Symptom | Possible Sources | Action |
Loss of oil | * Oil leaks on components that are either coated in oil themselves or on components local to them. | * CHECK for evidence of oil leaks on components. Use an ultraviolet (UV) leak tester if an oil leak is not evident. INSTALL new gaskets or components as required. |
* Internal or external leak at the oil cooler. | * CHECK the coolant expansion tank for a film of oil on the coolant surface. INSTALL a new oil cooler or oil cooler gasket. |
* Leak at the crankshaft seal. | * INSTALL a new crankshaft seal. |
* Leaks from oil carrying components or basic engine. | * CHECK for cracks in oil carrying components of the basic engine by means of a UV leak test. INSTALL new components or seals as necessary. |
Oil consumption | * Use of the wrong type of engine oil. | * DETERMINE the last type of engine oil used and compare with the specification. Change the engine oil to the specification. |
* Faulty positive crankcase ventilation (PCV) system. - Hoses or ventilation or breather valves are blocked. This causes excessive pressure in the crankcase which causes more oil to enter the combustion chamber. - PCV oil separator is faulty and engine oil can enter the combustion chamber through the intake manifold. | * CHECK if the PCV system is operating correctly and repair as necessary. REFER to: Engine Emission Control (303-08A Engine Emission Control - 1.25L Duratec-16V (Sigma)/1.3L Duratec-8V (Rocam)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), Diagnosis and Testing), Engine Emission Control (303-08C Engine Emission Control - 2.0L Duratec-HE (MI4), Diagnosis and Testing), Engine Emission Control - Vehicles With: Vacuum Exhaust Gas Recirculation (EGR) Valve (303-08B Engine Emission Control - 1.4L Duratorq-TDCi (DV) Diesel, Diagnosis and Testing), Engine Emission Control (303-08D Engine Emission Control - 1.6L Duratorq-TDCi (DV) Diesel, Description and Operation). |
* Turbocharger seals (diesel engine only). | * INSTALL a new turbocharger. REFER to: Turbocharger (303-04D Fuel Charging and Controls - Turbocharger - 1.4L Duratorq-TDCi (DV) Diesel, Removal and Installation), Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel (303-04G Fuel Charging and Controls - Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel, Removal and Installation). |
* Damaged gaskets or mating surfaces. - Cylinder head gasket is damaged or mating face are warped. - Valve stem oil seals are worn and engine oil can enter the combustion chamber between the valve stem and the valve stem guide. | * CHECK the gaskets and mating surfaces for damage. - Remove the cylinder head. CHECK the mating faces, cylinder head gasket and the evenness of the cylinder head and engine block mating faces. - INSTALL new valve seals.REFER to: Valve Seals (303-01A Engine - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), In-vehicle Repair), Valve Seals (303-01C Engine - 1.3L Duratec-8V (Rocam), In-vehicle Repair), Valve Seals (303-01D Engine - 2.0L Duratec-HE (MI4), In-vehicle Repair), Valve Seals (303-01B Engine - 1.4L Duratorq-TDCi (DV) Diesel, In-vehicle Repair), Valve Seals (303-01E Engine - 1.6L Duratorq-TDCi (DV) Diesel, In-vehicle Repair). |
* Piston ring or cylinder liner wear. | * INSTALL new components as necessary. |
* Damaged cylinder liners or excessive clearance of engine components. - Pistons - Piston rings (clearance in groove and end gap) - Cylinder liners | * CHECK the running surfaces and clearances of the individual engine components. INSTALL new components as necessary. INSTALL a new cylinder block if necessary. * CHECK the pistons. REFER to: Piston Inspection (303-00 Engine System - General Information, General Procedures). * CHECK the piston rings. REFER to: (303-00 Engine System - General Information) Piston Ring-to-Groove Clearance (General Procedures), Piston Ring End Gap (General Procedures). |
Coolant consumption | * Cooling system components. | * CHECK the coooling system. REFER to: Engine Cooling (303-03A Engine Cooling - 1.25L Duratec-16V (Sigma)/1.3L Duratec-8V (Rocam)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), Diagnosis and Testing), Engine Cooling (303-03C Engine Cooling - 2.0L Duratec-HE (MI4), Diagnosis and Testing), Engine Cooling (303-03B Engine Cooling - 1.4L Duratorq-TDCi (DV) Diesel, Diagnosis and Testing), Engine Cooling (303-03D Engine Cooling - 1.6L Duratorq-TDCi (DV) Diesel, Diagnosis and Testing). |
* Oil cooler. | * INSTALL a new oil cooler. |
* Damaged gaskets or warped mating faces. | * CHECK the cylinder head gasket for damage. CHECK the cylinder head for distortion. |
* Cracks or fractures in engine components surrounded by coolant, such as cylinder liners and cylinder head combustion chamber. | * DETERMINE the damaged engine component(s) and install new component(s) as necessary. |
Engine will not crank | * Battery or cables. | * CHECK the battery, bracket and cables. REFER to: Battery (414-01 Battery, Mounting and Cables, Diagnosis and Testing). |
* Starter motor or cables. | * CHECK the starting system. REFER to: Starting System (303-06 Starting System, Diagnosis and Testing). |
Engine cranks but will not start | * Fuel tank is empty. | * CHECK the fuel level. |
* Water in fuel (diesel engine only). | * Drain the water from the fuel system. Engine - 1.4L Duratorq-TDCi (DV) Diesel/Engine - 1.6L Duratorq-TDCi (DV) Diesel. REFER to: Fuel System - 1.4L Duratorq-TDCi (DV) Diesel/1.6L Duratorq-TDCi (DV) Diesel (310-00 Fuel System - General Information, Diagnosis and Testing). |
* Fuel filter blocked. | * INSTALL a new fuel filter. REFER to: (310-01 Fuel Tank and Lines) Fuel Filter - 1.4L Duratorq-TDCi (DV) Diesel (Removal and Installation), Fuel Filter - 1.6L Duratorq-TDCi (DV) Diesel (Removal and Installation). |
* Engine intake air system. | * CHECK the intake air system. REFER to: Intake Air Distribution and Filtering (303-12 Intake Air Distribution and Filtering, Diagnosis and Testing). |
* Glow plug faulty (diesel engine only). | * CHECK the glow plugs. INSTALL new glow plugs as necessary. REFER to: Glow Plug (303-07B Glow Plug System - 1.4L Duratorq-TDCi (DV) Diesel, Removal and Installation), Glow Plugs (303-07D Glow Plug System - 1.6L Duratorq-TDCi (DV) Diesel, Removal and Installation). |
* Engine management system. | * CHECK the engine management system. REFER to: Electronic Engine Controls (303-14 Electronic Engine Controls, Diagnosis and Testing). |
* Ignition system (petrol engines only). | * CHECK the ignition system. REFER to: Engine Ignition (303-07A Engine Ignition, Diagnosis and Testing), Engine Ignition (303-07C Engine Ignition - 2.0L Duratec-HE (MI4), Diagnosis and Testing). |
* Incorrect valve timing. | * CHECK and adjust the valve timing. REFER to: Timing Belt (303-01A Engine - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), In-vehicle Repair), Timing Chain (303-01C Engine - 1.3L Duratec-8V (Rocam), In-vehicle Repair), Crankshaft Pulley (303-01D Engine - 2.0L Duratec-HE (MI4), In-vehicle Repair), Timing Belt (303-01B Engine - 1.4L Duratorq-TDCi (DV) Diesel, In-vehicle Repair), Timing Belt (303-01E Engine - 1.6L Duratorq-TDCi (DV) Diesel, In-vehicle Repair). |
* Broken or damaged timing belt/timing chain or pulley/sprocket. | * CHECK the timing belt/timing chain and sprockets/pulleys. INSTALL new components as necessary. REFER to: Timing Belt (303-01A Engine - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), In-vehicle Repair), Timing Belt (303-01E Engine - 1.6L Duratorq-TDCi (DV) Diesel, In-vehicle Repair), Timing Chain (303-01C Engine - 1.3L Duratec-8V (Rocam), In-vehicle Repair), Timing Chain (303-01D Engine - 2.0L Duratec-HE (MI4), In-vehicle Repair), Timing Belt (303-01B Engine - 1.4L Duratorq-TDCi (DV) Diesel, In-vehicle Repair). |
Very poor power output or fuel consumption too high or engine running rough | * Fuel system. | * CHECK the fuel system. REFER to: Fuel Charging and Controls (303-04B Fuel Charging and Controls - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), Diagnosis and Testing), Fuel Charging and Controls (303-04A Fuel Charging and Controls - 1.3L Duratec-8V (Rocam), Diagnosis and Testing), Fuel Charging and Controls (303-04C Fuel Charging and Controls - 1.4L Duratorq-TDCi (DV) Diesel, Diagnosis and Testing), Fuel Charging and Controls (303-04F Fuel Charging and Controls - 1.6L Duratorq-TDCi (DV) Diesel, Diagnosis and Testing). |
* Engine intake air system. | * CHECK the intake air system. REFER to: Intake Air Distribution and Filtering (303-12 Intake Air Distribution and Filtering, Diagnosis and Testing). |
* Exhaust system blocked. | * CHECK the exhaust system. REFER to: Exhaust System (309-00 Exhaust System, Description and Operation). |
* Engine management system. | * CHECK the engine management system. REFER to: Electronic Engine Controls (303-14 Electronic Engine Controls, Diagnosis and Testing). |
* Fault in ignition system (petrol engines only). | * CHECK the ignition system. REFER to: Engine Ignition (303-07A Engine Ignition, Diagnosis and Testing), Engine Ignition (303-07C Engine Ignition - 2.0L Duratec-HE (MI4), Diagnosis and Testing). |
* Turbocharger (diesel engine only). | * CHECK the turbocharger. REFER to: Turbocharger (303-04D Fuel Charging and Controls - Turbocharger - 1.4L Duratorq-TDCi (DV) Diesel, Diagnosis and Testing), Turbocharger (303-04G Fuel Charging and Controls - Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel, Diagnosis and Testing). |
* Incorrect valve timing. Timing belt/timing sprocket or pulley/sprocket damaged. | * CHECK and adjust the valve timing. REFER to: Timing Belt (303-01A Engine - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), In-vehicle Repair), Timing Chain (303-01C Engine - 1.3L Duratec-8V (Rocam), In-vehicle Repair), Crankshaft Pulley (303-01D Engine - 2.0L Duratec-HE (MI4), In-vehicle Repair), Timing Belt (303-01B Engine - 1.4L Duratorq-TDCi (DV) Diesel, In-vehicle Repair), Timing Belt (303-01E Engine - 1.6L Duratorq-TDCi (DV) Diesel, In-vehicle Repair). |
* Ignition timing incorrect (petrol engines only). | * CHECK the electronic engine controls. REFER to: Electronic Engine Controls (303-14 Electronic Engine Controls, Diagnosis and Testing). |
Noisy running | * Engine auxiliary components loose or damaged. | * CHECK engine auxiliary components for damage or looseness. REFER to: Timing Belt (303-01A Engine - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), In-vehicle Repair), Timing Chain (303-01C Engine - 1.3L Duratec-8V (Rocam), In-vehicle Repair), Timing Chain (303-01D Engine - 2.0L Duratec-HE (MI4), In-vehicle Repair), Timing Belt (303-01B Engine - 1.4L Duratorq-TDCi (DV) Diesel, In-vehicle Repair), Timing Belt (303-01E Engine - 1.6L Duratorq-TDCi (DV) Diesel, In-vehicle Repair). |
Noisy running, misfiring, backfiring or knocking | * Incorrect fuel | * DETERMINE which type of fuel was last put in the tank (note the country specific fuel specifications). |
* Water in fuel or fuel contaminated. | * CHECK the fuel system for water or other contamination. |
* Valve timing incorrect, timing belt/chain or pulley/sprocket damaged. | * CHECK and adjust the valve timing. REFER to: Timing Belt (303-01A Engine - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), In-vehicle Repair), Timing Chain (303-01C Engine - 1.3L Duratec-8V (Rocam), In-vehicle Repair), Crankshaft Pulley (303-01D Engine - 2.0L Duratec-HE (MI4), In-vehicle Repair), Timing Belt (303-01B Engine - 1.4L Duratorq-TDCi (DV) Diesel, In-vehicle Repair), Timing Belt (303-01E Engine - 1.6L Duratorq-TDCi (DV) Diesel, In-vehicle Repair). |
Noisy running or valve train noise | * Valve clearance too large due to faulty valve tappets or worn valve train components. | * INSTALL new hydraulic lash adjusters or adjust the valve clearance. REFER to: Valve Clearance Adjustment (303-01A Engine - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), General Procedures), Camshaft Followers (303-01C Engine - 1.3L Duratec-8V (Rocam), In-vehicle Repair), Valve Clearance Adjustment (303-01D Engine - 2.0L Duratec-HE (MI4), General Procedures), Hydraulic Lash Adjuster (303-01B Engine - 1.4L Duratorq-TDCi (DV) Diesel, In-vehicle Repair), Camshaft (303-01E Engine - 1.6L Duratorq-TDCi (DV) Diesel, In-vehicle Repair). |
* Timing belt or timing chain damaged. | * INSTALL a new timing belt or timing chain. REFER to: Timing Belt (303-01A Engine - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), In-vehicle Repair), Timing Chain (303-01C Engine - 1.3L Duratec-8V (Rocam), In-vehicle Repair), Timing Chain (303-01D Engine - 2.0L Duratec-HE (MI4), In-vehicle Repair), Timing Belt (303-01B Engine - 1.4L Duratorq-TDCi (DV) Diesel, In-vehicle Repair), Timing Belt (303-01E Engine - 1.6L Duratorq-TDCi (DV) Diesel, In-vehicle Repair). |
* Timing belt or timing chain incorrectly tensioned. | * CHECK the timing belt or timing chain tension. INSTALL a new timing belt or timing chain as necessary. REFER to: Timing Belt (303-01A Engine - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), In-vehicle Repair), Timing Chain (303-01C Engine - 1.3L Duratec-8V (Rocam), In-vehicle Repair), Timing Chain (303-01D Engine - 2.0L Duratec-HE (MI4), In-vehicle Repair), Timing Belt (303-01B Engine - 1.4L Duratorq-TDCi (DV) Diesel, In-vehicle Repair), Timing Belt (303-01E Engine - 1.6L Duratorq-TDCi (DV) Diesel, In-vehicle Repair). |
Noisy running or engine noise | * Engine components - Pistons - Piston rings - Connecting rod big end, main bearing or thrust bearing journals - Connecting rods bent or damaged. | * CHECK the engine components for wear or damage. Make sure all components are within specification. INSTALL new components as necessary. |