general procedures FORD KUGA 2011 1.G Workshop Manual

Intake Manifold(21 183 0)
Removal
NOTE:Removal steps in this procedure may
contain installation details.
1. Refer to: Fuel System Pressure Release
(310-00 Fuel System - General Information,
General Procedures).
2. Refer to: Battery Disconnect and Connect
(414-01 Battery, Mounting and Cables,
General Procedures).
3. Refer to: Air Cleaner (303-12 Intake Air
Distribution and Filtering - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
4.
E65070
5. CAUTION: Make sure that the inside of the pipe ends are clean and free of oil
residue.
1. Torque: 10Nm
2. Torque: 4Nm
3. Torque: 10Nm
2
1
3
E68504
6.
E67375
7.
E68413
8.Torque: 10Nm
E67741
G1079020en2008.50 Kuga8/2011
303-01- 20
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
20
REMOVAL AND INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

9.
E67742
10.
E67743
11 .
E67907
12.Torque: 10Nm
E67906
13.
E64165
14.Torque: 19Nm
Installation
1.To install, reverse the removal procedure.
2. Refer to: Door Window Motor Initialization
(501-11 Glass, Frames and Mechanisms,
General Procedures).
G1079020en2008.50 Kuga8/2011
303-01- 21
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
21
REMOVAL AND INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
E67382

Installation
1.Refer to: Valve Clearance Adjustment (303-01
Engine - 2.5L Duratec (147kW/200PS) - VI5,
General Procedures).
2. X=15mm.
•
E68818
3. Apply a thin coating.
Material: Engine Oil - 5W-30 (WSS-M2C913-C)
engine oil
E113630
4. Material: Flange Sealant - Anaerobic LP
(WSK-M2G348-A7 / 5U7J-M2G348-BA)
sealant
E68870
5. Tighten each bolt 2 turns at a time.
Torque: 17
Nm
G543491en2008.50 Kuga8/2011
303-01- 33
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
33
REMOVAL AND INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Cylinder Head(21 163 0)
General EquipmentFluid Container
Tire Lever
Materials
Specification
Name
WSS-M2C913-C
Engine Oil - 5W-30
SA-M1C9107-A / YS5J-
M1C9107-AA
Grease KS-PS
Removal
NOTE:
Removal steps in this procedure may
contain installation details.
1. Refer to: Cooling System Draining and Vacuum
Filling (303-03 Engine Cooling, General
Procedures).
2. Refer to: Fuel System Pressure Release
(310-00 Fuel System - General Information,
General Procedures).
3. Refer to: Battery Disconnect and Connect
(414-01 Battery, Mounting and Cables,
General Procedures).
4. Refer to: Air Cleaner (303-12 Intake Air
Distribution and Filtering - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
5.
E98184
6. Torque: 24Nm
E68748
7. Torque: 48Nm1.
2. Torque: 80
Nm
E65766
1
2
8. CAUTION: Make sure that the exhaust
flexible pipe is not forcibly bent.
General Equipment: Tire Lever
Material: Grease KS-PS (SA-M1C9107-A /YS5J-M1C9107-AA) grease
Torque: 50
Nm
E66052
x2
G1079022en2008.50 Kuga8/2011
303-01- 50
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
50
REMOVAL AND INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

2. CAUTION: Make sure that fluid level isto the MAX mark.
Refer to: Specifications (303-01 Engine - 2.5L
Duratec (147kW/200PS) - VI5, Specifications).
Material: Engine Oil - 5W-30 (WSS-M2C913-C) engine oil
E116204
3. Refer to: Door Window Motor Initialization
(501-11 Glass, Frames and Mechanisms,
General Procedures).
G1079022en2008.50 Kuga8/2011
303-01- 55
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
55
REMOVAL AND INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Oil Cooler(21 764 0)
General EquipmentFluid Container
Hose Clamp(s)
Materials
Specification
Name
WSS-M2C913-C
Engine Oil - 5W-30
Removal
NOTE: Removal steps in the procedure may
contain installation details.
1.
E65299
2.
WARNING: Be prepared to collect
escaping fluid.
General Equipment: Fluid Container
Torque: 38
Nm
E92766
3.
WARNING: Be prepared to collect
escaping fluids.
1. General Equipment: Fluid Container General Equipment: Hose Clamp(s)
2. Torque: 3
Nm
3. Torque: 17Nm
E74103
x4
x2
2
3
1
Installation
1. To install, reverse the removal procedure.
2. CAUTION: Make sure that fluid level is to the MAX mark.
Refer to: Specifications (303-01 Engine - 2.5L
Duratec (147kW/200PS) - VI5, Specifications).
Material: Engine Oil - 5W-30 (WSS-M2C913-C) engine oil
3. Refer to: Cooling System Draining and Vacuum
Filling (303-03 Engine Cooling, General
Procedures).
G834604en2008.50 Kuga8/2011
303-01- 58
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
58
REMOVAL AND INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Engine — Vehicles With: 5-Speed Automatic Transaxle(AW55)(21 132 0; 21 132 6; 21 132 7)
Removal
Special Tool(s) / General Equipment
303-122
Lifting Bracket, Engine
21068A
Cable Ties
Hose Clamp Remover/Installer
Hydraulic Jib Crane
Mounting Table Set
Special Tool(s) / General EquipmentRetaining Strap
Trolley Jack
Wooden Block
1. Refer to: Fuel System Pressure Release
(310-00 Fuel System - General Information,
General Procedures).
2. Refer to: Cowl Panel Grille (501-02 Front End
Body Panels, Removal and Installation).
3. Refer to: Battery(414-01 Battery, Mounting and
Cables, Removal and Installation).
4.
E114689
5. On both sides.
Loosen: 3
turn(s)
E99147
x3
G1191240en2008.50 Kuga8/2011
303-01- 59
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
59
REMOVAL
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

25.Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
26. Refer to: Cooling System Draining and Vacuum
Filling (303-03 Engine Cooling, General
Procedures).
27.
E98184
28.
E112511
29. On both sides.
E99722
30mm1
30.
G1191240en2008.50 Kuga8/2011
303-01- 65
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
65
REMOVAL
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

38.
E67408
39. WARNING: Be prepared to collectescaping fluid.
Refer to: Quick Release Coupling (310-00 Fuel
System - General Information, General
Procedures).
E68475
41. General Equipment: Hose Clamp
Remover/Installer
E112312
42.
E66479
G1191240en2008.50 Kuga8/2011
303-01- 70
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
70
REMOVAL
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
TO MODEL INDEX
BACK TO CHAPTER INDEX
E65220
37.40.
E68429

26.Torque: 48Nm1.
2. Torque: 9
Nm
E114610
27.Torque: 25
E114609
28.
E114728
29.Torque: 25Nm
E114606
30. CAUTION: Gearshift cables must not be
kinked or bent.
Refer to: Selector Lever Cable Adjustment -
Vehicles With: 5-Speed Automatic Transaxle
- AW55 AWD (307-05 Automatic
Transmission/Transaxle External Controls -
Vehicles With: 5-Speed Automatic Transaxle
- AW55 AWD/6-Speed Automatic Transaxle
- 6DCT450, General Procedures).
G1191241en2008.50 Kuga8/2011
303-01- 126
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
126
INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
1
1
2
Nm
E114436
x2