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General Procedures > < 303-00 Engine System - General Information|Engine

Puma 1998 Engine Diagnosis and Testing

Engine System - General Information - Engine Puma 1998 (06/1997-12/2001)
Diagnosis and Testing

Since troubleshooting actually begins when repairs are taken on, the following procedure is recommended:

  1. Check customer concern is clear. If necessary, reconstruct the concern on the vehicle.
  1. If the concern cannot be reproduced, carry out a road test and/or a visual check with the aid of the following table:

Visual Inspection Chart

Mechanical
  • Leaks in the cooling system
  • Leaks in the engine oil circuit
  • Leaks in the fuel system
  • Visibly damaged or worn parts
  • Loose or missing nuts or bolts
  1. If a concern is clearly identified during visual inspection, repair it and check that the system operates correctly.
  1. If the concern cannot be clearly identified, use the following table to identify it.

Troubleshooting Table

Symptom Possible Sources Action
Loss of oil
*
Use of the wrong type of engine oil.
*
Establish what oil was last used in the engine (refer to the last bill or oil label), compare it with the specification and change it if necessary.
*
Pressure in the cylinder block too high
-
Faulty crankcase ventilation system
-
Poor sealing between combustion chamber and crankcase
*
Unscrew and remove the oil filler cap. Close off the opening by hand. If pressure can be felt when the engine is running:
-
Check that the crankcase ventilation system works correctly, repair it if necessary.
-
Screw the compressed air supply connector into each cylinder in turn, apply the compressed air and observe how the air escapes when the oil filler cap is removed. If there is a noticeable current of air, check the cylinder bores and pistons for damage and measure them.
*
Leak at a rotating shaft caused by a faulty oil seal or incorrect alignment of the oil seal carrier
-
Camshaft
-
Crankshaft front
-
Crankshaft rear
*
Check the alignment of the seal carrier and correct as necessary. Renew the oil seal if necessary.
*
Damaged gaskets or mating faces
-
Cylinder head gasket or mating face is damaged, engine oil can escape from the engine between cylinder head and cylinder block or get into the cooling system.
*
Check gaskets and mating faces for damage.
-
Open the coolant reservoir and check whether oil emulsion or a film of oil is visible on the coolant surface.
-
Remove the cylinder head. Check the mating faces, cylinder head gasket and evenness. Renew the cylinder head if necessary.
*
Leaks from engine or ancillary components with oilways or which are supplied with an oil film.
*
Locate cracks in ancillary components with oilways or in the engine itself by using a UV leak tester, and renew the affected component or gasket.
Oil consumption
*
Use of the wrong type of engine oil.
*
Establish which engine oil was last used (e.g. by referring to the last bill or oil change label) and compare it with the specification. Change the engine oil if necessary.
*
Faulty crankcase ventilation system.
-
Hoses or ventilation/breather valve are blocked. This causes excessive pressure in the crankcase which causes more oil to enter the combustion chamber.
-
The crankcase ventilation system oil thrower is faulty and engine oil can reach the combustion chamber via the inlet manifold.
*
Check that the crankcase ventilation system works correctly, repair it if necessary.
*
Damaged cylinder liners or too much clearance on engine components.
-
Pistons
-
Piston rings (clearance in groove and end gap)
-
Cylinder liners
-
Valve stems and guides.
*
Check the running surfaces and clearances of each individual engine component and renew as necessary.
-
Pistons
-
Piston rings
-
Cylinder liners
-
Valve stems and guides
*
Damaged gaskets or mating faces
-
Cylinder head gasket or mating face is damaged, and engine oil can enter the combustion chamber.
-
Valve stem oil seals are damaged and engine oil can enter the combustion chamber between valve stem and valve guide. This becomes particularly apparent on overrun.
*
Check gaskets and mating faces for damage.
-
Remove the cylinder head. Check the mating faces, cylinder head gasket and evenness. Renew the cylinder head if necessary.
-
Renew the valve stem oil seals.
*
Cracks in engine components with oilways or engine components coated in oil, e.g. cylinder liners, pistons and oil galleries and passages.
*
Add UV testing additive to the engine oil and run the engine until the oil temperature is at least 80°C, so that the additive can penetrate into any cracks that are present. Allow the engine to cool to ambient temperature, remove the affected component and disassemble it as necessary. Check the engine component using UV leak detection and renew as necessary.
Coolant consumption
*
Damaged gaskets or mating faces
-
The cylinder head gasket or mating face is damaged. Coolant can enter the combustion chamber or the crankcase.
*
Check the gaskets and mating faces for damage.
-
Remove the cylinder head. Check the mating faces, cylinder head gasket and evenness. Renew the cylinder head if necessary.
*
Cracks or fractures in engine components surrounded by coolant, such as cylinder liners and cylinder head combustion chamber recesses.
*
Identify the damaged engine component and renew it.
Engine will not start
*
Battery or wiring is faulty.
*
Check battery, bracket and cables REFER to Section  414-01 Battery, Mounting and Cables.
*
Starter motor or wiring is faulty
*
Check the starter system REFER to Section  303-06 Starting System.
*
Fuel system is faulty.
-
Fuel tank is empty.
*
Check the fuel system
-
REFER to Section  303-04 Fuel Charging and Controls.
-
Check the fuel level.
*
Ignition system is faulty.
*
Check the ignition system REFER to Section  303-07 Engine Ignition.
*
Engine management system is faulty.
*
Check the engine management system REFER to Section  303-14 Electronic Engine Controls.
*
Intake system is faulty
-
Leaking intake system
-
Air cleaner is blocked
-
Idle air control valve faulty.
*
Check the intake system REFER to Section  303-12 Intake Air Distribution and Filtering.
-
Carry out a test of the intake vacuum system.
*
Valve train is damaged
-
Burned out exhaust valve
-
Timing incorrectly adjusted
-
Toothed belt ripped or damaged.
*
Connect compressed air to the cylinders. If air flows out through the intake manifold or the exhaust pipe, check the valve train. Renew the toothed belt.
*
Engine components faulty
-
Burned out piston
-
Piston rings
-
Cylinder head gasket
-
Big-end and/or main bearing journals
*
Connect compressed air to the cylinders. If air escapes with the cylinder head cover blanking plug open, disassemble the engine as described in the manual and check the components.
Low power / fuel consumption too high / rough engine running
*
Fuel system faulty
*
Check the fuel system REFER to Section  303-04 Fuel Charging and Controls.
*
Ignition system faulty.
*
Check the ignition system REFER to Section  303-07 Engine Ignition.
*
Engine management system is faulty.
*
Check the engine management system. REFER to Section  303-14 Electronic Engine Controls.
*
Intake system is faulty
-
Leaking intake system
-
Air cleaner is blocked
-
Idle air control valve is faulty.
*
Check the intake system REFER to Section  303-12 Intake Air Distribution and Filtering.
-
Carry out a vacuum test on the intake system.
*
Valve train damaged
-
Burned out exhaust valve
-
Timing incorrectly adjusted
-
Toothed belt ripped or damaged.
*
Connect compressed air to the cylinders. If air escapes from the intake manifold or the exhaust pipe, check the valve train. Renew the toothed belt.
*
Faulty engine components
-
Piston burned out
-
Piston rings
-
Cylinder head gasket
-
Big-end and/or main bearing journal
*
Connect compressed air to the cylinders. If air flows out when the cylinder head cover cap is open, dismantle the engine and check the components.
*
Variable camshaft timing (VCT) faulty.
*
Check the inlet camshaft toothed pulley wheel with VCT unit and the VCT solenoid valve for damage or oil leaks.
Noise development
*
Misfiring/backfiring
-
Fuel tank contains the wrong type of fuel or fuel with the incorrect octane rating.
-
Ignition system is faulty
-
Engine temperature too high
-
Carbon deposits in the combustion chamber start to glow and cause misfiring
-
Timing incorrectly adjusted, which causes misfiring in the intake/exhaust system.
*
Determine the cause for the misfiring and rectify it.
-
Determine which type of fuel was last put in the tank (note the country specific fuel specifications).
-
Check the ignition system REFER to Section  303-07 Engine Ignition.
-
Check the engine cooling REFER to Section  303-03 Engine Cooling.
-
Remove the carbon deposits by using fuel additives and driving more carefully
-
Check the valve timings.
*
Valve train damaged
-
Valve clearances too great, because of faulty bucket tappets or because they are set incorrectly.
-
Valve timing incorrectly adjusted - valves and pistons are touching.
-
Toothed belt ripped or damaged.
-
Timing belt is too loose (rattling or rubbing noises) or too tight (whistling or humming noises)
*
Check the valve train
-
Adjust the valve clearances and/or renew faulty bucket tappets as necessary.
-
Check the valve timing and adjust it if necessary.
-
Check the toothed belt, pistons and valves for damage and renew all damaged components.
-
Check the toothed belt tension and correct it if necessary.
*
Engine components faulty
-
Pistons
-
Piston rings
-
Cylinder head gasket
-
Big-end and/or main bearing journals.
*
Disassemble the engine and check components.
*
Engine ancillary components broken or have come loose.
*
Check that the ancillary components are fitted correctly and firmly and tighten them to the specified torque if necessary.

Oil Leaks - Engine

NOTE:
NOTE:Before renewing gaskets or oil seals, make sure that the cause of the fault is clearly established.

If the oil leak cannot be identified clearly by a visual inspection, carry out a UV test:

UV Testing

  1. Clean the engine and transmission with a suitable cleaning fluid (brake cleaner).
  1. Put the amount of test fluid GV-2911-3090A recommended by the manufacturers into the oil filler neck and screw the oil filler cap back on.
WARNING:
WARNING:Put the transmission into neutral. Failure to keep to the instructions may cause injury.
  1. Start the engine and let it run for about five minutes (engine oil temperature at least 80° C).
  1. Switch off the engine.
NOTE:
NOTE:If no leak can be found, road test the vehicle under various loads and again check the engine for leaks.
  1. Check the engine for oil leaks using UV leak tester GV-2929 or UV leak tester GV-2911 B11.
  1. Rectify any leaks found and check the engine for oil leaks.

Measure the compression pressure (engine warm)

General Remarks

CAUTION:
CAUTION:After the measurement, clear the PCM fault memory using FDS2000.
NOTE:
NOTE:When fuses are removed or electrical components disconnected the powertrain control module (PCM) receives an error message.
NOTE:
NOTE:Measure the compression only when the valve clearances are to specification and the engine is at operating temperature.

Different forms of compression pressure recorders and varying starter motor speeds usually only allow a check that the compression is the same in all cylinders.

Compression Pressure - Check

  1. Detach the cover from the central junction box (CJB).

Pull out the fuel pump relay.

Start the engine: the engine will start up, run for a few seconds and then stall.

  1. Remove the cover plate from the cylinder head cover.
  1. Remove the spark plugs.

Pull off the EI coil connector.

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. Refit the components in the reverse order, observing the specified tightening torques.
  1. Reset the PCM fault memory.

Compression Pressure - Check

  1. Remove the fuel pump relay.
  • Pull off the sealing rubber and open the central junction box (CJB).

  1. Remove the fuel pump relay (continued).
  1. Start the engine.
  • The engine will run for a few seconds and then stop.

  1. Remove the cover plate from the cylinder head cover.
  • To remove the cylinder head cover, unscrew the oil filler cap and screw it back on again afterwards.

  1. Remove the spark plugs.
  • CAUTION:
    CAUTION:Do not pull the cable when removing the spark plug connector. If necessary remove the ignition coil plug to avoid bending the cable. Turn the spark plug connector slightly before removing to loosen the seal.
    CAUTION:
    CAUTION:Pull off the spark plug connector keeping it in line with the spark plug itself.
    Pull off the spark plug connectors and the connectors from the EI coil.

NOTE:
NOTE:The time taken to carry out the measurement must be the same for all cylinders. Carry out the measurement on all cylinders, following the measuring equipment manufacturer's instructions.
  1. Compression Pressure - Check

  1. Install the spark plugs.
  • Push on the spark plug connectors and the connectors onto the EI coil.

  1. Attach the cylinder head cover.
  • To install the cylinder head cover, unscrew the oil filler cap and screw it back on again afterwards.

  1. Install the fuel pump relay.

  1. Install the fuel pump relay (continued).
  • Close the CJB and push on the sealing rubber.

Measuring the Oil Pressure

General

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

Measure the oil pressure at the specified engine speed and when the oil temperature is 80°C.

Measuring the Oil Pressure

  1. Raise the vehicle.
  1. Remove the oil filter.

  1. Attach oil pressure manometer adapter number 39.

  1. Attach oil pressure manometer GV 2134 so that it can be read from above.
  1. Lower the vehicle and start the engine. The oil pressure at 850 rev/min must be at least 1,0 bar. The oil pressure at 6000 rev/min must be at least 4,0 bar. Afterwards switch off the engine and raise the vehicle.
  1. Detach the oil pressure gauge and connector and refit the components in reverse order, observing the specified torques.

Measuring the Oil Pressure

  1. Raise the vehicle.

  1. Disconnect the connector and remove the oil pressure switch.

  1. Connect the oil pressure gauge using adaptor number 39.
  1. Lower the vehicle.

  1. Measuring the Oil Pressure
  • Start the engine.
  • The minimum pressure at 800 rev/min must be 1.0 bar.
  • The minimum pressure at 2000 rev/min must be 2.5 bar.
  • Switch off the engine.
  1. Raise the vehicle.
  1. Detach the oil pressure gauge and adaptor number 39.

  1. Install the oil pressure switch and push on the connector.
  1. Lower the vehicle.

Valve Timing - Static (engine not running)

Remove the cylinder head cover.

Check all components of the valve train for damage and wear. Make sure that only genuine Ford components are fitted and that all nuts and bolts are tightened to the correct torque.

General Procedures > < 303-00 Engine System - General Information|Engine