Engine Mechanical - 2.0L: Other Ford Kuga II

Lubricants

Oil Pressure

Cylinder Block

Piston

Piston Pin

Crankshaft

Cylinder Head

Valve

Valve Spring [] Compression Pressure

Valve Tappet

Camshaft

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.

Ti-VCT

The Ti-VCT system allows variable control of intake valve closing 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.

Scheme 618

Scheme 619

Engine - Lower Block Components

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

Balance Shaft Backlash

BALANCE SHAFT BACKLASH SPECIAL TOOLS DESCRIPTION 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge 303-507 Timing Peg, Crankshaft TDC TKIT-2001N-FLM TKIT-2001N-ROW

Scheme 620

Scheme 621

1. Rotate the crankshaft slowly clockwise until the crankshaft balance weight is against the Crankshaft TDC Timing Peg. The engine is now at TDC . Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC .
2. Mark the balancer unit and shafts on the top for reference that the balancer unit is at TDC .
3. NOTE: Due to the precision interior construction of the balancer unit, it should not be disassembled.
4. Remove the adjustment shims from the seat faces of the balancer unit.
5. NOTE: Visually inspect the balancer unit gear for damage and verify that the shaft turns smoothly. If there is any damage or malfunction, replace the balancer unit. Install the master adjustment shims (No. 50) on the seat faces of the balancer unit.
6. With the balancer unit shaft marks at the TDC position, slowly install the balancer unit to the cylinder block to avoid interference between the crankshaft drive gear and the balancer unit driven gear.
7. Torque : Stage 1: 18 lb.ft (25 Nm) Stage 2: 31 lb.ft (42 Nm)
8. Rotate the crankshaft to confirm that there are no meshing problems between the balancer unit gear and the crankshaft gear. Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC .
9. Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg. The engine is now at TDC . Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC .
10. NOTE: Measure the backlash and verify that it is within specified range at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees. It will be necessary to reset the measuring equipment between measurements. NOTE: The measurement must be taken with the Dial Indicator Gauge with Holding Fixture, a 5-mm Allen wrench and worm clamp set up as shown below. Mark the Allen wrench with a file 80 mm (3.149 in) above the driven gear shaft center. Make sure the worm clamp and Allen wrench are not touching the balance shaft housing. NOTE: For an accurate measurement while measuring the gear backlash, insert a screwdriver as shown below into the crankshaft No. 1 crankweight area and set both the rotation and the thrust direction with the screwdriver, using a prying action as shown below. Position as shown below. Measure the gear backlash. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge . Position the Dial Indicator Gauge with Holding Fixture (1) on the Allen wrench 80 mm (3.149 in) above the driven gear shaft center (2) on the balancer unit. Rotate the crankshaft clockwise and measure the backlash at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees.
11. NOTE: If maximum backlash exceeds 0.120 mm (0.0047 in), install a new balancer unit. Using the backlash measurement, select the proper shims from the Adjustment Shim Selection Table. Remove the balancer unit from the cylinder block. Install the selected adjustment shims on the seat faces of the balancer unit.
12. Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg. The engine is now at TDC . Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC .
13. With the balancer unit shaft marks at the TDC position, slowly install the balancer unit to the cylinder block to avoid interference between the crankshaft drive gear and the balancer unit driven gear.
14. Torque : Stage 1: 18 lb.ft (25 Nm) Stage 2: 31 lb.ft (42 Nm)
15. NOTE: Measure the backlash and verify that it is within specified range at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees. It will be necessary to reset the measuring equipment between measurements. NOTE: The measurement must be taken with the Dial Indicator Gauge with Holding Fixture, a 5-mm Allen wrench and worm clamp set up as shown below. Mark the Allen wrench with a file 80 mm (3.149 in) above the driven gear shaft center. Make sure the worm clamp and Allen wrench are not touching the balance shaft housing. NOTE: For an accurate measurement while measuring the gear backlash, insert a screwdriver as shown below into the crankshaft No. 1 crankweight area and set both the rotation and the thrust direction with the screwdriver, using a prying action as shown below. Position as shown below. Measure the gear backlash. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge . Position the Dial Indicator Gauge with Holding Fixture (1) on the Allen wrench 80 mm (3.149 in) above the driven gear shaft center (2) on the balancer unit. Rotate the crankshaft clockwise and measure the backlash at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees. If the backlash exceeds the specified range of 0.020 to 0.120 mm (0.00078 to 0.0047 in), install a new balancer unit and repeat the procedure.

Check

1. Remove the following items: Valve cover. Refer to: «VALVE COVER»(ref-658858-S15803108392014092900000) . RH fender splash shield. Refer to: «FENDER SPLASH SHIELD»(ref-658872-S14314641892014092900000) .
2. NOTE: Turn the engine clockwise only, and only use the crankshaft bolt. NOTE: Measure the clearance of each valve at base circle, with the lobe pointed away from the tappet. Use a feeler gauge to measure the clearance of each valve and record its location. Use the General Equipment: Feeler Gauge
3. NOTE: The number on the valve tappet only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm. NOTE: Select tappets using this formula: tappet thickness = measured clearance + the existing tappet thickness - nominal clearance. NOTE: The nominal clearance is: intake: 0.25 mm (0.0095 in). exhaust: 0.36 mm (0.0142 in). NOTE: The acceptable clearances after being fully installed are: intake: 0.19-0.31 mm (0.007-0.012 in). exhaust: 0.30-0.42 mm (0.012-0.017 in). Select the closest tappet size to the ideal tappet thickness available and mark the installation location.
4. If any tappets do not measure within specifications, install new tappets in these locations.

Camshafts

CAMSHAFTS SPECIAL TOOLS DESCRIPTION 303-1565 Alignment Tool, Camshaft TKIT-2010C-FLM TKIT-2010C-FLM 303-507 Timing Peg, Crankshaft TDC TKIT-2001N-FLM TKIT-2001N-ROW Feeler Gauge

MATERIAL SPECIFICATIONS

Crankshaft Front Seal

CRANKSHAFT FRONT SEAL SPECIAL TOOLS DESCRIPTION 303-096 (T74P-6150-A) Installer, Camshaft Front Oil Seal TKIT-2009TC-F 303-1521 Alignment Tool, Crankshaft Position Sensor TKIT-2010C-FLM TKIT-2010C-FLM 303-1565 Alignment Tool, Camshaft TKIT-2010C-FLM TKIT-2010C-FLM 303-409 (T92C-6700-CH) Remover, Crankshaft Seal TKIT-1992-FH/FMH/FLMH TKIT-1993-LMH/MH 303-507 Timing Peg, Crankshaft TDC TKIT-2001N-FLM TKIT-2001N-ROW Strap Wrench

Scheme 622

Scheme 623

Scheme 624

MATERIAL SPECIFICATIONS

MATERIAL SPECIFICATIONS

Flexplate

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

Scheme 625

Scheme 626

1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-658843-S31152527922014092900000) .
2. Refer to: «TRANSMISSION»(ref-658852-S29891352772014092900000) .
3. NOTE: Do not reuse the flexplate bolts. Use Special Service Tool: 303-103 (T74P-6375-A) Holding Tool, Flywheel .

Scheme 627

1. NOTE: Special bolts are used for installation. Do not use standard bolts. Use Special Service Tool: 303-103 (T74P-6375-A) Holding Tool, Flywheel . Torque : Stage 1: 37 lb.ft (50 Nm) Stage 2: 59 lb.ft (80 Nm) Stage 3: 83 lb.ft (112 Nm)
2. Refer to: «TRANSMISSION»(ref-658852-S29891352772014092900000) .
3. After completing the repairs, perform the Misfire Monitor Neutral Profile Correction procedure.

Oil Pan

MATERIAL SPECIFICATIONS

Oil Pump

OIL PUMP SPECIAL TOOLS DESCRIPTION 303-290-05A Adapter for 303-290A TKIT-2012A-FL TKIT-2012A-ROW 303-290B-19 Adapter for 303-290B TKIT-2012A-FL TKIT-2012A-ROW 303-F072 Support Bar, Engine Trolley Jack Round-Ended Steel Rule Wooden Block

Scheme 628

Scheme 629

MATERIAL SPECIFICATIONS

Scheme 630

Scheme 631

1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-658843-S31152527922014092900000) .
2. Refer to: «BATTERY DISCONNECT AND CONNECT»(ref-658873-S03187421432014092900000) .
3. Refer to: «ENGINE FRONT COVER»(ref-658858-S33310742882014092900000) .
4. Install Special Service Tool: 303-290-05A Adapter for 303-290A , 303-F072 Support Bar, Engine , 303-290B-19 Adapter for 303-290B .
5. Refer to: «AIR CONDITIONING (A/C) COMPRESSOR BELT»(ref-658865-S23768654432014092900000) .
6. Torque: 20 lb.ft (27 Nm)
7. WARNING: Take extra care when handling the compressed spring.

Scheme 632

Scheme 633

Scheme 634

Scheme 635

1. Material: Motorcraft® Metal Surface Prep/ZC-31-B
2. Torque : Stage 1: 89 lb.in (10 Nm) Stage 2: 177 lb.in (20 Nm)
3. Torque: 18 lb.ft (25 Nm)
4. WARNING: Take extra care when handling the compressed spring. Torque: 89 lb.in (10 Nm)
5. Torque: 89 lb.in (10 Nm)
6. 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. Plastic scraper.
7. NOTE: If the oil pan is not secured within 10 minutes of sealant application, the sealant must be removed and the sealing area cleaned with metal surface prep. Allow to dry until there is no sign of wetness, or 10 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Material: Silicone Gasket and Sealant/TA-30 (WSE-M4G323-A4)
8. Finger tight.
9. Align the front surface of the oil pan flush with the front surface of the engine block. Use the General Equipment: Round-Ended Steel Rule
10. Torque: 177 lb.in (20 Nm)
11. Torque: 35 lb.ft (48 Nm)
12. Torque: 35 lb.ft (48 Nm)
13. Torque: 18 lb.ft (25 Nm) Torque: 80 lb.in (9 Nm) Torque: 18 lb.ft (25 Nm)
14. Torque: 44 lb.in (5 Nm) Torque: 97 lb.in (11 Nm)
15. Refer to: «AIR CONDITIONING (A/C) COMPRESSOR BELT»(ref-658865-S23768654432014092900000) .
16. Use the General Equipment: Trolley Jack Use the General Equipment: Wooden Block
17. Remove Special Service Tool: 303-F072 Support Bar, Engine , 303-290-05A Adapter for 303-290A , 303-290B-19 Adapter for 303-290B .
18. Refer to: «ENGINE FRONT COVER»(ref-658858-S33310742882014092900000) .
19. Refer to: «BATTERY DISCONNECT AND CONNECT»(ref-658873-S03187421432014092900000) .
20. Fill the engine with clean engine oil. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W30-QSP (U.S.) (WSS-M2C946-A)

Valve Cover

VALVE COVER SPECIAL TOOLS DESCRIPTION 205-153 (T80T-4000-W) Handle 303-1247 VCT Spark Plug Tube Seal Remover and Installer TKIT-2006UF-FLM TKIT-2006UF-ROW

Scheme 636

MATERIAL SPECIFICATIONS

Crankshaft Rear Seal

CRANKSHAFT REAR SEAL SPECIAL TOOLS DESCRIPTION 303-328 (T88P-6701-B1) Replacer, Rear Seal TKIT-1988-F TKIT-1988-FLM TKIT-1988-LM

Scheme 637

MATERIAL SPECIFICATIONS

Engine Mount

ENGINE MOUNT SPECIAL TOOLS DESCRIPTION

Oil Pressure Switch

MATERIAL SPECIFICATIONS

Timing Chain

TIMING CHAIN SPECIAL TOOLS DESCRIPTION 303-1565 Alignment Tool, Camshaft TKIT-2010C-FLM TKIT-2010C-FLM

MATERIAL SPECIFICATIONS

Engine Front Cover

MATERIAL SPECIFICATIONS

CYLINDER HEAD SPECIAL TOOLS 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

Scheme 638

Scheme 639

Scheme 640

Scheme 641

MATERIAL SPECIFICATIONS

MATERIAL SPECIFICATIONS