Symptom Chart

SYMPTOM CHART

Condition	Possible Sources	Action
Excessive oil consumption	Use of the wrong type of engine oil	Determine the latest engine oil used (refer to latest invoice or oil receipt) and compare with the specification, renew if necessary.
	Pressure in the cylinder block too high.	Remove cylinder head cover cap. Close the opening by hand. If excess pressure is detected when the engine is running:
	Poor sealing between combustion chamber and crankcase.	Check the operation of the crankcase ventilation system and repair it as necessary.
	Leak caused by a faulty oil seal or incorrect alignment of the oil seal carrier.	Check and, if necessary, align the oil seal carrier. Renew the seal.
	Camshaft Crankshaft front or rear.	Repair as necessary.
	Damaged gaskets or mating faces	Check the gaskets and mating faces for damage.
Cylinder head gasket or mating face is damaged, engine oil can escape from the engine between cylinder head and cylinder block or enter the cooling system.		Open the cover of the coolant expansion tank and check for any oil scum or film on the coolant surface. Remove the cylinder head. Zetec-E REFER to ENGINE - 2.0L DURATEC ST article SPI-REFER to ENGINE - 2.0L SPI article . Check the mating faces, cylinder head gasket and renew the evenness of the cylinder head mating face. REFER to GENERAL SERVICE PROCEDURES . If necessary, install a new cylinder head.
Oil leaks on components that are either coated in oil or have oilways, oil leaks on ancillary components	Locate any cracks in components which have oilways or in the engine itself with a UV leak tester and install new relevant components or gaskets.
Oil leakage	Inspect and repair oil leakage
Diluted oil.	Inspect for dilution and fill in new the oil, if necessary.
Incorrect oil pressure	Measure the oil pressure and fill in new the oil.
Oil baffle damaged inside of valve cover.	Install a new valve cover.
Inoperative positive crankcase ventilation (PCV). Hoses or ventilation/breather valve are blocked. This causes excessive pressure in the crankcase which causes more oil to enter the combustion chamber. Crankcase ventilation oil separator is damaged and engine oil can enter the combustion chamber through the inlet manifold.	Check that the PCV works correctly, repair if necessary.
Too much clearance on engine components.	Check and install new engine components as necessary. If necessary, install a new cylinder block.
Pistons.	Pistons
Piston rings (ring clearances and ring gap).	Piston rings
Valve stems and guides.	Valve stems and guides
Coolant consumption	Damaged gaskets or mating faces.	Check the gaskets and mating faces for damage.
	The cylinder head gasket or mating face is damaged. Coolant can enter the combustion chamber or the crankcase.	Remove the cylinder head. Zetec-E REFER to ENGINE - 2.0L DURATEC ST article SPI-REFER to ENGINE - 2.0L SPI article . Check the mating faces, cylinder head gasket and the evenness of the cylinder headmating face. REFER to GENERAL SERVICE PROCEDURES . If necessary, renew the cylinder head.
	Cracks or fractures in engine components surrounded by coolant, such as cylinder and cylinder head combustion chamber recesses.	Determine the damaged engine component and install new ones
Engine will not start during cold and hot start.	Battery or wiring inoperative	Check the battery, electrical connections and cables.
	Starter motor or wiring inoperative	Check starter system.
	Fuel system inoperative.	Inspect the fuel system. Refer to FUEL SYSTEMS article.
	Fuel tank is empty.	Check the fuel level.
	Ignition system inoperative	Inspect the ignition system. Refer to IGNITION SYSTEMS article.
	Engine management system inoperative	Inspect the engine management system. REFER to SELF-DIAGNOSTICS - EEC-V - GASOLINE & NGV article.
	Intake system is damaged or inoperative. Intake system air leak. Air cleaner is blocked. Idle air control valve (IAC) is damaged or inoperative.	Inspect the intake system. REFER to AIR INDUCTION SYSTEMS article.
	Valve train damaged or inoperative. Incorrect valve-to-valve seat contact. Burned out exhaust valve. Valve sticking. Valve tappet damaged (SPI) Valve tappet bore damaged (SPI) Timing incorrectly adjusted. Timing belt broken or damaged	Connect compressed air to the cylinders. Observe that the piston is in top dead center (TDC) position in compression stroke. If air flows out through the intake manifold or the exhaust pipe, inspect or repair the valve train.
	Engine components damaged or malfunctioning Burned through piston Piston rings Worn cylinder Cylinder head damaged Cylinder head gasket Big-end or main bearing journals	Connect compressed air to the cylinders. Observe that the piston is in top dead center (TDC) position in compression stroke. If air flows out of the opened cylinder head cover cap hole, remove the cylinder head according to the operating procedure, inspect and repair the components. Remove the cylinder head. Zetec-E REFER to ENGINE - 2.0L DURATEC ST article SPI-REFER to ENGINE - 2.0L SPI article .
Poor idling	Fuel system inoperative	Inspect the fuel system. Refer to FUEL SYSTEMS article.
	Ignition system inoperative.	Inspect the ignition system. Refer to IGNITION SYSTEMS article.
	Engine management system inoperative.	Inspect the engine management system. REFER to SELF-DIAGNOSTICS - EEC-V - GASOLINE & NGV article.
	Intake system inoperative. Intake system air leak. Air cleaner is blocked. Inoperative idle air control (IAC) valve.	Inspect the intake system. REFER to AIR INDUCTION SYSTEMS article.
	Valve train damaged or inoperative Incorrect valve-to-valve seat contact. Burned out exhaust valve. Valve sticking Valve tappet damaged (SPI) Valve tappet bore damaged (SPI) Timing incorrectly adjusted. Timing belt damaged.	Connect compressed air to the cylinders. Observe that the piston is in top dead center (TDC) position. If air flows out through the intake manifold or the exhaust pipe, inspect or repair the valve train.
	Engine components damaged or inoperative. Burned through piston Piston rings Worn cylinder Cylinder head damaged Cylinder head gasket Big-end or main bearing journals	Connect compressed air to the cylinders. Observe that the piston is in top dead center (TDC) position. If air flows out of the opened cylinder head cover cap hole, remove the cylinder head according to the operating procedure and inspect and repair the components. If necessary dismantle the engine, inspect and repair the components. Remove the cylinder head. Zetec-E REFER to ENGINE - 2.0L DURATEC ST article SPI-REFER to ENGINE - 2.0L SPI article .
Insufficient power	Fuel system inoperative.	Inspect the fuel system. Refer to FUEL SYSTEMS article.
	Ignition system inoperative.	Inspect the ignition system. Refer to IGNITION SYSTEMS article.
	Engine management system inoperative.	Inspect the engine management system. REFER to SELF-DIAGNOSTICS - EEC-V - GASOLINE & NGV article.
	Intake system inoperative	Inspect the intake system. REFER to AIR INDUCTION SYSTEMS article.
	Intake air leak.	Air cleaner is blocked.
	Restricted exhaust system	Inspect the exhaust system.
	Valve train inoperative Burned out exhaust valve. Valve sticking. Valve spring weak or broken. Valve tappet damaged (SPI). Valve tappet bore damaged (SPI) Timing incorrectly adjusted. Timing belt damaged Camshaft position sensor inoperative	Connect compressed air to the cylinder. Observe that the piston is in TDC position. If air flows out through the intake manifold or the exhaust pipe, inspect the valve train.
Engine components inoperative. Piston ring(s) sticking worn or damaged. Piston worn or burned through. Worn cylinder. Cylinder head damaged. Cylinder head gasket damaged.		Connect compressed air to the cylinders. Observe that the piston is in top dead center (TDC) position. If air flows out of the opened cylinder head cover cap hole, remove the cylinder head according to the operating procedure, inspect and repair the components. Remove the cylinder head. Zetec-E REFER to ENGINE - 2.0L DURATEC ST article SPI-REFER to ENGINE - 2.0L SPI article .
Tire size/pressure incorrect.	Check the tire size/pressures. REFER to the owners guide.
Transmission inoperative.	REFER to MANUAL TRANSAXLE article or AUTOMATIC TRANSAXLE/TRANSMISSION article.
Excessive or insufficient compression	Fuel system damaged or inoperative.	Inspect the fuel system. Refer to FUEL SYSTEMS article.
	Valve train inoperative. Burned out exhaust valve. Incorrect valve-to-valve seat contact. Valve sticking. Valve spring weak or broken Camshaft worn.	Connect compressed air to the cylinder. Observe that the piston is in TDC position in compression stroke. If air flows air through the intake manifold or the exhaust pipe inspect and repair the valve train.
	Valve tappet damaged (SPI).	Replace valve tappets.
	Valve tappet bore damaged (SPI).	Replace cylinder head.
	Engine component inoperative.	Connect compressed air to the cylinders. Observe that the piston is in top dead center (TDC) position in compression stroke. If air flows out of the opened cylinder head cover cap hole, remove the cylinder head according to the operating procedure, inspect and repair the components. Zetec-E REFER to ENGINE - 2.0L DURATEC ST article SPI-REFER to ENGINE - 2.0L SPI article .
	Piston ring(s) sticking, worn, damaged.	Inspect and install new piston ring(s).
	Worn piston.	Install a new piston
	Worn cylinder.	Inspect and repair the cylinder.
	Cylinder head gasket damaged.	Inspect and renew the cylinder head gasket.
	Carbon accumulation in combustion chamber.	Eliminate carbon building.
Engine noise	Misfiring/backfiring.	Located and rectify the cause of the misfiring and backfiring.
	Fuel in tank has wrong octane/cetane number, or is wrong type of fuel.	Determine which type of fuel was last put in the tank (note the country specific fuels specifications).
	Fuel system inoperative.	Inspect the fuel system. Refer to FUEL SYSTEMS article.
	Ignition system inoperative.	Inspect the ignition system. Refer to IGNITION SYSTEMS article.
Engine temperature too high.		Inspect the engine cooling. REFER to ENGINE COOLING article .
Carbon deposits in the combustion chamber start to glow and cause misfiring.	Remove the carbon deposits by using fuel additives and driving the vehicle carefully.
Timing incorrect, which causes misfiring in the intake/exhaust system	Inspect the timing.
Valve train inoperative.	Inspect the valve train.
Valve clearance too large due to malfunctioning tappets or incorrect adjustment of valve clearance.	Adjust valve clearance if possible and renew faulty bucket tappets
Valve timing incorrectly adjusted-valves and pistons are touching.	Check the valve timing and adjust if necessary. Zetec-E REFER to ENGINE - 2.0L DURATEC ST article SPI-REFER to ENGINE - 2.0L SPI article .
Timing belt broken or damaged. Valve spring broken. Excessive valve guide clearance. Inoperative of tappets (SPI). Worn tappets (Zetec-E). Worn camshaft(s).	Inspect timing belt. In addition check pistons and valves for damage and install new parts if necessary
Engine components inoperative. Piston(s) worn or damaged. Piston pin worn or damaged. Piston ring(s) worn or damaged. Excessive connecting rod bearing clearance. Cylinder head gasket damaged. Connecting rod bend. Cylinder worn. Excessive crankshaft main bearing clearance. Excessive crankshaft end play.	Disassemble the engine and check components. Zetec-E REFER to ENGINE - 2.0L DURATEC ST article SPI-REFER to ENGINE - 2.0L SPI article . Inspect the exhaust system.
Exhaust system damaged.	Inspect the exhaust system.
Cooling system inoperative (water pump, vibration of radiator).	REFER to ENGINE COOLING article .
Incorrect drive belt tension.	Inspect drive belt tension. REFER to SPECIFICATIONS & DRIVE BELT ROUTING article.
Generator front bearing inoperative.	Inspect and install a new generator. REFER to GENERATORS & REGULATORS article.
Transaxle inoperative.	REFER to MANUAL TRANSAXLE article or AUTOMATIC TRANSAXLE/TRANSMISSION article.
Engine components or auxiliary components are broken or have come loose.	Check that the auxiliary components are securely and correctly fitted, if necessary tighten them to the specified torque. Install new components if necessary.
Tappet noise when engine is started (does not continue for more than 10 minutes) (SPI engine only)	Insufficient oil in engine.	Check the engine oil level ADD oil as necessary.
	Deteriorated or diluted oil.	Inspect for dilution and fill in new oil.
	Insufficient oil in valve tappet (SPI engine).	Warm the engine. Drive vehicle at 3000 rpm for 8 minutes.
Tappet noise when engine is started (continues for more than 10 minutes)	Insufficient or diluted oil.	Check the engine oil level. Add oil as necessary.
	Deteriorated oil.	Inspect for dilution and fill in new oil.
	Defective valve tappet(s) (SPI engine).	Locate and install new valve tappet (SPI engine).
	Worn valve tappet(s) (Zetec-E engine).	Locate worn valve shims and install new ones (Zetec engine).
Tappet noise during engine operation	Insufficient oil in engine.	Check the engine oil level.
	Deteriorated oil	Fill in new the oil.
	Insufficient oil pressure.	Check the oil pressure.
	Defective valve tappet (s) (SPI engine)	Locate worn valve tappets and install new ones (SPI engine).
	Worn valve tappet(s) (Zetec-E engine)	Locate worn valve shims and install ones (Zetec engine).