Engine cooling system draining FORD KUGA 2011 1.G Workshop Manual

Auxiliary Coolant Flow Pump
General Equipment
Hose Clamp(s) General Equipment
Hose Clamp Remover/Installer
Removal
1. Refer to: Engine Cooling System Health and
Safety Precautions (100-00 General
Information, Description and Operation).
2. Refer to: Jacking(100-02 Jacking and Lifting,
Description and Operation).
3. General Equipment: Hose Clamp(s)
General Equipment: Hose Clamp
Remover/Installer Installation
1.
To install, reverse the removal procedure.
2. Check the coolant level.
Refer to: Cooling System Draining and Vacuum
Filling (303-03 Engine Cooling, General
Procedures). G1163562en
2008.50 Kuga 8/2011 412-02-17
Auxiliary Climate Control
412-02-17
REMOVAL AND INSTALLATIONTO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL11E112651

7.
Installation
1.
To install, reverse the removal procedure.
2. Check the coolant level.
Refer to: Cooling System Draining and Vacuum
Filling (303-03 Engine Cooling, General
Procedures). G1163563en
2008.50 Kuga 8/2011 412-02-24
Auxiliary Climate Control
412-02-24
REMOVAL AND INSTALLATIONTO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUALE112645

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
303-01- 50
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
50
REMOVAL AND INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Oil Cooler(21 764 0)
General EquipmentFluid Container
Hose Clamp(s)
Materials
Specification
Name
WSS-M2C913-C
Engine Oil - 5W-30
Removal
NOTE: Removal steps in the procedure may
contain installation details.
1.
E65299
2.
WARNING: Be prepared to collect
escaping fluid.
General Equipment: Fluid Container
Torque: 38
Nm
E92766
3.
WARNING: Be prepared to collect
escaping fluids.
1. General Equipment: Fluid Container General Equipment: Hose Clamp(s)
2. Torque: 3
Nm
3. Torque: 17Nm
E74103
x4
x2
2
3
1
Installation
1. To install, reverse the removal procedure.
2. CAUTION: Make sure that fluid level is to the MAX mark.
Refer to: Specifications (303-01 Engine - 2.5L
Duratec (147kW/200PS) - VI5, Specifications).
Material: Engine Oil - 5W-30 (WSS-M2C913-C) engine oil
3. Refer to: Cooling System Draining and Vacuum
Filling (303-03 Engine Cooling, General
Procedures).
G834604en2008.50 Kuga8/2011
303-01- 58
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
58
REMOVAL AND INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

25.Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
26. Refer to: Cooling System Draining and Vacuum
Filling (303-03 Engine Cooling, General
Procedures).
27.
E98184
28.
E112511
29. On both sides.
E99722
30mm1
30.
G1191240en2008.50 Kuga8/2011
303-01- 65
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
65
REMOVAL
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

67.Install the following items:
1. Refer to: Battery(414-01 Battery, Mounting
and Cables, Removal and Installation).
2. Refer to: Cowl Panel Grille (501-02 Front
End Body Panels, Removal and
Installation).
68.
E79327
69. Refer to: Cooling System Draining and Vacuum
Filling (303-03 Engine Cooling, General
Procedures).
70. Refer to: Power Steering System Filling (211-00
Steering System - General Information,
General Procedures).
71. Refer to: Door Window Motor Initialization
(501-11 Glass, Frames and Mechanisms,
General Procedures).
G1191241en2008.50 Kuga8/2011
303-01- 138
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
138
INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

SECTION 303-03 Engine Cooling
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
DESCRIPTION AND OPERATION
303-03-2
Engine Cooling — 2.5L Duratec (147kW/200PS) - VI5 (Component Location) .................
303-03-3
Engine Cooling — 2.5L Duratec (147kW/200PS) - VI5 (Overview) ....................................
303-03-3
Auxiliary coolant pump ........................................................................\
...............................
DIAGNOSIS AND TESTING 303-03-4
Engine Cooling ........................................................................\
...........................................
303-03-4
Inspection and Verification ........................................................................\
..........................
GENERAL PROCEDURES 303-03-5
Cooling System Draining and Vacuum Filling .....................................................................
303-03-5
Draining ........................................................................\
......................................................
303-03-6
Evacuating and Filling ........................................................................\
................................
303-03-7
Radiator Lower Mounting Repair ........................................................................\
................
REMOVAL AND INSTALLATION 303-03-10
(24 404 0)
Coolant Pump — 2.5L Duratec (147kW/200PS) - VI5 ...................................
303-03-11
(24 222 0)
Cooling Fan Motor and Shroud — 2.5L Duratec (147kW/200PS) - VI5 .........
303-03-14
(24 254 0)
Radiator — 2.5L Duratec (147kW/200PS) - VI5 .............................................
303-03-19
(24 454 0)
Thermostat — 2.5L Duratec (147kW/200PS) - VI5 ........................................
303-03-20
(24 001 0)
Thermostat Housing — 2.5L Duratec (147kW/200PS) - VI5 ..........................
303-03-1
Engine Cooling
303-03- 1
.
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Cooling System Draining and Vacuum Filling
General EquipmentCooling System Vacuum Tester and Refiller
Fluid Container
Materials
Specification
Name
WSS-M97B44-D / 4U7J-
19544-AA2A
Antifreeze Super Plus
Premium
Draining
WARNING: When releasing the cooling
system pressure, cover the coolant
expansion tank cap with a thick cloth.
NOTE: Always follow the manufacturer's
instructions when handling the equipment.
1. Refer to: Engine Cooling System Health and
Safety Precautions (100-00 General
Information, Description and Operation).
2.
Release the cooling system pressure by slowly
turning the coolant expansion tank cap between
2 and 3 turns.
E68577
3. Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
4.
E65299
5.
WARNING: Be prepared to collect
escaping fluid.
Use a suitable coolant hose to drain the coolant.
General Equipment: Fluid Container
Loosen: 4
turn(s)
E97501
6.
E97501
G1034816en2008.50 Kuga8/2011
303-03- 5
Engine Cooling
303-03- 5
GENERAL PROCEDURES
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Coolant Pump — 2.5L Duratec (147kW/200PS) - VI5(24 404 0)
General EquipmentTrolley Jack
Removal
NOTE: Removal steps in this procedure may
contain installation details.
1. Drain the cooling system.
Refer to: Cooling System Draining and Vacuum
Filling (303-03 Engine Cooling, General
Procedures).
2. Remove the timing belt.
Refer to: Timing Belt (303-01 Engine - 2.5L
Duratec (147kW/200PS) - VI5, Removal and
Installation).
3. CAUTION: Use a wooden block to protect the oil pan when supporting the
engine.
Position the trolley jack with the wooden block
under the oil pan. Raise the trolley jack until the
front of the engine is free from load and the
coolant pump bolts can be accessed.
General Equipment: Trolley Jack
4. Torque: 17
Nm
E63823
x4
5.Lower the engine.
General Equipment: Trolley Jack 6.
Torque: 17
Nm
x3
E63856
Installation
1. NOTE: Install all the bolts finger tight before
final tightening.
To install, reverse the removal procedure.
G544632en2008.50 Kuga8/2011
303-03- 10
Engine Cooling
303-03- 10
REMOVAL AND INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

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
G1156381en2008.50 Kuga8/2011
303-03- 14
Engine Cooling
303-03- 14
REMOVAL AND INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL