FORD KUGA 2011 1.G Workshop Manual

Installation
Vehicles with mechanical timing belt tensioner
1. NOTE:Make sure that new components are
installed.
1. Torque: 25
Nm
3. Torque: 25Nm
E68489
3
1
2
-20 C 20 C 50 C
Vehicles with automatic timing belt tensioner
2. 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
3. WARNING: Take extra care when handling the compressed spring.
Remove the Special Tool(s): 303-1054
E113802
303-1054
G543492en2008.50 Kuga8/2011
303-01- 28
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
28
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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

10.Torque: 115Nm1.
2. Torque: 90
Nm
E68740
1
2
11 .
E68741
12.Refer to: Air Conditioning (A/C) Compressor
Belt (303-05 Accessory Drive - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
G543492en2008.50 Kuga8/2011
303-01- 30
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
30
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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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E68743
1
2
3
4
913202834423327198
7
6
511243837231610
4112
18263240464335292114
17253139454436302215
G543491en2008.50 Kuga8/2011
303-01-32
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
32
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Installation
1.Refer to: Valve Clearance Adjustment (303-01
Engine - 2.5L Duratec (147kW/200PS) - VI5,
General Procedures).
2. X=15mm.
•
E68818
3. Apply a thin coating.
Material: Engine Oil - 5W-30 (WSS-M2C913-C)
engine oil
E113630
4. Material: Flange Sealant - Anaerobic LP
(WSK-M2G348-A7 / 5U7J-M2G348-BA)
sealant
E68870
5. Tighten each bolt 2 turns at a time.
Torque: 17
Nm
G543491en2008.50 Kuga8/2011
303-01- 33
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
33
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

E87508
46
45
44
43
3834271913514202839
40
41
423623910243137
635
29211571412182633
30221682311172532
G543491en2008.50 Kuga8/2011
303-01-34
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
34
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6.Install the Special Tool(s): 303-1178
Torque: 10
Nm
E113631
x2
303-1178
303-1178
12
3
7.
E113641
8.Refer to: Camshaft Seal (303-01 Engine - 2.5L
Duratec (147kW/200PS) - VI5, Removal and
Installation).
G543491en2008.50 Kuga8/2011
303-01- 35
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
35
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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

4.
E67905
5.
E68491
6.
E68745
7.Refer to: Timing Belt (303-01 Engine - 2.5L
Duratec (147kW/200PS) - VI5, Removal and
Installation).
8. Install the Special Tool(s): 303-1178
Torque: 10
Nm
E66324
303-1178
9.
E68749
10.
E74333
x2
G1166799en2008.50 Kuga8/2011
303-01- 37
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
37
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL