all FORD KUGA 2011 1.G Workshop 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
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E99948
31.General Equipment: Hose Clamp
Remover/Installer
G1191240en2008.50 Kuga8/2011
303-01- 66
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
66
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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
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E65220
37.40.
E68429

43.General Equipment: Hose Clamp
Remover/Installer
E114436
45.
303-01- 71
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
71
REMOVAL
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
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G1191240en2008.50 Kuga8/2011
44. CAUTION: Gearshift cables must not be
kinked or bent.
E114606
46.
E114728
47.
E114609
E68473
x2

48.
1
1
2
E114610
49.
E114612
51.
x2
52.
x6
E114614
53. CAUTION: Make sure that all openingsare sealed.
G1191240en2008.50 Kuga8/2011
303-01- 72
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
72
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E114611
50.
E64738

54.
E66050
55.
E112254
56. CAUTION: Make sure that the exhaustflexible pipe is not forcibly bent.
E112253
x2
57.Remove the following items:
1. Refer to: Transfer Case (307-07 Transfer
Case - Vehicles With: 5-Speed Automatic
Transaxle - AW55 AWD/6-Speed Automatic
Transaxle - 6DCT450, Removal).
2. Refer to: Front Halfshaft LH (205-04 Front
Drive Halfshafts, Removal and Installation).
3. Refer to: Accessory Drive Belt (303-05
Accessory Drive - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
58.
x2x2
E114619
G1191240en2008.50 Kuga8/2011
303-01- 73
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
73
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59. WARNING: Be prepared to collectescaping fluid.General Equipment: Hose Clamp
Remover/Installer
3.
E112533
1
3
x3
2
x34
x3
2
4x3
60.
E112534
1
2
61. WARNING: Be prepared to collect
escaping fluid.
General Equipment: Cable Ties
G1191240en2008.50 Kuga8/2011
303-01- 74
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
74
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4.
x4
7.
G1079024en2008.50 Kuga8/2011
303-01-79
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
79
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
E68413
5.
E67890
6.
E67893
x3
E115172
x5
8.
Install the Special Tool(s): 303-435, 303-435-06,
303-435-14B
x3
303-435-06
303-435-14B
E67897303-435

Vehicles with automatic timing belt tensioner
5. WARNING: Take extra care whenhandling the compressed spring.
6. WARNING: Take extra care whenhandling the compressed spring.
All vehicles
7.
G543498en2008.50 Kuga8/2011
303-01- 85
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
85
DISASSEMBLY
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Install the Special Tool(s): 303-1054
1
2
E113799
303-1054
Special Tool(s): 303-1054
E113800
1
2
3
303-1054
E68408
1
2
8.
E68490
1
2

Cylinder Head(21 165 6)
Special Tool(s)303-361B
Compressor, Valve Spring
E62757
303-361B-06
Adapter for 303-361B
E62041
303-508
Pliers, Valve Stem Seal
21211
Disassembly
1.Special Tool(s): 303-361B, 303-361B-06
E66326
303-361B
303-361B-06
2.Special Tool(s): 303-508
E66114
303-508
Assembly
3.To install, reverse the assembly procedure.
G543499en2008.50 Kuga8/2011
303-01- 93
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
93
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