Engine System - General Information: Other Ford Focus I facelift

Material

Material

Engine Oil Leaks

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 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 fluorescent additive 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. If the oil is not premixed, the fluorescent additive 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 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. Oil pressure sensor

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 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

Oil leaks at crimped seams in sheet metal parts and cracks in cast or stamped parts can be detected when using the dye method.

Cylinder Leakage Detection

When a cylinder produces a low reading, use of the Engine Cylinder Leak Detection/Air Pressurization Kit will be helpful in pinpointing the exact cause.

The leakage detector is inserted in the spark plug hole, the piston is brought up to top dead center on the compression stroke, and compressed air is admitted.

Once the combustion chamber is pressurized, a special gauge included in the kit will read the percentage of leakage. Leakage exceeding 20 percent 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. A leak at the exhaust valve can be heard at the tailpipe. Leakage past the piston rings will be audible at the positive crankcase ventilation (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 Guide. 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 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 «DIAGNOSTIC TESTS»(ref-278256-S20862419522008012400000) .
4. Inspect the crankcase ventilation system for: disconnected hoses at the valve cover or throttle body. 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 PRESSURE LIMIT CHART»(ref-278256-S19679726982008012400000) for pressure range limits.
2. Compression should be consistent across all cylinders. For additional information, refer to «Compression Test - Compression Gauge Check»(ref-278256-S26076658602008012400000) . 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 an Engine Cylinder Leak Detection/Air Pressurization Kit. 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. 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 - 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 - Engine Off

1. Check for loose mounting bolts on camshaft caps.
2. Check valve shim to camshaft gap.

Valve Train Analysis - Engine Off, Camshaft - Engines

1. Check for broken or damaged parts.

Valve Train Analysis - Valve Springs

1. Check for broken or damaged parts.

Valve Train Analysis - Engine Off, Valve Spring Retainer and Valve Spring Retainer Keys

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 - Engine Off, Valves and Cylinder Head

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 valve tappet shim gap.
5. Check for missing or worn valve spring seats.
6. Check for plugged oil metering orifice in cylinder head oil reservoir (if equipped).

Static checks (engine off) are to be made on the engine prior to the dynamic procedure.

Valve Train Analysis - Engine Off, Camshaft Lobe Lift - OHC Engines

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

1. Remove the valve covers.
2. Remove the spark plugs.
3. Install the special tool so the rounded tip of indicator is on top of the camshaft lobe and on the same plane as the valve tappet.
4. 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.
5. 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).
6. To check the accuracy of the original 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 1 through 6.
7. Install the spark plugs.
8. Install the valve covers.

Valve Train Analysis - Engine Off, Valve Tappet

Valve tappet noise can be caused by any of the following

1. Excessive valve tappet shim gap
2. Excessive valve guide wear

Excessive collapsed valve tappet shim gap can be caused by incorrect initial adjustment or wear of valve tappet shim face.

For additional information, refer to the valve train shim and gap inspection procedure in ENGINE - 2.0L AND 2.3L article.

Sprockets

1. Inspect the sprockets for cracks and worn or chipped teeth.

Camshaft Bearing Journal Diameter

1. Measure each camshaft journal diameter in 2 directions. If out of specification, install new components as necessary. Refer to «ENGINE - 2.0L AND 2.3L»(ref-278254) for the procedure.

Camshaft End Play - OHC Engines

Special Tools Illustration Tool Name Tool Number Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent

Note. Refer to ENGINE - 2.0L AND 2.3L article for the specification.

1. Using the special tool, measure the camshaft end play.
2. Position the camshaft to the rear of the cylinder head.
3. Zero the indicator.
4. Move the camshaft to the front of the cylinder head. Note and record the camshaft end play. If camshaft end play exceeds specifications, install a new camshaft and recheck end play. If camshaft end play exceeds specification after camshaft installation, install a new cylinder head.

Camshaft Lobe Lift

Special Tools Illustration Tool Name Tool Number Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent

1. Use a Dial Indicator Gauge with Holding Fixture to measure camshaft intake/exhaust lobe lift. Rotate the camshaft and subtract the lowest indicator reading from the highest indicator reading to figure the camshaft lobe lift. Refer to «ENGINE - 2.0L AND 2.3L»(ref-278254) article for the procedure.

Camshaft Runout

Special Tools Illustration Tool Name Tool Number Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent

Note. Refer to ENGINE - 2.0L AND 2.3L article for the specification.

1. Using the special tool, measure the camshaft runout. Rotate the camshaft and subtract the lowest indicator reading from the highest indicator reading.

Crankshaft End Play

Special Tools Illustration Tool Name Tool Number Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent

1. Measure the crankshaft end play. Use a Dial Indicator Gauge with Holding Fixture to measure crankshaft end play.
2. Position the crankshaft to the rear of the cylinder block.
3. Zero the indicator.
4. Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play. If crankshaft end play exceeds specifications, install a new crankshaft thrust washer or crankshaft thrust main bearing. Refer to «ENGINE - 2.0L AND 2.3L»(ref-278254) article for the procedure.

Valve Stem Diameter

1. Measure the diameter of each intake and exhaust valve stem at the points shown. Verify the diameter is within specification. Refer to «ENGINE - 2.0L AND 2.3L»(ref-278254) article for the procedure. If out of specification, install new components as necessary. Refer to «ENGINE - 2.0L AND 2.3L»(ref-278254) article for the procedure.

Valve Guide Inner Diameter

Note. Refer to ENGINE - 2.0L AND 2.3L article for the specification.

1. Use a ball gauge to determine the inner diameter of the valve guides in 2 directions at the top, middle and bottom of the valve guide.
2. Measure the ball gauge with a micrometer.
3. If the valve guide is not within specifications, install a new cylinder head assembly.

Valve Spring Free Length

1. Measure the free length of each valve spring. Refer to «ENGINE - 2.0L AND 2.3L»(ref-278254) article for the procedure. If out of specification, install new components as necessary. Refer to «ENGINE - 2.0L AND 2.3L»(ref-278254) article for the procedure.

Valve Spring Squareness

1. Measure the out-of-square on each valve spring. Turn the valve spring and observe the space between the top of the valve spring and the square. Install a new valve spring if out of square. Refer to «ENGINE - 2.0L AND 2.3L»(ref-278254) article for the procedure.

Valve Spring Strength

Special Tools Illustration Tool Name Tool Number Pressure Gauge, Valve/Clutch Spring 303-006 (TOOL-6513-DD) or equivalent

Note. Refer to ENGINE - 2.0L AND 2.3L article for the specification.

1. Use the special tool to check the valve spring for correct strength at the specified valve spring length.

Valve and Seat Refacing Measurements

Note. Refer to ENGINE - 2.0L AND 2.3L article for the specification.

Note. After grinding valves or valve seats, check valve clearance.

1. Check the valve head and seat. Check valve angles. Check margin width. Be sure margin width is within specification.
2. Inspect for abnormalities on the valve face and seat. Install a new cylinder head assembly if abnormalities are found.

Cylinder Head Distortion

Special Tools Illustration Tool Name Tool Number Straight Edge 303-D039 (D83L-4201-A) or equivalent

Scheme 91

1. Use a straight edge and a feeler gauge to inspect the cylinder head for flatness. If the cylinder head is distorted, install a new cylinder head.

Cylinder Block Distortion

Special Tools Illustration Tool Name Tool Number Feeler Gauge Set 303-D027 (D81L-4201-A) or equivalent

Note. Refer to ENGINE - 2.0L AND 2.3L article for the specification.

1. Use a straightedge and a feeler gauge to inspect the cylinder block for flatness.