exhaust FORD KUGA 2011 1.G Owner's Manual

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:
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Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
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SPECIFICATIONS
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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
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Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
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2
E62614
1
Description
Item
Engine speed curve
1
Power output curve
2
By the use of VCT for the intake and exhaust
camshafts it is possible to attain maximum torque
across a wide engine speed range.
Cylinder head
The cylinder head consists of two parts. The top
half of the cylinder head consists of a valve cover
with integral camshaft bearing caps.
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Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
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E62857
1
2
3
6
5
4
Description
Item
Camshaft bearings
1
Valve cover
2
Cylinder head
3Description
Item
Spark plug well sealing ring
4
Exhaust camshaft
5
intake camshaft
6
A conventional cylinder head gasket is installed
between the cylinder head and the cylinder block. The gaskets between the other mating faces are
fluid gaskets.
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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-
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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.
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Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
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Engine – System Operation and Component Description
System Operation
The variable camshaft timing occurs
electro-hydraulically and individually for both
camshafts.
The camshaft adjusters work according to the vane
cell principle and have an adjustment range of 52°
crank angle on the intake side and 47° crank angle
on the exhaust side. On starting the engine and
during idling, both camshafts are mechanically
locked in their starting positions. The exhaust
camshaft is in the early position and the intake
camshaft is in the late position. The camshaftadjuster on the exhaust side has a torsion spring
which compensates the camshaft drive torque.
This ensures that the assembly can return to the
starting position under all operating conditions and
when the engine is turned off.
Internal exhaust gas recirculation can be realized
through continuous adjustment of the timings. This
results in better fuel consumption and more
favorable combustion temperatures which produce
less pollutants. This means that pollutant level IV
can be adhered to with a 3-way catalytic converter.
The variable timings also make it possible to
optimize performance with wide open throttle.
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Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
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Valve Clearance Adjustment
Special Tool(s)303-1183
Holder, Camshaft
E62756
1.Remove the camshafts.
Refer to: Camshafts (303-01 Engine - 2.5L
Duratec (147kW/200PS) - VI5, Removal and
Installation).
2. CAUTION: Make sure that the valve tappets are installed in their original
locations.
E68493
x20
x5
3.Install only one pair of tappets and the camshaft
for the first measurement.
Special Tool(s): 303-1183
Torque: 17
Nm
E68822
303-1183
4.Measure the valve clearance and if neccessary,
adjust by installing new tappets.
Special Tool(s): 303-1183
Torque: 12
Nm
E66325
303-1183
5.Repeat the measuring procedures for all
cylinders on the intake and on the exhaust side.
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Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
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GENERAL PROCEDURES
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Exhaust Manifold(21 187 0)
Removal
1.Refer to: Turbocharger (303-04 Fuel Charging
and Controls - Turbocharger - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
Installation
1. Refer to: Turbocharger (303-04 Fuel Charging
and Controls - Turbocharger - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
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REMOVAL AND INSTALLATION
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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
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Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
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