check oil FORD KUGA 2011 1.G Owner's Manual

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.
G1183442en2008.50 Kuga8/2011
303-04B- 10
Fuel Charging and Controls - Turbocharger
—
2.5L Duratec (147kW/200PS) - VI5
303-04B- 10
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
303-05- 7
Accessory Drive— 2.5L Duratec (147kW/200PS) - VI5303-05-
7
DIAGNOSIS AND TESTING
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Intake Air Distribution and Filtering
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanicalor electrical damage.
Visual Inspection Chart
Electrical
Mechanical
– Mass air flow (MAF)sensor
– Manifold absolute pressure (MAP)
sensor
– Electrical connector(s)
– Air cleaner element
– Air cleaner intake
pipe
– Air cleaner outlet pipe
– Charge air cooler
– Charge air cooler intake pipe
– Charge air cooler outlet pipe 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.
Symptom Chart
Action
Possible Sources
Symptom
• CHECK the pipe(s) for securityand leaks to atmosphere.
INSTALL new intake air
components as necessary.
TEST the system for normal
operation.
• Detached air cleaner pipe(s).
• Detached turbocharger pipe(s).
• Detached charge air cooler
pipe(s).
• Excessive intake air noise
• REFER to:Engine Emission
Control (303-08 Engine
Emission Control - 2.5L
Duratec (147kW/200PS) -
VI5, Diagnosis and Testing).
• Blocked or damaged PCV
pipe(s)/hose(s).
• Blocked or damaged crankcase vent oil separator.
• Oil in the air intake system
• REFER to:Turbocharger(303-
04 Fuel Charging and
Controls - Turbocharger -
2.5L Duratec (147kW/200PS)
- VI5, Diagnosis and Testing).
• Turbocharger.
• CHECK the air intake pipesplash shield for correct install-
ation and alignment.
REPAIR/INSTALL the air intake
pipe splash shield as neces-
sary. TEST the system for
normal operation.
• Air intake pipe splash shield.
• Water in the air cleaner
G1183447en2008.50 Kuga8/2011
303-12- 4
Intake Air Distribution and Filtering
— 2.5L Duratec
(147kW/200PS) - VI5
303-12- 4
DIAGNOSIS AND TESTING
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If one of the two APP sensors fails, then only a
proportion of the engine's power will be available
when accelerating. Top speed can nevertheless
be achieved.
If both of the APP sensors fail, the engine is
regulated to a defined speed following a plausibility
check after the BPP (brake pedal position) switch
and brake light switch have been actuated once.
The vehicle can then only be accelerated to a
defined speed.
In either case, a fault is saved in the error memory
of the PCM.
Throttle control unit
E74167
1
2
Description
Item
TP (throttle position) sensor
1
Electric motor
2
CAUTION: The throttle control unit must
not be repaired or adjusted. The stop of
the throttle valve must on no account be
adjusted.
After disconnecting the battery or replacing the
throttle control unit or the PCM, initialization is
necessary. • engine off
• Accelerator pedal not pressed
• Battery voltage 11 ... 14 V
• Ignition key in ON position
• Wait approximately 30 seconds until initialization
is complete.
Engine Coolant Temperature (ECT)
sensor
E94804
The ECT (engine coolant temperature) sensor is
designed as an NTC (negative temperature
coefficient) resistor.
If the signal from the ECT sensor fails, the cooling
fan is on all the time and the A/C (air conditioning)
is turned off. When the ignition is switched on, the
value from the IAT (intake air temperature) sensor
is read. When the engine is running, the
temperature is calculated using a temperature map
stored in the PCM according to how long the
engine has been running. This substitute value is
then used as the basis for calculating the injected
fuel quantity and the ignition timing.
Ignition coil-on-plug
E73540
G1021907en2008.50 Kuga8/2011
303-14- 10
Electronic Engine Controls— 2.5L Duratec (147kW/200PS) - VI5303-14-
10
DESCRIPTION AND OPERATION
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The resistance in the ignition coil primary circuit
cannot be checked using a multimeter because
the power output stage is integrated into the ignition
coil.
G1021907en2008.50 Kuga8/2011
303-14-11
Electronic Engine Controls— 2.5L Duratec (147kW/200PS) - VI5303-14-
11
DESCRIPTION AND OPERATION
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current value is reached. The PCM then
permanently connects the heating element to earth.
The catalyst monitor sensor is used by the PCM
to measure the oxygen content in the exhaust gas
in the TWC. If all the conditions for catalyst
diagnostics are met, based on this information the
PCM can check that the TWC is working
satisfactorily. The information is also used to
improve the air/fuel mixture adjustment.
The catalyst monitor sensor is similar in function
to an HO2S. The signal transmitted by the catalyst
monitor sensor changes sharply if the oxygen
content in the exhaust gas changes. For this
reason, catalyst monitor sensors are also called
"jump lambda sensors".
Fuel tank purging
The EVAP purge valve is only actuated by the PCM
if the coolant temperature is at least 60°C.
Actuation is done ground side by means of a PWM
signal. This makes it possible to have the full range
of opening widths, from fully closed to fully open.
The PCM determines from the operating conditions
when and how wide to open the EVAP tank purge
valve. If the EVAP purge valve is opened, the
engine sucks in ambient air through the activated
charcoal in the evaporative emission canister as
a result of the vacuum in the intake manifold. In
this way the adsorbed hydrocarbons are led to the
combustion chamber of the engine.
The EVAP tank purge valve is not actuated and
system cleaning is interrupted if the engine
switches to idle and/or a closed-loop control
process is initiated.
Power (battery voltage) is supplied via the
Powertrain Control Module relay in the BJB. The
solenoid coil resistance is between 17 and 24 ohms
at 20°C.
Engine speed control
The APP sensor provides the PCM with information
about the driver's request for acceleration.
The throttle control unit receives a corresponding
input signal from the PCM. An electric motor then
moves the throttle valve shaft by means of a set
of gears. The position of the throttle is continuously
recorded by the TP sensor. Information on throttle
position is processed and monitored by the PCM.
The TP sensor comprises two potentiometers.
These work in opposite ways to each other. In one
potentiometer, the resistance increases when the
throttle is opened, in the other it decreases. Thisallows the operation of the potentiometers to be
checked. The signal from the TP sensor is
amplified in the lower range (idle to a quarter open)
by the PCM to enable more precise control of the
throttle in this range. This is necessary because
the engine is very sensitive to changes in throttle
angle in this throttle opening range.
With the throttle valve position kept constant, the
ignition angle and the injected fuel quantity are
then varied to meet the torque demands.
Depending on the operating state of the engine, a
change in the position of the throttle flap may not
be necessary when the APP sensor changes.
If a fault develops in the throttle control unit, a
standby function is executed. This standby function
allows a slight opening of the throttle flap, so that
enough air passes through to allow limited engine
operation. For this purpose, there is a throttle flap
adjustment screw on the throttle housing. The
return spring closes the throttle flap until the stop
of the toothed segment touches the stop screw. In
this way a defined throttle flap gap is formed for
limp home mode.
The stop screw has a spring loaded pin, which
holds the throttle flap open for limp home mode.
In normal operating mode, this spring loaded pin
is pushed in by the force of the electric motor when
the throttle flap must be closed past the limp home
position (e.g. for idle speed control or overrun
shutoff).
Oil monitoring
The engine does not have an oil pressure
switch.
The oil level and oil quality are calculated.
Calculating the engine oil level
The oil level is determined by continuous
measurement of the capacitance (i.e. the ability to
store an electrical charge) between the two
capacitive elements of the engine oil
level/temperature/quality sensor. The different oil
levels cause the capacitance between the elements
to change. The data are recorded by the PCM and
converted into an oil level value. Temporary
fluctuations in oil level are automatically filtered out
by the PCM.
Calculating oil quality
The PCM calculates the oil quality from the oil level
measurement and the oil temperature measured
by the sensor, plus the engine speed and the
average fuel consumption. The driver is informed
about when an oil change is due.
G1021908en2008.50 Kuga8/2011
303-14- 22
Electronic Engine Controls— 2.5L Duratec (147kW/200PS) - VI5303-14-
22
DESCRIPTION AND OPERATION
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307-01-29
Automatic transmission, selector lever in position "D". ...................................................
307-01-29
Sport mode, selector lever in position "S" .......................................................................
307-01-29
Changing gear in select-shift mode........................................................................\
........
307-01-30
Selector lever from 'N' to 'R' position ........................................................................\
......
307-01-30
Self-test and Diagnosis ........................................................................\
...........................
307-01-30
Temperature controlled torque converter lockup ............................................................
307-01-30
Slip locking ........................................................................\
..............................................
307-01-30
Hill climbing ........................................................................\
.............................................
307-01-31
Downhill driving ........................................................................\
.......................................
307-01-31
Hill-hold function ........................................................................\
.....................................
307-01-31
Altitude correction ........................................................................\
...................................
307-01-31
Selector lever lock ........................................................................\
..................................
307-01-31
Shifting from P into another transmission range .............................................................
307-01-31
Shifting from N into another transmission range .............................................................
307-01-31
Power flow through the transmission ........................................................................\
......
307-01-31
Clutches and brakes ........................................................................\
...............................
307-01-33
Position P (park) ........................................................................\
.....................................
307-01-34
Position N (neutral) ........................................................................\
.................................
307-01-35
Position D, 1st gear........................................................................\
................................
307-01-36
Position D, 2nd gear ........................................................................\
...............................
307-01-37
Position D, 3rd gear ........................................................................\
................................
307-01-38
Position D, 4th gear ........................................................................\
................................
307-01-39
Position D, 5th gear ........................................................................\
................................
307-01-40
Position R (reverse) ........................................................................\
................................
307-01-41
Service instructions ........................................................................\
.................................
307-01-41
Towing procedure ........................................................................\
...................................
307-01-42
Reset adaptation data ........................................................................\
.............................
307-01-42
Limp home mode ........................................................................\
....................................
307-01-42
Component Description ........................................................................\
..............................
Tasks of the electronic components ........................................................................\
........
307-01-44
Input signals ........................................................................\
............................................
307-01-45
Output signals ........................................................................\
.........................................
Control valve assembly ........................................................................\
...........................
Shift solenoids S1 - S5 ........................................................................\
...........................
PWM-

solenoid valve – TCC (SLU) ........................................................................\
........
PWM solenoid valve – shift pressure (SLS) ...................................................................
PWM solenoid valve for main line pressure (SLT) ..........................................................
307-01-52
Installation position ........................................................................\
.................................
Operation ........................................................................\
................................................
Selector lever with integrated select-shift switch module ...............................................
Oil pump ........................................................................\
..................................................
Torque converter with TCC ........................................................................\
.....................
The TSS sensor ........................................................................\
......................................
The OSS sensor ........................................................................\
.....................................
The TFT sensor ........................................................................\
......................................
The TR sensor ........................................................................\
........................................
GENERAL PROCEDURES
T ransmission Fluid Level Check ........................................................................\
.................
307-01-63
T ransmission Fluid Drain and Refill ........................................................................\
............
REMOVAL AND INSTALLATION 307-01-67
Halfshaft Seal LH ........................................................................\
........................................
307-01-68
Halfshaft Seal RH........................................................................\
.......................................
307-01-69
Main Control Valve Body ........................................................................\
............................
307-01-2
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 2
.
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307-01-42
307-01-49
307-01-52 307-01-47
307-01-45
307-01-50
307-01-51
307-01-53
307-01-55
307-01-54
307-01-56
307-01-57
307-01-58
307-01-61 307-01-60
PAGE 2 OF 3 FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Transmission Fluid Level Check
General EquipmentFord Diagnostic Equipment
Materials
Specification
Name
WSS-M2C924-A / 4U7J-
M2C924-AA
Automatic Transmission
Oil E-AW
Inspection
1.
Refer to: Health and Safety Precautions (100-00
General Information, Description and
Operation).
2. Connect the Ford diagnostic equipment.
General Equipment: Ford Diagnostic Equipment
3. Make sure that the transmission is not in
emergency operation mode.
4. Make sure that the transmission fluid
temperature is between 70° and 80°C.
General Equipment: Ford Diagnostic Equipment
80
70
E114667
5. WARNING: Make sure that the brake pedal and parking brake are fully applied
during the test.
Start and run the engine at idle. 6.
E114668
7. NOTE:
Make sure that the selector lever and
the gearshift mechanism are in the park (P)
position.
8. Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
9.
E98183
G1163606en2008.50 Kuga8/2011
307-01- 61
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 61
GENERAL PROCEDURES
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Transfer Case Fluid Level Check
MaterialsSpecification
Name
8U7J-19G518-BA
Rear Axle Oil SAE 75W-
90
Inspection
1. Refer to: Health and Safety Precautions (100-00
General Information, Description and
Operation).
2.
E139436
3. Material: Rear Axle Oil SAE 75W-90
(8U7J-19G518-BA) transmission fluid
•
• Correct the rear axle oil level if neccessary.
• 20ml~1mm
0mm0mm
E114595
4. NOTE:
Make sure that a new component is
installed.
Torque: 34
Nm
E139434
G1164988en2008.50 Kuga8/2011
307-07- 9
Transfer Case
— Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450
307-07- 9
GENERAL PROCEDURES
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• Parking brake switch.– The parking brake switch is hard-wired to theGEM. The parking brake switch sends a
signal to the GEM when the parking brake is
operated. The GEM activates the parking
brake indicator lamp in the instrument cluster.
If the parking brake indicator lamp is lit,
cruise control cannot be activated.
• Back-up light switch – The backup lamp switch is hard-wired to the GEM. The backup lamp switch sends a signal
to the GEM when reverse gear is engaged.
The GEM activates the reversing lamp.
Cruise control cannot be activated when
reverse gear is engaged.
Component Description
Speed control switches
E103768
3
4
5
1
2
Description
Item
"ON" button
Comments:
1
"OFF" button
2Description
Item
"RES" button
3
"SET+" button
4
"SET-" button
5
The cruise control buttons are non-locking push
buttons. They are connected to the coil spring via
a hard-wired 9-pin plug connection.
The cruise control buttons operate according to
the resistance bridge circuit principle. The buttons
receive a 5 Volt reference voltage. When operated,
each button passes a particular voltage to the
GEM. The GEM measures this voltage and from
it determines which button has been pressed.
The operation of the cruise control buttons can be
checked by a simple measurement of the
resistance between pin 4 and pin 5 at the coil
spring 9-pin connector. A change of resistance
must occur when a button is pressed.
G1044191en2008.50 Kuga8/2011
310-03- 6
Speed Control
310-03- 6
DESCRIPTION AND OPERATION
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