filter FORD KUGA 2011 1.G Owner's Manual

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
SPECIFICATIONS
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Intake Manifold(21 183 0)
Removal
NOTE:Removal steps in this procedure may
contain installation details.
1. Refer to: Fuel System Pressure Release
(310-00 Fuel System - General Information,
General Procedures).
2. Refer to: Battery Disconnect and Connect
(414-01 Battery, Mounting and Cables,
General Procedures).
3. Refer to: Air Cleaner (303-12 Intake Air
Distribution and Filtering - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
4.
E65070
5. CAUTION: Make sure that the inside of the pipe ends are clean and free of oil
residue.
1. Torque: 10Nm
2. Torque: 4Nm
3. Torque: 10Nm
2
1
3
E68504
6.
E67375
7.
E68413
8.Torque: 10Nm
E67741
G1079020en2008.50 Kuga8/2011
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Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
20
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-
50
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Radiator — 2.5L Duratec (147kW/200PS) - VI5(24 254 0)
General EquipmentCable Ties
Hose Clamp Remover/Installer
Removal
NOTE: Removal steps in this procedure may
contain installation details.
1.
E112311
2.
E112335
3. Refer to: Charge Air Cooler (303-12 Intake Air
Distribution and Filtering - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
4. Refer to: Cooling System Draining and Vacuum
Filling (303-03 Engine Cooling, General
Procedures).
5. Torque: 25
Nm
E112625
x2x2
6. NOTE: The gasket is to be reused unless
damaged.
E99980
Vehicles with automatic transmission
7. General Equipment: Cable Ties
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303-03- 14
Engine Cooling
303-03- 14
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Thermostat — 2.5L Duratec (147kW/200PS) - VI5(24 454 0)
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: Air Cleaner (303-12 Intake Air
Distribution and Filtering - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
3.
E64638
4. Torque: 8Nm
E64639
x3
5.
E64640
Installation
1.To install, reverse the removal procedure.
G962443en2008.50 Kuga8/2011
303-03- 19
Engine Cooling
303-03- 19
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Thermostat Housing — 2.5L Duratec (147kW/200PS) -VI5(24 001 0)
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: Air Cleaner (303-12 Intake Air
Distribution and Filtering - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
3. Torque: 17
Nm
E63828
2
4
x3
1
3
4.
E67780
Installation
1.To install, reverse the removal procedure.
G962444en2008.50 Kuga8/2011
303-03- 20
Engine Cooling
303-03- 20
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Fuel Charging and Controls
General EquipmentFord diagnostic equipment
Inspection and Verification
1. Verify the customer concern by operating the system.
2. Visually inspect for obvious signs of mechanical or electrical damage. Visual Inspection Chart
Electrical
Mechanical
– Loose or corrodedconnector(s)
– Wiring harness
– Fuel injector(s)
– Fuel leaks
– Blocked or contamin-
ated fuel filter
– Damaged fuel supply manifold
– Damaged fuel line connections
– Damaged vacuum hoses
– Fuel rail pressure sensor
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible)
before proceeding to the next step.
4. If the concern is not visually evident, verify the symptom and refer to the Ford diagnostic
equipment .
Symptom Chart
Action
Possible Sources
Symptom
• CHECK the PATS LED extin-guishes within 3 seconds when
the ignition is turned on.
REFER to: Anti-Theft - Passive
(419-01 Anti-Theft - Passive,
Diagnosis and Testing).
• PAT S .
• Engine does not crank
• REFER to:Starting System
(303-06 Starting System -
2.5L Duratec (147kW/200PS)
- VI5, Diagnosis and Testing).
• Starting system.
• REFER to the Wiring Diagrams.
• Ignition switch.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• Powertrain control module
(PCM).
• RESET the IFS switch.
• Inertia fuel shutoff (IFS) switch.
• Engine cranks but does not
start
• Check the fuel system pres-sure.
• Low fuel system pressure.
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Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 4
DIAGNOSIS AND TESTING
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Action
Possible Sources
Symptom
• INSPECT the fuel lines.INSTALL new components as
necessary. TEST the system
for normal operation.
• Fuel lines damaged or blocked.
• INSTALL a new fuel filter.
• Fuel filter blocked.
• REFER to:Fuel Pump and
Sender Unit - 2.5L Duratec
(147kW/200PS) - VI5 (310-01
Fuel Tank and Lines,
Removal and Installation).
• Fuel pump and sender unit.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• Crankshaft position (CKP)
sensor.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• Camshaft position (CMP)
sensor.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
•PCM.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• Fuel rail fuel pressure sensor.
• INSPECT the fuel injectors.CLEAN the fuel injectors or
INSTALL a new set of injectors
as required only after the
checks have been carried out.
REFER to: Fuel Injectors (303-
04 Fuel Charging and
Controls - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
• Fuel injectors.
• CHECK the valve timing.REFER to: Timing Belt (303-01
Engine - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
• Incorrect valve timing.
• TEST the cylinder compres-sion.
REFER to: Engine(303-00
Engine System - General
Information, Diagnosis and
Testing).
• Low cylinder compression.
G1183441en2008.50 Kuga8/2011
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Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 5
DIAGNOSIS AND TESTING
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Action
Possible Sources
Symptom
• Check the fuel system pres-sure.
• Low fuel system pressure.
• Poor starting
• CHECK the system for fuelleak(s). REPAIR the system as
necessary.
• Fuel system leak.
• INSPECT the fuel system.INSTALL new components as
necessary. TEST the system
for normal operation.
• Fuel system restriction.
• INSTALL a new fuel filter.
• Fuel filter blocked.
• INSTALL a new air cleanerelement.
• Air cleaner element blocked.
• INSTALL a new engine oil filterand engine oil.
• Incorrect engine oil.
• DRAIN and REFILL the powersteering system with the correct
fluid.
REFER to: Power Steering
System Filling (211-00
Steering System - General
Information, General Proced-
ures).
• Incorrect power steering fluid.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• CKP sensor.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• Engine coolant temperature
(ECT) sensor.
• INSPECT the fuel injectors.CLEAN the fuel injectors or
INSTALL a new set of injectors
as required only after the
checks have been carried out.
REFER to: Fuel Injectors (303-
04 Fuel Charging and
Controls - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
• Fuel injector(s).
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• Fuel rail fuel pressure sensor.
G1183441en2008.50 Kuga8/2011
303-04A-
6
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 6
DIAGNOSIS AND TESTING
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Action
Possible Sources
Symptom
• REMOVE and visuallyINSPECT the catalytic
converter as necessary.
REFER to: Catalytic Converter
(309-00 Exhaust System -
2.5L Duratec (147kW/200PS)
- VI5, Removal and Installa-
tion).
• Catalytic converter blocked.
• TEST the engine cylindercompression.
REFER to: Engine(303-00
Engine System - General
Information, Diagnosis and
Testing).
• Low cylinder compression.
• INSTALL a new air cleanerelement.
• Air cleaner element blocked.
• Engine starts but immediately
stops
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• CKP sensor.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• CMP sensor.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
•PCM.
• Check the fuel system pres-sure.
• Low fuel system pressure.
• INSPECT the fuel system.INSTALL new components as
necessary. TEST the system
for normal operation.
• Fuel system restriction.
• INSTALL a new fuel filter.
• Fuel filter blocked.
• INSTALL a new air cleanerelement.
• Air cleaner element blocked.
• Poor idling
G1183441en2008.50 Kuga8/2011
303-04A- 7
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 7
DIAGNOSIS AND TESTING
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL