Compressor FORD KUGA 2011 1.G Owner's Manual

Cylinder Head(21 165 6)
Special Tool(s)303-361B
Compressor, Valve Spring
E62757
303-361B-06
Adapter for 303-361B
E62041
303-508
Pliers, Valve Stem Seal
21211
Disassembly
1.Special Tool(s): 303-361B, 303-361B-06
E66326
303-361B
303-361B-06
2.Special Tool(s): 303-508
E66114
303-508
Assembly
3.To install, reverse the assembly procedure.
G543499en2008.50 Kuga8/2011
303-01- 93
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
93
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
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Engine(21 134 8)
Assembly
Special Tool(s) / General Equipment303-1054
Locking Tool, Timing Belt
Tensioner
3031054
303-1178
Timing Tool Camshaft
E62051
303-1179
Holding Wrench, Crankshaft
E62035
303-1180
Installer, Crankshaft Front
Seal
E62050
Special Tool(s) / General Equipment303-1181
Installer, Crankshaft Rear
Seal
E62048
303-1182
Timing Tool, Crankshaft
E62027
303-318
Aligner/Installer, Crankshaft
Front Seal
21148
Piston Ring Compressor
Round-Ended Steel Rule
Materials
Specification
Name
WSS-M2C913-C
Engine Oil - 5W-30
WSK-M2G348-A7 /
5U7J-M2G348-BA
Flange Sealant - Anaer-
obic LP
1. NOTE: This step is only necessary when
installing a new component.
Refer to: Specifications (303-01 Engine - 2.5L
Duratec (147kW/200PS) - VI5, Specifications).
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Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
94
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

E122634
1
2
3
4
5
12345
11. CAUTION: Make sure that thecomponents are installed to the position
noted before removal.
General Equipment: Piston Ring Compressor
E122334
x5
12. CAUTION: Make sure that thecomponents are installed to the position
noted before removal.
Apply a thin coating.
Material: Engine Oil - 5W-30 (WSS-M2C913-C)engine oil
E77266
13. CAUTIONS:
Make sure that the components are
installed to the position noted before
removal.
Make sure that new bolts are installed.
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100
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Turbocharger – Overview
Turbocharger(s)
CAUTION: Do not switch off the engine
while it is running at high speed. If the
engine is switched off while it is running
at high speed, the turbocharger will
continue to run after the engine oil
pressure has already dropped to zero. This
will cause premature wear in the
turbocharger bearings.
A TC consists of an exhaust turbine located in the
exhaust gas flow, this turbine is connected to a
compressor by a shaft. The turbine is made to
rotate by the exhaust gas flow from the engine and
thus drives the compressor. The compressor
increases the pressure in the engine intake tract
so that a greater mass of air enters the cylinder
during the intake stroke.
The turbine housing of the TC is integrated into the
exhaust manifold. This construction offers
thermodynamic advantages compared with the
usual construction, the maximum exhaust
temperature is up to 1050°C.
The maximum boost pressure is 0.65 bar.
The exhaust manifold is secured to the exhaust
side of the cylinder head with 12 self-locking nuts.
The exhaust manifold gasket is a multi-layer steel
gasket and cannot be reused. In order to
compensate for the thermal expansion of the
exhaust manifold, the flange of the TC is provided
with two grooves.
The TC and the exhaust manifold are joined by a
hose clip. The hose clip must not be loosened or
removed. The TC and the exhaust manifold are
not available as separate replacement parts,
exchange is only possible as a complete unit.
The turbocharger heat shield is secured to the
exhaust manifold by four bolts. Two of the bolts
have spring washers underneath their heads.
During removal, make a note of the installation
location of the spring washers to refer to during
installation.
The recirculated air valve is built into the TC
housing and cannot be changed.
The Ford diagnostic unit can test the operation of
the wastegate control valve using actuator
diagnosis.
The boost pressure regulator is set in the factory.
Adjustments to the boost pressure regulator must never be attempted. A red colored seal is applied
to the adjustment nut of the operating rod, in order
to monitor the factory setting of the boost pressure.
The bearings of the TC are lubricated with engine
oil. The engine oil passes from the cylinder block
through the oil supply pipe to the TC. The oil is
returned to the oil pan through the oil return pipe,
The TC is cooled by the engine coolant circuit.
When installing hoses and lines, make certain that
their ends are free of oil residues and dirt.
G1032425en2008.50 Kuga8/2011
303-04B-
4
Fuel Charging and Controls - Turbocharger
—
2.5L Duratec (147kW/200PS) - VI5
303-04B- 4
DESCRIPTION AND OPERATION
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Description
Item
PWM (pulse width modulation) signal
Comments:from PCM (powertrain control module)
5
Atmospheric pressure
6
Turbocharger boost pressure.
7
from air filter
8
Intake air
9Description
Item
Recirculated air valveRefertoComponentDescription:(page
7)
10
Vacuum line, recirculated air valve
11
to intake manifold
12
Throttle plate
13
Compressor
14
Turbine
15
System Operation
Turbocharger(s)
The TC consists of a turbine and a compressor.
The turbine is driven by the exhaust gas flow. A
common shaft drives the compressor and this then
compresses the intake air.
Turbocharger boost pressure control
E98942
1
2
3
4
Description
Item
Atmospheric pressure
1
Turbocharger boost pressure.
2
Wastegate control valve
3
Pilot pressure
4
The size of the TC is designed to produce a charge
effect even at medium engine speeds and lower
exhaust gas flows. This means that, when the engine speed is high and there is a large amount
of exhaust gas, either the boost pressure of the
TC will become too high or its speed will be too
high. The TC must therefore be regulated. The
best regulation is achieved by an electronically
controlled wastegate control valve. The wastegate
control valve controls the pressure on the
membrane in the boost pressure regulator.
The wastegate control valve is actuated by the
PCM with a PWM signal according to a map. The
boost pressure is applied to the wastegate control
valve via the pressure line from the compressor.
This pressure is passed to the boost pressure
regulator via the wastegate control valve. This
opens the bypass valve using a linkage. This
channels a portion of the exhaust gases around
the turbine. If the wastegate control valve is
actuated by the PCM, a bypass is opened in the
wastegate control valve. This causes the pressure
which can act on the membrane in the boost
pressure regulator to be reduced. This occurs until
the boost pressure has reached a set value. By
actuation with a PWM signal, it is also possible to
partially open or close the wastegate control valve.
This results in a constant boost pressure and
therefore high torque over a wide range of engine
speeds.
Because the PCM calculates the boost pressure
using the signal from the boost pressure sensor
and the IAT (intake air temperature) sensor, the
atmospheric pressure and the temperature are
automatically compensated for. Because of this
compensation, the engine power is not noticeably
affected by variations in atmospheric temperature
or pressure.
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303-04B-
6
Fuel Charging and Controls - Turbocharger
—
2.5L Duratec (147kW/200PS) - VI5
303-04B- 6
DESCRIPTION AND OPERATION
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Recirculated air valve
E97052
43
2
1
Description
Item
Recirculated air valve
1
Vacuum hose to intake manifold
2
Air ingress
3
Air discharge
4
If the throttle valve is closed quickly, the moving
air column hits the throttle valve. The air column
is reversed, flows back onto the rotating impeller
of the TC and powerfully decelerates it. A
recirculated air valve is installed to prevent this
deceleration of the impeller and thus allow the TC
to respond faster. The recirculated air valve is
controlled via a vacuum line which is connected to
the intake manifold. When the throttle valve is
suddenly closed, a high vacuum occurs in the
intake manifold. This opens the recirculated air
valve and the compressed air is returned to a point
before the compressor. This causes the speed of
the turbocharger to drop less rapidly and the boost
pressure can build up more rapidly when the
accelerator pedal is pressed again.
Component Description
Wastegate control valve
1
2
3
E98852
Description
Item
from turbocharger (boost pressure)
1
from turbocharger (atmospheric pressure)
2
to boost pressure regulator (control
pressure)
3
The wastegate control valve operates as a cycle
valve. The pressure acting on the membrane in
the boost pressure regulator is controlled by
appropriate pulsing of the wastegate control valve.
The pressure acting on the membrane in the boost
pressure regulator is reduced when the wastegate
control valve opens.
The operating voltage of the wastegate control
valve is 12V.
The internal resistance of the wastegate control
valve is 28.5 ± 1.5 Ohms.
The operating states are:
• De-energised: gate open between 1 and 3 – Boost pressure high > wastegate controlvalve closed > boost pressure regulator open
> turbine receives restricted exhaust gas
flow.
• Energised: gate open between 2 and 3 – Boost pressure low > wastegate control valveopen > boost pressure regulator closed >
turbine receives full exhaust gas flow.
G1032426en2008.50 Kuga8/2011
303-04B- 7
Fuel Charging and Controls - Turbocharger
—
2.5L Duratec (147kW/200PS) - VI5
303-04B- 7
DESCRIPTION AND OPERATION
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Action
Possible Sources
Symptom
• INSPECT the turbocharger forsigns of damage. INSTALL a
new turbocharger as neces-
sary.
REFER to: Turbocharger (303-
04 Fuel Charging and
Controls - Turbocharger -
2.5L Duratec (147kW/200PS)
- VI5, Removal and Installa-
tion).
• Turbocharger compressor
rubbing on housing walls.
• Turbocharger turbine rubbing on housing walls.
• Turbocharger bearings and oil seal(s).
• Turbocharger oil supply tube blocked or damaged.
• Blue smoke with excessive
turbocharger noise
• Check the oil return tube forblockage or damage, INSTALL
a new oil return tube as neces-
sary.
• Turbocharger oil return tube
blocked or damaged.
• Blue smoke without excessive
turbocharger noise
• CHECK all vacuum line(s) areinstalled and no signs of air
leaks are present. REPAIR as
necessary.
• Vacuum diaphragm unit
vacuum line(s).
• Poor engine performance
• CHECK the charge air cooler,charge air cooler pipes and
charge air cooler hoses for
leaks and obstructions.
REPAIR as necessary.
• Charge air cooler system.
• CHECK the air cleaner intakepipe for obstruction. REPAIR
the necessary.
• Air cleaner intake pipe.
• The turbocharger boost pres-sure is factory set and must not
be adjusted. CHECK the paint
seal on the vacuum diaphragm
unit actuator rod has not been
broken. If the paint seal has
been broken, INSTALL a new
turbocharger.
REFER to: Turbocharger (303-
04 Fuel Charging and
Controls - Turbocharger -
2.5L Duratec (147kW/200PS)
- VI5, Removal and Installa-
tion).
• Unauthorized adjustment of the
vacuum diaphragm unit actu-
ator rod.
• CHECK the vacuum diaphragmunit actuator rod moves freely,
If the vacuum diaphragm unit
actuator rod does not move
freely. CHECK for signs of
damage or signs of foreign
material. REPAIR as neces-
sary.
• Vacuum diaphragm unit actu-
ator rod.
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303-04B- 10
Fuel Charging and Controls - Turbocharger
—
2.5L Duratec (147kW/200PS) - VI5
303-04B- 10
DIAGNOSIS AND TESTING
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SECTION 303-05 Accessory Drive— 2.5L Duratec (147kW/200PS) - VI5
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
DESCRIPTION AND OPERATION
303-05-2
Accessory Drive ........................................................................\
..........................................
DIAGNOSIS AND TESTING 303-05-4
Accessory Drive ........................................................................\
..........................................
303-05-4
Inspection and Verification ........................................................................\
..........................
303-05-4
Accessory Drive Belt Concerns ........................................................................\
..................
303-05-6
Symptom Chart ........................................................................\
...........................................
303-05-9
Component Tests ........................................................................\
........................................
REMOVAL AND INSTALLATION 303-05-11
(21 569 0)
Accessory Drive Belt Tensioner ......................................................................
303-05-12
(21 567 0)
Accessory Drive Belt ........................................................................\
..............
303-05-13
(21 567 0)
Air Conditioning (A/C) Compressor Belt .........................................................
303-05-14
Air Conditioning (A/C) Compressor Belt Tensioner ............................................................
303-05-1
Accessory Drive— 2.5L Duratec (147kW/200PS) - VI5303-05-
1
.
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Accessory Drive
2
1
E63663
Description
Item
Accessory drive belt
1
Air conditioning (A/C) compressor belt
2
G510168en2008.50 Kuga8/2011
303-05- 2
Accessory Drive— 2.5L Duratec (147kW/200PS) - VI5303-05-
2
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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
G510168en2008.50 Kuga8/2011
303-05- 3
Accessory Drive— 2.5L Duratec (147kW/200PS) - VI5303-05-
3
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