Toyota
Ford Kuga
 Service Manual
Engine- 2.5L Duratec (147kW/200PS) - VI5
Engine - Vehicles With: 5-Speed Automatic Transaxle (AW55)

Installation

Special Tool(s) / General Equipment

303-122 Lifting Bracket, Engine

Hose Clamp Remover/Installer

Hydraulic Jib Crane

Mounting Table Set

Retaining Strap

Round-Ended Steel Rule

Trolley Jack

Wooden Block

1. Special Tool(s): 303-122 General Equipment: Hydraulic Jib Crane

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

2. General Equipment: Round-Ended Steel Rule

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

3. Torque: 48 Nm

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

4. Torque: 48 Nm

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

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

Torque: 60 Nm

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

WARNING: Make sure that the engine and transmission assembly is on wooden blocks and secured with suitable retaining straps.

General Equipment: Retaining Strap

General Equipment: Mounting Table Set

General Equipment: Wooden Block

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

CAUTION: Make sure that no components catch.

Lower the vehicle.

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

9. 1. Torque: 148 Nm

2. Torque: 10 Nm

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

10.NOTE: Only tighten the nuts and bolts finger tight at this stage.

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

11. Remove the following items:

  • General Equipment: Retaining Strap

12.Torque: 25 Nm

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

13. 1. Torque: 23 Nm

2. Torque: 7 Nm

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

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

15. 1. Torque: 10 Nm

2. General Equipment: Hose Clamp Remover/Installer

4. Torque: 30 Nm

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

16. Install the following items: 1. Refer to: Transfer Case (307-07 Transfer Case - Vehicles With: 5-Speed Automatic Transaxle - AW55 AWD/6-Speed Automatic Transaxle - 6DCT450, Removal).

2. Refer to: Front Halfshaft LH (205-04 Front Drive Halfshafts, Removal and Installation).

3. Refer to: Accessory Drive Belt (303-05 Accessory Drive - 2.5L Duratec (147kW/200PS) - VI5, Removal and Installation).

CAUTION: Make sure that the exhaust flexible pipe is not forcibly bent.

Torque: 48 Nm

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

18.Torque: 24 Nm

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

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

20.Torque: 6 Nm

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

21.Torque: 50 Nm

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

CAUTION: Make sure that the exhaust flexible pipe is not forcibly bent.

Torque: 28 Nm

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

23. 1. Torque: 48 Nm

2. Torque: 80 Nm

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

24.Torque: 10 Nm

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

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

26. 1. Torque: 48 Nm

2. Torque: 9 Nm

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

27.Torque: 25 Nm

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

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

29.Torque: 25 Nm

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

CAUTION: Gearshift cables must not be kinked or bent.

Refer to: Selector Lever Cable Adjustment - Vehicles With: 5-Speed Automatic Transaxle - AW55 AWD (307-05 Automatic Transmission/Transaxle External Controls - Vehicles With: 5-Speed Automatic Transaxle - AW55 AWD/6-Speed Automatic Transaxle - 6DCT450, General Procedures).

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

31. General Equipment: Hose Clamp Remover/Installer

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

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

33. 1. Torque: 48 Nm

2. Torque: 25 Nm

3. Torque: 10 Nm

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

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

35. Refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).

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

36. - Torque: 12 Nm

- Torque: 24 Nm

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

37.Torque: 10 Nm

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

38.Torque: 20 Nm

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

39.NOTE: The gasket is to be reused unless damaged.

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

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

41. 1. Torque: 25 Nm

2. Torque: 5 Nm

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

42. General Equipment: Hose Clamp Remover/Installer

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

43.Torque: 5 Nm

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

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

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

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

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

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

CAUTION: Make sure that no components catch.

General Equipment: Retaining Strap

General Equipment: Trolley Jack

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

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

Vehicles without PCM security shield

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

52.Torque: 7 Nm

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

Vehicles with PCM security shield

53.Torque: 7 Nm

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

All vehicles

CAUTION: Make sure that no components catch.

Remove the following items:

  • General Equipment: Retaining Strap

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

Remove the following items:

  • General Equipment: Trolley Jack

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

CAUTION: Make sure that the inside of the pipe ends are clean and free of oil residue.

1. Torque: 4 Nm

2. Torque: 10 Nm

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

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

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

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

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

61. 1. Torque: 115 Nm

2. Torque: 90 Nm

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

62. General Equipment: Hose Clamp Remover/Installer

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

63.Torque: 10 Nm

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

64.Torque: 12 Nm

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

65.On both sides.

Torque: 35 Nm

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

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

67. Install the following items: 1. Refer to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation).

2. Refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation).

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

69. Refer to: Cooling System Draining and Vacuum Filling (303-03 Engine Cooling, General Procedures).

70. Refer to: Power Steering System Filling (211-00 Steering System - General Information, General Procedures).

71. Refer to: Door Window Motor Initialization (501-11 Glass, Frames and Mechanisms, General Procedures).

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

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