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). |