2011 FORD KUGA open

E112634
2
1
8.Torque: 4Nm
E99258
9. WARNING: Be prepared to collect
escaping fluid.
CAUTION: Make sure that all openings
are sealed.
Torque: 18
Nm
E114705
10.
G1185535en2008.50 Kuga8/2011
211-02- 22
Power Steering
211-02- 22
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

E99054
13.Torque: 4Nm
E99258
14. WARNING: Be prepared to collect
escaping fluid.
CAUTION: Make sure that all openings
are sealed.
Torque: 20
Nm
E99257
15.
G1001271en2008.50 Kuga8/2011
211-02- 27
Power Steering
211-02- 27
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

E112634
2
1
8.Torque: 4Nm
E99258
9. WARNING: Be prepared to collect
escaping fluid.
CAUTION: Make sure that all openings
are sealed.
Torque: 18
Nm
E114705
10.
G1185536en2008.50 Kuga8/2011
211-02- 37
Power Steering
211-02- 37
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Measure the compression pressure
(Engine - 2.5L Duratec-ST (VI5))
TIE44608
1. Remove the central junction box (CJB) cover.
TIE44609
2. Open the CJB and remove the fuel pump relay.
3. NOTE: The engine will start, run for a fewseconds and then stop.
Start the engine.
4. Remove the ignition coil-on-plug.
REFER to: Ignition Coil-On-Plug (303-07 Engine
Ignition - 2.5L Duratec (147kW/200PS) - VI5,
Removal and Installation). 5. Connect the battery ground cable.
REFER to: Battery Disconnect and Connect
(414-01 Battery, Mounting and Cables,
General Procedures).
E68679
x5
6. Using Special Tool 303-499, remove the spark plugs.
E68434
NOTE: Operate the starter motor with wide open
throttle until the pointer on the measuring device
stops rising.
7. Carry out the measurement in accordance with the instructions supplied with the measuring
device on every cylinder using a suitable
compression pressure recorder with a suitable
adapter.
E68680
28 Nm
8. Using Special Tool 303-499, install the sparkplugs.
G1055128en2008.50 Kuga8/2011
303-00- 10
Engine System - General Information
303-00- 10
DIAGNOSIS AND TESTING
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

9. Install the ignition coil-on-plug.REFER to: Ignition Coil-On-Plug (303-07 Engine
Ignition - 2.5L Duratec (147kW/200PS) - VI5,
Removal and Installation).
TIE44609
10. Install the fuel pump relay and close the CJB.
TIE44608
11. Install the CJB cover.
Measure the compression pressure
(Engine - 2.0L Duratorq-TDCi (DW)
Diesel)
WARNINGS:
Do not smoke or carry lighted tobacco or
open flame of any type when working on or near any fuel related components.
Highly flammable vapors are always
present and can ignite. Failure to follow
these instructions may result in personal
injury.
Do not carry out any repairs to the fuel
injection system without checking that the
fuel pressure has dropped to zero and that
the fuel temperature has either reached
ambient temperature or is below 30°C,
whichever is the greater. Failure to follow
these instructions may result in personal
injury.
1. Using datalogger in the Ford diagnostic
equipment , check that the fuel pressure has
dropped to zero and that the fuel temperature
has either reached ambient temperature or is
below 30°C, whichever is the greater.
2. Raise and support the vehicle.
REFER to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
VFE0035742
3. Remove the engine undershield.
VFE0035752
4. Remove the radiator undershield.
G1055128en2008.50 Kuga8/2011
303-00- 11
Engine System - General Information
303-00- 11
DIAGNOSIS AND TESTING
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Bar
Description
4.8
Oil pressure relief valve opening pressure
Valve Clearance
mm
Description
0.17 - 0.23
Valve clearance (engine cold), intake
0.36 - 0.43
Valve clearance (engine cold), exhaust
Valves
mm
Description
101.93 - 102.07
Intake valve lenght
5.87 - 6.01
Intake valve shaft diameter
0.05 - 0.07
Intake valve guide clearance
101.43 - 101.57
Exhaust valve lenght
5.87 - 6.01
Exhaust valve shaft diameter
0.05 - 0.07
Exhaust valve guide clearance
Valve Seats
degree
Description
45.33 - 45.67
Intake valve seat angle
45.33 - 45.67
Exhaust valve seat angle
Cylinder Head
mm
Description
149.25 - 149.55
Cylinder head height
0.05
Maximum mating face distortion (lengthwise)
0.02
Maximum mating face distortion (crosswise)
0.30
Maximum face milling
Camshafts
mm
Description
8.68
Intake camshaft lobe lift
9.05
Exhaust camshaft lobe lift
Crankshaft
mm
Description
0.08 - 0.19
Crankshaft axial clearance
Crankshaft Main Bearing Selection
Code - Cylinder block
Code - Cylinder block
Code - Cylinder block
C
B
A
Crankshaft
main bearing carrier
Cylinder
block
Crankshaft
main bearing carrier
Cylinder
block
Crankshaft
main bearing carrier
Cylinder
block
Crankshaft
main bearing
for:
G1079019en2008.50 Kuga8/2011
303-01-
4
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
4
SPECIFICATIONS
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Engine – System Operation and Component Description
System Operation
The variable camshaft timing occurs
electro-hydraulically and individually for both
camshafts.
The camshaft adjusters work according to the vane
cell principle and have an adjustment range of 52°
crank angle on the intake side and 47° crank angle
on the exhaust side. On starting the engine and
during idling, both camshafts are mechanically
locked in their starting positions. The exhaust
camshaft is in the early position and the intake
camshaft is in the late position. The camshaftadjuster on the exhaust side has a torsion spring
which compensates the camshaft drive torque.
This ensures that the assembly can return to the
starting position under all operating conditions and
when the engine is turned off.
Internal exhaust gas recirculation can be realized
through continuous adjustment of the timings. This
results in better fuel consumption and more
favorable combustion temperatures which produce
less pollutants. This means that pollutant level IV
can be adhered to with a 3-way catalytic converter.
The variable timings also make it possible to
optimize performance with wide open throttle.
G1032416en2008.50 Kuga8/2011
303-01-
16
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
16
DESCRIPTION AND OPERATION
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48.
1
1
2
E114610
49.
E114612
51.
x2
52.
x6
E114614
53. CAUTION: Make sure that all openingsare sealed.
G1191240en2008.50 Kuga8/2011
303-01- 72
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
72
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E114611
50.
E64738