Ford Kuga

 Service Manual

Engine- 2.5L Duratec (147kW/200PS) - VI5
Engine

Assembly

Special Tool(s) / General Equipment

	303-1054 Locking Tool, Timing Belt Tensioner
	303-1178 Timing Tool Camshaft
	303-1179 Holding Wrench, Crankshaft
	303-1180 Installer, Crankshaft Front Seal
	303-1181 Installer, Crankshaft Rear Seal
	303-1182 Timing Tool, Crankshaft
	303-318 Aligner/Installer, Crankshaft Front Seal

Piston Ring Compressor

Round-Ended Steel Rule

Materials

Name	Specification
Engine Oil - 5W-30	WSS-M2C913-C
Flange Sealant - Anaerobic LP	WSK-M2G348-A7 / 5U7J-M2G348-BA

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).

CAUTION: Make sure that the components are installed to the position noted before removal.

Apply a thin coating.

Material: Engine Oil - 5W-30 (WSS-M2C913-C) engine oil

CAUTION: Make sure that the components are installed to the position noted before removal.

Apply a thin coating.

Material: Engine Oil - 5W-30 (WSS-M2C913-C) engine oil

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

CAUTION: Make sure that new bolts are installed.

Torque:

• Stage 1: M10: 1-12 20 Nm
• Stage 2: M10: 1-12 45 Nm

7. Torque:

• M8: 13-24 24 Nm

8. Torque:

• M7: 25-29 17 Nm

9. Torque:

• M10: 1-12 90

10.NOTE: This step is only necessary when installing a new component.

CAUTION: Make sure that the components are installed to the position noted before removal.

General Equipment: Piston Ring Compressor

CAUTION: Make sure that the components are installed to the position noted before removal.

Apply a thin coating.

Material: Engine Oil - 5W-30 (WSS-M2C913-C) engine oil

13.CAUTIONS:

• Make sure that the components are installed to the position noted before removal.
• Make sure that new bolts are installed.

Apply a thin coating.

Material: Engine Oil - 5W-30 (WSS-M2C913-C) engine oil

Torque:

• Stage 1: 30 Nm
• Stage 2: 90

14.Torque: 10 Nm

15.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

16.NOTE: Only tighten the bolts finger tight at this stage.

17. General Equipment: Round-Ended Steel Rule

18.Torque: 17 Nm

19.Torque: 17 Nm

20.Torque: 6 Nm

21. Special Tool(s): 303-1180

22. Special Tool(s): 303-1181

23.Torque:

• Stage 1: 20 Nm
• Stage 2: 60 Nm
• Stage 3: 130

24. - X = 15 mm.

27. Apply a thin coating.

Material: Engine Oil - 5W-30 (WSS-M2C913-C) engine oil

28. Material: Flange Sealant - Anaerobic LP (WSK-M2G348-A7 / 5U7J-M2G348-BA) sealant

29.Torque: 17 Nm

30. Special Tool(s): 303-318

31.NOTE: The crankshaft timing pulley can only be installed in 1 position on the crankshaft splines.

Torque: 17 Nm

32.NOTE: Only tighten the bolts finger tight at this stage.

33. 1. Torque: 25 Nm

2. Torque: 12 Nm

34.NOTE: Install all the bolts finger tight before final tightening.

1. Torque:

• Stage 1: 35 Nm
• Stage 2:75

2. Torque:

• Stage 1: 15 Nm
• Stage 2: 90

35. Install the Special Tool(s): 303-1178

Torque: 10 Nm

CAUTION: Only rotate the crankshaft clockwise.

Rotate the crankshaft slowly until the crankshaft stops.

Install the Special Tool(s): 303-1182

CAUTION: Make sure that the installation marks are aligned.

Vehicles with mechanical timing belt tensioner 39.NOTE: Make sure that new components are installed.

1. Torque: 25 Nm

3. Torque: 25 Nm

Vehicles with automatic timing belt tensioner 40.NOTE: Make sure that new components are installed.

1. Torque: 25 Nm

3. Special Tool(s): 303-1054

Torque: 25 Nm

WARNING: Take extra care when handling the compressed spring.

Remove the Special Tool(s): 303-1054

All vehicles

42.Torque: 120 Nm

43.Remove the Special Tool(s): 303-1178

CAUTION: Only rotate the crankshaft clockwise.

Rotate the crankshaft slowly until the crankshaft stops.

Remove the Special Tool(s): 303-1182

CAUTION: Only rotate the crankshaft clockwise.

Rotate the crankshaft slowly until the crankshaft stops.

Install the Special Tool(s): 303-1182

47. Install the Special Tool(s): 303-1178 Torque: 10 Nm

CAUTION: Make sure that the installation marks are aligned.

49.Torque: 35 Nm

50.Remove the Special Tool(s): 303-1182

51.Remove the Special Tool(s): 303-1178

53.Torque: 40 Nm

54. NOTE: Make sure that new components are installed.

2. Torque: 40 Nm

55.Torque: 10 Nm

56.Torque: 10 Nm

57. NOTE: Only tighten the bolts finger tight at this stage.

Install the Special Tool(s): 303-1179 1.

2. Torque: 180 Nm

58.Remove the Special Tool(s): 303-1179

59.Torque:

• Stage 1: 25 Nm
• Stage 2: 60

Engine (Component Location)

Engine (Overview)

Engine (System Operation and Component Description).

Valve Clearance Adjustment

Intake Manifold (21 183 0) Removal

Crankshaft Front Seal  (21 467 0)

Valve Stem Seals  (21 238 0)

Timing Belt (21 304 0)

Camshafts  (21 284 0)

Camshaft Seal (21 288 0)

Oil Pan (21 154 0)

Oil Pump (21 714 0)

Exhaust Manifold (21 187 0)

Cylinder Head (21 163 0)

Crankshaft Rear Seal (21 468 4)

Oil Cooler

Engine - Vehicles With: 5-Speed Automatic Transaxle (AW55)

Engine Accessories

Engine

Cylinder Head

Engine

Engine Accessories (21 139 4)

Engine - Vehicles With: 5-Speed Automatic Transaxle (AW55)