Diesel FORD KUGA 2011 1.G User Guide

Vehicles with 2.0L diesel engine
9.Torque:
• Stage 1: 35
Nm
• Stage 2: Loosen 360°
• Stage 3: 85Nm
E114034
Vehicles with 2.5L engine
10.
11 .Torque:
• Stage 1: 35
Nm
• Stage 2: Loosen 360°
• Stage 3: 85Nm
E114375
All vehicles
12.
E98543
x7
13.Lower the vehicle.
G1070580en2008.50 Kuga8/2011
205-01- 7
Driveshaft
205-01- 7
REMOVAL AND INSTALLATION
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Differential Case
General EquipmentCable Ties
Removal
All vehicles
1. Refer to: Rear Halfshaft (205-05 Rear Drive
Halfshafts, Removal and Installation).
Vehicles with 2.0L diesel engine
2.
1
2x6x3
1
2x6x3
E101687
3.
E101709
Vehicles with 2.5L engine
4. Refer to: Driveshaft (205-01 Driveshaft,
Removal and Installation).
5.
E114256
6.
x2x2
E114255
G1061458en2008.50 Kuga8/2011
205-02- 21
Rear Drive Axle/Differential
205-02- 21
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All vehicles
7.
E101710
Vehicles with 2.0L diesel engine
8.General Equipment: Cable Ties
30 mm
30 mm
x2
30 mm
30 mm
x2
E101711
All vehicles
9.
x2x2
E101713
Installation
All vehicles
1.
x2x2
E101714
G1061458en2008.50 Kuga8/2011
205-02- 22
Rear Drive Axle/Differential
205-02- 22
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Vehicles with 2.0L diesel engine
2.
x2x2
E101712
All vehicles
3.Torque: 80Nm
E101710
Vehicles with 2.0L diesel engine
4.Torque: 80Nm
E101709
5. CAUTION: Make sure that the
installation marks are aligned.
1. Torque: 35Nm
2. Torque: 35Nm
3. Torque: 35Nm
3
x2
1
2
2x3
13
x2
1
2
2x3
1
E101688
G1061458en2008.50 Kuga8/2011
205-02- 23
Rear Drive Axle/Differential
205-02- 23
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Active On-Demand Coupling Module
MaterialsSpecification
Name
8U7J-8708687-AA
Transmission Oil AWD
Removal
All vehicles
1. Refer to: Health and Safety Precautions (100-00
General Information, Description and
Operation).
2. Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
Vehicles with 2.0L diesel engine
3.
x2x2
E102531
4.
1
2x6x3
1
2x6x3
E101687
5.
x4
x2
x4
x2
E102544
G1076971en2008.50 Kuga8/2011
205-02- 25
Rear Drive Axle/Differential
205-02- 25
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All vehicles
14.
E102545
Installation
All vehicles
1.Material: Transmission Oil AWD
(8U7J-8708687-AA) transmission fluid
E102554
Vehicles with 2.0L diesel engine
2. Torque: 25Nm
x4
x2
x4
x2
E102544
G1076971en2008.50 Kuga8/2011
205-02- 28
Rear Drive Axle/Differential
205-02- 28
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Action
Possible Sources
Symptom
• ADJUST the parking brakecable or switch
REFER to: Parking Brake
Cable Adjustment (206-05
Parking Brake and Actuation,
General Procedures).
• Incorrectly adjusted parking
brake or brake pedal switch
• Brake drag
• REFER to brake booster opera-tion check in this procedure.
• Brake booster.
• INSTALL a new wheel cylinderor brake caliper.
REFER to: Brake Caliper (206-
03 Front Disc Brake,
Removal and Installation).
• Seized wheel cylinder or brake
caliper.
• INSTALL a new brake caliper.REFER to: Brake Caliper (206-
03 Front Disc Brake,
Removal and Installation).
• Seized brake caliper slide pins.
• INSTALL new parking brakecables.
REFER to: Parking Brake
Cable Adjustment (206-05
Parking Brake and Actuation,
General Procedures).
• Seized parking brake cables.
• Check the parking brake leaverposition and make sure there
are no obstructions.
• Parking brake not fully
released.
• Check all brake hose(s) forcorrect fitment.
REFER to: Rear Brake Flexible
Hose (206-04 Rear Disc
Brake, Removal and Installa-
tion)
/ Front Brake Flexible Hose
(206-03 Front Disc Brake,
Removal and Installation).
• Brake hose incorrectly fitted.
• INSTALL new brake shoes orbrake pads.
REFER to: Brake Pads (206-03
Front Disc Brake, Removal
and Installation).
• Worn or contaminated brake
shoes or brake pads.
• Excessive brake pedal effort
• INSTALL a new brake vacuumpump.
• Malfunctioning vacuum pump
(diesel).
• CONNECT or INSTALL a newbrake booster vacuum pipe as
necessary.
• Disconnected or damaged
brake booster vacuum pipe.
• GO toPinpoint Test D.
• Brake booster.
G1058975en2008.50 Kuga8/2011
206-00- 9
Brake System - General Information
206-00- 9
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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
.
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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
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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
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