mondeo 2011 - Fuel Issue

Moni23 · 01-04-2025, 10:42 PM

Hi Crew a Newbie here so hopefully I am posting correctly. Need some advice.

I have a 2011 Ford Mondeo Zetec Diesel version beautiful car. I fueled up car at local garage, drove 30km was travelling down the freeway at about 80km/h then all off a sudden lights came on the dash. And the car died.

Pushed it to side of road as car would not start, looks like not getting any fuel to engine.

Put a scan tool on (kincrome OBD code reader) Code 194: Fuel Rail Pressure Sensor CKT Intermittent came up on screen.

My question is: Would that be the issue? or is there something else

Today I replace a fuel filter which was black, manage to pump up fuel with a hand pump but still the same issue.
Even had the RAC come and have a look who thumped the fuel tank with a rubber mallet. (Didn't think they had fuel pumps in the tank?)

Anyone have any advice

**russellw** · 02-04-2025, 03:23 PM

I suspect the fuel rail pressure sensor is the issue as without a valid reading the vehicle won't start. The sensor is located just under the fuel rail but isn't really a DIY job.

Intermittent faults are often wiring related so check for loose or corroded connections in the fuel rail pressure sensor circuit and check the wiring from the sensor for signs of chafing.

Here is the information from the PCED reference library.

This DTC sets when the FRP voltage is intermittent or erratic.
• FRP circuit open
• FRP circuit short to voltage
• FRP circuit short to VREF circuit
• SIGRTN circuit open
• VREF circuit open
• VREF circuit short to SIGRTN circuit
• VREF circuit short to ground
• Damaged FRP sensor connector
• Damaged FRP sensor

The presence of this DTC may indicate the vehicle is operating in derate mode and may experience a loss of power.

Pinpoint tests (DTCs P0190, P0192, P0193, P0194, P1168 or P1169).

MB2 INTERMITTENT CHECK
• Ignition ON, engine OFF.
• Access the PCM and monitor the FRP (VOLT) PID.
• While observing the PID, carry out the following:
Wiggle all accessible harness from the FRP sensor to the PCM and lightly tap on the sensor.
Wiggle the FRP sensor connector.
Look for sudden changes in the voltage when the harness and connector are wiggled or when the FRP sensor is tapped.

MB3 CHECK FOR VREF VOLTAGE AT THE FRP SENSOR
• Ignition OFF.
• FRP Sensor connector disconnected.
• Ignition ON, engine OFF.
• Measure the voltage between: ( + ) FRP Sensor Connector, Harness Side (VREF) and ( - ) FRP Sensor Connector, Harness Side (SIGRTN)

Is the voltage between 4.5 - 5.5 V?
YES - go to MB4. NO - go to Pinpoint Test B (not shown here)

MB4 CHECK THE FRP CIRCUIT FOR AN OPEN
⦁ Ignition OFF.
⦁ PCM-E connector disconnected.
⦁ Measure the resistance between: ( + ) FRP Sensor Connector, Harness Side and (-) PCM-E Connector, Harness Side

Is the resistance less than 5 ohms?
YES - go to MB5. NO - Repair the open circuit.

MB5 CHECK THE FRP CIRCUIT FOR A SHORT
• Measure the resistance between: ( + ) FRP Sensor Connector, Harness Side FRP and ( - ) Ground
• Measure the resistance between: ( + ) FRP Sensor Connector, Harness Side FRP and ( - ) FRP Sensor Connector, Harness Side VREF
• Measure the resistance between: ( + ) FRP Sensor Connector, Harness Side FRP and ( - ) FRP Sensor Connector, Harness Side SIGRTN

Are the resistances greater than 10K ohms?
YES - go to MB6. NO - Repair the short circuit.

MB6 CHECK THE FRP CIRCUIT FOR A SHORT TO VOLTAGE
• Ignition ON, engine OFF.
⦁ Measure the voltage between: ( + ) FRP Sensor Connector, Harness Side FRP and (-) Ground

Is any voltage present?
YES - Repair the short circuit. NO - go to MB7.

M87 CHECK THE FUNCTIONALITY OF THE FRP SENSOR
⦁ Ignition OFF.
⦁ PCM-E connector connected.
⦁ FRP Sensor connector connected.
⦁ Ignition ON, engine running.
⦁ Access the PCM and monitor the FRP (VOLT) PIO.
⦁ Access the PCM and control the RPMOSO (RPM) PIO.
⦁ Increase the engine speed to 1,400 RPM.
⦁ Access the PCM and control the FRP_OSO (PRESS) PIO.
⦁ Increase the FRP OSD PIO pressure to 180 MPa (26,106 psi) and monitor the FRP voltage.
⦁ Decrease the FRP_OSO PIO pressure to 40 MPa (5,801 psi) and monitor the FRP voltage.

Does the FRP voltage increase and decrease when the FRP_D5D PID pressure is increased and decreased during each step?
YES - No concerns are present. NO - Install a new FRP sensor.

As you can see some of those require an advanced scan tool to read values or control actions but some can be done with a multimeter.

The FRP sensor should have 3 pins. VREF is a plain grey wire , the Grey / Orange stripe wire is Ground and the Blue / Brown stripe wire is SIGRTN although there are two versions and the other has a Green wire with a Violet stripe for Ground.

Moni23 · 02-04-2025, 11:14 PM

Thank you russellw

Another question . . . . . or two

We took the fuel line off the pump, the one that goes to the injectors. Went to start the car and no fuel coming up thru the fuel pump? Is that a sign of a stuffed fuel pump?

and

does the battery need to be at a certain % to make the high-pressure fuel pump run properly?

Citroënbender · Yesterday, 05:41 AM

Silly question perhaps, but you definitely, 100% put diesel in the tank - not petrol?

**russellw** · Yesterday, 11:00 AM

Quote:

Originally Posted by Moni23

Thank you russellwAnother question . . . . . or twoWe took the fuel line off the pump, the one that goes to the injectors. Went to start the car and no fuel coming up thru the fuel pump? Is that a sign of a stuffed fuel pump?and does the battery need to be at a certain % to make the high-pressure fuel pump run properly?

Not necessarily and yes. Generally fuel pump issues (there are two, a transfer pump and a pressure pump) will throw their own DTC's. If you want to know a bit more have a read of section 3603-04d of the MC Mondeo workshop manual which you can find in our technical portal.