Index FORD KUGA 2011 1.G Workshop Manual

2
1
3
4
5
E63662
Description
Item
Generator
1
Accessory drive belt tensioner
2
A/C compressor
3
A/C drive belt tensioner
4
Crankshaft pulley
5
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Accessory Drive— 2.5L Duratec (147kW/200PS) - VI5303-05-
3
DESCRIPTION AND OPERATION
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Accessory Drive
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanicaldamage.
Visual Inspection Chart
Mechanical
– Damaged or contaminated accessory drive belt or air conditioning (A/C) compressor belt
– Damaged or contaminated pulley(s)
– Incorrect accessory drive belt or A/C compressor belt
– Incorrect fitment of the accessory drive belt or A/C compressor belt
– Accessory drive belt tensioner
– Accessory drive belt idler pulley
– Generator
– A/C compressor
– A/C compressor belt tensioner
– Pulley(s)
– Loose hardware
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible)
before proceeding to the next step.
Accessory Drive Belt Concerns
CAUTION: Do not lubricate the accessory
drive belt, accessory drive belt tensioner(s)
or idler pulley(s) as potential damage to
the accessory drive belt material
construction, accessory drive belt
tensioner damping mechanism, accessory
drive belt tensioner pulley bearing and idler
pulley(s) bearing may occur.
NOTE: All the diagnosis and testing information
contained within this procedure can be used for
the accessory drive belt and the A/C compressor
belt.
Cracking
Accessory drive belts are made from rubber which
hardens with time and can develop cracks. As the
accessory drive belt runs on the back of some of
the pulleys, the cracks are opened up. Small cracks
are not considered to be a failure of the accessory drive belt. Only if the crack is deep enough to reach
the bottom of the groove to expose the cord or any
chunks are found to be missing from the accessory
drive belt, is the accessory drive belt condition
considered to be unacceptable.
1. Check the accessory drive belt for cracks. If the
damage exceeds the acceptable limit, install a
new accessory drive belt.
REFER to: Accessory Drive Belt (303-05
Accessory Drive - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
and/or
REFER to: Air Conditioning (A/C) Compressor
Belt (303-05 Accessory Drive - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
Chunking
Chunking describes the condition where long
lengths of rubber become detached from the ribs
of the accessory drive belt. This is considered to
be a failure of the accessory drive belt.
MPZ9632071
2. Check the accessory drive belt for damage. If any chunks are found to be missing, install a
new accessory drive belt.
REFER to: Accessory Drive Belt (303-05
Accessory Drive - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
and/or
REFER to: Air Conditioning (A/C) Compressor
Belt (303-05 Accessory Drive - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
G1183443en2008.50 Kuga8/2011
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Accessory Drive— 2.5L Duratec (147kW/200PS) - VI5303-05-
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DIAGNOSIS AND TESTING
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Pilling
Pilling is dust that forms in between the ribs of the
accessory drive belt from rubber that is worn off
the accessory drive belt when it is new. There may
also be loose particles left on the accessory drive
belt during the manufacturing process. These are
worn off and form into small balls of rubber that
then get trapped in the grooves of the accessory
drive belt. This condition will usually clear itself
within 4800 km - 8000 km (3000 miles - 5000 miles)
of normal driving.
VUE0037805
3. Check the accessory drive belt for pilling. Thecondition of the accessory drive belt should be
compared against the illustration.
1. Small scattered pills. Not considered a concern. No action required.
2. Small scattered pills. Not considered a concern. No action required.
3. Longer pills up to 50% of the rib height. Possible noise concern. INSTALL a new
accessory drive belt if noise is apparent.
REFER to: Accessory Drive Belt (303-05
Accessory Drive - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation). and/or
REFER to:
Air Conditioning (A/C)
Compressor Belt (303-05 Accessory Drive
- 2.5L Duratec (147kW/200PS) - VI5,
Removal and Installation).
4. Longer pills up to 50% of the rib height. Possible noise concern. INSTALL a new
accessory drive belt if noise is apparent.
REFER to: Accessory Drive Belt (303-05
Accessory Drive - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
and/or
REFER to: Air Conditioning (A/C)
Compressor Belt (303-05 Accessory Drive
- 2.5L Duratec (147kW/200PS) - VI5,
Removal and Installation).
5. Heavy deposits in the grooves. Possible noise and stability concern. INSTALL a new
accessory drive belt.
REFER to: Accessory Drive Belt (303-05
Accessory Drive - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
and/or
REFER to: Air Conditioning (A/C)
Compressor Belt (303-05 Accessory Drive
- 2.5L Duratec (147kW/200PS) - VI5,
Removal and Installation).
6. Heavy deposits in the grooves. Possible noise and stability concern. INSTALL a new
accessory drive belt.
REFER to: Accessory Drive Belt (303-05
Accessory Drive - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
and/or
REFER to: Air Conditioning (A/C)
Compressor Belt (303-05 AccessoryDrive
- 2.5L Duratec (147kW/200PS) - VI5,
Removal and Installation).
Incorrect fitment
Accessory drive belt noise can be generated by
the accessory drive belt being incorrectly fitted on
the pulley as shown in the following illustration.
Make sure that all the V grooves on the accessory
drive belt contact correctly with the pulley.
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Accessory Drive— 2.5L Duratec (147kW/200PS) - VI5303-05-
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VUE0037806
4. If the cause is not visually evident, verify thesymptom and refer to the Symptom Chart.
Symptom Chart
Action
Possible Sources
Symptom
• CHECK the system with theengine running and the
accessory drive belt removed
(only run the engine for a very
short period). If a noise is
apparent, the cause is not the
accessory drive system. If a
noise is not apparent, the
cause is the accessory drive
system. CHECK where the
noise is coming from. Use a
stethoscope or other listening
device to determine the source
of the noise. INSTALL new
components as necessary.
TEST the system for normal
operation.
• Accessory drive system
• Accessory drive belt noise
• CHECK the accessory drivebelt is correctly installed in the
pulley grooves. INSTALL a new
accessory drive belt as neces-
sary.
REFER to: Accessory Drive
Belt (303-05 Accessory Drive
- 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
and/or
REFER to: Air Conditioning
(A/C) Compressor Belt (303-
05 Accessory Drive - 2.5L
Duratec (147kW/200PS) -
VI5, Removal and Installa-
tion).
TEST the system for normal
operation.
• Accessory drive belt incorrectly
installed.
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Accessory Drive— 2.5L Duratec (147kW/200PS) - VI5303-05-
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DIAGNOSIS AND TESTING
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Action
Possible Sources
Symptom
• CHECK the pulley(s) fordamage, freedom of rotation,
stone entrapment and align-
ment. INSTALL new compon-
ents as necessary. TEST the
system for normal operation.
• Pulley(s).
• CHECK the accessory drivebelt for contamination or
damage. RECTIFY the source
of the leak and INSTALL a new
accessory drive belt.
REFER to: Accessory Drive
Belt (303-05 Accessory Drive
- 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
and/or
REFER to: Air Conditioning
(A/C) Compressor Belt (303-
05 Accessory Drive - 2.5L
Duratec (147kW/200PS) -
VI5, Removal and Installa-
tion).
TEST the system for normal
operation.
• Lubricant or other contamina-
tion.
• CHECK the accessory drivebelt tensioner for correct opera-
tion, damage or contamination.
REFER to the Accessory Drive
Belt Tensioner Component Test
in this procedure. INSTALL a
new accessory drive belt
tensioner as necessary.
REFER to: Accessory Drive
Belt Tensioner (303-05
Accessory Drive - 2.5L
Duratec (147kW/200PS) -
VI5, Removal and Installa-
tion).
or
REFER to: Air Conditioning
(A/C) Compressor Belt
Tensioner (303-05 Accessory
Drive - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
TEST the system for normal
operation.
• Accessory drive belt tensioner
worn, damaged or contamin-
ated with oil.
NOTE:
Squeal is defined as a
continuous shriek, most noticeable
when the engine is being acceler-
ated or with electrical load.
• Accessory drive belt squeal
G1183443en2008.50 Kuga8/2011
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Accessory Drive— 2.5L Duratec (147kW/200PS) - VI5303-05-
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DIAGNOSIS AND TESTING
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Action
Possible Sources
Symptom
• REMOVE the accessory drivebelt.
REFER to: Accessory Drive
Belt (303-05 Accessory Drive
- 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
and/or
REFER to: Air Conditioning
(A/C) Compressor Belt (303-
05 Accessory Drive - 2.5L
Duratec (147kW/200PS) -
VI5, Removal and Installa-
tion).
INSPECT the idler pulley(s) for
surface finish. INSTALL a new
idler pulley(s) as necessary.
TEST the system for normal
operation.
• Poor surface finish on
accessory drive belt idler pulley
flat surface(s).
NOTE:
Whine is defined as a
continuous noise at the same
frequency, generally associated
with plastic pulleys.
• Accessory drive belt whine
• REMOVE the accessory drivebelt.
REFER to: Accessory Drive
Belt (303-05 Accessory Drive
- 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
and/or
REFER to: Air Conditioning
(A/C) Compressor Belt (303-
05 Accessory Drive - 2.5L
Duratec (147kW/200PS) -
VI5, Removal and Installa-
tion).
INSPECT the idler pulley(s) for
smooth rotation. INSTALL a
new idler pulley(s) as neces-
sary. TEST the system for
normal operation.
• Accessory drive belt idler pulley
bearing failure.
• CHECK that the accessorydrive belt is running centrally
on the flat pulleys. TEST the
system for normal operation.
• CHECK the pulleys for excessive end float and bent
flanges.
• With the engine running at idle, use a stethoscope to identify
the source of the noise.
INSTALL new components as
necessary. TEST the system
for normal operation.
• Pulley misalignment (usually
evident at idle).
NOTE:
Chirp is defined as a twit-
tering noise, often intermittent
• Accessory drive belt chirp
G1183443en2008.50 Kuga8/2011
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Accessory Drive— 2.5L Duratec (147kW/200PS) - VI5303-05-
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DIAGNOSIS AND TESTING
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Action
Possible Sources
Symptom
• CHECK the accessory drivebelt tensioner for correct opera-
tion or damage. REFER to the
Accessory Drive Belt Tensioner
Component Test in this
procedure. INSTALL a new
accessory drive belt tensioner
as necessary.
REFER to: Accessory Drive
Belt Tensioner (303-05
Accessory Drive - 2.5L
Duratec (147kW/200PS) -
VI5, Removal and Installa-
tion).
or
REFER to: Air Conditioning
(A/C) Compressor Belt
Tensioner (303-05 Accessory
Drive - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
TEST the system for normal
operation.
• Accessory drive belt tensioner
hitting the end stops.
NOTE:
Rattle is defined as a
metallic knocking noise
• Accessory drive belt rattle
• CHECK the components orhardware for correct installation
and tighten as necessary.
TEST the system for normal
operation.
• Loose components or hard-
ware.
Component Tests
Accessory Drive Belt Tensioner - Static
Check
The accessory drive belt tensioner may be checked
statically as follows:
1. Inspect the area surrounding the accessorydrive belt tensioner for lubricant or other
contamination. Rectify any leaks before
installing a new accessory drive belt tensioner.
If the accessory drive belt tensioner is
contaminated, do not attempt to clean it as the
damping mechanism inside may be damaged.
INSTALL a new accessory drive belt tensioner
as necessary.
REFER to: Accessory Drive Belt Tensioner
(303-05 Accessory Drive - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation). or
REFER to:
Air Conditioning (A/C) Compressor
Belt Tensioner (303-05 Accessory Drive - 2.5L
Duratec (147kW/200PS) - VI5, Removal and
Installation).
TEST the system for normal operation.
2. Detach the accessory drive belt in the area of the accessory drive belt tensioner.
3. NOTE: The accessory drive belt tensioner has a damping feature, which is usually a
friction device, therefore some friction within
the system is normal.
Using the correct tool, move the accessory drive
belt tensioner from its relaxed position through
its full stroke and back to the relaxed position
to make sure there is no excessive stick, grab
or bind, and to make sure there is tension on
the accessory drive belt tensioner spring.
4. Rotate the accessory drive belt tensioner pulley and check for damage, freedom of rotation and
G1183443en2008.50 Kuga8/2011
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Accessory Drive— 2.5L Duratec (147kW/200PS) - VI5303-05-
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DIAGNOSIS AND TESTING
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alignment. INSTALL a new accessory drive belt
tensioner as necessary.
REFER to:Accessory Drive Belt Tensioner
(303-05 Accessory Drive - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
or
REFER to: Air Conditioning (A/C) Compressor
Belt Tensioner (303-05 Accessory Drive - 2.5L
Duratec (147kW/200PS) - VI5, Removal and
Installation).
TEST the system for normal operation.
5. If the accessory drive belt tensioner meets the above criteria, proceed to test the accessory
drive belt tensioner dynamically. If the accessory
drive belt tensioner does not meet the above
criteria, INSTALL a new accessory drive belt
tensioner.
REFER to: Accessory Drive Belt Tensioner
(303-05 Accessory Drive - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
or
REFER to: Air Conditioning (A/C) Compressor
Belt Tensioner (303-05 Accessory Drive - 2.5L
Duratec (147kW/200PS) - VI5, Removal and
Installation).
TEST the system for normal operation.
Accessory Drive Belt Tensioner - Dynamic
Check
The accessory drive belt tensioner may be checked
dynamically as follows:
1. With the engine running, observe the accessory drive belt tensioner movement. The accessory
drive belt tensioner should move (respond)
when the engine is accelerated rapidly or when
the A/C clutch cycles ON and OFF (the degree
of movement can be up to 4 mm). If the
accessory drive belt tensioner movement is not
constant without engine acceleration or A/C
clutch cycling, a pulley or shaft is possibly bent,
out of round, or the damping mechanism inside
the accessory drive belt tensioner may be
damaged. INSTALL a new accessory drive belt
tensioner as necessary.
REFER to: Accessory Drive Belt Tensioner
(303-05 Accessory Drive - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation). or
REFER to:
Air Conditioning (A/C) Compressor
Belt Tensioner (303-05 Accessory Drive - 2.5L
Duratec (147kW/200PS) - VI5, Removal and
Installation).
TEST the system for normal operation.
2. Excessive accessory drive belt rideout (uneven depth of grooves in the accessory drive belt)
may cause excessive accessory drive belt
tensioner movement. Check the condition by
installing a new accessory drive belt.
REFER to: Accessory Drive Belt (303-05
Accessory Drive - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
and/or
REFER to: Air Conditioning (A/C) Compressor
Belt (303-05 Accessory Drive - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
TEST the system for normal operation.
G1183443en2008.50 Kuga8/2011
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Accessory Drive— 2.5L Duratec (147kW/200PS) - VI5303-05-
10
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Accessory Drive Belt Tensioner(21 569 0)
Removal
NOTE:Removal steps in this procedure may
contain installation details.
1. Remove the air conditioning (A/C) compressor
belt tensioner.
Refer to: Air Conditioning (A/C) Compressor
Belt Tensioner (303-05 Accessory Drive - 2.5L
Duratec (147kW/200PS) - VI5, Removal and
Installation).
2. Remove the accessory drive belt.
Refer to: Accessory Drive Belt (303-05
Accessory Drive - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
3. Torque: 45
Nm
E65525
Installation
1. NOTE: Make sure that the belt tensioner is
aligned to the belt tensioner bracket.
To install, reverse the removal procedure.
E65526
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Accessory Drive— 2.5L Duratec (147kW/200PS) - VI5303-05-
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REMOVAL AND INSTALLATION
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Accessory Drive Belt(21 567 0)
Removal
1.Remove the air conditioning (A/C) compressor
belt.
Refer to: Air Conditioning (A/C) Compressor
Belt (303-05 Accessory Drive - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
2.
E64287
2
1
Installation
1. To install, reverse the removal procedure.
G543728en2008.50 Kuga8/2011
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Accessory Drive— 2.5L Duratec (147kW/200PS) - VI5303-05-
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REMOVAL AND INSTALLATION
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