Vacuum pump FORD KUGA 2011 1.G User Guide

Turbocharger
Special Tool(s) / General EquipmentHand Vacuum/Pressure
Pump
416 - D001 (23 - 036A)
23036A
Fuel Pressure Gauge
310-053 (23-046)
23046
Ford diagnostic equipment
Inspection and Verification
NOTE:It is normal for a small amount of
combustion gas to pass into the crankcase. This
gas is scavenged into the air intake system through
the positive crankcase ventilation (PCV) system,
which incorporates an crankcase vent oil separator.
Some engine oil, in the form of a vapor is carried
into the air intake system with the blow-by gases
(this engine oil also contributes to valve seat
durability). This means that oil will collect inside
the air intake components and the turbocharger.
This is not an indication that the turbocharger oil
seal has failed. The turbocharger oil seal will not
fail unless the bearings fail first, which will cause
the turbocharger to become noisy or seize. Do not
install a new turbocharger due to oil inside the
turbocharger or the air intake components. If a leak
is detected in the oil supply or return tubes or connections, locate and rectify the source. Do not
install a new turbocharger due to an oil leak.
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical
or electrical damage.
Visual Inspection Chart
Electrical
Mechanical
• Wiring harness
• Boost controlsolenoid valve
• Powertrain control module (PCM)
• Oil leak(s)
• Air cleaner element
• Air cleaner outlet
pipe
• Air cleaner intake pipe
• Turbocharger oil supply or oil return
tube
• Turbocharger intake pipe
• Turbocharger vacuum diaphragm
unit
• Turbocharger housing
• Charge air cooler
• Charge air cooler intake pipe and
hose(s)
• Charge air cooler outlet pipe and
hose(s)
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.
NOTE: The vacuum diaphragm unit is a fixed part of the turbocharger and cannot be adjusted or renewed.
G1183442en2008.50 Kuga8/2011
303-04B- 9
Fuel Charging and Controls - Turbocharger
—
2.5L Duratec (147kW/200PS) - VI5
303-04B- 9
DIAGNOSIS AND TESTING
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Perform the leak test, by closing the hand valves
on the gauge set, switching off the service unit
vacuum pump and observing the low pressure
gauge.
10. N O T E : This step is only necessary if the
pressure increase exceeds 20 mbar.
Locate and rectify any leaks in the A/C
refrigerant circuit using a leak tester.
General Equipment: UV Leak Detector
General Equipment: Electronic Leak Detector
General Equipment: Automatic Calibration Halogen Leak Detector
11 . Add refrigerant oil to the air conditioning system.
Refer to: Specifications (412-00 Climate Control
System - General Information, Specifications).
Refer to: Refrigerant Oil Adding (412-00 Climate
Control System - General Information, General
Procedures).
12. Fill the air conditioning system with liquid
through the high-pressure connection.
Refer to: Specifications (412-00 Climate Control
System - General Information, Specifications).
13. Open the shut-off valve on the high-pressure
side.
1.
2. Switch the service unit to "Fill" mode and fill
the system with the specified quantity of
liquid refrigerant (R134a).
14. Fill the air conditioning system with gas through
the low-pressure connection.
Refer to: Specifications (412-00 Climate Control
System - General Information, Specifications).
15. Open the shut-off valve on the low-pressure
side.
1.
2. Switch the service unit to "Fill" mode and fill
the system with the specified quantity of
gaseous refrigerant.
3. Add the remaining amount of refrigerant with the air conditioning switched on. To do so
run the engine at about 1200-1500 rev/min.
Set the air conditioning system to full cooling
power and fresh air mode. Set the blower
motor to the highest setting. Fill with the
remainder of the specified fill capacity.
16. Disconnect the service unit. 17.
Close the shut-off valve.
1.
2. Switch off the service unit.
3. Disconnect the service unit lines from the
filling connections of the air conditioning
system.
4. Screw the protective caps onto the charging connections.
18. Install all components in reverse order.
G1022208en2008.50 Kuga8/2011
412-00- 8
Climate Control System - General Information
412-00- 8
GENERAL PROCEDURES
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL