Engine System - General Information: Other Ford C-MAX II

Engine Information

Note. When repairing engines, all parts must be contamination free. If contamination/foreign material is present when repairing an engine, premature engine failure may occur.

Note. Specifications show the expected minimum or maximum condition. Refer to the appropriate engine article for the specifications.

Note. If a component fails to meet the specifications, it is necessary to refinish it or install a new component. Wear limits are provided as an aid to determine if the component can be refinished. A new component must be installed when any component fails to meet specifications and cannot be refinished.

Note. This article contains information, steps and procedures that may not be specific to this engine.

This article covers general procedures and diagnosis and testing of the engine system, except for exhaust emission control devices, which are covered in the ENGINE CONTROLS article.

The engine incorporates the following features: Refer to the appropriate engine article for the procedure.

1. Crankcase ventilation or breather system
2. Exhaust emission control system
3. EVAP

Some engines incorporate a fail-safe cooling system. Refer to the appropriate engine article for the procedure.

The engine, fuel system, ignition system, emissions system and exhaust system all affect exhaust emission levels and must be maintained according to the maintenance schedule. Refer to the Scheduled Maintenance Guide.

Correct engine identification is required to order parts. Refer to the appropriate engine article for the procedure.

For complete vehicle and engine identification codes

Refer to: IDENTIFICATION CODES .

Component Tests

The following component tests are used to diagnose engine concerns.

Engine Oil Leaks

Note. If an overnight drive is done, the fan air or road air blast can cause erroneous readings.

Note. When diagnosing engine oil leaks, the source and location of the leak must be positively identified prior to repair.

Prior to carrying out this procedure, clean the cylinder block, cylinder heads, valve covers, oil pan and flywheel/flexplate with a suitable solvent to remove all traces of oil.

Engine Oil Leaks - Fluorescent Oil Additive Method

Use the 12 Volt Master UV Diagnostic Inspection Kit to carry out the following procedure for OIL LEAK DIAGNOSIS .

1. Add 29.6 ml (1 oz.) of gasoline engine oil dye to a minimum of 0.47L (1/2 qt) and a maximum of 0.95L (1 qt) engine oil and fill through the engine oil fill. Thoroughly premix the gasoline engine oil dye or it will not have enough time to reach the crankcase, oil galleries and seal surfaces during this particular 15 minute test. The additive must be mixed well with oil and added through the oil fill. Check the level on the oil level indicator to determine what amount of oil to premix. If it is in the middle of the crosshatch area or below the full mark, use 0.95L (1 qt). If it is at the full mark, use 0.47L (1/2 qt).
2. Run the engine for 15 minutes. Stop the engine and inspect all seal and gasket areas for leaks using the UV Leak Detector Kit. A clear bright yellow or orange area will identify the leak. For extremely small leaks, several hours may be required for the leak to appear.
3. At the end of test, make sure the oil level is within the upper and lower oil indicator marks. Remove oil as necessary if it registers above the full mark.

Leakage Points - Underhood

Examine the following areas for oil leakage

1. Valve cover gaskets
2. Cylinder head gaskets
3. Oil cooler, if equipped
4. Oil filter adapter
5. Engine front cover
6. Oil filter adapter and filter body
7. Oil level indicator tube connection
8. EOP switch

Leakage Points - Under Engine, With Vehicle on Hoist

Examine the following areas for oil leakage

1. Oil pan gaskets
2. Oil pan sealer
3. Engine front cover gasket
4. Crankshaft front seal
5. Crankshaft rear oil seal
6. Oil filter adapter and filter body
7. Oil cooler, if equipped

Leakage Points - With Transmission and Flywheel/Flexplate Removed

Examine the following areas for oil leakage

1. Crankshaft rear oil seal
2. Rear main bearing cap parting line
3. Flexplate mounting bolt holes (with flexplate installed)
4. Pipe plugs at the end of oil passages

Compression Pressure Limit Chart

If one or more cylinders reads low, squirt approximately one tablespoon of engine oil meeting Ford specification on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders.

Cylinder Leakage Detection

When a cylinder produces a low reading, use of a cylinder leakage tester will be helpful in pinpointing the exact cause.

The leakage tester is inserted in the spark plug hole, the piston is brought up to TDC on the compression stroke, and compressed air is admitted.

Once the combustion chamber is pressurized, the leakage tester gauge will read the percentage of leakage. Leakage exceeding 20% is excessive.

While the air pressure is retained in the cylinder, listen for the hiss of escaping air. A leak at the intake valve will be heard in the Throttle Body (TB). A leak at the exhaust valve can be heard at the tailpipe. Leakage past the piston rings will be audible at the PCV connection. If air is passing through a blown head gasket to an adjacent cylinder, the noise will be evident at the spark plug hole of the cylinder into which the air is leaking. Cracks in the cylinder block or gasket leakage into the cooling system may be detected by a stream of bubbles in the radiator.

Excessive Engine Oil Consumption

Nearly all engines consume oil, which is essential for normal lubrication of the cylinder bore walls and pistons and rings. Determining the level of oil consumption may require testing by recording how much oil is being added over a given set of miles.

Customer driving habits greatly influence oil consumption. Mileage accumulated during towing or heavy loading generates extra heat. Frequent short trips, stop-and-go type traffic or extensive idling, prevent the engine from reaching normal operating temperature. This prevents component clearances from reaching specified operating ranges.

The following diagnostic procedure may be utilized to determine internal oil consumption. Make sure that the concern is related to internal oil consumption, and not external leakage, which also consumes oil. Verify there are no leaks before carrying out the test. Once verified, the rate of internal oil consumption can be tested.

A new engine may require extra oil in the early stages of operation. Internal piston-to-bore clearances and sealing characteristics improve as the engine breaks in. Engines are designed for close tolerances and do not require break-in oils or additives. Use the oil specified in the Owner's Literature. Ambient temperatures may determine the oil viscosity specification. Verify that the correct oil is being used for the vehicle in the geographic region in which it is driven.

Basic Pre-checks

1. For persistent complaints of oil consumption, interview the customer to determine the oil consumption characteristics. If possible, determine the brand and grade of oil currently in the oil pan. Look at the oil filter or oil-change station tags to determine if Ford-recommended maintenance schedules have been followed. Make sure that the oil has been changed at the specified mileage intervals. If vehicle mileage is past the first recommended drain interval, the Original Equipment Manufacturer (OEM) production filter should have been changed.
2. Ask how the most current mileage was accumulated. That is, determine whether the vehicle was driven under the following conditions: Extended idling or curbside engine operation Stop-and-go traffic or taxi operation Towing a trailer or vehicle loaded heavily Frequent short trips (engine not up to normal operating temperature) Excessive throttling or high engine-rpm driving
3. Verify that there are no external leaks. If necessary, review the diagnostic procedure under Engine Oil Leaks in the Diagnosis and Testing portion of this article.
4. Inspect the crankcase ventilation system for: disconnected hoses at the valve cover or TB. loose or missing valve cover fill cap. missing or incorrectly seated engine oil level indicator. incorrect or dirty PCV valve. a PCV valve grommet unseated in the valve cover (if so equipped).
5. Inspect for signs of sludge. Sludge affects PCV performance and can plug or restrict cylinder head drainback wells. It can also increase oil pressure by restricting passages and reducing the drainback capability of piston oil control rings. Sludge can result from either excessive water ingestion in the crankcase or operation at extremely high crankcase temperatures.
6. Inspect the air filter for dirt, sludge or damage. A hole in the filter element will allow unfiltered air to bypass into the air induction system. This can cause premature internal wear (engine dusting), allowing oil to escape past rings, pistons, valves and guides.
7. If the engine is hot or was recently shut down, wait at least 5 minutes to allow the oil to drain back. Ask the customer if this requirement has been followed. Adding oil without this wait period can cause an overfill condition, leading to excessive oil consumption and foaming which may cause engine damage.
8. Make sure the oil level indicator (dipstick) is correctly and fully seated in the indicator tube. Remove the oil level indicator and record the oil level.

Detailed Pre-checks

1. Check the thermostat opening temperature to make sure that the cooling system is operating at the specified temperature. If it is low, internal engine parts are not running at specified internal operating clearances.
2. Verify the spark plugs are not oil saturated. Oil leaking into one or more cylinders will appear as an oil soaked condition on the plug. If a plug is saturated, a compression check may be necessary at the conclusion of the oil consumption test.

Post Checks, Evaluation and Corrective Action

1. If test results indicate excessive oil consumption, carry out a cylinder compression test. The cylinder compression test should be carried out with a fully charged battery and all spark plugs removed. See the «COMPRESSION TEST CHART»(ref-635246-S35532713132014070200000) for pressure range limits.
2. Compression should be consistent across all cylinders. Refer to the «COMPRESSION TESTING»(ref-635246-S35532713132014070200000) portion of this article. If compression tested within the specifications found in this article, the excessive oil consumption may be due to wear on the valve guides, valves or valve seals.
3. A cylinder leak detection test can be carried out using a cylinder leakage detector. This can help identify valves, piston rings, or worn valve guides/valve stems, inoperative valve stem seals or other related areas as the source of oil consumption.
4. NOTE: An oil-soaked appearance on the porcelain tips of the spark plugs also indicates excessive oil use. A typical engine with normal oil consumption will exhibit a light tan to brown appearance. A single or adjoining, multiple cylinder leak can be traced by viewing the tips. If an internal engine part is isolated as the root cause, determine if the repair will exceed cost limits and proceed with a repair strategy as required.
5. Once corrective action to engine is complete and verifying that all pre-check items were eliminated in the original diagnosis, repeat the Oil Consumption Test as described above and verify consumption results.

Valve Train Analysis

The following component tests are used to diagnose valve train concerns.

Valve Train Analysis - Engine Off, Valve Cover Removed

Check for damaged or severely worn parts and correct assembly. Make sure correct parts are used with the static engine analysis as follows.

Valve Train Analysis - Camshafts and Valve Tappets

1. Check for broken or damaged parts.
2. Check for loose mounting bolts on camshaft caps.
3. Check for worn or damaged valve tappets.

Valve Train Analysis - Valve Springs, Valve Tappets Removed

1. Check for broken or damaged parts.

Valve Train Analysis - Valve Spring Retainer and Valve Spring Retainer Keys, Valve Tappets Removed

1. Check for correct seating of the valve spring retainer key on the valve stem and in valve spring retainer.
2. Check for correct seating on the valve stem.

Valve Train Analysis - Valves and Cylinder Head, Valve Tappets Removed

1. Check for plugged oil drain back holes.
2. Check for worn or damaged valve tips.
3. Check for missing or damaged valve stem seals or guide-mounted valve stem seal.
4. Check for missing or worn valve spring seats.

Valve Train Analysis - Camshaft Lobe Lift

Check the lift of each camshaft lobe in consecutive order and make a note of the readings.

1. Remove the spark plugs. REFER to: «SPARK PLUGS»(ref-635247-S37507406972014070200000) .
2. Install the Dial Indicator Gauge with Holding Fixture so the rounded tip of the dial indicator is on top of the camshaft lobe and on the same plane as the valve tappet.
3. Rotate the crankshaft using a breaker bar and socket attached to the crankshaft pulley retainer bolt. Rotate the crankshaft until the base circle of the camshaft lobe is reached.
4. Zero the dial indicator. Continue to rotate the crankshaft until the high-lift point of the camshaft lobe is in the fully raised position (highest indicator reading).
5. To check the accuracy of the original dial indicator reading, continue to rotate crankshaft until the base circle is reached. The indicator reading should be zero. If zero reading is not obtained, repeat Steps 2 through 5.
6. If the lift on any lobe is below specified service limits, install a new camshaft and valve tappets.
7. Install the spark plugs. REFER to: «SPARK PLUGS»(ref-635247-S37507406972014070200000) .

Scheme 2

1. Cratering - fatigue failure Spot glazing - incorrect seating Scratching - dirty engine oil Base exposed - poor lubrication Both edges worn - journal damaged One edge worn - journal tapered or bearing not seated

Check

Note. Refer to the appropriate engine article for the specification.

1. NOTE: The crankshaft connecting rod journals must be within specifications to check the connecting rod bearing journal clearance. Remove the connecting rod bearing cap and connecting rod bearing.
2. Position a piece of Plastigage across the bearing surface.
3. NOTE: Do not turn the crankshaft during this step. Install and tighten to specifications, then remove the connecting rod bearing cap.
4. Measure the Plastigage to get the connecting rod bearing journal clearance. The Plastigage should be smooth and flat. A changing width indicates a tapered or damaged connecting rod or connecting rod bearing.

Note. Refer to the appropriate engine article for the specification.

1. NOTE: Crankshaft main bearing journals must be within specifications before checking journal clearance. Remove the crankshaft main bearing cap and crankshaft main bearing.
2. Position a piece of Plastigage across the crankshaft main bearing surface.
3. NOTE: Do not turn the crankshaft while carrying out this procedure. Install and tighten to specifications, then remove the crankshaft main bearing cap.
4. Measure the Plastigage to get the crankshaft main bearing clearance. The Plastigage should be smooth and flat. A changing width indicates a tapered or damaged crankshaft or crankshaft bearing.

Repair

All core plugs

1. NOTE: Cylinder block core plug shown, cylinder head core plug similar. Using the Slide Hammer and a commercially available body dent puller attachment or commercially available freeze plug puller remove the core plug. Use Special Service Tool: 100-001 (T50T-100-A) Slide Hammer .
2. NOTE: Oversize plugs are identified by the OS stamped in the flat located on the cup side of the plug. Inspect the core plug bore for any damage that would interfere with the correct sealing of the plug. If the core plug bore is damaged, bore for the next oversize plug. Cup-type
3. NOTE: Use care during this procedure so as not to disturb or distort the cup sealing surface. NOTE: When installed, the flanged edge must be below the chamfered edge of the bore to effectively seal the bore. Coat the cup-type core plug and bore lightly with sealant and install the core plug using a freeze plug installer. Remove the excess sealant after installation. Material : Threadlock and Sealer/TA-25-B Expansion-type
4. NOTE: Do not contact the crown when installing an expansion-type core plug. This could expand the plug before seating and result in leakage. Coat the expansion-type core plug and bore lightly with sealant and install the core plug using a freeze plug installer. Remove the excess sealant after installation. Material : Threadlock and Sealer/TA-25-B

Note. Refer to the appropriate engine article for the specification.

1. NOTE: Use a Straightedge that is calibrated by the manufacturer to be flat within 0.005 mm (0.0002 in) per running foot of length, such as Snap-On® GA438A or equivalent. For example, if the Straightedge is 61 cm (24 in) long, the machined edge must be flat within 0.010 mm (0.0004 in) from end to end. Use a Straightedge and a Feeler Gauge Set to inspect the cylinder block for flatness. Use the General Equipment: Feeler Gauge

Note. Refer to the appropriate engine article for the specification.

1. Measure the cylinder bore at the top, middle and bottom of piston ring travel in 2 directions as indicated. Verify the cylinder bore is within the wear limit. The difference indicates the cylinder bore taper. If the cylinder bore taper does not meet specification, bore the cylinder to the next oversize limit.

Note. Refer to the appropriate engine article for the specification.

1. NOTE: Make sure all cylinder head surfaces are clear of any gasket material, silicone sealant, oil and coolant. The cylinder head surface must be clean and dry before running a flatness check. NOTE: Use a Straightedge that is calibrated by the manufacturer to be flat within 0.005 mm (0.0002 in) per running foot of length, such as Snap-On® GA438A or equivalent. For example, if the Straightedge is 61 cm (24 in) long, the machined edge must be flat within 0.010 mm (0.0004 in) from end to end. Using a Straightedge and a Feeler Gauge Set, inspect the cylinder head for flatness in the sequence shown below. Use the General Equipment: Feeler Gauge

Cleaning

1. Clean the exhaust manifold using a suitable solvent. Use a plastic scraping tool to clean the gasket sealing surfaces.

Note. Refer to the appropriate engine article for the specification.

1. Measure the piston diameter 90 degrees from the piston pin and 41 mm (1.61 in) down from the top of the piston at the point indicated.

Note. Refer to the appropriate engine article for the specification.

1. NOTE: Use care when fitting piston rings to avoid possible damage to the piston ring or the cylinder bore. NOTE: Piston rings should not be transferred from one piston to another. NOTE: The cylinder bore must be within specification for taper and out-of-round. Use a piston without rings to push a piston ring in a cylinder to the bottom of ring travel.
2. Using the Feeler Gauge Set measure the top piston ring end gap and the second piston ring end gap Use the General Equipment: Feeler Gauge

Note. Refer to the appropriate engine article for the specifications.

1. NOTE: The cylinder bore must be within the specifications for taper and out-of-round before fitting a piston. Measure the cylinder bore in 2 directions. Select a piston size based on the cylinder bore.
2. NOTE: For precision fit, new pistons are divided into 3 categories within each size range based on their relative position within the range. A paint spot or specific size grade on a new piston indicates the position within the size range. Choose the piston with the correct paint color or specific size grade.

Note. Refer to the appropriate engine article for the specification.

1. NOTE: Valve guides tend to wear in an hourglass pattern. The ball gauge can be inserted into the combustion chamber side of the valve guide, if necessary. Use a ball gauge to determine the inside diameter of the valve guides in 2 directions at the top, middle and bottom of the valve guide. Measure the ball gauge with a micrometer. If the valve guide is not within specifications, install a new cylinder head assembly.

Note. Refer to the appropriate engine article for the specification.

1. Measure the diameter of each intake and exhaust valve stem at the points shown below. Verify the diameter is within specification.