303-03 FORD KUGA 2011 1.G User Guide

Engine Cooling
Special Tool(s) / General EquipmentPressure Tester, Cooling
System
303-396 (24-001 A)
IA24001A
Adaptor for 303-396
303-396-09
E55030
Ford approved diagnostic tool
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanicalor electrical damage.
Visual Inspection Chart
Electrical
Mechanical
– Fuse(s)
– Wiring harness
– Electricalconnector(s)
– Engine coolant temperature (ECT)
sensor
– Cooling fan motor
– Cooling fan module
– Powertrain control module (PCM)
– Coolant shut off valve
– Coolant degas shut off valve
– Coolant leaks
– Gaskets/seals
– Core plug(s)
– Hose(s)/hose joints
– Coolant expansion
tank cap and seal(s)
– Coolant expansion tank
– Radiator
– Coolant pump
– Thermostat
– Heater core
– Exhaust gas recircu- lation (EGR) cooler
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 diagnostic tab within
the Ford approved diagnostic tool.
G1058974en2008.50 Kuga8/2011
303-03- 4
Engine Cooling
303-03- 4
DIAGNOSIS AND TESTING
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

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
GENERAL PROCEDURES
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

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
GENERAL PROCEDURES
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Radiator Lower Mounting Repair
General Equipment5mmDrillBit
Cable Ties
Flat File
1. General Equipment: Cable Ties
E100039
2.Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
3.
E98183
4.
E98184
5.
E100040
x4
6. General Equipment: Flat File
1.
2. General Equipment: 5 mm Drill Bit
G1062292en2008.50 Kuga8/2011
303-03- 7
Engine Cooling
303-03- 7
GENERAL PROCEDURES
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

E87749
5mm
1
2
7.
E87750
G1062292en2008.50 Kuga8/2011
303-03-8
Engine Cooling
303-03- 8
GENERAL PROCEDURES
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

8.Torque: 25Nm
E100040
x4
9.
E98184
10.
E98183
11 .Remove the cable ties securing the radiator and
condenser assembly.
G1062292en2008.50 Kuga8/2011
303-03- 9
Engine Cooling
303-03- 9
GENERAL PROCEDURES
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Coolant Pump — 2.5L Duratec (147kW/200PS) - VI5(24 404 0)
General EquipmentTrolley Jack
Removal
NOTE: Removal steps in this procedure may
contain installation details.
1. Drain the cooling system.
Refer to: Cooling System Draining and Vacuum
Filling (303-03 Engine Cooling, General
Procedures).
2. Remove the timing belt.
Refer to: Timing Belt (303-01 Engine - 2.5L
Duratec (147kW/200PS) - VI5, Removal and
Installation).
3. CAUTION: Use a wooden block to protect the oil pan when supporting the
engine.
Position the trolley jack with the wooden block
under the oil pan. Raise the trolley jack until the
front of the engine is free from load and the
coolant pump bolts can be accessed.
General Equipment: Trolley Jack
4. Torque: 17
Nm
E63823
x4
5.Lower the engine.
General Equipment: Trolley Jack 6.
Torque: 17
Nm
x3
E63856
Installation
1. NOTE: Install all the bolts finger tight before
final tightening.
To install, reverse the removal procedure.
G544632en2008.50 Kuga8/2011
303-03- 10
Engine Cooling
303-03- 10
REMOVAL AND INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Cooling Fan Motor and Shroud — 2.5L Duratec (147kW/200PS)- VI5(24 222 0)
Removal
NOTE: Removal steps in this procedure may
contain installation details.
1. Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
2.
E98183
3.
E98184
4.
E112584
5.
E112335
6. Torque: 25Nm
G1156382en2008.50 Kuga8/2011
303-03- 11
Engine Cooling
303-03- 11
REMOVAL AND INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

E112585
x2
7.
G1156382en2008.50 Kuga8/2011
303-03-12
Engine Cooling
303-03- 12
REMOVAL AND INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
x2
E112336

Installation
1.To install, reverse the removal procedure.
G1156382en2008.50 Kuga8/2011
303-03- 13
Engine Cooling
303-03- 13
REMOVAL AND INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL