303-01 FORD KUGA 2011 1.G Service Manual

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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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-
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11 .
E71704
Installation
1.Special Tool(s): 303-318
E68747
303-318
2. NOTE: Only tighten the bolts finger tight at this
stage.
E74333
x2
3.
E83911
4. Using the special tool, align the crankshaft.
Install the Special Tool(s): 303-1182
E66328
303-1182
G1166799en2008.50 Kuga8/2011
303-01- 38
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
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5. CAUTION: Make sure that theinstallation marks are aligned.
E113883
Vehicles with mechanical timing belt tensioner
6. NOTE: Make sure that new components are
installed.
1. Torque: 25
Nm
3. NOTE: The timing belt tensioner setting is
dependant on the engine temperature.
Torque: 25
Nm
E68489
3
1
2
-20 C 20 C 50 C
G1166799en2008.50 Kuga8/2011
303-01- 39
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
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Vehicles with automatic timing belt tensioner
7. 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
8. WARNING: Take extra care when handling the compressed spring.
Remove the Special Tool(s): 303-1054
E113802
303-1054
All vehicles
9.Torque: 120Nm
E68746
10.Remove the Special Tool(s): 303-1178
E66324
303-1178
11 .Remove the Special Tool(s): 303-1182
E66328
303-1182
G1166799en2008.50 Kuga8/2011
303-01- 40
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
40
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

G1166799en2008.50 Kuga8/2011
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x2
E66328
303-1182
E68749
12.15. CAUTION: Make sure that theinstallation marks are aligned.
303-01- 41
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
41
REMOVAL AND INSTALLATION
E112858
13. Using the special tool, align the crankshaft.
Install the Special Tool(s): 303-1182
14.Install the Special Tool(s): 303-1178
Torque: 10
Nm
16.Torque: 35Nm
E66324
303-1178
E113365
1
2

17.Remove the Special Tool(s): 303-1182
E66328
303-1182
18.Remove the Special Tool(s): 303-1178
E66324
303-1178
19.Torque: 17Nm
E68745
20.Torque: 40Nm
E83911
21. N O T E : Make sure that new components are
installed.
1.
2. Torque: 40
Nm
E113556
x21
x22
22.
Torque: 10Nm
E67905
G1166799en2008.50 Kuga8/2011
303-01- 42
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
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23.Torque: 28Nm
x5
24.
25.Refer to: Ignition Coil-On-Plug (303-07 Engine
Ignition - 2.5L Duratec (147kW/200PS) - VI5,
Removal and Installation).
26. Torque: 10
E68742
27. To r q u e : 115Nm1.
2. Torque: 90
Nm
E68740
1
2
28.
E68741
29. N O T E : Only tighten the bolts finger tight at
this stage.
Install the Special Tool(s): 303-1179
1.
2. Torque: 180
30.
Remove the Special Tool(s): 303-1179
E122486
x41
2
303-1179
G1166799en2008.50 Kuga8/2011
303-01- 43
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
E68679
E67902
Nm
Nm

31.Torque:
• Stage 1: 25
Nm
• Stage 2: 60°
E122520
x4
32.Install the following items:
1. Refer to: Air Conditioning (A/C) Compressor
Belt (303-05 Accessory Drive - 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).
G1166799en2008.50 Kuga8/2011
303-01- 44
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Oil Pan(21 154 0)
General EquipmentCable Ties
Materials
Specification
Name
WSS-M2C913-C
Engine Oil - 5W-30
WSK-M2G348-A7 /
5U7J-M2G348-BA
Flange Sealant - Anaer-
obic LP
Removal
NOTE:
Removal steps in the procedure may
contain installation details.
1. Refer to: Accessory Drive Belt (303-05
Accessory Drive - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
2. General Equipment: Cable Ties
Torque: 25
Nm
E138810
x3
3.
G543325en2008.50 Kuga8/2011
303-01- 45
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
45
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL