2011 FORD KUGA 111

Spring(15 621 0)
Special Tool(s)204-167
Compressor, Coil Spring
14042
204-215
Adapter for 204-167
15111
Removal
NOTE:Removal steps in this procedure may
contain installation details. 1.
Refer to: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation).
2. CAUTION: Make sure that the ball joint ball does not rotate.
Torque: 70Nm
E98878
3.Install the Special Tool(s): 204-167, 204-215
E98877
1
2
204-167
204-215
Installation
1.To install, reverse the removal procedure.
G1000236en2008.50 Kuga8/2011
204-02- 25
Rear Suspension
204-02- 25
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Brake Caliper(12 253 0)
General EquipmentHose Clamp(s)
Materials
Specification
Name
WSS-M6C57-A2
Brake Fluid - Super
DOT4
Removal
NOTE: Removal steps in this procedure may
contain installation details.
1. Refer to: Brake System Health and Safety
Precautions (100-00 General Information,
Description and Operation).
2. Refer to: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation).
3.
E70112
1
2
4. General Equipment: Hose Clamp(s)
1.
2. Torque: 28
Nm
3. Torque: 35Nm
E70110
1
2
x2
3
5. CAUTION: Make sure that all openings
are sealed.
NOTE: Note the position of each component
before removal.
E70111
6. NOTE: This step is only necessary when
installing a new component.
Refer to: Rear Brake Flexible Hose (206-04
Rear Disc Brake, Removal and Installation).
Installation
1. To install, reverse the removal procedure.
2. Refer to: Brake System Bleeding (206-00 Brake
System - General Information, General
Procedures).
Refer to: Brake System Pressure Bleeding
(206-00 Brake System - General Information,
General Procedures).
3.
CAUTION: Make sure that the mating
faces are clean and free of foreign
material.
Depress the brake pedal, check the brake fluid
level in the brake fluid reservoir and top up as
necessary with brake fluid.
Material: Brake Fluid - Super DOT4 (WSS-M6C57-A2) brake fluid
G1001208en2008.50 Kuga8/2011
206-04- 4
Rear Disc Brake
206-04- 4
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

PRINCIPLES OF OPERATION
E97570
12
3
4
5
6
7910111213
815
16
14
G1001304en2008.50 Kuga8/2011
206-09B-9
Anti-Lock Control - Stability Assist
206-09B- 9
DESCRIPTION AND OPERATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

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
303-01- 23
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
23
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

E87508
46
45
44
43
3834271913514202839
40
41
423623910243137
635
29211571412182633
30221682311172532
G543491en2008.50 Kuga8/2011
303-01-34
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
34
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

27. CAUTION: Note the position of thecomponents before removal.
E68493
x20
x5
28. CAUTION: Make sure that no fluids arepresent in the threaded bores.
Torque:
• Stage 1: 20
Nm
• Stage 2: 60Nm
• Stage 3: 130°
E68494
1591284
37111062
29. WARNING: Be prepared to collectescaping fluid.
General Equipment: Fluid Container
Torque: 38
Nm
E115890
30.Torque: 25Nm
E115891
31.
E116077
Installation
1.To install, reverse the removal procedure.
G1079022en2008.50 Kuga8/2011
303-01- 54
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
54
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

E84406
x20
20.
21.
22.
x4
23.
E84206
24.
25. CAUTION: Note the position of thecomponents before removal.
G543498en2008.50 Kuga8/2011
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUALBACK TO CHAPTER INDEX
TO MODEL INDEX
1591284
3711106
2
E64878E68495
19.
E84582
303-01-
88
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
88
DISASSEMBLY

E87508
46
45
44
43
3834271913514202839
40
41
423623910243137
635
29211571412182633
30221682311172532
30.Special Tool(s): 303-318
E68747
303-318
31. N O T E : The crankshaft timing pulley can only
be installed in 1 position on the crankshaft
splines.
Torque: 17
Nm
E69623
x7
G543500en2008.50 Kuga8/2011
303-01- 105
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
105
ASSEMBLY
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL