2011 FORD KUGA Pipe

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
303-01- 20
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
20
REMOVAL AND INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
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
REMOVAL AND INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

9.Torque: 24Nm
E112254
G1079022en2008.50 Kuga8/2011
303-01- 51
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
51
REMOVAL AND INSTALLATION
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
TO MODEL INDEX
BACK TO CHAPTER INDEX
E66726
10. CAUTION: Make sure that the inside of the pipe ends are clean and free of oil
residue.
11 .Torque: 24Nm
E112607
1
2
34
12. CAUTION: Make sure that the gaskets
are correctly located.
E112806
13.
E65070
Torque: 24Nm

15. CAUTION: Make sure that the inside ofthe pipe ends are clean and free of oil
residue.
1. Torque: 10
E68504
16. CAUTION: Make sure that the inside ofthe pipe ends are clean and free of oil
residue.
E68413
18.Torque: 10Nm
E113004
x8
19.
G1079022en2008.50 Kuga8/2011
303-01- 52
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
52
REMOVAL AND INSTALLATION
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
TO MODEL INDEX
BACK TO CHAPTER INDEX
E67743
14.
E106249
Nm
2. Torque: 4Nm
3. Torque: 10Nm
2
1
3
17.
E67375

35.General Equipment: Cable Ties
E98634
36. CAUTION: Make sure that the exhaust
flexible pipe is not forcibly bent.
G1191240en2008.50 Kuga8/2011
303-01- 69
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
69
REMOVAL
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
E112439
1
2
2
x3
E114754

54.
E66050
55.
E112254
56. CAUTION: Make sure that the exhaustflexible pipe is not forcibly bent.
E112253
x2
57.Remove 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).
58.
x2x2
E114619
G1191240en2008.50 Kuga8/2011
303-01- 73
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
73
REMOVAL
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

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).
17. CAUTION: Make sure that the exhaust flexible pipe is not forcibly bent.
Torque: 48Nm
E112253
x2
18.Torque: 24Nm
E112254
19.
E66050
G1191241en2008.50 Kuga8/2011
303-01- 124
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
124
INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

20.Torque: 6Nm
E114754
23. Torque: 48Nm1.
2. Torque: 80
303-01- 125
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
125
INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
E114624
21.
Torque: 50
x2
22. CAUTION: Make sure that the exhaust
flexible pipe is not forcibly bent.
Torque: 28Nm
Nm
E114913
24.Torque: 10
E114612
25.
E114611
G1191241en2008.50 Kuga8/2011
Nm
1
2
Nm
x3