2.5L FORD KUGA 2011 1.G Service Manual

Measure the compression pressure
(Engine - 2.5L Duratec-ST (VI5))
TIE44608
1. Remove the central junction box (CJB) cover.
TIE44609
2. Open the CJB and remove the fuel pump relay.
3. NOTE: The engine will start, run for a fewseconds and then stop.
Start the engine.
4. Remove the ignition coil-on-plug.
REFER to: Ignition Coil-On-Plug (303-07 Engine
Ignition - 2.5L Duratec (147kW/200PS) - VI5,
Removal and Installation). 5. Connect the battery ground cable.
REFER to: Battery Disconnect and Connect
(414-01 Battery, Mounting and Cables,
General Procedures).
E68679
x5
6. Using Special Tool 303-499, remove the spark plugs.
E68434
NOTE: Operate the starter motor with wide open
throttle until the pointer on the measuring device
stops rising.
7. Carry out the measurement in accordance with the instructions supplied with the measuring
device on every cylinder using a suitable
compression pressure recorder with a suitable
adapter.
E68680
28 Nm
8. Using Special Tool 303-499, install the sparkplugs.
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303-00- 10
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303-00- 10
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9. Install the ignition coil-on-plug.REFER to: Ignition Coil-On-Plug (303-07 Engine
Ignition - 2.5L Duratec (147kW/200PS) - VI5,
Removal and Installation).
TIE44609
10. Install the fuel pump relay and close the CJB.
TIE44608
11. Install the CJB cover.
Measure the compression pressure
(Engine - 2.0L Duratorq-TDCi (DW)
Diesel)
WARNINGS:
Do not smoke or carry lighted tobacco or
open flame of any type when working on or near any fuel related components.
Highly flammable vapors are always
present and can ignite. Failure to follow
these instructions may result in personal
injury.
Do not carry out any repairs to the fuel
injection system without checking that the
fuel pressure has dropped to zero and that
the fuel temperature has either reached
ambient temperature or is below 30°C,
whichever is the greater. Failure to follow
these instructions may result in personal
injury.
1. Using datalogger in the Ford diagnostic
equipment , check that the fuel pressure has
dropped to zero and that the fuel temperature
has either reached ambient temperature or is
below 30°C, whichever is the greater.
2. Raise and support the vehicle.
REFER to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
VFE0035742
3. Remove the engine undershield.
VFE0035752
4. Remove the radiator undershield.
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303-00- 11
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Put the engine cover into installation position
and clip it in place by pressing at the places
shown.• Make sure that the engine upper cover is fully engaged in the area of the fuel filter, if
necessary apply more pressure in the areas
shown.
25. Install the cowl panel grille.
REFER to: Cowl Panel Grille (501-02 Front End
Body Panels, Removal and Installation).
26. Raise and support the vehicle.
REFER to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
TIE44583
27. Install the glow plug relay.
VFE0035752
28. Install the radiator undershield.
VFE0035742
29. Install the engine undershield.
30. Lower the vehicle.
31. Reset the PCM fault memory.
Measure the oil pressure (21 113 0)
The oil pressure depends on various factors
(engine speed, oil temperature, oil viscosity,
amount of oil filter contamination etc.).
Measure the oil pressure (Engine - 2.5L
Duratec-ST (VI5))
1. Raise and support the vehicle.
REFER to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
E65955
2. Remove the engine undershield.
E68443
3. Disconnect the oil pressure switch electrical connector.
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303-00- 14
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303-00- 14
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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)
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303-01- 3
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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:
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303-01-
4
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
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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
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7
DESCRIPTION AND OPERATION
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