Index FORD KUGA 2011 1.G Workshop Manual
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Page 1583 of 2057
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
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Page 1584 of 2057
9.Torque: 24Nm
E112254
G1079022en2008.50 Kuga8/2011
303-01- 51
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
51
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E66726
10. CAUTION: Make sure that the inside of the pipe ends are clean and free of oil
residue.
11 .Torque: 24Nm
E112607
1
2
34
12. CAUTION: Make sure that the gaskets
are correctly located.
E112806
13.
E65070
Torque: 24Nm
Page 1585 of 2057
15. CAUTION: Make sure that the inside ofthe pipe ends are clean and free of oil
residue.
1. Torque: 10
E68504
16. CAUTION: Make sure that the inside ofthe pipe ends are clean and free of oil
residue.
E68413
18.Torque: 10Nm
E113004
x8
19.
G1079022en2008.50 Kuga8/2011
303-01- 52
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
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E67743
14.
E106249
Nm
2. Torque: 4Nm
3. Torque: 10Nm
2
1
3
17.
E67375
Page 1586 of 2057
20.
21.Torque: 10Nm
E67906
22.
E64165
23.Torque: 19Nm
24.
E68474
25.Refer to: Camshafts (303-01 Engine - 2.5L
Duratec (147kW/200PS) - VI5, Removal and
Installation).
26. Torque: 25
Nm
G1079022en2008.50 Kuga8/2011
303-01- 53
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
53
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E67907E67382
E68998
Page 1587 of 2057
27. CAUTION: Note the position of thecomponents before removal.
E68493
x20
x5
28. CAUTION: Make sure that no fluids arepresent in the threaded bores.
Torque:
• Stage 1: 20
Nm
• Stage 2: 60Nm
• Stage 3: 130°
E68494
1591284
37111062
29. WARNING: Be prepared to collectescaping fluid.
General Equipment: Fluid Container
Torque: 38
Nm
E115890
30.Torque: 25Nm
E115891
31.
E116077
Installation
1.To install, reverse the removal procedure.
G1079022en2008.50 Kuga8/2011
303-01- 54
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
54
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Page 1588 of 2057
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
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Page 1589 of 2057
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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Page 1590 of 2057
Installation
1.Special Tool(s): 303-1181
E64891
303-1181
Vehicles with manual transmission
2. CAUTIONS:
Make sure that new bolts are installed.
Make sure that no excess sealant
residue is evident.
NOTE: Make sure that the locating pin on the
crankshaft is aligned with the guide hole in the
flywheel or flexplate.
Special Tool(s): 303-254
Torque:
• Stage 1: 45
Nm
• Stage 2: 65°
E124911
1
2
3
4
5
67
8
9
10
3.
Vehicles with automatic transmission
4. CAUTIONS:
Make sure that new bolts are installed.
Make sure that no excess sealant
residue is evident. NOTE:
Make sure that the locating pin on the
crankshaft is aligned with the guide hole in the
flywheel or flexplate.
Special Tool(s): 303-254
Torque:
• Stage 1: 45
Nm
• Stage 2: 50°
E124911
1
2
3
4
5
67
8
9
10
5. Refer to: Transmission (307-01 Automatic
Transmission/Transaxle - Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD,
Removal).
G1268481en2008.50 Kuga8/2011
303-01- 57
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
57
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Page 1591 of 2057
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
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Page 1592 of 2057
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