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Diagnosis and Testing|Removal and Installation > < 303-01F Engine - 2.0L Duratorq-TDCi (DW) Diesel|Engine

Mondeo 2007.5 (02.2007-)

Engine - 2.0L Duratorq-TDCi (DW) Diesel - Engine Mondeo 2007.5 (02/2007-)
Diagnosis and Testing

Special Tool(s)

Compression Test Adapter

303-1056

General Equipment
Worldwide Diagnostic System (WDS)
Materials
Name
Specification
Adhesive - Loctite 243
WSK-M2G349-A7 

Principles of Operation

Inspection and Verification

  1. Verify the customer concern.
  1. Visually inspect for obvious signs of mechanical or electrical damage.
  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 cause is not visually evident, verify the symptom and refer to the Symptom Chart.

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)

Symptom Chart

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.
REFER to: Specifications (303-01G Engine - 2.2L Duratorq-TDCi (DW) Diesel, Specifications).
*
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 (303-08F Engine Emission Control - 2.2L Duratorq-TDCi (DW) Diesel, Description and Operation).
*
Turbocharger seals.
*
INSTALL a new turbocharger.
REFER to: Turbocharger (303-04J Fuel Charging and Controls - Turbocharger - 2.2L Duratorq-TDCi (DW) Diesel, Removal and Installation).
*
Damaged gaskets or mating surfaces.
-
Cylinder head gasket is damaged or mating face are warped.
-
Valve stem 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.
REFER to: Cylinder Head (303-01D Engine - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation).
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 Stem Seals (303-01G Engine - 2.2L Duratorq-TDCi (DW) Diesel, Removal and Installation).
*
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 and piston rings.
Coolant consumption
*
Cooling system components.
*
Check the cooling system components.
REFER to: Engine Cooling (303-03F Engine Cooling - 2.2L Duratorq-TDCi (DW) 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.
*
Starter motor or cables.
*
CHECK the starting system.
REFER to: Starting System (303-06E Starting System - 2.0L Duratorq-TDCi (DW) Diesel, Diagnosis and Testing).
Engine cranks but will not start
*
Fuel tank is empty.
*
CHECK the fuel level.
*
Water in fuel.
*
Drain the water from the fuel system.
*
Fuel filter blocked.
*
INSTALL a new fuel filter.
REFER to: Fuel Filter - 1.6L Duratec-16V Ti-VCT (Sigma)/2.0L Duratec-HE (MI4)/2.3L Duratec-HE (MI4)/2.5L Duratec (VI5) (310-01 Fuel Tank and Lines, Removal and Installation).
*
Engine intake air system.
*
CHECK the intake air system.
*
Glow plug faulty.
*
CHECK the glow plugs. INSTALL new glow plugs as necessary.
REFER to: Glow Plug (303-07F Glow Plug System - 2.2L Duratorq-TDCi (DW) Diesel, Removal and Installation).
*
Engine management system.
*
CHECK the engine management system.
REFER to: Electronic Engine Controls (303-14D Electronic Engine Controls - 2.0L Duratorq-TDCi (DW) Diesel, Description and Operation).
*
Incorrect valve timing.
*
CHECK and adjust the valve timing.
REFER to: Timing Belt (303-01G Engine - 2.2L Duratorq-TDCi (DW) Diesel, Removal and Installation).
*
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 (303-01G Engine - 2.2L Duratorq-TDCi (DW) Diesel, Removal and Installation).
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 (303-04F Fuel Charging and Controls - 2.2L Duratorq-TDCi (DW) Diesel, Diagnosis and Testing).
*
Engine intake air system.
*
CHECK the intake air system.
REFER to: Intake Air Distribution and Filtering (303-12F Intake Air Distribution and Filtering - 2.2L Duratorq-TDCi (DW) Diesel, Description and Operation).
*
Exhaust system blocked.
*
CHECK the exhaust system.
REFER to: Exhaust System (309-00F Exhaust System - 2.2L Duratorq-TDCi (DW) Diesel, Description and Operation).
*
Engine management system.
*
CHECK the engine management system.
REFER to: Electronic Engine Controls (303-14D Electronic Engine Controls - 2.0L Duratorq-TDCi (DW) Diesel, Description and Operation).
*
Turbocharger.
*
CHECK the turbocharger.
REFER to: Turbocharger (303-04J Fuel Charging and Controls - Turbocharger - 2.2L Duratorq-TDCi (DW) Diesel, Diagnosis and Testing).
*
Incorrect valve timing. Timing belt/timing sprocket or pulley/sprocket damaged.
*
CHECK and adjust valve timing. INSTALL new components as necessary.
REFER to: Timing Belt (303-01G Engine - 2.2L Duratorq-TDCi (DW) Diesel, Removal and Installation).
Noisy running
*
Engine auxiliary components loose or damaged.
*
CHECK engine auxiliary components for damage or looseness. CHECK and adjust valve timing. INSTALL new components as necessary. Engine - 2.0L Duratorq-TDCi (DW) Diesel -
REFER to: Timing Belt (303-01G Engine - 2.2L Duratorq-TDCi (DW) Diesel, Removal and Installation).
Noisy running, misfiring or knocking
*
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 valve timing. INSTALL new components as necessary.
REFER to: Timing Belt (303-01G Engine - 2.2L Duratorq-TDCi (DW) Diesel, Removal and Installation).
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.
REFER to: Camshafts (303-01G Engine - 2.2L Duratorq-TDCi (DW) Diesel, Removal and Installation).
*
Timing belt or timing chain damaged.
*
INSTALL a new timing belt or timing chain.
REFER to: Timing Belt (303-01G Engine - 2.2L Duratorq-TDCi (DW) Diesel, Removal and Installation).
*
Timing belt or timing chain incorrectly tensioned.
*
CHECK the timing belt tension. INSTALL a new timing belt or timing chain as necessary.
REFER to: Timing Belt (303-01G Engine - 2.2L Duratorq-TDCi (DW) Diesel, Removal and Installation).
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.
REFER to: Specifications (303-01G Engine - 2.2L Duratorq-TDCi (DW) Diesel, Specifications).

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 an ultraviolet (UV) test:

Ultraviolet (UV) Testing

  1. Clean the engine and transmission with a suitable cleaning fluid.
  1. Pour the UV-test fluid in accordance with the quantity specified by the manufacturer through the oil filler neck into the engine and install the oil filler cap.
  1. Start the engine and let it run for about five minutes.
  1. Switch off the engine.
NOTE:
NOTE:If no leak can be found, road test the vehicle under various loads and check the engine for leaks again.
  1. Check the engine for oil leaks using a suitable UV lamp.
  1. Rectify any leaks found and check the engine for oil leaks.

Measure the compression pressure

NOTE:
NOTE:The powertrain control module (PCM) receives an error message when the fuel pump relay is removed or electrical components are disconnected. This error message must be deleted from the fault memory using worldwide diagnostic system (WDS) after completing the compression test.
NOTE:
NOTE:Valve clearance must be set correctly before performing a compression test. Make sure the engine is at the normal operating temperature.
NOTE:
NOTE:The varying design of compression checking devices and fluctuating starter motor speeds normally only allows for a comparison to be made of the compression pressures in all cylinders.

Measure the compression pressure

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 worldwide 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. Raise and support the vehicle. REFER to: (100-04 Noise, Vibration and Harshness)
    Jacking (Description and Operation),
    Lifting (Description and Operation).

  1. Remove the engine undershield.

  1. Remove the radiator undershield.

  1. Remove the glow plug relay.
  1. Lower the vehicle.
  1. Remove the cowl panel grille.
    REFER to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation).

  1. NOTE:
    NOTE:The engine upper cover is held in place by 3 ball clips. The ball clips are not vertical, but are angled backwards by approximately 20 degrees.
    Location of the engine upper cover ball clips.

  1. CAUTION:
    CAUTION:Contact of the engine upper cover with the cowl panel may cause damage (scratches) on the engine upper cover. If the ambient temperature is below 0°C, detach the engine upper cover with extreme caution. Failure to follow this instruction may cause the engine upper cover to be damaged.
    NOTE:
    NOTE:Only remove and install the engine upper cover in the sequence shown.
    Remove the engine upper cover.
    • Detach the engine upper cover ball clips in the sequence shown.

  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 exhaust gas recirculation (EGR) cooler.
    REFER to: Exhaust Gas Recirculation (EGR) Cooler (303-08F Engine Emission Control - 2.2L Duratorq-TDCi (DW) Diesel, Removal and Installation).
  1. Remove the EGR valve.
    REFER to: Exhaust Gas Recirculation (EGR) Valve (303-08F Engine Emission Control - 2.2L Duratorq-TDCi (DW) Diesel, Removal and Installation).

  1. Remove the glow plug power supply.

  1. Remove the glow plugs.

  1. Install the special tool and a suitable compression tester into the glow plug bore.
NOTE:
NOTE:Crank the engine with the starter motor until the pointer 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 the special tool.

  1. Install the glow plugs.

  1. Install the glow plug power supply.
  1. Install the EGR valve.
    REFER to: Exhaust Gas Recirculation (EGR) Valve (303-08F Engine Emission Control - 2.2L Duratorq-TDCi (DW) Diesel, Removal and Installation).
  1. Install the EGR cooler.
    REFER to: Exhaust Gas Recirculation (EGR) Cooler (303-08F Engine Emission Control - 2.2L Duratorq-TDCi (DW) Diesel, Removal and Installation).

  1. Connect the fuel injector electrical connectors.
  1. Apply soap solution to the ball clip mountings in the engine upper cover.
    • Soap solution (maximum concentration of soap in water 1:200).

  1. CAUTION:
    CAUTION:Contact of the engine upper cover with the cowl panel may cause damage (scratches) on the engine upper cover. Failure to follow this instruction may cause the engine upper cover to be damaged.
    Put the engine cover into installation position and clip it in place by pressing at the places shown.
    • Make sure that the engine upper cover is fully engaged in the area of the fuel filter, if necessary apply more pressure in the areas shown.
  1. Install the cowl panel grille.
    REFER to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation).
  1. Raise and support the vehicle. REFER to: (100-04 Noise, Vibration and Harshness)
    Jacking (Description and Operation),
    Lifting (Description and Operation).

  1. Install the glow plug relay.

  1. Install the radiator undershield.

  1. Install the engine undershield.
  1. Lower the vehicle.
  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.).

Measure the oil pressure

  1. Raise and support the vehicle. REFER to: (100-04 Noise, Vibration and Harshness)
    Jacking (Description and Operation),
    Lifting (Description and Operation).

  1. Remove the engine under shield.

  1. Disconnect the oil pressure switch electrical connector.

  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 the specified engine speed. Measure the oil pressure at an oil temperature of 80° C.
    NOTE:
    NOTE:Measure the oil pressure at 2000 rpm and at 4000 rpm.
    NOTE:
    NOTE:Oil pressure at 2000 rpm: 2.0 bar.
    NOTE:
    NOTE:Oil pressure at 4000 rpm: 4.0 bar.
    Check the oil pressure.

  1. Detach the oil pressure gauge and the oil pressure gauge connector.
  1. Coat the oil pressure switch with adhesive.

  1. Install the oil pressure switch.

  1. Connect the oil pressure switch electrical connector.

  1. Install the engine under shield.
  1. Lower the vehicle.

Valve train analysis - static (engine off)

Remove the valve cover.

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.
REFER to: Specifications (303-01G Engine - 2.2L Duratorq-TDCi (DW) Diesel, Specifications).

Diagnosis and Testing|Removal and Installation > < 303-01F Engine - 2.0L Duratorq-TDCi (DW) Diesel|Engine