engine remove FORD KUGA 2011 1.G Owner's Manual

TIE44583
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).
E50527
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.
E50472
2
1
3
4
9.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 0°C, 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.
TIE39594
10.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.
TIE39687
13. Remove the glow plug power supply.
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18. Install the glow plugs.
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.
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TIE39592TIE39688
E39706
303-1056
TIE39593
3Nm
TIE39594
E50473
3Nm
5Nm 5Nm
14. Remove the glow plugs.
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.
19. Install the glow plug power supply.
20. Install the EGR valve.
21. Install the EGR cooler.
22. Connect the fuel injector electrical connectors.
23. Apply soap solution to the ball clip mountingsin the engine upper cover.
• Soap solution (maximum concentration of soap in water 1:200).
24.

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).
TIE44583
27. Install the glow plug relay.
VFE0035752
28. Install the radiator undershield.
VFE0035742
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.).
Measure the oil pressure (Engine - 2.5L
Duratec-ST (VI5))
1. Raise and support the vehicle.
REFER to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
E65955
2. Remove the engine undershield.
E68443
3. Disconnect the oil pressure switch electrical connector.
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E68435
4. Remove the oil pressure switch.
E68436
5. Attach the oil pressure gauge with the oilpressure gauge connector to the oil pressure
switch bore, and position it to allow reading from
above.
6. Lower the vehicle.
E68436
7. NOTE: Measure the oil pressure at an oil temperature of 100°C.
NOTE: Measure the oil pressure at idle speed and
at 4000 rpm.
NOTE: Minimum oil pressure at idle speed: 1.0
bar.
NOTE: Minimum oil pressure at 4000 rpm: 3.5 bar.
NOTE: Maximum oil pressure: 4.8 bar. Measure the oil pressure.
8. Raise and support the vehicle.
REFER to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
E68436
9. Detach the oil pressure gauge and connector from the oil pressure switch bore.
10. Coat the oil pressure switch with adhesive.
E68435
11. Install the oil pressure switch.
E68443
12. Connect the oil pressure switch electrical
connector to the oil pressure switch.
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E65955
13. Install the engine undershield.
14. Lower the vehicle.
Measure the oil pressure (Engine - 2.0L
Duratorq-TDCi (DW) Diesel)
1. Raise and support the vehicle.REFER to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
TIE40578
2. Remove the engine under shield.
TIE39595
3. Disconnect the oil pressure switch electrical connector.
TIE39596
4. Remove the oil pressure switch.
TIE39705
5. Attach the oil pressure gauge with the oilpressure gauge connector.
6. NOTE: Measure the oil pressure at the specified engine speed. Measure the oil
pressure at an oil temperature of 80° C.
NOTE: Measure the oil pressure at 2000 rpm and
at 4000 rpm.
NOTE: Oil pressure at 2000 rpm: 2.0 bar.
NOTE: Oil pressure at 4000 rpm: 4.0 bar.
Check the oil pressure.
TIE39705
7. Detach the oil pressure gauge and the oil pressure gauge connector.
8. Coat the oil pressure switch with adhesive.
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TIE39704
35 Nm
9. Install the oil pressure switch.
TIE39595
10. Connect the oil pressure switch electricalconnector.
VFE0035742
11. Install the engine under shield.
12. Lower the vehicle.
Valve train analysis - static (engine off)
Remove the valve cover.
Check all valve train components for damage and
wear. Make sure that only original components are
installed and that all bolts and nuts have been
tightened to the correct tightening torque.
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Valve Clearance Adjustment
Special Tool(s)303-1183
Holder, Camshaft
E62756
1.Remove the camshafts.
Refer to: Camshafts (303-01 Engine - 2.5L
Duratec (147kW/200PS) - VI5, Removal and
Installation).
2. CAUTION: Make sure that the valve tappets are installed in their original
locations.
E68493
x20
x5
3.Install only one pair of tappets and the camshaft
for the first measurement.
Special Tool(s): 303-1183
Torque: 17
Nm
E68822
303-1183
4.Measure the valve clearance and if neccessary,
adjust by installing new tappets.
Special Tool(s): 303-1183
Torque: 12
Nm
E66325
303-1183
5.Repeat the measuring procedures for all
cylinders on the intake and on the exhaust side.
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Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
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Crankshaft Front Seal(21 467 0)
Special Tool(s)211-014
Remover, Steering Wheel
13019
303-1180
Installer, Crankshaft Front
Seal
E62050
303-293
Remover, Crankshaft Seal
21143
Removal
1.Refer to: Timing Belt (303-01 Engine - 2.5L
Duratec (147kW/200PS) - VI5, Removal and
Installation).
2. Special Tool(s): 211-014
E64877
211-014
3.Special Tool(s): 303-293
E65179
303-293
Installation
1.Special Tool(s): 303-1180
E64880
303-1180
2. NOTE: The crankshaft timing pulley can only
be installed in 1 position on the crankshaft
splines.
E64881
3. Refer to: Timing Belt (303-01 Engine - 2.5L
Duratec (147kW/200PS) - VI5, Removal and
Installation).
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REMOVAL AND INSTALLATION
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Valve Stem Seals(21 238 0)
Special Tool(s)303-361B
Compressor, Valve Spring
E62757
303-361B-06
Adapter for 303-361B
E62041
303-363
Adapter, Air Supply (Cylinder
Head)
21157
303-508
Pliers, Valve Stem Seal
21211
Removal
1.Remove the camshafts.
Refer to: Camshafts (303-01 Engine - 2.5L
Duratec (147kW/200PS) - VI5, Removal and
Installation). 2.
E66111
3.
Using the special tool, apply 7 to 10 bar of
compressed air into the cylinder.
Special Tool(s): 303-363
E66112
303-363
4.Special Tool(s): 303-361B, 303-361B-06
E66326
303-361B
303-361B-06
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Installation
Vehicles with mechanical timing belt tensioner
1. NOTE:Make sure that new components are
installed.
1. Torque: 25
Nm
3. Torque: 25Nm
E68489
3
1
2
-20 C 20 C 50 C
Vehicles with automatic timing belt tensioner
2. NOTE: Make sure that new components are
installed.
1. Torque: 25
Nm
3. Special Tool(s): 303-1054 Torque: 25
Nm
E113801
12
3
303-1054
3. WARNING: Take extra care when handling the compressed spring.
Remove the Special Tool(s): 303-1054
E113802
303-1054
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