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General Procedures > < Ignition Switch
Engine System - General Information - Engine Transit 2000.5 (01/2000-05/2006)
Diagnosis and Testing

Inspection and Verification

  1. Verify the customer concern.
  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 cause is not visually evident, verify the symptom and refer to the Symptom Chart.

Symptom Chart

Symptom Possible Sources Action
Loss of oil
*
Oil leaks from the engine or auxiliary components.
*
Look for evidence of oil leaks on components. Use an ultraviolet (UV) leak tester if 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 oil film on the coolant surface. Install a new oil cooler or oil cooler gasket.
*
Leak at the crankshaft front or rear oil seal.
*
Install a new oil seal.
*
Align the front cover.
Oil consumption
*
Use of the wrong type of engine oil.
*
Determine the last type of engine oil used (refer to the latest invoice or oil receipt) and compare with the specification. Change the engine oil.
*
Faulty positive crankcase ventilation system.
-
Hoses or ventilation/breather valves are blocked. This causes excessive pressure in the crankcase which causes oil to enter the combustion chamber.
-
Crankcase ventilation oil separator is faulty and engine oil can enter the combustion chamber through the intake manifold.
*
Check that the crankcase ventilation system is operating correctly and repair as necessary. REFER to Section  303-08 Engine Emission Control.
*
Turbocharger seals.
*
*
Damaged gaskets or mating surfaces.
-
Cylinder head gasket is damaged or mating faces are warped.
-
Valve stem oil seals are worn causing engine oil to 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 gaskets and the flatness of the cylinder head and engine block mating faces.
-
Install new valve stem oil seals.
*
Piston ring or cylinder liner wear.
*
Install new components as necessary.
Coolant consumption
*
Cooling system components.
*
REFER to Section  303-03 Engine Cooling.
*
Exhaust gas recirculation (EGR) cooler (if equipped).
*
Install a new EGR cooler.
*
Oil cooler.
*
Install a new oil cooler.
*
Damaged gaskets or warped mating faces.
*
Check the cylinder head gasket for damage. Check the cylinder head and cylinder block for distortion.
REFER to Cylinder Head Distortion /
Cylinder Block Distortion in this section.
*
Cracks or fractures in engine components surrounded by coolant, such as cylinder liners and cylinder head combustion chamber.
*
Determine the damaged engine component and install a new component.
Engine will not crank
*
Battery or cables.
*
Check the battery, bracket and cables. REFER to Section  414-00 Charging System - General Information.
*
Starter motor or cables.
*
Check the starting system. REFER to Section  303-06 Starting System.
Engine cranks but will not start
*
Fuel tank is empty.
*
Check the fluid level.
*
Water in fuel.
*
Drain the water from the fuel system. REFER to Section  310-00A Fuel System - General Information / 310-00B Fuel System - General Information.
*
Fuel filter blocked (only vehicles with diesel engine).
*
Install a new fuel filter. REFER to Section  310-01A Fuel Tank and Lines / 310-01B Fuel Tank and Lines.
*
Air in fuel lines (only vehicles with diesel engine).
*
Bleed the fuel system. Check the fuel system for leaks. REFER to Section  310-00A Fuel System - General Information / 310-00B Fuel System - General Information.
*
Engine intake air system.
*
Check the intake air system. REFER to Section  303-12 Intake Air Distribution and Filtering.
*
Glow plug faulty (only vehicles with diesel engine).
*
Check the glow plugs. Install new glow plugs as necessary. Engine - 2.4L Diesel - REFER to Section  303-07A Glow Plug System / 303-07B Glow Plug System / 303-07C Engine Ignition. Engine - 2.0L Diesel - REFER to Section  303-07A Glow Plug System / 303-07B Glow Plug System / 303-07C Engine Ignition.
*
Engine management system.
*
Check the engine management system. REFER to Section  303-14 Electronic Engine Controls.
*
Fuel injection pump faulty or incorrect timing (only vehicles with diesel engine).
*
*
Incorrect valve timing.
*
Check and adjust the valve timing. Engine - 2.4L Diesel - REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine. Engine - 2.0L Diesel - REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine. Engine - 2.3L REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine.
*
Broken or damaged timing chain or sprocket.
*
Check the timing chain and sprockets. Install new components as necessary.
Very poor power output/fuel consumption too high/engine running rough
*
Fuel system.
*
*
*
*
Engine intake air system.
*
Check the intake air system. REFER to Section  303-12 Intake Air Distribution and Filtering.
*
Exhaust system blocked.
*
Check the exhaust system. REFER to Section  309-00 Exhaust System.
*
Engine management system.
*
Check the engine management system. REFER to Section  303-14 Electronic Engine Controls.
*
Turbocharger (only vehicles with diesel engine).
*
*
Fuel injection pump faulty or incorrect timing (only vehicles with diesel engine).
*
*
Incorrect valve timing, timing chain or timing sprocket damaged.
*
Check and adjust valve timing. Install new components as necessary. Engine - 2.4L Diesel - REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine. Engine - 2.0L Diesel - REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine. Engine - 2.3L REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine.
Noisy running
*
Engine auxiliary components loose or damaged.
*
Check engine auxiliary components for damage/looseness.
Noisy running, misfiring/backfiring
*
Incorrect fuel
*
Determine which type of fuel was the 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.
*
Fuel injection pump faulty or incorrect timing (only vehicles with diesel engine).
*
*
Valve timing incorrect, timing chain or timing sprocket damaged.
*
Check and adjust valve timing. Install new components as necessary. Engine - 2.4L Diesel - REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine. Engine - 2.0L Diesel - REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine. Engine - 2.3L REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine.
Noisy running/valve train noise
*
Excessive valve clearance due to faulty hydraulic valve tappets.
*
Install new hydraulic valve tappets. Engine - 2.4L Diesel - REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine. Engine - 2.0L Diesel - REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine. Engine - 2.3L REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine.
*
Timing chain damaged.
*
Install a new timing chain. Engine - 2.4L Diesel - REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine. Engine - 2.0L Diesel - REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine. Engine - 2.3L REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine.
*
Timing chain incorrectly tensioned.
*
Check the timing chain tension. Install a new tensioner, as necessary. Engine - 2.4L Diesel - REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine. Engine - 2.0L Diesel - REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine. Engine - 2.3L REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine.
*
Timing chain guides worn or damaged.
*
Check the timing chain guides. Install new guides as necessary. Engine - 2.4L Diesel - REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine. Engine - 2.0L Diesel - REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine. Engine - 2.3L REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine.
Noisy running/engine block
*
Engine components
-
Pistons
-
Piston rings
-
Connecting rod large 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. Engine - 2.4L Diesel - REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine. Engine - 2.0L Diesel - REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine. Engine - 2.3L REFER to Section  303-01A Engine / 303-01B Engine / 303-01C Engine.

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 transmission with a suitable cleaning fluid such as brake cleaner.
  1. Pour test fluid GV-2911-3090A 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:On manual transmissions put the transmission into NEUTRAL. Failure to follow these instructions may result in personal injury.
  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 again check the engine for leaks.
  1. Check the engine for oil leaks using a UV leak tester GV-2929 or UV leak tester GV-2911 B11.
  1. Rectify any leaks found and recheck 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 or electrical components are disconnected. This error message must be deleted from the fault memory by connecting Worldwide Diagnostic System (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 (Engine - 2.4L Diesel with EGR)

  1. Open the Battery Junction Box (BJB) and remove the glow plug relay.

  1. Disconnect the fuel injection pump electrical connector.

  1. Remove the glow plug power supply.

  1. Remove the glow plugs.

  1. Install compression tester 623.002.1101 with adapter GV-2186 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 glow plug relay.
  1. Reset the PCM fault memory.

Measure the compression (Engine - 2.4L Diesel without EGR)

  1. Open the Battery Junction Box (BJB) and remove the glow plug relay.

  1. Disconnect the fuel shutoff solenoid valve electrical connector.

  1. Remove the glow plug power supply.

  1. Remove the glow plugs.

  1. Install compression tester 623.002.1101 with adapter GV-2186 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 shutoff solenoid valve electrical connector.

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

Measure the compression (Engine - 2.0L Diesel)

  1. Open the BJB and remove the glow plug relay.

  1. Disconnect the fuel injector electrical connectors from the fuel injectors (vehicles with common rail fuel injection).

  1. Disconnect the injection pump electrical connector (vehicles without common rail fuel injection).

  1. Remove the glow plug power supply.

  1. Remove the glow plugs.

  1. Install compression tester 623.002.1101 with adapter GV-2186 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 to the fuel injectors (vehicles with common rail fuel injection).

  1. Connect the injection pump electrical connector (vehicles without common rail fuel injection).

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

Measure the compression (Engine - 2.3L)

  1. Open the Battery Junction Box (BJB) and remove the fuel pump relay.
NOTE:
NOTE:The engine will start, run for a few seconds and then stop.
  1. Start the engine.

  1. Remove the spark plug cover.

  1. Disconnect the ignition coil electrical connectors.

NOTE:
NOTE:Twist the spark plug connectors slightly before disconnecting them. Pull on the connector and not on the cable.
  1. Remove the spark plug connectors of cylinder one and three.

  1. Remove the ignition coils.

  1. Using the special tool, remove the spark plugs.

NOTE:
NOTE:Crank the engine with the starter motor and with wide open throttle, 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. Using the special tool, install the spark plugs.

  1. Install the ignition coils.

  1. Install the spark plug connectors of cylinder one and three.

  1. Connect the ignition coil electrical connectors.

  1. Install the spark plug cover.

  1. Install the fuel pump relay.
  1. Reset the PCM fault memory.

Oil Pressure - Measure (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 (Engine - 2.4L Diesel)

  1. Disconnect the oil pressure switch electrical connector.

  1. Remove the oil pressure switch.

  1. Attach the oil pressure gauge (GV 2134) with the oil pressure gauge connector.
  1. Lower the vehicle.
  1. Start the engine

NOTE:
NOTE:Oil pressure at 2000 rpm must be 2.0 bar minimum.
NOTE:
NOTE:Oil pressure at idle must be 1.25 bar minimum.
  1. Measure the oil pressure.
  1. Lower the vehicle.
  1. Stop the engine.

  1. Remove the oil pressure gauge and the oil pressure gauge connector.

  1. Install the oil pressure switch.

  1. Connect the oil pressure switch electrical connector.
  1. Lower the vehicle.

Measure the oil pressure (Engine - 2.0L Diesel)

  1. Disconnect the oil pressure switch electrical connector.

  1. Remove the oil pressure switch.

  1. Attach the oil pressure gauge (GV 2134) with the oil pressure gauge connector.
  1. Lower the vehicle.
  1. Start the engine.

NOTE:
NOTE:Oil pressure at 2000 rpm must be 2.0 bar minimum.
NOTE:
NOTE:Oil pressure at idle must be 1.25 bar minimum.
  1. Measure the oil pressure.
  1. Lower the vehicle.
  1. Stop the engine.

  1. Remove the oil pressure gauge and the oil pressure gauge connector.

  1. Install the oil pressure switch.

  1. Connect the oil pressure switch electrical connector.
  1. Lower the vehicle.

Measure the oil pressure (Engine - 2.3L)

  1. Disconnect the oil pressure switch electrical connector.

  1. Remove the oil pressure switch.

  1. Attach the oil pressure gauge (GV 2134) with the oil pressure gauge connector.
  1. Lower the vehicle.
  1. Start the engine.

NOTE:
NOTE:Oil pressure a idle: 1.6 bar.
NOTE:
NOTE:Maximum oil pressure: 6.5 bar.
  1. Measure the oil pressure.
  1. Lower the vehicle.
  1. Stop the engine.

  1. Remove the oil pressure gauge and the oil pressure gauge connector.

  1. Install the oil pressure switch.

  1. Connect the oil pressure switch electrical connector.
  1. Lower the vehicle.

Valve train analysis - static (engine off)

  1. Remove the valve cover.

Check all components of the valve train for damage and wear. Make sure that only original components are installed and that all nuts and bolts are tightened to the specified torque.

General Procedures > < Ignition Switch