FORD KUGA 2011 1.G Workshop Manual

E68435
4. Remove the oil pressure switch.
E68436
5. Attach the oil pressure gauge with the oilpressure gauge connector to the oil pressure
switch bore, and position it to allow reading from
above.
6. Lower the vehicle.
E68436
7. NOTE: Measure the oil pressure at an oil temperature of 100°C.
NOTE: Measure the oil pressure at idle speed and
at 4000 rpm.
NOTE: Minimum oil pressure at idle speed: 1.0
bar.
NOTE: Minimum oil pressure at 4000 rpm: 3.5 bar.
NOTE: Maximum oil pressure: 4.8 bar. Measure the oil pressure.
8. Raise and support the vehicle.
REFER to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
E68436
9. Detach the oil pressure gauge and connector from the oil pressure switch bore.
10. Coat the oil pressure switch with adhesive.
E68435
11. Install the oil pressure switch.
E68443
12. Connect the oil pressure switch electrical
connector to the oil pressure switch.
G1055128en2008.50 Kuga8/2011
303-00- 15
Engine System - General Information
303-00- 15
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E65955
13. Install the engine undershield.
14. Lower the vehicle.
Measure the oil pressure (Engine - 2.0L
Duratorq-TDCi (DW) Diesel)
1. Raise and support the vehicle.REFER to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
TIE40578
2. Remove the engine under shield.
TIE39595
3. Disconnect the oil pressure switch electrical connector.
TIE39596
4. Remove the oil pressure switch.
TIE39705
5. Attach the oil pressure gauge with the oilpressure gauge connector.
6. NOTE: Measure the oil pressure at the specified engine speed. Measure the oil
pressure at an oil temperature of 80° C.
NOTE: Measure the oil pressure at 2000 rpm and
at 4000 rpm.
NOTE: Oil pressure at 2000 rpm: 2.0 bar.
NOTE: Oil pressure at 4000 rpm: 4.0 bar.
Check the oil pressure.
TIE39705
7. Detach the oil pressure gauge and the oil pressure gauge connector.
8. Coat the oil pressure switch with adhesive.
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303-00-16
Engine System - General Information
303-00- 16
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TIE39704
35 Nm
9. Install the oil pressure switch.
TIE39595
10. Connect the oil pressure switch electricalconnector.
VFE0035742
11. Install the engine under shield.
12. Lower the vehicle.
Valve train analysis - static (engine off)
Remove the valve cover.
Check all valve train components for damage and
wear. Make sure that only original components are
installed and that all bolts and nuts have been
tightened to the correct tightening torque.
G1055128en2008.50 Kuga8/2011
303-00- 17
Engine System - General Information
303-00- 17
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SECTION 303-01 Engine— 2.5L Duratec (147kW/200PS) - VI5
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
SPECIFICATIONS
303-01-3
Specifications ........................................................................\
..............................................
303-01-3
Engine Data ........................................................................\
............................................
303-01-3
Engine Oil ........................................................................\
...............................................
303-01-3
Engine Oil Capacity ........................................................................\
................................
303-01-3
Oil Pressure ........................................................................\
............................................
303-01-4
Valve Clearance ........................................................................\
......................................
303-01-4
Crankshaft Main Bearing Selection ........................................................................\
........
DESCRIPTION AND OPERATION 303-01-6
Engine (Component Location) ........................................................................\
....................
303-01-9
Engine (Overview) ........................................................................\
......................................
303-01-9
General ........................................................................\
.......................................................
303-01-10
Cylinder head ........................................................................\
.............................................
303-01-14
Cylinder block ........................................................................\
.............................................
303-01-16
Engine (System Operation and Component Description) ...................................................
303-01-16
System Operation ........................................................................\
.......................................
303-01-17
Variable camshaft timing ........................................................................\
.........................
GENERAL PROCEDURES 303-01-19
Valve Clearance Adjustment ........................................................................\
.......................
REMOVAL AND INSTALLATION 303-01-20
(21 183 0)
Intake Manifold ........................................................................\
.......................
303-01-22
(21 467 0)
Crankshaft Front Seal ........................................................................\
.............
303-01-23
(21 238 0)
Valve Stem Seals ........................................................................\
...................
303-01-25
(21 304 0)
Timing Belt ........................................................................\
..............................
303-01-31
(21 284 0)
Camshafts ........................................................................\
..............................
303-01-36
(21 288 0)
Camshaft Seal ........................................................................\
........................
303-01-45
(21 154 0)
Oil Pan ........................................................................\
....................................
303-01-48
(21 714 0)
Oil Pump ........................................................................\
.................................
303-01-49
(21 187 0)
Exhaust Manifold ........................................................................\
....................
303-01-50
(21 163 0)
Cylinder Head ........................................................................\
.........................
303-01-56
(21 468 4)
Crankshaft Rear Seal ........................................................................\
.............
303-01-58
(21 764 0)
Oil Cooler ........................................................................\
................................
REMOVAL
303-01-59
(21

132 0;
21 132 6;
21 132 7)
Engine — Vehicles With: 5-Speed Automatic Transaxle (AW55)
...................
303-01-78
(21 139 4)
Engine Accessories ........................................................................\
................
303-01-1
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
1
.
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DISASSEMBLY303-01-84
(21 134 8)
Engine ........................................................................\
....................................
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES 303-01-93
(21 165 6)
Cylinder Head ........................................................................\
.........................
ASSEMBLY 303-01-94
(21 134 8)
Engine ........................................................................\
....................................
INSTALLATION 303-01-112
(21 139 4)
Engine Accessories ........................................................................\
................
303-01-119
(21 132 0;
21 132 6;
21 132 7)
Engine — Vehicles With: 5-Speed Automatic Transaxle (AW55)
...................
303-01-2
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
2
.
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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
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Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
3
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Bar
Description
4.8
Oil pressure relief valve opening pressure
Valve Clearance
mm
Description
0.17 - 0.23
Valve clearance (engine cold), intake
0.36 - 0.43
Valve clearance (engine cold), exhaust
Valves
mm
Description
101.93 - 102.07
Intake valve lenght
5.87 - 6.01
Intake valve shaft diameter
0.05 - 0.07
Intake valve guide clearance
101.43 - 101.57
Exhaust valve lenght
5.87 - 6.01
Exhaust valve shaft diameter
0.05 - 0.07
Exhaust valve guide clearance
Valve Seats
degree
Description
45.33 - 45.67
Intake valve seat angle
45.33 - 45.67
Exhaust valve seat angle
Cylinder Head
mm
Description
149.25 - 149.55
Cylinder head height
0.05
Maximum mating face distortion (lengthwise)
0.02
Maximum mating face distortion (crosswise)
0.30
Maximum face milling
Camshafts
mm
Description
8.68
Intake camshaft lobe lift
9.05
Exhaust camshaft lobe lift
Crankshaft
mm
Description
0.08 - 0.19
Crankshaft axial clearance
Crankshaft Main Bearing Selection
Code - Cylinder block
Code - Cylinder block
Code - Cylinder block
C
B
A
Crankshaft
main bearing carrier
Cylinder
block
Crankshaft
main bearing carrier
Cylinder
block
Crankshaft
main bearing carrier
Cylinder
block
Crankshaft
main bearing
for:
G1079019en2008.50 Kuga8/2011
303-01-
4
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
4
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Code - Cylinder block
Code - Cylinder block
Code - Cylinder block
Code -
Crankshaft blue thick
blue thick
blue thick
yellow
medium
yellow
medium
yellow
medium
A
blue thick
yellow
medium
yellow
medium
yellow
medium
yellow
medium
red thin
B
yellow
medium
yellow
medium
yellow
medium
red thin
red thin
red thin
C
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Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
5
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Engine – Component Location
Engine
E62441
1
65
4
3
2
9
10
13
12
11
8
7
Description
Item
Front engine cover
1
Rear engine cover
2
CMP (camshaft position) Sensor - intake
camshaft
3
CMP Sensor - exhaust camshaft
4Description
Item
Intake variable camshaft timing oil control
solenoid
5
Exhaust variable camshaft timing oil
control solenoid
6
Exhaust VCT control unit
7
Intake VCT control unit
8
G1032415en2008.50 Kuga8/2011
303-01- 6
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
6
DESCRIPTION AND OPERATION
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Description
Item
Timing belt idler pulley
9
Crankshaft timing belt pulley
10
Timing belt tensioner
11Description
Item
Coolant pump pulley
12
Timing belt
13
Cylinder block
E64016
1
2
3
G1032415en2008.50 Kuga8/2011
303-01- 7
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
7
DESCRIPTION AND OPERATION
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