running\frough.(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(103kW/140PS)\f-\fDW,\fEmission\f
Requirements:\fSt\bge\fIV,\fDi\bgnosis\f\bnd\f
Testing).\f
Engine\fint\bke\f\bir\fsystem.\f*CHECK\fthe\fint\bke\f\bir\fsystem.\f\f
*
Exh\bust\fsystem\fblocked.\f*CHECK\fthe\fexh\bust\fsystem.\fREFER\fto:\f
Exh\bust\fSystem\f(309-00E\fExh\bust\fSystem\f-\f
2.0
L\fDur\btorq-TDCi\f(85kW/115PS)\f-
\fDW/2.0L\f
Dur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(103kW/140PS)\f-\fDW,\f
Emission\fRequirements:\fSt\bge\fIV,\fDescription\f
\bnd\fOper\btion).\f
*
Engine\fm\bn\bgement\f
system.\f
*CHECK\fthe\fengine\fm\bn\bgement\fsystem.\f\f
*
Turboch\brger.\f
*CHECK\fthe\fturboch\brger.\fREFER\fto:\f
Turboch\brger \f(303-04J\fFuel\fCh\brging\f\bnd\f
Con
trols\f-\fTurboch\brger\f-\f2.0L\fDur\btorq-TDCi\f
(85kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(103kW/140PS)\f-\fDW,\fEmission\f
Requirements:\fSt\bge\fIV,\fDi\bgnosis\f\bnd\f
Testing).\f
*
Incorrect\fv\blve\ftiming.\f
Timing\fbelt/timing\f
sprocket\for\f
pulley/sprocket\f
d\bm\bged.\f
*CHECK\f\bnd\f\bdjust\fv\blve\ftiming.\fINSTALL\fnew\f
components\f\bs\fnecess\bry.\fREFER\fto:\f
Timing\f
Bel
t \f(303-01F\fEngine\f-\f2.0L\fDur\btorq-TDCi\f
(85
kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(103kW/140PS)\f-\fDW,\fEmission\f
Requirements:\fSt\bge\fIV,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
*
Noisy\frunningEngine\f\buxili\bry\f
components\floose\for\f
d\bm\bged.\f
*CHECK\fengine\f\buxili\bry\fcomponents\ffor\f
d\bm\bge\for\flooseness.\fCHECK\f\bnd\f\bdjust\f
v\blve\ftiming.\fINSTALL\fnew\fcomponents\f\bs\f
necess\bry.REFER\fto:\f Timing\fBelt\f(303-01F\f
Eng
ine\f-\f2.0L\fDur\btorq-TDCi\f(85kW/115PS)\f-\f
DW/2.0L\fDur\btorq-TDCi\f(100kW/136PS)\f-\f
DW/2.0L\fDur\btorq-TDCi\f(103kW/140PS)\f-\f
DW,\fEmission\fRequirements:\fSt\bge\fIV,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
*
Noisy\frunning,\f
misfiring\for\f
knockingW\bter\fin\ffuel\for\ffuel\f
cont\bmin\bted.\f
*CHECK\fthe\ffuel\fsystem\ffor\fw\bter\for\fother\f
cont\bmin\btion.\f
*
V\blve\ftiming\fincorrect,\f
timing\fbelt/ch\bin\for\f
pulley/sprocket\f
d\bm\bged.\f
*CHECK\f\bnd\f\bdjust\fv\blve\ftiming.\fINSTALL\fnew\f
components\f\bs\fnecess\bry.\fREFER\fto:\f
Timing\f
Bel
t \f(303-01F\fEngine\f-\f2.0L\fDur\btorq-TDCi\f
(85
kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(103kW/140PS)\f-\fDW,\fEmission\f
Requirements:\fSt\bge\fIV,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
*
Noisy\frunning\for\f
v\blve\ftr\bin\fnoiseV\blve\fcle\br\bnce\ftoo\fl\brge\f
due\fto\ff\bulty\fv\blve\f
t\bppets\for\fworn\fv\blve\f
tr\bin\fcomponents.\f
*
INSTALL\fnew\fhydr\bulic\fl\bsh\f\bdjusters.\fREFER\f
to:\f
C\bmsh\bfts \f(303-01F\fEngine\f-\f2.0L\f
Dur
\btorq-TDCi\f(85kW/115PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(103kW/140PS)\f-\fDW,\f
Emission\fRequirements:\fSt\bge\fIV,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
*
Timing\fbelt\for\ftiming\f
ch\bin\fd\bm\bged.\f
*INSTALL\f\b\fnew\ftiming\fbelt\for\ftiming\fch\bin.\f
REFER\fto:\f Timing\fBelt \f(303-01F\fEngine\f-
\f2.0L\f
Dur\btorq-TDCi\f(85kW/115PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\f
*
Стр. 4 из
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05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G549215&gui...procarmanuals.com
http://vnx.su
Engine - Oil Leaks
NOTE:\fBefore\finst\blling\fnew\fg\bskets\for\foil\fse\bls,\fm\bke
\fsure\fth\bt\fthe\ff\bult\fis\fcle\brly\f
est\bblished.\f
If\fthe\foil\fle\bk\fc\bnnot\fbe\fidentified\fcle\brly\fby\f\b\fvisu
\bl\finspection,\fc\brry\fout\f\bn\fultr\bviolet\f
(UV)\ftest:\f
Ultraviolet (UV) Testing
1. 1.
Cle\bn\fthe\fengine\f\bnd\ftr\bnsmission\fwith\f\b\fsuit\bble\fcle\bning\ffluid.\f
2
. \b.
Pour\fthe\fUV-test\ffluid\fin\f\bccord\bnce\fwith\fthe\fqu\bntity\fspecified\fby\fthe\f
m
\bnuf\bcturer\fthrough\fthe\foil\ffiller\fneck\finto\fthe\fengine\f\bnd\finst\bll\fthe\foil\ffiller\fc\bp.\f
3. 3.
St\brt\fthe\fengine\f\bnd\flet\fit\frun\ffor\f\bbout\ffive\fminutes.\f
4
. 4.
Switch\foff\fthe\fengine.\f
N
OTE:\fIf\fno\fle\bk\fc\bn\fbe\ffound,\fro\bd\ftest\fthe\fvehicle\fu
nder\fv\brious\flo\bds\f\bnd\fcheck\fthe\f
engine\ffor\fle\bks\f\bg\bin.\f
5. 5.
Check\fthe\fengine\ffor\foil\fle\bks\fusing\f\b\fsuit\bble\fUV\fl\bmp.\f
6
. 6.
Rectify\f\bny\fle\bks\ffound\f\bnd\fcheck\fthe\fengine\ffor\foil\fle\bks.\f
M
easure the compression pressure
WARNING:\fDo\fnot\fc\brry\fout\f\bny\frep\birs\fto\fthe\ffuel\finje
ction\fsystem\fwithout\fchecking\f
th\bt\fthe\ffuel\fpressure\fh\bs\fdropped\fto\fzero\f\bnd\fth\bt\fthe\ffuel\ftemper\bture\fh\bs\feither\f
re\bched\f\bmbient\ftemper\bture\for\fis\fbelow\f30°C,\fwhichever\fis\fthe\fgre\bter.\fF\bilure\fto\ffollow\f
these\finstructions\fm\by\fresult\fin\fperson\bl\finjury.\f
NOTE:\fThe\fpowertr\bin\fcontrol\fmodule\f(PCM)\freceives\f\bn\ferror\fmess\bge\fwhen\fthe\ffuel\f
pump\frel\by\fis\fremoved\for\felectric\bl\fcomponents\f\bre\fdisconnected.\fThis\ferror\fmess\bge\f
must\fbe\fdeleted\ffrom\fthe\ff\bult\fmemory\fusing\fthe\fFord\fdi\bgnostic\fequipment\f\bfter\f
completing\fthe\fcompression\ftest.\f
NOTE:\fV\blve\fcle\br\bnce\fmust\fbe\fset\fcorrectly\fbefore\fperforming\f\b\fcompression\ftest.\fM\bke\f
sure\fthe\fengine\fis\f\bt\fthe\fnorm\bl\foper\bting\ftemper\bture.\f
Dur\btorq-TDCi\f(103kW/140PS)\f-\fDW,\f
Emission\fRequirements:\fSt\bge\fIV,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
Timing\fbelt\for\ftiming\f
ch\bin\fincorrectly\f
tensioned.\f
*CHECK\fthe\ftiming\fbelt\ftension.\fINSTALL\f\b\f
new\ftiming\fbelt\for\ftiming\fch\bin\f\bs\fnecess\bry.\f
REFER\fto:\f Timing\fBelt \f(303-01F\fEngine\f-
\f2.0L\f
Dur\btorq-TDCi\f(85kW/115PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(103kW/140PS)\f-\fDW,\f
Emission\fRequirements:\fSt\bge\fIV,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
*
Noisy\frunning\for\f
engine\fnoiseEngine\fcomponents\f
Pistons.\f
Piston\frings.\f
Connecting\frod\fbig\fend,\f
m\bin\fbe\bring\for\fthrust\f
be\bring\fjourn\bls.\f
Connecting\frods\fbent\for\f
d\bm\bged.\f
*
-
-
-
-CHECK\fthe\fengine\fcomponents\ffor\fwe\br\for\f
d\bm\bge.\fM\bke\fsure\f\bll\fcomponents\f\bre\fwithin\f
specific\btion.\fINSTALL\fnew\fcomponents\f\bs\f
necess\bry.\fREFER\fto:\f
Specific\btions\f(303-01F\f
Eng
ine\f-\f2.0L\fDur\btorq-TDCi\f(85kW/115PS)\f-\f
DW/2.0L\fDur\btorq-TDCi\f(100kW/136PS)\f-\f
DW/2.0L\fDur\btorq-TDCi\f(103kW/140PS)\f-\f
DW,\fEmission\fRequirements:\fSt\bge\fIV,\f
Specific\btions).\f
*
Стр. 5 из
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05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G549215&gui...procarmanuals.com
http://vnx.su
NOTE:\fThe\fv\brying\fdesign\fof\fcompression\fchecking\fdevices\f\bnd\ffluctu\bting\fst\brter\fmotor\f
speeds\fnorm\blly\fonly\f\bllows\ffor\f\b\fcomp\brison\fto\fbe\fm\bde\fof\fthe\fcompression\fpressures\fin\f
\bll\fcylinders.\f1. 1.
Using\fd\bt\blogger\fin\fthe\f F
ord\fdi\bgnostic\fequipment,\fcheck\fth\bt\fthe\ffuel\fpressure\f
h\bs
\fdropped\fto\fzero\f\bnd\fth\bt\fthe\ffuel\ftemper\bture\fh\bs\feither\fre\bched\f\bmbient\f
temper\bture\for\fis\fbelow\f30°C,\fwhichever\fis\fthe\fgre\bter.\f
2. \b.
R\bise\f\bnd\fsupport\fthe\fvehicle.\fREFER\fto:\f L
ifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des
cription\f\bnd\fOper\btion).\f
3. 3.
Remove\fthe\fengine\fundershield.\f
4
. 4.
Remove\fthe\fr\bdi\btor\fundershield.\f
5
. 5.
Remove\fthe\fglow\fplug\frel\by.\f
6
. 6.
Lower\fthe\fvehicle.\f
7
. 7.
Remove\fthe\fcowl\fp\bnel\fgrille.\f\f
R
EFER\fto:\f Cowl\fP\bnel\fGrille \f(501-02\fFront\fEnd\fBody\fP\bnels,\fRemov\bl\f\bnd\f
In s
t\bll\btion).\f \f\f
\f\f
\f\f
Стр. 6 из
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05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G549215&gui...procarmanuals.com
http://vnx.su
8.NOTE:\fThe\fengine\fupper\fcover\fis\fheld\fin\fpl\bce\fby\f3\fb\bll\fclips.\fThe\fb\bll\fclips\f\bre\fnot\f
ve
rtic\bl,\fbut\f\bre\f\bngled\fb\bckw\brds\fby\f\bpproxim\btely\f20\fdegrees.\f
8. Loc\btion\fof\fthe\fengine\fupper\fcover\fb\bll\fclips.\f\f
9. CAUTION:\fCont\bct\fof\fthe\fengine\fupper\fcover\fwith\fthe\fcowl\fp\bnel\fm\by\fc\buse\f
d \b
m\bge\f(scr\btches)\fon\fthe\fengine\fupper\fcover.\fIf\fthe\f\bmbient\ftemper\bture\fis\fbelow\f
0°C,\fdet\bch\fthe\fengine\fupper\fcover\fwith\fextreme\fc\bution.\fF\bilure\fto\ffollow\fthis\f
instruction\fm\by\fc\buse\fthe\fengine\fupper\fcover\fto\fbe\fd\bm\bged.\f
NOTE:\fOnly\fremove\f\bnd\finst\bll\fthe\fengine\fupper\fcover\fin\fthe\fsequence\fshown.\f
9. Remove\fthe\fengine\fupper\fcover.\f
Det\bch\fthe\fengine\fupper\fcover\fb\bll\fclips\fin\fthe\fsequence\fshown.\f
1 0
. CAUTION:\fDo\fnot\fdisconnect\fthe\ffuel\finjection\fpump\felectric\bl\fconnectors\f\bnd\f
cr
\bnk\fthe\fengine.\f
10. Disconnect\fthe\ffuel\finjector\felectric\bl\fconnectors.\f
11. 11.
Remove\fthe\fexh\bust\fg\bs\frecircul\btion\f(EGR)\fcooler.\fREFER\fto:\f E
xh\bust\fG\bs\f
Rec
ircul\btion\f(EGR)\fCooler \f(303-08C\fEngine\fEmission\fControl\f-\f1.8L\fDur\btorq-TDCi
\f
(74kW/100PS)\f-\fLynx/1.8L\fDur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
12. 1\b.
Remove\fthe\fEGR\fv\blve.\fREFER\fto:\f E
xh\bust\fG\bs\fRecircul\btion\f(EGR)\fV\blve\f(303-
08D
\fEngine\fEmission\fControl\f-\f2.0L\fDur\btorq-TDCi\f(85kW/115PS)\f-\fDW/2.0L\f
\f\f
\f\f
\f\f
Стр. 7 из 13
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G549215&gui...procarmanuals.com
http://vnx.su
Dur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f(103kW/140PS)\f-\fDW,\fEmission\fRequirements:\fSt\bge\fIV,\fRemov\bl\f\bnd\fInst\bll\btion).\f
13. 13.
Remove\fthe\fglow\fplug\fpower\fsupply.\f
1
4. 14.
Remove\fthe\fglow\fplugs.\f
1
5. 15.
Inst\bll\fthe\fspeci\bl\ftool\f\bnd\f\b\fsuit\bble\fcompression\ftester\finto\fthe\fglow\fplug\fbore.\f
N
OTE:\fCr\bnk\fthe\fengine\fwith\fthe\fst\brter\fmotor\funtil\fth
e\fpointer\fon\fthe\fcompression\f
tester\fstops\frising.\f
16. 16.
C\brry\fout\fthe\fme\bsurement\fon\f\bll\fcylinders,\ffollowing\fthe\fme\bsuring\fequipment\f
m
\bnuf\bcturer's\finstructions.\f
17. 17.
Det\bch\fthe\fcompression\ftester\f\bnd\fthe\fspeci\bl\ftool.\f \f
\f
\f\f
\f\f
Стр. 8 из
13
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G549215&gui...procarmanuals.com
http://vnx.su
18.18.
Inst\bll\fthe\fglow\fplugs.\f
1
9. 19.
Inst\bll\fthe\fglow\fplug\fpower\fsupply.\f
2
0. \b0.
Inst\bll\fthe\fEGR\fv\blve.\f\f
R
EFER\fto:\f Exh\bust\fG\bs\fRecircul\btion\f(EGR)\fV\blve \f(303-
08D\fEngine\fEmission\fControl\f
-\f2.0L\fDur\btorq-TDCi\f(85kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f(100kW/136PS)\f-\f
DW/2.0L\fDur\btorq-TDCi\f(103kW/140PS)\f-\fDW,\fEmission\fRequirements:\fSt\bge\fIV,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
21. \b1.
Inst\bll\fthe\fEGR\fcooler.\fREFER\fto:\f E
xh\bust\fG\bs\fRecircul\btion\f(EGR)\fCooler\f(303-
08C
\fEngine\fEmission\fControl\f-\f1.8L\fDur\btorq-TDCi\f(74kW/100PS)\f-\fLynx/1.8L\f
Dur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\fInst\bll\btion).\f
22. \b\b.
Connect\fthe\ffuel\finjector\felectric\bl\fconnectors.\f
2
3. \b3.
Apply\fso\bp\fsolution\fto\fthe\fb\bll\fclip\fmountings\fin\fthe\fengine\fupper\fcover.\f
S
o\bp\fsolution\f(m\bximum\fconcentr\btion\fof\fso\bp\fin\fw\bter\f1:200).\f \f
\f
\f\f
\f\f
Стр. 9 из 13
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G549215&gui...procarmanuals.com
http://vnx.su
24.CAUTION:\fCont\bct\fof\fthe\fengine\fupper\fcover\fwith\fthe\fcowl\fp\bnel\fm\by\fc\buse\f
d\b
m\bge\f(scr\btches)\fon\fthe\fengine\fupper\fcover.\fF\bilure\fto\ffollow\fthis\finstruction\f
m\by\fc\buse\fthe\fengine\fupper\fcover\fto\fbe\fd\bm\bged.\f
\b4. Put\fthe\fengine\fcover\finto\finst\bll\btion\fposition\f\bnd\fclip\fit\fin\fpl\bce\fby\fpressing\f\bt\f
th
e\fpl\bces\fshown.\f
M\bke\fsure\fth\bt\fthe\fengine\fupper\fcover\fis\ffully\feng\bged\fin\fthe\f\bre\b\fof\fthe\ffuel\ffilter,\f
if\fnecess\bry\f\bpply\fmore\fpressure\fin\fthe\f\bre\bs\fshown.\f
25. \b5.
Inst\bll\fthe\fcowl\fp\bnel\fgrille.\f\f
R
EFER\fto:\f Cowl\fP\bnel\fGrille \f(501-02\fFront\fEnd\fBody\fP\bnels,\fRemov\bl\f\bnd\f
Ins
t\bll\btion).\f
26. \b6.
R\bise\f\bnd\fsupport\fthe\fvehicle.\fREFER\fto:\f L
ifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des
cription\f\bnd\fOper\btion).\f
27. \b7.
Inst\bll\fthe\fglow\fplug\frel\by.\f
2
8. \b8.
Inst\bll\fthe\fr\bdi\btor\fundershield.\f
\f\f
\f\f
\f\f
Стр. 10 из 13
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G549215&gui...procarmanuals.com
http://vnx.su
29.\b9.
Inst\bll\fthe\fengine\fundershield.\f
3
0. 30.
Lower\fthe\fvehicle.\f
3
1. 31.
Reset\fthe\fPCM\ff\bult\fmemory.\f
M
easure the oil pressure (\b1 113 0)
The\foil\fpressure\fdepends\fon\fv\brious\ff\bctors\f(engine\fspeed,\foil\ftemper\bture,\foil\fviscosity,\f
\bmount\fof\foil\ffilter\fcont\bmin\btion\fetc.).\f
Measure the oil pressure
1. 1.
R\bise\f\bnd\fsupport\fthe\fvehicle.\fREFER\fto:\f L
ifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des
cription\f\bnd\fOper\btion).\f
2. \b.
Remove\fthe\fengine\funder\fshield.\f
3
. 3.
Disconnect\fthe\foil\fpressure\fswitch\felectric\bl\fconnector.\f \f
\f
\f\f
\f\f
Стр. 11 из
13
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G549215&gui...procarmanuals.com
http://vnx.su