Ford Escape Quiz
Powertrain

Diagnosis and Testing - Engine

In this manual: Powertrain
General Information — 26Chassis — 160Powertrain — 323Electrical — 356Body and Paint — 290
~39min read

Symptom Charts

Symptom Chart - Gasoline Engine Operation

The diagnosis in this manual assumes a certain level of skill and knowledge of Ford-approved diagnostic procedures.
REFER TO: Diagnostic Methods (100-00 General Information, Description and Operation).

Condition Action
Excessive Engine Oil Consumption GO to Pinpoint Test A
Coolant Loss GO to Pinpoint Test B
Coolant in Engine Oil GO to Pinpoint Test B
Engine Emits Excessive Blue Smoke GO to Pinpoint Test C
Engine Emits Excessive White Smoke GO to Pinpoint Test C
Engine Emits Excessive Black Smoke GO to Pinpoint Test C
Engine Emits Excessive Gray Smoke GO to Pinpoint Test C
Loss of Power, Poor Idle or Rough Idle GO to Pinpoint Test D
Low or High Engine Oil Pressure GO to Pinpoint Test E

Symptom Chart - NVH

The diagnosis in this manual assumes a certain level of skill and knowledge of Ford-approved diagnostic procedures.
REFER TO: Diagnostic Methods (100-00 General Information, Description and Operation).

Condition Action
Engine Noise - Upper Engine GO to Pinpoint Test F
Engine Noise - Low Engine GO to Pinpoint Test F
Engine Noise - Front of Engine GO to Pinpoint Test F
Engine Noise - Rear of Engine GO to Pinpoint Test F

Pinpoint Tests


PINPOINT TEST A: EXCESSIVE ENGINE OIL CONSUMPTION

Possible Sources

  • Gasket
  • Seal
  • Turbocharger Oil Drain Tube Restricted or Blocked
  • Air Intake Hoses and Tubes Damaged or Deformed
  • Turbocharger Seals
  • PCV System Inoperative
  • Incorrect Engine Oil
  • Worn Valve Stem Seal
  • Worn Valve Stem or Valve Guide
  • Stuck Piston Ring
  • Worn Piston Ring Groove
  • Damaged Oil Control Ring
  • Worn Piston or Cylinder Bore
A1 CHECK ENGINE OIL CONSUMPTION FOR ACCEPTABLE LEVEL
  • Perform the engine oil consumption test.
    REFER TO: Oil Consumption Check (303-00 Engine System - General Information, General Procedures).

Is engine oil consumption within acceptable limits?
Yes Vehicle operating correctly.
No GO to A2
A2 CHECK PCM (POWERTRAIN CONTROL MODULE) DIAGNOSTIC TROUBLE CODES (DTCS)
  • The ignition is on.
  • Perform PCM Self-Test KOEO and KOER.

Are any diagnostic trouble codes (DTCs) present?
Yes REFER to the Master DTC Chart to diagnose the DTC present.
No GO to A3
A3 CHECK FOR EXTERNAL ENGINE OIL LEAK
  • Ignition OFF.
  • Inspect the engine for signs of engine oil leakage.
    REFER TO: Oil Leak Check (303-00 Engine System - General Information, General Procedures).

Are there any visible engine oil leaks?
Yes REPAIR as necessary.
No GO to A4
A4 CHECK VEHICLE SERVICE HISTORY
  • Check the vehicle service history and confirm that the documentation specifies the correct engine oil being used.

Is the correct engine oil being used based on the vehicle service history?
Yes GO to A5
No REPLACE the engine oil and filter using the correct engine oil specification. REFER to the Specifications procedure in Section 303-01 for the engine being diagnosed. REFER to the appropriate section in Group 303 for the procedure.
A5 CHECK THE AIR INTAKE SYSTEM
  • Inspect the air intake system and confirm that all hoses and tubes are securely connected and undamaged.

Is the air intake system undamaged and all connections secure?
Yes GO to A6
No REPAIR as necessary.
A6 CHECK THE PCV (POSITIVE CRANKCASE VENTILATION) SYSTEM
  • Inspect the PCV system and confirm that all hoses and tubes are securely connected and undamaged, and that the PCV valve is operating correctly.

Is the PCV system undamaged, all connections secure and the PCV valve operating correctly?
Yes GO to A7
No REPAIR as necessary.
A7 CHECK FOR ENGINE OIL IN THE COOLING SYSTEM
  • Check for engine oil in the cooling system.

Is engine oil found in the cooling system?
Yes If equipped with an engine oil cooler, GO to A8.
If not equipped with an engine oil cooler, GO to A11.
No If equipped with a turbocharger, GO to A9.
If not equipped with a turbocharger, GO to A11.
A8 CHECK THE ENGINE OIL COOLER
  • Inspect the engine oil cooler and seals for damage.

Is the engine oil cooler and seals undamaged?
Yes GO to A9
No REPAIR as necessary.
A9 CHECK THE TURBOCHARGER(S)
  • Inspect the turbocharger(s) for signs of oil leakage past the seal into the air intake or exhaust system. REFER to the Diagnosis and Testing procedure in Section 303-04 Turbocharger for the engine being diagnosed. REFER to the appropriate section in Group 303 for the procedure.

Is there oil leakage from the turbocharger into the intake or exhaust?
Yes REPAIR as necessary. REFER to Removal and Installation in the Turbocharger section 303-04 for the engine being diagnosed. REFER to the appropriate section in Group 303 for the procedure.
No GO to A10
A10 CHECK THE SPARK PLUGS
  • Inspect the spark plugs for oil fouling.
    REFER TO: Spark Plug Check (303-00 Engine System - General Information, General Procedures).
    Using a borescope, inspect the pistons for oil deposits.

Are there oil deposits on the spark plugs or pistons, or signs that the engine is burning oil?
Yes GO to A11
No The engine is not the source of the concern. Check for other possible sources of oil consumption. Recheck oil consumption for acceptable level. Check the PCV system and turbochargers.
A11 CHECK THE CYLINDER HEAD GASKET, CYLINDER HEAD SURFACE AND ENGINE BLOCK SURFACE
  • Remove the cylinder head(s). Inspect the cylinder head gasket, cylinder head and engine block for damage.
    REFER TO: Engine Block Distortion (303-00 Engine System - General Information, General Procedures).
    and REFER TO: Cylinder Head Distortion (303-00 Engine System - General Information, General Procedures).

Are the engine block and cylinder head(s) undamaged?
Yes GO to A12
No REPAIR as necessary.
A12 CHECK THE VALVE STEM SEALS
  • Remove the cylinder head(s). Remove the valves from the cylinder head and inspect the valve stem seals for damage, excessive wear and proper sealing.

Are the valve stem seals undamaged?
Yes Install new valve stem seals. REFER to Disassembly and Assembly of Sub-Systems - Cylinder Head Procedure for the engine being diagnosed. REFER to the appropriate section in Group 303 for the procedure.
No GO to A13
A13 CHECK THE VALVES
  • Inspect the valves for excessive oil or carbon buildup. Inspect the valves, valve stems and valve guides for damage.
    REFER TO: Valve Guide Inside Diameter (303-00 Engine System - General Information, General Procedures).
    REFER TO: Valve Stem Diameter (303-00 Engine System - General Information, General Procedures).

Are the valves damaged or excessively worn?
Yes INSTALL new valve seals, valves or a new cylinder head.
No GO to A14
A14 CHECK THE ENGINE
  • Disassemble the engine. Inspect the pistons and piston rings for excessive carbon buildup. Inspect the pistons, piston rings and cylinder bores for excessive wear or damage.
    REFER TO: Piston Inspection (303-00 Engine System - General Information, General Procedures).
    REFER TO: Piston Ring Gap (303-00 Engine System - General Information, General Procedures).
    REFER TO: Cylinder Bore Taper (303-00 Engine System - General Information, General Procedures).

Are pistons or piston rings damaged, excessively worn or excessively carboned?
Yes REPAIR as necessary.
No INSTALL a new short block.
PINPOINT TEST B: ENGINE COOLANT LOSS

Possible Sources

  • Seal
  • Coolant Hose
  • Engine Oil Cooler
  • Coolant Pump
  • Radiator
  • Heater Core
  • Front Engine Cover
  • Exhaust Gas Recirculation (EGR) Cooler
  • Cylinder Head Gasket
  • Cylinder head cover
  • Cylinder block

Visual Inspection and Pre-checks

  • Check for engine coolant leaks around sealed areas, such as the coolant pump, intake manifold and cylinder heads.
  • Inspect the coolant hoses and tubes for damage.
  • Inspect the coolant hose and tube connections and make sure they are securely connected.
B1 CHECK FOR OBVIOUS SIGNS OF A PROBLEM
  • Ignition OFF.
  • Inspect the engine and cooling system for signs of external coolant leakage. REFER TO the Diagnosis and Testing procedure in Section 303-03 for the engine being diagnosed. Refer to the appropriate section in Group 303 for the procedure.

Are there any external coolant leaks?
Yes REPAIR as necessary.
No GO to B2
B2 CHECK FOR EXCESSIVE EXHAUST SMOKE
  • Start the engine.
  • NOTE: Coolant entering the cylinders causes white smoke from the exhaust. Allow the engine to reach normal operating temperature. Inspect the exhaust pipe for excessive white smoke.

Is there excessive white smoke from the exhaust?
Yes GO to B6
No GO to B3
B3 CHECK FOR COOLANT IN THE ENGINE OIL
  • Ignition OFF.
  • Remove and inspect the engine oil dipstick for signs of coolant in the oil.

Is coolant present in the engine oil?
Yes If the engine is equipped with an engine oil cooler, GO to B4.
If the engine is not equipped with an engine oil cooler, GO to B5.
No GO to B6
B4 CHECK THE ENGINE OIL COOLER
  • Inspect the engine oil cooler and seals for damage.

Is the engine oil cooler and seals undamaged?
Yes GO to B5
No REPAIR as necessary.
B5 CHECK THE FRONT COVER
  • Remove the front cover. REFER TO the Engine Front Cover procedure in 303-01 for the engine being diagnosed. Refer to the appropriate section in Group 303 for the procedure. Inspect the front cover seals for damage and signs of coolant entering the engine oil.

Are the front cover seals or sealing surfaces damaged, allowing coolant to enter the engine oil?
Yes INSTALL new engine front cover seals or a new front cover. REFER TO the Engine Front Cover procedure in 303-01 for the engine being diagnosed. Refer to the appropriate section in Group 303 for the procedure.
No GO to B6
B6 CHECK FOR COOLANT LEAKAGE INTO THE CYLINDERS
  • Remove the spark plugs. REFER TO Section 303-07 for the engine being diagnosed. Refer to the appropriate section in Group 303 for the procedure. Inspect the spark plugs for signs of coolant intrusion.
    REFER TO: Spark Plug Inspection (303-00 Engine System - General Information, General Procedures).
    Using a borescope, inspect the cylinders and pistons for signs of coolant intrusion.

Are there signs of coolant entry on the spark plugs or cylinders?
Yes GO to B7
No GO to B8
B7 CHECK THE EXHAUST GAS RECIRCULATION (EGR) COOLING SYSTEM
  • NOTE: On engines equipped with an EGR cooler, hot exhaust gas is cooled by a cooler that uses engine coolant. Coolant can be lost to the EGR system if the cooler is damaged. Inspect the exhaust gas recirculation system for damage that allows coolant intrusion. If necessary, REMOVE any EGR components for access to inspect the components for signs of coolant intrusion. For information on the engine being diagnosed, refer to Section 303-08.

Is coolant leaking into the EGR system?
Yes REPAIR as necessary.
No GO to B8
B8 CHECK THE CYLINDER COMPRESSION AND LEAKAGE
  • Ignition OFF.
  • Perform the cylinder compression and cylinder leakage tests. Inspect the test results for signs of damage to the cylinder head gasket or cylinder head sealing surfaces. Check the coolant for bubbles caused by air entering the cooling system from compression.
    REFER TO: Cylinder Compression and Cylinder Leakage Test (303-00 Engine System - General Information, General Procedures).

Does the compression check or cylinder leakage test indicate a loss of compression or a cylinder leak into the cooling system?
Yes GO to B9
No Condition causing coolant loss not present. Attempt to recreate the conditions that cause coolant loss. Allow the engine to cool to ambient temperature, or install the spark plugs and run the engine until it reaches normal operating temperature. Recheck cylinder compression and cylinder leakage. Check for other possible sources of coolant loss. REFER to the Diagnosis and Testing procedure in Section 303-03 for the engine being diagnosed. Refer to the appropriate section in Group 303 for the procedure.
B9 CHECK THE ENGINE
  • Remove the cylinder heads. REFER to the cylinder head procedure(s) in 303-01 for the engine being diagnosed. Refer to the appropriate section in Group 303 for the procedure. Inspect the cylinder head gasket(s) for signs of damage or failure. Inspect the cylinder block and cylinder head(s) for damage.
    REFER TO: Cylinder Block Distortion (303-00 Engine System - General Information, General Procedures).
    and REFER TO: Cylinder Head Distortion (303-00 Engine System - General Information, General Procedures).

Are the cylinder head gasket(s), cylinder head(s) or cylinder block damaged?
Yes REPAIR as necessary.
No Install a new long block.
PINPOINT TEST C: ENGINE EXHAUST SMOKE

Possible Sources

  • Condensation accumulates in the exhaust
  • air cleaner element
  • Fuel Injection System
  • Coolant entering the combustion chamber
  • Excessive Engine Oil Consumption
C1 CHECK FOR NORMAL OPERATING CONDITION
  • Start the engine while observing the exhaust outlet and allow the engine to reach normal operating temperature.

Is water vapor (white smoke) present and does the visible water vapor dissipate over time as the engine warms to normal operating temperature?
Yes If no blue or black smoke is present, the vehicle is operating normally.
If blue or black smoke is present, GO to C2.
No GO to C2
C2 CHECK THE PCM (POWERTRAIN CONTROL MODULE) FOR DIAGNOSTIC TROUBLE CODES (DTCS)
  • The ignition is on.
  • Perform PCM Self-Test KOEO and KOER.

Are any diagnostic trouble codes (DTCs) present?
Yes REFER to the Master DTC Chart to diagnose the DTC present.
No If white smoke is the concern, GO to Pinpoint Test B.
If black smoke is the concern, GO to C3.
If blue or gray smoke is the concern, GO to Pinpoint Test A.
C3 CHECK THE AIR CLEANER ELEMENT
  • Inspect the air cleaner element.

Is the air cleaner element relatively clean and free of debris?
Yes GO TO C4
No INSTALL a new air cleaner element.
C4 CHECK THE FUEL SYSTEM
  • Check the fuel system for normal operation. REFER to the Diagnosis and Testing procedures in 303-04 Fuel Charging and Controls for the engine being diagnosed. Refer to the appropriate section in Group 303 for the procedure.

Is the fuel system operating correctly?
Yes The problem is currently not present or the fuel system is not the cause of the concern. Review the customer concern and symptom details.
No REPAIR as necessary.
PINPOINT TEST D: LOSS OF POWER, POOR IDLE OR ROUGH IDLE

Possible Sources

  • Accessory Drive Concern
  • Air Intake System Concern
  • Brake System Concern
  • Cooling system problem
  • Exhaust System Concern
  • Fuel System Concern
  • Ignition System Concern
  • Throttle Body Concern
  • Lubrication System Concern
  • Turbocharger Concern
  • Turbocharger Wastegate
  • Transmission System Concern
  • Clutch System Concern
  • Intake or Exhaust Valve Concern
  • Valve Spring Concern
  • Valve Lifter
  • Camshaft
  • Cylinder Head Gasket
  • Cylinder head cover
  • Piston or Piston Ring Concern

Visual Inspection and Pre-checks

  • Make sure the accessory drive operates correctly.
  • Make sure the brake system operates correctly.
  • Make sure the fuel system has no leaks.
  • Make sure the throttle body is not damaged.
  • Make sure the engine oil level is correct.
  • Make sure the transmission operates correctly.
  • Make sure the clutch system (if equipped) operates correctly.
D1 CHECK THE PCM (POWERTRAIN CONTROL MODULE) FOR DIAGNOSTIC TROUBLE CODES (DTCS)
  • The ignition is on.
  • Perform PCM Self-Test KOEO and KOER.

Are any diagnostic trouble codes (DTCs) present?
Yes REFER to the Master DTC Chart to diagnose the DTC present.
No GO to D2
D2 CHECK FOR PREVIOUS SIMULTANEOUS BRAKE PEDAL AND ACCELERATOR PEDAL APPLICATION
  • Check the following parameter identifications (PIDs) for simultaneous brake pedal and accelerator pedal application:

    • Access the PCM and monitor the BRKOVR_ACTION PID

    • Access the PCM and monitor the BRKOVRD_POSS PID

    • Access the PCM and monitor the DIST_BRKOVRD (km) PID


Is there an indication of simultaneous application of both pedals?
Yes ADVISE the vehicle owner that simultaneous brake pedal and accelerator pedal operation activates the brake over accelerator feature.
No GO to D3
D3 CHECK THE AIR CLEANER
  • Inspect the air cleaner.

Is the air cleaner clogged?
Yes REPLACE the air cleaner. Check the system for normal operation.
No GO to D4
D4 CHECK THE AIR INTAKE SYSTEM
  • Inspect the air intake system, air cleaner and CAC components, ducts, pipes and hoses. Make sure all components are installed correctly and securely. Make sure all components are aligned correctly. Check for damage that could cause an air leak leading to a loss of boost. For additional information, REFER to 303-12 Engine Air Intake Distribution and Filtration System for the engine being diagnosed. Refer to the appropriate section in Group 303 for the procedure.

Are there any leaks in the air intake system?
Yes Repair as necessary. Refer to 303-12 Intake Air Distribution and Filtering System for the diagnosed engine. Refer to the appropriate section in Group 303 for the procedure.
No GO to D5
D5 CHECK FOR VACUUM LEAKS
  • Check for vacuum leaks.
  • Perform the intake manifold vacuum test, if necessary.
    REFER TO: Intake Manifold Vacuum Test (303-00 Engine System - General Information, General Procedures).
    Use the intake manifold vacuum test procedure to determine possible causes of the concern.

Are vacuum leaks present?
Yes REPAIR as necessary.
No GO to D6
D6 CHECK INTAKE MANIFOLD LEAKS
  • Check the intake manifold for vacuum leaks or damage.

Does the intake manifold show leaks or damage?
Yes REPAIR as necessary.
No GO to D7
D7 CHECK THE EXHAUST SYSTEM
  • Check the exhaust system for restrictions or damage. Refer to the Exhaust System 309-00 section for the diagnosed engine. Refer to the appropriate section in Group 309 for the procedure.

Is the exhaust system restricted or damaged?
Yes Repair as necessary. Refer to Exhaust Pipe 309-00 for the diagnosed engine system section. Refer to the appropriate section in Group 309 for the procedure.
No GO to D8
D8 CHECK FOR OVERHEATING
  • Inspect the engine and cooling system for the cause of overheating. Refer to the diagnosis and testing procedure in section 303-03 for the diagnosed engine. Refer to the appropriate section in Group 303 for the procedure.

Is the engine overheating?
Yes REPAIR as necessary.
No GO to D9
D9 CHECK THE IGNITION SYSTEM
  • Inspect the ignition system. Refer to the diagnosis and testing procedure in section 303-07 for the diagnosed engine. Refer to the appropriate section in Group 303 for the procedure.

Are there ignition system concerns?
Yes REPAIR as necessary.
No GO to D10
D10 CHECK COMPRESSION AND CYLINDER LEAKAGE
  • Ignition OFF.
  • Remove the spark plugs. Refer to section 303-07 for the diagnosed engine. Refer to the appropriate section in Group 303 for the procedure. Inspect the spark plugs for signs of inefficient combustion.
    REFER TO: Spark Plug Inspection (303-00 Engine System - General Information, General Procedures).
    Use the spark plug inspection procedure to determine possible causes of the concern.
  • Perform the compression and cylinder leakage tests. Check the test results for signs of cylinder head gasket damage, cylinder head sealing surface damage, loss of compression or blow-by. Check the coolant for bubbles caused by air entering the cooling system from combustion.
    REFER TO: Compression and Cylinder Leakage Test (303-00 Engine System - General Information, General Procedures).

Does the compression test or cylinder leakage test indicate loss of compression or excessive cylinder leakage?
Yes GO to D15
No GO to D11
D11 CHECK THE FUEL SYSTEM
  • Inspect the fuel system. Refer to the diagnosis and testing procedure in section 303-04 Fuel or 310-00 for the diagnosed engine. Refer to the appropriate section in Group 303 for the procedure. Refer to the appropriate section in Group 310 for the procedure.

Is the fuel system operating correctly?
Yes GO to D12
No REPAIR as necessary.
D12 CHECK THE FUEL PRESSURE
  • Check the fuel pressure. Refer to the fuel system pressure test procedure in section 310-00 for the diagnosed engine. Refer to the appropriate section in Group 310 for the procedure. Compare the fuel pressure to the specification given in the Specifications procedure 310-00.
  • Draw a fuel sample. Check the fuel for contamination.

Is the fuel pressure within specification and free of contamination?
Yes GO to D13
No REPAIR as necessary or DRAIN the fuel and fill the fuel tank with good quality fuel.
D13 CHECK THE ENGINE OIL PRESSURE
  • Check the engine oil pressure.
    REFER TO: Oil Pressure Test (303-00 Engine System - General Information, General Procedures).
    Compare the engine oil pressure gauge reading to the engine oil pressure specification in the Specifications procedure 303-01 for the diagnosed engine. Refer to the appropriate section in Group 303 for the procedure.

Is the engine oil pressure within specification?
Yes GO to D14
No If concerned about the engine oil pressure, GO to Pinpoint Test E.
D14 CHECK THE TURBOCHARGER(S)
  • Inspect the turbocharger(s) for damage that may cause loss of boost. GO to the diagnosis and testing procedure in 303-04 Turbocharger section for the diagnosed engine. Refer to the appropriate section in Group 303 for the procedure.

Are the turbocharger(s) damaged?
Yes INSTALL a new turbocharger. REFER TO the Removal and Installation procedure in section 303-04 Turbocharger for the diagnosed engine. Refer to the appropriate section in Group 303 for the procedure.
No GO to D15
D15 CHECK THE VALVE TRAIN COMPONENTS
  • Remove the front engine cover. Inspect the timing components for excessive wear or damage that may cause concern. Check the timing chain or belt for stretch. Check the timing guides for excessive wear. Check the tensioner plungers for over-extension. Inspect the VCT unit(s) for damage or excessive wear.

Are timing drive components damaged?
Yes INSTALL new timing drive components.
No GO to D16
D16 CHECK THE VALVE FOR DAMAGE
  • Remove the valve cover(s). Visually inspect the camshafts and valvetrain for obvious signs of excessive wear or damage. Check for broken valve springs, damaged valve seals, missing or damaged valve keepers, or bent valves.

Are valve train components damaged?
Yes INSTALL new components.
No GO to D17
D17 PERFORM VALVETRAIN ANALYSIS
  • Perform the valvetrain analysis.
    REFER TO: Valvetrain Analysis - 2 L EcoBoost (177 kW/240 L hp) – MI4/2.5 L Duratec – Hybrid (121 kW/164 L hp) (BG) (303-00 Engine System - General Information, General Procedures).
    Compare the camshaft lift to the specifications in Section 303-01 for the engine being diagnosed. Refer to the appropriate section in Group 303 for the procedure.

Camshaft lift and valve clearance within specification?
Yes GO to D18
No ADJUST the valve clearance. If necessary, INSTALL new camshafts, camshaft followers, or valve lifters.
D18 CHECK CYLINDER HEAD GASKET
  • Remove the cylinder heads. REFER to the cylinder head procedure(s) in 303-01 for the engine being diagnosed. Refer to the appropriate section in Group 303 for the procedure. Inspect the cylinder head gasket(s) for signs of damage or failure. Inspect the cylinder block and cylinder head(s) for damage.
    REFER TO: Cylinder Block Distortion (303-00 Engine System - General Information, General Procedures).
    and REFER TO: Cylinder Head Distortion (303-00 Engine System - General Information, General Procedures).

Are the cylinder head gasket(s), cylinder head(s), or cylinder block damaged?
Yes REPAIR as necessary.
No GO to D19
D19 CHECK VALVE STEM SEALS
  • Remove the cylinder head(s). Remove the valves from the cylinder head and inspect the valve stem seals for damage, excessive wear and proper sealing.

Are the valve stem seals undamaged?
Yes Install new valve stem seals. REFER to Disassembly and Assembly of Sub-Systems - Cylinder Head Procedure for the engine being diagnosed. REFER to the appropriate section in Group 303 for the procedure.
No GO to D20
D20 CHECK VALVES
  • Inspect the valves for excessive engine oil or carbon buildup. Inspect the valve seat contact surface and valve seat for damage or wear. Inspect the sealing contact surface for burnt or pitted areas. Inspect the even sealing contact surface around the valve and valve seat. Inspect the valves, valve stems, and valve guides for damage.
    REFER TO: Valve Guide Inside Diameter (303-00 Engine System - General Information, General Procedures).
    REFER TO: Valve Stem Diameter (303-00 Engine System - General Information, General Procedures).

Are the valves damaged or excessively worn, or is the seal contact uneven?
Yes INSTALL new valve seals, valves or a new cylinder head.
No GO to D21
D21 CHECK ENGINE
  • Disassemble the engine. Check the pistons and piston rings for signs of excessive blow-by. Check for excessive carbon buildup on top of the pistons. Check the pistons, piston rings, and cylinder bores for excessive wear or damage.
    REFER TO: Piston Inspection (303-00 Engine System - General Information, General Procedures).
    REFER TO: Piston Ring Gap (303-00 Engine System - General Information, General Procedures).
    REFER TO: Cylinder Bore Taper (303-00 Engine System - General Information, General Procedures).

Are pistons or piston rings damaged, excessively worn or excessively carboned?
Yes REPAIR as necessary.
No INSTALL a new short block.
PINPOINT TEST E: LOW OR HIGH ENGINE OIL PRESSURE

Possible Sources

  • Engine Oil
  • Engine oil filter housing
  • Engine Oil Filter
  • Engine oil pump
  • Engine oil pressure control solenoid valve
  • VCT unit(s)
  • Engine oil pickup tube clogged
  • Excessive connecting rod bearing clearance
  • Excessive crankshaft main bearing clearance

Visual Inspection and Pre-checks

  • Make sure the engine oil level is within specification.
E1 CHECK PCM DIAGNOSTIC TROUBLE CODES (DTCs)
  • The ignition is on.
  • Perform the PCM KOEO and KOER self-test.

Are any diagnostic trouble codes (DTCs) present?
Yes Refer to the Master Trouble Code Chart to diagnose the present fault code.
No GO to E2
E2 CHECK VEHICLE SERVICE HISTORY
  • Check the vehicle service history and make sure the documentation specifies the correct oil being used.

Is the correct oil being used based on the vehicle service history?
Yes GO to E3
No REPLACE the engine oil and filter using the correct oil specification. Refer to the Specifications in Section 303-01 for the engine being diagnosed. Refer to the appropriate section in Group 303 for the procedure.
E3 CHECK ENGINE OIL FILTER HOUSING AND SEAL
  • For 2.7 L and 3 L EcoBoost engines, remove the oil filter housing. Inspect:
    • the oil filter housing for a clogged center stem.
    • the oil filter housing for a missing or damaged center stem.
    • the stem O-ring for missing or damaged O-ring.
  • For all other engines, remove the oil filter. Inspect:
    • the oil filter for damage.
    • the oil filter manifold for damage to the center stem.
    • for missing or damaged O-ring.

Are any concerns found?
Yes REPAIR as necessary.
No INSTALL a new oil filter. GO to E4
E4 PERFORM ENGINE OIL PRESSURE CHECK
  • Install the engine oil filter housing or engine oil filter.
  • Check the engine oil pressure.
    REFER TO: Oil Pressure Test (303-00 Engine System - General Information, General Procedures).
    Compare the engine oil pressure gauge reading to the engine oil pressure specification in the Specifications procedure 303-01 for the diagnosed engine. Refer to the appropriate section in Group 303 for the procedure.

Is the engine oil pressure within specification?
Yes The system is currently operating normally.
Refer to: Instrument Cluster, Message Center and Warning Chimes (413-01 Instrument Cluster, Message Center and Warning Chimes, Diagnosis and Testing).
to diagnose instrument cluster concerns.
No If concerned about low engine oil pressure, GO to E5.
If concerned about high engine oil pressure, DETERMINE the cause of the restriction in engine oil pressure after the engine oil pressure sensor. REPAIR as necessary.
E5 CHECK ENGINE OIL PICKUP TUBE
  • Remove the engine oil pan. Refer to Removal and Installation Procedure in Section 303-01. Refer to the appropriate section in Group 303 for the procedure. CHECK the engine oil pickup tube for clogging.
  • Check the engine oil pickup tube for blockage.

Is the engine oil pickup tube free of obstructions and blockage?
Yes GO to E6
No REPAIR as necessary.
E6 CHECK FOR OBVIOUS SIGNS OF EXCESSIVE WEAR
  • Visually inspect the engine oil pan for signs of mechanical damage or excessive wear, such as metal flakes settled on the bottom of the engine oil pan, pieces of metal, or other debris from timing components.

Are there any signs of excessive wear or mechanical damage?
Yes REPAIR as necessary.
No INSTALL a new oil pump. REFER to Oil Pump in Section 303-01 for the engine being diagnosed. CHECK the system for normal operation. If the condition is still present, GO to E7.
E7 CHECK THE CONNECTING ROD BEARINGS
  • Remove the engine oil pan. Remove the connecting rod cap and inspect the bearings for signs of excessive wear or damage. Check the connecting rod bearing journal clearance.
    REFER TO: Connecting Rod Bearing Journal Clearance (303-00 Engine System - General Information, General Procedures).
    Compare the connecting rod bearing journal clearance with the specification. Refer to the bearing journal clearance specification in the procedure for 303-01 in the section for the engine being diagnosed. Refer to the appropriate section in Group 303 for the procedure.

Are the connecting rod journal bearing clearances within specification?
Yes GO to E8
No If debris from failed bearings or the crankshaft appears to have contaminated the engine oil, GO to E8. INSTALL new connecting rod bearings.
E8 CHECK THE CRANKSHAFT MAIN BEARINGS
  • Remove the crankshaft main bearing caps and inspect the bearings for signs of excessive wear or damage. Check the crankshaft main bearing clearance.
    REFER TO: Crankshaft Main Bearing Clearance (303-00 Engine System - General Information, General Procedures).
    Compare the crankshaft main bearing clearance with the specification. Refer to the main bearing journal clearance specification in the procedure for 303-01 in the section for the engine being diagnosed. Refer to the appropriate section in Group 303 for the procedure.

Are the crankshaft main bearing clearances within specification?
Yes The rotating assembly at the bottom end (connecting rods or crankshaft) is not the cause of low engine oil pressure. REFER to Section 303-14 for the engine being diagnosed for all engine oil pressure related Diagnostic Trouble Codes. Refer to the appropriate section in Group 303 for the procedure.
No INSTALL a new long block.
PINPOINT TEST F: ENGINE NOISE

Normal Operation and Fault Symptoms

Since any one of several systems may be the cause of the symptom, it may be necessary to use a process of elimination type diagnostic approach to accurately identify the responsible system. NVH symptoms must be identified using the diagnostic tools and methods that are available. For a list of these methods, tools, an explanation of their use and a glossary of common terms, REFER TO: Noise, Vibration and Harshness (NVH) (100-04 Noise, Vibration and Harshness, Diagnosis and Testing).

In some cases, the noise may be a normal characteristic of this type of engine. In other cases, the noise may require further investigation. Comparing the noise with a similar year/model vehicle equipped with the same engine helps determine whether the noise is normal or abnormal.

Once the noise is identified as abnormal engine noise, it is very important to determine the location of the specific noise. Use EngineEAR/ChassisEAR or a stethoscope (noise is always louder closer to the source) to isolate the location of the noise to one of the following areas.

  • Fuel injector(s)
  • Upper end of the engine
  • Lower end of the engine
  • Front of the engine
  • Rear of the engine

Fuel injector noise

A common source of a ticking engine noise may be related to the high-pressure fuel pump (Ecoboost engine) or the fuel injector(s). This is a normal engine noise that can be verified by listening to another similar vehicle. If the injector noise is excessive or irregular, use EngineEAR/ChassisEAR or a stethoscope to isolate the noise to a specific fuel injector.

Upper end engine noise

A common source of upper end engine noise (ticking, knocking or rattling) includes the camshaft(s) and the valvetrain. The level of upper end engine noise can be determined using EngineEAR/ChassisEAR or a stethoscope on the valve cover bolts. If the noise is loudest at the valve cover bolts, the noise is within the upper end. EngineEAR/ChassisEAR or a stethoscope can be used to further isolate the noise to a specific bank and cylinder. Removal of the valve cover may be necessary to accurately determine the source of the noise.

Engine Noise - Low Engine

A common source of lower end engine noise (ticking or knocking) includes the crankshaft, connecting rod(s) and bearings. Lower end noise can be determined using the engine oil pan or the lower cylinder block. If the noise is loudest at these areas, the noise is within the lower end. If the engine noise is isolated to the lower end, some engine disassembly may be necessary to inspect for damage or wear.

Engine Noise - Front of Engine

A common source of noise at the front of the engine (squeal, chirp, screech or whine) is the FEAD components. To isolate FEAD noise, perform an accessory drive check. REFER TO: Noise, Vibration and Harshness (NVH) (100-04 Noise, Vibration and Harshness, Diagnosis and Testing).

Some other noises at the front of the engine (ticking, tapping or knocking) may be internal to the engine. Use EngineEAR/ChassisEAR or a stethoscope on the front engine cover to determine whether the noise is internal to the engine. Removal of the front engine cover may be necessary to inspect internal engine components.

Engine Noise - Rear of Engine

A common source of noise at the rear of the engine (knocking) is the flywheel/flexplate. Inspection of the flywheel/flexplate is required.

Some engines have valvetrain drive components at the rear of the engine and may be a source of noise (ticking, knocking or rattling). Use EngineEAR/ChassisEAR or a stethoscope at the rear of the engine if the noise is suspected to come from the engine. Some engine disassembly may be necessary to inspect for damage or wear.

Turbocharger noise (Ecoboost engine)

A common source of noise is the turbocharger. A slight whine or airflow noise is an acceptable condition.

To locate the source of engine noise, REFER TO: Engine Noise Identification and Location (303-00 Engine System - General Information, General Procedures).

Possible Sources

  • Expansion/Contraction Materials
  • Thin or diluted engine oil
  • Low engine oil level
  • Vacuum leak
  • Cooling system problem
  • Powertrain mount(s)
  • Transmission
  • Accessory drive system concern
  • Air Intake System Concern
  • Turbocharger wastegate
  • Turbocharger
  • Engine or transmission interaction with chassis or body
  • Starter motor
  • Fuel Injector
  • Fuel pump
  • HPFP (direct injection engines only)
  • Flywheel/flex plate
  • Timing drive system concern
  • Valvetrain component concern
  • Cylinder head cover
  • Balance Shaft Assembly
  • Engine oil pump
  • Rotating lower end assembly (connecting rods or crankshaft) concern
  • Pistons/cylinder walls
F1 COMPARE TO A SIMILAR VEHICLE
  • Compare the noise level to a similarly equipped vehicle.

Is the concern noise present on a similar vehicle?
Yes The vehicle is operating as designed.
No GO to F2
F2 CHECK FOR OBVIOUS SIGNS OF MECHANICAL DAMAGE
  • Ignition OFF.
  • Visually inspect the powertrain components and all possible causes for obvious signs of mechanical damage.

Is there evidence of mechanical damage?
Yes REPAIR as necessary.
No GO to F3
F3 CHECK THE ENGINE OIL LEVEL
  • Check the engine oil level.

Is the engine oil level correct?
Yes GO to F4
No FILL the engine oil to specification.
F4 CHECK THE ENGINE OIL FOR CONTAMINATION
  • Check the engine oil for contamination.

Is the engine oil free of contamination?
Yes GO to F5
No IDENTIFY the source of contamination and REPAIR as necessary.
F5 CHECK THE VEHICLE SERVICE HISTORY
  • Check the vehicle service history and confirm that the documentation specifies the correct engine oil being used.

Is the correct engine oil being used based on the vehicle service history?
Yes GO to F6
No REPLACE the engine oil and filter using the correct engine oil specification. REFER to the Specifications procedure in Section 303-01 for the engine being diagnosed. REFER to the appropriate section in Group 303 for the procedure.
F6 CHECK THE PCM (POWERTRAIN CONTROL MODULE) FOR DIAGNOSTIC TROUBLE CODES (DTCS)
  • The ignition is on.
  • Perform PCM Self-Test KOEO and KOER.

Are any diagnostic trouble codes (DTCs) present?
Yes REFER to the Master DTC Chart to diagnose the DTC present.
No GO to F7
F7 CHECK FOR ENGINE OVERHEATING
  • Check the engine for overheating.

Is an engine overheating condition present?
Yes REFER to the Diagnosis and Testing procedure in Section 303-03 for the engine being diagnosed. Refer to the appropriate section in Group 303 for the procedure.
No GO to F8
F8 CHECK THE ENGINE COOLANT PUMP END PLAY
  • Check the engine coolant pump for excessive end play. Inspect the engine coolant pump for imbalance with the drive belt removed.

Is there a concern with the engine coolant pump?
Yes REPAIR as necessary.
No GO to F9
F9 CHECK FOR A VACUUM LEAK
  • Inspect the vacuum hoses for leaks and check the engine for vacuum leaks.

Is a vacuum leak present?
Yes REPAIR as necessary.
No GO to F10
F10 CHECK THE AIR INTAKE SYSTEM
  • Inspect the air intake system.
  • Check the air intake ducts, air cleaner and throttle body for leaks and proper installation.
  • If equipped, check the turbocharger/supercharger, CAC and tubes for leaks, proper alignment and damage.

Are any concerns found with the air intake system?
Yes REPAIR or adjust as necessary.
No GO to F11
F11 CHECK THE IGNITION SYSTEM
  • Inspect the ignition system. Inspect the spark plugs for normal firing.
    REFER TO: Spark Plug Inspection (303-00 Engine System - General Information, General Procedures).

Are there ignition system concerns?
Yes REPAIR as necessary.
No GO to F12
F12 CHECK THE ACCESSORY DRIVE SYSTEM
  • Inspect the accessory drive system.
  • If necessary, perform the engine accessory drive check.
    REFER TO: Noise, Vibration and Harshness (NVH) (100-04 Noise, Vibration and Harshness, Diagnosis and Testing).

Are any concerns found with the accessory drive system?
Yes REPAIR as necessary.
No GO to F13
F13 CHECK THE FUEL SYSTEM
  • Inspect the fuel injection system. REFER to the Diagnosis and Testing procedures in Sections 303-04 and 310-01 for the engine being diagnosed. Refer to the appropriate section in Group 303 for the procedure.

Are any concerns found with the fuel injection system?
Yes REPAIR as necessary.
No GO to F14
F14 CHECK THE STARTER MOTOR
  • Inspect the starter motor for damage and correct the mounting. REFER to the Diagnosis and Testing procedure in Section 303-06 for the engine being diagnosed. Refer to the appropriate section in Group 303 for the procedure.

Are any concerns found with the starter motor?
Yes REPAIR as necessary.
No GO to F15
F15 CHECK THE POWERTRAIN MOUNTS
  • Inspect the powertrain mounts for damage.

Are any concerns found with the powertrain mounts?
Yes PERFORM the powertrain mount neutralization procedure.
REFER TO: Powertrain/Suspension Mount Neutralization (303-00 Engine System - General Information, General Procedures).
. If the condition is not resolved, REPAIR or INSTALL new powertrain mounts as necessary.
No Go to F16.
F16 CHECK THE EXHAUST SYSTEM
  • Inspect the exhaust system for damage. REFER TO the Diagnostic and Testing Procedure in Section 309-00 for the engine being diagnosed. Refer to the appropriate section in Group 303 for the procedure.

Is the exhaust system the source of the noise?
Yes REPAIR or INSTALL new components as necessary.
No Go to F17.
F17 CHECK THE TURBOCHARGER NOISE
  • Check the turbocharger(s) for excessive noise. Compare the noise level with another vehicle with similar equipment. REFER TO 303-04 Turbocharger Diagnostic and Testing Procedure for the engine being diagnosed. Refer to the appropriate section in Group 303 for the procedure.

Are the turbochargers the source of the noise?
Yes INSTALL new turbochargers.
No Go to F18.
F18 CHECK THE ENGINE OIL PRESSURE
  • Check the engine oil pressure.
    REFER TO: Oil Pressure Test (303-00 Engine System - General Information, General Procedures).
    Compare the engine oil pressure gauge reading to the engine oil pressure specification in the Specifications procedure 303-01 for the diagnosed engine. Refer to the appropriate section in Group 303 for the procedure.

Is the engine oil pressure within specification?
Yes GO to F19.
No GO to Pinpoint Test E
F19 LOCATE THE ENGINE NOISE
  • Using the EngineEAR/ChassisEAR, stethoscope and accelerometer together with the VCMM, locate the engine noise.
    REFER TO: Engine Noise Identification and Location (303-00 Engine System - General Information, General Procedures).

Is the noise coming from the engine?
Yes If the noise is coming from the rear of the engine, GO to F20. If the noise is coming from the front of the engine, GO to F21. If the noise is coming from the top of the engine, GO to F22. If the noise is coming from the bottom of the engine, GO to F25.
No Condition no longer present.
F20 CHECK THE FLEXPLATE OR FLYWHEEL AND CLUTCH
  • If equipped, remove the torque converter access plug bolt/nut. If equipped, remove the inspection cover. If necessary, remove the starter. Check the torque converter nuts or bolts for looseness. Visually inspect the flexplate or flywheel and clutch for damage. With an assistant, manually rotate the crankshaft pulley while visually inspecting the flexplate or flywheel and clutch and listening for abnormal noises coming from between the engine and transmission. Check to make sure the flexplate or flywheel is not loose on the crankshaft. Restrict the movement of the flexplate or flywheel while the assistant manually rotates the crankshaft, if necessary, to identify the possible noise source.

Is the flexplate, flywheel or clutch damaged, are the torque converter, flexplate or flywheel attaching bolts loose, or does the noise appear to come from between the engine and the transmission?
Yes REMOVE the transmission. INSPECT the flexplate or flywheel and clutch for damage. INSTALL a new flexplate or flywheel and clutch as necessary.
No GO to F25.
F21 CHECK THE TIMING COMPONENTS
  • Remove the front engine cover. Inspect the timing components for excessive wear or damage. Inspect the front engine cover for evidence of contact with the timing chain or belt. Inspect the VCT unit(s) for damage or excessive wear.

Are timing drive components damaged?
Yes INSTALL new timing drive components.
No Go to F22.
F22 CHECK THE VALVE TRAIN FOR DAMAGE
  • Remove the valve cover(s). Visually inspect the camshafts and valvetrain for obvious signs of excessive wear or damage. Check for broken valve springs, damaged valve seals, missing or damaged valve keepers, or bent valves.

Are valve train components damaged?
Yes INSTALL new components.
No GO to F23.
F23 PERFORM THE VALVE TRAIN ANALYSIS
  • Perform the valvetrain analysis.
    REFER TO: Valvetrain Analysis - 2 L EcoBoost (177 kW/240 L hp) – MI4/2.5 L Duratec – Hybrid (121 kW/164 L hp) (BG) (303-00 Engine System - General Information, General Procedures).
    Compare the camshaft lift to the specifications in Section 303-01 for the engine being diagnosed. Refer to the appropriate section in Group 303 for the procedure.

Camshaft lift and valve clearance within specification?
Yes Go to F24.
No ADJUST the valve clearance. If necessary, INSTALL new camshafts, camshaft followers, or valve lifters.
F24 CHECK THE CYLINDER HEAD AND VALVES
  • Remove the cylinder head(s). Remove the valves from the cylinder head and inspect the valves and valve guides for excessive wear or damage.
    REFER TO: Valve Stem Diameter (303-00 Engine System - General Information, General Procedures).
    REFER TO: Valve Guide Inside Diameter (303-00 Engine System - General Information, General Procedures).
    Compare the measurement with the valve stem-to-guide clearance specifications in Specifications 303-01 for the engine being diagnosed. Refer to the appropriate section in Group 303 for the procedure.

Are the valve clearances within specification?
Yes GO to F29.
No INSTALL new cylinder heads and valves.
F25 CHECK THE BALANCE SHAFTS FOR DAMAGE OR EXCESSIVE WEAR
  • If equipped, remove the balance shaft assembly. Inspect the balance shaft assembly for excessive wear or damage. Inspect the bearing surfaces for excessive wear or damage.

Is the balance shaft assembly or bearings damaged or excessively worn?
Yes If balance shaft or bearing debris is found in the engine oil, GO to F26. INSTALL a new balance shaft assembly.
No GO to F26.
F26 CHECK THE ENGINE OIL PUMP
  • Remove the engine oil pump. Inspect the engine oil pump for damage or excessive wear. Inspect for cracks in the housing. Inspect for scoring or excessive clearance on the gear or internal moving parts.

Is the engine oil pump damaged?
Yes If balance shaft or bearing debris is found in the engine oil, GO to F27. INSTALL a new engine oil pump.
No GO to F27.
F27 CHECK THE CONNECTING ROD BEARINGS
  • Remove the engine oil pan. Remove the connecting rod cap and inspect the bearings for signs of excessive wear or damage. Check the connecting rod bearing journal clearance.
    REFER TO: Connecting Rod Bearing Journal Clearance (303-00 Engine System - General Information, General Procedures).
    Compare the connecting rod bearing journal clearance with the specification. Refer to the bearing journal clearance specification in the procedure for 303-01 in the section for the engine being diagnosed. Refer to the appropriate section in Group 303 for the procedure.

Are the connecting rod journal bearing clearances within specification?
Yes GO to F28.
No If debris from failed bearings or the crankshaft appears to be in the engine oil, GO to F28. INSTALL new connecting rod bearings.
F28 CHECK THE CRANKSHAFT MAIN BEARINGS
  • Remove the crankshaft main bearing caps and inspect the bearings for signs of excessive wear or damage. Check the crankshaft main bearing clearance.
    REFER TO: Crankshaft Main Bearing Clearance (303-00 Engine System - General Information, General Procedures).
    Compare the crankshaft main bearing clearance with the specification. Refer to the main bearing journal clearance specification in the procedure for 303-01 in the section for the engine being diagnosed. Refer to the appropriate section in Group 303 for the procedure.

Are the crankshaft main bearing clearances within specification?
Yes GO to F29.
No INSTALL a new long block.
F29 CHECK THE PISTON-TO-CYLINDER WALL CLEARANCE
  • Remove the engine. Remove the piston and connecting rod assemblies from the engine. Inspect the pistons, piston rings and cylinder walls for signs of piston slap. Inspect the pistons.
    Refer to: Piston Inspection (303-00 Engine System - General Information, General Procedures).
    Check the piston ring end gap. Refer to: Piston Ring Gap (303-00 Engine System - General Information, General Procedures).
    Measure the cylinder bore taper. Refer to: Cylinder Bore Taper (303-00 Engine System - General Information, General Procedures).
    Measure the piston diameter. Refer to: Piston Diameter (303-00 Engine System - General Information, General Procedures).
    Calculate the piston-to-cylinder clearance and compare with the specifications in the procedure specifications in Section 303-01 for the engine being diagnosed. Refer to the appropriate section in Group 303 for the procedure.

Is the piston-to-cylinder wall clearance within specification?
Yes INSTALL new piston rings. Hone the cylinder walls.
No INSTALL a new short block.

Test yourself

A quick Ford Escape quiz: every answer comes with an explanation and a link to the manual page.