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Ford Mondeo Duratec 2.0 2005 - Cylinder head machined after overheating - Fixed #

Posted by Simon Forsey on November 8, 2010, 8:08 am

Year of Manufacture *: 2005
Engine Size and Code *: 2.0
( Optional ) Scanner Used: Autodiagnos
( Optional) Fault Codes: None

This car overheated and the cylinder head was removed and the head was machined before it was replaced [I dont know how much of the head was machined at this time]

Now when the car is started the engine 'kicks' and the engine seems to lurch backwards, when you rev the engine it 'pinks' severley.

I have scoped the cam and crank sensors [ok]
Injection duration and ignition coils [ok]
TPS, O2 and MAP respond correctly.
Vacuum is 21inHG which I feel is slightly high.
The compressions are
Cylinder 1 191 psi
Cylinder 2 187 psi
Cylinder 3 190 psi
Cylinder 4 188 psi

I feel that the compressions could be too high due to the head being skimmed too much.

Your comments would be great.

Regards

Simon

Re: Ford Mondeo Duratech 2.0

Posted by Chris Angus User icon on November 8, 2010, 10:16 am, in reply to "Ford Mondeo Duratech 2.0"

Hi Simon, I had something similar a while ago and it turned out to be crank timing, worth double checking.

Re: Ford Mondeo Duratech 2.0

Posted by Simon Forsey User icon on November 8, 2010, 6:36 pm, in reply to "Re: Ford Mondeo Duratech 2.0"

Hi

The garage has checked the cam timming 3 times! I checked it on scope via crank and cam and compaired it with a known good.

All ok.

However, is there anyway that you CAN cock up the cam timing? I believe the garage has followed the service manual. But I WILL check!

Regards

Simon

Re: Ford Mondeo Duratech 2.0

Posted by lee woods User icon on November 9, 2010, 10:56 pm, in reply to "Re: Ford Mondeo Duratech 2.0"
Lee Woods

I would of thought to get the compression so high it would be pinking the surface grind would of had to take a big chunk off, normal surface grind is only a few thou.
21 inches vac sounds good to me , is crank reluctor ring on front crank pulley or on flywheel ?
If the knock sensor got disturbed or damaged could this cause it to go over advanced ?

Can you get the firing degrees reading from live data on your scan tool just to see what its doing
?

Re: Ford Mondeo Duratech 2.0

Posted by david briscoe User icon on November 10, 2010, 7:03 pm, in reply to "Re: Ford Mondeo Duratech 2.0"

had a similar sympthoms as this with a land rover sum time ago turned out the machine shop had let a trainee do the job and he took a huge amount off the head. the land rover ended up breaking its crankshaft within 3 mths.

Fixed #

Posted by Simon Forsey on November 16, 2010, 7:15 am, in reply to "Re: Ford Mondeo Duratech 2.0"
Message modified by board administrator November 18, 2010, 8:41 am

I went back to the garage to diagnose another car.

The Mondeo had had its timing checked for a fourth time using factory tools. It was OK.

Decided to put a smoke machine on it and low and behold, there was a split in the beather pipe behind the starter that goes up under the manifold.

Many thanks for all your help.

Simon

Re: Ford Mondeo Duratech 2.0 FIXED

Posted by chris Angus User icon on November 16, 2010, 7:08 pm, in reply to "Re: Ford Mondeo Duratech 2.0 FIXED"

Hi Simon

Glad you got a fix for this one but, I think this is worthy of a discussion.

As far as my knowledge and experience goes, with the symptoms you originally described, with regards to high compression, kicking when started and severe pinking when revved stationary, I would've bet my arse it was over advanced timing.

I believe if it had such a huge air leak, being MAP based it would've been very rich, high idle and would have expected engine vacuum to be low, which this car had a very healthy, if not a slightly higher vacuum of 21in. I always associate pinking with lean fuel control and timing.

I can't help thinking there was another problem besides the air leak.

Not wanting to get your back up and start an argument but like I said, got to be worth a discussion?

Chris

Re: Ford Mondeo Duratech 2.0

Posted by Kevin Apps User icon on November 16, 2010, 7:57 pm, in reply to "Re: Ford Mondeo Duratech 2.0"
Kevin Apps

Chris.
I read this earlier and it had me confused, as does Lee,s head grinding ?

Kev.

Re: Ford Mondeo Duratech 2.0

Posted by Simon Forsey User icon on November 17, 2010, 9:34 am, in reply to "Re: Ford Mondeo Duratech 2.0"

Hi

I have to agree with some of the issues Chris mentioned.

After I found the air leak I didn't think the split hose would cause such a violent reaction to this engine. However, the garage fitted the new hose, they gave it an extended test drive and reported it to be mint. It is now back with the owner.

To answer the question about the vac. There were 2 places to take a vac reading on the manifold. One is at the center top of the manifold and one is by the throttle body, both these places showed a good vac.

My theory is that both of these points are up stream from the split, thus air is passing through the manifold [through the throttle body and the split hose] and past these access points. I could be wrong, but I have no other theory.

I think a discussion about this is a great idea, I haven't come across this issue before and would like to be sure of where we are at.

Regards

Simon

Re: Ford Mondeo Duratech 2.0

Posted by Kevin Apps User icon on November 17, 2010, 9:57 am, in reply to "Re: Ford Mondeo Duratech 2.0"
Kevin Apps

Simon.

If you took a Vac reading at the throttle body, i can,t see how a split would NOT affect the Vacuum.
Kev.

Re: Ford Mondeo Duratech 2.0

Posted by Simon Forsey User icon on November 17, 2010, 6:55 pm, in reply to "Re: Ford Mondeo Duratech 2.0"

Appart from it having a slightly elevated idle speed I cant answer your question.

I wanted to have a look at the car after it was repaired however it had to go back to the customer.

Simon

Re: Ford Mondeo Duratech 2.0

Posted by lee woods User icon on November 17, 2010, 8:10 pm, in reply to "Re: Ford Mondeo Duratech 2.0"
Lee Woods

" lees head grinding" have you read my post Kev ? are you getting me mixed up with the other post with a broken crankshaft after skim ?

Re: Ford Mondeo Duratech 2.0

Posted by Kevin Apps User icon on November 17, 2010, 9:15 pm, in reply to "Re: Ford Mondeo Duratech 2.0"
Kevin Apps

Lee
4th post down !!! I have read it.
Kev

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