Turbo control FORD KUGA 2011 1.G Wiring Diagram Workshop Manual

2011.0 Kuga
Wiring Diagrams
Table of Contents
GROUP 1 General Information
Service InformationGeneral Information 100-00
GROUP 2 Chassis
Brake System
Parking Brake and Actuation 206-05
Hydraulic Brake Actuation 206-06
Power Brake Actuation 206-07
Anti-Lock Control 206-09A
Anti-Lock Control - Stability Assist 206-09B
Anti-Lock Brake System (ABS) and Stability Control 206-09C
Steering System Power Steering 211-02
Steering Column Switches 211-05
GROUP 3 Powertrain
Engine
Engine Cooling 303-03
Fuel Charging and Controls - 2.5L Duratec (147kW/200PS) -
VI5 303-04A
Fuel Charging and Controls - Turbocharger - 2.5L Duratec
(147kW/200PS) - VI5 303-04B
Fuel Charging and Controls - 2.0L Duratorq-TDCi (100kW/136PS) - DW,
Emission Requirements: Stage
IV 303-04C
Fuel Charging and Controls - 2.0L Duratorq-TDCi (100kW/136PS) -
DW/2.0L Duratorq-TDCi
(103kW/140PS) - DW/2.0L Duratorq-TDCi (120kW/163PS) - DW,
Emission Requirements: Stage
V
303-04D
Fuel Charging and Controls - Turbocharger - 2.0L Duratorq-TDCi
(100kW/136PS) - DW, Emission
Requirements: Stage IV 303-04E
Fuel Charging and Controls - Turbocharger - 2.0L Duratorq-TDCi
(100kW/136PS) - DW/2.0L
Duratorq-TDCi (103kW/140PS) -
DW/2.0L Duratorq-TDCi
(120kW/163PS) - DW, Emission
Requirements: Stage V 303-04F
Starting System - 2.5L Duratec (147kW/200PS) - VI5 303-06A
Starting System - 2.0L Duratorq-TDCi (100kW/136PS) - DW, Emission
Requirements: Stage IV 303-06B
Starting System - 2.0L Duratorq-TDCi (100kW/136PS) - DW/2.0L
Duratorq-TDCi (103kW/140PS) -
DW/2.0L Duratorq-TDCi
(120kW/163PS) - DW, Emission
Requirements: Stage V 303-06C
Engine Ignition - 2.5L Duratec (147kW/200PS) - VI5 303-07A
Glow Plug System - 2.0L Duratorq-TDCi (100kW/136PS) - DW, Emission
Requirements: Stage IV 303-07B
Engine Emission Control - 2.5L Duratec (147kW/200PS) - VI5 303-08A
Engine Emission Control - 2.0L Duratorq-TDCi (100kW/136PS) - DW,
Emission Requirements: Stage IV,
2.0L Duratorq-TDCi (DW)
Diesel 303-08B
Evaporative Emissions 303-13
Electronic Engine Controls - 2.5L Duratec (147kW/200PS) -
VI5 303-14A
201

1.0 Kuga
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GROUP
Powertrain
3
SECTION TITLEPAGE
Engine Engine Cooling.................................................................\
..............................................303 -03
Fuel Charging and Controls2.5L Duratec (147kW/200PS) - VI5...................................303-04A
Fuel Charging and Controls - Turbocharger2.5L Duratec (147kW/200PS) - VI5........................................................................\
.................................................... ..303-04B
Fuel Charging and Controls2.0L Duratorq-TDCi (100kW/136PS) - DW, Emission Requirements: Stage IV......................................................................\
.......................303-04C
Fuel Charging and Controls2.0L Duratorq-TDCi (100kW/136PS) - DW/2.0L Duratorq-TDCi (103kW/140PS) - DW/2.0L Duratorq-TDCi (120kW/163PS) - DW,
Emission Requirements: Stage V.......................................................................\
.......303-04D
Fuel Charging and Controls - Turbocharger2.0L Duratorq-TDCi (100kW/136PS) - DW, Emission Requirements: Stage IV......................................................................\
303-04E
Fuel Charging and Controls - Turbocharger2.0L Duratorq-TDCi (100kW/136PS) - DW/2.0L Duratorq-TDCi (103kW/140PS) - DW/2.0L Duratorq-TDCi
(120kW/163PS) - DW, Emission Requirements: Stage V..........................................303-04F
Starting System2.5L Duratec (147kW/200PS) - VI5......................................................303-06A
Starting System2.0L Duratorq-TDCi (100kW/136PS) - DW, Emission Requirements: Stage IV......................................................................\
................................................30 3-06B
Starting System2.0L Duratorq-TDCi (100kW/136PS) - DW/2.0L Duratorq-TDCi (103kW/140PS) - DW/2.0L Duratorq-TDCi (120kW/163PS) - DW, Emission
Requirements: Stage V.......................................................................\
.......................303-06C
Engine Ignition2.5L Duratec (147kW/200PS) - VI5.......................................................303-07A
Glow Plug System2.0L Duratorq-TDCi (100kW/136PS) - DW, Emission Requirements: Stage IV......................................................................\
.......................303-07B
Engine Emission Control2.5L Duratec (147kW/200PS) - VI5........................................303-08A
Engine Emission Control2.0L Duratorq-TDCi (100kW/136PS) - DW, Emission Requirements: Stage IV, 2.0L Duratorq-TDCi (DW) Diesel........................................303-08B
Evaporative Emissions...............................................................\
....................................303-13
Electronic Engine Controls2.5L Duratec (147kW/200PS) - VI5.....................................303-14A
Electronic Engine Controls2.0L Duratorq-TDCi (100kW/136PS) - DW, Emission Requirements: Stage IV......................................................................\
.......................303-14B
Electronic Engine Controls2.0L Duratorq-TDCi (100kW/136PS) - DW/2.0L Duratorq-TDCi (103kW/140PS) - DW/2.0L Duratorq-TDCi (120kW/163PS) - DW,
Emission Requirements: Stage V.......................................................................\
.......303-14C
2011.0 Kuga
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FORD KUGA 2011.0MY WIRING DIAGRAMS

SECTION 303-04B Fuel Charging and Controls -
Turbocharger
— 2.5L Duratec (147kW/200PS) - VI5
VEHICLE APPLICATION:2011.0 Kuga
PA G E
CONTENTS
ELECTRICAL CONNECTORS
303-04B-2
Turbocharger Variable Vane Actuator ........................................................................\
.........
303-04B-2
Wastegate Control Valve ........................................................................\
............................
303-04B-1
Fuel Charging and Controls - Turbocharger
—
2.5L Duratec (147kW/200PS) - VI5
303-04B- 1
.
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Turbocharger Variable Vane Actuator (G1246048)
12
6M5T-14A464-HBA
HARNESS 12A690 TO VARIABLE TURBO CONTROL C790 G
0.75
WKBK-BU91S-RL50CG
0.75WKGN-BU15-RL50C
Wastegate Control Valve (G1226702)
12
6M5T-14A464-GBA
C929
TO TURBO CONTROL VALVE
HARNESS 12A690
15-RL22BUWE0.75
91-RL22GYWE0.75
201

1.0 Kuga
303-04B- 2
Fuel Charging and Controls - Turbocharger
—
2.5L Duratec (147kW/200PS) - VI5
303-04B-2
.
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SECTION 303-04E Fuel Charging and Controls -
Turbocharger
— 2.0L Duratorq-TDCi (100kW/136PS) - DW, Emission Requirements: Stage IV
VEHICLE APPLICATION:2011.0 Kuga
PA G E
CONTENTS
ELECTRICAL CONNECTORS
303-04E-2
Turbocharger Variable Vane Position Sensor .....................................................................
303-04E-1
Fuel Charging and Controls - Turbocharger
—
2.0L Duratorq-TDCi (100kW/136PS) - DW, Emission Requirements: Stage IV
303-04E- 1
.
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Turbocharger Variable Vane Position Sensor (G1230331)
2
3
1
3M5T-14A464-RCA
2 3
1
HARNESS 12A690 TO TURBO POSITION SENSOR(GY) C984 0.50
WKYE-BK7-RL220.50WKBN-YE9-RL22
0.50WKWH-BK8-RL22
201

1.0 Kuga
303-04E-2
Fuel Charging and Controls - Turbocharger
—
2.0L Duratorq-TDCi (100kW/136PS) - DW, Emission Requirements: Stage IV
303-04E-2
.
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SECTION 303-04F Fuel Charging and Controls -
Turbocharger
— 2.0L Duratorq-TDCi (100kW/136PS) - DW/2.0L Duratorq-TDCi (103kW/140PS)
- DW/2.0L Duratorq-TDCi (120kW/163PS) - DW, Emission Requirements: Stage V
VEHICLE APPLICATION: 2011.0 Kuga
PA G E
CONTENTS
ELECTRICAL CONNECTORS
303-04F-2
Turbocharger Variable Vane Actuator ........................................................................\
.........
303-04F-2
Turbocharger Variable Vane Position Sensor .....................................................................
303-04F-1
Fuel Charging and Controls - Turbocharger
—
2.0L Duratorq-TDCi (100kW/136PS) - DW/2.0L Duratorq-TDCi (103kW/140PS) - DW/2.0L Duratorq-TDCi (120kW/163PS) - DW, Emission Requirements: Stage V
303-04F- 1
.
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Turbocharger Variable Vane Actuator (G1336752)
12
6M5T-14A464-KBA
HARNESS 12A690 TO VGT ACTUATOR C1E432 G0.50WK
WH-OG
VE814A
G0.50WK
BU-OG
RE814A
Turbocharger Variable Vane Position Sensor (G1336753)
123
6M5T-14A464-ACA
HARNESS 12A690 TO VGT TURBO POSITION SENSOR C1E825 G0.50WK
VT-BN
VE825A
G
0.50WKYE
LE437A
G
0.50WKGY
RE437A
201

1.0 Kuga
303-04F-2
Fuel Charging and Controls - Turbocharger
—
2.0L Duratorq-TDCi (100kW/136PS) - DW/2.0L Duratorq-TDCi (103kW/140PS) - DW/2.0L Duratorq-TDCi (120kW/163PS) - DW, Emission Requirements: Stage V
303-04F-2
.
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.
TO TURBO I5 PCM
6.0
WA
BK
31-PA1
C281
4
0.50
WA
BU
49-PA6
A4
PWM
A2
GND
PWR A1
INCLUDING
COOLING FAN MOTORM
EC01.
25.0
FWK
RD
30-DA25
PM
(+) (-)
.
B+11B-
GROUND
ENGINE
G8
G1
BATTERY
GROUND
25.0
FLR9
BK
31-BA11A25.0
FLR9
BK
31-BA11
BB03 .
+40AF1
GROUND LEFT FRONT
G37
C90_34
C281
1
C281
2
49-PA6 BU R2 0.50
S
C681
8
R14
.
EC05
15-PA41 GN-BK WA 1.030-PA1 RD WA 6.0
60
WA
RD
30-PA10.50
WA
BK
31-PA41
S1201.0
WA
GN-RD
15-RH10A
+
F9 20A
30-RH10 RD WA 1.0
GROUND
LEFT FRONT G37
2.5
WA
BK
31-DA3
S121
.Cooling Fan Motor
Battery
GROUNDGGROUNDGGGROUNDSUPPORTGROUNDGROUNDGROUNDSUPPORTEJB
GROUNDGGROUNDGGGROUNDFENDER
.Cooling Fan Relay
GROUNDGGROUNDGGGROUNDFENDER
303-14A-2 Engine Control—Vehicles With: 6-Speed Manual Transaxle - M66 AWD, LHD 4WD
2011.0 Kuga (G1313076)
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.CAN LOW
.START LOCK RLY (-)
.TO 150A ALT (LIN)
.A/C CYCLING SWITCH.STOP LAMP SWITCH
.FUEL PUMP RLY CTRL.
.START LOCK RELAY PWR
.FJB (F34 10A)
.FJB (F30 3A)
.FJB (F35 15A)
.CAN HIGH
.KVM (CRANK SIGNAL)
.A/C RELAY COIL
.A/C RELAY PWR
.A/C PRESSURE SNS
.A/C PRESSURE SNS +
.A/C PRESSURE SNS GND
.ENGINE MGT. RLY. COIL
.DECOS (PWM)
.ACCEL. PEDAL SNS
.START LOCK RLY +
.COOLING FAN MODULE
.FJB (F32 10A)
.PJB (F138 10A)
.FJB (F33 10A)
.FJB (F36 10A)
.STARTER MOTOR VIA INLINE TO 14A280
.COOL. AFTER RUN RELAY
.BOTTOM CLUTCH SW.(KV)
CG
2C6431.
E7119-RJ4
BN-RD R2 0.758-RJ4WH-RD R2 0.757753
46
2.5R2
BK-YE
91-RE8B2.5R2
BK-YE
91-RE8A
2
16
21C902+.
E135
31S-RL2 BK-OG R2 0.7550
MAF.
E807
1
3
C840
2
45C591
3
215-RJ22 GN-BU R2 0.75
6118
87
9-RJ22 BN-BU R2 0.758-RJ21 WH-RD R2 0.75
8-RJ20 WH-GN R2 0.75
9-RJ21 BN-RD R2 0.7563
38
73
1.0R2
GN-YE
15-RJ1415-RJ15 GN-BU WE 1.0
49
0.75WE
GY
91S-RJ153C936
1
2
4C9360.75WE
BK-GN
8-RJ15
95
0.75WE
GY
9-RJ15
90
0.50R2
BK-BU
91S-RH927
26
E801
.21
4C644
3
7
79
8-RJ18 WH-BK R2 0.759-RJ18 BN-YE R2 0.75
8-RJ19 WH-RD R2 0.759-RJ19 BN-RD R2 0.75
30
15
55
31
43
15-RN2 GN-BU R2 1.5
VREFVOUTVGRD.
.
E803
486
C92921510.75WE
GY
91-RL22
0.75R2
GY
7-RJ20A
3
10-RJ30 GY R2 0.50
91-RE8C BK-YE R2 2.5
0.75R2
GN-BU
15-RL2
1.5R2
GN-YE
15-RN1
1.0R2
GN-BU
15-RE8A
1.5R2
GN-BU
15-RR4
+.
E731
916892
67+E735
.
0.75R2
BK-YE
91S-RJ14
WH R2 0.75
8-RJ149-RJ14 0.75R2
BNGN-RD R2 0.75
15S-RJ25BK-OG R2 0.75
91S-RJ25
3
4
1C935
5
C935
62
+
E435
.
0.75R2
BK-GN
8-RJ20B9-RJ20 BN R2 0.75
15-RL22 BU WE 0.75
91S-RH5 BK-BU R2 0.50
49-PA6 BU R2 0.508
30-RE8 RD R2 0.50
0.75R2
GN-WH
15S-LG23
5
S54
27
54
41
9
0.50R2
BK-YE
31S-FA1110
5-EC7H BU-RD R2 0.50
4-EC7H GY-RD R2 0.50
31S-BB16 BK-RD R2 0.50
49-RE31 BU-YE R2 0.7521
1.0R2
GN-BU
15-RE8
1.0R2
GN-YE
15S-FA6
H302
S53
6.0R2
BK
91-RN2A
C9521
0.50R2
YE-VT
7-FA8831
0.50R2
WH-VT
8-FA88
0.50R2
BN-WH
9-FA88
51
53
250.50R2
GN-OG
15S-FA17
E801
.
0.50R2
GN-BU
50-RE817
R2
GY
50-BB12A 2.5C1201
118 REF. SUPPLY VOLTAGE 2
GND
204
227 ENG. MANAGEMENT REL.
251 A/C LINEAR SNS HIGH PRESSURE
151 TURBO CTRL. VALVE (PWM)
FUEL PRESSURE SNS (DECOS) 189115GND
CAM SNS 1, INTAKE 183136GND
163 MAF / HFM5
INLET AIR TEMP. SNS (TMAP)
187
213 P/N POSITION (AT) / CLUTCH SWITCH (MT)
208 ENGINE COOLANT FAN (PWM)
B+ PWR
216
138 GND
131 KNOCK SNS 2 -KNOCK SNS 2 +
179
FLYWHEEL SNS +
177
VVT SOL. 1 INTAKE (PWM) 172
FLYWHEEL SNS -
153
STARTER REL. LOW-SIDE DRIVER
209
MANIFOLD AIR PRESSURE SNS 1
186
REF. SUPPLY VOLTAGE 2 144
FUEL PUMP RELAY
127
221 FUEL PUMP CTRL. (DECOS, PWM)
146 LIN
141
FUEL TEMP SNS (DECOS)
101
INJECTOR VALVE A
206 GND
THROTTLE VALVE DC MOTOR - 175
109
OIL PRESSURE SWITCH
203 PCM PWR (IGN)
161 GND
GND
202
150 EVAP. PURGE CTRL. VALVE (PWM)
KNOCK SNS 1 -
155KNOCK SNS 1 +
107
REF. SUPPLY VOLTAGE 2
143OXYGEN SNS 1 HEATING
149
195 OXYGEN SNS HEATINGOXYGEN SNS 1 SIGNAL +
190
OXYGEN SNS 1 HEATING
173192 OXYGEN SNS TRIM. CURRENT168 OXYGEN SNS PUMP CURRENT191 OXYGEN SNS SIGNAL -167 OXYGEN SNS SIGNAL +
210 A/C REL.
215 IGN (FROM IGN2 REL. / KEYLESS GO)
217 CRANK SIGNAL (50-) (FROM KVM)
241 HS CAN LOW
254 HS CAN HIGH
A/C PRESSURE SNS GND
253
REF. SUPPLY VOLTAGE 2
231
A/C LOW PRESSURE CYCLING SW.
225
STOP LAMP SWITCH
230
226 ACCEL. PEDAL SNS (PWM)
PCM PWR (IGN)
205
125
INJECTOR VALVE B
102
INJECTOR VALVE C
126
INJECTOR VALVE D
103
INJECTOR VALVE E
IGNITION PWR A 181
IGNITION PWR B 157
IGNITION PWR C 182
IGNITION PWR D 158
IGNITION PWR E 134
VVT SOL. 2 EXHAUST (PWM) 196
REF. SUPPLY VOLTAGE 3 116
117
REF. SUPPLY VOLTAGE 3CAM SNS 2, EXHAUST 159137GND
GND 114REF. SUPPLY VOLTAGE 1 119THROTTLE VALVE DC MOTOR + 174188
THROTTLE VALVE POS. SNS 2THROTTLE VALVE POS. SNS 1 165
ENGINE COOLANT TEMP SNS 1 142112GND
STARTER REL. HIGH-SIDE DRIVER
211
257 HS CAN HIGH
244 HS CAN LOW
105 BACKUP LAMP RELAY (AT)
COOL AFTER RUN CTRL.
245
CAN
ENGINE CONTROL MODULE PCM HAS TWO CONNECTORS
NUMBERS STARTING WITH:
1XX REFLECT C680
2XX REFLECT C681
E108 .
0.50WE
WH-RD
8-EE11
C87346
110.50R2
GY-VT
50-BB13
1
C90
C90 4
C905
C908
C90 9
C9011
C9012
C9013
14
C90
C90 15
C9016
17
C90
18
C90
19
C90
C90 29
C9032
C90 21
C9024
C9028
31
C90
C90 34
C9036
C90 37
C9040
C9041
G57C
LEFT FRONT
GROUND
15-RE17 GN-YE R2 0.50
45C90
70.50R2
BK-RD
91S-FC14
1391S-PG17 BK-BU R2 0.50C90 6
.Crankshaft Position (CKP) Sensor
.Evaporative Emission Canister Purge Valve
RJBN BUR.Mass Air Flow (MAF) Sensor
.Knock Sensor (KS)
28RJ28RJ2RJVREF7RVREFEF.
Manifold Absolute Pressure (MAP) Sensor
2.Catalyst Monitor Sensor
.
Heated Oxygen Sensor (HO2S)
.
Wastegate Control Valve
Clutch and Clutch Field Coil
.Knock Sensor (KS)
.Powertrain Control Module (PCM)GROUNDGGROUNDGGGROUNDFENDER 2
303-14A-4 Engine Control—Vehicles With: 6-Speed Manual Transaxle - M66 AWD, LHD 4WD
2011.0 Kuga (G1313076)
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