Ford Kuga

 Service Manual

Engine- 2.5L Duratec (147kW/200PS) - VI5
Camshaft Seal (21 288 0)

Special Tool(s)

	303-1054 Locking Tool, Timing Belt Tensioner
	303-1178 Timing Tool Camshaft
	303-1179 Holding Wrench, Crankshaft
	303-1182 Timing Tool, Crankshaft
	303-318 Aligner/Installer, Crankshaft Front Seal

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).

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

Installation

1. Special Tool(s): 303-318

2. NOTE: Only tighten the bolts finger tight at this stage.

4. Using the special tool, align the crankshaft.

Install the Special Tool(s): 303-1182

CAUTION: Make sure that the installation marks are aligned.

Vehicles with mechanical timing belt tensioner 6. NOTE: Make sure that new components are installed.

1. Torque: 25 Nm

3. NOTE: The timing belt tensioner setting is dependant on the engine temperature.

Torque: 25 Nm

Vehicles with automatic timing belt tensioner

7. NOTE: Make sure that new components are installed.

1. Torque: 25 Nm

3. Special Tool(s): 303-1054

Torque: 25 Nm

WARNING: Take extra care when handling the compressed spring.

Remove the Special Tool(s): 303-1054

All vehicles

9. Torque: 120 Nm

10.Remove the Special Tool(s): 303-1178

11. Remove the Special Tool(s): 303-1182

13. Using the special tool, align the crankshaft.

Install the Special Tool(s): 303-1182

14. Install the Special Tool(s): 303-1178 Torque: 10 Nm

CAUTION: Make sure that the installation marks are aligned.

16.Torque: 35 Nm

17.Remove the Special Tool(s): 303-1182

18.Remove the Special Tool(s): 303-1178

19.Torque: 17 Nm

20.Torque: 40 Nm

21. 1.NOTE: Make sure that new components are installed.

2. Torque: 40 Nm

22.Torque: 10 Nm

23.Torque: 28 Nm

25. Refer to: Ignition Coil-On-Plug (303-07 Engine Ignition - 2.5L Duratec (147kW/200PS) - VI5, Removal and Installation).

26.Torque: 10 Nm

27. 1. Torque: 115 Nm

2. Torque: 90 Nm

29. 1. NOTE: Only tighten the bolts finger tight at this stage.

Install the Special Tool(s): 303-1179

2. Torque: 180 Nm

30.Remove the Special Tool(s): 303-1179

31.Torque:

• Stage 1: 25 Nm
• Stage 2: 60

32. Install the following items: 1. Refer to: Air Conditioning (A/C) Compressor Belt (303-05 Accessory Drive - 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).

Engine (Component Location)

Engine (Overview)

Engine (System Operation and Component Description).

Valve Clearance Adjustment

Intake Manifold (21 183 0) Removal

Crankshaft Front Seal  (21 467 0)

Valve Stem Seals  (21 238 0)

Timing Belt (21 304 0)

Camshafts  (21 284 0)

Camshaft Seal (21 288 0)

Oil Pan (21 154 0)

Oil Pump (21 714 0)

Exhaust Manifold (21 187 0)

Cylinder Head (21 163 0)

Crankshaft Rear Seal (21 468 4)

Oil Cooler

Engine - Vehicles With: 5-Speed Automatic Transaxle (AW55)

Engine Accessories

Engine

Cylinder Head

Engine

Engine Accessories (21 139 4)

Engine - Vehicles With: 5-Speed Automatic Transaxle (AW55)