Toyota
Ford Kuga
 Service Manual
Engine System - General Information
Measure the compression pressure (Engine - 2.0L Duratorq-TDCi (DW) Diesel)

WARNINGS:

Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components.

Highly flammable vapors are always present and can ignite. Failure to follow these instructions may result in personal injury.

Do not carry out any repairs to the fuel injection system without checking that the fuel pressure has dropped to zero and that the fuel temperature has either reached ambient temperature or is below 30C, whichever is the greater. Failure to follow these instructions may result in personal injury.

1. Using datalogger in the Ford diagnostic equipment, check that the fuel pressure has dropped to zero and that the fuel temperature has either reached ambient temperature or is below 30C, whichever is the greater.

2. Raise and support the vehicle.

REFER to: Lifting (100-02 Jacking and Lifting, Description and Operation).

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

3. Remove the engine undershield.

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

4. Remove the radiator undershield.

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

5. Remove the glow plug relay.

6. Lower the vehicle.

7. Remove the cowl panel grille.

REFER to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation).

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

8. NOTE: The engine upper cover is held in place by 3 ball clips. The ball clips are not vertical, but are angled backwards by approximately 20 degrees.

Location of the engine upper cover ball clips.

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

CAUTION: Contact of the engine upper cover with the cowl panel may cause damage (scratches) on the engine upper cover. If the ambient temperature is below 0C, detach the engine upper cover with extreme caution. Failure to follow this instruction may cause the engine upper cover to be damaged.

NOTE: Only remove and install the engine upper cover in the sequence shown.

Remove the engine upper cover.

  • Detach the engine upper cover ball clips in the sequence shown.

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

CAUTION: Do not disconnect the fuel injection pump electrical connectors and crank the engine.

Disconnect the fuel injector electrical connectors.

11. Remove the exhaust gas recirculation (EGR) cooler.

12. Remove the EGR valve.

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

13. Remove the glow plug power supply.

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

14. Remove the glow plugs.

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

15. Install the special tool and a suitable compression tester into the glow plug bore.

NOTE: Crank the engine with the starter motor until the pointer on the compression tester stops rising.

16. Carry out the measurement on all cylinders, following the measuring equipment manufacturer's instructions.

17. Detach the compression tester and the special tool.

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

18. Install the glow plugs.

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

19. Install the glow plug power supply.

20. Install the EGR valve.

21. Install the EGR cooler.

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

22. Connect the fuel injector electrical connectors.

23. Apply soap solution to the ball clip mountings in the engine upper cover.

  • Soap solution (maximum concentration of soap in water 1:200).

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

CAUTION: Contact of the engine upper cover with the cowl panel may cause damage (scratches) on the engine upper cover. Failure to follow this instruction may cause the engine upper cover to be damaged.

Put the engine cover into installation position and clip it in place by pressing at the places shown.

  • Make sure that the engine upper cover is fully engaged in the area of the fuel filter, if necessary apply more pressure in the areas shown.

25. Install the cowl panel grille.

REFER to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation).

26. Raise and support the vehicle.

REFER to: Lifting (100-02 Jacking and Lifting, Description and Operation).

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

27. Install the glow plug relay.

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

28. Install the radiator undershield.

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

29. Install the engine undershield.

30. Lower the vehicle.

31. Reset the PCM fault memory.

Measure the oil pressure (21 113 0)

The oil pressure depends on various factors (engine speed, oil temperature, oil viscosity, amount of oil filter contamination etc.).

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