.75 in} Is the gap within the specification?	Yes	Go to the next step.
13		No	Adjust the CKP sensor. (See CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/INSTALLATION [YF (2.0L Zetec)].)
14	Inspect the ignition coil-related wiring harnesses (intermittent open or short circuit) for all cylinders. Are the wiring harnesses normal?	Yes	Go to the next step.
14		No	Repair the wiring harnesses.
15	Perform the spark test. (See Spark Test.) Is a strong blue spark visible at each cylinder?	Yes	Go to the next step.
15		No	Repair or replace the malfunctioning part according to spark test result.
16	Inspect the spark plugs. Is any spark plug wet, covered with carbon, or grayish white?	Yes	Spark plug is wet or covered with carbon: Inspect for fuel leakage from injector. Spark plug is grayish white: Inspect the fuel injector for clogging.
16		No	Install the spark plugs on original cylinders. Go to the next step.
17	Remove and shake the PCV valve. Does the PCV valve rattle?	Yes	Go to the next step.
17	Remove and shake the PCV valve. Does the PCV valve rattle?	No	Replace the PCV valve.
18	Visually inspect the exhaust system parts. Is there any deformed exhaust system part?	Yes	Replace the part.
18		No	Go to the next step.
19	Inspect the inertia fuel shutoff (IFS) switch. Is the IFS switch okay?	Yes	Go to the next step.
19		No	Replace the IFS switch.
20	Install a fuel pressure gauge to the fuel line. Connect the WDS or equivalent to the DLC-2. Turn ON and/or OFF using the FP PID. Is fuel line pressure correct when the FP PID is turned On/Off five times? (See FUEL LINE PRESSURE INSPECTION [YF (2.0L Zetec)].)	Yes	Go to the next step.
20		No	Zero or low: Inspect the fuel pump, IFS switch, and the fuel pump relay related circuit. Inspect the fuel line for clogging. • If there is no malfunction, replace the fuel pump unit. (See FUEL PUMP UNIT REMOVAL/INSTALLATION [YF (2.0L Zetec)].) High: Replace the fuel pump unit. (See FUEL PUMP UNIT REMOVAL/INSTALLATION [YF (2.0L Zetec)].)
21	Visually inspect the fuel injector, O-ring, and fuel line for fuel leakage. Service as necessary. Is fuel line pressure held after the ignition switch is turned off? (See FUEL LINE PRESSURE INSPECTION [YF (2.0L Zetec)].)	Yes	Go to the next step.
21		No	Inspect the fuel injector. (See FUEL INJECTOR INSPECTION [YF (2.0L Zetec)].) • If fuel injector is normal, replace fuel pump unit. (See FUEL PUMP UNIT REMOVAL/INSTALLATION [YF (2.0L Zetec)])
22	Disconnect the vacuum hose between the purge valve and intake manifold from the purge valve side. Plug the open end of vacuum hose. Start the engine. Is starting condition improved?	Yes	Inspect if the purge valve is stuck open mechanically. Inspect the evaporative emission control system.
22		No	Go to the next step.
23	Is air leakage felt or heard at the intake-air system components while racing the engine to a higher speed?	Yes	Repair or replace any malfunctioning part.
23		No	Go to the next step.
24	Inspect engine condition while tapping the EGR valve housing. Does the engine condition improved?	Yes	Replace the EGR valve.
24		No	Go to the next step.
25	Is engine compression correct?	Yes	Inspect the valve timing.
25	Is engine compression correct?	No	Inspect for causes.
26	Verify test results. • If normal, return to the diagnostic index to service any additional symptoms. (See ENGINE SYMPTOM TROUBLESHOOTING [YF (2.0L Zetec)].) • If any malfunction remains, inspect related service information and, repair or diagnosis accordingly. - If the vehicle is repaired, troubleshooting completed. - If the vehicle is not repaired or additional diagnostic information is not available, replace the PCM. (See PCM REMOVAL/INSTALLATION [YF (2.0L Zetec)].)