2011 FORD KUGA Timing belt

Timing marks
132
45
6
78
E62440
Description
Item
Exhaust camshaft pulley timing mark
1
Engine front cover with timing marks
2
Intake camshaft pulley timing mark
3
Intake camshaft drive gear
4Description
Item
Exhaust camshaft drive gear
5
Crankshaft timing belt pulley timing mark
6
Crankshaft timing belt pulley
7
Crankshaft
8
The front engine cover must always be fitted when
checking and adjusting the valve timing or timing
belt tension, as the timing marks for both camshaft
pulleys are provided on its front end.
Correct timing belt tension is ensured by the
automatic timing belt tensioner.
No direction of movement is specified when using
a new timing belt. If, however, the old timing belt
is reused, the direction of movement must be
marked prior to removal.
Once the timing belt has been correctly tensioned,
the engine must be rotated by hand two turns
clockwise at the crankshaft in order to allow a subsequent check of the timing belt tension and
adjustment.
Cylinder block
The cylinder block consists of three parts. These
are the cylinder block, the lower crankcase and the
sump pan. The cylinder block has five cylinder
liners made of cast iron, which cannot be replaced.
The pistons are made of a homogeneous aluminum
alloy with a graphite coating on the sides. This
coating serves to reduce friction and dampen noise.
The pistons are cooled from below via oil-spray
nozzles screwed into the cylinder block.
G1092773en2008.50 Kuga8/2011
303-01-
14
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
14
DESCRIPTION AND OPERATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Crankshaft
E62853
123
467
5
Description
Item
Crankshaft
1
Timing belt pulley
2
Dowel
3Description
Item
Timing belt pulley splines
4
Wide spline
5
Crankshaft outer splines
6
Crankshaft inner splines
7
Located on the drive side of the crankshaft are two
sets of splines. The inner splines drive the oil
pump. The outer splines engage in the timing belt
pulley. The timing belt pulley can only be fitted onto the outer splines in a particular position. For this
purpose, one spline on the timing belt pulley and
one on the crankshaft have been made wider. The
dowel fixes the vibration damper in place.
G1092773en2008.50 Kuga8/2011
303-01-
15
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
15
DESCRIPTION AND OPERATION
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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
303-01- 22
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
22
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Timing Belt(21 304 0)
Special Tool(s) / General Equipment303-1054
Locking Tool, Timing Belt
Tensioner
3031054
303-1179
Holding Wrench, Crankshaft
E62035
Trolley Jack
Two Leg Puller
Removal
1.Refer to: Air Conditioning (A/C) Compressor
Belt (303-05 Accessory Drive - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
2.
E68741
3. General Equipment: Trolley Jack
E66944
4.
E68472
2
1
5.
E68742
G543492en2008.50 Kuga8/2011
303-01- 25
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
25
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Vehicles with mechanical timing belt tensioner
9.
E68488
1
3
2
Vehicles with automatic timing belt tensioner
10. WARNING: Take extra care whenhandling the compressed spring.
Install the Special Tool(s): 303-1054
1
2
E113799
303-1054
11. WARNING: Take extra care whenhandling the compressed spring.
Special Tool(s): 303-1054
E113800
1
2
3
303-1054
G543492en2008.50 Kuga8/2011
303-01- 27
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
27
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Installation
Vehicles with mechanical timing belt tensioner
1. NOTE:Make sure that new components are
installed.
1. Torque: 25
Nm
3. Torque: 25Nm
E68489
3
1
2
-20 C 20 C 50 C
Vehicles with automatic timing belt tensioner
2. NOTE: Make sure that new components are
installed.
1. Torque: 25
Nm
3. Special Tool(s): 303-1054 Torque: 25
Nm
E113801
12
3
303-1054
3. WARNING: Take extra care when handling the compressed spring.
Remove the Special Tool(s): 303-1054
E113802
303-1054
G543492en2008.50 Kuga8/2011
303-01- 28
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
28
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Camshaft Seal(21 288 0)
Special Tool(s)303-1054
Locking Tool, Timing Belt
Tensioner
3031054
303-1178
Timing Tool Camshaft
E62051
303-1179
Holding Wrench, Crankshaft
E62035
303-1182
Timing Tool, Crankshaft
E62027
303-318
Aligner/Installer, Crankshaft
Front Seal
21148
Removal
1.Remove the following items:
1. Refer to: Ignition Coil-On-Plug (303-07
Engine Ignition - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
2. Refer to: Starter Motor (303-06 Starting
System - 2.5L Duratec (147kW/200PS) -
VI5, Removal and Installation).
2.
E67902
3.
E68679
x5
G1166799en2008.50 Kuga8/2011
303-01- 36
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
36
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

4.
E67905
5.
E68491
6.
E68745
7.Refer to: Timing Belt (303-01 Engine - 2.5L
Duratec (147kW/200PS) - VI5, Removal and
Installation).
8. Install the Special Tool(s): 303-1178
Torque: 10
Nm
E66324
303-1178
9.
E68749
10.
E74333
x2
G1166799en2008.50 Kuga8/2011
303-01- 37
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
37
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL