2011 FORD KUGA Cylinder head

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
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Cylinder Head(21 163 0)
General EquipmentFluid Container
Tire Lever
Materials
Specification
Name
WSS-M2C913-C
Engine Oil - 5W-30
SA-M1C9107-A / YS5J-
M1C9107-AA
Grease KS-PS
Removal
NOTE:
Removal steps in this procedure may
contain installation details.
1. Refer to: Cooling System Draining and Vacuum
Filling (303-03 Engine Cooling, General
Procedures).
2. Refer to: Fuel System Pressure Release
(310-00 Fuel System - General Information,
General Procedures).
3. Refer to: Battery Disconnect and Connect
(414-01 Battery, Mounting and Cables,
General Procedures).
4. Refer to: Air Cleaner (303-12 Intake Air
Distribution and Filtering - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
5.
E98184
6. Torque: 24Nm
E68748
7. Torque: 48Nm1.
2. Torque: 80
Nm
E65766
1
2
8. CAUTION: Make sure that the exhaust
flexible pipe is not forcibly bent.
General Equipment: Tire Lever
Material: Grease KS-PS (SA-M1C9107-A /YS5J-M1C9107-AA) grease
Torque: 50
Nm
E66052
x2
G1079022en2008.50 Kuga8/2011
303-01- 50
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
50
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Cylinder Head(21 165 6)
Special Tool(s)303-361B
Compressor, Valve Spring
E62757
303-361B-06
Adapter for 303-361B
E62041
303-508
Pliers, Valve Stem Seal
21211
Disassembly
1.Special Tool(s): 303-361B, 303-361B-06
E66326
303-361B
303-361B-06
2.Special Tool(s): 303-508
E66114
303-508
Assembly
3.To install, reverse the assembly procedure.
G543499en2008.50 Kuga8/2011
303-01- 93
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
93
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
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Action
Possible Sources
Symptom
• CHECK for signs of contamina-tion such as strange odors from
the fuel tank.
• If contaminated fuel is found, DRAIN the complete fuel
system. FLUSH the fuel system
through with clean gasoline.
REFER to: Fuel Tank Draining
(310-00 Fuel System -
General Information, General
Procedures).
INSTALL a new fuel filter.
• INSPECT the fuel injectors. CLEAN the fuel injectors or
INSTALL a new set of injectors
as required only after the
checks have been carried out.
REFER to: Fuel Injectors (303-
04 Fuel Charging and
Controls - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
• INSTALL a new fuel rail.
REFER to: Fuel Rail(303-04
Fuel Charging and Controls -
2.5L Duratec (147kW/200PS)
- VI5, Removal and Installa-
tion).
• Incorrect or contaminated fuel.
• INSPECT for visible signs ofdamage or blockage. CLEAN,
REPAIR or INSTALL new parts
as necessary.
• Positive crankcase ventilation
(PCV) system.
• REMOVE the cylinder head.INSPECT the cylinder head,
pistons and cylinder bores for
signs of wear or damage.
REFER to: Cylinder Head (303-
01 Engine - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
• Worn or damaged valve
guide(s), piston ring(s), cylinder
bore(s), cylinder head or
gasket.
G1183441en2008.50 Kuga8/2011
303-04A- 14
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 14
DIAGNOSIS AND TESTING
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Action
Possible Sources
Symptom
• CHECK for signs of contamina-tion such as strange odors from
the fuel tank.
• If contaminated fuel is found, DRAIN the complete fuel
system. FLUSH the fuel system
through with clean gasoline.
REFER to: Fuel Tank Draining
(310-00 Fuel System -
General Information, General
Procedures).
INSTALL a new fuel filter.
• INSPECT the fuel injectors. CLEAN the fuel injectors or
INSTALL a new set of injectors
as required only after the
checks have been carried out.
REFER to: Fuel Injectors (303-
04 Fuel Charging and
Controls - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
• INSTALL a new fuel rail.
REFER to: Fuel Rail(303-04
Fuel Charging and Controls -
2.5L Duratec (147kW/200PS)
- VI5, Removal and Installa-
tion).
• Incorrect or contaminated fuel.
• White smoke
• CARRY OUT a cooling systempressure test.
REFER to: Engine Cooling
(303-03 Engine Cooling,
Diagnosis and Testing).
• REMOVE the cylinder head. INSPECT the cylinder head,
cylinder head gasket and
cylinder bores for wear or
damage.
REFER to: Cylinder Head (303-
01 Engine - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
• Coolant in the combustion
chamber.
G1183441en2008.50 Kuga8/2011
303-04A- 15
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 15
DIAGNOSIS AND TESTING
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Action
Possible Sources
Symptom
• INSPECT the fuel injectors.CLEAN the fuel injectors or
INSTALL a new set of injectors
as required only after the
checks have been carried out.
REFER to: Fuel Injectors (303-
04 Fuel Charging and
Controls - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
• Fuel injectors.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• Fuel rail fuel pressure sensor.
• CHECK the engine compres-sion.
REFER to: Engine(303-00
Engine System - General
Information, Diagnosis and
Testing).
• Low cylinder compression.
• REMOVE the cylinder head.INSPECT the cylinder head,
valves, tappets and camshafts
for signs of wear or damage.
REFER to: Cylinder Head (303-
01 Engine - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
• Worn or damaged valve(s),
tappet(s) or camshaft(s).
• REMOVE the cylinder head.INSPECT the cylinder head
gasket and cylinder bores for
wear or damage.
REFER to: Cylinder Head (303-
01 Engine - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
• Damaged cylinder head gasket.
• CHECK the engine oil level.REFILL as necessary.
• Low engine oil level.
• Engine knock at idle
G1183441en2008.50 Kuga8/2011
303-04A- 17
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 17
DIAGNOSIS AND TESTING
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Action
Possible Sources
Symptom
• CHECK the valve timing.REFER to: Timing Belt (303-01
Engine - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
• Incorrect valve timing.
• REMOVE the cylinder head.INSPECT the cylinder head
and pistons for signs carbon
build up.
REFER to: Cylinder Head (303-
01 Engine - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
• Excessive carbon build up.
• INSPECT the engine compon-ents.
• Worn or damaged oil pump.
• Worn or damaged timing chain
or sprocket.
• Major mechanical engine failure.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• KS.
• Engine knock during accelera-
tion
• INSPECT the fuel injectors.CLEAN the fuel injectors or
INSTALL a new set of injectors
as required only after the
checks have been carried out.
REFER to: Fuel Injectors (303-
04 Fuel Charging and
Controls - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
• Fuel injectors.
• REFER to:Engine(303-00
Engine System - General
Information, Diagnosis and
Testing).
• Major mechanical engine
failure.
• CHECK the braking system.REFER to: Brake System (206-
00 Brake System - General
Information, Diagnosis and
Testing).
• Brakes binding.
• Excessive fuel consumption
• ADVISE the customer aboutthe effects of overloading the
vehicle and wind resistance on
the fuel consumption.
• Vehicle overloaded, or
excessive wind resistance (roof
racks, towing etc).
• INSTALL a new air cleanerelement.
• Air cleaner element blocked.
G1183441en2008.50 Kuga8/2011
303-04A-
19
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 19
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6
79108
123
4
5
6
79108
E97592
Description
Item
Exhaust manifold
1
PCV (positive crankcase ventilation)- hose
Comments:to cylinder head
2
Vacuum line - recirculated air valve
Comments:to intake manifold
3
Coolant return pipe
4Description
Item
Turbo boost pressure controller
5
Oil supply pipe - TC
6
Wastegate control valve
7
TC
Comments:Contains the recirculated air valve
8
Coolant supply pipe
9
Oil return pipe - TC
10
G1032424en2008.50 Kuga8/2011
303-04B- 3
Fuel Charging and Controls - Turbocharger
—
2.5L Duratec (147kW/200PS) - VI5
303-04B- 3
DESCRIPTION AND OPERATION
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