B-MAX 2012 – Engine – 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost (90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) – Engine – Visual Inspection Chart

Engine - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost (90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - EngineB-MAX 2012.75 (01/2012-)
Diagnosis and Testing

Ford diagnostic equipment
Ultraviolet (UV) leak tester
Materials
Name
Specification
Adhesive - Loctite 243
WSK-M2G349-A7 
  1. Verify the customer concern by operating the system.

  1. Visually inspect for obvious signs of mechanical or electrical damage.

Visual Inspection Chart

MechanicalElectrical
  • Coolant leaks
  • Oil leaks
  • Fuel system leaks
  • Visibly damaged or worn parts
  • Loose or missing nuts or bolts
  • Fuse(s)
  • Loose or corroded connector(s)
  • Powertrain control module (PCM)
  • Damaged or worn switch(es)
  1. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.

  1. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart.

Symptom Chart

SymptomPossible SourcesAction
Loss of oil
*
Oil leaks on components that are either coated in oil themselves or on components local to them.
*
CHECK for evidence of oil leaks on components. Use an ultraviolet (UV) leak tester if an oil leak is not evident. INSTALL new gaskets or components as required.
*
Internal or external leak at the engine oil cooler.
*
CHECK the coolant expansion tank for a film of oil on the coolant surface. INSTALL a new engine oil cooler or engine oil cooler gasket.
*
Crankshaft front seal.
*
INSTALL a new crankshaft front seal.
*
Leaks from oil carrying components or basic engine.
*
CHECK for cracks in oil carrying components of the basic engine by means of an ultraviolet UV leak tester. INSTALL new components or seals as necessary.
Oil consumption
*
Use of the wrong type of engine oil.
*
INSTALL a new engine oil filter and the correct engine oil.
REFER to: Specifications (303-01A Engine - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost (90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY), Specifications).
*
Faulty positive crankcase ventilation (PCV) system.
-
Hoses or ventilation or breather valves are blocked. This causes excessive pressure in the crankcase which causes more oil to enter the combustion chamber.
-
PCV oil separator is faulty and engine oil can enter the combustion chamber through the intake manifold.
*
CHECK if the PCV system is operating correctly and repair as necessary.
REFER to: Engine Emission Control (303-08A Engine Emission Control - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost (90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY), Diagnosis and Testing).
*
Damaged gaskets or mating surfaces.
-
Cylinder head gasket is damaged or mating face are warped.
*
Remove the cylinder head. CHECK the mating faces, cylinder head gasket and the evenness of the cylinder head and engine block mating faces.
*
Valve stem seals.
-
Engine oil can enter the combustion chamber between the valve stem and the valve stem guide.
*
INSTALL new valve stem seals.
*
Piston ring or cylinder liner wear.
*
INSTALL new components as necessary.
*
Damaged cylinder liners or excessive clearance of engine components.
-
Pistons
-
Piston rings (clearance in groove and end gap)
-
Cylinder liners
*
CHECK the running surfaces and clearances of the individual engine components. INSTALL new components as necessary. INSTALL a new cylinder block if necessary.
*
CHECK the pistons.
*
CHECK the piston rings.
Coolant consumption
*
Cooling system components.
*
CHECK the coooling system.
REFER to: Engine Cooling (303-03A Engine Cooling - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost (90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY), Diagnosis and Testing).
*
Engine oil cooler.
*
INSTALL a new engine oil cooler.
*
Damaged gaskets or warped mating faces.
*
Remove the cylinder head. CHECK the mating faces, cylinder head gasket and the evenness of the cylinder head and engine block mating faces.
*
Cracks or fractures in engine components surrounded by coolant, such as cylinder liners and cylinder head combustion chamber.
*
DETERMINE the damaged engine component(s) and install new component(s) as necessary.
Engine does not crank
*
Passive anti-theft system (PATS).
*
CHECK the PATS LED extinguishes within 3 seconds when the ignition is turned on.
REFER to: Passive Anti-Theft System (PATS) (419-01B Passive Anti-Theft System (PATS), Diagnosis and Testing).
*
Starting system.
*
CHECK the starting system.
REFER to: Starting System (303-06A Starting System - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost (90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY), Diagnosis and Testing).
*
Ignition switch.
*
REFER to the Wiring Diagrams.
*
Powertrain control module (PCM).
*
Carry out a full engine diagnosis using the symptom based diagnostic menu in the Ford diagnostic equipment.
Engine cranks but does not start
*
Fuel tank fuel level low.
*
CHECK the fuel level.
*
Fuel filter blocked.
*
INSTALL a new fuel filter.
*
Engine intake air system.
*
CHECK the intake air system.
REFER to: Intake Air Distribution and Filtering (303-12A Intake Air Distribution and Filtering - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost (90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY), Diagnosis and Testing).
*
Engine management system.
*
CHECK the engine management system.
REFER to: Electronic Engine Controls (303-14A Electronic Engine Controls - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost (90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY), Diagnosis and Testing).
*
Ignition system.
*
CHECK the ignition system.
REFER to: Engine Ignition (303-07A Engine Ignition - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost (90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY), Diagnosis and Testing).
*
Incorrect valve timing.
*
CHECK and adjust the valve timing.
REFER to: Timing Belt (303-01A Engine - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost (90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY), Removal and Installation).
*
Broken or damaged timing belt or pulley(s).
*
CHECK the timing belt and pulley(s). INSTALL new components as necessary.
REFER to: Timing Belt (303-01A Engine - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost (90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY), Removal and Installation).
Very poor power output or fuel consumption too high or engine running rough
*
Fuel system.
*
CHECK the fuel system.
REFER to: Fuel Charging and Controls (303-04A Fuel Charging and Controls - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost (90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY), Diagnosis and Testing).
*
Engine intake air system.
*
CHECK the intake air system.
REFER to: Intake Air Distribution and Filtering (303-12A Intake Air Distribution and Filtering - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost (90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY), Diagnosis and Testing).
*
Exhaust system blocked.
*
CHECK the exhaust system.
*
Engine management system.
*
CHECK the engine management system.
REFER to: Electronic Engine Controls (303-14A Electronic Engine Controls - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost (90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY), Diagnosis and Testing).
*
Fault in ignition system.
*
CHECK the ignition system.
REFER to: Engine Ignition (303-07A Engine Ignition - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost (90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY), Diagnosis and Testing).
*
Incorrect valve timing.
*
CHECK and adjust the valve timing.
REFER to: Timing Belt (303-01A Engine - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost (90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY), Removal and Installation).
*
Broken or damaged timing belt or pulley(s).
*
CHECK the timing belt and pulley(s). INSTALL new components as necessary.
REFER to: Timing Belt (303-01A Engine - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost (90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY), Removal and Installation).
Noisy running
*
Engine auxiliary components loose or damaged.
*
CHECK engine auxiliary components for damage or looseness.
Noisy running, misfiring, backfiring or knocking
*
Incorrect fuel
*
DETERMINE which type of fuel was last put in the tank (note the country specific fuel specifications).
*
Water in fuel or fuel contaminated.
*
CHECK the fuel system for water or other contamination.
*
Incorrect valve timing.
*
CHECK and adjust the valve timing.
REFER to: Timing Belt (303-01A Engine - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost (90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY), Removal and Installation).
*
Broken or damaged timing belt or pulley(s).
*
CHECK the timing belt and pulley(s). INSTALL new components as necessary.
REFER to: Timing Belt (303-01A Engine - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost (90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY), Removal and Installation).
Noisy running or valve train noise
*
Valve clearance too large due to faulty valve tappets or worn valve train components.
*
CHECK and adjust the valve clearances.
*
Timing belt damaged.
*
INSTALL a new timing belt.
REFER to: Timing Belt (303-01A Engine - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost (90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY), Removal and Installation).
*
Timing belt incorrectly tensioned.
*
CHECK the timing belt tensioner. INSTALL a new timing belt tensioner or timing belt as necessary.
REFER to: Timing Belt (303-01A Engine - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost (90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY), Removal and Installation).
Noisy running or engine noise
*
Engine components
-
Pistons
-
Piston rings
-
Connecting rod big end, main bearing or thrust bearing journals
-
Connecting rods bent or damaged.
*
CHECK the engine components for wear or damage. Make sure all components are within specification. INSTALL new components as necessary.

Engine - Oil Leaks

NOTE: Before installing new gaskets or seals, make sure that the fault is clearly established.

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

Ultraviolet (UV) Testing

  1. Clean the engine and transmission with a suitable cleaning fluid.

  1. Pour the UV-test fluid in accordance with the quantity specified by the manufacturer through the oil filler neck into the engine and install the oil filler cap.

warningWARNING: Vehicles with manual transaxle, shift the transaxle into Neutral. Failure to follow this instruction may result in personal injury.

  1. Start the engine and let it run for about five minutes.

  1. Switch off the engine.

NOTE: If no leak can be found, road test the vehicle under various loads and check the engine for leaks again.

  1. Check the engine for oil leaks using a suitable UV lamp.

  1. Rectify any leaks found and check the engine for oil leaks.

Measure the compression pressure

warningWARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable mixtures are always present and can ignite. Failure to follow these instructions may result in personal injury.

NOTE: The powertrain control module (PCM) receives an error message when the fuel pump relay is removed or electrical components are disconnected. This error message must be deleted from the fault memory using the Ford diagnostic equipment after completing the compression test.

NOTE: Valve clearance must be set correctly before performing a compression test. Make sure the engine is at the normal operating temperature.

NOTE: The varying design of compression checking devices and fluctuating starter motor speeds normally only allows for a comparison to be made of the compression pressures in all cylinders.

NOTE: The readings from the compression pressure check should be used as an indication of cylinder balance. If one or more of the readings is significantly lower than the others, investigate that particular cylinder for concerns.

  1. Open the CJB and remove fuse 56 - fuel pump relay.

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  1. Start and run the engine at idle speed until the engine stops.

  1. Remove the engine cover.

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  1. Remove the ignition coil-on-plugs.

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  1. Using a suitable tool, remove the spark plugs.

NOTE: Operate the starter motor with wide open throttle until the reading on the compression tester stops rising.

  1. Carry out the measurement in accordance with the instructions supplied with the measuring device on every cylinder using a suitable compression pressure recorder with a suitable adapter.

  1. Using a suitable tool, install the spark plugs and tighten to 15 Nm.

  1. NOTE: Install all the bolts finger tight before final tightening.

    Install the ignition coil-on-plugs.

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  1. Tighten the ignition coil-on-plug bolts to 10 Nm.

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  1. Install the engine cover.

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  1. Install fuse 56 (fuel pump relay) and close the central junction box (CJB).

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  1. Using the Ford diagnostic equipment, clear the DTC(s) from the PCM.

Measure the oil pressure

NOTE: The oil pressure depends on various factors (engine speed, oil temperature, oil viscosity, extent of oil filter contamination).

NOTE: Measure the oil pressure at the specified engine speed.

NOTE: The graphics used are for illustration purposes only.

  1. Raise and support the vehicle.
    REFER to:
    Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).

  1. Disconnect the oil pressure switch electrical connector from the oil pressure switch.

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  1. Remove the oil pressure switch.

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  1. Attach the oil pressure gauge with the oil pressure gauge connector to the oil pressure switch bore, and position it to allow reading from above.

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  1. Lower the vehicle.

  1. NOTE: Measure the oil pressure at an oil temperature of 80°C.

    NOTE: Oil pressure at 2000 rpm: 2.0 bar.

    Measure the oil pressure.

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  1. Raise and support the vehicle.
    REFER to:
    Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).

  1. Detach the oil pressure gauge and connector from the oil pressure switch bore.

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  1. Install the oil pressure switch.

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  1. Connect the oil pressure switch electrical connector to the oil pressure switch.

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  1. Lower the vehicle.

Valve train analysis - static (engine off)

Remove the valve cover.
REFER to:
Valve Cover (303-01A Engine - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost (90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY), Removal and Installation).

Check all components of the valve train for damage and wear. Make sure that only original components are installed and that all nuts and bolts are tightened to the specified torque.

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