Toyota
Ford Kuga
 Service Manual
Engine System - General Information
Engine - Oil Leaks

Engine

Special Tool(s) / General Equipment

Socket, Spark Plug 303-499
Compression Test Adapter 303-1056

Ford diagnostic equipment

Materials

Name Specification
Adhesive - Loctite 243 WSK-M2G349-A7

1. Verify the customer concern by operating the system 2. Visually inspect for obvious signs of mechanical or electrical damage.

3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.

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

Visual Inspection Chart

Mechanical Electrical
  • 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)
  • Control module
  • Damaged or worn switch(es)
Symptom Possible Sources Action
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 oil cooler. CHECK the coolant expansion tank for a film of oil on the coolant surface. INSTALL a new oil cooler or oil cooler gasket
Leak at the crankshaft seal. INSTALL a new crankshaft seal.
Leaks from oil carrying components or basic engine. CHECK for cracks in oilcarrying components of the basic engine by means of a UV leak test. INSTALL new components or seals as necessary.
Oil consumption Use of the wrong type of engine oil. DETERMINE the last type of engine oil used and compare with the specification. Change the engine oil to the specification.
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. Engine - 2.5L Duratec-ST (VI5) - REFER to: Engine Emission Control (303-08 Engine Emission Control - 2.5L Duratec (147kW/200PS) - VI5, Diagnosis and Testing).

Engine - 2.0L Duratorq-TDCi (DW) Diesel -

Turbocharger seals. INSTALL a new turbocharger.

Engine - 2.5L Duratec-ST (VI5) - REFER to: Turbocharger (303- 04 Fuel Charging and Controls - Turbocharger - 2.5L Duratec (147kW/200PS) - VI5, Removal and Installation).

Engine - 2.0L Duratorq-TDCi (DW) Diesel -

Damaged gaskets or mating surfaces.
  • Cylinder head gasket is damaged or mating face are warped.
  • Valve stem seals are worn and engine oil can enter the combustion chamber between the valve stem and the valve stem guide.
CHECK the gaskets and mating surfaces for damage.

Remove the cylinder head.

CHECK the mating faces, cylinder head gasket and the evenness of the cylinder head and engine block mating faces.

INSTALL new valve seals. Engine - 2.5L Duratec-ST (VI5) - REFER to: Valve Stem Seals (303-01 Engine - 2.5L Duratec (147kW/200PS) - VI5, Removal and Installation).

Engine - 2.0L Duratorq-TDCi (DW) Diesel -

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 and piston rings.
Coolant consumption Cooling system components. Check the cooling system components. Engine - 2.5L Duratec-ST (VI5) - REFER to: Engine Cooling (303-03 Engine Cooling, Diagnosis and Testing).

Engine - 2.0L Duratorq-TDCi (DW) Diesel - REFER to: Engine Cooling (303-03 Engine Cooling, Diagnosis and Testing).

Oil cooler. INSTALL a new oil cooler.
Damaged gaskets or warped mating faces. CHECK the cylinder head gasket for damage. CHECK the cylinder head for distortion.
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 will not crank Battery or cables. CHECK the battery and cables.

REFER to: Charging System (414-00 Charging System - General Information, Diagnosis and Testing).

Starter motor or cables. CHECK the starting system.

Engine - 2.5L Duratec-ST (VI5) - REFER to: Starting System (303-06 Starting System - 2.5L Duratec (147kW/200PS) - VI5, Diagnosis and Testing).

Engine - 2.0L Duratorq-TDCi (DW) Diesel -

Engine cranks but will not start Fuel tank is empty. CHECK the fuel level.
Water in fuel (diesel engine only). Drain the water from the fuel system.
Fuel filter blocked. INSTALL a new fuel filter.

Engine - 2.0L Duratorq-TDCi (DW) Diesel -

Engine intake air system. CHECK the intake air system.

Engine - 2.5L Duratec-ST (VI5) - REFER to: Intake Air Distribution and Filtering (303-12 Intake Air Distribution and Filtering - 2.5L Duratec (147kW/200PS) - VI5, Diagnosis and Testing).

Engine - 2.0L Duratorq-TDCi (DW) Diesel -

Glow plug faulty (diesel engine only). CHECK the glow plugs.

INSTALL new glow plugs as necessary.

Engine management system CHECK the engine management system. Engine - 2.5L Duratec-ST (VI5) - REFER to: Electronic Engine Controls (303-14 Electronic Engine Controls - 2.5L Duratec (147kW/200PS) - VI5, Diagnosis and Testing).

Engine - 2.0L Duratorq-TDCi (DW) Diesel -

Ignition system (petrol engine only). CHECK the ignition system.

Engine - 2.5L Duratec-ST (VI5) - REFER to: Engine Ignition (303-07 Engine Ignition - 2.5L Duratec (147kW/200PS) - VI5, Diagnosis and Testing).

Incorrect valve timing. CHECK and adjust the valve timing. Engine - 2.5L Duratec- ST (VI5) - REFER to: Timing Belt (303-01 Engine - 2.5L Duratec (147kW/200PS) - VI5, Removal and Installation).

Engine - 2.0L Duratorq-TDCi (DW) Diesel -

Broken or damaged timing belt/timing chain or pulley/sprocket. CHECK the timing belt/timing chain and sprockets/pulleys.

INSTALL new components as necessary. Engine - 2.5L Duratec-ST (VI5) - REFER to: Timing Belt (303-01 Engine - 2.5L Duratec (147kW/200PS) - VI5, Removal and Installation).

Engine - 2.0L Duratorq-TDCi (DW) Diesel -

Very poor power output or fuel - Fuel system.

consumption too high or engine running rough.

Fuel system. CHECK the fuel system.

Engine - 2.5L Duratec-ST (VI5) - REFER to: Fuel Charging and Controls (303-04 Fuel Charging and Controls - 2.5L Duratec (147kW/200PS) - VI5, Diagnosis and Testing).

Engine - 2.0L Duratorq-TDCi (DW) Diesel -

Engine intake air system. CHECK the intake air system.

Engine - 2.5L Duratec-ST (VI5) - REFER to: Intake Air Distribution and Filtering (303-12 Intake Air Distribution and Filtering - 2.5L Duratec (147kW/200PS) - VI5, Diagnosis and Testing).

Engine - 2.0L Duratorq-TDCi (DW) Diesel -

Exhaust system blocked. CHECK the exhaust system
Engine management system. CHECK the engine management system. Engine - 2.5L Duratec-ST (VI5) - REFER to: Electronic Engine Controls (303-14 Electronic Engine Controls - 2.5L Duratec (147kW/200PS) - VI5, Diagnosis and Testing).

Engine - 2.0L Duratorq-TDCi (DW) Diesel -

Fault in ignition system (petrol engine only). CHECK the ignition system.

Engine - 2.5L Duratec-ST (VI5) - REFER to: Engine Ignition (303-07 Engine Ignition - 2.5L Duratec (147kW/200PS) - VI5, Diagnosis and Testing).

Turbocharger. CHECK the turbocharger.

Engine - 2.5L Duratec-ST (VI5) - REFER to: Turbocharger (303- 04 Fuel Charging and Controls - Turbocharger - 2.5L Duratec (147kW/200PS) - VI5, Diagnosis and Testing).

Engine - 2.0L Duratorq-TDCi (DW) Diesel -

Incorrect valve timing. Timing belt/timing sprocket or pulley/sprocket damaged. CHECK and adjust valve timing. INSTALL new components as necessary. Engine - 2.5L Duratec-ST (VI5) - REFER to: Timing Belt (303-01 Engine - 2.5L Duratec (147kW/200PS) - VI5, Removal and Installation).

Engine - 2.0L Duratorq-TDCi (DW) Diesel -

Ignition timing incorrect (petrol engine only). CHECK the electronic engine controls. Engine - 2.5L Duratec- ST (VI5) - REFER to: Electronic Engine Controls (303-14 Electronic Engine Controls - 2.5L Duratec (147kW/200PS) - VI5, Diagnosis and Testing).
Noisy running Engine auxiliary components loose or damaged. CHECK engine auxiliary components for damage or looseness. CHECK and adjust valve timing. INSTALL new components as necessary.

Engine - 2.5L Duratec-ST (VI5) - REFER to: Timing Belt (303-01 Engine - 2.5L Duratec (147kW/200PS) - VI5, Removal and Installation).

Engine - 2.0L Duratorq-TDCi (DW) Diesel -

Noisy running, misfiring, back- firing or knocking Incorrect fuel DETERMINE which type of fuel was last put into the fuel tank (note the country specific fuel specifications).
Water in fuel or fuel contaminated. CHECK the fuel system for water or other contamination.
Valve timing incorrect, timing belt/chain or pulley/sprocket damaged. CHECK and adjust valve timing. INSTALL new components as necessary. Engine - 2.5L Duratec-ST (VI5) - REFER to: Timing Belt (303-01 Engine - 2.5L Duratec (147kW/200PS) - VI5, Removal and Installation).

Engine - 2.0L Duratorq-TDCi (DW) Diesel -

Noisy running or valve train noise Valve clearance too large due to faulty valve tappets or worn valve train components. INSTALL new hydraulic lash adjusters or adjust the valve clearance. Engine - 2.5L Duratec-ST (VI5) - REFER to: Valve Clearance Adjustment (303-01 Engine - 2.5L Duratec (147kW/200PS) - VI5, General Procedures).

Engine - 2.0L Duratorq-TDCi (DW) Diesel -

Timing belt or timing chain damaged. INSTALL a new timing belt or timing chain. Engine - 2.5L Duratec-ST (VI5) - REFER to: Timing Belt (303-01 Engine - 2.5L Duratec (147kW/200PS) - VI5, Removal and Installation).

Engine - 2.0L Duratorq-TDCi (DW) Diesel -

Timing belt or timing chain incorrectly tensioned. CHECK the timing belt tension.

INSTALL a new timing belt or timing chain as necessary.

Engine - 2.5L Duratec-ST (VI5) - REFER to: Timing Belt (303-01 Engine - 2.5L Duratec (147kW/200PS) - VI5, Removal and Installation).

Engine - 2.0L Duratorq-TDCi (DW) Diesel -

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 that all components are within specification. INSTALL new components as necessary.

Engine - 2.5L Duratec-ST (VI5) - REFER to: Specifications (303- 01 Engine - 2.5L Duratec (147kW/200PS) - VI5, Specifications).

Engine - 2.0L Duratorq-TDCi (DW) Diesel -

NOTE: Before installing new gaskets or oil 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:

    More about «Engine System - General Information»:

    Engine - Oil Leaks

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    Measure the compression pressure (Engine - 2.5L Duratec-ST (VI5)

    Measure the compression pressure (Engine - 2.0L Duratorq-TDCi (DW) Diesel)

    Measure the oil pressure (Engine - 2.5L Duratec-ST (VI5)

    Measure the oil pressure (Engine - 2.0L Duratorq-TDCi (DW) Diesel)

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