Engine diagnostics and checks

– Coolant leaks

– Oil leaks

– Leaks in the fuel system

– Visibly damaged or worn components

– Loose or missing nuts or bolts

- Fuse (And)

– Loose or corroded connector (s)

– Control module

– Damaged or worn switch (And)

• Loss of oil

•Using the wrong type of engine oil

Determine the type of oil that was last used (for example, according to the latest receipt or oil change tag), and compare it with the specification; change oil if necessary. Excessively high pressure in the cylinder block

• Faulty crankcase ventilation system

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

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

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

• Turn out a cap of a cover of a head of the block of cylinders.

• Connect the compressed air 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 airflow, inspect the cylinder liner surfaces and pistons for damage. REFER to ch. "General Procedures" provided in this section.

• Leakage caused by a damaged oil seal or misalignment of the oil seal carrier:

•Oil seal of the camshaft.

• Front or rear camshaft oil seal.

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

• Damage to gaskets or mating surfaces

• Check gaskets and mating surfaces for damage.

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

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

• Remove the cylinder head. Zetec-SE - Refer to Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E for more information. Zetec-E - 1.8L Endura-DI and 1.8L Duratorq TDCi -

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

• If necessary, replace the cylinder head.

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

•Using ultraviolet (UV) tester, check for cracks in the auxiliary elements with oil paths or in the engine and replace the defective element or gasket.

• Malfunction of the PCV system

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

• The PCV oil separator is defective and engine oil may enter the combustion chamber through the intake manifold.

•Check that the PCV system is working properly; repair the system if necessary.

• Damage to cylinder liners or excessive clearances in engine components

•Check the running surfaces and clearances of the engine components and, if necessary, replace the items listed below. Replace the cylinder block if necessary.

• pistons

• pistons

•piston rings (between ring and groove, ring and 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 gasket or mating surface of the cylinder head is damaged and engine oil may enter the combustion chamber

• Remove the cylinder head. Zetec-SE - Refer to Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E for more information. Zetec-E - 1.8L Endura-DI and 1.8L Duratorq TDCi -

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

• If necessary, replace the cylinder head.

• Valve stem oil seals are damaged and engine oil can enter the combustion chamber through the gap between the valve stem and valve guide. This is especially noticeable when braking the engine.

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

• Cracks in engine parts with oil paths or in engine parts coated with oil, such as cylinder liners, pistons, oil galleries and crankcase passages.

•Add an engine oil additive designed to test UV for leaks and bring the engine oil to a minimum temperature of 80°C to allow the engine oil additive to penetrate any existing cracks. Allow the engine to cool to ambient temperature, remove and (if necessary) disassemble the defective element. Check the engine element with a UV leak detector and replace the element if necessary.

•Coolant consumption

• Damage to gaskets or mating surfaces

– Damaged gasket or mating surface of cylinder head. The coolant may enter the combustion chamber or crankcase.

• Remove the cylinder head. Zetec-SE - Refer to Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E for more information. Zetec-E - 1.8L Endura-DI and 1.8L Duratorq TDCi -

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

– If necessary, replace the cylinder head.

• Cracks or tears in engine components that are exposed to coolant, such as cylinder liners and gouges (cavities) combustion chambers, cylinder heads

• Identify the damaged engine element and replace it.

•Engine does not start

• Faulty battery or wiring

•Check the battery, bracket and cables. See Section 414-00 for more information.

• Faulty starter or wiring

•Check the starter system. See Section 303-06 for more information.

• Malfunction in the fuel supply system

•Check the fuel supply system. Zetec-SE - Refer to Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E for more information. Zetec-E - 1.8L Endura-DI and 1.8L Duratorq TDCi -

•Empty fuel tank

•Check the fluid level.

• Malfunction in the ignition system

•Check the ignition system. Zetec-SE - Refer to Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E for more information. Zetec-E-

• Fault in the engine management system

•Check the engine management system. See Section 303-14 for more information.

• Malfunction in the air intake system

• Air leakage in the air intake system

• The air cleaning filter is blocked.

• Faulty idle air control valve.

•Check the intake system. See Section 303-12 for more information.

• Damaged valve mechanism

•Burn exhaust valve

• Improper valve timing

• Cracking or damage to the timing belt

• Connect the compressed air source to the cylinders. If air is escaping through the intake manifold or exhaust pipe, check the valve train.

• Malfunction of engine elements

• burnt pistons

•piston rings

• cylinder head gasket

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

• Connect the compressed air source to the cylinders. If air escapes through an open oil filler cap, remove the cylinder head according to the procedure described and check the components. Zetec-SE - Refer to Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E for more information. Zetec-E - 1.8L Endura-DI and 1.8L Duratorq TDCi -

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

• Malfunction in the fuel system

•Check the fuel system. Zetec-SE - Refer to Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E for more information. Zetec-E - 1.8L Endura-DI and 1.8L Duratorq TDCi -

• Malfunction in the ignition system (only petrol engines)

•Check the ignition system. Zetec-SE - Refer to Section 303-07A / 303-07B / 303-07C / 303-07D for more information. Zetec-E-

• Fault in the engine management system

•Check the engine management system. See Section 303-14 for more information.

• Malfunction in the air intake system

•Leakage in the air intake system

•Clogged air filter

• Faulty idle air control valve

•Check the air intake system. See Section 303-12 for more information.

• Damaged valve mechanism

•Burn exhaust valve

• Improper valve timing

• Cracking or damage to the timing belt

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

• Malfunction of engine elements

• burnt pistons

•piston rings

• cylinder head gasket

• necks for bearings of the lower heads of connecting rods or main bearings

• Connect the compressed air source to the cylinders. If air escapes through an open oil filler cap, remove the cylinder head according to the procedure described and check the components. Disassemble the engine as described in the manual and check the components. Zetec-SE - Refer to Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E for more information. Zetec-E - 1.8L Endura-DI and 1.8L Duratorq TDCi -

•Noisy operation

•Interruptions (passes) ignition/reverse flash

– Wrong octane number of fuel (only petrol engines) or using the wrong type of fuel.

– Malfunction in the ignition system (only petrol engines)

– Excessively high engine temperature

– Carbon deposits (soot) in the combustion chamber begin to heat up and cause misfiring

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

• Determine the cause of the misfiring and correct it.

– Determine which brand of fuel was last filled into the tank (pay attention to specifications (specifications) country-specific fuel).

– Check the ignition system. Zetec-E - Refer to Section 303-07A / 303-07B / 303-07C / 303-07D for more information. Zetec-SE - 1.8L Endura DI and 1.8L Duratorq TDCi -

– Check engine cooling. See Section 303-03 for more information.

– Remove carbon deposits using special fuel additives while driving.

– Check the valve timing.

• Damaged valve mechanism

•Check the valve train.

•Excessively large valve clearances caused by faulty hydraulic tappets or incorrect valve clearance adjustment

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

• Incorrect adjustment of the valve timing: valves and pistons are in contact

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

• Cracking or damage to the timing belt

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

• Malfunction of engine elements

• pistons

•piston rings

• cylinder head gasket

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

• Dismantle the engine and check the elements. Zetec-SE - Refer to Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E for more information. 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 elements, make sure that they are securely fastened and properly seated. If necessary, tighten the fasteners to the specified tightening torque. Replace damaged items.