501 FORD KUGA 2011 1.G Repair Manual

Turbocharger(23 612 0)
General EquipmentCable Ties
Hose Clamp Remover/Installer
Materials
Specification
Name
SA-M1C9107-A / YS5J-
M1C9107-AA
Grease KS-PS
Removal
NOTE:
Removal steps in this procedure may
contain installation details.
1. Refer to: Battery Disconnect and Connect
(414-01 Battery, Mounting and Cables,
General Procedures).
2. Refer to: Cooling System Draining and Vacuum
Filling (303-03 Engine Cooling, General
Procedures).
3. Refer to: Cowl Panel Grille (501-02 Front End
Body Panels, 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.
E67948
2
1
7.Torque: 26Nm1.
2. Torque: 26
Nm
3. Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
Torque: 38
Nm
E112143
3
2
1
G1079058en2008.50 Kuga8/2011
303-04B- 11
Fuel Charging and Controls - Turbocharger
—
2.5L Duratec (147kW/200PS) - VI5
303-04B- 11
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

19.Torque: 12Nm
E66829
x2
20.Torque: 24Nm
E112772
x12
1
2
3
Installation
1.To install, reverse the removal procedure.
2. Refer to: Door Window Motor Initialization
(501-11 Glass, Frames and Mechanisms,
General Procedures).
G1079058en2008.50 Kuga8/2011
303-04B- 14
Fuel Charging and Controls - Turbocharger
—
2.5L Duratec (147kW/200PS) - VI5
303-04B- 14
REMOVAL AND INSTALLATION
TO MODEL INDEX
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Air Conditioning (A/C) Compressor Belt(21 567 0)
Removal
1.Remove the right-hand front wheel and tire.
Refer to: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation).
2.
E65955
3.
E64285
4.
E64286
2
1
Installation
1. To install, reverse the removal procedure.
G545010en2008.50 Kuga8/2011
303-05- 13
Accessory Drive— 2.5L Duratec (147kW/200PS) - VI5303-05-
13
REMOVAL AND INSTALLATION
TO MODEL INDEX
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Starter Motor(26 204 0)
Removal
NOTE:Removal steps in this procedure may
contain installation details.
1. Refer to: Battery Disconnect and Connect
(414-01 Battery, Mounting and Cables,
General Procedures).
2. Refer to: Air Cleaner (303-12 Intake Air
Distribution and Filtering - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
3.
E63784
4. Torque: 10Nm
E63785
5.Torque: 12Nm
E64737
6.Torque: 50Nm
E64738
x2
Installation
1.To install, reverse the removal procedure.
2. Refer to: Door Window Motor Initialization
(501-11 Glass, Frames and Mechanisms,
General Procedures).
G962446en2008.50 Kuga8/2011
303-06- 10
Starting System— 2.5L Duratec (147kW/200PS) - VI5303-06-
10
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Transmission Range (TR) Sensor
Special Tool(s)501-028A
Pliers, Door Trim Removal
43001A
Removal
1.
E114413
2.
E114504
3.
E114505
4.
20 mm20 mm
E114506
G1163634en2008.50 Kuga8/2011
307-01-77
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 77
REMOVAL AND INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

5.
E114436
6.
E114437
7.1. CAUTION: Use an open-ended
wrench to prevent the component
from turning.
3. Special Tool(s): 501-028A
E114438
8.
E114439
G1163634en2008.50 Kuga8/2011
307-01- 78
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 78
REMOVAL AND INSTALLATION
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUALBACK TO CHAPTER INDEX
TO MODEL INDEX
1
2
3501-028A
x3

Transmission
Removal
Special Tool(s) / General Equipment303-290-01
Adapter for 303-290A
2114001
303-290-03A
Adapter for 303-290A
30329003A
303-290-05A
Adapter for 303-290A
30329005A
Special Tool(s) / General Equipment303-290A
Support Bar, Engine
303290A
303-290A-14
Adapter for 303-290A
303290A14
Cable Ties
Transmission Jack
Wooden Block
1. Refer to: Health and Safety Precautions (100-00
General Information, Description and
Operation).
2. Refer to: Cowl Panel Grille (501-02 Front End
Body Panels, Removal and Installation).
3.
E114689
G1163644en2008.50 Kuga8/2011
307-01- 82
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 82
REMOVAL
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

40.Torque: 10Nm
E101006
41.Refer to: Battery(414-01 Battery, Mounting and
Cables, Removal and Installation).
42. On both sides.
Torque: 35
Nm
E99147
x3
43.Refer to: Air Cleaner (303-12 Intake Air
Distribution and Filtering - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
44.
E114689
45. Refer to: Cowl Panel Grille (501-02 Front End
Body Panels, Removal and Installation).
Refer to: Transmission Fluid Level Check
(307-01 Automatic Transmission/Transaxle -
Vehicles With: 5-Speed Automatic Transaxle
- AW55 AWD, General Procedures).
G1163646en2008.50 Kuga8/2011
307-01- 100
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 100
INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

7.
E114513
8.Lower the Vehicle.
9. Refer to: Floor Console Extension - Vehicles
With: Center Armrest (501-12 Instrument
Panel and Console, Removal and Installation).
10.
E114518
11 . Torque: 25Nm
x4x4
E100949
12.
E114519
13.Torque: 25Nm
x4x4
E114516
14.
x4x4
E101415
G1163686en2008.50 Kuga8/2011
REMOVAL AND INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
307-05-
8
Automatic Transmission/Transaxle External
Controls
— Vehicles With: 5-Speed Automatic Transaxle - AW55 AWD/6-Speed
Automatic Transaxle - 6DCT450
307-05-8
.

Selector Lever Assembly — Vehicles With: 5-Speed AutomaticTransaxle - AW55 AWD
Removal
CAUTION: Gearshift cables must not be
kinked or bent.
NOTE: Removal steps in this procedure may
contain installation details.
1. Refer to: Floor Console Extension - Vehicles
With: Center Armrest (501-12 Instrument
Panel and Console, Removal and Installation).
2.
E114518
3.
E114519
4.
x4x4
E101415
5. Torque: 9Nm
50 mm
x4
50 mm
x4
E114520
G1163687en2008.50 Kuga8/2011
REMOVAL AND INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
307-05-
11
Automatic Transmission/Transaxle External
Controls
— Vehicles With: 5-Speed Automatic Transaxle - AW55 AWD/6-Speed
Automatic Transaxle - 6DCT450
307-05-11
.