2011 FORD KUGA engine remove

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
G1156381en2008.50 Kuga8/2011
303-03- 14
Engine Cooling
303-03- 14
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

E112626
1
2
1
2
All vehicles
8.General Equipment: Hose Clamp
Remover/Installer
G1156381en2008.50 Kuga8/2011
303-03- 15
Engine Cooling
303-03- 15
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Action
Possible Sources
Symptom
• REMOVE and visuallyINSPECT the catalytic
converter as necessary.
REFER to: Catalytic Converter
(309-00 Exhaust System -
2.5L Duratec (147kW/200PS)
- VI5, Removal and Installa-
tion).
• Catalytic converter blocked.
• TEST the engine cylindercompression.
REFER to: Engine(303-00
Engine System - General
Information, Diagnosis and
Testing).
• Low cylinder compression.
• INSTALL a new air cleanerelement.
• Air cleaner element blocked.
• Engine starts but immediately
stops
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• CKP sensor.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• CMP sensor.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
•PCM.
• Check the fuel system pres-sure.
• Low fuel system pressure.
• INSPECT the fuel system.INSTALL new components as
necessary. TEST the system
for normal operation.
• Fuel system restriction.
• INSTALL a new fuel filter.
• Fuel filter blocked.
• INSTALL a new air cleanerelement.
• Air cleaner element blocked.
• Poor idling
G1183441en2008.50 Kuga8/2011
303-04A- 7
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 7
DIAGNOSIS AND TESTING
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Action
Possible Sources
Symptom
• CHECK the cylinder compres-sion.
REFER to: Engine(303-00
Engine System - General
Information, Diagnosis and
Testing).
• Low cylinder compression.
• REMOVE and visuallyINSPECT the catalytic
converter for damage. INSTALL
a new catalytic converter as
necessary.
REFER to: Catalytic Converter
(309-00 Exhaust System -
2.5L Duratec (147kW/200PS)
- VI5, Removal and Installa-
tion).
• Catalytic converter blocked.
• INSTALL a new air cleanerelement as necessary.
• Air cleaner element blocked.
• Black smoke at idle
• INSPECT the fuel injectors.CLEAN the fuel injectors or
INSTALL a new set of injectors
as required only after the
checks have been carried out.
REFER to: Fuel Injectors (303-
04 Fuel Charging and
Controls - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
• Fuel injectors.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• ECT sensor.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• Fuel rail fuel pressure sensor.
• REMOVE and visuallyINSPECT the catalytic
converter for damage. INSTALL
a new catalytic converter as
necessary.
REFER to: Catalytic Converter
(309-00 Exhaust System -
2.5L Duratec (147kW/200PS)
- VI5, Removal and Installa-
tion).
• Catalytic converter blocked.
G1183441en2008.50 Kuga8/2011
303-04A-
11
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 11
DIAGNOSIS AND TESTING
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Action
Possible Sources
Symptom
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• Fuel rail fuel pressure sensor.
• REMOVE and visuallyINSPECT the catalytic
converter for damage. INSTALL
a new catalytic converter as
necessary.
REFER to: Catalytic Converter
(309-00 Exhaust System -
2.5L Duratec (147kW/200PS)
- VI5, Removal and Installa-
tion).
• Catalytic converter blocked.
• INSTALL a new air cleanerelement.
• Air cleaner element blocked.
• Black smoke at cruising speeds
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• ECT sensor.
• INSPECT the fuel injectors.CLEAN the fuel injectors or
INSTALL a new set of injectors
as required only after the
checks have been carried out.
REFER to: Fuel Injectors (303-
04 Fuel Charging and
Controls - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
• Fuel injectors.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• Fuel rail fuel pressure sensor.
• REMOVE and visuallyINSPECT the catalytic
converter for damage. INSTALL
a new catalytic converter as
necessary.
REFER to: Catalytic Converter
(309-00 Exhaust System -
2.5L Duratec (147kW/200PS)
- VI5, Removal and Installa-
tion).
• Catalytic converter blocked.
• CARRY OUT a controlled oilconsumption test over 1000 km
(600 miles). CONFIRM that the
oil consumption is less than 0.1
litre per 1000 km (600 miles).
• Engine burning oil.
• Blue smoke
G1183441en2008.50 Kuga8/2011
303-04A- 13
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 13
DIAGNOSIS AND TESTING
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Action
Possible Sources
Symptom
• CHECK for signs of contamina-tion such as strange odors from
the fuel tank.
• If contaminated fuel is found, DRAIN the complete fuel
system. FLUSH the fuel system
through with clean gasoline.
REFER to: Fuel Tank Draining
(310-00 Fuel System -
General Information, General
Procedures).
INSTALL a new fuel filter.
• INSPECT the fuel injectors. CLEAN the fuel injectors or
INSTALL a new set of injectors
as required only after the
checks have been carried out.
REFER to: Fuel Injectors (303-
04 Fuel Charging and
Controls - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
• INSTALL a new fuel rail.
REFER to: Fuel Rail(303-04
Fuel Charging and Controls -
2.5L Duratec (147kW/200PS)
- VI5, Removal and Installa-
tion).
• Incorrect or contaminated fuel.
• INSPECT for visible signs ofdamage or blockage. CLEAN,
REPAIR or INSTALL new parts
as necessary.
• Positive crankcase ventilation
(PCV) system.
• REMOVE the cylinder head.INSPECT the cylinder head,
pistons and cylinder bores for
signs of wear or damage.
REFER to: Cylinder Head (303-
01 Engine - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
• Worn or damaged valve
guide(s), piston ring(s), cylinder
bore(s), cylinder head or
gasket.
G1183441en2008.50 Kuga8/2011
303-04A- 14
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 14
DIAGNOSIS AND TESTING
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Action
Possible Sources
Symptom
• CHECK for signs of contamina-tion such as strange odors from
the fuel tank.
• If contaminated fuel is found, DRAIN the complete fuel
system. FLUSH the fuel system
through with clean gasoline.
REFER to: Fuel Tank Draining
(310-00 Fuel System -
General Information, General
Procedures).
INSTALL a new fuel filter.
• INSPECT the fuel injectors. CLEAN the fuel injectors or
INSTALL a new set of injectors
as required only after the
checks have been carried out.
REFER to: Fuel Injectors (303-
04 Fuel Charging and
Controls - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
• INSTALL a new fuel rail.
REFER to: Fuel Rail(303-04
Fuel Charging and Controls -
2.5L Duratec (147kW/200PS)
- VI5, Removal and Installa-
tion).
• Incorrect or contaminated fuel.
• White smoke
• CARRY OUT a cooling systempressure test.
REFER to: Engine Cooling
(303-03 Engine Cooling,
Diagnosis and Testing).
• REMOVE the cylinder head. INSPECT the cylinder head,
cylinder head gasket and
cylinder bores for wear or
damage.
REFER to: Cylinder Head (303-
01 Engine - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
• Coolant in the combustion
chamber.
G1183441en2008.50 Kuga8/2011
303-04A- 15
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 15
DIAGNOSIS AND TESTING
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Action
Possible Sources
Symptom
• INSPECT the fuel injectors.CLEAN the fuel injectors or
INSTALL a new set of injectors
as required only after the
checks have been carried out.
REFER to: Fuel Injectors (303-
04 Fuel Charging and
Controls - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
• Fuel injectors.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• Fuel rail fuel pressure sensor.
• CHECK the engine compres-sion.
REFER to: Engine(303-00
Engine System - General
Information, Diagnosis and
Testing).
• Low cylinder compression.
• REMOVE the cylinder head.INSPECT the cylinder head,
valves, tappets and camshafts
for signs of wear or damage.
REFER to: Cylinder Head (303-
01 Engine - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
• Worn or damaged valve(s),
tappet(s) or camshaft(s).
• REMOVE the cylinder head.INSPECT the cylinder head
gasket and cylinder bores for
wear or damage.
REFER to: Cylinder Head (303-
01 Engine - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
• Damaged cylinder head gasket.
• CHECK the engine oil level.REFILL as necessary.
• Low engine oil level.
• Engine knock at idle
G1183441en2008.50 Kuga8/2011
303-04A- 17
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 17
DIAGNOSIS AND TESTING
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL