FORD KUGA 2011 1.G Workshop Manual
Manufacturer: FORD, Model Year: 2011, Model line: KUGA, Model: FORD KUGA 2011 1.GPages: 2057
Page 1511 of 2057
Steering Column Switches – Overview
Switch unit, steering column
E98629
1
2
3
4
5
Description
Item
Left-hand switch, steering column
1
Switch unit carrier, steering column
2
Right-hand switch, steering column
3Description
Item
Steering wheel rotation sensor
Refer to: Anti-Lock Control - Stability
Assist (206-09 Anti-Lock Control -
Stability Assist, Description and
Operation).
4
Clockspring
5
Clockspring
The clockspring is designed to carry signals
between the RCM and the driver air bag module.
The clockspring is installed on the steering column,
and consists of fixed and moving parts connected
by a coiled Mylar tape with internal conducting
tracks. The Mylar tape is able to 'wind up' and
'unwind' as the steering wheel is rotated,
maintaining electrical contact at all times between
the RCM and the driver air bag module. During removal and installation or renewal of the
clockspring, pay attention to the following:
• Before installation of the clockspring, it must be
aligned according to the installation instructions.
• Make sure that the vehicle electrical system is fully depowered and no other power source is
connected.
• Secure the clockspring rotor with adhesive tape to the clockspring outer.
• The clockspring rotor must not be turned during removal or installation of the steering wheel or
the steering column switch unit.
G1030755en2008.50 Kuga8/2011
211-05- 3
Steering Column Switches
211-05- 3
DESCRIPTION AND OPERATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
Page 1512 of 2057
Steering Column Lock Module
General EquipmentFord approved diagnostic tool
Removal
NOTE: Removal steps in this procedure may
contain installation details.
1.
E99717
1
2
3
2. Refer to: Floor Console (501-12 Instrument
Panel and Console, Removal and Installation).
3.
E99718
4.
E99719
5.
E99720
6.
E99721
x2
Installation
1. To install, reverse the removal procedure.
G1058706en2008.50 Kuga8/2011
211-05- 4
Steering Column Switches
211-05- 4
REMOVAL AND INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
Page 1513 of 2057
2.Initialize the Steering Column Lock Module.
General Equipment: Ford approved diagnostic
tool
G1058706en2008.50 Kuga8/2011
211-05- 5
Steering Column Switches
211-05- 5
REMOVAL AND INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
Page 1514 of 2057
Steering Column Multifunction Switch LH
Removal
NOTE:Removal steps in this procedure may
contain installation details.
1.
E91152
2.
E99639
1
2
3.
E99649
Installation
1. To install, reverse the removal procedure.
G1058704en2008.50 Kuga8/2011
211-05- 6
Steering Column Switches
211-05- 6
REMOVAL AND INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
Page 1515 of 2057
Steering Column Multifunction Switch RH
Removal
NOTE:Removal steps in this procedure may
contain installation details.
1.
E91152
2.
E99639
1
2
3.
E99650
Installation
1. To install, reverse the removal procedure.
G1058705en2008.50 Kuga8/2011
211-05- 7
Steering Column Switches
211-05- 7
REMOVAL AND INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
Page 1516 of 2057
* 5 2 8 3
3 R Z H U W U D L Q
6 ( & 7 , 2 1 7 , 7 / ( 3 $ * (
( Q J L Q H ( Q J L Q H 6 \ V W H P * H Q H U D O , Q I R U P D W L R Q
( Q J L Q H / ' X U D W H F N : 3 6 9 ,
( Q J L Q H & R R O L Q J
) X H O & K D U J L Q J D Q G & R Q W U R O V / ' X U D W H F N : 3 6 9 , $
) X H O & K D U J L Q J D Q G & R Q W U R O V 7 X U E R F K D U J H U / ' X U D W H F N : 3 6 9 , %
$ F F H V V R U \ ' U L Y H / ' X U D W H F N : 3 6 9 ,
6 W D U W L Q J 6 \ V W H P / ' X U D W H F N : 3 6 9 ,
( Q J L Q H , J Q L W L R Q / ' X U D W H F N : 3 6 9 ,
( Q J L Q H ( P L V V L R Q & R Q W U R O / ' X U D W H F N : 3 6 9 ,
, Q W D N H $ L U ' L V W U L E X W L R Q D Q G ) L O W H U L Q J / ' X U D W H F N : 3 6 9 ,
( Y D S R U D W L Y H ( P L V V L R Q V
( O H F W U R Q L F ( Q J L Q H & R Q W U R O V / ' X U D W H F N : 3 6 9 ,
$ X W R P D W L F 7 U D Q V P L V V L R Q 7 U D Q V D [ O H $ X W R P D W L F 7 U D Q V P L V V L R Q 7 U D Q V D [ O H 9 H K L F O H V : L W K 6 S H H G $ X W R P D W L F 7 U D Q V D [ O H $ : $ : '
7 U D Q V P L V V L R Q 7 U D Q V D [ O H & R R O L Q J 9 H K L F O H V : L W K 6 S H H G $ X W R P D W L F 7 U D Q V D [ O H $ : $ : ' 6 S H H G $ X W R P D W L F 7 U D Q V D [ O H ' & 7
$ X W R P D W L F 7 U D Q V P L V V L R Q 7 U D Q V D [ O H ( [ W H U Q D O & R Q W U R O V 9 H K L F O H V : L W K 6 S H H G $ X W R P D W L F 7 U D Q V D [ O H $ : $ : ' 6 S H H G $ X W R P D W L F 7 U D Q V D [ O H
' & 7
7 U D Q V I H U & D V H 9 H K L F O H V : L W K 6 S H H G $ X W R P D W L F 7 U D Q V D [ O H $ : $ : ' 6 S H H G $ X W R P D W L F 7 U D Q V D [ O H ' & 7
( [ K D X V W 6 \ V W H P ( [ K D X V W 6 \ V W H P / ' X U D W H F N : 3 6 9 ,
) X H O 6 \ V W H P * H Q H U D O , Q I R U P D W L R Q ) X H O 6 \ V W H P * H Q H U D O , Q I R U P D W L R Q
) X H O 7 D Q N D Q G / L Q H V
$ F F H O H U D W L R Q & R Q W U R O
6 S H H G & R Q W U R O
. X J D
TO MODEL INDEX
BACK TO MAIN INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
Page 1517 of 2057
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
.
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
Page 1518 of 2057
Engine
Special Tool(s) / General EquipmentSocket, Spark Plug
303-499
ES21202
Compression Test Adapter
303-1056
E42936
Ford diagnostic equipment
Materials
Specification
Name
WSK-M2G349-A7
Adhesive - Loctite 243 1. Verify the customer concern by operating the
system
2. Visually inspect for obvious signs of mechanical or electrical damage.
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible)
before proceeding to the next step.
4. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart.
Visual Inspection Chart
Electrical
Mechanical
– Fuse(s)
– Loose or corrodedconnector(s)
– Control module
– Damaged or worn switch(es)
– Coolant leaks
– Oil leaks
– Fuel system leaks
– Visibly damaged or
worn parts
– Loose or missing nuts or bolts
Action
Possible Sources
Symptom
• CHECK for evidence of oilleaks on components. Use an
ultraviolet (UV) leak tester if an
oil leak is not evident. INSTALL
new gaskets or components as
required.
• Oil leaks on components that
are either coated in oil them-
selves or on components local
to them.
• Loss of oil
• CHECK the coolant expansiontank for a film of oil on the
coolant surface. INSTALL a
new oil cooler or oil cooler
gasket.
• Internal or external leak at the
oil cooler.
• INSTALL a new crankshaftseal.
• Leak at the crankshaft seal.
• CHECK for cracks in oil-carrying components of the
basic engine by means of a UV
leak test. INSTALL new
components or seals as
necessary.
• Leaks from oil carrying
components or basic engine.
• DETERMINE the last type ofengine oil used and compare
with the specification. Change
the engine oil to the specifica-
tion.
• Use of the wrong type of engine
oil.
• Oil consumption
G1055128en2008.50 Kuga8/2011
303-00-
2
Engine System - General Information
303-00- 2
DIAGNOSIS AND TESTING
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
Page 1519 of 2057
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
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
Page 1520 of 2057
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
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL