2011 FORD KUGA filter

Action
Possible Sources
Symptom
• Check the cooling systemcomponents. Engine - 2.5L
Duratec-ST (VI5) -
REFER to: Engine Cooling
(303-03 Engine Cooling,
Diagnosis and Testing).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
REFER to: Engine Cooling
(303-03 Engine Cooling,
Diagnosis and Testing).
• Cooling system components.
• Coolant consumption
• INSTALL a new oil cooler.
• Oil cooler.
• CHECK the cylinder headgasket for damage. CHECK the
cylinder head for distortion.
• Damaged gaskets or warped
mating faces.
• DETERMINE the damagedengine component(s) and
install new component(s) as
necessary.
• Cracks or fractures in engine
components surrounded by
coolant, such as cylinder liners
and cylinder head combustion
chamber.
• CHECK the battery and cables.REFER to: Charging System
(414-00 Charging System -
General Information,
Diagnosis and Testing).
• Battery or cables.
• Engine will not crank
• CHECK the starting system.Engine - 2.5L Duratec-ST (VI5)
-
REFER to: Starting System
(303-06 Starting System -
2.5L Duratec (147kW/200PS)
- VI5, Diagnosis and Testing).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Starter motor or cables.
• CHECK the fuel level.
• Fuel tank is empty.
• Engine cranks but will not start
• Drain the water from the fuelsystem.
• Water in fuel (diesel engine
only).
• INSTALL a new fuel filter.Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Fuel filter blocked.
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303-00-
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Engine System - General Information
303-00- 4
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Action
Possible Sources
Symptom
• CHECK the intake air system.Engine - 2.5L Duratec-ST (VI5)
-
REFER to: Intake Air Distribu-
tion and Filtering (303-12
Intake Air Distribution and
Filtering - 2.5L Duratec
(147kW/200PS) - VI5,
Diagnosis and Testing).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Engine intake air system.
• CHECK the glow plugs.INSTALL new glow plugs as
necessary.
• Glow plug faulty (diesel engine
only).
• CHECK the engine manage-ment system. Engine - 2.5L
Duratec-ST (VI5) -
REFER to: Electronic Engine
Controls (303-14 Electronic
Engine Controls - 2.5L
Duratec (147kW/200PS) -
VI5, Diagnosis and Testing).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Engine management system.
• CHECK the ignition system.Engine - 2.5L Duratec-ST (VI5)
-
REFER to: Engine Ignition
(303-07 Engine Ignition - 2.5L
Duratec (147kW/200PS) -
VI5, Diagnosis and Testing).
• Ignition system (petrol engine
only).
• CHECK and adjust the valvetiming. Engine - 2.5L Duratec-
ST (VI5) -
REFER to: Timing Belt (303-01
Engine - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Incorrect valve timing.
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Engine System - General Information
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Action
Possible Sources
Symptom
• CHECK the timing belt/timingchain and sprockets/pulleys.
INSTALL new components as
necessary. Engine - 2.5L
Duratec-ST (VI5) -
REFER to: Timing Belt (303-01
Engine - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Broken or damaged timing
belt/timing chain or
pulley/sprocket.
• CHECK the fuel system.Engine - 2.5L Duratec-ST (VI5)
-
REFER to: Fuel Charging and
Controls (303-04 Fuel Char-
ging and Controls - 2.5L
Duratec (147kW/200PS) -
VI5, Diagnosis and Testing).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Fuel system.
• Very poor power output or fuel
consumption too high or engine
running rough.
• CHECK the intake air system.Engine - 2.5L Duratec-ST (VI5)
-
REFER to: Intake Air Distribu-
tion and Filtering (303-12
Intake Air Distribution and
Filtering - 2.5L Duratec
(147kW/200PS) - VI5,
Diagnosis and Testing).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Engine intake air system.
• CHECK the exhaust system.
• Exhaust system blocked.
• CHECK the engine manage-ment system. Engine - 2.5L
Duratec-ST (VI5) -
REFER to: Electronic Engine
Controls (303-14 Electronic
Engine Controls - 2.5L
Duratec (147kW/200PS) -
VI5, Diagnosis and Testing).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Engine management system.
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303-00-
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Engine System - General Information
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Put the engine cover into installation position
and clip it in place by pressing at the places
shown.• Make sure that the engine upper cover is fully engaged in the area of the fuel filter, if
necessary apply more pressure in the areas
shown.
25. Install the cowl panel grille.
REFER to: Cowl Panel Grille (501-02 Front End
Body Panels, Removal and Installation).
26. Raise and support the vehicle.
REFER to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
TIE44583
27. Install the glow plug relay.
VFE0035752
28. Install the radiator undershield.
VFE0035742
29. Install the engine undershield.
30. Lower the vehicle.
31. Reset the PCM fault memory.
Measure the oil pressure (21 113 0)
The oil pressure depends on various factors
(engine speed, oil temperature, oil viscosity,
amount of oil filter contamination etc.).
Measure the oil pressure (Engine - 2.5L
Duratec-ST (VI5))
1. Raise and support the vehicle.
REFER to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
E65955
2. Remove the engine undershield.
E68443
3. Disconnect the oil pressure switch electrical connector.
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303-00- 14
Engine System - General Information
303-00- 14
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Engine Data
DescriptionHYDC
HYDB
Engine code
1-2-4-5-3
Firing order
Stage V
Stage IV
Emission level
83 mm
Bore
93.2 mm
Stroke
2522 cm³
Cubic capacity
9:1
Compression ratio
147 kW (200 PS)
Power output at 6000 rpm
320 Nm
Maximum torque at 1600
rpm
6850 rpm
Maximum engine speed
(intermittent)
6500 rpm
Maximum engine speed
(continous)
770 rpm
Idle speed
6
Number of main bearings
Belt
Camshaft drive
0.5 l/1000 Km
Oil consumption
Engine Oil
Specification
Ty p e
Viscosity / ambient temper-
ature
Recommended engine oil WSS-M2C913-C
Ford Formula E
SAE 5W-30 / below -20°C to over
+40°C
Alternative engine oils (for top-
up only)
ACEA A3/B3
Ford Formula XR+
SAE 10W-40 / -20°C to over
+40°C
ACEA A3/B3
Ford Formula S
SAE 5W-40 / below -20°C to over
+40°C
Engine Oil Capacity
Liters
Description
5.8
Service fill including filter
5.5
Service fill excluding filter
Oil Pressure
Bar
Description
1.0
Minimum oil pressure at 800 - 850 rpm (normal operating temperature)
3.5
Minimum oil pressure at 4000 rpm (normal operating temperature)
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Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
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SPECIFICATIONS
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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
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Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
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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
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Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
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Radiator — 2.5L Duratec (147kW/200PS) - VI5(24 254 0)
General EquipmentCable Ties
Hose Clamp Remover/Installer
Removal
NOTE: Removal steps in this procedure may
contain installation details.
1.
E112311
2.
E112335
3. Refer to: Charge Air Cooler (303-12 Intake Air
Distribution and Filtering - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
4. Refer to: Cooling System Draining and Vacuum
Filling (303-03 Engine Cooling, General
Procedures).
5. Torque: 25
Nm
E112625
x2x2
6. NOTE: The gasket is to be reused unless
damaged.
E99980
Vehicles with automatic transmission
7. General Equipment: Cable Ties
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303-03- 14
Engine Cooling
303-03- 14
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL