Engine Mechanical - 1.6L: Other Ford Kuga II

Lubricants

Oil Pressure

Cylinder Block

Piston

Piston Pin

Cylinder Head

Valve

Crankshaft

Rings

Valve Tappet

Camshaft

Connecting Rod

Engine Code Information Label

The engine code information label, located on the front side of the timing cover, contains the following

Scheme 290

Valve Train

The valve train uses direct acting mechanical buckets (DAMB). The camshaft lobes are positioned directly above mechanical buckets which are positioned on top of the valves.

Twin Independent Variable Cam Timing (Ti-VCT)

The Ti-VCT system allows variable control of the valves which optimizes combustion at full load providing improved power and low speed torque (broadening the torque curve) which enables variable valve overlap which provides better fuel economy and emissions and provides optimized cold start operation with improved exhaust emissions.

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Lower Engine

1. Refer to: «ENGINE»(ref-658863-S16845662912014092900000) . For basic mechanical concerns or to the «ENGINE CONTROLS - INTRODUCTION (EXCEPT DIESEL & HYBRID) (SECTION 0)»(ref-608989) for driveability concerns.

Check

1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-658843-S31152527922014092900000) .
2. Remove the following items: Refer to: «VALVE COVER»(ref-658856-S37139780532014092900000) . Refer to: «SPARK PLUGS»(ref-658901-S06452373172014092900000) .
3. NOTE: Turn the engine clockwise only and use the crankshaft bolt only. NOTE: Measure the valve clearance at base circle, with the lobe pointed away from the tappet, before removing the camshafts. Failure to measure all clearances prior to removing the camshafts will necessitate repeated removal and installation and wasted labor time. Measure each valve's clearance and record its location. Use the General Equipment: Feeler Gauge
4. NOTE: The nominal clearance is: intake: 0.0079 in (0.2 mm) exhaust: 0.0134 in (0.34 mm) NOTE: The acceptable clearance is: intake: 0.007-0.009 in (0.17-0.23 mm) exhaust: 0.012-0.015 in (0.31-0.37 mm)
5. NOTE: The number on the valve tappet only reflects the digits that follow the decimal. For example, a tappet with the number has the thickness of 3.650 mm. NOTE: Select the closest tappet size to the ideal tappet thickness available and mark the installation location. Select tappets using this formula: tappet thickness = measured clearance + the existing tappet thickness - nominal clearance. Select the closest tappet size to the ideal tappet thickness available and mark the installation location.
6. If any tappets do not measure within specifications, install the correct valve tappet.

Camshafts

SPECIAL TOOL DESCRIPTION 303-1532 Installer, Camshaft Seal TKIT-2010B-FLM TKIT-2010B-ROW 303-393-02 Adapter for 303-393 TKIT-2012A-FL TKIT-2012A-ROW 303-393A Locking Tool, Flywheel TKIT-2012A-FL TKIT-2012A-ROW 303-409 (T92C-6700-CH) Remover, Crankshaft Seal TKIT-1992-FH/FMH/FLMH TKIT-1993-LMH/MH 303-748 Locking Tool, Crankshaft TKIT-2010B-FLM TKIT-2010B-ROW Feeler Gauge Hot Air Gun

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MATERIALS SPECIFICATION

Crankshaft Front Seal

SPECIAL TOOL DESCRIPTION 100-001 (T50T-100-A) Slide Hammer 303-175 (T82L-6316-A) Installer, Crankshaft Vibration Damper TKIT-1982-F 303-335 (T88T-6701-A) Installer, Front Cover Oil Seal TKIT-1988-F TKIT-1988-FLM 303-420 (T92P-6701-BH) Installer, Crankshaft Front Oil Seal TKIT-1992-FLMH/LMH TKIT-1992-LMH/MH 308-375 Remover, Input Shaft Seal TKIT-1999-F/FLM/LT TKIT-2005U-M

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MATERIALS SPECIFICATION

Scheme 298

1. Refer to: «TIMING BELT»(ref-658856-S17915395852014092900000) .
2. Install Special Service Tool: 308-375 Remover, Input Shaft Seal , 100-001 (T50T-100-A) Slide Hammer .

Scheme 299

1. NOTE: Make sure that the mating faces are clean and free of foreign material. Use Special Service Tool: 303-175 (T82L-6316-A) Installer, Crankshaft Vibration Damper , 303-335 (T88T-6701-A) Installer, Front Cover Oil Seal , 303-420 (T92P-6701-BH) Installer, Crankshaft Front Oil Seal . Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
2. Refer to: «TIMING BELT»(ref-658856-S17915395852014092900000) .

Intake Manifold

Special Tool(s)/General Equipment

Hose Clamp Remover/Installer

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Scheme 303

1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-658843-S31152527922014092900000) .
2. Refer to: «BATTERY DISCONNECT AND CONNECT»(ref-658873-S03187421432014092900000) .
3. Refer to: «GENERATOR - 1.6L ECOBOOST (132KW/180PS) - SIGMA»(ref-658902-S08678315172014092900000) .
4. Refer to: «QUICK RELEASE COUPLING»(ref-658885-S17306120802014092900000) . Use the General Equipment: Hose Clamp Remover/Installer
5. NOTE: Note the different lengths of the bolts for installation.

Timing Belt

SPECIAL TOOL DESCRIPTION 303-050 (T70P-6000) Lifting Bracket, Engine 303-1097 Locking Tool, Variable Camshaft Timing Oil Control Unit TKIT-2010B-FLM TKIT-2010B-ROW 303-1502 Lifting Device Engine TKIT-2012A-FL TKIT-2012A-ROW 303-1550 Alignment Tool, Crankshaft Vibration Damper TKIT-2012A-FL TKIT-2012A-ROW 303-290B-18 Adapter for 303-290B TKIT-2012A-FL TKIT-2012A-ROW 303-393-02 Adapter for 303-393 TKIT-2012A-FL TKIT-2012A-ROW 303-393A Locking Tool, Flywheel TKIT-2012A-FL TKIT-2012A-ROW 303-748 Locking Tool, Crankshaft TKIT-2010B-FLM TKIT-2010B-ROW 303-F072 Support Bar, Engine Trolley Jack Wooden Block

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Camshaft Seal

SPECIAL TOOL DESCRIPTION 303-1532 Installer, Camshaft Seal TKIT-2010B-FLM TKIT-2010B-ROW 303-409 (T92C-6700-CH) Remover, Crankshaft Seal TKIT-1992-FH/FMH/FLMH TKIT-1993-LMH/MH

Scheme 310

MATERIALS SPECIFICATION

Variable Camshaft Timing (VCT) Unit

SPECIAL TOOL DESCRIPTION 303-1097 Locking Tool, Variable Camshaft Timing Oil Control Unit TKIT-2010B-FLM TKIT-2010B-ROW 303-1552 Alignment Tool, Camshaft TKIT-2012A-FL TKIT-2012A-ROW Trolley Jack Wooden Block

SPECIAL TOOL DESCRIPTION

MATERIALS SPECIFICATION

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1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-658843-S31152527922014092900000) .
2. Refer to: «FUEL SYSTEM PRESSURE RELEASE»(ref-658885-S01347622612014092900000) .
3. Refer to: «COOLING SYSTEM DRAINING AND VACUUM FILLING»(ref-658853-S08190757262014092900000) .
4. Remove the following items: Refer to: «TURBOCHARGER»(ref-658899-S05677888122014092900000) . Refer to: «CAMSHAFTS»(ref-658856-S33047028942014092900000) . Refer to: «INTAKE MANIFOLD»(ref-658856-S23744743342014092900000) .
5. Use the General Equipment: Hose Clamp Remover/Installer
6. Use the General Equipment: Hose Clamp Remover/Installer
7. Use the General Equipment: Oil Drain Equipment Use the General Equipment: Strap Wrench
8. NOTE: If the camshafts and valve tappets are to be reused, mark the location of the valve tappets to make sure they are assembled in their original positions. NOTE: The number on the valve tappets only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 0.1437 in (3.65 mm).
9. NOTE: Install new components as necessary.
10. NOTE: Make sure that the cylinder head is at ambient air temperature before removing the cylinder head bolts.
11. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion. Refer to: «CYLINDER HEAD DISTORTION»(ref-658863-S16405846182014092900000) . Refer to: «CYLINDER BLOCK DISTORTION»(ref-658863-S42792501642014092900000) .

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Scheme 321

1. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket. NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces. NOTE: Material : Motorcraft® Metal Surface Prep/ZC-31-B
2. NOTE: Make sure that the cylinder head is at ambient air temperature before removing the cylinder head bolts. NOTE: Make sure that new bolts are installed. Torque : Stage 1: 44 lb.in (5 Nm) Stage 2: 133 lb.in (15 Nm) Stage 3: 26 lb.ft (35 Nm) Stage 4: 90° Stage 5: 90°
3. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
4. Use the General Equipment: Hose Clamp Remover/Installer
5. Use the General Equipment: Hose Clamp Remover/Installer
6. Install the following items: Refer to: «INTAKE MANIFOLD»(ref-658856-S23744743342014092900000) . Refer to: «CAMSHAFTS»(ref-658856-S33047028942014092900000) .
7. Use the General Equipment: Oil Drain Equipment Torque : 21 lb.ft (28 Nm)
8. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A) Torque : 128 lb.in (14.5 Nm)
9. Refer to: «TURBOCHARGER»(ref-658899-S05677888122014092900000) .
10. Fill the engine with clean engine oil. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
11. Refer to: «COOLING SYSTEM DRAINING AND VACUUM FILLING»(ref-658853-S08190757262014092900000) .

Engine Mount

SPECIAL TOOL DESCRIPTION

Scheme 322

1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-658843-S31152527922014092900000) .
2. Install the following items: Use the General Equipment: Trolley Jack Use the General Equipment: Wooden Block

Scheme 323

1. Torque : 89 lb.in (10 Nm)
2. Torque : 66 lb.ft (90 Nm) Finger tight.
3. Remove the following items: Use the General Equipment: Trolley Jack Use the General Equipment: Wooden Block
4. Torque : 66 lb.ft (90 Nm)

Scheme 324

1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-658843-S31152527922014092900000) .
2. Refer to: «TURBOCHARGER»(ref-658899-S05677888122014092900000) .
3. Refer to: «EXHAUST MANIFOLD CLEANING AND INSPECTION»(ref-658863-S21216123242014092900000) .

Scheme 325

Scheme 326

1. Torque : 89 lb.in (10 Nm)
2. Torque : Tighten:: 15 lb.ft (21 Nm) Retighten:: 15 lb.ft (21 Nm)
3. Refer to: «TURBOCHARGER»(ref-658899-S05677888122014092900000) .

Flexplate

SPECIAL TOOL DESCRIPTION 303-103 (T74P-6375-A) Holding Tool, Flywheel TKIT-2009TC-F T74P-77000-A

Scheme 327

1. Refer to: «TRANSMISSION»(ref-658852-S29891352772014092900000) .

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1. Finger tight.
2. Install Special Service Tool: 303-103 (T74P-6375-A) Holding Tool, Flywheel .
3. Torque : Stage 1: 133 lb.in (15 Nm) Stage 2: 18 lb.ft (25 Nm) Stage 3: 22 lb.ft (30 Nm) Stage 4: 90°
4. Remove Special Service Tool: 303-103 (T74P-6375-A) Holding Tool, Flywheel .
5. Refer to: «TRANSMISSION»(ref-658852-S29891352772014092900000) .
6. After completing the repairs, perform the Misfire Monitor Neutral Profile Correction procedure.

Oil Cooler

SPECIAL TOOL DESCRIPTION

MATERIALS SPECIFICATION

Oil Pan

SPECIAL TOOL DESCRIPTION

MATERIALS SPECIFICATION

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1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-658843-S31152527922014092900000) .
2. Use the General Equipment: Oil Drain Equipment Torque : 21 lb.ft (28 Nm)
3. Use the General Equipment: Strap Wrench
4. Pry pads.

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1. NOTE: Do not use metal scrapers, plastic scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. NOTE: Make sure that the mating faces are clean and free of foreign material. Do not use any type of scrapers . There is a rubber sealing surface on the bottom of the crankshaft rear seal, take extra care when cleaning the specified area by peeling off the old sealant by hand.
2. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove traces of sealant. NOTE: Make sure that the mating faces are clean and free of foreign material. Clean only the specified area with the specified material and a plastic scraping tool to remove traces of sealant. Material : Motorcraft® Metal Surface Prep/ZC-31-A Material : Motorcraft® Silicone Gasket Remover/ZC-30-A
3. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove traces of sealant. Make sure that the mating faces are clean and free of foreign material. Material : Motorcraft® Metal Surface Prep/ZC-31-A Material : Motorcraft® Silicone Gasket Remover/ZC-30-A
4. Install the following items: NOTE: The use of the two studs will aid in the alignment of the oil pan. Two M8x20 studs.
5. NOTE: The component must be installed within 5 minutes of applying the sealant. Material : Silicone Gasket and Sealant/TA-30 (WSE-M4G323-A4)
6. Remove the following items: Two M8x20 studs.
7. NOTE: Only tighten the bolts finger tight at this stage.
8. Torque : 1 - 4: 35 lb.ft (47 Nm) 5 - 17: 89 lb.in (10 Nm) 5 - 17: 168 lb.in (19 Nm)
9. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A) Torque : 128 lb.in (14.5 Nm)
10. Torque : 159 lb.in (18 Nm) Torque : 44 lb.in (5 Nm)
11. Torque : 44 lb.in (5 Nm)
12. Fill the engine with engine oil. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)

Oil Pressure Switch

SPECIAL TOOL DESCRIPTION

MATERIALS SPECIFICATION

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1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-658843-S31152527922014092900000) .
2. Use the General Equipment: Oil Drain Equipment Use the General Equipment: Strap Wrench

Scheme 345

1. Material : Thread Sealant with PTFE/TA-24-B (WSK-M2G350-A2) Torque : 159 lb.in (18 Nm)
2. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A) Torque : 128 lb.in (14.5 Nm)
3. Torque : 89 lb.in (10 Nm) Torque : 44 lb.in (5 Nm)

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1. Remove the following items: Refer to: «CRANKSHAFT FRONT SEAL»(ref-658856-S13854009022014092900000) . Refer to: «OIL PAN»(ref-658856-S04442427762014092900000) .
2. NOTE: Note the different lengths of the bolts.

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1. NOTE: Only tighten the bolts finger tight at this stage.
2. Torque : Stage 1: 49 lb.in (5.5 Nm) Stage 2: 84 lb.in (9.5 Nm)
3. NOTE: The O-ring seal is to be reused unless damaged.
4. Torque : 84 lb.in (9.5 Nm)
5. Install the following items: Refer to: «OIL PAN»(ref-658856-S04442427762014092900000) . Refer to: «CRANKSHAFT FRONT SEAL»(ref-658856-S13854009022014092900000) .

Valve Cover

SPECIAL TOOL DESCRIPTION

MATERIALS SPECIFICATION

SPECIAL TOOL DESCRIPTION 303-1249 Valve Spring Compressor TKIT-2006UF-FLM TKIT-2006UF-ROW 303-300 (T87C-6565-A) Set, Valve Spring Compressor TKIT-2009TC-F T88C-1000-ST TKIT-1988-FESTIVA TKIT-1988-TRACER 303-350 (T89P-6565-A) Compressor, Valve Spring TKIT-1989-F TKIT-1989-FM TKIT-1989-FLM TKIT-1990-LMH 303-468 (T94P-6510-AH) Remover, Valve Stem Oil Seal TKIT-1994-FH/FMH/FLMH TKIT-1994-LMH/MH2 303-470 (T94P-6510-CH) Installer, Valve Stem Oil Seal TKIT-2009TC-F TKIT-1994-FH/FMH/FLMH TKIT-1994-LMH/MH2 303-472 (T94P-6565-AH) Adapter, Valve Spring Compressor TKIT-1994-FH/FMH/FLMH TKIT-1994-LMH/MH2 307-005 (T59L-100-B) Slide Hammer

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MATERIALS SPECIFICATION

MATERIALS SPECIFICATION