belt FORD KUGA 2011 1.G User Guide

Action
Possible Sources
Symptom
• CHECK the intake air system.Engine - 2.5L Duratec-ST (VI5)
-
REFER to: Intake Air Distribu-
tion and Filtering (303-12
Intake Air Distribution and
Filtering - 2.5L Duratec
(147kW/200PS) - VI5,
Diagnosis and Testing).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Engine intake air system.
• CHECK the glow plugs.INSTALL new glow plugs as
necessary.
• Glow plug faulty (diesel engine
only).
• CHECK the engine manage-ment system. Engine - 2.5L
Duratec-ST (VI5) -
REFER to: Electronic Engine
Controls (303-14 Electronic
Engine Controls - 2.5L
Duratec (147kW/200PS) -
VI5, Diagnosis and Testing).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Engine management system.
• CHECK the ignition system.Engine - 2.5L Duratec-ST (VI5)
-
REFER to: Engine Ignition
(303-07 Engine Ignition - 2.5L
Duratec (147kW/200PS) -
VI5, Diagnosis and Testing).
• Ignition system (petrol engine
only).
• CHECK and adjust the valvetiming. Engine - 2.5L Duratec-
ST (VI5) -
REFER to: Timing Belt (303-01
Engine - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Incorrect valve timing.
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303-00-
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Engine System - General Information
303-00- 5
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Action
Possible Sources
Symptom
• CHECK the timing belt/timingchain and sprockets/pulleys.
INSTALL new components as
necessary. Engine - 2.5L
Duratec-ST (VI5) -
REFER to: Timing Belt (303-01
Engine - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Broken or damaged timing
belt/timing chain or
pulley/sprocket.
• CHECK the fuel system.Engine - 2.5L Duratec-ST (VI5)
-
REFER to: Fuel Charging and
Controls (303-04 Fuel Char-
ging and Controls - 2.5L
Duratec (147kW/200PS) -
VI5, Diagnosis and Testing).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Fuel system.
• Very poor power output or fuel
consumption too high or engine
running rough.
• CHECK the intake air system.Engine - 2.5L Duratec-ST (VI5)
-
REFER to: Intake Air Distribu-
tion and Filtering (303-12
Intake Air Distribution and
Filtering - 2.5L Duratec
(147kW/200PS) - VI5,
Diagnosis and Testing).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Engine intake air system.
• CHECK the exhaust system.
• Exhaust system blocked.
• CHECK the engine manage-ment system. Engine - 2.5L
Duratec-ST (VI5) -
REFER to: Electronic Engine
Controls (303-14 Electronic
Engine Controls - 2.5L
Duratec (147kW/200PS) -
VI5, Diagnosis and Testing).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Engine management system.
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303-00-
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Engine System - General Information
303-00- 6
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Action
Possible Sources
Symptom
• CHECK the ignition system.Engine - 2.5L Duratec-ST (VI5)
-
REFER to: Engine Ignition
(303-07 Engine Ignition - 2.5L
Duratec (147kW/200PS) -
VI5, Diagnosis and Testing).
• Fault in ignition system (petrol
engine only).
• CHECK the turbocharger.Engine - 2.5L Duratec-ST (VI5)
-
REFER to: Turbocharger (303-
04 Fuel Charging and
Controls - Turbocharger -
2.5L Duratec (147kW/200PS)
- VI5, Diagnosis and Testing).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Turbocharger.
• CHECK and adjust valvetiming. INSTALL new compon-
ents as necessary. Engine -
2.5L Duratec-ST (VI5) -
REFER to: Timing Belt (303-01
Engine - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Incorrect valve timing. Timing
belt/timing sprocket or
pulley/sprocket damaged.
• CHECK the electronic enginecontrols. Engine - 2.5L Duratec-
ST (VI5) -
REFER to: Electronic Engine
Controls (303-14 Electronic
Engine Controls - 2.5L
Duratec (147kW/200PS) -
VI5, Diagnosis and Testing).
• Ignition timing incorrect (petrol
engine only).
• CHECK engine auxiliarycomponents for damage or
looseness. CHECK and adjust
valve timing. INSTALL new
components as necessary.
Engine - 2.5L Duratec-ST (VI5)
-
REFER to: Timing Belt (303-01
Engine - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Engine auxiliary components
loose or damaged.
• Noisy running
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303-00-
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Engine System - General Information
303-00- 7
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Action
Possible Sources
Symptom
• DETERMINE which type of fuelwas last put into the fuel tank
(note the country specific fuel
specifications).
• Incorrect fuel
• Noisy running, misfiring, back-
firing or knocking
• CHECK the fuel system forwater or other contamination.
• Water in fuel or fuel contamin-
ated.
• CHECK and adjust valvetiming. INSTALL new compon-
ents as necessary. Engine -
2.5L Duratec-ST (VI5) -
REFER to: Timing Belt (303-01
Engine - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Valve timing incorrect, timing
belt/chain or pulley/sprocket
damaged.
• INSTALL new hydraulic lashadjusters or adjust the valve
clearance. Engine - 2.5L
Duratec-ST (VI5) -
REFER to: Valve Clearance
Adjustment (303-01 Engine -
2.5L Duratec (147kW/200PS)
- VI5, General Procedures).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Valve clearance too large due
to faulty valve tappets or worn
valve train components.
• Noisy running or valve train
noise
• INSTALL a new timing belt ortiming chain. Engine - 2.5L
Duratec-ST (VI5) -
REFER to: Timing Belt (303-01
Engine - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Timing belt or timing chain
damaged.
• CHECK the timing belt tension.INSTALL a new timing belt or
timing chain as necessary.
Engine - 2.5L Duratec-ST (VI5)
-
REFER to: Timing Belt (303-01
Engine - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Timing belt or timing chain
incorrectly tensioned.
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303-00- 8
Engine System - General Information
303-00- 8
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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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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)
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Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
3
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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
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DESCRIPTION AND OPERATION
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Engine – Overview
General
E62439
The 2.5L Duratec (VI5) engine is a turbo engine
with 5 cylinders and 20 valves, with electronically
controlled camshaft adjustment for both camshafts.The valve train is driven by a timing belt.
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Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
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Description
Item
Exhaust camshaft
1
intake camshaft
2
Valve cover
3
CMP Sensor - intake camshaft
4Description
Item
Intake camshaft reference mark
5
Exhaust camshaft reference mark
6
CMP Sensor - exhaust camshaft
7
CAUTION: Before removal, mark the
camshafts as the intake and exhaust
camshafts can be mixed up.
A reference mark for the CMP sensor is machined
into each camshaft. When the camshafts are set
precisely to the timing marks, the machined mark
on the exhaust camshaft is located roughly at the
5 o'clock position and the machined mark on the
intake camshaft is located at 8 o'clock.
When changing the toothed belts it is not necessary
to dismantle the camshaft adjustment units. A
special tool prevents the VCT control units from
turning during the adjustment process by locking
the two VCT control units to one another.
A further special tool is needed to fix the camshafts
in the adjustment position. The special tool
engages in corresponding recesses for the
reference marks on the CMP sensors. Each camshaft is fixed in place using four bearing
caps and the bearing cap VVT. The bearing caps
must not be changed around and must always be
fitted in their original positions.
The VCT control units for the intake and exhaust
camshafts are moved into the locked base position
when the engine is stopped through the
engagement of a spring-loaded locking pin. The
movement to the locked base position is assisted
by the tensile force of the timing belt for the intake
VCT control unit. With the exhaust VCT control
unit, a spring inside the control unit additionally
assists in reaching the locked base position. The
intake VCT control unit is in the "retarded timing"
position and the exhaust VCT control unit is in the
"advanced timing" position when in the locked base
position. The lock is hydraulically released when
the engine is started depending on the oil pressure.
The mechanical valve tappets are maintenance
free.
G1092773en2008.50 Kuga8/2011
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Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
13
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Timing marks
132
45
6
78
E62440
Description
Item
Exhaust camshaft pulley timing mark
1
Engine front cover with timing marks
2
Intake camshaft pulley timing mark
3
Intake camshaft drive gear
4Description
Item
Exhaust camshaft drive gear
5
Crankshaft timing belt pulley timing mark
6
Crankshaft timing belt pulley
7
Crankshaft
8
The front engine cover must always be fitted when
checking and adjusting the valve timing or timing
belt tension, as the timing marks for both camshaft
pulleys are provided on its front end.
Correct timing belt tension is ensured by the
automatic timing belt tensioner.
No direction of movement is specified when using
a new timing belt. If, however, the old timing belt
is reused, the direction of movement must be
marked prior to removal.
Once the timing belt has been correctly tensioned,
the engine must be rotated by hand two turns
clockwise at the crankshaft in order to allow a subsequent check of the timing belt tension and
adjustment.
Cylinder block
The cylinder block consists of three parts. These
are the cylinder block, the lower crankcase and the
sump pan. The cylinder block has five cylinder
liners made of cast iron, which cannot be replaced.
The pistons are made of a homogeneous aluminum
alloy with a graphite coating on the sides. This
coating serves to reduce friction and dampen noise.
The pistons are cooled from below via oil-spray
nozzles screwed into the cylinder block.
G1092773en2008.50 Kuga8/2011
303-01-
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Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
14
DESCRIPTION AND OPERATION
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