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General Procedures > < Specifications - 2.0L Duratec-RS (Zetec)

Focus RS 2003 (09.2002-)

Engine System - General Information - Engine—2.0L Duratec-RS (Zetec) Focus RS 2003 (09/2002-)
Diagnosis and Testing

  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)
  • 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 concern 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.
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  303-08E Engine Emission Control.
*
Turbocharger seals.
*
Install a new turbocharger. REFER to Section  303-04I Fuel Charging and Controls / 303-04J Fuel Charging and Controls - Turbocharger.
*
Damaged gaskets or mating surfaces.
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Cylinder head gasket is damaged or mating faces are warped.
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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.
Engine will not start
*
Battery or wiring is faulty.
*
Check the battery, electrical connections and cables. REFER to Section  414-00 Charging System - General Information.
*
Starter motor or wiring is faulty.
*
Check the starter system. REFER to Section  303-06 Starting System.
*
Fault in fuel system.
*
Check the fuel system. REFER to Section  303-01F Engine.
*
Fuel tank is empty.
*
Check the fluid level.
*
Fault in ignition system.
*
Check the ignition system. REFER to Section  303-07F Engine Ignition.
*
Fault in engine management system.
*
Check the engine management system. REFER to Section  303-14 Electronic Engine Controls.
*
Intake system is faulty.
-
Intake system air leak.
-
Blocked air cleaner.
-
Faulty idle air control valve.
*
Check the intake system. REFER to Section  303-12 Intake Air Distribution and Filtering.
*
Fault in valve train.
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Burned out exhaust valve.
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Timing incorrectly adjusted.
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Cracked or damaged timing belt.
*
Connect compressed air to the cylinders. If air flows out through the intake manifold or the exhaust pipe, check the valve train.
*
Faulty engine components.
-
Burned through piston.
-
Piston rings.
-
Cylinder head gasket.
-
Big-end and/or main bearing journals.
*
Connect the compressed air line to the cylinder. If air is escaping from the opened oil filler cap, remove the cylinder head in accordance with the operation and check the components. REFER to Section  303-01F Engine.
Very poor power output / fuel consumption too high / rough engine running
*
Fault in fuel system.
*
Check the fuel system. REFER to Section  303-01F Engine.
*
Fault in ignition system.
*
Check the ignition system. REFER to Section  303-07F Engine Ignition.
*
Fault in engine management system.
*
Check the engine management system. REFER to Section  303-14 Electronic Engine Controls.
*
Intake system is faulty.
-
Intake air leak.
-
Air cleaner is blocked.
-
Faulty idle air control valve.
*
Check the intake system. REFER to Section  303-12 Intake Air Distribution and Filtering.
*
Turbocharger.
*
Check the turbocharger. REFER to Section  303-04I Fuel Charging and Controls / 303-04J Fuel Charging and Controls - Turbocharger.
*
Fault in valve train.
-
Burned out exhaust valve.
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Timing incorrectly adjusted.
-
Cracked or damaged timing belt.
*
Connect compressed air to the cylinders. If air flows out through the intake manifold or the exhaust pipe, check the valve train.
*
Engine components faulty.
-
Piston burned through.
-
Piston rings.
-
Cylinder head gasket.
-
Big-end and/or main bearing journal.
*
Connect the compressed air line to the cylinder. If air is escaping from the opened oil filler cap, remove the cylinder head and check the components. Dismantle the engine if necessary and check the components. REFER to Section  303-01F Engine.
Noisy running
*
Misfiring/backfiring
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Fuel has wrong octane number (petrol engines only), or the wrong type of fuel is filled.
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Fault in ignition system (petrol engines only).
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Engine temperature too high.
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Carbon deposits in the combustion chamber start to glow and cause misfiring.
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Timing incorrect, which causes misfiring in the intake/exhaust system.
*
Determine the cause of the misfiring and rectify it.
-
Determine which type of fuel was last put in the tank (note the country specific fuel specifications).
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Check the ignition system. REFER to Section  303-07F Engine Ignition.
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Check the engine cooling. REFER to Section  303-03 Engine Cooling.
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Remove the carbon deposits by using fuel additives and driving the vehicle carefully
-
Check the valve timing.
*
Fault in valve train.
*
Check the valve train.
*
Valve clearance too large, resulting from faulty bucket tappet or incorrect valve clearance setting.
*
Set the valve clearance (if possible) or replace the faulty bucket tappet.
*
Valve timing incorrectly adjusted - valves and pistons are touching.
*
Check and set the valve timing if required. REFER to Section  303-01F Engine.
*
Cracked or damaged timing belt.
*
Check the timing belt. In addition, check the pistons and valves for damage and renew all faulty parts.
*
Engine components faulty.
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Pistons.
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Piston rings.
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Cylinder head gasket.
-
Big-end and/or main bearing journals.
*
Disassemble the engine and check components. REFER to Section  303-07F Engine Ignition.
*
Engine components or ancillary components are broken or loosened.
*
Check the condition of the engine components and check that they are tight and seated correctly. If necessary, tighten to the prescribed torque. Renew the broken components.

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 transaxle with a suitable cleaning fluid.
  1. Fill with test fluid through the oil filler neck according to the manufacturer's instructions and screw the oil filler cap back on.
  1. Start the engine and run it for approximately five minutes.
  1. Switch off the engine.
NOTE:
NOTE:If no oil leak is found, carry out a road test under various load conditions and check the engine for leaks again.
  1. Check the engine for oil leaks using a suitable UV leak tester.
  1. Rectify any leaks found.

Measure the compression pressure

NOTE:
NOTE:The powertrain control module (PCM) receives an error message when the relay is removed out or electrical components are disconnected. This error message must be deleted from the fault memory by connecting 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.

  1. Open the central junction box (CJB) and remove the fuel pump relay.
  1. NOTE:
    NOTE:The engine will start, run for a few seconds and then stops.
    Start the engine.

  1. NOTE:
    NOTE:Turn the spark plug connector slightly before disconnecting it. Pull the connector and not the lead.
    Detach the spark plug connectors and remove the spark plugs.

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

NOTE:
NOTE:Operate the starter motor with wide open throttle until the pointer on the measuring device stops rising.
  1. Using a suitable compression pressure recorder carry out the measurement on every cylinder.
  1. Refit the components in reverse order, observing the specified tightening torques. Coat the spark plug connector seal with silicone grease (A960-M1C-AA) before fitting. Coat the spark plug thread with lubricant (ESE-M1244-A).
  1. Reset the PCM fault memory.

Measure the oil pressure

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.

  1. Raise and support the vehicle. REFER to Section  101-02 .

  1. Disconnect the oil pressure switch electrical connector and remove the oil pressure switch.
  1. Attach the oil pressure gauge with oil pressure gauge connector, and arrange it so that the reading can be made from above.
  1. Lower the vehicle.
  1. Check the oil pressure.
  1. Raise and support the vehicle. REFER to Section  101-02 .
  1. Detach the oil pressure gauge and connector.
  1. Coat the oil pressure switch with oil pressure switch sealer (WSK-M2G349-A7).
  1. Install the oil pressure switch and connect the oil pressure switch electrical connector.
  1. Lower the vehicle.

Valve train analysis - static (engine off)

Remove the valve cover. REFER to Section  303-01F Engine.

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 > < Specifications - 2.0L Duratec-RS (Zetec)