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Ford Workshop Service and Repair Manuals

303-03 Engine Cooling > < Engine - Vehicles With: Automatic Transaxle
Engine - 2.5L - Engine Cougar 1999 (08/1998-01/2001)
Description and Operation

The 2.5L Duratec engine is of all aluminium construction with a two piece cylinder block made by a special casting process.

The 2.5 liter 24 valve V6 engine has an electrically controlled lower intake manifold switching system to optimize torque and power output.

The four overhead camshafts are driven by two timing chains. The engine incorporates the latest engineering: electronic engine management with Distributorless Ignition (EI) System, sequential multiport electronic returnless fuel injection, electronically controlled exhaust gas recirculation and two catalytic converters in the exhaust manifolds.

The Cougar ST200 includes the following power upgrades:

  • Higher power output: 151 kW
  • Extruded honed primary and secondary cylinder head intake ports.
  • Extruded honed upper intake manifolds.
  • Larger 60 mm throttle body.
  • New intake and exhaust camshafts with revised valve timing.
  • Compression ratio is increased to 10:1.
  • Low restriction air inlet using a conical filter element.
  • Large diameter low restriction exhaust system with dual outlets.

Engine Component View

 
Item
Part Number
Description
1
-
EI system ignition coil
2
-
EGR vacuum regulator solenoid
3
-
Idle air control (IAC) valve
4
-
Exhaust gas recirculation (EGR) valve
5
-
Differential pressure feedback EGR sensor, mounted on bracket at rear of right-hand cylinder head
6
-
Knock sensor (vehicles with returnless fuel system only)
7
-
Intake air temperature (IAT) sensor
8
-
Air cleaner (ACL)
9
-
Battery junction box (BJB)
10
-
Mass air flow (MAF) sensor
11
-
Engine coolant temperature (ECT) sensor in engine coolant bypass tube between cylinder heads
12
-
Water pump pulley shield
13
-
Fuel pressure sensor (vehicles with returnless fuel system only)
14
-
One pre-catalyst for each cylinder bank (one unit in each exhaust manifold)
15
-
One heated oxygen sensor (HO2S) for each cylinder bank, in exhaust manifold
16
-
Throttle body and throttle position (TP) sensor
17
-
Electric intake manifold runner control (IMRC) actuator
18
-
Upper intake manifold
19
-
Camshaft position (CMP) sensor, on engine front cover (exhaust camshaft, left-hand cylinder head)
20
-
Crankshaft position (CKP) sensor, on lower engine front cover
21
-
Hydraulic engine mount
22
-
Engine mounting bracket
23
-
Power steering pressure (PSP) switch
24
-
Powertrain control module (PCM) EEC V
25
-
Service connector (octane adjust)

Engine Components View

 
Item
Part Number
Description
1
-
EGR vacuum regulator solenoid
2
-
Idle air control (IAC) valve
3
-
Idle air control (IAC) gasket
4
-
Throttle body gasket
5
-
Throttle body
6
-
EGR valve gasket
7
-
EGR valve
8
-
Differential pressure feedback EGR (DPFE)
9
-
Positive crankcase ventilation PCV hose
10
-
Positive crankcase ventilation (PCV) valve
11
-
Fuel charging wiring
12
-
Electric IMRC actuator
13
-
Valve cover gasket (LH)
14
-
Oil filler cap
15
-
Water pump drive belt
16
-
Water pump drive pulley
17
-
Camshaft rear oil seal
18
-
Camshaft oil seal retainer gasket
19
-
Camshaft rear oil seal retainer
20
-
Alignment dowel (2 required)
21
-
Water pump drive belt tensioner
22
-
Water pump
23
-
Engine lifting eye (LH)
24
-
Exhaust manifold (LH)
25
-
Exhaust manifold gasket (LH)
26
-
Cylinder head gasket (LH)
27
-
Cylinder head (LH)
28
-
A/C compressor
29
-
Exhaust camshaft (LH)
30
-
Intake camshaft (LH)
31
-
Camshaft journal thrust cap (LH) (2 required)
32
-
Adaptor plate
33
-
Camshaft journal cap (LH) (7 required)
34
-
Flywheel
35
-
Valve cover (LH)
36
-
Water pump pulley shield
37
-
EGR valve to exhaust manifold tube
38
-
Fuel injector retainer (6 required)
39
-
Fuel injector (6 required)
40
-
Intake manifold upper
41
-
Intake manifold upper gasket, (2 required)
42
-
Intake manifold lower
43
-
Intake manifold lower gasket, (2 required)
44
-
Fuel injector seal (6 required)
45
-
Fuel rail (engine with returnless fuel system shown)
46
-
Oil separator
47
-
Oil separator to cylinder block gasket
48
-
Engine coolant tube
49
-
Oil cooler insert
50
-
Crankshaft rear oil seal
51
-
Oil level indicator tube
52
-
(not Cougar)
53
-
Oil filter
54
-
Oil pan
55
-
Oil pan gasket
56
-
Lower cylinder block
57
-
Engine front cover gasket
58
-
Crankshaft position(CKP) sensor
59
-
Camshaft position(CMP) sensor
60
-
Crankshaft front oil seal
61
-
Accessory drive belt tensioner
62
-
Dust cover
63
-
Drive belt idler pulley
64
-
Power steering pump
65
-
Power steering pump brace
66
-
Generator
67
-
Generator mounting bracket
68
-
Engine front cover
69
-
Cylinder head gasket (RH)
70
-
Cylinder block
71
-
Engine mounting bracket
72
-
Intake camshaft (RH)
73
-
Generator brace
74
-
Exhaust manifold (RH)
75
-
Exhaust manifold gasket (RH)
76
-
Engine lifting eye (RH)
77
-
Exhaust camshaft (RH)
78
-
Camshaft journal thrust cap (RH) (2 required)
79
-
Valve cover (RH)
80
-
Inline connector bracket
81
-
Radio ignition Interference capacitor
82
-
Ignition coil
83
-
Ignition wire (RH)
84
-
Ignition wire (LH)
85
-
Spark plug (6 required)
86
-
Water bypass tube
87
-
Camshaft journal cap (6 required)
88
-
Cylinder head (RH)
89
-
Knock sensor (vehicles with returnless fuel system only)

Engine Component View

 
Item
Part Number
Description
1
-
Oil separator
2
-
Oil separator to cylinder block gasket
3
-
Engine coolant tube
4
-
Cylinder block
5
-
Crankshaft rear oil seal
6
-
Valve stem oil seal (12 required each side)
7
-
Valve collets (12 required each side)
8
-
Valve spring retainer key (24 required each side)
9
-
Valve spring (12 required each side)
10
-
Valve tappet (12 required each side)
11
-
Roller finger follower
12
-
Cylinder head (LH)
13
-
Exhaust valve (6 required each side)
14
-
Intake valve (6 required each side)
15
-
Crankshaft thrust washer (1 required)
16
-
Crankshaft
17
-
Lower crankshaft thrust main bearing (1 required)
18
-
Lower crankshaft main bearing (3 required)
19
-
Lower cylinder block
20
-
Oil pan baffle
21
-
Oil pump screen cover and tube
22
-
Crankshaft timing chain sprocket
23
-
Crankshaft position sensor pulse wheel
24
-
Crankshaft bolt and washer
25
-
Crankshaft pulley
26
-
Timing chain (2required)
27
-
Oil pump
28
-
Connecting rod bolt (12 required)
29
-
Connecting rod cap (6 required)
30
-
Connecting rod bearing (12 required)
31
-
Connecting rod (6 required)
32
-
Piston pin retainer (12 required)
33
-
Piston pin (6 required)
34
-
Piston (6 required)
35
-
Timing chain tensioner arm (RH)
36
-
Cylinder head (RH)
37
-
Timing chain guide (RH)
38
-
Cylinder head gasket (RH)
39
-
Timing chain tensioner (RH)
40
-
Timing chain tensioner arm (LH)
41
-
Timing chain tensioner (LH)
42
-
Timing chain guide (LH)
43
-
Cylinder head gasket (LH)
44
-
Upper crankshaft main bearing (4 required)
45
-
Piston ring set (6 required)
46
-
Timing chain tensioner adapter plate (LH)
47
-
Timing chain tensioner adapter plate (RH)

303-03 Engine Cooling > < Engine - Vehicles With: Automatic Transaxle