Toyota
Ford Kuga
 Service Manual
Engine- 2.5L Duratec (147kW/200PS) - VI5
Engine

Assembly

Special Tool(s) / General Equipment

303-1054 Locking Tool, Timing Belt Tensioner
303-1178 Timing Tool Camshaft
303-1179 Holding Wrench, Crankshaft
303-1180 Installer, Crankshaft Front Seal
303-1181 Installer, Crankshaft Rear Seal
303-1182 Timing Tool, Crankshaft
303-318 Aligner/Installer, Crankshaft Front Seal

Piston Ring Compressor

Round-Ended Steel Rule

Materials

Name Specification
Engine Oil - 5W-30 WSS-M2C913-C
Flange Sealant - Anaerobic LP WSK-M2G348-A7 / 5U7J-M2G348-BA

1. NOTE: This step is only necessary when installing a new component.

Refer to: Specifications (303-01 Engine - 2.5L Duratec (147kW/200PS) - VI5, Specifications).

Engine

CAUTION: Make sure that the components are installed to the position noted before removal.

Apply a thin coating.

Material: Engine Oil - 5W-30 (WSS-M2C913-C) engine oil

Engine

CAUTION: Make sure that the components are installed to the position noted before removal.

Apply a thin coating.

Material: Engine Oil - 5W-30 (WSS-M2C913-C) engine oil

Engine

Engine

5. NOTE: The component must be installed within 5 minutes of applying the sealant.

Material: Flange Sealant - Anaerobic LP (WSK-M2G348-A7 / 5U7J-M2G348-BA) sealant

Engine

CAUTION: Make sure that new bolts are installed.

Torque:

  • Stage 1: M10: 1-12 20 Nm
  • Stage 2: M10: 1-12 45 Nm

7. Torque:

  • M8: 13-24 24 Nm

8. Torque:

  • M7: 25-29 17 Nm

9. Torque:

  • M10: 1-12 90

Engine

10.NOTE: This step is only necessary when installing a new component.

Engine

CAUTION: Make sure that the components are installed to the position noted before removal.

General Equipment: Piston Ring Compressor

Engine

CAUTION: Make sure that the components are installed to the position noted before removal.

Apply a thin coating.

Material: Engine Oil - 5W-30 (WSS-M2C913-C) engine oil

Engine

13.CAUTIONS:

  • Make sure that the components are installed to the position noted before removal.
  • Make sure that new bolts are installed.

Apply a thin coating.

Material: Engine Oil - 5W-30 (WSS-M2C913-C) engine oil

Torque:

  • Stage 1: 30 Nm
  • Stage 2: 90

Engine

14.Torque: 10 Nm

Engine

15.NOTE: The component must be installed within 5 minutes of applying the sealant.

Material: Flange Sealant - Anaerobic LP (WSK-M2G348-A7 / 5U7J-M2G348-BA) sealant

Engine

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

Engine

17. General Equipment: Round-Ended Steel Rule

Engine

18.Torque: 17 Nm

Engine

19.Torque: 17 Nm

Engine

20.Torque: 6 Nm

Engine

21. Special Tool(s): 303-1180

Engine

22. Special Tool(s): 303-1181

Engine

23.Torque:

  • Stage 1: 20 Nm
  • Stage 2: 60 Nm
  • Stage 3: 130

Engine

24. - X = 15 mm.

Engine

Engine

Engine

27. Apply a thin coating.

Material: Engine Oil - 5W-30 (WSS-M2C913-C) engine oil

Engine

28. Material: Flange Sealant - Anaerobic LP (WSK-M2G348-A7 / 5U7J-M2G348-BA) sealant

Engine

29.Torque: 17 Nm

Engine

30. Special Tool(s): 303-318

Engine

31.NOTE: The crankshaft timing pulley can only be installed in 1 position on the crankshaft splines.

Torque: 17 Nm

Engine

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

Engine

33. 1. Torque: 25 Nm

2. Torque: 12 Nm

Engine

34.NOTE: Install all the bolts finger tight before final tightening.

1. Torque:

  • Stage 1: 35 Nm
  • Stage 2:75

2. Torque:

  • Stage 1: 15 Nm
  • Stage 2: 90

Engine

35. Install the Special Tool(s): 303-1178

Torque: 10 Nm

Engine

Engine

CAUTION: Only rotate the crankshaft clockwise.

Rotate the crankshaft slowly until the crankshaft stops.

Install the Special Tool(s): 303-1182

Engine

CAUTION: Make sure that the installation marks are aligned.

Engine

Vehicles with mechanical timing belt tensioner 39.NOTE: Make sure that new components are installed.

1. Torque: 25 Nm

3. Torque: 25 Nm

Engine

Vehicles with automatic timing belt tensioner 40.NOTE: Make sure that new components are installed.

1. Torque: 25 Nm

3. Special Tool(s): 303-1054

Torque: 25 Nm

Engine

WARNING: Take extra care when handling the compressed spring.

Remove the Special Tool(s): 303-1054

Engine

All vehicles

42.Torque: 120 Nm

Engine

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

Engine

CAUTION: Only rotate the crankshaft clockwise.

Rotate the crankshaft slowly until the crankshaft stops.

Remove the Special Tool(s): 303-1182

Engine

Engine

CAUTION: Only rotate the crankshaft clockwise.

Rotate the crankshaft slowly until the crankshaft stops.

Install the Special Tool(s): 303-1182

Engine

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

Engine

CAUTION: Make sure that the installation marks are aligned.

Engine

49.Torque: 35 Nm

Engine

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

Engine

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

Engine

Engine

53.Torque: 40 Nm

Engine

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

2. Torque: 40 Nm

Engine

55.Torque: 10 Nm

Engine

56.Torque: 10 Nm

Engine

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

Install the Special Tool(s): 303-1179 1.

2. Torque: 180 Nm

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

Engine

59.Torque:

  • Stage 1: 25 Nm
  • Stage 2: 60

Engine

    More about «Engine- 2.5L Duratec (147kW/200PS) - VI5»:

    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)

    Ford Kuga Service Manual / Engine- 2.5L Duratec (147kW/200PS) - VI5 / Engine

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