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General Procedures > < Steering Column - 3.0L Duratec-ST (VE6)

Mondeo 2001 (10.2000-02.2007)

  • Mechanical Repairs
  • 3 Powertrain
  • 303 Engine
  • 303-00 Engine System - General Information
  • Diagnosis and Testing
  • Engine

Engine System - General Information - Engine Mondeo 2001 (10/2000-02/2007)
Diagnosis and Testing

Special Tool(s)

Compression Test Adapter

303-1051
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)
  • 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 on components that are either coated in oil or have always oil leaks on ancillary 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 seal or incorrect front cover alignment.
*
Install a new crankshaft front seal.
*
Align the front cover.
*
Leaks from oil carrying components or basic engine.
*
Locate cracks in oil-carrying components of the basic engine by means of a UV leak test, and renew the relevant components or seals.
Oil consumption
*
Use of the wrong type of engine oil.
*
Determine the last type of engine oil used (refer of the latest invoice of oil receipt) and compare with the specification. Change the engine oil.
*
Faulty positive crankcase ventilation 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.
-
Crankcase ventilation oil separator is faulty and engine oil can enter the combustion chamber through the intake manifold.
*
Check if the crankcase ventilation system is operating correctly and repair as necessary.
REFER to: Engine Emission Control (303-08B Engine Emission Control - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4), Diagnosis and Testing).
*
Turbocharger seals (only diesel engines).
*
Install a new turbocharger.
REFER to: Turbocharger - Vehicles With: Turbocharger Variable Vane Vacuum Actuator (303-04F Fuel Charging and Controls - Turbocharger - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation) /
Turbocharger - Vehicles Built Up To: 07/2004, Vehicles With: Turbocharger Variable Vane Electric Actuator (303-04F Fuel Charging and Controls - Turbocharger - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) 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 gaskets and the evenness of the cylinder head and engine block mating faces.
-
Install new valve seals. Engine - 1.8L Duratec-SCi (MI4) -
REFER to: Valve Seals (303-01A Engine - 1.8L Duratec-SCi (MI4), In-vehicle Repair).
Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) -
REFER to: Valve Seals (303-01B Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4), In-vehicle Repair).
Engine - 2.5L Duratec-VE (VE6) -
REFER to: Valve Seals (303-01D Engine - 3.0L Duratec-SE (VE6)/3.0L Duratec-ST (VE6), In-vehicle Repair).
Engine - 3.0L Duratec-SE (VE6)/3.0L Duratec-ST (VE6) -
REFER to: Valve Seals (303-01D Engine - 3.0L Duratec-SE (VE6)/3.0L Duratec-ST (VE6), In-vehicle Repair).
Engine - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel -
REFER to: Valve Seals (303-01E Engine - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) 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, and renew if necessary. Renew the cylinder block if necessary.
-
Pistons
-
Piston rings
-
Cylinder liners
Coolant consumption
*
Cooling system components.
*
REFER to: Engine Cooling (303-03 Engine Cooling, Diagnosis and Testing).
*
Exhaust gas recirculation (EGR) cooler (only diesel engine).
*
Install a new EGR cooler.
*
Oil cooler.
*
Install a new oil cooler.
*
Damaged gaskets or warped mating faces.
*
Check the cylinder head gasket for damage. Check the cylinder head for flatness.
*
Cracks or fractures in engine components surrounded by coolant, such as cylinder liners and cylinder head combustion chamber.
*
Determine the damaged engine component and install a new component.
Engine will not crank
*
Battery or cables.
*
Check the battery, bracket and cables.
REFER to: 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 (only diesel engine).
*
Drain the water from the fuel system.
REFER to: Fuel System - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel (310-00 Fuel System - General Information, Diagnosis and Testing).
*
Fuel filter blocked.
*
Install a new fuel filter.
*
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.
*
Check the glow plugs. Install new glow plugs as necessary. REFER to: (303-07D Glow Plug System - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel)
Glow Plugs (Removal and Installation),
Glow Plugs - Vehicles Built Up To: 06/2003, Vehicles With: Common Rail Fuel Injection (Removal and Installation),
Glow Plugs - Vehicles Built From: 06/2003, Vehicles With: Common Rail Fuel Injection (Removal and Installation).
*
Engine management system.
*
Check the engine management system. Engine - 1.8L Duratec-SCi (MI4) -
REFER to: Electronic Engine Controls (303-14C Electronic Engine Controls - 2.5L Duratec-VE (VE6)/3.0L Duratec-SE (VE6)/3.0L Duratec-ST (VE6), Diagnosis and Testing).
Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) -
REFER to: Electronic Engine Controls (303-14C Electronic Engine Controls - 2.5L Duratec-VE (VE6)/3.0L Duratec-SE (VE6)/3.0L Duratec-ST (VE6), Diagnosis and Testing).
Engine - 2.5L Duratec-VE (VE6)/ Engine - 3.0L Duratec-SE (VE6)/3.0L Duratec-ST (VE6) -
REFER to: Electronic Engine Controls (303-14C Electronic Engine Controls - 2.5L Duratec-VE (VE6)/3.0L Duratec-SE (VE6)/3.0L Duratec-ST (VE6), Diagnosis and Testing).
2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel -
REFER to: Electronic Engine Controls (303-14D Electronic Engine Controls - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, Diagnosis and Testing).
*
Ignition system (petrol engines only).
*
Check the ignition system. Engine - 1.8L Duratec-SCi (MI4) -
REFER to: Engine Ignition (303-07A Engine Ignition - 1.8L Duratec-SCi (MI4), Diagnosis and Testing).
Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) -
REFER to: Engine Ignition (303-07C Engine Ignition - 2.5L Duratec-VE (VE6)/3.0L Duratec-SE (VE6)/3.0L Duratec-ST (VE6), Diagnosis and Testing).
Engine - 2.5L Duratec-VE (VE6)/ Engine - 3.0L Duratec-SE (VE6)/3.0L Duratec-ST (VE6) -
REFER to: Engine Ignition (303-07C Engine Ignition - 2.5L Duratec-VE (VE6)/3.0L Duratec-SE (VE6)/3.0L Duratec-ST (VE6), Diagnosis and Testing).
*
Incorrect valve timing.
*
Check and adjust the valve timing. Engine - 1.8L Duratec-SCi (MI4) -
REFER to: Timing Chain (303-01A Engine - 1.8L Duratec-SCi (MI4), In-vehicle Repair).
Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) -
REFER to: Timing Chain (303-01B Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4), In-vehicle Repair).
Engine - 2.5L Duratec-VE (VE6) -
REFER to: Engine (303-01C Engine - 2.5L Duratec-VE (VE6), Disassembly).
Engine - 3.0L Duratec-SE (VE6)/3.0L Duratec-ST (VE6) -
REFER to: Engine (303-01D Engine - 3.0L Duratec-SE (VE6)/3.0L Duratec-ST (VE6), Disassembly).
Engine - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel
REFER to: Camshafts (303-01E Engine - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, In-vehicle Repair).
*
Broken or damaged timing chain or sprocket.
*
Check the timing chain and sprockets. Install new components as necessary. Engine - 1.8L Duratec-SCi (MI4) -
REFER to: Timing Chain (303-01A Engine - 1.8L Duratec-SCi (MI4), In-vehicle Repair).
Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) -
REFER to: Timing Chain (303-01B Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4), In-vehicle Repair).
Engine - 2.5L Duratec-VE (VE6) -
REFER to: Engine (303-01C Engine - 2.5L Duratec-VE (VE6), Disassembly).
Engine - 3.0L Duratec-SE (VE6)/3.0L Duratec-ST (VE6) -
REFER to: Engine (303-01D Engine - 3.0L Duratec-SE (VE6)/3.0L Duratec-ST (VE6), Disassembly).
Engine - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel
REFER to: Camshafts (303-01E Engine - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, In-vehicle Repair).
Very poor power output or fuel consumption too high or engine running rough
*
Fuel system.
*
Check the fuel system. Engine - 1.8L Duratec-SCi (MI4) -
REFER to: Fuel Charging and Controls (303-04A Fuel Charging and Controls - 1.8L Duratec-SCi (MI4), Diagnosis and Testing).
Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) -
REFER to: Fuel Charging and Controls (303-04B Fuel Charging and Controls - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4), Diagnosis and Testing).
Engine - 2.5L Duratec-VE (VE6) -
REFER to: Fuel Charging and Controls (303-04C Fuel Charging and Controls - 2.5L Duratec-VE (VE6)/3.0L Duratec-SE (VE6)/3.0L Duratec-ST (VE6), Diagnosis and Testing).
Engine - 3.0L Duratec-SE (VE6)/3.0L Duratec-ST (VE6) -
REFER to: Fuel Charging and Controls (303-04D Fuel Charging and Controls - 2.0L Duratorq-Di/TDDi (Puma) Diesel, Diagnosis and Testing).
Engine - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel -
REFER to: Fuel Charging and Controls (303-04E Fuel Charging and Controls - 2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) 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.
*
Engine management system.
*
Check the engine management system. Engine - 1.8L Duratec-SCi (MI4) -
REFER to: Electronic Engine Controls (303-14C Electronic Engine Controls - 2.5L Duratec-VE (VE6)/3.0L Duratec-SE (VE6)/3.0L Duratec-ST (VE6), Diagnosis and Testing).
Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) -
REFER to: Electronic Engine Controls (303-14C Electronic Engine Controls - 2.5L Duratec-VE (VE6)/3.0L Duratec-SE (VE6)/3.0L Duratec-ST (VE6), Diagnosis and Testing).
Engine - 2.5L Duratec-VE (VE6)/ Engine - 3.0L Duratec-SE (VE6)/3.0L Duratec-ST (VE6) -
REFER to: Electronic Engine Controls (303-14C Electronic Engine Controls - 2.5L Duratec-VE (VE6)/3.0L Duratec-SE (VE6)/3.0L Duratec-ST (VE6), Diagnosis and Testing).
2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel -
REFER to: Electronic Engine Controls (303-14D Electronic Engine Controls - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, Diagnosis and Testing).
*
Fault in ignition system (petrol engines only).
*
Check the ignition system. Engine - 1.8L Duratec-SCi (MI4) -
REFER to: Engine Ignition (303-07A Engine Ignition - 1.8L Duratec-SCi (MI4), Diagnosis and Testing).
Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) -
REFER to: Engine Ignition (303-07C Engine Ignition - 2.5L Duratec-VE (VE6)/3.0L Duratec-SE (VE6)/3.0L Duratec-ST (VE6), Diagnosis and Testing).
Engine - 2.5L Duratec-VE (VE6)/ Engine - 3.0L Duratec-SE (VE6)/3.0L Duratec-ST (VE6) -
REFER to: Engine Ignition (303-07C Engine Ignition - 2.5L Duratec-VE (VE6)/3.0L Duratec-SE (VE6)/3.0L Duratec-ST (VE6), Diagnosis and Testing).
*
Turbocharger (only diesel engine).
*
Check the turbocharger.
REFER to: Turbocharger - Vehicles With: Turbocharger Variable Vane Vacuum Actuator (303-04F Fuel Charging and Controls - Turbocharger - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation) /
Turbocharger - Vehicles Built Up To: 07/2004, Vehicles With: Turbocharger Variable Vane Electric Actuator (303-04F Fuel Charging and Controls - Turbocharger - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation).
*
Incorrect valve timing. Timing chain or timing sprocket damaged.
*
Check and adjust valve timing. Install new components as necessary. Engine - 1.8L Duratec-SCi (MI4) -
REFER to: Timing Chain (303-01A Engine - 1.8L Duratec-SCi (MI4), In-vehicle Repair).
Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) -
REFER to: Timing Chain (303-01B Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4), In-vehicle Repair).
Engine - 2.5L Duratec-VE (VE6) -
REFER to: Engine (303-01C Engine - 2.5L Duratec-VE (VE6), Disassembly).
Engine - 3.0L Duratec-SE (VE6)/3.0L Duratec-ST (VE6) -
REFER to: Engine (303-01D Engine - 3.0L Duratec-SE (VE6)/3.0L Duratec-ST (VE6), Disassembly).
Engine - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel
REFER to: Camshafts (303-01E Engine - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, In-vehicle Repair).
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 - 1.8L Duratec-SCi (MI4) -
REFER to: Timing Chain (303-01A Engine - 1.8L Duratec-SCi (MI4), In-vehicle Repair).
Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) -
REFER to: Timing Chain (303-01B Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4), In-vehicle Repair).
Engine - 2.5L Duratec-VE (VE6) -
REFER to: Engine (303-01C Engine - 2.5L Duratec-VE (VE6), Disassembly).
Engine - 3.0L Duratec-SE (VE6)/3.0L Duratec-ST (VE6) -
REFER to: Engine (303-01D Engine - 3.0L Duratec-SE (VE6)/3.0L Duratec-ST (VE6), Disassembly).
Engine - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel
REFER to: Camshafts (303-01E Engine - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, In-vehicle Repair).
Noisy running, misfiring, backfiring or knocking
*
Incorrect fuel
*
Determine which type of fuel was the last put in the tank (note the country specific fuel specifications).
*
Water in fuel or fuel contaminated.
*
Check the fuel system for water or other contamination.
*
Valve timing incorrect, timing chain or timing sprocket damaged.
*
Check and adjust valve timing. Install new components as necessary. Engine - 1.8L Duratec-SCi (MI4) -
REFER to: Timing Chain (303-01A Engine - 1.8L Duratec-SCi (MI4), In-vehicle Repair).
Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) -
REFER to: Timing Chain (303-01B Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4), In-vehicle Repair).
Engine - 2.5L Duratec-VE (VE6) -
REFER to: Engine (303-01C Engine - 2.5L Duratec-VE (VE6), Disassembly).
Engine - 3.0L Duratec-SE (VE6)/3.0L Duratec-ST (VE6) -
REFER to: Engine (303-01D Engine - 3.0L Duratec-SE (VE6)/3.0L Duratec-ST (VE6), Disassembly).
Engine - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel
REFER to: Camshafts (303-01E Engine - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, In-vehicle Repair).
Noisy running or valve train noise
*
Valve clearance too large due to faulty valve tappets or valve rocker arms.
*
Install new hydraulic valve tappets. Engine - 2.5L Duratec-VE (VE6) -
REFER to: Engine (303-01C Engine - 2.5L Duratec-VE (VE6), Disassembly).
Engine - 3.0L Duratec-SE (VE6)/3.0L Duratec-ST (VE6) -
REFER to: Engine (303-01D Engine - 3.0L Duratec-SE (VE6)/3.0L Duratec-ST (VE6), Disassembly).
Engine - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel
REFER to: Camshafts (303-01E Engine - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, In-vehicle Repair).
*
Timing chain damaged.
*
Install a new timing chain. Engine - 1.8L Duratec-SCi (MI4) -
REFER to: Timing Chain (303-01A Engine - 1.8L Duratec-SCi (MI4), In-vehicle Repair).
Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) -
REFER to: Timing Chain (303-01B Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4), In-vehicle Repair).
Engine - 2.5L Duratec-VE (VE6) -
REFER to: Engine (303-01C Engine - 2.5L Duratec-VE (VE6), Disassembly).
Engine - 3.0L Duratec-SE (VE6)/3.0L Duratec-ST (VE6) -
REFER to: Engine (303-01D Engine - 3.0L Duratec-SE (VE6)/3.0L Duratec-ST (VE6), Disassembly).
Engine - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel
REFER to: Camshafts (303-01E Engine - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, In-vehicle Repair).
*
Timing chain incorrectly tensioned.
*
Check the timing chain tension. Install a new tensioner, as necessary. Engine - 1.8L Duratec-SCi (MI4) -
REFER to: Timing Chain (303-01A Engine - 1.8L Duratec-SCi (MI4), In-vehicle Repair).
Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) -
REFER to: Timing Chain (303-01B Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4), In-vehicle Repair).
Engine - 2.5L Duratec-VE (VE6) -
REFER to: Engine (303-01C Engine - 2.5L Duratec-VE (VE6), Disassembly).
Engine - 3.0L Duratec-SE (VE6)/3.0L Duratec-ST (VE6) -
REFER to: Engine (303-01D Engine - 3.0L Duratec-SE (VE6)/3.0L Duratec-ST (VE6), Disassembly).
Engine - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel
REFER to: Camshafts (303-01E Engine - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, In-vehicle Repair).
*
Timing chain guides worn of damaged.
*
Check the timing chain guides. Install new guides as necessary. Engine - 1.8L Duratec-SCi (MI4) -
REFER to: Timing Chain (303-01A Engine - 1.8L Duratec-SCi (MI4), In-vehicle Repair).
Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) -
REFER to: Timing Chain (303-01B Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4), In-vehicle Repair).
Engine - 2.5L Duratec-VE (VE6) -
REFER to: Engine (303-01C Engine - 2.5L Duratec-VE (VE6), Disassembly).
Engine - 3.0L Duratec-SE (VE6)/3.0L Duratec-ST (VE6) -
REFER to: Engine (303-01D Engine - 3.0L Duratec-SE (VE6)/3.0L Duratec-ST (VE6), Disassembly).
Engine - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel
REFER to: Camshafts (303-01E Engine - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, In-vehicle Repair).
Noisy running or engine block
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Engine components
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Pistons
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Piston rings
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Connecting rod large end, main bearing or thrust bearing journals
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Connecting rods bent or damaged.
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Check the engine components for wear or damage. Make sure all components are within specification. Install new components as necessary. Engine - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel
REFER to: Engine (303-01E Engine - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, Disassembly).

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 a suitable UV testing 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:On manual transmissions put the transmission into Neutral. Failure to follow these instructions may result in personal injury.
  1. Start the engine and let it run for about five minutes.
  1. Switch off the engine.
NOTE:
NOTE:If no leak can be found, road test the vehicle under various loads and 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 (21 111 0)

NOTE:
NOTE:The powertrain control module (PCM) receives an error message when the relay is removed or electrical components are disconnected. This error message must be deleted from the fault memory by connecting WDS after completing the measurement.
NOTE:
NOTE:Valve clearances must be set correctly before performing a compression test. Make sure engine is at the normal operating temperature.
NOTE:
NOTE:The varying design of compression checking devices and fluctuating starter motor speeds normally only allows to check if the compression is even in all cylinders.

Measure the compression (Engine - 1.8L Duratec-SCi (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 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 compression pressure recorder 623.000.101 with the 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 fuel pump relay.
  1. Reset the PCM fault memory.

Measure the compression (Engine - 1.8L Duratec-HE (MI4)/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. Detach the positive crankcase ventilation (PCV) hose and the vacuum hose from the engine cover.

  1. Remove the engine cover.

  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. Attach the positive crankcase ventilation (PCV) hose and the vacuum hose to the engine cover.

  1. Install the engine cover.

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

Measure the compression (Engine - 2.5L Duratec-VE (VE6))

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

  1. Remove the engine cover.

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. 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.

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

  1. Install the spark plug connectors.

  1. Install the engine cover.

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

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

Measure the compression (Engine - 3.0L Duratec-SE (VE6)/ Engine - 3.0L Duratec-ST (VE6))

  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 upper intake manifold.
    REFER to: Upper Intake Manifold (303-01D Engine - 3.0L Duratec-SE (VE6)/3.0L Duratec-ST (VE6), In-vehicle Repair).
  1. Connect the battery.
    REFER to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).

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

  1. Disconnect the left-hand spark plug electrical connectors.

  1. Disconnect the right-hand spark plug electrical connectors.
    • Detach the bracket.
  1. 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.

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

  1. Disconnect the left-hand spark plug electrical connectors.

  1. Disconnect the right-hand spark plug electrical connectors.
    • Detach the bracket.

  1. Connect the EI coil electrical connector to the EI coil.
  1. Install the upper intake manifold.
    REFER to: Upper Intake Manifold (303-01D Engine - 3.0L Duratec-SE (VE6)/3.0L Duratec-ST (VE6), In-vehicle Repair).

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

Measure the compression (Engine - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel)

  1. Open the central junction box (CJB) and remove the glow plug relay.
  1. Remove the intake manifold.
    REFER to: Intake Manifold (303-01E Engine - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, In-vehicle Repair).

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

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

  1. Disconnect the glow plug wire electrical connector.

  1. Disconnect the glow plug electrical connector.

  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. Remove the special tool and the suitable compression tester.

  1. Install the glow plugs.

  1. Connect the glow plug electrical connector.

  1. Connect the glow plug wire electrical connector.

  1. Connect the fuel injector electrical connectors to the fuel injectors (vehicles with common rail fuel injection).

  1. Connect the fuel injection pump electrical connector to the fuel injection pump (vehicles without common rail fuel injection).
  1. Install the intake manifold.
    REFER to: Intake Manifold (303-01E Engine - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, In-vehicle Repair).

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

Oil Pressure - Measure (21 113 0)

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

NOTE:
NOTE:Measure the oil pressure at the specified engine speed. Measure the oil pressure at an oil temperature of 80°C.

Measure the oil pressure (Engine - 1.8L Duratec-SCi (MI4), Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4))

  1. Raise and support the vehicle.
    REFER to: Lifting (100-02 Jacking and Lifting, Description and Operation).

  1. Remove the radiator lower cover.

  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: Lifting (100-02 Jacking and 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 radiator lower cover.
  1. Lower the vehicle.

Measure the oil pressure (Engine - 2.5L Duratec-VE (VE6), Engine - 3.0L Duratec-SE (VE6)/3.0L Duratec-ST (VE6))

  1. Raise and support the vehicle. REFER to: (100-02 Jacking and Lifting)
    Lifting (Description and Operation),
    Lifting - 3.0L Duratec-ST (VE6) (Description and Operation).

  1. Remove the radiator lower cover.

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

  1. Measure the oil pressure.
    REFER to: Specifications (303-01C Engine - 2.5L Duratec-VE (VE6), Specifications) /
    Specifications (303-01D Engine - 3.0L Duratec-SE (VE6)/3.0L Duratec-ST (VE6), Specifications).
  1. Raise and support the vehicle. REFER to: (100-02 Jacking and Lifting)
    Lifting (Description and Operation),
    Lifting - 3.0L Duratec-ST (VE6) (Description and Operation).
  1. Detach the oil pressure gauge and connector from the oil pressure switch bore.
  1. Coat the oil pressure switch with adhesivesealant.

  1. Install the oil pressure switch.

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

  1. Install the radiator lower cover.
  1. Lower the vehicle.

Measure the oil pressure (Engine - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel)

  1. Raise and support the vehicle.
    REFER to: Lifting (100-02 Jacking and Lifting, Description and Operation).

  1. Remove the engine undershield.

  1. Remove the radiator lower cover.

  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, and position it to allow reading from above.
  1. Lower the vehicle.

  1. Measure the oil pressure.
    REFER to: Specifications (303-01E Engine - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, Specifications).
  1. Raise and support the vehicle.

  1. Remove 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.

  1. Install the engine undershield.

  1. Install the radiator lower cover.
  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.

  • Mechanical Repairs
  • 3 Powertrain
  • 303 Engine
  • 303-00 Engine System - General Information
  • Diagnosis and Testing
  • Engine

General Procedures > < Steering Column - 3.0L Duratec-ST (VE6)