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

Mondeo 1997 (08.1996-09.2000)

Engine System - General Information - Engine Mondeo 1997 (08/1996-09/2000)
Diagnosis and Testing

Since troubleshooting actually begins when repairs are taken on, the following procedure is recommended:

  1. Check customer concern is clear. If necessary, reproduce the concern on the vehicle.
  1. If the concern cannot be reproduced, carry out a road test and/or a visual check with the aid of the following table:

Visual Inspection Chart

Mechanical
  • Coolant leaks
  • Oil leaks
  • Fuel system leaks
  • Visibly damaged or worn parts
  • Loose or missing nuts or bolts
  1. If a fault can be clearly identified by the visual check, rectify the fault and test the system to see that it functions perfectly.
  1. If the fault cannot be clearly determined, use the following symptom chart.

Symptom Chart

Symptom Possible Sources Action
Loss of oil
*
Use of the wrong type of engine oil.
*
Determine the last engine oil used (eg, refer to latest invoice or oil receipt) and compare with the specification, renew if necessary.
Loss of oil
*
Pressure in the cylinder block too high
-
Faulty positive crankcase ventilation system
-
Poor sealing between combustion chamber and crankcase
*
Remove the cylinder head cover blanking plug. Close the opening by hand. If overpressure is detected when the engine is running:
-
Check the operation of the crankcase ventilation system and repair it as necessary.
-
With the cylinder head cover cap removed, insert the compressed air connection in the spark plug bore of each cylinder, apply compressed air and look to see if air comes out from the cylinder head cover cap hole. If a definite flow of air is detected, check the cylinder liners and pistons for damage and measure them.
Loss of oil
*
Leak at a rotating shaft caused by a faulty oil seal or incorrect alignment of the oil seal carrier
-
Camshaft
-
Crankshaft front
-
Crankshaft rear
-
Auxiliary shaft.
*
Check and, if necessary, align the oil seal carrier. Renew the seal.
Loss of oil
*
Damaged gaskets or mating faces
-
Cylinder head gasket or mating face is damaged, engine oil can escape from the engine between cylinder head and cylinder block or get into the cooling system.
*
Check gaskets and mating faces for damage.
-
Open the cover of the coolant expansion tank and check for any oil scum or film on the coolant surface.
-
Remove the cylinder head. Check the mating faces, cylinder head gasket and the evenness of the cylinder head mating face. If necessary, rework or renew the cylinder head.
Loss of oil
*
Oil leaks on components that are either coated in oil or have oilways, oil leaks on ancillary components.
*
Locate any cracks in components which have oilways or in the engine itself with a UV leak tester and renew the relevant component or gasket.
Oil consumption
*
Use of the wrong type of engine oil.
*
Determine the last type of engine oil used (eg, refer to latest invoice or oil receipt) and compare with the specification, renew if necessary.
Oil consumption
*
Faulty positive crankcase ventilation system
-
Hoses or ventilation/breather valve are blocked. This causes excessive pressure in the crankcase which causes more oil to enter the combustion chamber.
-
Crankcase ventilation oil separator is faulty and engine oil can enter the combustion chamber through the inlet manifold.
*
Check that the crankcase ventilation system is operating correctly and repair if necessary.
Oil consumption
*
Damaged cylinder liners or too much clearance on engine components.
-
Pistons
-
Piston rings (ring clearances and ring gap)
-
Cylinder liners
-
Valve stems and guides.
*
Check the running surfaces and clearances of individual engine components and renew as necessary.
-
Pistons
-
Piston rings
-
Cylinder liners
-
Valve stems and guides
Oil consumption
*
Damaged gaskets or mating faces
-
Cylinder head gasket or mating face is damaged, and engine oil can enter the combustion chamber.
-
Valve stem seals are faulty and engine oil can enter the combustion chamber between the valve stem and valve stem guide. This occurs particularly on overrun.
*
Check gaskets and mating faces for damage.
-
Remove the cylinder head. Check the mating faces, cylinder head gasket and the evenness of the cylinder head mating face. If necessary, rework or renew the cylinder head.
-
Renew the valve stem oil seals.
Oil consumption
*
Cracks in engine components with oilways or engine components coated in oil, e.g. cylinder liners, pistons and oil galleries and passages.
*
Add additive to the engine oil for the UV leak tester and heat the engine oil to at least 80°C so that the engine additive can enter any cracks. Leave the engine to cool down to the ambient temperature, remove the affected component and dismantle (if necessary). Check the engine component with a UV leak tester and renew if necessary.
Coolant consumption
*
Damaged gaskets or mating faces
-
The cylinder head gasket or mating face is damaged. Coolant can enter the combustion chamber or the crankcase.
*
Check the gaskets and mating faces for damage.
-
Remove the cylinder head. Check the mating faces, cylinder head gasket and the evenness of the cylinder head face. If necessary, rework or renew the cylinder head.
Coolant consumption
*
Cracks or fractures in engine components surrounded by coolant, such as cylinder liners and cylinder head combustion chamber recesses.
*
Determine the damaged engine component and renew it.
Engine will not start
*
Battery or cables faulty.
*
Check battery, bracket and cables. REFER to Section  414-00 Charging System - General Information.
Engine will not start
*
Starter motor or cables faulty.
*
Check the starter system. REFER to Section  303-06 Starting System.
Engine will not start
*
Fuel system faulty.
-
Fuel tank is empty.
*
Check the fuel system.
-
Zetec–E - REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls / 303-04D Fuel Charging and Controls - Turbocharger / 303-04E Fuel Charging and Controls. Duratec–VE - REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls / 303-04D Fuel Charging and Controls - Turbocharger / 303-04E Fuel Charging and Controls. TCI diesel - REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls / 303-04D Fuel Charging and Controls - Turbocharger / 303-04E Fuel Charging and Controls.
-
Check the fuel level.
Engine will not start
*
Ignition system faulty.
*
Check ignition system. Zetec–E - REFER to Section  303-07A Engine Ignition / 303-07B Engine Ignition. Duratec–VE - REFER to Section  303-07A Engine Ignition / 303-07B Engine Ignition.
Engine will not start
*
Engine management system faulty.
*
Check the engine management system. REFER to Section  303-14 Electronic Engine Controls.
Engine will not start
*
Intake system is faulty
-
Intake system air leak
-
Air cleaner is blocked
-
Idle air control valve faulty.
*
Check the intake system. REFER to Section  303-12 Intake Air Distribution and Filtering.
Engine will not start
*
Valve train faulty
-
Burned out exhaust valve
-
Timing incorrectly adjusted
-
Timing chain or timing pulley broken or damaged.
*
Connect compressed air to the cylinders. If air flows out through the intake manifold or the exhaust pipe, check the valve train.
Engine will not start
*
Faulty engine components
-
Burned through piston
-
Piston rings
-
Cylinder head gasket
-
Big-end and/or main bearing journals
*
Connect the compressed air connection to the cylinder. If air flows out of the opened cylinder head cover cap, dismantle the engine according to the operating procedure and check the components.
Very poor power output / fuel consumption too high / rough engine running
*
Fuel system faulty.
*
Check the fuel system. Zetec–E - REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls / 303-04D Fuel Charging and Controls - Turbocharger / 303-04E Fuel Charging and Controls. Duratec–VE - REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls / 303-04D Fuel Charging and Controls - Turbocharger / 303-04E Fuel Charging and Controls. TCI Diesel - REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls / 303-04D Fuel Charging and Controls - Turbocharger / 303-04E Fuel Charging and Controls.
Very poor power output / fuel consumption too high / rough engine running
*
Ignition system faulty.
*
Check the ignition system. Zetec–E - REFER to Section  303-07A Engine Ignition / 303-07B Engine Ignition. Duratec–VE - REFER to Section  303-07A Engine Ignition / 303-07B Engine Ignition.
Very poor power output / fuel consumption too high / rough engine running
*
Engine management system faulty.
*
Check the engine management system. REFER to Section  303-14 Electronic Engine Controls.
Very poor power output / fuel consumption too high / rough engine running
*
Intake system is faulty
-
Intake air leak
-
Air cleaner is blocked
-
Idle air control valve faulty.
*
Check the intake system. REFER to Section  303-12 Intake Air Distribution and Filtering.
Very poor power output / fuel consumption too high / rough engine running
*
Valve train faulty
-
Burned out exhaust valve
-
Timing incorrectly adjusted
-
Timing chain or timing pulley broken or damaged
*
Connect compressed air to the cylinders If air escapes from the intake manifold or the exhaust pipe, check the valve train.
Very poor power output / fuel consumption too high / rough engine running
*
Engine components faulty
-
Piston burned through
-
Piston rings
-
Cylinder head gasket
-
Big-end and/or main bearing journal
*
Connect the compressed air connection to the cylinder. If air flows out of the opened cylinder head cover cap, dismantle the engine and check the components.
Noisy running
*
Misfiring/backfiring
-
Fuel in tank has wrong octane/cetane number, or is wrong type of fuel.
-
Ignition system faulty
-
Engine temperature too high
-
Carbon deposits in the combustion chamber start to glow and cause misfiring
-
Timing incorrect, which causes misfiring in the intake/exhaust system.
*
Locate and rectify the cause of the misfiring and backfiring.
-
Determine which type of fuel was last put in the tank (note the country specific fuel specifications).
-
Check the ignition system. Zetec–E - REFER to Section  303-07A Engine Ignition / 303-07B Engine Ignition. Duratec–VE - REFER to Section  303-07A Engine Ignition / 303-07B Engine Ignition.
-
Check the engine cooling. REFER to Section  303-03 Engine Cooling.
-
Remove the carbon deposits by using fuel additives and driving the vehicle carefully
-
Check the timing.
Noisy running
*
Valve train faulty
-
Valve clearance too large due to faulty hydraulic valve tappets or incorrect adjustment of valve clearance.
-
Valve timing incorrectly adjusted - valves and pistons are touching.
-
Timing chain or timing belt broken or damaged.
-
Timing belt is too loose (rattling or rubbing noises) or too tight (whistling or humming noises)
-
Timing chain incorrectly tensioned
-
Timing chain guides worn or damaged
*
Check the valve train
-
Adjust valve clearance (if possible) or renew faulty hydraulic valve tappets.
-
Check the valve timing and adjust if necessary
-
Check timing chain or timing belt. In addition, check pistons and valves for damage and renew any faulty parts.
-
Check timing belt tension and adjust if necessary.
-
Check the timing chain tension and if necessary renew the hydraulic chain tensioner
-
Check the timing chain guides and renew if necessary.
Noisy running
*
Engine components faulty
-
Pistons
-
Piston rings
-
Cylinder head gasket
-
Big-end and/or main bearing journals.
*
Disassemble the engine and check components.
Noisy running
*
Engine components or ancillary components are broken or have come loose.
*
Check that the ancillary components are securely and correctly fitted, if necessary tighten them to the specified torque.

Engine oil leaks

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

If the oil leak cannot be identified clearly by a visual inspection, carry out a UV test:

UV Testing

  1. Clean the engine and transmission with a suitable cleaning fluid (e.g. 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 refit the oil filler cap.
WARNING:
WARNING:On manual transmissions put the transmission into neutral. On automatic transmissions select "P".
  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 UV leak tester GV-2929 or UV leak tester GV-2911 B11.
  1. Rectify any leaks found and check the engine for oil leaks.

Check the Compression Pressure (21 111 0).

General Remarks

NOTE:
NOTE:If fuses are removed or electrical components are disconnected the PCM receives an error message. After a reading is taken, this error message is deleted from the memory by connecting the FDS2000.
NOTE:
NOTE:Only check the compression pressure with the valve clearances set to specification (if they can be adjusted).

The compression pressure should be checked with the engine at operating temperature.

Differing designs of compressure pressure recorder and varying starter motor speeds usually only make it possible to check that the compression is the same in all cylinders.

Check the compression pressure (Zetec-E engine)

  1. Open the central electrical box (CJB) and remove the fuel pump relay.

Fuel pump relay (relay R9).

Start the engine: the engine will start up, run for a few seconds and then stall.

  1. Remove the cylinder head cover.
  1. Remove the spark plugs.

Pull off the spark plug connectors.

Pull out the ignition coil plug.

NOTE:
NOTE:Operate the starter motor with wide open throttle until the pointer on the measuring device stops rising.
  1. Carry out the measurement on all the cylinders with compression tester 623.000.101 according to the tester instructions.
  1. Refit the components in the reverse order, observing the specified tightening torques.
  1. Reset the PCM error memory.

Check the Compression Pressure (Duratec-VE engine)

  1. Open the central electrical box (CJB) and remove the fuel pump relay.
  1. Start the engine. The engine will start up, run for a few seconds and then stall.

  1. Remove the engine cover.

  1. Pull off the HT leads and remove the spark plugs.

  1. Disconnect the EI ignition coil multiplug.

NOTE:
NOTE:Operate the starter motor with wide open throttle until the pointer on the measuring device stops rising.
  1. Carry out the measurement on all the cylinders with compression tester 623.000.101 in accordance with the tester instructions.
  1. Refit the components in the reverse order, observing the specified tightening torques.
  1. Reset the PCM error memory.

Check the Compression Pressure (TCI diesel engine)

  1. Open the central electrical box (CJB) and remove fuse No. 4.

 
Item
Part Number
Description
1
-
Glow plug power supply
2
-
Glow plugs
  1. WARNING:
    WARNING:Switch off the ignition.
    Disconnect the glow plug power supply and remove the glow plugs.

WARNING:
WARNING:Insulate the glow plug power connector for the length of the measurement.
NOTE:
NOTE:The shut-off valve is not closed (injection pump injects during the measurement).
NOTE:
NOTE:On cylinders one and two also use angled connector 622.010.3163.
  1. Carry out the measurement on all the cylinders with compression tester 623.000.101 and adapter 622.010.3307 according to the tester instructions.
  1. Install the components in reverse order keeping to the specified torques.
  1. Reset the PCM error memory.

Check the Oil Pressure (21 113 0)

General Remarks

The oil pressure depends on various factors (engine speed, oil temperature, oil viscosity, degree of contamination of the oil filter etc.).

NOTE:
NOTE:Check the oil pressure at the given engine speeds.

Carry out the measurement of the oil pressure at a temperature of 80°C.

Check the Oil Pressure (Zetec-E engine)

  1. Raise the vehicle.

  1. Disconnect the oil pressure switch connector and remove the oil pressure switch.
  1. Install oil pressure gauge GV 2134 and oil pressure gauge adapter No. 39 so that it can be read from above.
  1. Measure the oil pressure.
  1. Remove the oil pressure gauge and adapter.
  1. Install the components in reverse order keeping to the specified torques.

Check the Oil Pressure (TCI diesel engine)

 
Item
Part Number
Description
1
-
MAF multiplug
2
-
Hose clip
3
-
Vacuum hose
4
-
Rubber retainer
  1. Disconnect the plug from the MAF. Undo the hose clip and pull off the intake pipe. Pull off the vacuum hose and take off the rubber retainer. Remove the air cleaner.
  1. Detach the fuel filter. Disconnect the plug of the oil pressure switch.
  1. Remove the oil pressure switch.

NOTE:
NOTE:Measure the oil pressure at idle speed and at 2000 rev/min.
  1. Install oil pressure gauge GV 2134 and oil pressure gauge adapter no. GV2134.
  1. Measure the oil pressure.
  1. Detach the oil pressure gauge and adapter.
  1. Install the components in reverse order keeping to the specified torques.

Static valve train analysis (engine off)

Remove the cylinder head cover or the plenum section.

Check all the parts of the valve train for damage and wear. Verify that only original parts are installed and that all nuts and bolts are tightened to the specified torques.

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