Index FORD KUGA 2011 1.G Workshop Manual

48. CAUTION: Make sure that the
installation marks are aligned.
E113365
49.Torque: 35Nm
E68749
50.Remove the Special Tool(s): 303-1182
303-1182
51.Remove the Special Tool(s): 303-1178
303-1178
E68745
G543500en2008.50 Kuga8/2011
303-01-11 0 Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-11 0
ASSEMBLY
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53.Torque: 40Nm
E83911
54. N O T E : Make sure that new components are
installed.
1.
2. Torque: 40
Nm
E113556
x21
x22
55.
Torque: 10Nm
E65076
56.Torque: 10Nm
E68416
57. N O T E : Only tighten the bolts finger tight at
this stage.
Install the Special Tool(s): 303-1179
1.
2. Torque: 180
Nm
58.
Remove the Special Tool(s): 303-1179
E122486
x41
2
303-1179
59.Torque:
• Stage 1: 25
Nm
• Stage 2: 60°
E122520
x4
G543500en2008.50 Kuga8/2011
303-01- 111
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
111
ASSEMBLY
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Engine Accessories(21 139 4)
Installation
Special Tool(s)303-122
Lifting Bracket, Engine
21068A
303-254
Locking Tool, Flywheel
21135
303-435
Mounting Stand
21187
303-435-06
Mounting Bracket for 303-435
21031B
303-435-14B
Mounting Plate for
303-435-06
E62805
1.Torque: 17Nm•
E68407
12
2.Torque: 48Nm
E84148
x4
Vehicles with manual transmission
3. CAUTIONS:
Make sure that new bolts are installed.
Make sure that no excess sealant
residue is evident.
G1079026en2008.50 Kuga8/2011
303-01- 11 2
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
11 2
INSTALLATION
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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
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
All vehicles
5. Torque: 17Nm
E68412
6.
E67909
7.Torque: 24Nm
x12
E66830
G1079026en2008.50 Kuga8/2011
303-01- 11 3
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
11 3
INSTALLATION
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8.Torque: 12Nm
x2
9. Torque: 26Nm1.
2. Torque: 38
Nm
10.Torque: 38Nm
11 .Torque: 19Nm
E67382
12.Torque: 10Nm
13.Torque: 10Nm
G1079026en2008.50 Kuga8/2011
303-01- 11 4
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
11 4
INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
E66829
E66827
E66826
E67906
E67905

14.
E67907
15.
16.Torque:10Nm
E67904
E67743
E67901
E67742
303-01-115Engine—2.5LDuratec(147kW/200PS)-VI5303-01-115
INSTALLATION
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E67903
17.
18.
19.
G1079026en2008.50 Kuga8/2011

23.Install the Special Tool(s): 303-122
G1079026en2008.50 Kuga8/2011
303-01- 11 6
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
11 6
INSTALLATION
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
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E67741
E67899
E67898
20. Torque: 10Nm
21.
22.
303-122
24.Remove the Special Tool(s): 303-435,
303-435-06, 303-435-14B
E67897
E84188
303-435-06
303-435-14B
303-435
x3

25.Torque: 24Nm27.Torque: 20Nm
303-01- 11 7
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
11 7
INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
x5
26.
Torque: 17
G1079026en2008.50 Kuga8/2011
E115172
Nm1.
2. Torque: 16
Nm
3. Torque: 24Nm
E67894
2
3
1
E67890
28.
E68413
29.
E67378

30.Torque: 24Nm1.
2. Torque: 15
Nm
E84101
1
2
31.Torque: 10Nm
E74122
G1079026en2008.50 Kuga8/2011
303-01- 11 8
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
11 8
INSTALLATION
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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)
Installation
Special Tool(s) / General Equipment
303-122
Lifting Bracket, Engine
21068A
Hose Clamp Remover/Installer
Hydraulic Jib Crane
Mounting Table Set
Retaining Strap
Round-Ended Steel Rule
Trolley Jack
Wooden Block
1. Special Tool(s): 303-122
General Equipment: Hydraulic Jib Crane
E84188
303-122
2.General Equipment: Round-Ended Steel Rule
14 mm14 mm
E114801
3.Torque: 48Nm
E84187
G1191241en2008.50 Kuga8/2011
303-01- 11 9
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
11 9
INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL