Engine diagnostics and checks

– Coolant leaks

- Oil leaks

– Leaks in the fuel system

– 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)

•Loss of oil

•Using the wrong type of motor oil

Determine the type of oil that was last used (e.g. from your last receipt or oil change tag) and compare it to the specification; change oil if necessary. Excessive pressure in the cylinder block

•Faulty crankcase ventilation system

•Remove the oil filler cap. If noticeable pressure is felt when the engine is running: Check the operation of the crankcase ventilation system and repair it if necessary.

• Malfunction of the positive crankcase ventilation (PCV) system.

•Check the operation of the PCV system and repair the system if necessary.

•Unscrew the cylinder head cover plug.

•Connect the compressed air supply line to the spark plug hole of each cylinder one by one, apply compressed air, and check for air leakage with the oil filler cap removed. If there is noticeable air flow, inspect the cylinder liner surfaces and pistons for damage. REFER to General Procedures in this section.

•Leakage caused by a damaged oil seal or improper alignment of the oil seal retainer:

* Camshaft oil seal.

•Front or rear camshaft oil seal.

•Check the alignment of the oil seal holder; adjust if necessary. Replace the oil seal.

•Damage to gaskets or mating surfaces

•Check gaskets and mating surfaces for damage.

•The cylinder head gasket or mating surface is damaged, engine oil may leak from the engine in the area between the head and the cylinder block or enter the cooling system.

•Open the cap of the expansion tank of the cooling system and check if there is oil foam or oil film on the surface of the coolant.

•Remove the cylinder head. Zetec-SE - For additional information, refer to Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E. Zetec-E - 1.8L Endura-DI and 1.8L Duratorq TDCi -

•Check the mating surfaces and cylinder head gasket and check for out-of-flatness of the cylinder head mating surface. REFER to General Procedures in this section.

•Replace the cylinder head if necessary.

• Oil leaks in elements that are coated with oil or have oil paths, oil leaks in auxiliary elements

•Using an ultraviolet (UV) tester, check for cracks in auxiliary components with oil paths or in the engine and replace the faulty component or gasket.

•PCV system malfunction

• Clogged hoses or vent valve/breather. This causes increased crankcase pressure, which in turn increases the amount of oil entering the combustion chamber.

•The PCV system oil separator is faulty and engine oil can enter the combustion chamber through the intake manifold.

•Make sure the PCV system is working properly; repair the system if necessary.

•Damaged cylinder liners or excessively large clearances in engine components

•Check the running surfaces and clearances of engine components and replace the following components if necessary. Replace the cylinder block if necessary.

•pistons

•pistons

•piston rings (between the ring and the groove, the ring and the piston wall, etc.)

•piston rings

•cylinder liners

•cylinder liners

•valve stems and guides

•valve stems and guides

•Damage to gaskets or mating surfaces

•Check gaskets and mating surfaces for damage.

•The cylinder head gasket or mating surface is damaged and engine oil may enter the combustion chamber

•Remove the cylinder head. Zetec-SE - For additional information, refer to Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E. Zetec-E - 1.8L Endura-DI and 1.8L Duratorq TDCi -

•Check the mating surfaces and cylinder head gasket and check for out-of-flatness of the cylinder head mating surface. REFER to General Procedures in this section.

•Replace the cylinder head if necessary.

•The valve stem oil seals are damaged and engine oil can enter the combustion chamber through the gap between the valve stem and the valve guide. This becomes especially noticeable during engine braking.

•Replace valve stem oil seals. Zetec-SE - Refer to Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E for additional information. Zetec-E - 1.8L Endura-DI and 1.8L Duratorq TDCi -

•Cracks in engine components that have oil paths or in engine components coated with oil, such as cylinder liners, pistons, oil galleries and crankcase channels.

•Add a UV leak test additive to the engine oil and bring the engine oil to a minimum temperature of 80°C to allow the engine oil additive to penetrate any cracks present. Allow the engine to cool to ambient temperature, remove and (if necessary) disassemble the faulty component. Check the engine component with a UV leak detector and replace the component if necessary.

•Coolant consumption

•Damage to gaskets or mating surfaces

– Cylinder head gasket or mating surface is damaged. Coolant may be leaking into the combustion chamber or crankcase.

•Remove the cylinder head. Zetec-SE - For additional information, refer to Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E. Zetec-E - 1.8L Endura-DI and 1.8L Duratorq TDCi -

– Check the mating surfaces and cylinder head gasket and check for out-of-flatness of the cylinder head mating surface. REFER to General Procedures in this section.

– Replace the cylinder head if necessary.

•Cracks or tears in engine components washed by coolant, such as cylinder liners and recesses (cavities) of the combustion chamber, cylinder heads

•Identify the damaged engine component and replace it.

•The engine does not start

•Battery or wiring fault

•Check the battery, bracket, and cables. Refer to Section 414-00 for additional information.

•Starter or wiring faulty

•Check the starting system. Refer to Section 303-06 for additional information.

• Malfunction in the fuel supply system

•Check the fuel delivery system. Zetec-SE - For additional information, refer to Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E. Zetec-E - 1.8L Endura-DI and 1.8L Duratorq TDCi -

•Empty fuel tank

•Check the working fluid level.

• Malfunction in the ignition system

•Check the ignition system. Zetec-SE - For additional information, refer to Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E. Zetec-E -

• Malfunction in the engine management system

•Check the engine management system. Refer to Section 303-14 for additional information.

• Malfunction in the air intake system

•Air leak in the air intake system

•The air purification filter is blocked.

•The idle air control valve is faulty.

•Check the intake system. Refer to Section 303-12 for additional information.

•The valve mechanism is damaged

•Burning of the exhaust valve

•Incorrect valve timing adjustment

•Cracking or damage to the timing belt

•Connect a source of compressed air to the cylinders. If air comes out through the intake manifold or exhaust pipe, check the valve mechanism.

• Engine component failure

•burnt pistons

•piston rings

•cylinder head gasket

• journals for bearings of lower heads of connecting rods and/or main bearings

•Connect a source of compressed air to the cylinders. If air is escaping through the open oil filler cap, remove the cylinder head in accordance with the procedure described and inspect the components. Zetec-SE - For additional information, refer to Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E. Zetec-E - 1.8L Endura-DI and 1.8L Duratorq TDCi -

•Excessively low power output/excessively high fuel consumption/uneven engine operation

•Fuel system malfunction

•Check the fuel system. Zetec-SE - For additional information, refer to Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E. Zetec-E - 1.8L Endura-DI and 1.8L Duratorq TDCi -

• Malfunction in the ignition system (petrol engines only)

•Check the ignition system. Zetec-SE - For additional information, refer to Section 303-07A / 303-07B / 303-07C / 303-07D. Zetec-E -

• Malfunction in the engine management system

•Check the engine management system. Refer to Section 303-14 for additional information.

• Malfunction in the air intake system

• Leak in the air intake system

•The air filter is clogged

•Idle air control valve is faulty

•Check the air intake system. Refer to Section 303-12 for additional information.

•The valve mechanism is damaged

•Burning of the exhaust valve

•Incorrect valve timing adjustment

•Cracking or damage to the timing belt

•Connect a source of compressed air to the cylinders. If air comes out of the intake manifold or exhaust pipe, check the valve mechanism.

• Engine component failure

•burnt pistons

•piston rings

•cylinder head gasket

• journals for bearings of lower heads of connecting rods or main bearings

•Connect a source of compressed air to the cylinders. If air is escaping through the open oil filler cap, remove the cylinder head in accordance with the procedure described and inspect the components. Disassemble the engine as described in the Manual and inspect the components. Zetec-SE - For additional information, refer to Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E. Zetec-E - 1.8L Endura-DI and 1.8L Duratorq TDCi -

•Noisy operation

* Ignition outages/ reverse flash

– Incorrect octane rating of fuel (petrol engines only) or use of unsuitable fuel type.

– Malfunction in the ignition system (petrol engines only)

– Excessively high engine temperature

– Carbon deposits (carbon) in the combustion chamber begin to heat up and cause misfires

– Incorrect valve timing, causing interruptions in the intake/exhaust system

• Determine the cause of misfires and eliminate it.

– Determine what brand of fuel was last added to the tank (pay attention to the specifications (technical characteristics) of the fuel of a particular country).

– Check ignition system. Zetec-E - For additional information, refer to Section 303-07A / 303-07B / 303-07C / 303-07D. Zetec-SE - 1.8L Endura DI and 1.8L Duratorq TDCi -

– Check engine cooling. For additional information, refer to Section 303-03.

– Remove carbon deposits using special fuel additives while driving the vehicle.

– Check the valve timing.

•The valve mechanism is damaged

•Check the valve mechanism.

•Excessively large valve clearances caused by faulty hydraulic lifters or improper valve clearance adjustment

•If possible, adjust valve clearances or replace faulty hydraulic lifters.

•Incorrect valve timing adjustment: valves and pistons touch

•Check and adjust valve timing if necessary. Zetec-SE - For additional information, refer to Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E. Zetec-E - 1.8L Endura-DI and 1.8L Duratorq TDCi -

•Cracking or damage to the timing belt

•Check the timing belt. Also check the pistons and valves for damage and replace any faulty components.

• Engine component failure

•pistons

•piston rings

•cylinder head gasket

• journals for bearings of lower heads of connecting rods and/or main bearings

•Disassemble engine and inspect components. Zetec-SE - For additional information, refer to Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E. Zetec-E - 1.8L Endura-DI and 1.8L Duratorq TDCi -

•Engine components or accessories are damaged or loose.

•Check the condition of the engine components, make sure they are securely fastened and seated correctly. If necessary, tighten the fastening components to the specified tightening torque. Replace damaged components.