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Condition Value
expand_moreAir intake system
expand_moreIntake manifold
2.5 4x4 with gasoline straight-5 2.5 L 197 HP engine (2009.3–) 14.01 lbf⋅ft
2.5 with gasoline straight-5 2.5 L 197 HP engine (2009.3–2012.11) 14.01 lbf⋅ft
2.5 with gasoline straight-5 2.5 L 197 HP engine (2009.3–2012.11) 14.01 lbf⋅ft
expand_moreAll other modifications
Figure 1. Air intake system, Intake manifold, All other modifications.
Figure 1. Air intake system, Intake manifold, All other modifications.
With exhaust gas norm EURO 4 6.64 lbf⋅ft
Tighten in several steps. See figure 1.
Figure 2. Air intake system, Intake manifold, All other modifications.
Figure 2. Air intake system, Intake manifold, All other modifications.
With exhaust gas norm EURO 5 7.38 lbf⋅ft
Tighten in several steps. See figure 2.
expand_moreAuxiliary assemblies
expand_moreAuxiliary drive belt tensioner
2.5 4x4 with gasoline straight-5 2.5 L 197 HP engine (2009.3–) 33.19 lbf⋅ft
Air-conditioning compressor 18.44 lbf⋅ft
expand_moreAir-conditioning compressor bracket
2.5 4x4 with gasoline straight-5 2.5 L 197 HP engine (2009.3–) 17.7 lbf⋅ft
Air-conditioning compressor pressure line 14.75 lbf⋅ft
expand_moreAlternator
2.5 4x4 with gasoline straight-5 2.5 L 197 HP engine (2009.3–) 17.7 lbf⋅ft
2.5 with gasoline straight-5 2.5 L 197 HP engine (2009.3–2012.11) 17.7 lbf⋅ft
2.5 with gasoline straight-5 2.5 L 197 HP engine (2009.3–2012.11) 17.7 lbf⋅ft
All other modifications 35.4 lbf⋅ft
expand_moreGenerator bracket
2.5 4x4 with gasoline straight-5 2.5 L 197 HP engine (2009.3–) 17.7 lbf⋅ft
Hydraulic lines at the servo-steering pump 17.7 lbf⋅ft
expand_moreTensioning device for air-conditioning compressor auxiliary drive belt
2.5 4x4 with gasoline straight-5 2.5 L 197 HP engine (2009.3–) 18.44 lbf⋅ft
Vacuum pump 6.64 lbf⋅ft
expand_moreCarburetion
Fuel-distributing pipe 16.23 lbf⋅ft
High-pressure pump 14.75 lbf⋅ft
expand_moreInjection hoses
First stage 13.28 lbf⋅ft
Replace injection line.
expand_moreWith exhaust gas norm EURO 4
Second stage 22.13 lbf⋅ft
expand_moreWith exhaust gas norm EURO 5
Second stage 19.91 lbf⋅ft
expand_moreInjection nozzle (injector)
expand_moreWith exhaust gas norm EURO 4
Stud screws 7.38 lbf⋅ft
expand_moreWith exhaust gas norm EURO 4, nuts
First stage 2.95 lbf⋅ft
Second stage 45°
expand_moreWith exhaust gas norm EURO 5
First stage 5.16 lbf⋅ft
Second stage 55°
expand_moreCharging
expand_moreTurbo charger
2.0 TDCi 4x4 with diesel straight-4 2.0 L 134 HP at 4000 RPM, 320 N⋅m at 2000 RPM engine (2008.3–2012.11) 18.44 lbf⋅ft
2.0 TDCi 4x4 with diesel straight-4 2.0 L 134 HP at 4000 RPM, 320 N⋅m at 2000 RPM engine (2008.3–2012.11) 18.44 lbf⋅ft
expand_more2.0 TDCi with diesel straight-4 2.0 L 134 HP at 4000 RPM, 320 N⋅m at 2000 RPM engine (2008.3–2012.11)
On exhaust manifold 18.44 lbf⋅ft
expand_moreTurbocharger bracket
At the turbocharger 22.13 lbf⋅ft
On the engine block 11.8 lbf⋅ft
expand_moreTurbocharger oil feed line
At the turbocharger 20.65 lbf⋅ft
Use new parts.
On the engine block 29.5 lbf⋅ft
Turbocharger oil return line 7.38 lbf⋅ft
expand_moreCooling system
expand_moreCoolant pump
2.5 4x4 with gasoline straight-5 2.5 L 197 HP engine (2009.3–) 12.54 lbf⋅ft
2.5 with gasoline straight-5 2.5 L 197 HP engine (2009.3–2012.11) 12.54 lbf⋅ft
2.5 with gasoline straight-5 2.5 L 197 HP engine (2009.3–2012.11) 12.54 lbf⋅ft
All other modifications 11.8 lbf⋅ft
expand_moreRadiator mounting
Bottom 3.69 lbf⋅ft
expand_moreCylinder head
expand_moreCamshaft bearing
2.5 4x4 with gasoline straight-5 2.5 L 197 HP engine (2009.3–) 12.54 lbf⋅ft
helically from the inside out
2.5 with gasoline straight-5 2.5 L 197 HP engine (2009.3–2012.11) 12.54 lbf⋅ft
2.5 with gasoline straight-5 2.5 L 197 HP engine (2009.3–2012.11) 12.54 lbf⋅ft
expand_moreAll other modifications
Figure 3. Cylinder head, Camshaft bearing, All other modifications.
Figure 3. Cylinder head, Camshaft bearing, All other modifications.
With exhaust gas norm EURO 4 7.38 lbf⋅ft
Tighten in several steps. See figure 3.
With exhaust gas norm EURO 5 8.11 lbf⋅ft
See figure 3.
expand_moreCylinder head screws
expand_more2.5 4x4 with gasoline straight-5 2.5 L 197 HP engine (2009.3–)
Figure 4. Cylinder head, Cylinder head screws, 2.5 4x4 with gasoline straight-5 2.5 L 197 HP engine (2009.3–).
Figure 4. Cylinder head, Cylinder head screws, 2.5 4x4 with gasoline straight-5 2.5 L 197 HP engine (2009.3–).
First stage 14.75 lbf⋅ft
Use new screws See figure 4.
Second stage 44.25 lbf⋅ft
Third stage 130°
expand_more2.5 with gasoline straight-5 2.5 L 197 HP engine (2009.3–2012.11)
First stage 14.75 lbf⋅ft
Use new screws See figure 4.
Second stage 44.25 lbf⋅ft
Third stage 130°
expand_moreAll other modifications
First stage 44.25 lbf⋅ft
Replace screws.
Second stage 220°
expand_moreValve cover
2.5 4x4 with gasoline straight-5 2.5 L 197 HP engine (2009.3–) 7.38 lbf⋅ft
2.5 with gasoline straight-5 2.5 L 197 HP engine (2009.3–2012.11) 7.38 lbf⋅ft
2.5 with gasoline straight-5 2.5 L 197 HP engine (2009.3–2012.11) 7.38 lbf⋅ft
expand_moreAll other modifications
Figure 5. Cylinder head, Valve cover, All other modifications.
Figure 5. Cylinder head, Valve cover, All other modifications.
With exhaust gas norm EURO 4 6.64 lbf⋅ft
See figure 5.
Figure 6. Cylinder head, Valve cover, All other modifications.
Figure 6. Cylinder head, Valve cover, All other modifications.
With exhaust gas norm EURO 5 7.38 lbf⋅ft
See figure 6.
expand_moreEngine block
expand_moreConnecting rod bearing
expand_more2.5 4x4 with gasoline straight-5 2.5 L 197 HP engine (2009.3–)
First stage 22.13 lbf⋅ft
Replace screws.
Second stage 90°
expand_more2.5 with gasoline straight-5 2.5 L 197 HP engine (2009.3–2012.11)
First stage 22.13 lbf⋅ft
Second stage 90°
expand_moreAll other modifications
First stage 14.75 lbf⋅ft
Second stage 70°
expand_moreCrankshaft central screws
2.5 4x4 with gasoline straight-5 2.5 L 197 HP engine (2009.3–) 132.76 lbf⋅ft
Use new screws.
2.5 with gasoline straight-5 2.5 L 197 HP engine (2009.3–2012.11) 132.76 lbf⋅ft
Use new screws.
2.5 with gasoline straight-5 2.5 L 197 HP engine (2009.3–2012.11) 132.76 lbf⋅ft
Use new screws.
expand_moreAll other modifications
First stage 51.63 lbf⋅ft
Use new screw.
Second stage 60°
expand_moreDrive plate
First stage 33.19 lbf⋅ft
Use new screws and tighten them crosswise.
Second stage 50°
expand_moreFlywheel
expand_more2.5 4x4 with gasoline straight-5 2.5 L 197 HP engine (2009.3–)
First stage 33.19 lbf⋅ft
Replace screws.
Second stage 65°
expand_more2.5 with gasoline straight-5 2.5 L 197 HP engine (2009.3–2012.11)
First stage 33.19 lbf⋅ft
Replace screws.
Second stage 65°
All other modifications 35.4 lbf⋅ft
Tighten the screws crosswise.
expand_moreMain bearing
expand_more2.5 4x4 with gasoline straight-5 2.5 L 197 HP engine (2009.3–)
expand_moreM10
First stage 14.75 lbf⋅ft
Replace screws.
Second stage 33.19 lbf⋅ft
cross-wise from inside to outside
Fifth stage 90°
expand_moreM8
Third stage 17.7 lbf⋅ft
Replace screws.
expand_moreM7
Fourth stage 12.54 lbf⋅ft
Replace screws.
expand_moreAll other modifications
First stage 22.13 lbf⋅ft
Second stage 63°
expand_moreVibration damper
First stage 18.44 lbf⋅ft
Second stage 60°
expand_moreEngine control
expand_moreCamshaft drive belt deflection pulley
2.5 4x4 with gasoline straight-5 2.5 L 197 HP engine (2009.3–) 18.44 lbf⋅ft
2.5 with gasoline straight-5 2.5 L 197 HP engine (2009.3–2012.11) 14.75 lbf⋅ft
2.5 with gasoline straight-5 2.5 L 197 HP engine (2009.3–2012.11) 14.75 lbf⋅ft
All other modifications 41.3 lbf⋅ft
Camshaft timing chain tensioner 4.43 lbf⋅ft
expand_moreCamshaft timing gear
2.5 with gasoline straight-5 2.5 L 197 HP engine (2009.3–2012.11) 88.51 lbf⋅ft
2.5 with gasoline straight-5 2.5 L 197 HP engine (2009.3–2012.11) 88.51 lbf⋅ft
expand_moreAll other modifications
First stage 14.75 lbf⋅ft
Second stage 60°
expand_moreInlet camshaft wheel
expand_more2.5 4x4 with gasoline straight-5 2.5 L 197 HP engine (2009.3–)
Central screws 88.51 lbf⋅ft
Locking screws 25.81 lbf⋅ft
expand_moreOutlet camshaft wheel
expand_more2.5 4x4 with gasoline straight-5 2.5 L 197 HP engine (2009.3–)
Central screws 88.51 lbf⋅ft
Locking screws 25.81 lbf⋅ft
Toothed belt guard 5.16 lbf⋅ft
expand_moreToothed belt guard at the bottom
2.5 4x4 with gasoline straight-5 2.5 L 197 HP engine (2009.3–) 7.38 lbf⋅ft
2.5 with gasoline straight-5 2.5 L 197 HP engine (2009.3–2012.11) 7.38 lbf⋅ft
2.5 with gasoline straight-5 2.5 L 197 HP engine (2009.3–2012.11) 7.38 lbf⋅ft
All other modifications 5.16 lbf⋅ft
expand_moreToothed belt guard at the top
2.5 4x4 with gasoline straight-5 2.5 L 197 HP engine (2009.3–) 7.38 lbf⋅ft
2.5 with gasoline straight-5 2.5 L 197 HP engine (2009.3–2012.11) 7.38 lbf⋅ft
2.5 with gasoline straight-5 2.5 L 197 HP engine (2009.3–2012.11) 7.38 lbf⋅ft
All other modifications 5.16 lbf⋅ft
expand_moreToothed belt tensioning roller
2.5 4x4 with gasoline straight-5 2.5 L 197 HP engine (2009.3–) 18.44 lbf⋅ft
2.5 with gasoline straight-5 2.5 L 197 HP engine (2009.3–2012.11) 18.44 lbf⋅ft
2.5 with gasoline straight-5 2.5 L 197 HP engine (2009.3–2012.11) 18.44 lbf⋅ft
All other modifications 15.49 lbf⋅ft
expand_moreEngine lubrication
Oil cooler 12.54 lbf⋅ft
Oil cooler lines 2.21 lbf⋅ft
expand_moreOil drain plug
2.5 4x4 with gasoline straight-5 2.5 L 197 HP engine (2009.3–) 28.03 lbf⋅ft
2.5 with gasoline straight-5 2.5 L 197 HP engine (2009.3–2012.11) 28.03 lbf⋅ft
2.5 with gasoline straight-5 2.5 L 197 HP engine (2009.3–2012.11) 28.03 lbf⋅ft
expand_moreAll other modifications
Engine oil 25.08 lbf⋅ft
expand_moreOil filter housing
expand_more2.5 4x4 with gasoline straight-5 2.5 L 197 HP engine (2009.3–)
Oil filter cover 18.44 lbf⋅ft
On the engine block 11.8 lbf⋅ft
expand_more2.5 with gasoline straight-5 2.5 L 197 HP engine (2009.3–2012.11)
Oil filter cover 18.44 lbf⋅ft
On the engine block 11.8 lbf⋅ft
All other modifications 14.75 lbf⋅ft
expand_moreOil pump
2.5 4x4 with gasoline straight-5 2.5 L 197 HP engine (2009.3–) 4.43 lbf⋅ft
2.5 with gasoline straight-5 2.5 L 197 HP engine (2009.3–2012.11) 4.43 lbf⋅ft
2.5 with gasoline straight-5 2.5 L 197 HP engine (2009.3–2012.11) 4.43 lbf⋅ft
All other modifications 11.8 lbf⋅ft
expand_moreOil sump
2.5 4x4 with gasoline straight-5 2.5 L 197 HP engine (2009.3–) 12.54 lbf⋅ft
Use sealant.
2.5 with gasoline straight-5 2.5 L 197 HP engine (2009.3–2012.11) 12.54 lbf⋅ft
Use sealant.
2.5 with gasoline straight-5 2.5 L 197 HP engine (2009.3–2012.11) 12.54 lbf⋅ft
Use sealant.
expand_moreAll other modifications
At the gearbox 35.4 lbf⋅ft
Otherwise 11.8 lbf⋅ft
expand_moreEngine management
expand_moreCamshaft sensor
2.5 4x4 with gasoline straight-5 2.5 L 197 HP engine (2009.3–) 7.38 lbf⋅ft
2.5 with gasoline straight-5 2.5 L 197 HP engine (2009.3–2012.11) 7.38 lbf⋅ft
2.5 with gasoline straight-5 2.5 L 197 HP engine (2009.3–2012.11) 7.38 lbf⋅ft
All other modifications 1.48 lbf⋅ft
expand_moreCrankshaft sensor
2.5 4x4 with gasoline straight-5 2.5 L 197 HP engine (2009.3–) 7.38 lbf⋅ft
2.5 with gasoline straight-5 2.5 L 197 HP engine (2009.3–2012.11) 7.38 lbf⋅ft
2.5 with gasoline straight-5 2.5 L 197 HP engine (2009.3–2012.11) 7.38 lbf⋅ft
All other modifications 5.9 lbf⋅ft
Exhaust gas temperature sensor 22.13 lbf⋅ft
Glow plugs 4.43 lbf⋅ft
Knock sensor 14.75 lbf⋅ft
Lambda sensor 33.19 lbf⋅ft
expand_moreEngine mounting
expand_moreEngine bracket
expand_more2.5 4x4 with gasoline straight-5 2.5 L 197 HP engine (2009.3–)
expand_moreAt the cylinder head
First stage 25.81 lbf⋅ft
Second stage 75°
expand_moreAll other modifications
On the engine block 41.3 lbf⋅ft
expand_moreEngine mounting
expand_more2.5 4x4 with gasoline straight-5 2.5 L 197 HP engine (2009.3–)
On the engine block 84.82 lbf⋅ft
expand_more2.5 with gasoline straight-5 2.5 L 197 HP engine (2009.3–2012.11)
On the engine block 84.82 lbf⋅ft
On chassis 66.38 lbf⋅ft
expand_moreAll other modifications
On engine bracket 98.1 lbf⋅ft
expand_moreSubframe
expand_moreOn chassis
Front 92.2 lbf⋅ft
expand_moreRear
First stage 103.26 lbf⋅ft
Second stage 180°
expand_moreSubframe stiffening plate
On chassis 51.63 lbf⋅ft
expand_moreTorque arm
expand_more2.5 4x4 with gasoline straight-5 2.5 L 197 HP engine (2009.3–)
At the subframe 59 lbf⋅ft
expand_moreOnto torque support bracket
First stage 25.81 lbf⋅ft
Second stage loosen by 360°
Third stage 62.69 lbf⋅ft
expand_more2.5 with gasoline straight-5 2.5 L 197 HP engine (2009.3–2012.11)
At the subframe 59 lbf⋅ft
expand_moreOnto torque support bracket
First stage 25.81 lbf⋅ft
Second stage loosen by 360°
Third stage 62.69 lbf⋅ft
expand_moreAll other modifications
First stage 25.81 lbf⋅ft
Second stage loosen by 360°
Third stage 62.69 lbf⋅ft
expand_moreTorque support bracket
At the gearbox 35.4 lbf⋅ft
expand_moreExhaust system
expand_moreCatalytic converter
expand_more2.0 TDCi with diesel straight-4 2.0 L 134 HP at 4000 RPM, 320 N⋅m at 2000 RPM engine (2008.3–2012.11)
At the bracket 17.7 lbf⋅ft
Clamps at the turbocharger 17.7 lbf⋅ft
Replace clamps.
On particle filter 35.4 lbf⋅ft
2.5 4x4 with gasoline straight-5 2.5 L 197 HP engine (2009.3–) 20.65 lbf⋅ft
expand_moreAll other modifications
Clamps at the turbocharger 17.7 lbf⋅ft
Replace clamps.
Nuts on particle filter 35.4 lbf⋅ft
Catalytic converter bracket 17.7 lbf⋅ft
Diesel particulate filter 35.4 lbf⋅ft
expand_moreExhaust manifold
2.5 4x4 with gasoline straight-5 2.5 L 197 HP engine (2009.3–) 17.7 lbf⋅ft
2.5 with gasoline straight-5 2.5 L 197 HP engine (2009.3–2012.11) 17.7 lbf⋅ft
2.5 with gasoline straight-5 2.5 L 197 HP engine (2009.3–2012.11) 17.7 lbf⋅ft
All other modifications 22.13 lbf⋅ft
Replace nuts.
expand_moreExhaust pipe
expand_more2.5 4x4 with gasoline straight-5 2.5 L 197 HP engine (2009.3–)
At the turbocharger 20.65 lbf⋅ft
On catalytic converter 35.4 lbf⋅ft
expand_more2.5 with gasoline straight-5 2.5 L 197 HP engine (2009.3–2012.11)
At the turbocharger 20.65 lbf⋅ft
On catalytic converter 35.4 lbf⋅ft
All other modifications 35.4 lbf⋅ft
expand_moreFuel supply
expand_moreFuel lines
First stage 13.28 lbf⋅ft
Replace fuel line.
expand_moreWith exhaust gas norm EURO 4
Second stage 22.13 lbf⋅ft
expand_moreWith exhaust gas norm EURO 5
Second stage 19.91 lbf⋅ft
expand_moreIgnition system
Spark plugs 20.65 lbf⋅ft
expand_moreStart system
expand_moreStarter
expand_more2.5 4x4 with gasoline straight-5 2.5 L 197 HP engine (2009.3–)
With 6-speed gearbox 35.4 lbf⋅ft
With automatic 5-gear gearbox 29.5 lbf⋅ft
2.5 with gasoline straight-5 2.5 L 197 HP engine (2009.3–2012.11) 36.88 lbf⋅ft
2.5 with gasoline straight-5 2.5 L 197 HP engine (2009.3–2012.11) 36.88 lbf⋅ft
All other modifications 25.81 lbf⋅ft

Please be noted that all capacities listed here are approximate. Check fluid levels when adding or refilling as recommended in your 2009 Ford Kuga user's manual. Keep in mind that all information here is provided “as is” without any warranty of any kind.

Before doing any DIY service please check your insurance policy and Ford warranty policy for your region. In some regions DIY service may invalidate your warranty.

Conquer your fears and never give up!

DIY car service is not as difficult as it looks like and it might save you thousands of dollars per year. It might be even fun and a good thing to do with your kids on a weekend to teach them how basic machinery works. It's really hard to screw something up and damage your car permanently if you use right tools, follow Ford Kuga service manual and use right parts and fluids in prescribed amounts. Even modern cars stuffed with electronics can be serviced in your garage or even in your driveway. Changing engine oil, brake fluid, ATF, replacing brake pads, and etc. It's all may be done by yourself in a mater of a couple of hours.

Doing basic service for your 2009 Ford Kuga you're not only saving money, but also also improving your technical skills and learning something new.

Ford Kuga First generation (MK1) model years

Units:
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