Engine Mechanical - 2.5L: Other Ford Kuga II

Lubricants

Oil Pressure

Cylinder Block

Piston

Piston Pin

Cylinder Head

Valve

Valve Spring - Compression Pressure

Crankshaft

Rings

Valve Tappet

Camshaft

Connecting Rod

Engine Code Information Label

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

Scheme 481

Scheme 482

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.

Induction System

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

Lower Engine Block (View 1)

Lower Engine Block (View 2)

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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

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Scheme 488

1. Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC . Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg. The engine is now at 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: 38 lb.ft (52 Nm)
8. Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC . Rotate the crankshaft to confirm that there are no meshing problems between the balancer unit gear and the crankshaft gear.
9. Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC . Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg. The engine is now at TDC . Remove 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 0.101 mm (0.0039 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. Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC . Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg. The engine is now at 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: 38 lb.ft (52 Nm)
15. Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC .
16. 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 0.005 to 0.101 mm (0.00019 to 0.0039 in), install a new balancer unit and repeat the procedure.

Check

1. Refer to: «VALVE COVER»(ref-658857-S20944727802014092900000) .
2. NOTE: Turn the engine clockwise only, and only use the crankshaft bolt. NOTE: Before removing the camshafts, measure the clearance of each valve at base circle, with the lobe pointed away from the tappet. Failure to measure all clearances prior to removing the camshafts will necessitate repeated removal and installation and wasted labor time. 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: The nominal clearance is: intake: 0.25 mm (0.0098 in) exhaust: 0.30 mm (0.0118 in) NOTE: The acceptable clearances after being fully installed are: intake: 0.23-0.28 mm (0.009-0.011 in) exhaust: 0.27-0.33 mm (0.010-0.013 in) Select the closest tappet size to the ideal tappet thickness available and mark the installation location.
4. NOTE: Select tappets using this formula: tappet thickness = measured clearance + the existing tappet thickness - nominal clearance. If any tappets do not measure within specifications, install new tappets in these locations.

Camshafts

CAMSHAFTS SPECIAL TOOLS DESCRIPTION 303-465 Tool, Camshaft Align Timing TKIT-1994-FH/FMH/FLMH TKIT-1994-LMH/MH2 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 303-1416 Tool, Crank Damper Holding TKIT-2008ET-FLM 303-465 Tool, Camshaft Align Timing TKIT-1994-FH/FMH/FLMH TKIT-1994-LMH/MH2 303-507 Timing Peg, Crankshaft TDC TKIT-2001N-FLM TKIT-2001N-ROW

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 489

MATERIAL SPECIFICATIONS

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Scheme 494

1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-658843-S31152527922014092900000) .
2. Refer to: «FLEXPLATE»(ref-658857-S31613231262014092900000) .
3. Refer to: «AIR CONDITIONING (A/C) COMPRESSOR BELT»(ref-658866-S22879634802014092900000) .
4. Torque : 21 lb.ft (28 Nm)
5. NOTE: If the oil pan is not removed, damage to the rear oil seal retainer joint may occur.

Scheme 495

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, which make leak paths. Use a plastic scraping tool to remove traces of sealant. Clean all mating surfaces. Material : Motorcraft® Metal Surface Prep/ZC-31-A Material : Motorcraft® Silicone Gasket Remover/ZC-30-A
2. Use Special Service Tool: 303-328 (T88P-6701-B1) Replacer, Rear Seal . Torque : 89 lb.in (10 Nm)
3. 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)
4. Tighten finger tight.
5. NOTE: The engine front cover-to-oil pan bolts must be tightened first to align the front surface of the oil pan flush with the front surface of the engine block. Torque : 89 lb.in (10 Nm)
6. Torque : 177 lb.in (20 Nm)
7. Torque : 80 lb.in (9 Nm)
8. Torque : 18 lb.ft (25 Nm)
9. Refer to: «AIR CONDITIONING (A/C) COMPRESSOR BELT»(ref-658866-S22879634802014092900000) .
10. Refer to: «FLEXPLATE»(ref-658857-S31613231262014092900000) .
11. 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)

Special Tool(s)/General Equipment

Hose Clamp Remover/Installer

MATERIAL SPECIFICATIONS

Engine Mount

ENGINE MOUNT SPECIAL TOOLS DESCRIPTION

Flexplate

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

Scheme 496

Scheme 497

1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-658843-S31152527922014092900000) .
2. Refer to: «TRANSMISSION - 2.5L DURATEC (125KW/170PS)»(ref-658852-S07330495022014092900000) .
3. Use Special Service Tool: 303-103 (T74P-6375-A) Holding Tool, Flywheel .

Scheme 498

1. 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: «AUTOMATIC TRANSMISSION - 2.5L DURATEC (125KW/170PS)»(ref-658852-S24593398542014092900000) .
3. After completing the repairs, preform the Misfire Monitor Neutral Profile Correction procedure.

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Scheme 505

1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-658843-S31152527922014092900000) .
2. Refer to: «AIR CLEANER OUTLET PIPE»(ref-658908-S39359363192014092900000) .
3. Refer to: «QUICK RELEASE COUPLING»(ref-658910-S40667565442014092900000) .
4. If equipped.
5. Squeeze the 2 crankcase vent oil separator tube tabs and disconnect the tube from the intake manifold.

Scheme 506

1. NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage. NOTE: Visually inspect the intake manifold gaskets for nicks, cuts and abrasions. If these conditions are not present, the gaskets may be re-used.
2. Torque : 159 lb.in (18 Nm)
3. If equipped.
4. Refer to: «QUICK RELEASE COUPLING»(ref-658910-S40667565442014092900000) .
5. Refer to: «AIR CLEANER OUTLET PIPE»(ref-658908-S39359363192014092900000) .

Oil Pan

MATERIAL SPECIFICATIONS

Scheme 507

Scheme 508

Scheme 509

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Scheme 511

1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-658843-S31152527922014092900000) .
2. Remove the following items: Refer to: «AIR CLEANER»(ref-658908-S40071574252014092900000) . Refer to: «AIR CLEANER OUTLET PIPE»(ref-658908-S39359363192014092900000) . Refer to: «COWL PANEL»(ref-658872-S27388717752014092900000) . Refer to: «HEATED OXYGEN SENSOR (HO2S)»(ref-658892-S19334192602014092900000) . Refer to: «CATALYST MONITOR SENSOR»(ref-658892-S30318854792014092900000) .
3. NOTE: To prevent damage to the transmission, do not loosen the transmission-to-engine bolts more than 5 mm (0.19 in). Loosen 5 mm (0.19 in).
4. NOTE: To prevent damage to the transmission, do not loosen the transmission-to-engine bolts more than 5 mm (0.19 in). Loosen 5 mm (0.19 in).
5. Refer to: «AIR CONDITIONING (A/C) COMPRESSOR BELT»(ref-658866-S22879634802014092900000) .
6. Loosen 5 mm (0.19 in).
7. Slide the transaxle rearward 5 mm (0.19 in).
8. Torque : 21 lb.ft (28 Nm)
9. 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. Clean all mating surfaces. Material : Motorcraft® Silicone Gasket Remover/ZC-30-A Material : Motorcraft® Metal Surface Prep/ZC-31-A

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Scheme 513

1. 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)
2. Finger tight.
3. NOTE: The engine front cover-to-oil pan bolts must be tightened first to align the front surface of the oil pan flush with the front surface of the engine block. Torque : 89 lb.in (10 Nm)
4. Torque : 177 lb.in (20 Nm)
5. Alternate tightening the 1 LH bellhousing-to-engine and 1 RH engine-to-bellhousing bolts to slide the transaxle and engine together.
6. Torque : 35 lb.ft (48 Nm)
7. Torque : 35 lb.ft (48 Nm)
8. Torque : 35 lb.ft (48 Nm)
9. Torque : 92 lb.ft (125 Nm)
10. Torque : 80 lb.in (9 Nm)
11. Torque : 18 lb.ft (25 Nm)
12. Refer to: «AIR CONDITIONING (A/C) COMPRESSOR BELT»(ref-658866-S22879634802014092900000) .
13. Torque : 35 lb.ft (48 Nm)
14. Torque : 35 lb.ft (48 Nm)
15. Torque : 97 lb.in (11 Nm)
16. Install the following items: Refer to: «CATALYST MONITOR SENSOR»(ref-658892-S30318854792014092900000) . Refer to: «HEATED OXYGEN SENSOR (HO2S)»(ref-658892-S19334192602014092900000) . Refer to: «COWL PANEL»(ref-658872-S27388717752014092900000) . Refer to: «AIR CLEANER OUTLET PIPE»(ref-658908-S39359363192014092900000) . Refer to: «AIR CLEANER»(ref-658908-S40071574252014092900000) .
17. 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)

Oil Pressure Switch

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

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Scheme 515

MATERIAL SPECIFICATIONS

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Scheme 518

1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-658843-S31152527922014092900000) .
2. Refer to: «ENGINE FRONT COVER»(ref-658857-S42707169382014092900000) .
3. Install Special Service Tool: 303-290-05A Adapter for 303-290A , 303-290B-19 Adapter for 303-290B , 303-F072 Support Bar, Engine .
4. Remove the General Equipment: Floor Jack and Wood Block.
5. Torque : 21 lb.ft (28 Nm)

Scheme 519

Scheme 520

1. NOTE: Clean the oil pump and cylinder block mating surfaces with Motorcraft® Metal Surface Prep. Material : Motorcraft® Metal Surface Prep/ZC-31-A Torque : Stage 1: 89 lb.in (10 Nm) Stage 2: 177 lb.in (20 Nm)
2. Torque : 18 lb.ft (25 Nm)
3. Torque : 89 lb.in (10 Nm) Hook the tensioner spring around the shoulder bolt.
4. NOTE: A new gasket must be installed. Torque : 89 lb.in (10 Nm)
5. 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. Clean all mating surfaces. Material : Motorcraft® Silicone Gasket Remover/ZC-30-A Material : Motorcraft® Metal Surface Prep/ZC-31-A
6. 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)
7. Finger tight.
8. General Equipment: Straight Edge.
9. Torque : 177 lb.in (20 Nm)
10. Torque : 35 lb.ft (48 Nm)
11. Torque : 35 lb.ft (48 Nm)
12. Torque : 80 lb.in (9 Nm)
13. Torque : 18 lb.ft (25 Nm)
14. NOTE: Failure to position the wood block and floor jack as illustrated can result in damage to the oil pan. Install the General Equipment: Floor Jack and Wood Block.
15. Remove Special Service Tool: 303-290-05A Adapter for 303-290A , 303-290B-19 Adapter for 303-290B , 303-F072 Support Bar, Engine .
16. Refer to: «ENGINE FRONT COVER»(ref-658857-S42707169382014092900000) .
17. 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)

Timing Chain

TIMING CHAIN SPECIAL TOOLS DESCRIPTION 100-010 Remover, O-Ring Seal

Scheme 521

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 522

MATERIAL SPECIFICATIONS

Engine Front Cover

MATERIAL SPECIFICATIONS

CYLINDER HEAD SPECIAL TOOLS DESCRIPTION 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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MATERIAL SPECIFICATIONS

MATERIAL SPECIFICATIONS

Scheme 527

1. NOTE: If the piston and connecting rod are to be reinstalled, they must be assembled in the same orientation. Mark the piston orientation to the connecting rod for reassembly. Clean and inspect the piston. Refer to: «PISTON INSPECTION»(ref-658863-S05050837942014092900000) .