2011 FORD KUGA index

Engine – System Operation and Component Description
System Operation
The variable camshaft timing occurs
electro-hydraulically and individually for both
camshafts.
The camshaft adjusters work according to the vane
cell principle and have an adjustment range of 52°
crank angle on the intake side and 47° crank angle
on the exhaust side. On starting the engine and
during idling, both camshafts are mechanically
locked in their starting positions. The exhaust
camshaft is in the early position and the intake
camshaft is in the late position. The camshaftadjuster on the exhaust side has a torsion spring
which compensates the camshaft drive torque.
This ensures that the assembly can return to the
starting position under all operating conditions and
when the engine is turned off.
Internal exhaust gas recirculation can be realized
through continuous adjustment of the timings. This
results in better fuel consumption and more
favorable combustion temperatures which produce
less pollutants. This means that pollutant level IV
can be adhered to with a 3-way catalytic converter.
The variable timings also make it possible to
optimize performance with wide open throttle.
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303-01-
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Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
16
DESCRIPTION AND OPERATION
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Variable camshaft timing
Timing retard
E62711
Description
Item
Camshaft pulley
1
Locking pin
2
Valve rotor
3
Rotor vane
4
Plunger
5Description
Item
Return spring
6
Camshaft adjuster solenoid
7
Duct connected to chamber (a)
A
Duct connected to chamber (b)
B
Oil feed duct
C
Oil return duct
Drive
G1032416en2008.50 Kuga8/2011
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Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
17
DESCRIPTION AND OPERATION
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The engine oil is drawn from the oil pan and routed
to the camshaft oil ducts via the engine oil circuit
before passing from there to the VCT oil control
solenoid and to the locking pin. This releases the
locking pin and separates the positive engagement
between the camshaft pulley and the rotor. Whenthe control unit is being retarded, the chamber (b)
fills with engine oil. The rotor turns clockwise
because of the oil pressure in the chamber (b). The
engine oil returning from the chamber (a) flows via
the oil return duct (D) to the VCT oil control
solenoid and from there back into the oil pan.
E62710
When the VCT control unit is being advanced, the
chamber (a) fills with engine oil. The rotor turns
counter-clockwise because of the oil pressure in
the chamber (a). This completes the advance
adjustment. The engine oil returning from the
chamber (b) flows via the oil return duct (D) to the
VCT oil control solenoid and from there back into
the oil pan.
G1032416en2008.50 Kuga8/2011
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Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
18
DESCRIPTION AND OPERATION
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Valve Clearance Adjustment
Special Tool(s)303-1183
Holder, Camshaft
E62756
1.Remove the camshafts.
Refer to: Camshafts (303-01 Engine - 2.5L
Duratec (147kW/200PS) - VI5, Removal and
Installation).
2. CAUTION: Make sure that the valve tappets are installed in their original
locations.
E68493
x20
x5
3.Install only one pair of tappets and the camshaft
for the first measurement.
Special Tool(s): 303-1183
Torque: 17
Nm
E68822
303-1183
4.Measure the valve clearance and if neccessary,
adjust by installing new tappets.
Special Tool(s): 303-1183
Torque: 12
Nm
E66325
303-1183
5.Repeat the measuring procedures for all
cylinders on the intake and on the exhaust side.
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Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
19
GENERAL PROCEDURES
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Intake Manifold(21 183 0)
Removal
NOTE:Removal steps in this procedure may
contain installation details.
1. Refer to: Fuel System Pressure Release
(310-00 Fuel System - General Information,
General Procedures).
2. Refer to: Battery Disconnect and Connect
(414-01 Battery, Mounting and Cables,
General Procedures).
3. Refer to: Air Cleaner (303-12 Intake Air
Distribution and Filtering - 2.5L Duratec
(147kW/200PS) - VI5, 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.
E67375
7.
E68413
8.Torque: 10Nm
E67741
G1079020en2008.50 Kuga8/2011
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Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
20
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9.
E67742
10.
E67743
11 .
E67907
12.Torque: 10Nm
E67906
13.
E64165
14.Torque: 19Nm
Installation
1.To install, reverse the removal procedure.
2. Refer to: Door Window Motor Initialization
(501-11 Glass, Frames and Mechanisms,
General Procedures).
G1079020en2008.50 Kuga8/2011
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Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
21
REMOVAL AND INSTALLATION
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E67382

Crankshaft Front Seal(21 467 0)
Special Tool(s)211-014
Remover, Steering Wheel
13019
303-1180
Installer, Crankshaft Front
Seal
E62050
303-293
Remover, Crankshaft Seal
21143
Removal
1.Refer to: Timing Belt (303-01 Engine - 2.5L
Duratec (147kW/200PS) - VI5, Removal and
Installation).
2. Special Tool(s): 211-014
E64877
211-014
3.Special Tool(s): 303-293
E65179
303-293
Installation
1.Special Tool(s): 303-1180
E64880
303-1180
2. NOTE: The crankshaft timing pulley can only
be installed in 1 position on the crankshaft
splines.
E64881
3. Refer to: Timing Belt (303-01 Engine - 2.5L
Duratec (147kW/200PS) - VI5, Removal and
Installation).
G543324en2008.50 Kuga8/2011
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Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
22
REMOVAL AND INSTALLATION
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Valve Stem Seals(21 238 0)
Special Tool(s)303-361B
Compressor, Valve Spring
E62757
303-361B-06
Adapter for 303-361B
E62041
303-363
Adapter, Air Supply (Cylinder
Head)
21157
303-508
Pliers, Valve Stem Seal
21211
Removal
1.Remove the camshafts.
Refer to: Camshafts (303-01 Engine - 2.5L
Duratec (147kW/200PS) - VI5, Removal and
Installation). 2.
E66111
3.
Using the special tool, apply 7 to 10 bar of
compressed air into the cylinder.
Special Tool(s): 303-363
E66112
303-363
4.Special Tool(s): 303-361B, 303-361B-06
E66326
303-361B
303-361B-06
G543490en2008.50 Kuga8/2011
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Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
23
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL