2011 FORD KUGA general procedures

38.
E67408
39. WARNING: Be prepared to collectescaping fluid.
Refer to: Quick Release Coupling (310-00 Fuel
System - General Information, General
Procedures).
E68475
41. General Equipment: Hose Clamp
Remover/Installer
E112312
42.
E66479
G1191240en2008.50 Kuga8/2011
303-01- 70
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
70
REMOVAL
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E65220
37.40.
E68429

26.Torque: 48Nm1.
2. Torque: 9
Nm
E114610
27.Torque: 25
E114609
28.
E114728
29.Torque: 25Nm
E114606
30. 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).
G1191241en2008.50 Kuga8/2011
303-01- 126
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
126
INSTALLATION
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1
1
2
Nm
E114436
x2

34.
E68429
35.Refer to: Quick Release Coupling (310-00 Fuel
System - General Information, General
Procedures).
36. Torque: 12Nm•
• Torque: 24
Nm
2
37.Torque: 10Nm
E65220
38.Torque: 20Nm
E112607
1
2
34
39. N O T E : The gasket is to be reused unless
damaged.
E99980
40.
G1191241en2008.50 Kuga8/2011
303-01- 128
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
128
INSTALLATION
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E68475
E116433
1

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
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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
.
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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
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7.
E65299
Evacuating and Filling
1.If the cooling system was completely drained,
fill the fluid container with the full cooling
•
system fill capacity plus 0.5L of additional
coolant.
Material: Antifreeze Super Plus Premium(WSS-M97B44-D / 4U7J-19544-AA2A)
antifreeze
• If the cooling system was partially drained, fill the fluid container with the removed and
spilled amount of coolant plus 1.0L of
additional coolant. When in doubt always use
the full cooling system fill capacity plus 0.5L
of additional coolant.
Material: Antifreeze Super Plus Premium(WSS-M97B44-D / 4U7J-19544-AA2A)
antifreeze
2. General Equipment: Cooling System Vacuum
Tester and Refiller
•
3. Close the valve, install the coolant hose and
place it into the fluid container.
1.
2. Close the valve and connect the compressed
air hose.
E96739
1
2
4. Open the valve until the specificied vacuum
is achieved.
2.
E967406-10 bar
1
-0.85 bar
-0.95 bar2
5.
Open the valve until the coolant reservoir
fluid level is at the MAX mark.
•
• If no coolant is visible in the coolant
expansion tank, add 2.0L of coolant to the
fluid container and repeat the evacuating and
filling procedure.
E96741
6.
E68577
G1034816en2008.50 Kuga8/2011
303-03- 6
Engine Cooling
303-03- 6
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Radiator Lower Mounting Repair
General Equipment5mmDrillBit
Cable Ties
Flat File
1. General Equipment: Cable Ties
E100039
2.Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
3.
E98183
4.
E98184
5.
E100040
x4
6. General Equipment: Flat File
1.
2. General Equipment: 5 mm Drill Bit
G1062292en2008.50 Kuga8/2011
303-03- 7
Engine Cooling
303-03- 7
GENERAL PROCEDURES
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