fluid FORD KUGA 2011 1.G Workshop Manual

2. CAUTION: Make sure that fluid level isto the MAX mark.
Refer to: Specifications (303-01 Engine - 2.5L
Duratec (147kW/200PS) - VI5, Specifications).
Material: Engine Oil - 5W-30 (WSS-M2C913-C) engine oil
E116204
3. Refer to: Door Window Motor Initialization
(501-11 Glass, Frames and Mechanisms,
General Procedures).
G1079022en2008.50 Kuga8/2011
303-01- 55
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
55
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Oil Cooler(21 764 0)
General EquipmentFluid Container
Hose Clamp(s)
Materials
Specification
Name
WSS-M2C913-C
Engine Oil - 5W-30
Removal
NOTE: Removal steps in the procedure may
contain installation details.
1.
E65299
2.
WARNING: Be prepared to collect
escaping fluid.
General Equipment: Fluid Container
Torque: 38
Nm
E92766
3.
WARNING: Be prepared to collect
escaping fluids.
1. General Equipment: Fluid Container General Equipment: Hose Clamp(s)
2. Torque: 3
Nm
3. Torque: 17Nm
E74103
x4
x2
2
3
1
Installation
1. To install, reverse the removal procedure.
2. CAUTION: Make sure that fluid level is to the MAX mark.
Refer to: Specifications (303-01 Engine - 2.5L
Duratec (147kW/200PS) - VI5, Specifications).
Material: Engine Oil - 5W-30 (WSS-M2C913-C) engine oil
3. Refer to: Cooling System Draining and Vacuum
Filling (303-03 Engine Cooling, General
Procedures).
G834604en2008.50 Kuga8/2011
303-01- 58
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
58
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38.
E67408
39. WARNING: Be prepared to collectescaping fluid.
Refer to: Quick Release Coupling (310-00 Fuel
System - General Information, General
Procedures).
E68475
41. General Equipment: Hose Clamp
Remover/Installer
E112312
42.
E66479
G1191240en2008.50 Kuga8/2011
303-01- 70
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
70
REMOVAL
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E65220
37.40.
E68429

59. WARNING: Be prepared to collectescaping fluid.General Equipment: Hose Clamp
Remover/Installer
3.
E112533
1
3
x3
2
x34
x3
2
4x3
60.
E112534
1
2
61. WARNING: Be prepared to collect
escaping fluid.
General Equipment: Cable Ties
G1191240en2008.50 Kuga8/2011
303-01- 74
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
74
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Cooling System Draining and Vacuum Filling
General EquipmentCooling System Vacuum Tester and Refiller
Fluid Container
Materials
Specification
Name
WSS-M97B44-D / 4U7J-
19544-AA2A
Antifreeze Super Plus
Premium
Draining
WARNING: When releasing the cooling
system pressure, cover the coolant
expansion tank cap with a thick cloth.
NOTE: Always follow the manufacturer's
instructions when handling the equipment.
1. Refer to: Engine Cooling System Health and
Safety Precautions (100-00 General
Information, Description and Operation).
2.
Release the cooling system pressure by slowly
turning the coolant expansion tank cap between
2 and 3 turns.
E68577
3. Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
4.
E65299
5.
WARNING: Be prepared to collect
escaping fluid.
Use a suitable coolant hose to drain the coolant.
General Equipment: Fluid Container
Loosen: 4
turn(s)
E97501
6.
E97501
G1034816en2008.50 Kuga8/2011
303-03- 5
Engine Cooling
303-03- 5
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7.
E65299
Evacuating and Filling
1.If the cooling system was completely drained,
fill the fluid container with the full cooling
•
system fill capacity plus 0.5L of additional
coolant.
Material: Antifreeze Super Plus Premium(WSS-M97B44-D / 4U7J-19544-AA2A)
antifreeze
• If the cooling system was partially drained, fill the fluid container with the removed and
spilled amount of coolant plus 1.0L of
additional coolant. When in doubt always use
the full cooling system fill capacity plus 0.5L
of additional coolant.
Material: Antifreeze Super Plus Premium(WSS-M97B44-D / 4U7J-19544-AA2A)
antifreeze
2. General Equipment: Cooling System Vacuum
Tester and Refiller
•
3. Close the valve, install the coolant hose and
place it into the fluid container.
1.
2. Close the valve and connect the compressed
air hose.
E96739
1
2
4. Open the valve until the specificied vacuum
is achieved.
2.
E967406-10 bar
1
-0.85 bar
-0.95 bar2
5.
Open the valve until the coolant reservoir
fluid level is at the MAX mark.
•
• If no coolant is visible in the coolant
expansion tank, add 2.0L of coolant to the
fluid container and repeat the evacuating and
filling procedure.
E96741
6.
E68577
G1034816en2008.50 Kuga8/2011
303-03- 6
Engine Cooling
303-03- 6
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Action
Possible Sources
Symptom
• Check the fuel system pres-sure.
• Low fuel system pressure.
• Poor starting
• CHECK the system for fuelleak(s). REPAIR the system as
necessary.
• Fuel system leak.
• INSPECT the fuel system.INSTALL new components as
necessary. TEST the system
for normal operation.
• Fuel system restriction.
• INSTALL a new fuel filter.
• Fuel filter blocked.
• INSTALL a new air cleanerelement.
• Air cleaner element blocked.
• INSTALL a new engine oil filterand engine oil.
• Incorrect engine oil.
• DRAIN and REFILL the powersteering system with the correct
fluid.
REFER to: Power Steering
System Filling (211-00
Steering System - General
Information, General Proced-
ures).
• Incorrect power steering fluid.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• CKP sensor.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• Engine coolant temperature
(ECT) sensor.
• 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 injector(s).
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• Fuel rail fuel pressure sensor.
G1183441en2008.50 Kuga8/2011
303-04A-
6
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 6
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9.Torque: 10Nm
E64166
10. To r q u e : 2Nm1.
4.
WARNING: Be prepared to collect
escaping fluid.
Torque: 10
Nm
x5
x24
2
3
1
E93083
Installation
1. To install, reverse the removal procedure.
2. Refer to: Door Window Motor Initialization
(501-11 Glass, Frames and Mechanisms,
General Procedures).
G1079057en2008.50 Kuga8/2011
303-04A- 25
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 25
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Air conditioning (A/C) pressure sensor
E74157
The A/C pressure sensor is installed on the
high-pressure side of the A/C. The input voltage is
5V, the output voltage is between 0.5V and 4.5V
depending on the cryogenic fluid pressure. When
the cryogenic fluid pressure is low, the output
voltage is also low.
Voltage (Volts)
Pressure (bar)
3.9 - 4.0
Approx. 30
3.3 - 3.4
Approx. 25
2.7 - 2.8
Approx. 20
2.1 - 2.2
Approx. 15
1.6 - 1.7
Approx. 10
1.0 - 1.1
Approx. 5
0.5 - 0.7
Approx. 1
Throttle control unit
E74167
1
2
Description
Item
TP sensor
1
Electric motor
2
G1021908en2008.50 Kuga8/2011
303-14- 30
Electronic Engine Controls— 2.5L Duratec (147kW/200PS) - VI5303-14-
30
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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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