Ford Kuga

 Service Manual

Engine- 2.5L Duratec (147kW/200PS) - VI5
Engine - Vehicles With: 5-Speed Automatic Transaxle (AW55)

Installation

Special Tool(s) / General Equipment

303-122 Lifting Bracket, Engine

Hose Clamp Remover/Installer

Hydraulic Jib Crane

Mounting Table Set

Retaining Strap

Round-Ended Steel Rule

Trolley Jack

Wooden Block

1. Special Tool(s): 303-122 General Equipment: Hydraulic Jib Crane

2. General Equipment: Round-Ended Steel Rule

3. Torque: 48 Nm

4. Torque: 48 Nm

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

Torque: 60 Nm

WARNING: Make sure that the engine and transmission assembly is on wooden blocks and secured with suitable retaining straps.

General Equipment: Retaining Strap

General Equipment: Mounting Table Set

General Equipment: Wooden Block

CAUTION: Make sure that no components catch.

Lower the vehicle.

9. 1. Torque: 148 Nm

2. Torque: 10 Nm

10.NOTE: Only tighten the nuts and bolts finger tight at this stage.

11. Remove the following items:

• General Equipment: Retaining Strap

12.Torque: 25 Nm

13. 1. Torque: 23 Nm

2. Torque: 7 Nm

15. 1. Torque: 10 Nm

2. General Equipment: Hose Clamp Remover/Installer

4. Torque: 30 Nm

16. Install the following items: 1. Refer to: Transfer Case (307-07 Transfer Case - Vehicles With: 5-Speed Automatic Transaxle - AW55 AWD/6-Speed Automatic Transaxle - 6DCT450, Removal).

2. Refer to: Front Halfshaft LH (205-04 Front Drive Halfshafts, Removal and Installation).

3. Refer to: Accessory Drive Belt (303-05 Accessory Drive - 2.5L Duratec (147kW/200PS) - VI5, Removal and Installation).

CAUTION: Make sure that the exhaust flexible pipe is not forcibly bent.

Torque: 48 Nm

18.Torque: 24 Nm

20.Torque: 6 Nm

21.Torque: 50 Nm

CAUTION: Make sure that the exhaust flexible pipe is not forcibly bent.

Torque: 28 Nm

23. 1. Torque: 48 Nm

2. Torque: 80 Nm

24.Torque: 10 Nm

26. 1. Torque: 48 Nm

2. Torque: 9 Nm

27.Torque: 25 Nm

29.Torque: 25 Nm

CAUTION: Gearshift cables must not be kinked or bent.

Refer to: Selector Lever Cable Adjustment - Vehicles With: 5-Speed Automatic Transaxle - AW55 AWD (307-05 Automatic Transmission/Transaxle External Controls - Vehicles With: 5-Speed Automatic Transaxle - AW55 AWD/6-Speed Automatic Transaxle - 6DCT450, General Procedures).

31. General Equipment: Hose Clamp Remover/Installer

33. 1. Torque: 48 Nm

2. Torque: 25 Nm

3. Torque: 10 Nm

35. Refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).

36. - Torque: 12 Nm

- Torque: 24 Nm

37.Torque: 10 Nm

38.Torque: 20 Nm

39.NOTE: The gasket is to be reused unless damaged.

41. 1. Torque: 25 Nm

2. Torque: 5 Nm

42. General Equipment: Hose Clamp Remover/Installer

43.Torque: 5 Nm

CAUTION: Make sure that no components catch.

General Equipment: Retaining Strap

General Equipment: Trolley Jack

Vehicles without PCM security shield

52.Torque: 7 Nm

Vehicles with PCM security shield

53.Torque: 7 Nm

All vehicles

CAUTION: Make sure that no components catch.

Remove the following items:

• General Equipment: Retaining Strap

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

Remove the following items:

• General Equipment: Trolley Jack

CAUTION: Make sure that the inside of the pipe ends are clean and free of oil residue.

1. Torque: 4 Nm

2. Torque: 10 Nm

61. 1. Torque: 115 Nm

2. Torque: 90 Nm

62. General Equipment: Hose Clamp Remover/Installer

63.Torque: 10 Nm

64.Torque: 12 Nm

65.On both sides.

Torque: 35 Nm

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).

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).

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)