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General Procedures > < 303-01B Engine - 2.3L Duratec-HE (MI4)|Engine

S-MAX.Galaxy 2006.5 (03.2006-)

Engine - 2.3L Duratec-HE (MI4) - Engine S-MAX/Galaxy 2006.5 (03/2006-)
Diagnosis and Testing

Special Tool(s)

Socket, Spark Plug

303-499
General Equipment
Use a compression tester
Materials
Name
Specification
Adhesive - Loctite 243
WSK-M2G349-A7 
  1. Verify the customer concern.
  1. Visually inspect for obvious signs of mechanical or electrical damage.
  1. Resolve any obvious causes for a concern found during the visual inspection before carrying out any further tests.
  1. If the concern persists, check the symptoms and continue with the Symptom Chart.

Visual Inspection Chart

Mechanical Electrical
  • Coolant leaks
  • Leaking oil.
  • Fuel leaks
  • Visibly damaged or worn parts
  • Loose or missing nuts or bolts
  • Fuse(s)
  • Loose or corroded connector(s)
  • Control unit
  • Damaged or worn switch(es)

Symptom Chart

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 whether there is an oil film on the coolant in the coolant expansion tank. INSTALL a new oil cooler or oil cooler seal.
*
Leak on the crankshaft oil seal
*
INSTALL a new crankshaft oil seal. REFER to: (303-01B Motor - 2.3L Duratec-HE (MI4))
Kurbelwellendichtring vorn (Removal and Installation),
Kurbelwellendichtring hinten (Removal and Installation).
*
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: Spezifikationen (303-01B Motor - 2.3L Duratec-HE (MI4), Specifications).
*
Faulty positive crankcase ventilation (PCV) system.
-
Hoses or ventilation or breather valves are blocked. This causes excessive pressure in the crankcase which causes oil to enter the combustion chamber.
-
The PCV oil separator is damaged. Oil can enter the combustion chamber through the intake manifold.
*
CHECK if the PCV system is operating correctly and repair as necessary.
*
Damaged gaskets or mating surfaces.
-
Damaged cylinder head gasket or warped mating faces.
-
Worn valve stem oil seals. Engine oil can enter the combustion chamber between the valve stem and the valve guide.
*
CHECK the gaskets and mating surfaces for damage.
-
Remove the cylinder head. CHECK the condition of the mating faces and the cylinder head gasket and CHECK the evenness of the cylinder head and cylinder block mating faces.
-
INSTALL new valve stem oil seals.
REFER to: Ventilschaftdichtringe (303-01B Motor - 2.3L Duratec-HE (MI4), Removal and Installation).
*
Piston ring or cylinder liner wear.
*
INSTALL a new cylinder block if 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 a new cylinder block if necessary.
Coolant consumption
*
Cooling system components.
*
Check the cooling system components.
REFER to: Kühlsystem (303-03B Kühlsystem - 2.3L Duratec-HE (MI4), 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 battery cable
*
CHECK the battery, battery holder and battery cable(s).
REFER to: Batterie (414-01 Batterie, Befestigung und Batteriekabel, Removal and Installation).
*
Starter motor or cables.
*
CHECK the starting system.
REFER to: Anlasssystem (303-06A Anlasssystem - 2.0L Duratec-HE (MI4)/2.3L Duratec-HE (MI4), Diagnosis and Testing).
Engine cranks but will not start.
*
Fuel tank is empty.
*
CHECK the fuel level.
*
Intake Air Distribution and Filtering
*
CHECK the intake air system.
*
Engine management
*
CHECK the engine management system.
*
Ignition system
*
CHECK the ignition system.
*
Incorrect valve timing.
*
CHECK and adjust valve timing.
REFER to: Ventilspiel einstellen (303-01B Motor - 2.3L Duratec-HE (MI4), General Procedures).
*
Timing chain or timing chain sprockets damaged or broken
*
CHECK the timing chain and timing chain sprockets. INSTALL new components as necessary.
REFER to: Steuerkette (303-01B Motor - 2.3L Duratec-HE (MI4), Removal and Installation).
Very poor power output or fuel consumption too high or engine running rough
*
Fuel system
*
CHECK the fuel system.
*
Intake Air Distribution and Filtering
*
CHECK the intake air system.
*
Restricted exhaust system.
*
CHECK the exhaust system.
REFER to: Auspuffsystem (309-00A Auspuffsystem - Allgemeine Informationen - 2.0L Duratec-HE (MI4)/2.3L Duratec-HE (MI4), Description and Operation).
*
Engine management
*
CHECK the engine management system.
*
Ignition system is faulty
*
CHECK the ignition system.
*
Incorrect valve timing, timing chain or timing chain sprockets damaged
*
CHECK and adjust valve timing. INSTALL new components as necessary. REFER to: (303-01B Motor - 2.3L Duratec-HE (MI4))
Ventilspiel einstellen (General Procedures),
Steuerkette (Removal and Installation).
*
Incorrect ignition timing
*
CHECK the electronic engine controls.
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. REFER to: (303-01B Motor - 2.3L Duratec-HE (MI4))
Ventilspiel einstellen (General Procedures),
Steuerkette (Removal and Installation).
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.
*
Incorrect valve timing, timing chain or timing chain sprockets damaged
*
CHECK and adjust valve timing. INSTALL new components as necessary. REFER to: (303-01B Motor - 2.3L Duratec-HE (MI4))
Ventilspiel einstellen (General Procedures),
Steuerkette (Removal and Installation).
Noisy running or valve train noise
*
Valve clearance too large due to faulty valve tappets or worn valve train components.
*
ADJUST valve clearance.
REFER to: Ventilspiel einstellen (303-01B Motor - 2.3L Duratec-HE (MI4), General Procedures).
*
Timing chain damaged.
*
INSTALL a new timing chain.
REFER to: Steuerkette (303-01B Motor - 2.3L Duratec-HE (MI4), Removal and Installation).
*
Timing chain incorrectly tensioned
*
CHECK the timing chain tension. INSTALL a new timing chain if required.
REFER to: Steuerkette (303-01B Motor - 2.3L Duratec-HE (MI4), 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 a new cylinder block if necessary.
REFER to: Spezifikationen (303-01B Motor - 2.3L Duratec-HE (MI4), Specifications).

Oil Leaks - Engine

NOTE:
NOTE:Before renewing gaskets or oil seals, make sure that the cause of the fault is clearly established.

If the oil leak cannot be identified clearly by a visual inspection, carry out an 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.
WARNING:
WARNING:Vehicles with manual transaxle, shift the transaxle into Neutral. Failure to observe this instruction can lead to injuries.
  1. Start the engine and let it run for about five minutes.
  1. Stop the engine.
NOTE:
NOTE:If no leak is found, perform a road test. Drive the vehicle under different loads and then re-check the engine for leaks.
  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

  1. Remove the central junction box cover.

  1. Detach the central junction box (CJB).

  1. Open the CJB and remove fuse 23 - fuel pump relay.
NOTE:
NOTE:The engine will start, run for a few seconds and then stop.
  1. Start the engine.

  1. Detach the engine cover.

  1. Disconnect the ignition coil-on-plug electrical connectors.

  1. Remove the ignition coil-on-plug

  1. Remove the spark plugs using the special tool.

NOTE:
NOTE:Operate the starter motor with wide open throttle until the reading on the compression tester stops rising.
  1. Perform the measurement on each cylinder according to the instructions provided by the manufacturer of the measuring device. Use a compression tester with a suitable adapter.

  1. Install the spark plugs using the special tool.

  1. Install the ignition coil-on-plug.

  1. Connect the ignition coil-on-plug electrical connectors.

  1. Install the engine cover.

  1. Install fuse 23 (fuel pump relay) and close the central junction box (CJB).

  1. Attach the CJB.

  1. Install the central junction box cover.
  1. Reset the PCM fault memory.

Measuring the oil pressure

  1. Raise vehicle. REFER to: (100-02 Fahrzeug anheben)
    Anheben mit Wagenheber (Description and Operation),
    Anheben mit Hebebühne (Description and Operation).

  1. Remove the engine undershield.

  1. Pull off the oil pressure switch connector.

  1. Remove the oil pressure switch.

  1. Attach the oil pressure gauge with the oil pressure gauge connector to the oil pressure switch bore, and position it to allow reading from above.
  1. Lower the vehicle.

  1. NOTE:
    NOTE:Measure the oil pressure at the specified engine speed. Measure the oil pressure at an oil temperature of 100 °C.
    NOTE:
    NOTE:Oil pressure at 1500 rev/min: 1.3 - 2.7 bar.
    NOTE:
    NOTE:Oil pressure at 3000 rev/min: 2.3 -5.2 bar.
    Check the oil pressure
  1. Raise vehicle. REFER to: (100-02 Fahrzeug anheben)
    Anheben mit Wagenheber (Description and Operation),
    Anheben mit Hebebühne (Description and Operation).

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

  1. Install the oil pressure switch.

  1. Push on the oil pressure switch connector.

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

Valve train analysis - static (engine off)

Remove the cylinder head 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.

General Procedures > < 303-01B Engine - 2.3L Duratec-HE (MI4)|Engine