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General Procedures > < Ignition Switch

Focus 1999 (08.1998-12.2004)

  • Mechanical Repairs
  • 3 Powertrain
  • 303 Engine
  • 303-00 Engine System - General Information
  • Diagnosis and Testing
  • Engine

Engine System - General Information - Engine Focus 1999 (08/1998-12/2004)
Diagnosis and Testing

  1. Verify the customer concern by operating the system
  1. Visually inspect for obvious signs of mechanical or electrical damage.

Visual Inspection Chart

Mechanical Electrical
  • Coolant leaks
  • Oil leaks
  • Fuel system leaks
  • Visibly damaged or worn parts
  • Loose or missing nuts or bolts
  • Fuse(s)
  • Loose or corroded connector(s)
  • Control module
  • Damaged or worn switch(es)
  1. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
  1. If the concern is not visually evident, verify the symptom and refer to the Symptom Chart.

Symptom Chart

Symptom Possible Sources Action
Loss of oil
*
Use of the wrong type of engine oil.
*
Determine the engine oil last filled (e.g. last invoice or receipt). Compare the specifications and renew if necessary.
*
Pressure in the cylinder block too high.
-
Faulty positive crankcase ventilation (PCV) system.
-
Poor sealing between combustion chamber and crankcase.
*
Remove the oil filler cap. Close off the opening by hand. If excess pressure is noticed when the engine is running:
-
Check the operation of the PCV system and repair it as necessary.
-
Screw the compressed air lines into the spark plug hole of each cylinder in turn, apply compressed air and check for escaping air when the oil filler cap is removed. If there is a perceptible flow of air, inspect the cylinder liner surfaces and pistons for damage. REFER to General Procedures in this section.
*
Leaking as a result of damaged oil seal or incorrect oil seal carrier alignment.
-
Camshaft oil seal.
-
Front or rear crankshaft oil seal.
*
Check the alignment of the oil seal carrier, and re-align if necessary. Renew the oil seal.
*
Damaged gaskets or mating faces.
*
Check gaskets and mating faces for damage.
*
Cylinder head gasket or mating face is damaged, engine oil can escape from the engine between cylinder head and cylinder block or get into the cooling system.
*
Open the coolant expansion tank cap and check for oil sludge or a film of oil on the surface of the coolant.
*
Remove the cylinder head. Zetec-SE -
REFER to: Cylinder Head (303-01A Engine - 1.4L/1.6L, In-vehicle Repair).
Zetec-E -
REFER to: Cylinder Head (303-01B Engine - 1.6L Zetec-E (Zetec)/1.8L Zetec-E (Zetec)/2.0L Zetec-E (Zetec), In-vehicle Repair).
1.8L Endura-DI and 1.8L Duratorque TDCi - REFER to: (303-01C Engine - 1.8L Diesel)
Cylinder Head - 1.8L Diesel, Vehicles With: Common Rail Fuel Injection (In-vehicle Repair),
Cylinder Head - 1.8L Diesel, Vehicles Without: Common Rail Fuel Injection (In-vehicle Repair).
-
Check the mating faces and cylinder head gasket, and check the flatness of the cylinder head mating face. REFER to General Procedures in this section.
-
Renew the cylinder head if necessary.
*
Oil leaks on components that are either coated in oil or have oilways, oil leaks on ancillary components.
*
Locate cracks in oil-carrying components or the basic engine by means of a UV leak test, and renew the relevant components or seals.
*
Faulty PCV system
-
Hoses or ventilation/breather valve are blocked. This causes excessive pressure in the crankcase which causes more oil to enter the combustion chamber.
-
The PCV system oil separator is faulty and engine oil can enter the combustion chamber through the intake manifold.
*
Check that the PCV system works correctly, repair it if necessary.
*
Damaged cylinder liners or too much clearance on engine components.
*
Check the running surfaces and clearances of the individual engine components, and renew if necessary. Renew the cylinder block if necessary.
*
Pistons.
*
Pistons.
*
Piston rings (ring clearances and ring gap).
*
Piston rings.
*
Cylinder liners.
*
Cylinder liners.
*
Valve stems and guides.
*
Valve stems and guides.
*
Damaged gaskets or mating faces
*
Check gaskets and mating faces for damage.
*
Cylinder head gasket or mating face is damaged, and engine oil can enter the combustion chamber.
*
Remove the cylinder head. Zetec-SE -
REFER to: Cylinder Head (303-01A Engine - 1.4L/1.6L, In-vehicle Repair).
Zetec-E -
REFER to: Cylinder Head (303-01B Engine - 1.6L Zetec-E (Zetec)/1.8L Zetec-E (Zetec)/2.0L Zetec-E (Zetec), In-vehicle Repair).
1.8L Endura-DI and 1.8L Duratorque TDCi - REFER to: (303-01C Engine - 1.8L Diesel)
Cylinder Head - 1.8L Diesel, Vehicles With: Common Rail Fuel Injection (In-vehicle Repair),
Cylinder Head - 1.8L Diesel, Vehicles Without: Common Rail Fuel Injection (In-vehicle Repair).
-
Check the mating faces and cylinder head gasket, and check the flatness of the cylinder head mating face. REFER to General Procedures in this section.
-
Renew the cylinder head if necessary.
*
Valve stem oil seals are damaged and engine oil can enter the combustion chamber between valve stem and valve guide. This becomes particularly apparent on overrun.
*
Renew the valve stem oil seals. Zetec-SE -
REFER to: Valve Seals (303-01A Engine - 1.4L/1.6L, In-vehicle Repair).
Zetec-E -
REFER to: Valve Seals (303-01B Engine - 1.6L Zetec-E (Zetec)/1.8L Zetec-E (Zetec)/2.0L Zetec-E (Zetec), In-vehicle Repair).
1.8L Endura-DI and 1.8L Duratorque TDCi -
REFER to: Valve Seals (303-01C Engine - 1.8L Diesel, In-vehicle Repair).
*
Cracks in engine components with oilways or engine components coated in oil, e.g. cylinder liners, pistons and oil galleries and passages.
*
Add the engine oil additive for the UV leak test and bring the engine oil to at least 80°C so that the engine oil additive can enter any existing cracks. Allow the engine to cool to ambient temperature, remove the affected component and dismantle it if necessary. Check the engine component using the UV leak test procedure, and renew it if necessary.
Coolant consumption
*
Damaged gaskets or mating faces
-
The cylinder head gasket or mating face is damaged. Coolant can enter the combustion chamber or the crankcase.
*
Remove the cylinder head. Zetec-SE -
REFER to: Cylinder Head (303-01A Engine - 1.4L/1.6L, In-vehicle Repair).
Zetec-E -
REFER to: Cylinder Head (303-01B Engine - 1.6L Zetec-E (Zetec)/1.8L Zetec-E (Zetec)/2.0L Zetec-E (Zetec), In-vehicle Repair).
1.8L Endura-DI and 1.8L Duratorque TDCi - REFER to: (303-01C Engine - 1.8L Diesel)
Cylinder Head - 1.8L Diesel, Vehicles With: Common Rail Fuel Injection (In-vehicle Repair),
Cylinder Head - 1.8L Diesel, Vehicles Without: Common Rail Fuel Injection (In-vehicle Repair).
-
Check the mating faces and cylinder head gasket, and check the flatness of the cylinder head mating face. REFER to General Procedures in this section.
-
Renew the cylinder head if necessary.
*
Cracks or material breaks in engine components around which coolant flows, such as cylinder liner surfaces and the cylinder head.
*
Determine the damaged engine component and renew it.
Engine will not start
*
Battery or wiring is faulty.
*
Check the battery, electrical connections and cables.
REFER to: Charging System (414-00 Charging System - General Information, Diagnosis and Testing).
*
Starter motor or wiring is faulty.
*
Check the starter system.
REFER to: Starting System (303-06 Starting System, Diagnosis and Testing).
*
Fault in fuel system.
*
Check the fuel system. Zetec-SE -
REFER to: Fuel Charging and Controls (303-04A Fuel Charging and Controls - 1.6L Zetec-SE (Sigma)/1.4L, Diagnosis and Testing).
Zetec-E -
REFER to: Fuel Charging and Controls (303-04B Fuel Charging and Controls - 1.6L Zetec-E (Zetec)/1.8L Zetec-E (Zetec)/2.0L Zetec-E (Zetec), Diagnosis and Testing).
1.8L Endura-DI and 1.8L Duratorque TDCi -
REFER to: Fuel Charging and Controls (303-04C Fuel Charging and Controls - 1.8L Diesel (75 PS/90 PS), Diagnosis and Testing).
*
Fuel tank is empty.
*
Check the fluid level.
*
Fault in ignition system (petrol engines only).
*
Check the ignition system. Zetec-SE -
REFER to: Engine Ignition (303-07A Engine Ignition - 1.6L Zetec-SE (Sigma)/1.4L, Diagnosis and Testing).
Zetec-E -
REFER to: Engine Ignition (303-07B Engine Ignition - 1.6L Zetec-E (Zetec)/1.8L Zetec-E (Zetec)/2.0L Zetec-E (Zetec), Diagnosis and Testing).
*
Fault in engine management system.
*
Check the engine management system.
REFER to: Electronic Engine Controls (303-14, Diagnosis and Testing).
*
Intake system is faulty.
-
Intake system air leak.
-
Blocked air cleaner.
-
Faulty idle air control valve.
*
Check the intake system.
REFER to: Intake Air Distribution and Filtering (303-12 Intake Air Distribution and Filtering, Diagnosis and Testing).
*
Fault in valve train.
-
Burned out exhaust valve.
-
Timing incorrectly adjusted.
-
Cracked or damaged timing belt.
*
Connect compressed air to the cylinders. If air flows out through the intake manifold or the exhaust pipe, check the valve train.
*
Faulty engine components.
-
Burned through piston.
-
Piston rings.
-
Cylinder head gasket.
-
Big-end and/or main bearing journals.
*
Connect the compressed air line to the cylinder. If air is escaping from the opened oil filler cap, remove the cylinder head in accordance with the operation and check the components. Zetec-SE -
REFER to: Cylinder Head (303-01A Engine - 1.4L/1.6L, In-vehicle Repair).
Zetec-E -
REFER to: Cylinder Head (303-01B Engine - 1.6L Zetec-E (Zetec)/1.8L Zetec-E (Zetec)/2.0L Zetec-E (Zetec), In-vehicle Repair).
1.8L Endura-DI and 1.8L Duratorque TDCi - REFER to: (303-01C Engine - 1.8L Diesel)
Cylinder Head - 1.8L Diesel, Vehicles With: Common Rail Fuel Injection (In-vehicle Repair),
Cylinder Head - 1.8L Diesel, Vehicles Without: Common Rail Fuel Injection (In-vehicle Repair).
Very poor power output / fuel consumption too high / rough engine running
*
Fault in fuel system.
*
Check the fuel system. Zetec-SE -
REFER to: Fuel Charging and Controls (303-04A Fuel Charging and Controls - 1.6L Zetec-SE (Sigma)/1.4L, Diagnosis and Testing).
Zetec-E -
REFER to: Fuel Charging and Controls (303-04B Fuel Charging and Controls - 1.6L Zetec-E (Zetec)/1.8L Zetec-E (Zetec)/2.0L Zetec-E (Zetec), Diagnosis and Testing).
1.8L Endura-DI and 1.8L Duratorque TDCi -
REFER to: Fuel Charging and Controls (303-04C Fuel Charging and Controls - 1.8L Diesel (75 PS/90 PS), Diagnosis and Testing).
*
Fault in ignition system (petrol engines only).
*
Check the ignition system. Zetec-SE -
REFER to: Engine Ignition (303-07A Engine Ignition - 1.6L Zetec-SE (Sigma)/1.4L, Diagnosis and Testing).
Zetec-E -
REFER to: Engine Ignition (303-07B Engine Ignition - 1.6L Zetec-E (Zetec)/1.8L Zetec-E (Zetec)/2.0L Zetec-E (Zetec), Diagnosis and Testing).
*
Fault in engine management system.
*
Check the engine management system.
REFER to: Electronic Engine Controls (303-14, Diagnosis and Testing).
*
Intake system is faulty.
-
Intake air leak.
-
Air cleaner is blocked.
-
Faulty idle air control valve.
*
Check the intake system.
REFER to: Intake Air Distribution and Filtering (303-12 Intake Air Distribution and Filtering, Diagnosis and Testing).
*
Fault in valve train.
-
Burned out exhaust valve.
-
Timing incorrectly adjusted.
-
Cracked or damaged timing belt.
*
Connect compressed air to the cylinders. If air flows out through the intake manifold or the exhaust pipe, check the valve train.
*
Engine components faulty.
-
Piston burned through.
-
Piston rings.
-
Cylinder head gasket.
-
Big-end and/or main bearing journal.
*
Connect the compressed air line to the cylinder. If air is escaping from the opened oil filler cap, remove the cylinder head and check the components. Dismantle the engine if necessary and check the components. Zetec-SE -
REFER to: Cylinder Head (303-01A Engine - 1.4L/1.6L, In-vehicle Repair).
Zetec-E -
REFER to: Cylinder Head (303-01B Engine - 1.6L Zetec-E (Zetec)/1.8L Zetec-E (Zetec)/2.0L Zetec-E (Zetec), In-vehicle Repair).
1.8L Endura-DI and 1.8L Duratorque TDCi - REFER to: (303-01C Engine - 1.8L Diesel)
Cylinder Head - 1.8L Diesel, Vehicles With: Common Rail Fuel Injection (In-vehicle Repair),
Cylinder Head - 1.8L Diesel, Vehicles Without: Common Rail Fuel Injection (In-vehicle Repair).
Noisy running
*
Misfiring/backfiring
-
Fuel has wrong octane number (petrol engines only), or the wrong type of fuel is filled.
-
Fault in ignition system (petrol engines only).
-
Engine temperature too high.
-
Carbon deposits in the combustion chamber start to glow and cause misfiring.
-
Timing incorrect, which causes misfiring in the intake/exhaust system.
*
Determine the cause of the misfiring and rectify it.
-
Determine which type of fuel was last put in the tank (note the country specific fuel specifications).
-
Check the ignition system. Zetec-SE -
REFER to: Engine Ignition (303-07A Engine Ignition - 1.6L Zetec-SE (Sigma)/1.4L, Diagnosis and Testing).
Zetec-E -
REFER to: Engine Ignition (303-07B Engine Ignition - 1.6L Zetec-E (Zetec)/1.8L Zetec-E (Zetec)/2.0L Zetec-E (Zetec), Diagnosis and Testing).
-
Check the engine cooling.
REFER to: Engine Cooling (303-03, Diagnosis and Testing).
-
Remove the carbon deposits by using fuel additives and driving the vehicle carefully
-
Check the valve timing.
*
Fault in valve train.
*
Check the valve train.
*
Valve clearance too large, resulting from faulty bucket tappet or incorrect valve clearance setting.
*
Set the valve clearance (if possible) or replace the faulty bucket tappet.
*
Valve timing incorrectly adjusted - valves and pistons are touching.
*
Check and set the valve timing if required. Zetec-SE -
REFER to: Timing Belt (303-01A Engine - 1.4L/1.6L, In-vehicle Repair).
Zetec-E -
REFER to: Timing Belt (303-01B Engine - 1.6L Zetec-E (Zetec)/1.8L Zetec-E (Zetec)/2.0L Zetec-E (Zetec), In-vehicle Repair).
1.8L Endura-DI and 1.8L Duratorque TDCi -
REFER to: Timing Belt (303-01B Engine - 1.6L Zetec-E (Zetec)/1.8L Zetec-E (Zetec)/2.0L Zetec-E (Zetec), In-vehicle Repair).
*
Cracked or damaged timing belt.
*
Check the timing belt. In addition, check the pistons and valves for damage and renew all faulty parts.
*
Engine components faulty.
-
Pistons.
-
Piston rings.
-
Cylinder head gasket.
-
Big-end and/or main bearing journals.
*
Disassemble the engine and check components. Zetec-SE -
REFER to: Engine (303-01A Engine - 1.4L/1.6L, Disassembly).
Zetec-E -
REFER to: Engine (303-01B Engine - 1.6L Zetec-E (Zetec)/1.8L Zetec-E (Zetec)/2.0L Zetec-E (Zetec), Disassembly).
1.8L Endura-DI and 1.8L Duratorque TDCi - REFER to: (303-01C Engine - 1.8L Diesel)
Engine - 1.8L Diesel, Vehicles Without: Common Rail Fuel Injection (Disassembly),
Engine - 1.8L Diesel, Vehicles With: Common Rail Fuel Injection (Assembly).
*
Engine components or ancillary components are broken or loosened.
*
Check the condition of the engine components and check that they are tight and seated correctly. If necessary, tighten to the prescribed torque. Renew the broken components.

Engine Oil Leaks

NOTE:
NOTE:Before installing new gaskets or oil seals, make sure that the fault is clearly established.

If the oil leak cannot be identified clearly by a visual inspection, carry out a UV test:

Ultraviolet (UV) Testing

  1. Clean the engine and transaxle with a suitable cleaning fluid.
  1. Fill in test fluid via the oil filler neck according to the manufacturer's instructions and screw the oil filler cap back on.
WARNING:
WARNING:On manual transaxles shift the transaxle into NEUTRAL. Failure to follow these instructions may result in personal injury.
  1. Start the engine and run it for approx. five minutes.
  1. Switch off the engine.
NOTE:
NOTE:If no oil leak is found, carry out a road test under various load conditions and check the engine for leaks again.
  1. Check the engine for oil leaks using a suitable UV leak tester.
  1. Rectify any leaks found and check the engine for oil leaks.

Measure the compression pressure (21 111 0).

NOTE:
NOTE:The powertrain control module (PCM) receives an error message when the relay is removed out or electrical components are disconnected. This error message must be deleted from the fault memory by connecting WDS after completing the measurement.
NOTE:
NOTE:Valve clearance must be set correctly before performing a compression test. Make sure engine is at the normal operating temperature.
NOTE:
NOTE:The varying design of compression checking devices and fluctuating starter motor speeds normally only allows to check if the compression is even in all cylinders.

Measure the compression pressure (1.4/1.6 Zetec-SE engine)

  1. Open the central junction box (CJB) and remove the fuel pump relay.
  1. NOTE:
    NOTE:The engine will start, run for a few seconds and then stops.
    Start the engine.

  1. Remove the spark plug cover from the valve cover.
  1. NOTE:
    NOTE:Turn the spark plug connector slightly before disconnecting it. Pull the connector and not the lead.
    Detach the spark plug connectors.
  1. Detach the ignition coil connector.
  1. Using the special tool, remove the spark plugs.

NOTE:
NOTE:Operate the starter motor with wide open throttle until the pointer on the measuring device stops rising.
  1. Carry out the measurement in accordance with the instructions supplied with the measuring device on every cylinder using a suitable compression pressure recorder.
  1. Install the components in reverse order, observing the prescribed torques. Coat the spark plug connector seal with silicone grease (A960-M1C-AA) before fitting. Coat the spark plug thread with lubricant (ESE-M1244-A). Valve cover torque: 6 Nm. Spark plug torque: 15 Nm.
  1. Reset the PCM fault memory.

Measure the compression pressure (Zetec-E engine)

  1. Open the central junction box (CJB) and remove the fuel pump relay.
  1. NOTE:
    NOTE:The engine will start, run for a few seconds and then stops.
    Start the engine.

  1. NOTE:
    NOTE:Turn the spark plug connector slightly before disconnecting it. Pull the connector and not the lead.
    Detach the spark plug connectors and remove the spark plugs.

  1. Disconnect the ignition coil (EI) electrical connector.

NOTE:
NOTE:Operate the starter motor with wide open throttle until the pointer on the measuring device stops rising.
  1. Using a suitable compression pressure recorder carry out the measurement on every cylinder.
  1. Refit the components in reverse order, observing the prescribed torques. Coat the spark plug connector seal with silicone grease (A960-M1C-AA) before fitting. Coat the spark plug thread with lubricant (ESE-M1244-A). Valve cover torque: Stage 1: 2 Nm; stage 2: 7 Nm. Spark plug torque: 15 Nm.
  1. Reset the PCM fault memory.

Measure the compression pressure (Endura DI engine)

WARNING:
WARNING:Do not smoke or carry lighted tabacco or open flame of any type when working on or near any fuel related components. Highly flammable mixtures are always present and can ignite. Failure to follow these instructions may result in personal injury.

  1. Open the central junction box (CJB) and remove the glow plug relay.

  1. Remove the engine upper cover.

  1. Remove the charge air cooler inlet and outlet hoses and the clamps.

  1. Remove the charge air cooler inlet and outlet pipes.

  1. Disconnect the fuel injection pump electrical connector.

  1. Remove the glow plug power supply.

  1. Remove the glow plugs.

  1. Install a suitable compression tester with a suitable adapter into the glow plug bore.
NOTE:
NOTE:Crank the engine with the starter motor until the reading on the compression tester stops rising.
  1. Carry out the measurement on all cylinders, following the measuring equipment manufacturer's instructions.
  1. Detach the compression tester and adapter.

  1. Install the glow plugs.

  1. Install the glow plug power supply.

  1. Connect the fuel injection pump electrical connector.

  1. Install the charge air cooler inlet and outlet pipes.

  1. NOTE:
    NOTE:Install the clamps with the worm drive screw in the eight o'clock position when viewed from the front of the vehicle.
    Install the charge air cooler inlet and outlet hoses and the clamps.

  1. Install the engine upper cover.

  1. Install the glow plug relay.
  1. Reset the PCM fault memory.

Measure the compression pressure (Duratorq TDCi engine)

WARNING:
WARNING:Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable mixtures are always present and can ignite. Failure to follow these instructions may result in personal injury.
WARNING:
WARNING:Do not carry out any repairs to the fuel injection system without checking that the fuel pressure has dropped to zero and that the fuel temperature has either reached ambient temperature or is below 30°C, whichever is the greater. Failure to follow these instructions may result in personal injury.
  1. Using datalogger in world wide diagnostic system (WDS), check that the fuel pressure has dropped to zero and that the fuel temperature has either reached ambient temperature or is below 30°C, whichever is the greater.

  1. Open the central junction box (CJB) and remove the glow plug relay.

  1. Remove the engine upper cover.

  1. Remove the charge air cooler inlet and outlet hoses and the clamps.

  1. Remove the charge air cooler inlet and outlet pipes.

  1. CAUTION:
    CAUTION:Do not disconnect the fuel injection pump electrical connectors and crank the engine.
    Disconnect the fuel injector electrical connectors.

  1. Remove the glow plug power supply.

  1. Remove the glow plugs.

  1. Install a suitable compression tester with a suitable adapter into the glow plug bore.
NOTE:
NOTE:Crank the engine with the starter motor until the reading on the compression tester stops rising.
  1. Carry out the measurement on all cylinders, following the measuring equipment manufacturer's instructions.
  1. Detach the compression tester and adapter.

  1. Install the glow plugs.

  1. Install the glow plug power supply.

  1. Connect the fuel injector electrical connectors.

  1. Install the charge air cooler inlet and outlet pipes.

  1. NOTE:
    NOTE:Install the clamps with the worm drive screw in the eight o'clock position when viewed from the front of the vehicle.
    Install the charge air cooler inlet and outlet hoses and the clamps.

  1. Install the engine upper cover.

  1. Install the glow plug relay.
  1. Reset the PCM fault memory.

Measure the oil pressure (21 113 0)

The oil pressure depends on various factors (engine speed, oil temperature, oil viscosity, amount of oil filter contamination etc.).

NOTE:
NOTE:Measure the oil pressure at the specified engine speed. Measure the oil pressure at an oil temperature of 80° C.

Measure the oil pressure (1.4/1.6 Zetec-SE engine)

  1. Raise and support the vehicle. REFER to: (100-02 Jacking and Lifting)
    Jacking (Description and Operation),
    Lifting (Description and Operation).

  1. Disconnect the oil pressure switch electrical connector and remove the oil pressure switch.
  1. Attach the oil pressure gauge with suitableoil pressure gauge connector, and arrange it so that the reading can be made from above.
  1. Lower the vehicle.
  1. Check the oil pressure.
  1. Raise and support the vehicle. REFER to: (100-02 Jacking and Lifting)
    Jacking (Description and Operation),
    Lifting (Description and Operation).
  1. Detach the oil pressure gauge and connector.
  1. Coat the oil pressure switch with oil pressure switch sealer (WSK-M2G349-A7).
  1. Install the oil pressure switch and connect the oil pressure switch electrical connector.
  1. Lower the vehicle.

Measure the oil pressure (1.8/2.0 Zetec-E engine)

  1. Raise and support the vehicle. REFER to: (100-02 Jacking and Lifting)
    Jacking (Description and Operation),
    Lifting (Description and Operation).

  1. Disconnect the oil pressure switch electrical connector and remove the oil pressure switch.
  1. Attach the oil pressure gauge with oil pressure gauge connector, and arrange it so that the reading can be made from above.
  1. Lower the vehicle.
  1. Check the oil pressure.
  1. Raise and support the vehicle. REFER to: (100-02 Jacking and Lifting)
    Jacking (Description and Operation),
    Lifting (Description and Operation).
  1. Detach the oil pressure gauge and connector.
  1. Coat the oil pressure switch with oil pressure switch sealer (WSK-M2G349-A7).
  1. Install the oil pressure switch and connect the oil pressure switch electrical connector.
  1. Lower the vehicle.

Measure the oil pressure (1.8L Endura DI and Duratorque TDCi engine)

  1. Remove the engine upper cover.

  1. Remove the positive crankcase ventilation (PCV) housing.

  1. Disconnect the oil pressure switch electrical connector from the oil pressure switch.

  1. Remove the oil pressure switch.

  1. Attach the oil pressure gauge with the oil pressure gauge connector.
  1. NOTE:
    NOTE:Measure the oil pressure at idle speed and at 2000 rev/min.
    Check the oil pressure.
  1. Detach the oil pressure gauge and the oil pressure gauge connector.

  1. Install the oil pressure switch.

  1. Connect the oil pressure switch electrical connector to the oil pressure switch.

  1. Install the PCV housing.

  1. Install the engine upper cover.

Valve train analysis - static (engine off)

Remove the valve cover.
REFER to: Valve Cover (303-01C Engine - 1.8L Diesel, In-vehicle Repair).

Check all valve train components for damage and wear. Ensure that only original components are installed and that all bolts and nuts have been tightened to the correct tightening torque.

  • Mechanical Repairs
  • 3 Powertrain
  • 303 Engine
  • 303-00 Engine System - General Information
  • Diagnosis and Testing
  • Engine

General Procedures > < Ignition Switch