100 FORD KUGA 2011 1.G Workshop Manual

Engine Data
DescriptionHYDC
HYDB
Engine code
1-2-4-5-3
Firing order
Stage V
Stage IV
Emission level
83 mm
Bore
93.2 mm
Stroke
2522 cm³
Cubic capacity
9:1
Compression ratio
147 kW (200 PS)
Power output at 6000 rpm
320 Nm
Maximum torque at 1600
rpm
6850 rpm
Maximum engine speed
(intermittent)
6500 rpm
Maximum engine speed
(continous)
770 rpm
Idle speed
6
Number of main bearings
Belt
Camshaft drive
0.5 l/1000 Km
Oil consumption
Engine Oil
Specification
Ty p e
Viscosity / ambient temper-
ature
Recommended engine oil WSS-M2C913-C
Ford Formula E
SAE 5W-30 / below -20°C to over
+40°C
Alternative engine oils (for top-
up only)
ACEA A3/B3
Ford Formula XR+
SAE 10W-40 / -20°C to over
+40°C
ACEA A3/B3
Ford Formula S
SAE 5W-40 / below -20°C to over
+40°C
Engine Oil Capacity
Liters
Description
5.8
Service fill including filter
5.5
Service fill excluding filter
Oil Pressure
Bar
Description
1.0
Minimum oil pressure at 800 - 850 rpm (normal operating temperature)
3.5
Minimum oil pressure at 4000 rpm (normal operating temperature)
G1079019en2008.50 Kuga8/2011
303-01- 3
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
3
SPECIFICATIONS
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6.
E101006
7.
E79327
8.
E112446
9.
E112311
G1191240en2008.50 Kuga8/2011
303-01-60
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
60
REMOVAL
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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
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67. CAUTION: Make sure that nocomponents catch.
Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
68.
70. Special Tool(s): 303-122
General Equipment: Hydraulic Jib Crane
71. Remove the following items:
• General Equipment: Retaining Strap
G1191240en2008.50 Kuga8/2011
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Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
77
REMOVAL
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
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E68472
2
E65770
1
65.69.
E114607
66.
1
2E84187
E84188
303-122

E122634
1
2
3
4
5
12345
11. CAUTION: Make sure that thecomponents are installed to the position
noted before removal.
General Equipment: Piston Ring Compressor
E122334
x5
12. CAUTION: Make sure that thecomponents are installed to the position
noted before removal.
Apply a thin coating.
Material: Engine Oil - 5W-30 (WSS-M2C913-C)engine oil
E77266
13. CAUTIONS:
Make sure that the components are
installed to the position noted before
removal.
Make sure that new bolts are installed.
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303-01- 100
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
100
ASSEMBLY
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63.Torque: 10Nm
E112446
64.Torque: 12Nm
E101006
65.On both sides.
Torque: 35
x3
66.
G1191241en2008.50 Kuga8/2011
303-01- 137
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
137
INSTALLATION
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Nm
E99147
E114689

Cooling System Draining and Vacuum Filling
General EquipmentCooling System Vacuum Tester and Refiller
Fluid Container
Materials
Specification
Name
WSS-M97B44-D / 4U7J-
19544-AA2A
Antifreeze Super Plus
Premium
Draining
WARNING: When releasing the cooling
system pressure, cover the coolant
expansion tank cap with a thick cloth.
NOTE: Always follow the manufacturer's
instructions when handling the equipment.
1. Refer to: Engine Cooling System Health and
Safety Precautions (100-00 General
Information, Description and Operation).
2.
Release the cooling system pressure by slowly
turning the coolant expansion tank cap between
2 and 3 turns.
E68577
3. Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
4.
E65299
5.
WARNING: Be prepared to collect
escaping fluid.
Use a suitable coolant hose to drain the coolant.
General Equipment: Fluid Container
Loosen: 4
turn(s)
E97501
6.
E97501
G1034816en2008.50 Kuga8/2011
303-03- 5
Engine Cooling
303-03- 5
GENERAL PROCEDURES
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Radiator Lower Mounting Repair
General Equipment5mmDrillBit
Cable Ties
Flat File
1. General Equipment: Cable Ties
E100039
2.Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
3.
E98183
4.
E98184
5.
E100040
x4
6. General Equipment: Flat File
1.
2. General Equipment: 5 mm Drill Bit
G1062292en2008.50 Kuga8/2011
303-03- 7
Engine Cooling
303-03- 7
GENERAL PROCEDURES
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

8.Torque: 25Nm
E100040
x4
9.
E98184
10.
E98183
11 .Remove the cable ties securing the radiator and
condenser assembly.
G1062292en2008.50 Kuga8/2011
303-03- 9
Engine Cooling
303-03- 9
GENERAL PROCEDURES
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Cooling Fan Motor and Shroud — 2.5L Duratec (147kW/200PS)- VI5(24 222 0)
Removal
NOTE: Removal steps in this procedure may
contain installation details.
1. Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
2.
E98183
3.
E98184
4.
E112584
5.
E112335
6. Torque: 25Nm
G1156382en2008.50 Kuga8/2011
303-03- 11
Engine Cooling
303-03- 11
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL