Contents: Checking the compression pressure… ↳ Compression pressure measurement… ↳ Compression Pressure Measurement… ↳ Measuring compression pressure… ↳
NOTE: The Powertrain Control Module (PCM) will receive an error message if the relay is removed or electrical components are disconnected. This error message must be cleared from the fault memory by connecting the WDS after the measurements have been taken.
NOTE: The valve clearances must be set correctly before performing a compression test. Make sure the engine is at normal operating temperature.
NOTE: Various compression tester designs and starter speed variations generally only allow one to verify that compression is equal in all cylinders.
Checking the compression pressure (engine 1.4/1.6 Zetec - SE)
1. Open the Central Junction Box (CJB) and remove the fuel pump relay.
NOTE: The engine will start, run for a few seconds, and then stall.
2. Start the engine: The engine will start, run for a few seconds and then stall.
3. Remove the spark plug cover from the valve cover.
NOTE: When disconnecting components, pull on the connector, not the wire. Disconnect the spark plug connector and remove the spark plugs.
4. Disconnect the spark plug connectors.
5. Disconnect the ignition coil connector.
6. Using a special tool, remove the spark plugs.
NOTE: Allow the starter to operate with the throttle wide open until the arrow on the meter stops moving in the direction of increasing the reading.
7. Take a measurement on each cylinder using the appropriate compression pressure recording device and following the instructions supplied with the measuring device.
8. Install the components in the reverse order and observe the specified tightening torques. Before installation, apply silicone grease (A960-M1C-AA) to the spark plug connector seal. Apply grease (ESE-M1244-A) to the spark plug threads. Tightening torque of the valve cover: 6 Nm. Tightening torque of the spark plug: 15 Nm.
9. Reset the PCM memory, which stores fault information.
Compression pressure measurement (Zetec-E engine)
1. Open the Central Junction Box (CJB) and remove the fuel pump relay.
NOTE: The engine will start, run for a few seconds, and then stall.
2. Start the engine: The engine will start, run for a few seconds and then stall.
NOTE: Twist the spark plug connector slightly before disconnecting it. When disconnecting the components, pull on the connector, not the wire.
3. Disconnect the spark plug connectors and remove the spark plugs.
4. Disconnect the ignition coil (EI) connector.
NOTE: Perform the required measurement on each cylinder using compression pressure recorder 623.000.101.
5. Take a measurement on each cylinder using an appropriate compression pressure recording device.
6. Install the components in the reverse order and observe the specified tightening torques. Before installation, apply silicone grease (A960-M1C-AA) to the spark plug connector seal. Apply grease (ESE-M1244-A) to the spark plug threads. Tightening torque of the valve cover: 1st stage: 2 Nm; 2nd stage: 7 Nm. Spark plug tightening torque: 15 Nm.
7. Reset the PCM memory, which stores fault information.
Compression Pressure Measurement (Endura DI Engine)
WARNING: Do not smoke or allow lighted cigarettes or any open flame when working with or near any fuel containing components. Highly flammable mixtures are always present in such situations and may ignite. Failure to follow these instructions may result in injury.
1. Open the Central Junction Box (CJB) and remove the glow plug relay.
2. Remove the top engine cover.
3. Remove the charge air cooler inlet and outlet hoses and clamps.
4. Remove the charge air cooler inlet and outlet pipes.
5. Disconnect the high pressure fuel pump connector.
6. Remove the power supply lead to the glow plugs.
7. Remove the glow plugs.
8. Install the appropriate compression tester with the appropriate adapter into the glow plug hole.
NOTE: Crank the engine with the starter until the compression gauge reading stops increasing.
9. Perform the measurement on all cylinders following the instrument manufacturer's instructions.
10. Disconnect the compression tester and adapter.
11. Install the glow plugs.
12. Install the power supply directed to the glow plugs.
13. Connect the high pressure fuel pump connector.
14. Install the charge air cooler inlet and outlet pipes.
NOTE: Install the worm drive clamps to the 8 o'clock position when viewed from the front of the vehicle.
15. Install the charge air cooler inlet and outlet hoses and clamps.
16. Install the top engine cover.
17. Install the glow plug relay.
18. Reset the PCM memory containing fault information.
Measuring compression pressure (Duratorq TDCi engine)
WARNING: Do not smoke or allow lighted cigarettes or any open flame when working with or near any fuel containing components. Highly flammable mixtures are always present in such situations and may ignite. Failure to follow these instructions may result in personal injury.
WARNING: Do not perform any repairs to the fuel injection system without checking that the fuel pressure has dropped to zero and the fuel temperature has reached the outside temperature or below 30°C, whichever is greater. Failure to follow these instructions may result in personal injury.
1. Using the Datalogger function of the Worldwide Diagnostic System (WDS), check that the fuel pressure has dropped to zero and the fuel temperature has reached the outside temperature or a temperature below 30°C, whichever is greater.
2. Open the Central Junction Box (CJB) and remove the glow plug relay.
3. Remove the top engine cover.
4. Remove the charge air cooler inlet and outlet hoses and clamps.
5. Remove the charge air cooler inlet and outlet pipes.
CAUTION: Do not disconnect the high pressure fuel pump connectors and crank the engine.
6. Disconnect the fuel injector plugs.
7. Remove the power supply lead to the glow plugs.
8. Remove the glow plugs.
9. Install the appropriate compression tester with the appropriate adapter into the glow plug hole.
NOTE: Crank the engine with the starter until the compression gauge reading stops increasing.
10. Perform the measurement on all cylinders following the instrument manufacturer's instructions.
11. Disconnect the compression tester and adapter.
12. Install the glow plugs.
13. Install the power supply directed to the glow plugs.
14. Connect the fuel injector plugs.
15. Install the charge air cooler inlet and outlet pipes.
NOTE: Set the worm drive clamps to the 8 o'clock position when viewed from the front of the vehicle.
16. Install the charge air cooler inlet and outlet hoses and clamps.
17. Install the top engine cover.
18. Install the glow plug relay.
19. Reset the PCM memory containing fault information.
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