all FORD KUGA 2011 1.G Workshop Manual

Engine(21 134 8)
Assembly
Special Tool(s) / General Equipment303-1054
Locking Tool, Timing Belt
Tensioner
3031054
303-1178
Timing Tool Camshaft
E62051
303-1179
Holding Wrench, Crankshaft
E62035
303-1180
Installer, Crankshaft Front
Seal
E62050
Special Tool(s) / General Equipment303-1181
Installer, Crankshaft Rear
Seal
E62048
303-1182
Timing Tool, Crankshaft
E62027
303-318
Aligner/Installer, Crankshaft
Front Seal
21148
Piston Ring Compressor
Round-Ended Steel Rule
Materials
Specification
Name
WSS-M2C913-C
Engine Oil - 5W-30
WSK-M2G348-A7 /
5U7J-M2G348-BA
Flange Sealant - Anaer-
obic LP
1. NOTE: This step is only necessary when
installing a new component.
Refer to: Specifications (303-01 Engine - 2.5L
Duratec (147kW/200PS) - VI5, Specifications).
G543500en2008.50 Kuga8/2011
303-01- 94
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
94
ASSEMBLY
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

6
1
2
3
4
5
6
E122606
1
2
3
4
5
6
123456
2. CAUTION: Make sure that thecomponents are installed to the position
noted before removal.Apply a thin coating.
Material: Engine Oil - 5W-30 (WSS-M2C913-C)engine oil
G543500en2008.50 Kuga8/2011
303-01- 95
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
95
ASSEMBLY
TO MODEL INDEX
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

E122293
x5
3. CAUTION: Make sure that thecomponents are installed to the position
noted before removal.Apply a thin coating.
Material: Engine Oil - 5W-30 (WSS-M2C913-C)engine oil
G543500en2008.50 Kuga8/2011
303-01- 96
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
96
ASSEMBLY
TO MODEL INDEX
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

E122294
x5
4.
E122227
5. NOTE:The component must be installed within
5 minutes of applying the sealant.
Material: Flange Sealant - Anaerobic LP (WSK-M2G348-A7 / 5U7J-M2G348-BA)
sealant
G543500en2008.50 Kuga8/2011
303-01- 97
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
97
ASSEMBLY
TO MODEL INDEX
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

E122323
6. CAUTION: Make sure that new bolts areinstalled.
Torque:
• Stage 1: M10: 1-12 20
Nm
• Stage 2: M10: 1-12 45Nm
7.Torque:
• M8: 13-24 24
Nm
8.Torque:
• M7: 25-29 17
Nm
9.Torque:
• M10: 1-12 90°
G543500en2008.50 Kuga8/2011
303-01- 98
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
98
ASSEMBLY
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

E122331
1
23
4
5
6
7
8
9
10
11
12
13
1415
16
17
18
19
20
21
22
23
24
2526272928
10. N O T E :This step is only necessary when
installing a new component.
G543500en2008.50 Kuga8/2011
303-01- 99
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
99
ASSEMBLY
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

E122634
1
2
3
4
5
12345
11. CAUTION: Make sure that thecomponents are installed to the position
noted before removal.
General Equipment: Piston Ring Compressor
E122334
x5
12. CAUTION: Make sure that thecomponents are installed to the position
noted before removal.
Apply a thin coating.
Material: Engine Oil - 5W-30 (WSS-M2C913-C)engine oil
E77266
13. CAUTIONS:
Make sure that the components are
installed to the position noted before
removal.
Make sure that new bolts are installed.
G543500en2008.50 Kuga8/2011
303-01- 100
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
100
ASSEMBLY
TO MODEL INDEX
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Apply a thin coating.
Material: Engine Oil - 5W-30 (WSS-M2C913-C)engine oil Torque:
• Stage 1: 30
Nm
• Stage 2: 90°
E122335
x10
14.
Torque: 10Nm
E68495
15. N O T E : The component must be installed within
5 minutes of applying the sealant.
Material: Flange Sealant - Anaerobic LP (WSK-M2G348-A7 / 5U7J-M2G348-BA)
sealant
G543500en2008.50 Kuga8/2011
303-01- 101
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
101
ASSEMBLY
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

E87508
46
45
44
43
3834271913514202839
40
41
423623910243137
635
29211571412182633
30221682311172532
30.Special Tool(s): 303-318
E68747
303-318
31. N O T E : The crankshaft timing pulley can only
be installed in 1 position on the crankshaft
splines.
Torque: 17
Nm
E69623
x7
G543500en2008.50 Kuga8/2011
303-01- 105
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
105
ASSEMBLY
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

32. N O T E :Only tighten the bolts finger tight at this
stage.34. N O T E : Install all the bolts finger tight before
final tightening.
1. Torque: • Stage 1: 35
G543500en2008.50 Kuga8/2011
303-01- 106
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
106
ASSEMBLY
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
E74333
x2
33.
Torque: 25Nm1.
2. Torque: 12
Nm
E68490
1
2
Nm
• Stage 2: 75°
2. Torque:
• Stage 1: 15
Nm
• Stage 2: 90°
E68408
1
2
35.Install the Special Tool(s): 303-1178
Torque: 10
E113631
12
3
Nm
x2
303-1178
303-1178