towing FORD KUGA 2011 1.G Workshop Manual

100-00-48
Lubricants and Greases ........................................................................\
.............................
100-00-48
Transmission Fluids ........................................................................\
....................................
100-00-49
Noise ........................................................................\
..........................................................
100-00-49
Noise Insulation Materials ........................................................................\
..........................
100-00-49
O-Rings (Fluoroelastomer) ........................................................................\
.........................
100-00-49
Paints ........................................................................\
..........................................................
100-00-50
Pressurized Equipment ........................................................................\
..............................
100-00-50
Solder ........................................................................\
.........................................................
100-00-50
Solvents ........................................................................\
......................................................
100-00-50
Sound Insulation ........................................................................\
.........................................
100-00-50
Suspended Loads ........................................................................\
.......................................
100-00-50
Transmission Brake Bands ........................................................................\
.........................
100-00-50
Underseal ........................................................................\
...................................................
100-00-50
Viton ........................................................................\
............................................................
100-00-51
Welding ........................................................................\
.......................................................
100-00-52
Warning Symbols on Vehicles ........................................................................\
....................
100-00-53
White Spirit ........................................................................\
.................................................
100-00-54
Standard Workshop Practices ........................................................................\
....................
100-00-54
Vehicle in Workshop ........................................................................\
...................................
100-00-54
Towing the Vehicle ........................................................................\
......................................
100-00-54
Connecting a Slave Battery Using Jumper Cables ............................................................
100-00-55
Component Cleaning ........................................................................\
..................................
100-00-55
Calibration of Essential Measuring Equipment ...................................................................
100-00-57
Solvents, Sealants and Adhesives ........................................................................\
.............
100-00-57
Introduction ........................................................................\
.................................................
100-00-58
Road/Roller Testing ........................................................................\
....................................
100-00-58
Pre-Test Checks ........................................................................\
.........................................
100-00-58
Starting the Engine ........................................................................\
.....................................
100-00-58
Road or Roller Testing ........................................................................\
................................
100-00-59
Brake Testing ........................................................................\
..............................................
100-00-60
Air Conditioning (A/C) System Health and Safety Precautions ..........................................
100-00-61
Battery and Battery Charging Health and Safety Precautions ............................................
100-00-62
Brake System Health and Safety Precautions
....................................................................
100-00-63
Engine

Cooling System Health and Safety Precautions .....................................................
100-00-64
Petrol and Petrol-Ethanol Fuel Systems Health and Safety Precautions ...........................
100-00-65
Supplemental Restraint System (SRS) Health and Safety Precautions .............................
100-00-66
Window Glass Health and Safety Precautions ...................................................................
100-00-67
Body Repair Health and Safety and General Precautions .................................................
100-00-67
General ........................................................................\
.......................................................
100-00-68
Personal protection ........................................................................\
.....................................
100-00-69
Protection of the vehicle ........................................................................\
.............................
100-00-2
General Information
100-00- 2
.
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PAGE 2 OF 2 FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Standard Workshop Practices
Vehicle in Workshop
When working on a vehicle in the workshop always
make sure that:
– the parking brake is applied or the wheels aresecurely chocked to prevent the vehicle moving
forwards or backwards.
– the key is removed from key operated hood locks before any work is carried out around the
front of the vehicle.
– if the engine is to be run, there is adequate ventilation, or an extraction hose to remove
exhaust fumes.
– there is adequate room to raise the vehicle and remove the wheels, if necessary.
– fender covers are always fitted if any work is to be carried out in the engine compartment.
– the battery is disconnected if working on the engine, underneath the vehicle, or if the vehicle
is raised.
CAUTION: When electric arc welding on a
vehicle, always disconnect the generator
wiring to prevent the possibility of a surge
of current causing damage to the internal
components of the generator.
– if using welding equipment on the vehicle, a suitable fire extinguisher is readily available.
Towing the Vehicle
WARNING: When the vehicle is being
towed, the ignition switch must be in
position II (steering lock released and
warning lamps illuminated). Only then will
the steering, turn signal lamps, horn and
stop lamps be operational. Failure to follow
these instructions may result in personal
injury.
NOTE: The removable towing eye (if equipped),
has a left-hand thread and must be fully tightened
before towing can commence.
When towing is necessary, the vehicle towing eyes
should be used. The rope must be securely
fastened to the towing eyes and must also be
attached to the other vehicle such that the rope will
not foul the bodywork.
When a vehicle with automatic transmission is
towed, the gear selector must be in position N (Neutral). Never tow a vehicle with automatic
transmission at a speed greater than 30 mph (50
km/h) or for a distance greater than 30 miles (50
km). If it is necessary to tow the vehicle a greater
distance, the drive wheels must be lifted clear off
the ground.
Alternatively the vehicle can be transported on a
low loader or a trailer.
Connecting a Slave Battery Using
Jumper Cables
WARNING: If the slave battery has recently
been charged and is gassing, cover the
vent plugs or covers with a damp cloth to
reduce the risk of explosion should arcing
occur when connecting the jumper cables.
Failure to follow these instructions may
result in personal injury.
CAUTIONS:
A discharged battery condition may have
been caused by an electrical short circuit.
If this condition exists there will be an
apparently live circuit on the vehicle even
when all normal circuits are switched off.
This can cause arcing when the jumper
cables are connected.
While it is not recommended that the
vehicle is jump started, it is recognized
that this may occasionally be the only
practical way to mobilize a vehicle. In such
an instance, the discharged battery must
be recharged immediately after jump
starting to avoid permanent damage.
– Always make sure that the jumper cables are adequate for the task. Heavy duty cables must
be used.
– Always make sure that the slave battery is of the same voltage as the vehicle battery. The
batteries must be connected in parallel.
– Always make sure that switched electric circuits are switched off before connecting jumper
cables. This reduces the risk of arcing occurring
when the final connection is made.
G17373en2008.50 Kuga8/2011
100-00- 54
General Information
100-00- 54
DESCRIPTION AND OPERATION
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Engine Cooling — 2.5L Duratec (147kW/200PS) - VI5 – Overview
Auxiliary coolant pump
An electrically operated auxiliary coolant pump is
installed on vehicles with a trailer coupling and/or
additional heating. The auxiliary coolant pump
ensures that the coolant is circulated when the
coolant pump (which is driven by the engine) is not
running.
The additional heating uses the auxiliary coolant
pump to circulate hot coolant through the heat
exchanger and the engine.
On vehicles with a trailer coupling the auxiliary
coolant pump is switched on for 6 minutes by the
PCM (powertrain control module) if the coolant
temperature exceeds 106°C when the engine is
switched off. This prevents the coolant circuit from
overheating. This could happen particularly if the
engine is switched off after towing a heavy trailer
up a steep hill before there has been sufficient time
for cooling.
G1088220en2008.50 Kuga8/2011
303-03-3
Engine Cooling
303-03- 3
DESCRIPTION AND OPERATION
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Action
Possible Sources
Symptom
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• Fuel injection supply manifold
fuel pressure sensor.
• REFER to:Engine Ignition
(303-07 Engine Ignition - 2.5L
Duratec (147kW/200PS) -
VI5, Diagnosis and Testing).
• Engine ignition.
• Engine stumbling
• INSPECT the fuel injectors.CLEAN the fuel injectors or
INSTALL a new set of injectors
as required only after the
checks have been carried out.
REFER to: Fuel Injectors (303-
04 Fuel Charging and
Controls - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
• Fuel injectors.
• Check the fuel system pres-sure.
• Low fuel system pressure.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• Fuel rail fuel pressure sensor.
• REFER to:Engine Ignition
(303-07 Engine Ignition - 2.5L
Duratec (147kW/200PS) -
VI5, Diagnosis and Testing).
• Engine ignition.
• Engine lacks power
• CHECK the braking system.REFER to: Brake System (206-
00 Brake System - General
Information, Diagnosis and
Testing).
• Brakes binding.
• ADVISE the customer aboutthe effects of overloading the
vehicle and wind resistance on
the fuel consumption.
• Vehicle overloaded, or
excessive wind resistance (roof
racks, towing etc).
• INSTALL a new air cleanerelement as necessary.
• Air cleaner element blocked.
• Check the fuel system pres-sure.
• Low fuel system pressure.
• INSPECT the fuel lines.INSTALL new components as
necessary. TEST the system
for normal operation.
• Kinked or restricted fuel lines.
G1183441en2008.50 Kuga8/2011
303-04A-
9
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 9
DIAGNOSIS AND TESTING
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Action
Possible Sources
Symptom
• CHECK the valve timing.REFER to: Timing Belt (303-01
Engine - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
• Incorrect valve timing.
• REMOVE the cylinder head.INSPECT the cylinder head
and pistons for signs carbon
build up.
REFER to: Cylinder Head (303-
01 Engine - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
• Excessive carbon build up.
• INSPECT the engine compon-ents.
• Worn or damaged oil pump.
• Worn or damaged timing chain
or sprocket.
• Major mechanical engine failure.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• KS.
• Engine knock during accelera-
tion
• INSPECT the fuel injectors.CLEAN the fuel injectors or
INSTALL a new set of injectors
as required only after the
checks have been carried out.
REFER to: Fuel Injectors (303-
04 Fuel Charging and
Controls - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
• Fuel injectors.
• REFER to:Engine(303-00
Engine System - General
Information, Diagnosis and
Testing).
• Major mechanical engine
failure.
• CHECK the braking system.REFER to: Brake System (206-
00 Brake System - General
Information, Diagnosis and
Testing).
• Brakes binding.
• Excessive fuel consumption
• ADVISE the customer aboutthe effects of overloading the
vehicle and wind resistance on
the fuel consumption.
• Vehicle overloaded, or
excessive wind resistance (roof
racks, towing etc).
• INSTALL a new air cleanerelement.
• Air cleaner element blocked.
G1183441en2008.50 Kuga8/2011
303-04A-
19
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 19
DIAGNOSIS AND TESTING
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SECTION 307-01 Automatic Transmission/Transaxle
— Vehicles With: 5-Speed Automatic Transaxle - AW55 AWD
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
SPECIFICATIONS
307-01-4
Specifications ........................................................................\
..............................................
DESCRIPTION AND OPERATION 307-01-5
Transmission Description (Component Location) ...............................................................
307-01-6
Transmission Description (Overview) ........................................................................\
.........
307-01-6
Components of the AW55 automatic transaxle ..................................................................
307-01-6
General overview ........................................................................\
....................................
307-01-8
Transaxle cooling ........................................................................\
....................................
307-01-8
External shift mechanism ........................................................................\
........................
307-01-9
Components of the electronic control ........................................................................\
.....
307-01-11
Overview of the brakes, clutches and one-way clutches ................................................
307-01-12
Input and output signals at the TCM ........................................................................\
.......
307-01-14
Knowing and Understanding Customer Concerns ..........................................................
307-01-14
Testing Possible Causes of Transmission Control Faults ...............................................
307-01-14
IDS Diagnosis ........................................................................\
.........................................
307-01-14
visual inspection ........................................................................\
.....................................
307-01-15
Towing the vehicle ........................................................................\
..................................
307-01-15
Push-starting the Vehicle ........................................................................\
........................
307-01-15
Jump-starting the Vehicle ........................................................................\
.......................
307-01-15
Selector Lever Emergency Release ........................................................................\
.......
307-01-16
Adjusting the Selector Lever Cable ........................................................................\
........
307-01-17
Transmission Fluid Level Check ........................................................................\
.............
307-01-17
Changing the Transmission Fluid ........................................................................\
...........
307-01-18
Diagnosis with IDS ........................................................................\
..................................
307-01-19
Resetting the counter for fluid change intervals. .............................................................
307-01-19
Programming the 'N' position of the TR sensor..............................................................
307-01-19
Resetting the values learned by the TCM .......................................................................
307-01-21
Transmission Description (System Operation and Component Description) .....................
307-01-21
System Operation ........................................................................\
.......................................
307-01-22
Functionality overview ........................................................................\
............................
307-01-24
Electronic Control System ........................................................................\
......................
307-01-24
Hydraulic Control System ........................................................................\
.......................
307-01-24
Type plate ........................................................................\
...............................................
307-01-25
Serial number of the transmission ........................................................................\
..........
307-01-25
Markings on the TCM ........................................................................\
.............................
307-01-25
Serial

number of the TCM ........................................................................\
.......................
307-01-25
Transmission Control ........................................................................\
..............................
307-01-27
Pin assignment for TCM connector 'C' (connection to transaxle) ...................................
307-01-28
Operation ........................................................................\
................................................
307-01-29
Gearshift control ........................................................................\
......................................
307-01-29
Adaptation ........................................................................\
...............................................
307-01-29
Shifting from 'P' to another transmission range ..............................................................
307-01-1
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 1
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PAGE 1 OF 3 FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

307-01-29
Automatic transmission, selector lever in position "D". ...................................................
307-01-29
Sport mode, selector lever in position "S" .......................................................................
307-01-29
Changing gear in select-shift mode........................................................................\
........
307-01-30
Selector lever from 'N' to 'R' position ........................................................................\
......
307-01-30
Self-test and Diagnosis ........................................................................\
...........................
307-01-30
Temperature controlled torque converter lockup ............................................................
307-01-30
Slip locking ........................................................................\
..............................................
307-01-30
Hill climbing ........................................................................\
.............................................
307-01-31
Downhill driving ........................................................................\
.......................................
307-01-31
Hill-hold function ........................................................................\
.....................................
307-01-31
Altitude correction ........................................................................\
...................................
307-01-31
Selector lever lock ........................................................................\
..................................
307-01-31
Shifting from P into another transmission range .............................................................
307-01-31
Shifting from N into another transmission range .............................................................
307-01-31
Power flow through the transmission ........................................................................\
......
307-01-31
Clutches and brakes ........................................................................\
...............................
307-01-33
Position P (park) ........................................................................\
.....................................
307-01-34
Position N (neutral) ........................................................................\
.................................
307-01-35
Position D, 1st gear........................................................................\
................................
307-01-36
Position D, 2nd gear ........................................................................\
...............................
307-01-37
Position D, 3rd gear ........................................................................\
................................
307-01-38
Position D, 4th gear ........................................................................\
................................
307-01-39
Position D, 5th gear ........................................................................\
................................
307-01-40
Position R (reverse) ........................................................................\
................................
307-01-41
Service instructions ........................................................................\
.................................
307-01-41
Towing procedure ........................................................................\
...................................
307-01-42
Reset adaptation data ........................................................................\
.............................
307-01-42
Limp home mode ........................................................................\
....................................
307-01-42
Component Description ........................................................................\
..............................
Tasks of the electronic components ........................................................................\
........
307-01-44
Input signals ........................................................................\
............................................
307-01-45
Output signals ........................................................................\
.........................................
Control valve assembly ........................................................................\
...........................
Shift solenoids S1 - S5 ........................................................................\
...........................
PWM-

solenoid valve – TCC (SLU) ........................................................................\
........
PWM solenoid valve – shift pressure (SLS) ...................................................................
PWM solenoid valve for main line pressure (SLT) ..........................................................
307-01-52
Installation position ........................................................................\
.................................
Operation ........................................................................\
................................................
Selector lever with integrated select-shift switch module ...............................................
Oil pump ........................................................................\
..................................................
Torque converter with TCC ........................................................................\
.....................
The TSS sensor ........................................................................\
......................................
The OSS sensor ........................................................................\
.....................................
The TFT sensor ........................................................................\
......................................
The TR sensor ........................................................................\
........................................
GENERAL PROCEDURES
T ransmission Fluid Level Check ........................................................................\
.................
307-01-63
T ransmission Fluid Drain and Refill ........................................................................\
............
REMOVAL AND INSTALLATION 307-01-67
Halfshaft Seal LH ........................................................................\
........................................
307-01-68
Halfshaft Seal RH........................................................................\
.......................................
307-01-69
Main Control Valve Body ........................................................................\
............................
307-01-2
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 2
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307-01-42
307-01-49
307-01-52 307-01-47
307-01-45
307-01-50
307-01-51
307-01-53
307-01-55
307-01-54
307-01-56
307-01-57
307-01-58
307-01-61 307-01-60
PAGE 2 OF 3 FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

• Selector lever position and selector leverposition display
• Fluid leakage
• Transmission fluid level check
• Transmission fluid quality check
• Modification/retrofitting
• Mechanical damage to the transmission
When inspecting connectors, remember that the
plugs may only be disconnected when they are not
energized.
The transaxle electronics may be destroyed by
static charge. To prevent damage, it must be
ensured that the technician complies with the
corresponding safeguards.
NOTE: Refer to the service literature for an exact
description of these safeguards.
Towing the vehicle
E66463
In general, vehicles with the AW55 transaxle can
be towed. Vehicles must never be towed
backwards.
As a result of the reduced lubrication of the
transaxle during towing, the following must be
remembered:
• The selector lever must be in the 'N' position.
• The maximum towing speed must not exceed 50 km/h.
• The maximum towing distance must not exceed 50 kilometers.
Push-starting the Vehicle
No torque is transmitted when towing or pushing
the vehicle. For this reason, vehicles with an
automatic transaxle cannot and must not be
tow-started or push-started.
Jump-starting the Vehicle
CAUTION: When jump-starting the vehicle
using a jumper lead there may be voltage
peaks. These may destroy the transaxle
electronics.
NOTE: When jump-starting the vehicle, the external
battery must remain connected for several minutes.
The voltage peaks dissipate after a few minutes.
Only then may the external battery be disconnected
without the risk of damage.
Selector Lever Emergency Release
E114512
1
2
3
4
If release of the selector lever lock by means of
the selector lever lock solenoid actuated by the
TCM fails in selector lever position 'P', it is possible
to perform an emergency release.
Procedure:
• Carefully slide a flat screwdriver into the slot (1).
• Turn the screwdriver (2).
• Press the screwdriver downwards to detach the gaiter frame from the trim panel (3).
G1163604en2008.50 Kuga8/2011
307-01- 15
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 15
DESCRIPTION AND OPERATION
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E127362
12
3
Input shaft:
The transmission input shaft rotates clockwise.
Clutch C2 (1) connects the transmission input shaft
with the sun gear. The sun gear rotates clockwise.
The rear planetary gear set rotates
counterclockwise. The front larger planetary gear
set rotates counterclockwise with the rear planetary
gear set as a single unit. The front smaller
planetary gear set rotates clockwise.
Brake B3 (2) blocks the ring gear in
counterclockwise direction. The front and rear
planetary gear carriers are turned clockwise by the
front smaller gear. The primary idler gear rotates
counterclockwise with the front and rear planetary
gear carriers as one unit.
Output shaft:
The secondary idler gear rotates clockwise. The
front annular gear rotates clockwise with the
secondary idler gear as a single unit. The front
planetary gear set rotates clockwise. The sun gear
rotates in counterclockwise direction.
Brake B5 (3) prevents rotation of the rear planetary
gear carrier. The rear annular gear rotates
clockwise. The front planetary gear carrier and the
final drive pinion rotate clockwise with the rearannular gear as one unit. The final drive rotates
counterclockwise.
Engine braking:
The power is transferred directly to the
transmission input shaft without one-way clutch
involvement. Engine braking is thus applied.
NOTE:
The clutch C2 and the brake B3 are only
activated at a speed below 7 km/h (approx. 4.35
mph) when shifting from a forward gear to the
reverse gear.
Service instructions
Towing procedure
Towing is only permitted travelling forwards, at a
maximum speed of 80 km/h and for up 80 km. The
gear selector lever must be in Neutral.
CAUTION: The vehicle must never be
towed backwards under any
circumstances.
G1163605en2008.50 Kuga8/2011
307-01- 41
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 41
DESCRIPTION AND OPERATION
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