2011 FORD KUGA belt

Description
Item
Timing belt idler pulley
9
Crankshaft timing belt pulley
10
Timing belt tensioner
11Description
Item
Coolant pump pulley
12
Timing belt
13
Cylinder block
E64016
1
2
3
G1032415en2008.50 Kuga8/2011
303-01- 7
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
7
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Engine – Overview
General
E62439
The 2.5L Duratec (VI5) engine is a turbo engine
with 5 cylinders and 20 valves, with electronically
controlled camshaft adjustment for both camshafts.The valve train is driven by a timing belt.
G1092773en2008.50 Kuga8/2011
303-01-
9
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
9
DESCRIPTION AND OPERATION
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Description
Item
Exhaust camshaft
1
intake camshaft
2
Valve cover
3
CMP Sensor - intake camshaft
4Description
Item
Intake camshaft reference mark
5
Exhaust camshaft reference mark
6
CMP Sensor - exhaust camshaft
7
CAUTION: Before removal, mark the
camshafts as the intake and exhaust
camshafts can be mixed up.
A reference mark for the CMP sensor is machined
into each camshaft. When the camshafts are set
precisely to the timing marks, the machined mark
on the exhaust camshaft is located roughly at the
5 o'clock position and the machined mark on the
intake camshaft is located at 8 o'clock.
When changing the toothed belts it is not necessary
to dismantle the camshaft adjustment units. A
special tool prevents the VCT control units from
turning during the adjustment process by locking
the two VCT control units to one another.
A further special tool is needed to fix the camshafts
in the adjustment position. The special tool
engages in corresponding recesses for the
reference marks on the CMP sensors. Each camshaft is fixed in place using four bearing
caps and the bearing cap VVT. The bearing caps
must not be changed around and must always be
fitted in their original positions.
The VCT control units for the intake and exhaust
camshafts are moved into the locked base position
when the engine is stopped through the
engagement of a spring-loaded locking pin. The
movement to the locked base position is assisted
by the tensile force of the timing belt for the intake
VCT control unit. With the exhaust VCT control
unit, a spring inside the control unit additionally
assists in reaching the locked base position. The
intake VCT control unit is in the "retarded timing"
position and the exhaust VCT control unit is in the
"advanced timing" position when in the locked base
position. The lock is hydraulically released when
the engine is started depending on the oil pressure.
The mechanical valve tappets are maintenance
free.
G1092773en2008.50 Kuga8/2011
303-01-
13
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
13
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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
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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
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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
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL