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General Procedures > < 303-00 Engine System - General Information|Engine

Fiesta 2002.25 (11.2001-)

Engine System - General Information - Engine Fiesta 2002.25 (11/2001-)
Diagnosis and Testing

Special Tool(s)

Socket, Spark Plug

303-499

Compression Test Adapter

303-1052

Pliers, Valve Stem Seal

303-508
Materials
Name
Specification
Adhesive - Loctite 243
WSK-M2G349-A7 
  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)
  • Powertrain 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 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.
*
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 (303-08A Engine Emission Control - 1.25L Duratec-16V (Sigma)/1.3L Duratec-8V (Rocam)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), Diagnosis and Testing),
Engine Emission Control (303-08C Engine Emission Control - 2.0L Duratec-HE (MI4), Diagnosis and Testing),
Engine Emission Control - Vehicles With: Vacuum Exhaust Gas Recirculation (EGR) Valve (303-08B Engine Emission Control - 1.4L Duratorq-TDCi (DV) Diesel, Diagnosis and Testing),
Engine Emission Control (303-08D Engine Emission Control - 1.6L Duratorq-TDCi (DV) Diesel, Description and Operation).
*
Turbocharger seals (diesel engine only).
*
INSTALL a new turbocharger. REFER to:
Turbocharger (303-04D Fuel Charging and Controls - Turbocharger - 1.4L Duratorq-TDCi (DV) Diesel, Removal and Installation),
Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel (303-04G Fuel Charging and Controls - Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel, Removal and Installation).
*
Damaged gaskets or mating surfaces.
-
Cylinder head gasket is damaged or mating face are warped.
-
Valve stem oil 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. 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 Seals (303-01A Engine - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), In-vehicle Repair),
Valve Seals (303-01C Engine - 1.3L Duratec-8V (Rocam), In-vehicle Repair),
Valve Seals (303-01D Engine - 2.0L Duratec-HE (MI4), In-vehicle Repair),
Valve Seals (303-01B Engine - 1.4L Duratorq-TDCi (DV) Diesel, In-vehicle Repair),
Valve Seals (303-01E Engine - 1.6L Duratorq-TDCi (DV) Diesel, In-vehicle Repair).
*
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.
REFER to: Piston Inspection (303-00 Engine System - General Information, General Procedures).
*
CHECK the piston rings. REFER to: (303-00 Engine System - General Information)
Piston Ring-to-Groove Clearance (General Procedures),
Piston Ring End Gap (General Procedures).
Coolant consumption
*
Cooling system components.
*
CHECK the coooling system. REFER to:
Engine Cooling (303-03A Engine Cooling - 1.25L Duratec-16V (Sigma)/1.3L Duratec-8V (Rocam)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), Diagnosis and Testing),
Engine Cooling (303-03C Engine Cooling - 2.0L Duratec-HE (MI4), Diagnosis and Testing),
Engine Cooling (303-03B Engine Cooling - 1.4L Duratorq-TDCi (DV) Diesel, Diagnosis and Testing),
Engine Cooling (303-03D Engine Cooling - 1.6L Duratorq-TDCi (DV) 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.
REFER to: Battery (414-01 Battery, Mounting and Cables, Diagnosis and Testing).
*
Starter motor or cables.
*
CHECK the starting system.
REFER to: Starting System (303-06 Starting System, Diagnosis and Testing).
Engine cranks but will not start
*
Fuel tank is empty.
*
CHECK the fuel level.
*
Water in fuel (diesel engine only).
*
Drain the water from the fuel system. Engine - 1.4L Duratorq-TDCi (DV) Diesel/Engine - 1.6L Duratorq-TDCi (DV) Diesel.
REFER to: Fuel System - 1.4L Duratorq-TDCi (DV) Diesel/1.6L Duratorq-TDCi (DV) Diesel (310-00 Fuel System - General Information, Diagnosis and Testing).
*
Fuel filter blocked.
*
INSTALL a new fuel filter. REFER to: (310-01 Fuel Tank and Lines)
Fuel Filter - 1.4L Duratorq-TDCi (DV) Diesel (Removal and Installation),
Fuel Filter - 1.6L Duratorq-TDCi (DV) Diesel (Removal and Installation).
*
Engine intake air system.
*
CHECK the intake air system.
REFER to: Intake Air Distribution and Filtering (303-12 Intake Air Distribution and Filtering, Diagnosis and Testing).
*
Glow plug faulty (diesel engine only).
*
CHECK the glow plugs. INSTALL new glow plugs as necessary. REFER to:
Glow Plug (303-07B Glow Plug System - 1.4L Duratorq-TDCi (DV) Diesel, Removal and Installation),
Glow Plugs (303-07D Glow Plug System - 1.6L Duratorq-TDCi (DV) Diesel, Removal and Installation).
*
Engine management system.
*
CHECK the engine management system.
REFER to: Electronic Engine Controls (303-14 Electronic Engine Controls, Diagnosis and Testing).
*
Ignition system (petrol engines only).
*
CHECK the ignition system. REFER to:
Engine Ignition (303-07A Engine Ignition, Diagnosis and Testing),
Engine Ignition (303-07C Engine Ignition - 2.0L Duratec-HE (MI4), Diagnosis and Testing).
*
Incorrect valve timing.
*
CHECK and adjust the valve timing. REFER to:
Timing Belt (303-01A Engine - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), In-vehicle Repair),
Timing Chain (303-01C Engine - 1.3L Duratec-8V (Rocam), In-vehicle Repair),
Crankshaft Pulley (303-01D Engine - 2.0L Duratec-HE (MI4), In-vehicle Repair),
Timing Belt (303-01B Engine - 1.4L Duratorq-TDCi (DV) Diesel, In-vehicle Repair),
Timing Belt (303-01E Engine - 1.6L Duratorq-TDCi (DV) Diesel, In-vehicle Repair).
*
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 (303-01A Engine - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), In-vehicle Repair),
Timing Belt (303-01E Engine - 1.6L Duratorq-TDCi (DV) Diesel, In-vehicle Repair),
Timing Chain (303-01C Engine - 1.3L Duratec-8V (Rocam), In-vehicle Repair),
Timing Chain (303-01D Engine - 2.0L Duratec-HE (MI4), In-vehicle Repair),
Timing Belt (303-01B Engine - 1.4L Duratorq-TDCi (DV) Diesel, In-vehicle Repair).
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 (303-04B Fuel Charging and Controls - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), Diagnosis and Testing),
Fuel Charging and Controls (303-04A Fuel Charging and Controls - 1.3L Duratec-8V (Rocam), Diagnosis and Testing),
Fuel Charging and Controls (303-04C Fuel Charging and Controls - 1.4L Duratorq-TDCi (DV) Diesel, Diagnosis and Testing),
Fuel Charging and Controls (303-04F Fuel Charging and Controls - 1.6L Duratorq-TDCi (DV) Diesel, Diagnosis and Testing).
*
Engine intake air system.
*
CHECK the intake air system.
REFER to: Intake Air Distribution and Filtering (303-12 Intake Air Distribution and Filtering, Diagnosis and Testing).
*
Exhaust system blocked.
*
CHECK the exhaust system.
REFER to: Exhaust System (309-00 Exhaust System, Description and Operation).
*
Engine management system.
*
CHECK the engine management system.
REFER to: Electronic Engine Controls (303-14 Electronic Engine Controls, Diagnosis and Testing).
*
Fault in ignition system (petrol engines only).
*
CHECK the ignition system. REFER to:
Engine Ignition (303-07A Engine Ignition, Diagnosis and Testing),
Engine Ignition (303-07C Engine Ignition - 2.0L Duratec-HE (MI4), Diagnosis and Testing).
*
Turbocharger (diesel engine only).
*
CHECK the turbocharger. REFER to:
Turbocharger (303-04D Fuel Charging and Controls - Turbocharger - 1.4L Duratorq-TDCi (DV) Diesel, Diagnosis and Testing),
Turbocharger (303-04G Fuel Charging and Controls - Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel, Diagnosis and Testing).
*
Incorrect valve timing. Timing belt/timing sprocket or pulley/sprocket damaged.
*
CHECK and adjust the valve timing. REFER to:
Timing Belt (303-01A Engine - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), In-vehicle Repair),
Timing Chain (303-01C Engine - 1.3L Duratec-8V (Rocam), In-vehicle Repair),
Crankshaft Pulley (303-01D Engine - 2.0L Duratec-HE (MI4), In-vehicle Repair),
Timing Belt (303-01B Engine - 1.4L Duratorq-TDCi (DV) Diesel, In-vehicle Repair),
Timing Belt (303-01E Engine - 1.6L Duratorq-TDCi (DV) Diesel, In-vehicle Repair).
*
Ignition timing incorrect (petrol engines only).
*
CHECK the electronic engine controls.
REFER to: Electronic Engine Controls (303-14 Electronic Engine Controls, Diagnosis and Testing).
Noisy running
*
Engine auxiliary components loose or damaged.
*
CHECK engine auxiliary components for damage or looseness. REFER to:
Timing Belt (303-01A Engine - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), In-vehicle Repair),
Timing Chain (303-01C Engine - 1.3L Duratec-8V (Rocam), In-vehicle Repair),
Timing Chain (303-01D Engine - 2.0L Duratec-HE (MI4), In-vehicle Repair),
Timing Belt (303-01B Engine - 1.4L Duratorq-TDCi (DV) Diesel, In-vehicle Repair),
Timing Belt (303-01E Engine - 1.6L Duratorq-TDCi (DV) Diesel, In-vehicle Repair).
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.
*
Valve timing incorrect, timing belt/chain or pulley/sprocket damaged.
*
CHECK and adjust the valve timing. REFER to:
Timing Belt (303-01A Engine - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), In-vehicle Repair),
Timing Chain (303-01C Engine - 1.3L Duratec-8V (Rocam), In-vehicle Repair),
Crankshaft Pulley (303-01D Engine - 2.0L Duratec-HE (MI4), In-vehicle Repair),
Timing Belt (303-01B Engine - 1.4L Duratorq-TDCi (DV) Diesel, In-vehicle Repair),
Timing Belt (303-01E Engine - 1.6L Duratorq-TDCi (DV) Diesel, In-vehicle Repair).
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 or adjust the valve clearance. REFER to:
Valve Clearance Adjustment (303-01A Engine - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), General Procedures),
Camshaft Followers (303-01C Engine - 1.3L Duratec-8V (Rocam), In-vehicle Repair),
Valve Clearance Adjustment (303-01D Engine - 2.0L Duratec-HE (MI4), General Procedures),
Hydraulic Lash Adjuster (303-01B Engine - 1.4L Duratorq-TDCi (DV) Diesel, In-vehicle Repair),
Camshaft (303-01E Engine - 1.6L Duratorq-TDCi (DV) Diesel, In-vehicle Repair).
*
Timing belt or timing chain damaged.
*
INSTALL a new timing belt or timing chain. REFER to:
Timing Belt (303-01A Engine - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), In-vehicle Repair),
Timing Chain (303-01C Engine - 1.3L Duratec-8V (Rocam), In-vehicle Repair),
Timing Chain (303-01D Engine - 2.0L Duratec-HE (MI4), In-vehicle Repair),
Timing Belt (303-01B Engine - 1.4L Duratorq-TDCi (DV) Diesel, In-vehicle Repair),
Timing Belt (303-01E Engine - 1.6L Duratorq-TDCi (DV) Diesel, In-vehicle Repair).
*
Timing belt or timing chain incorrectly tensioned.
*
CHECK the timing belt or timing chain tension. INSTALL a new timing belt or timing chain as necessary. REFER to:
Timing Belt (303-01A Engine - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), In-vehicle Repair),
Timing Chain (303-01C Engine - 1.3L Duratec-8V (Rocam), In-vehicle Repair),
Timing Chain (303-01D Engine - 2.0L Duratec-HE (MI4), In-vehicle Repair),
Timing Belt (303-01B Engine - 1.4L Duratorq-TDCi (DV) Diesel, In-vehicle Repair),
Timing Belt (303-01E Engine - 1.6L Duratorq-TDCi (DV) Diesel, In-vehicle Repair).
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.

Engine - Oil Leaks

NOTE:
NOTE:Before installing new gaskets or 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.
WARNING:
WARNING:Vehicles with manual transaxle, shift the transaxle into Neutral. Failure to follow this instruction 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 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 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 (Engine - 1.4L Duratorq-TDCi (DV) Diesel)

  1. Remove the air cleaner.
    REFER to: Air Cleaner - 1.4L Duratorq-TDCi (DV) Diesel (303-12 Intake Air Distribution and Filtering, Removal and Installation).

  1. Disconnect the fuel injector wiring harness main connector.

  1. Disconnect the glow plug relay electrical connector.

  1. Detach the exhaust gas recirculation (EGR) tube from the cylinder block and from the EGR valve (if equipped).

  1. Detach the EGR tube from the EGR cooler (if equipped).

  1. Remove the EGR tube from the intake manifold assembly.

  1. Disconnect the glow plug electrical connectors.

  1. Remove the glow plugs.

  1. Install a suitable compression pressure recorder with a suitable adapter into the glow plug bore.
NOTE:
NOTE:Operate the starter motor until the reading on the compression tester 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 with a suitable adapter.

  1. Detach the compression tester and adapter.

  1. Install the glow plugs.

  1. Connect the glow plug electrical connectors.

  1. NOTE:
    NOTE:Check the EGR tube O-ring seal. Install a new seal if necessary.
    Install the EGR tube to the intake manifold assembly.

  1. Attach the EGR tube to the cylinder block and to the EGR valve (if equipped).

  1. Attach the EGR tube to the EGR cooler (if equipped).

  1. Connect the glow plug relay electrical connector.

  1. Connect the fuel injector wiring harness main connector.
  1. Install the air cleaner.
    REFER to: Air Cleaner - 1.4L Duratorq-TDCi (DV) Diesel (303-12 Intake Air Distribution and Filtering, Removal and Installation).
  1. Using worldwide diagnostic system (WDS), clear the fault codes from the PCM.

Measure the compression pressure (Engine - 1.6L Duratorq-TDCi (DV) Diesel)

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. Raise and support the vehicle. REFER to: (100-02 Jacking and Lifting)
    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 engine upper cover.

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

  1. Detach the exhaust gas recirculation (EGR) cooler (if equipped) and position it to one side.

  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 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 the special tool.

  1. Install the glow plugs.

  1. Install the glow plug power supply.

  1. Attach the EGR cooler (if equipped).

  1. Connect the fuel injector electrical connectors.

  1. Install the engine upper cover.
  1. Raise and support the vehicle. REFER to: (100-02 Jacking and Lifting)
    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 compression pressure (Engine - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma))

  1. Open the central junction box (CJB) 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 air cleaner.
    REFER to: Air Cleaner - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) (303-12 Intake Air Distribution and Filtering, Removal and Installation).

  1. Disconnect the electronic ignition (EI) coil connector from the EI coil.

NOTE:
NOTE:Twist the spark plug connectors slightly before disconnecting them. Pull on the connector and not on the cable.
  1. Disconnect the spark plug connectors.

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

NOTE:
NOTE:Operate the starter motor with wide open throttle until the reading on the compression tester 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 with the suitable adapter.

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

  1. Connect the spark plug connectors.

  1. Connect the EI coil electrical connector to the EI coil.

  1. Install the fuel pump relay.
  1. Install the air cleaner.
    REFER to: Air Cleaner - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) (303-12 Intake Air Distribution and Filtering, Removal and Installation).
  1. Using worldwide diagnostic system (WDS), clear the fault codes from the PCM.

Measure the compression pressure (Engine - 1.3L Duratec-8V (Rocam))

  1. Open the central junction box (CJB) 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 air cleaner.
    REFER to: Air Cleaner - 1.3L Duratec-8V (Rocam) (303-12 Intake Air Distribution and Filtering, Removal and Installation).

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

NOTE:
NOTE:Twist the spark plug connectors slightly before disconnecting them. Pull on the connector and not on the cable.
  1. Disconnect the spark plug connectors.

  1. Remove the spark plugs.

NOTE:
NOTE:Operate the starter motor with wide open throttle until the reading on the compression tester 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 with the suitable adapter.

  1. Install the spark plugs.

  1. Connect the spark plug connectors.

  1. Connect the EI coil electrical connector to the EI coil.

  1. Install the fuel pump relay.
  1. Install the air cleaner.
    REFER to: Air Cleaner - 1.3L Duratec-8V (Rocam) (303-12 Intake Air Distribution and Filtering, Removal and Installation).
  1. Using worldwide diagnostic system (WDS), clear the fault codes from the PCM.

Measure the compression pressure (Engine - 2.0L Duratec-HE (MI4))

  1. Open the central junction box (CJB) 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 air cleaner.
    REFER to: Air Cleaner - 2.0L Duratec-HE (MI4) (303-12 Intake Air Distribution and Filtering, Removal and Installation).

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

NOTE:
NOTE:Twist the spark plug connectors slightly before disconnecting them. Pull on the connector and not on the cable.
  1. Using the special tool, remove the spark plug connectors.

  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 compression pressure recorder 623.000.101 with the suitable adapter.

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

  1. Install the spark plug connectors.

  1. Connect the EI coil electrical connector to the EI coil.

  1. Install the fuel pump relay.
  1. Install the air cleaner.
    REFER to: Air Cleaner - 2.0L Duratec-HE (MI4) (303-12 Intake Air Distribution and Filtering, Removal and Installation).
  1. Reset the PCM fault memory.

Measure the oil pressure (Engine - 1.4L Duratorq-TDCi (DV) Diesel)

NOTE:
NOTE:The oil pressure depends on various factors (engine speed, oil temperature, oil viscosity, extent of oil filter contamination).
NOTE:
NOTE:Measure the oil pressure at the specified engine speed.
  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 from the oil pressure switch.

  1. Remove the oil pressure switch.
    • Discard the washer.

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

  1. NOTE:
    NOTE:Measure the oil pressure at an oil temperature of 110°C.
    NOTE:
    NOTE:Oil pressure at 2000 rpm: 2.3 to 3.7 bar.
    Measure the oil pressure.
  1. Raise and support the vehicle. Engine - 1.4L Duratorq-TDCi (DV) Diesel

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

  1. NOTE:
    NOTE:Install a new oil pressure switch washer.
    Install the oil pressure switch.

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

Measure the oil pressure (Engine - 1.6L Duratorq-TDCi (DV) Diesel)

  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 the specified engine speed. Measure the oil pressure at an oil temperature of 125°C.
    NOTE:
    NOTE:Measure the oil pressure at idle speed and at 2000 rpm.
    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 to the oil pressure switch.

Measure the oil pressure (Engine - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma))

NOTE:
NOTE:The oil pressure depends on various factors (engine speed, oil temperature, oil viscosity, extent of oil filter contamination).
NOTE:
NOTE:Measure the oil pressure at the specified engine speed.
  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 from the oil pressure switch.

  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 an oil temperature of 80°C.
    NOTE:
    NOTE:Oil pressure at 2000 rpm: 3.5 bar.
    Measure 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 from the oil pressure switch bore.
  1. Coat the oil pressure switch with adhesive.

  1. Install the oil pressure switch.

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

Measure the oil pressure (Engine - 1.3L Duratec-8V (Rocam))

NOTE:
NOTE:The oil pressure depends on various factors (engine speed, oil temperature, oil viscosity, extent of oil filter contamination).
NOTE:
NOTE:Measure the oil pressure at the specified engine speed.
  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 from the oil pressure switch.

  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 an oil temperature of 80°C.
    NOTE:
    NOTE:Oil pressure at idle speed (750 rpm): 0.95 bar.
    NOTE:
    NOTE:Oil pressure at 2500 rpm: 2.7 bar.
    Measure 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 from the oil pressure switch bore.
  1. Coat the oil pressure switch with sealant adhesive.

  1. Install the oil pressure switch.

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

Measure the oil pressure (Engine - 2.0L Duratec-HE (MI4))

  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 from the oil pressure switch.

  1. Remove the oil pressure switch.

  1. Attach the oil pressure gauge (GV 2134) 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:Oil pressure at 2000 rpm: 3.5 bar.
    Measure 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 from the oil pressure switch bore.
  1. Coat the oil pressure switch with adhesive.

  1. Install the oil pressure switch.

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

Valve train analysis - static (engine off)

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 > < 303-00 Engine System - General Information|Engine