Index FORD KUGA 2011 1.G Workshop Manual

2.Initialize the Steering Column Lock Module.
General Equipment: Ford approved diagnostic
tool
G1058706en2008.50 Kuga8/2011
211-05- 5
Steering Column Switches
211-05- 5
REMOVAL AND INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Steering Column Multifunction Switch LH
Removal
NOTE:Removal steps in this procedure may
contain installation details.
1.
E91152
2.
E99639
1
2
3.
E99649
Installation
1. To install, reverse the removal procedure.
G1058704en2008.50 Kuga8/2011
211-05- 6
Steering Column Switches
211-05- 6
REMOVAL AND INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Steering Column Multifunction Switch RH
Removal
NOTE:Removal steps in this procedure may
contain installation details.
1.
E91152
2.
E99639
1
2
3.
E99650
Installation
1. To install, reverse the removal procedure.
G1058705en2008.50 Kuga8/2011
211-05- 7
Steering Column Switches
211-05- 7
REMOVAL AND INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

*5283
3RZHUWUDLQ

6(&7,21 7,7/(3$*(
(QJLQH (QJLQH 6\VWHP  *HQHUDO ,QIRUPDWLRQ 
(QJLQH/ 'XUDWHF N:36  9,
(QJLQH &RROLQJ
)XHO &KDUJLQJ DQG &RQWUROV/ 'XUDWHF N:36  9,$
)XHO &KDUJLQJ DQG &RQWUROV  7XUERFKDUJHU/ 'XUDWHF N:36  9,%
$FFHVVRU\ 'ULYH/ 'XUDWHF N:36  9,
6WDUWLQJ 6\VWHP/ 'XUDWHF N:36  9,
(QJLQH ,JQLWLRQ/ 'XUDWHF N:36  9,
(QJLQH (PLVVLRQ &RQWURO/ 'XUDWHF N:36  9,
,QWDNH $LU 'LVWULEXWLRQ DQG )LOWHULQJ/ 'XUDWHF N:36  9,
(YDSRUDWLYH (PLVVLRQV
(OHFWURQLF (QJLQH &RQWUROV/ 'XUDWHF N:36  9,
$XWRPDWLF 7UDQVPLVVLRQ7UDQVD[OH $XWRPDWLF 7UDQVPLVVLRQ7UDQVD[OH9HKLFOHV :LWK 6SHHG $XWRPDWLF 7UDQVD[OH $: $:'
7UDQVPLVVLRQ7UDQVD[OH &RROLQJ9HKLFOHV :LWK 6SHHG $XWRPDWLF 7UDQVD[OH  $: $:'6SHHG $XWRPDWLF 7UDQVD[OH  '&7
$XWRPDWLF 7UDQVPLVVLRQ7UDQVD[OH ([WHUQDO &RQWUROV9HKLFOHV :LWK 6SHHG $XWRPDWLF 7UDQVD[OH  $: $:'6SHHG $XWRPDWLF 7UDQVD[OH 
'&7  
7UDQVIHU &DVH9HKLFOHV :LWK 6SHHG $XWRPDWLF 7UDQVD[OH  $: $:'6SHHG $XWRPDWLF 7UDQVD[OH  '&7
([KDXVW 6\VWHP ([KDXVW 6\VWHP/ 'XUDWHF N:36  9,
)XHO 6\VWHP  *HQHUDO ,QIRUPDWLRQ )XHO 6\VWHP  *HQHUDO ,QIRUPDWLRQ 
)XHO 7DQN DQG /LQHV
$FFHOHUDWLRQ &RQWURO
6SHHG &RQWURO
 .XJD
TO MODEL INDEX
BACK TO MAIN INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

SECTION 303-00 Engine System - General Information
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
DIAGNOSIS AND TESTING
303-00-2
Engine ........................................................................\
.........................................................
303-00-9
Engine - Oil Leaks ........................................................................\
......................................
303-00-9
Ultraviolet (UV) Testing ........................................................................\
...............................
303-00-9
Measure the compression pressure ........................................................................\
...........
303-00-10
Measure the compression pressure (Engine - 2.5L Duratec-ST (VI5)) ..............................
303-00-11
Measure the compression pressure (Engine - 2.0L Duratorq-TDCi (DW) Diesel) .............
303-00-14
Measure the oil pressure (21 113 0) ........................................................................\
...........
303-00-14
Measure the oil pressure (Engine - 2.5L Duratec-ST (VI5)) ...............................................
303-00-16
Measure the oil pressure (Engine - 2.0L Duratorq-TDCi (DW) Diesel) ..............................
303-00-17
Valve train analysis - static (engine off) ........................................................................\
......
303-00-1
Engine System - General Information
303-00- 1
.
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Engine
Special Tool(s) / General EquipmentSocket, Spark Plug
303-499
ES21202
Compression Test Adapter
303-1056
E42936
Ford diagnostic equipment
Materials
Specification
Name
WSK-M2G349-A7
Adhesive - Loctite 243 1. Verify the customer concern by operating the
system
2. Visually inspect for obvious signs of mechanical or electrical damage.
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible)
before proceeding to the next step.
4. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart.
Visual Inspection Chart
Electrical
Mechanical
– Fuse(s)
– Loose or corrodedconnector(s)
– Control module
– Damaged or worn switch(es)
– Coolant leaks
– Oil leaks
– Fuel system leaks
– Visibly damaged or
worn parts
– Loose or missing nuts or bolts
Action
Possible Sources
Symptom
• CHECK for evidence of oilleaks on components. Use an
ultraviolet (UV) leak tester if an
oil leak is not evident. INSTALL
new gaskets or components as
required.
• Oil leaks on components that
are either coated in oil them-
selves or on components local
to them.
• Loss of oil
• CHECK the coolant expansiontank for a film of oil on the
coolant surface. INSTALL a
new oil cooler or oil cooler
gasket.
• Internal or external leak at the
oil cooler.
• INSTALL a new crankshaftseal.
• Leak at the crankshaft seal.
• CHECK for cracks in oil-carrying components of the
basic engine by means of a UV
leak test. INSTALL new
components or seals as
necessary.
• Leaks from oil carrying
components or basic engine.
• DETERMINE the last type ofengine oil used and compare
with the specification. Change
the engine oil to the specifica-
tion.
• Use of the wrong type of engine
oil.
• Oil consumption
G1055128en2008.50 Kuga8/2011
303-00-
2
Engine System - General Information
303-00- 2
DIAGNOSIS AND TESTING
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Action
Possible Sources
Symptom
• CHECK if the PCV system isoperating correctly and repair
as necessary. Engine - 2.5L
Duratec-ST (VI5) -
REFER to: Engine Emission
Control (303-08 Engine
Emission Control - 2.5L
Duratec (147kW/200PS) -
VI5, Diagnosis and Testing).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Faulty positive crankcase vent-
ilation (PCV) system.
- Hoses or ventilation orbreather valves are blocked.
This causes excessive
pressure in the crankcase
which causes more oil to
enter the combustion
chamber.
- PCV oil separator is faulty and engine oil can enter the
combustion chamber
through the intake manifold.
• INSTALL a new turbocharger.Engine - 2.5L Duratec-ST (VI5)
-
REFER to: Turbocharger (303-
04 Fuel Charging and
Controls - Turbocharger -
2.5L Duratec (147kW/200PS)
- VI5, Removal and Installa-
tion).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Turbocharger seals.
• CHECK the gaskets and matingsurfaces for damage.
Remove the cylinder head.
CHECK the mating faces, cylinder
head gasket and the evenness of
the cylinder head and engine block
mating faces.
INSTALL new valve seals. Engine
- 2.5L Duratec-ST (VI5) -
REFER to: Valve Stem Seals
(303-01 Engine - 2.5L Duratec
(147kW/200PS) - VI5, Removal
and Installation).
Engine - 2.0L Duratorq-TDCi (DW)
Diesel -
• Damaged gaskets or mating
surfaces.
- Cylinder head gasket isdamaged or mating face are
warped.
- Valve stem seals are worn and engine oil can enter the
combustion chamber
between the valve stem and
the valve stem guide.
• INSTALL new components asnecessary.
• Piston ring or cylinder liner
wear.
• CHECK the running surfacesand clearances of the individual
engine components. INSTALL
new components as necessary.
INSTALL a new cylinder block
if necessary.
• Check the pistons and piston rings.
• Damaged cylinder liners or
excessive clearance of engine
components.
- Pistons.
- Piston rings (clearance ingroove and end gap).
- Cylinder liners.
G1055128en2008.50 Kuga8/2011
303-00- 3
Engine System - General Information
303-00- 3
DIAGNOSIS AND TESTING
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Action
Possible Sources
Symptom
• Check the cooling systemcomponents. Engine - 2.5L
Duratec-ST (VI5) -
REFER to: Engine Cooling
(303-03 Engine Cooling,
Diagnosis and Testing).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
REFER to: Engine Cooling
(303-03 Engine Cooling,
Diagnosis and Testing).
• Cooling system components.
• Coolant consumption
• INSTALL a new oil cooler.
• Oil cooler.
• CHECK the cylinder headgasket for damage. CHECK the
cylinder head for distortion.
• Damaged gaskets or warped
mating faces.
• DETERMINE the damagedengine component(s) and
install new component(s) as
necessary.
• Cracks or fractures in engine
components surrounded by
coolant, such as cylinder liners
and cylinder head combustion
chamber.
• CHECK the battery and cables.REFER to: Charging System
(414-00 Charging System -
General Information,
Diagnosis and Testing).
• Battery or cables.
• Engine will not crank
• CHECK the starting system.Engine - 2.5L Duratec-ST (VI5)
-
REFER to: Starting System
(303-06 Starting System -
2.5L Duratec (147kW/200PS)
- VI5, Diagnosis and Testing).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Starter motor or cables.
• CHECK the fuel level.
• Fuel tank is empty.
• Engine cranks but will not start
• Drain the water from the fuelsystem.
• Water in fuel (diesel engine
only).
• INSTALL a new fuel filter.Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Fuel filter blocked.
G1055128en2008.50 Kuga8/2011
303-00-
4
Engine System - General Information
303-00- 4
DIAGNOSIS AND TESTING
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Action
Possible Sources
Symptom
• CHECK the intake air system.Engine - 2.5L Duratec-ST (VI5)
-
REFER to: Intake Air Distribu-
tion and Filtering (303-12
Intake Air Distribution and
Filtering - 2.5L Duratec
(147kW/200PS) - VI5,
Diagnosis and Testing).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Engine intake air system.
• CHECK the glow plugs.INSTALL new glow plugs as
necessary.
• Glow plug faulty (diesel engine
only).
• CHECK the engine manage-ment system. Engine - 2.5L
Duratec-ST (VI5) -
REFER to: Electronic Engine
Controls (303-14 Electronic
Engine Controls - 2.5L
Duratec (147kW/200PS) -
VI5, Diagnosis and Testing).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Engine management system.
• CHECK the ignition system.Engine - 2.5L Duratec-ST (VI5)
-
REFER to: Engine Ignition
(303-07 Engine Ignition - 2.5L
Duratec (147kW/200PS) -
VI5, Diagnosis and Testing).
• Ignition system (petrol engine
only).
• CHECK and adjust the valvetiming. Engine - 2.5L Duratec-
ST (VI5) -
REFER to: Timing Belt (303-01
Engine - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Incorrect valve timing.
G1055128en2008.50 Kuga8/2011
303-00-
5
Engine System - General Information
303-00- 5
DIAGNOSIS AND TESTING
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Action
Possible Sources
Symptom
• CHECK the timing belt/timingchain and sprockets/pulleys.
INSTALL new components as
necessary. Engine - 2.5L
Duratec-ST (VI5) -
REFER to: Timing Belt (303-01
Engine - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Broken or damaged timing
belt/timing chain or
pulley/sprocket.
• CHECK the fuel system.Engine - 2.5L Duratec-ST (VI5)
-
REFER to: Fuel Charging and
Controls (303-04 Fuel Char-
ging and Controls - 2.5L
Duratec (147kW/200PS) -
VI5, Diagnosis and Testing).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Fuel system.
• Very poor power output or fuel
consumption too high or engine
running rough.
• CHECK the intake air system.Engine - 2.5L Duratec-ST (VI5)
-
REFER to: Intake Air Distribu-
tion and Filtering (303-12
Intake Air Distribution and
Filtering - 2.5L Duratec
(147kW/200PS) - VI5,
Diagnosis and Testing).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Engine intake air system.
• CHECK the exhaust system.
• Exhaust system blocked.
• CHECK the engine manage-ment system. Engine - 2.5L
Duratec-ST (VI5) -
REFER to: Electronic Engine
Controls (303-14 Electronic
Engine Controls - 2.5L
Duratec (147kW/200PS) -
VI5, Diagnosis and Testing).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Engine management system.
G1055128en2008.50 Kuga8/2011
303-00-
6
Engine System - General Information
303-00- 6
DIAGNOSIS AND TESTING
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL