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

All vehicles
4.
E112858
1
x2
2
5. CAUTION: Make sure that theinstallation marks are aligned.
E113365
6. NOTE: Only tighten the bolts finger tight at
this stage.
Install the Special Tool(s): 303-1179
1.
2. Torque: 180
E122486
1
2
303-1179
G543492en2008.50 Kuga8/2011
303-01-
29
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
29
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Nm
7.
Remove the Special Tool(s): 303-1179
8.Torque:
• Stage 1: 25
Nm
• Stage 2: 60°
E122520
x4
9.Torque: 10
E68742
x4
Nm

Camshafts(21 284 0)
Special Tool(s) / General Equipment303-1178
Timing Tool Camshaft
E62051
Punch
Materials
Specification
Name
WSS-M2C913-C
Engine Oil - 5W-30
WSK-M2G348-A7 /
5U7J-M2G348-BA
Flange Sealant - Anaer-
obic LP
Removal
1.
Refer to: Camshaft Seal (303-01 Engine - 2.5L
Duratec (147kW/200PS) - VI5, Removal and
Installation).
2.
E113641
3. Remove the Special Tool(s): 303-1178
E66324
303-1178
4.General Equipment: Punch
E68948
5.Loosen each bolt 2 turns at a time until all bolts
are removed.
G543491en2008.50 Kuga8/2011
303-01- 31
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
31
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Camshaft Seal(21 288 0)
Special Tool(s)303-1054
Locking Tool, Timing Belt
Tensioner
3031054
303-1178
Timing Tool Camshaft
E62051
303-1179
Holding Wrench, Crankshaft
E62035
303-1182
Timing Tool, Crankshaft
E62027
303-318
Aligner/Installer, Crankshaft
Front Seal
21148
Removal
1.Remove the following items:
1. Refer to: Ignition Coil-On-Plug (303-07
Engine Ignition - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
2. Refer to: Starter Motor (303-06 Starting
System - 2.5L Duratec (147kW/200PS) -
VI5, Removal and Installation).
2.
E67902
3.
E68679
x5
G1166799en2008.50 Kuga8/2011
303-01- 36
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
36
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Vehicles with automatic timing belt tensioner
7. 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
8. WARNING: Take extra care when handling the compressed spring.
Remove the Special Tool(s): 303-1054
E113802
303-1054
All vehicles
9.Torque: 120Nm
E68746
10.Remove the Special Tool(s): 303-1178
E66324
303-1178
11 .Remove the Special Tool(s): 303-1182
E66328
303-1182
G1166799en2008.50 Kuga8/2011
303-01- 40
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
40
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

17.Remove the Special Tool(s): 303-1182
E66328
303-1182
18.Remove the Special Tool(s): 303-1178
E66324
303-1178
19.Torque: 17Nm
E68745
20.Torque: 40Nm
E83911
21. N O T E : Make sure that new components are
installed.
1.
2. Torque: 40
Nm
E113556
x21
x22
22.
Torque: 10Nm
E67905
G1166799en2008.50 Kuga8/2011
303-01- 42
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
42
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

23.Torque: 28Nm
x5
24.
25.Refer to: Ignition Coil-On-Plug (303-07 Engine
Ignition - 2.5L Duratec (147kW/200PS) - VI5,
Removal and Installation).
26. Torque: 10
E68742
27. To r q u e : 115Nm1.
2. Torque: 90
Nm
E68740
1
2
28.
E68741
29. N O T E : Only tighten the bolts finger tight at
this stage.
Install the Special Tool(s): 303-1179
1.
2. Torque: 180
30.
Remove the Special Tool(s): 303-1179
E122486
x41
2
303-1179
G1166799en2008.50 Kuga8/2011
303-01- 43
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
43
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
E68679
E67902
Nm
Nm

Oil Pump(21 714 0)
Special Tool(s)211-014
Remover, Steering Wheel
13019
Removal
NOTE:Removal steps in this procedure may
contain installation details.
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.Torque: 6Nm
E64878
4.Refer to: Crankshaft Front Seal (303-01 Engine
- 2.5L Duratec (147kW/200PS) - VI5, Removal
and Installation).
Installation
1. To install, reverse the removal procedure.
G543327en2008.50 Kuga8/2011
303-01- 48
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
48
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Crankshaft Rear Seal(21 468 4)
Special Tool(s)303-1181
Installer, Crankshaft Rear
Seal
E62048
303-254
Locking Tool, Flywheel
21135
303-293
Remover, Crankshaft Seal
21143
Removal
Vehicles with manual transmission
1.
Vehicles with automatic transmission
2.Refer to: Transmission (307-01 Automatic
Transmission/Transaxle - Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD,
Removal).
All vehicles
3. Special Tool(s): 303-254
E64889
4.Special Tool(s): 303-293
E64890
303-293
G1268481en2008.50 Kuga8/2011
303-01- 56
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
56
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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
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Vehicles with PCM security shield
14.
x4x4
E92343
Vehicles without PCM security shield
15.
E93509
16.
E65856
All vehicles
17.
E63326
11
2
18. CAUTION: Make sure that nocomponents catch.
Remove the following items:
• General Equipment: Retaining Strap
19. N O T E : Only tighten the bolts finger tight at this
stage.
G1191240en2008.50 Kuga8/2011
303-01- 62
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
62
REMOVAL
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL