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

Focus 2004.75 (07.2004-)

Engine System - General Information - Engine Focus 2004.75 (07/2004-)
Diagnosis and Testing

Special Tool(s)

Socket, Spark Plug

303-499

Compression Test Adapter

303-1049A

Compression Test Adapter

303-1052

Compression Test Adapter

303-1056
General Equipment
Worldwide Diagnostic System (WDS)
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.
  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.
*
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. Engine - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) -
REFER to: Engine Emission Control (303-08A Engine Emission Control - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma)/1.6L Duratec-16V Ti-VCT (Sigma), Diagnosis and Testing).
Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) -
REFER to: Engine Emission Control (303-08B Engine Emission Control - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4), Diagnosis and Testing).
Engine - 2.5L Duratec-ST (VI5) -
REFER to: Engine Emission Control (303-08G, Diagnosis and Testing).
Engine - 1.6L Duratorq-TDCi (DV) Diesel -
REFER to: Engine Emission Control (303-08C Engine Emission Control - 1.6L Duratorq-TDCi (DV) Diesel, Diagnosis and Testing).
Engine - 2.0L Duratorq-TDCi (DW) Diesel -
REFER to: Engine Emission Control (303-08D Engine Emission Control - 2.0L Duratorq-TDCi (DW) Diesel, Diagnosis and Testing).
Engine - 1.8L Duratorq-TDCi (Kent) Diesel -
REFER to: Engine Emission Control (303-08F Engine Emission Control - 1.8L Duratorq-TDCi (Kent) Diesel, Diagnosis and Testing).
*
Turbocharger seals.
*
INSTALL a new turbocharger. Engine - 2.5L Duratec-ST (VI5) -
REFER to: Turbocharger (303-04E, Removal and Installation) /
Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel (90 PS) (303-04I Fuel Charging and Controls - Turbocharger, Removal and Installation) /
Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel (110 PS) (303-04I Fuel Charging and Controls - Turbocharger, Removal and Installation) /
Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel (110 PS), VIN Plate Emission Level Code: K (303-04I Fuel Charging and Controls - Turbocharger, Removal and Installation) /
Turbocharger - 1.8L Duratorq-TDCi (Kent) Diesel (303-04I Fuel Charging and Controls - Turbocharger, Removal and Installation) /
Turbocharger - 2.0L Duratorq-TDCi (DW) Diesel (303-04I, 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. CHECK the mating faces, cylinder head gasket and the evenness of the cylinder head and engine block mating faces.
-
INSTALL new valve seals. Engine - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) -
REFER to: Valve Seals (303-01A Engine - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), In-vehicle Repair).
Engine - 1.6L Duratec-16V Ti-VCT
REFER to: Valve Seals (303-01B Engine - 1.6L Duratec-16V Ti-VCT (Sigma), In-vehicle Repair).
Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) -
REFER to: Valve Seals (303-01C Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4), In-vehicle Repair).
Engine - 2.5L Duratec-ST (VI5) -
REFER to: Valve Stem Seals (303-01D, Removal and Installation).
Engine - 1.6L Duratorq-TDCi (DV) Diesel -
REFER to: Valve Seals (303-01E Engine - 1.6L Duratorq-TDCi (DV) Diesel, In-vehicle Repair).
Engine - 2.0L Duratorq-TDCi (DW) Diesel -
REFER to: Valve Seals (303-01F Engine - 1.8L Duratorq-TDCi (Kent) Diesel, In-vehicle Repair).
Engine - 1.8L Duratorq-TDCi (Kent) Diesel -
REFER to: Valve Seals (303-01G Engine - 2.0L Duratorq-TDCi (DW) 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 and piston rings. REFER to: (303-00 Engine System - General Information)
Piston Inspection (General Procedures),
Piston Pin to Bore Diameter (General Procedures),
Piston Diameter (General Procedures),
Piston Ring End Gap (General Procedures),
Piston Ring-to-Groove Clearance (General Procedures),
Piston Pin Diameter (General Procedures).
Coolant consumption
*
Cooling system components.
*
Check the cooling system components. Engine - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) -
REFER to: Engine Cooling (303-03A Engine Cooling - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), Diagnosis and Testing).
Engine - 1.6L Duratec-16V Ti-VCT -
REFER to: Engine Cooling (303-03B Engine Cooling - 1.6L Duratec-16V Ti-VCT (Sigma), Diagnosis and Testing).
Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) -
REFER to: Engine Cooling (303-03C Engine Cooling - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4), Diagnosis and Testing).
Engine - 2.5L Duratec-ST (VI5) -
REFER to: Engine Cooling (303-03D, Diagnosis and Testing).
Engine - 1.6L Duratorq-TDCi (DV) Diesel -
REFER to: Engine Cooling (303-03E Engine Cooling - 1.6L Duratorq-TDCi (DV) Diesel, Diagnosis and Testing).
Engine - 2.0L Duratorq-TDCi (DW) Diesel -
REFER to: Engine Cooling (303-03G Engine Cooling - 2.0L Duratorq-TDCi (DW) Diesel, Diagnosis and Testing).
Engine - 1.8L Duratorq-TDCi (Kent) Diesel -
REFER to: Engine Cooling (303-03F Engine Cooling - 1.8L Duratorq-TDCi (Kent) 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 (303-06A Starting System, Diagnosis and Testing).
Engine cranks but will not start
*
Fuel tank is empty.
*
CHECK the fuel level.
*
Water in fuel (only diesel engine).
*
Drain the water from the fuel system.
*
Fuel filter blocked.
*
INSTALL a new fuel filter. REFER to: (310-01 Fuel Tank and Lines)
Fuel Filter - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) (Removal and Installation),
Fuel Filter - 1.6L Duratorq-TDCi (DV) Diesel (Removal and Installation),
Fuel Filter - 2.0L Duratorq-TDCi (DW) Diesel, Vehicles With: Water-in-Fuel Sensor (Removal and Installation),
Fuel Filter - 2.0L Duratorq-TDCi (DW) Diesel, Vehicles Without: Water-in-Fuel Sensor (Removal and Installation),
Fuel Filter - 1.8L Duratorq-TDCi (Kent) Diesel, Vehicles Without: Water-in-Fuel Sensor (Removal and Installation).
*
Engine intake air system.
*
CHECK the intake air system.
REFER to: Intake Air Distribution and Filtering (303-12A Intake Air Distribution and Filtering, Diagnosis and Testing).
*
Glow plug faulty (only diesel engine).
*
CHECK the glow plugs. INSTALL new glow plugs as necessary.
REFER to: Glow Plug System (303-07C Glow Plug System - 1.6L Duratorq-TDCi (DV) Diesel/2.0L Duratorq-TDCi (DW) Diesel, Diagnosis and Testing).
*
Engine management system.
*
CHECK the engine management system.
REFER to: Electronic Engine Controls (303-14A Electronic Engine Controls, Diagnosis and Testing).
*
Ignition system (only petrol engines).
*
CHECK the ignition system. Engine - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) -
REFER to: Engine Ignition (303-07A Engine Ignition - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma)/1.6L Duratec-16V Ti-VCT (Sigma), Diagnosis and Testing).
Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) -
REFER to: Engine Ignition (303-07B, Diagnosis and Testing).
Engine - 2.5L Duratec-ST (VI5) -
REFER to: Engine Ignition (303-07E, Diagnosis and Testing).
*
Incorrect valve timing.
*
CHECK and adjust the valve timing. Engine - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) -
REFER to: Timing Belt - Vehicles Built Up To: 04/2005 (303-01A Engine - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), In-vehicle Repair).
Engine - 1.6L Duratec-16V Ti-VCT -
REFER to: Timing Belt (303-01B Engine - 1.6L Duratec-16V Ti-VCT (Sigma), In-vehicle Repair).
Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) -
REFER to: Timing Chain (303-01C Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4), In-vehicle Repair).
Engine - 2.5L Duratec-ST (VI5) -
REFER to: Timing Belt (303-01D, Removal and Installation).
Engine - 1.6L Duratorq-TDCi (DV) Diesel -
REFER to: Timing Belt (303-01E Engine - 1.6L Duratorq-TDCi (DV) Diesel, In-vehicle Repair).
Engine - 1.8L Duratorq-TDCi (Kent) Diesel -
REFER to: Timing Belt (303-01F, In-vehicle Repair).
Engine - 2.0L Duratorq-TDCi (DW) Diesel -
REFER to: Timing Belt (303-01G Engine - 2.0L Duratorq-TDCi (DW) 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. Engine - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) -
REFER to: Timing Belt - Vehicles Built Up To: 04/2005 (303-01A Engine - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), In-vehicle Repair).
Engine - 1.6L Duratec-16V Ti-VCT -
REFER to: Timing Belt (303-01B Engine - 1.6L Duratec-16V Ti-VCT (Sigma), In-vehicle Repair).
Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) -
REFER to: Timing Chain (303-01C Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4), In-vehicle Repair).
Engine - 2.5L Duratec-ST (VI5) -
REFER to: Timing Belt (303-01D, Removal and Installation).
Engine - 1.6L Duratorq-TDCi (DV) Diesel -
REFER to: Timing Belt (303-01E Engine - 1.6L Duratorq-TDCi (DV) Diesel, In-vehicle Repair).
Engine - 1.8L Duratorq-TDCi (Kent) Diesel -
REFER to: Timing Belt (303-01F, In-vehicle Repair).
Engine - 2.0L Duratorq-TDCi (DW) Diesel -
REFER to: Timing Belt (303-01G Engine - 2.0L Duratorq-TDCi (DW) Diesel, In-vehicle Repair).
Very poor power output or fuel consumption too high or engine running rough.
*
Fuel system.
*
CHECK the fuel system. Engine - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) -
REFER to: Fuel Charging and Controls (303-04A Fuel Charging and Controls - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), Diagnosis and Testing).
Engine - 1.6L Duratec-16V Ti-VCT -
REFER to: Fuel Charging and Controls (303-04A Fuel Charging and Controls - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), Diagnosis and Testing).
Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) -
REFER to: Fuel Charging and Controls (303-04C Fuel Charging and Controls - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4), Diagnosis and Testing).
Engine - 2.5L Duratec-ST (VI5) -
REFER to: Fuel Charging and Controls (303-04D, Diagnosis and Testing).
Engine - 1.6L Duratorq-TDCi (DV) Diesel -
REFER to: Fuel Charging and Controls (303-04F Fuel Charging and Controls - 1.6L Duratorq-TDCi (DV) Diesel, Diagnosis and Testing).
Engine - 2.0L Duratorq-TDCi (DW) Diesel -
REFER to: Fuel Charging and Controls (303-04H Fuel Charging and Controls - 2.0L Duratorq-TDCi (DW) Diesel, Diagnosis and Testing).
Engine - 1.8L Duratorq-TDCi (Kent) Diesel -
REFER to: Fuel Charging and Controls - 1.8L Duratorq-TDCi (Kent) Diesel (303-04G Fuel Charging and Controls - 1.8L Duratorq-TDCi (Kent) Diesel, Diagnosis and Testing).
*
Engine intake air system.
*
CHECK the intake air system.
REFER to: Intake Air Distribution and Filtering (303-12A Intake Air Distribution and Filtering, Diagnosis and Testing).
*
Exhaust system blocked.
*
CHECK the exhaust system.
REFER to: Exhaust System (309-00A Exhaust System, Description and Operation).
*
Engine management system.
*
CHECK the engine management system.
REFER to: Electronic Engine Controls (303-14A Electronic Engine Controls, Diagnosis and Testing).
*
Fault in ignition system (only petrol engines).
*
CHECK the ignition system. Engine - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) -
REFER to: Engine Ignition (303-07A Engine Ignition - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma)/1.6L Duratec-16V Ti-VCT (Sigma), Diagnosis and Testing).
Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) -
REFER to: Engine Ignition (303-07E Engine Ignition - 2.5L Duratec-ST (VI5), Diagnosis and Testing).
Engine - 2.5L Duratec-ST (VI5) -
REFER to: Engine Ignition (303-07E, Diagnosis and Testing).
*
Turbocharger.
*
CHECK the turbocharger. Engine - 2.5L Duratec-ST (VI5) -
REFER to: Turbocharger (303-04E, Removal and Installation) /
Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel (303-04I Fuel Charging and Controls - Turbocharger, Diagnosis and Testing) /
Turbocharger - 2.0L Duratorq-TDCi (DW) Diesel (303-04I Fuel Charging and Controls - Turbocharger, Diagnosis and Testing) /
Turbocharger - 1.8L Duratorq-TDCi (Kent) Diesel (303-04I Fuel Charging and Controls - Turbocharger, Diagnosis and Testing).
*
Incorrect valve timing. Timing belt/timing sprocket or pulley/sprocket damaged.
*
CHECK and adjust valve timing. INSTALL new components as necessary. Engine - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) -
REFER to: Timing Belt - Vehicles Built Up To: 04/2005 (303-01A Engine - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), In-vehicle Repair).
Engine - 1.6L Duratec-16V Ti-VCT -
REFER to: Timing Belt (303-01B Engine - 1.6L Duratec-16V Ti-VCT (Sigma), In-vehicle Repair).
Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) -
REFER to: Timing Chain (303-01C Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4), In-vehicle Repair).
Engine - 2.5L Duratec-ST (VI5) -
REFER to: Timing Belt (303-01D, Removal and Installation).
Engine - 1.6L Duratorq-TDCi (DV) Diesel -
REFER to: Timing Belt (303-01E Engine - 1.6L Duratorq-TDCi (DV) Diesel, In-vehicle Repair).
Engine - 1.8L Duratorq-TDCi (Kent) Diesel -
REFER to: Timing Belt (303-01F, In-vehicle Repair).
Engine - 2.0L Duratorq-TDCi (DW) Diesel -
REFER to: Timing Belt (303-01G Engine - 2.0L Duratorq-TDCi (DW) Diesel, In-vehicle Repair).
*
Ignition timing incorrect (only petrol engines).
*
CHECK the electronic engine controls.
REFER to: Electronic Engine Controls (303-14A Electronic Engine Controls, Diagnosis and Testing).
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 - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) -
REFER to: Timing Belt - Vehicles Built Up To: 04/2005 (303-01A Engine - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), In-vehicle Repair).
Engine - 1.6L Duratec-16V Ti-VCT -
REFER to: Timing Belt (303-01B Engine - 1.6L Duratec-16V Ti-VCT (Sigma), In-vehicle Repair).
Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) -
REFER to: Timing Chain (303-01C Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4), In-vehicle Repair).
Engine - 2.5L Duratec-ST (VI5) -
REFER to: Timing Belt (303-01D, Removal and Installation).
Engine - 1.6L Duratorq-TDCi (DV) Diesel -
REFER to: Timing Belt (303-01E Engine - 1.6L Duratorq-TDCi (DV) Diesel, In-vehicle Repair).
Engine - 1.8L Duratorq-TDCi (Kent) Diesel -
REFER to: Timing Belt (303-01F, In-vehicle Repair).
Engine - 2.0L Duratorq-TDCi (DW) Diesel -
REFER to: Timing Belt (303-01G Engine - 2.0L Duratorq-TDCi (DW) 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 valve timing. INSTALL new components as necessary. Engine - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) -
REFER to: Timing Belt - Vehicles Built Up To: 04/2005 (303-01A Engine - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), In-vehicle Repair).
Engine - 1.6L Duratec-16V Ti-VCT -
REFER to: Timing Belt (303-01B Engine - 1.6L Duratec-16V Ti-VCT (Sigma), In-vehicle Repair).
Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) -
REFER to: Timing Chain (303-01C Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4), In-vehicle Repair).
Engine - 2.5L Duratec-ST (VI5) -
REFER to: Timing Belt (303-01D, Removal and Installation).
Engine - 1.6L Duratorq-TDCi (DV) Diesel -
REFER to: Timing Belt (303-01E Engine - 1.6L Duratorq-TDCi (DV) Diesel, In-vehicle Repair).
Engine - 1.8L Duratorq-TDCi (Kent) Diesel -
REFER to: Timing Belt (303-01F, In-vehicle Repair).
Engine - 2.0L Duratorq-TDCi (DW) Diesel -
REFER to: Timing Belt (303-01G Engine - 2.0L Duratorq-TDCi (DW) 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. Engine - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) -
REFER to: Valve Clearance Adjustment (303-01A Engine - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), General Procedures).
Engine - 1.6L Duratec-16V Ti-VCT -
REFER to: Valve Clearance Adjustment (303-01B Engine - 1.6L Duratec-16V Ti-VCT (Sigma), General Procedures).
Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) -
REFER to: Valve Clearance Adjustment (303-01C, General Procedures).
Engine - 2.5L Duratec-ST (VI5) -
REFER to: Valve Clearance Adjustment (303-01D, General Procedures).
Engine - 1.6L Duratorq-TDCi (DV) Diesel -
REFER to: Camshaft (303-01E Engine - 1.6L Duratorq-TDCi (DV) Diesel, In-vehicle Repair).
Engine - 2.0L Duratorq-TDCi (DW) Diesel -
REFER to: Camshafts (303-01G Engine - 2.0L Duratorq-TDCi (DW) Diesel, In-vehicle Repair).
Engine - 1.8L Duratorq-TDCi (Kent) Diesel -
REFER to: Camshafts (303-01F Engine - 1.8L Duratorq-TDCi (Kent) Diesel, In-vehicle Repair).
*
Timing belt or timing chain damaged.
*
INSTALL a new timing belt or timing chain. Engine - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) -
REFER to: Timing Belt - Vehicles Built Up To: 04/2005 (303-01A Engine - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), In-vehicle Repair).
Engine - 1.6L Duratec-16V Ti-VCT -
REFER to: Timing Belt (303-01B Engine - 1.6L Duratec-16V Ti-VCT (Sigma), In-vehicle Repair).
Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) -
REFER to: Timing Chain (303-01C Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4), In-vehicle Repair).
Engine - 2.5L Duratec-ST (VI5) -
REFER to: Timing Belt (303-01D, Removal and Installation).
Engine - 1.6L Duratorq-TDCi (DV) Diesel -
REFER to: Timing Belt (303-01E Engine - 1.6L Duratorq-TDCi (DV) Diesel, In-vehicle Repair).
Engine - 1.8L Duratorq-TDCi (Kent) Diesel -
REFER to: Timing Belt (303-01F, In-vehicle Repair).
Engine - 2.0L Duratorq-TDCi (DW) Diesel -
REFER to: Timing Belt (303-01G Engine - 2.0L Duratorq-TDCi (DW) Diesel, In-vehicle Repair).
*
Timing belt or timing chain incorrectly tensioned.
*
CHECK the timing belt tension. INSTALL a new timing belt or timing chain as necessary. Engine - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) -
REFER to: Timing Belt - Vehicles Built Up To: 04/2005 (303-01A Engine - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), In-vehicle Repair).
Engine - 1.6L Duratec-16V Ti-VCT -
REFER to: Timing Belt (303-01B Engine - 1.6L Duratec-16V Ti-VCT (Sigma), In-vehicle Repair).
Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) -
REFER to: Timing Chain (303-01C Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4), In-vehicle Repair).
Engine - 2.5L Duratec-ST (VI5) -
REFER to: Timing Belt (303-01D, Removal and Installation).
Engine - 1.6L Duratorq-TDCi (DV) Diesel -
REFER to: Timing Belt (303-01E Engine - 1.6L Duratorq-TDCi (DV) Diesel, In-vehicle Repair).
Engine - 1.8L Duratorq-TDCi (Kent) Diesel -
REFER to: Timing Belt (303-01F, In-vehicle Repair).
Engine - 2.0L Duratorq-TDCi (DW) Diesel -
REFER to: Timing Belt (303-01G Engine - 2.0L Duratorq-TDCi (DW) 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 - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) -
REFER to: Specifications (303-01A Engine - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), Specifications).
Engine - 1.6L Duratec-16V Ti-VCT -
REFER to: Specifications (303-01B Engine - 1.6L Duratec-16V Ti-VCT (Sigma), Specifications).
Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) -
REFER to: Specifications (303-01C, Specifications).
Engine - 1.6L Duratorq-TDCi (DV) Diesel -
REFER to: Specifications (303-01A, Specifications).
Engine - 1.8L Duratorq-TDCi (Kent) Diesel -
REFER to: Specifications (303-01F, Specifications).
Engine - 2.0L Duratorq-TDCi (DW) Diesel -
REFER to: Specifications (303-01G, 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.
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 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 (Engine - 1.6L Duratec-16V, Engine - 1.6L Duratec-16V Ti-VCT)

  1. Remove the central junction box (CJB) cover.

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

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.

  1. 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 a suitable compression pressure recorder with a suitable adapter.

  1. Install the spark plugs.

  1. Install the spark plug connectors.

  1. Connect the EI coil connector.

  1. Install the fuel pump relay and close the CJB.

  1. Install the CJB cover.
  1. Using worldwide diagnostic system (WDS), clear the fault codes from the powertrain control module (PCM).

Measure the compression pressure (Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4))

  1. Remove the central junction box (CJB) cover.

  1. Open the 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 cowl panel grille.
    REFER to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation).

  1. Remove the oil filler pipe.
    • Release the securing clip and rotate the oil filler pipe counterclockwise.

  1. Remove the engine cover.

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

  1. Remove the ignition coil-on-plug.

  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 a suitable compression pressure recorder with a suitable adapter.

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

  1. Install the ignition coil-on-plug.

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

  1. Install the engine cover.

  1. Install the oil filler pipe.
    • Rotate the oil filler pipe approximately 90 degrees clockwise until the securing clip snaps into position.
  1. Install the cowl panel grille.
    REFER to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation).

  1. Install the fuel pump relay and close the CJB.

  1. Install the CJB cover.
  1. Reset the PCM fault memory.

Measure the compression pressure (Engine - 2.5L Duratec-ST (VI5))

  1. Remove the central junction box (CJB) cover.

  1. Open the CJB and remove the fuel pump relay.
  1. NOTE:
    NOTE:The engine will start, run for a few seconds and then stop.
    Start the engine.
  1. Remove the ignition coil-on-plug.
    REFER to: Ignition Coil-On-Plug (303-07E, Removal and Installation).
  1. Connect the battery ground cable.
    REFER to: Battery Disconnect (414-01, General Procedures).

  1. 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 a suitable compression pressure recorder with a suitable adapter.

  1. Install the spark plugs.
  1. Install the ignition coil-on-plug.
    REFER to: Ignition Coil-On-Plug (303-07E, Removal and Installation).

  1. Install the fuel pump relay and close the CJB.

  1. Install the CJB cover.

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 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: (100-02 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 cowl panel grille.
    REFER to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation).

  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 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. Attach the EGR cooler (if equipped).

  1. Connect the fuel injector electrical connectors.

  1. Install the engine upper cover.
  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: (100-02 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 - 1.8L Duratorq-TDCI (Kent) 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 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. Open the central junction box (CJB) and remove the glow plug relay.

  1. NOTE:
    NOTE:The engine upper cover is held in place by 4 ball clips. The ball clips are not vertical, but are angled backwards by approximately 20 degrees.
    Location of the engine upper cover retaining clips.

  1. CAUTION:
    CAUTION:Care must be taken when releasing the 4th retaining clip and manoeuvering the engine upper cover past the manifold absolute pressure (MAP) sensor. Failure to follow this instruction may result in damage to the MAP sensor.
    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.

  1. Disconnect the fuel injector electrical connectors.
    • Detach the wiring harness clips from the cylinder head.

  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 power supply.

  1. Connect the fuel injector electrical connectors.
    • Attach the wiring harness clips to the cylinder head.
  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 glow plug relay and close the CJB.
  1. Reset the PCM fault memory.

Measure the compression pressure (Engine - 2.0L Duratorq-TDCi (DW) 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 vapors 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 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 (303-08D Engine Emission Control - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation).
  1. Remove the EGR valve.
    REFER to: Exhaust Gas Recirculation (EGR) Valve (303-08D Engine Emission Control - 2.0L 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 (303-08D Engine Emission Control - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation).
  1. Install the EGR cooler.
    REFER to: Exhaust Gas Recirculation (EGR) Cooler (303-08D Engine Emission Control - 2.0L 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: (100-02 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 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 (Engine - 1.6L Duratec-16V, Engine - 1.6L Duratec-16V Ti-VCT)

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.

  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: 2.5 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.
  1. Lower the vehicle.

Measure the oil pressure (Engine - 1.8L Duratec-HE (MI4)/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. Remove the engine undershield.

  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 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 rpm: 1.3 - 2.7 bar.
    NOTE:
    NOTE:Oil pressure at 3000 rpm: 2.3 - 5.2 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. Install the engine undershield.
  1. Lower the vehicle.

Measure the oil pressure (Engine - 2.5L Duratec-ST (VI5))

  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. 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 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 100°C.
    NOTE:
    NOTE:Measure the oil pressure at idle speed and at 4000 rpm.
    NOTE:
    NOTE:Minimum oil pressure at idle speed: 1.0 bar.
    NOTE:
    NOTE:Minimum oil pressure at 4000 rpm: 3.5 bar.
    NOTE:
    NOTE:Maximum oil pressure: 4.8 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. Install the engine undershield.
  1. Lower the vehicle.

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

  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 125° C.
    NOTE:
    NOTE:Measure the oil pressure at idle speed and at 2000 rpm.
    NOTE:
    NOTE:Oil pressure at idle speed: 1.0 - 2.0 bar.
    NOTE:
    NOTE:Oil pressure at 2000 rpm: 2.3 - 3.7 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.

Measure the oil pressure (Engine - 1.8L Duratorq-TDCI (Kent) Diesel)

  1. NOTE:
    NOTE:The engine upper cover is held in place by 4 ball clips. The ball clips are not vertical, but are angled backwards by approximately 20 degrees.
    Location of the engine upper cover retaining clips.

  1. CAUTION:
    CAUTION:Care must be taken when releasing the 4th retaining clip and manoeuvering the engine upper cover past the manifold absolute pressure (MAP) sensor. Failure to follow this instruction may result in damage to the MAP sensor.
    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.

  1. Disconnect the oil pressure switch electrical connector (components shown removed for clarity).

  1. Remove the oil pressure switch (components shown removed for clarity).
  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 idle speed and at 2000 rpm.
    NOTE:
    NOTE:Oil pressure at idle speed: 0.75 bar.
    NOTE:
    NOTE:Oil pressure at 2000 rpm: 1.5 bar.
    Attach the oil pressure gauge with the oil pressure gauge connector.
  1. 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. 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.

Measure the oil pressure (Engine - 2.0L Duratorq-TDCi (DW) Diesel)

  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 under shield.

  1. Disconnect the oil pressure switch electrical connector.

  1. CAUTION:
    CAUTION:I
    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.

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