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General Procedures > < 303-01E Engine - 1.8L Duratorq-TDCi (Lynx) Diesel|Engine

Mondeo 2007.5 (02.2007-)

Engine - 1.8L Duratorq-TDCi (Lynx) Diesel - Engine Mondeo 2007.5 (02/2007-)
Diagnosis and Testing

Special Tool(s)

Compression Test Adapter

303-1049A
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.
REFER to: Engine Emission Control (303-08, Diagnosis and Testing).
*
Turbocharger seals.
*
INSTALL a new turbocharger.
REFER to: Turbocharger (303-04, 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.
REFER to: Valve Stem Seals (303-01, Removal and Installation).
*
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.
Coolant consumption
*
Cooling system components.
*
Check the cooling system components.
REFER to: Engine Cooling (303-03, 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, Diagnosis and Testing).
*
Starter motor or cables.
*
CHECK the starting system.
REFER to: Starting System (303-06, 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.
*
Engine intake air system.
*
CHECK the intake air system.
REFER to: Intake Air Distribution and Filtering (303-12, Diagnosis and Testing).
*
Glow plug faulty (only diesel engine).
*
CHECK the glow plugs. INSTALL new glow plugs as necessary.
REFER to: Glow Plug System (303-07, Diagnosis and Testing).
*
Engine management system.
*
CHECK the engine management system.
REFER to: Electronic Engine Controls - 1.8L Duratorq-TDCi (Lynx) Diesel (303-14, Diagnosis and Testing).
*
Incorrect valve timing.
*
CHECK and adjust the valve timing.
REFER to: Valve Clearance Adjustment (303-01, General Procedures).
*
Broken or damaged timing belt/timing chain or pulley/sprocket.
*
CHECK the timing belt/timing chain and sprockets/pulleys. INSTALL new components as necessary.
REFER to: Timing Belt (303-01, Removal and Installation).
Very poor power output or fuel consumption too high or engine running rough.
*
Fuel system.
*
CHECK the fuel system.
REFER to: Turbocharger (303-04, Diagnosis and Testing).
*
Engine intake air system.
*
CHECK the intake air system.
REFER to: Intake Air Distribution and Filtering (303-12, Diagnosis and Testing).
*
Exhaust system blocked.
*
CHECK the exhaust system.
REFER to: Exhaust System (309-00, Description and Operation).
*
Engine management system.
*
CHECK the engine management system.
REFER to: Electronic Engine Controls - 1.8L Duratorq-TDCi (Lynx) Diesel (303-14, Diagnosis and Testing).
*
Turbocharger.
*
CHECK the turbocharger.
REFER to: Turbocharger (303-04, Diagnosis and Testing).
*
Incorrect valve timing. Timing belt/timing sprocket or pulley/sprocket damaged.
*
CHECK and adjust valve timing.
REFER to: Timing Belt (303-01, Removal and Installation).
*
Ignition timing incorrect (only petrol engines).
*
CHECK the electronic engine controls.
REFER to: Electronic Engine Controls - 1.8L Duratorq-TDCi (Lynx) Diesel (303-14, 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.
REFER to: Timing Belt (303-01, Removal and Installation).
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.
REFER to: Timing Belt (303-01, Removal and Installation).
Noisy running or valve train noise
*
Valve clearance too large due to faulty valve tappets or worn valve train components.
*
INSTALL new hydraulic lash adjusters or adjust the valve clearance.
REFER to: Valve Clearance Adjustment (303-01, General Procedures).
*
Timing belt or timing chain damaged.
*
INSTALL a new timing belt or timing chain.
REFER to: Timing Belt (303-01, Removal and Installation).
*
Timing belt or timing chain incorrectly tensioned.
*
CHECK the timing belt tension. INSTALL a new timing belt or timing chain as necessary.
REFER to: Timing Belt (303-01, Removal and Installation).
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.
REFER to: Specifications (211-00, 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 - 1.8L 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 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 - 1.8L Duratorq-TDCI (Kent) Diesel)

NOTE:
NOTE:Measure the oil pressure at the specified engine speed.

  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.

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 > < 303-01E Engine - 1.8L Duratorq-TDCi (Lynx) Diesel|Engine