Engine FORD KUGA 2011 1.G Workshop Manual

Action
Possible Sources
Symptom
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• Fuel rail fuel pressure sensor.
• Check the fuel system pres-sure.
• Low fuel system pressure.
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303-04A-
21
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 21
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Fuel Injectors
MaterialsSpecification
Name
WSS-M2C911-A
Engine Oil - 5W-30
Removal
NOTE: Removal steps in this procedure may
contain installation details.
1. Refer to: Fuel Rail (303-04 Fuel Charging and
Controls - 2.5L Duratec (147kW/200PS) - VI5,
Removal and Installation).
2. Torque: 10
Nm1.
4. Material: Engine Oil - 5W-30
(WSS-M2C911-A) engine oil
E64170
1
243
Installation
1.To install, reverse the removal procedure.
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303-04A- 22
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 22
REMOVAL AND INSTALLATION
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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.
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303-04B-
4
Fuel Charging and Controls - Turbocharger
—
2.5L Duratec (147kW/200PS) - VI5
303-04B- 4
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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
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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
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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.
G1183442en2008.50 Kuga8/2011
303-04B- 10
Fuel Charging and Controls - Turbocharger
—
2.5L Duratec (147kW/200PS) - VI5
303-04B- 10
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Turbocharger(23 612 0)
General EquipmentCable Ties
Hose Clamp Remover/Installer
Materials
Specification
Name
SA-M1C9107-A / YS5J-
M1C9107-AA
Grease KS-PS
Removal
NOTE:
Removal steps in this procedure may
contain installation details.
1. Refer to: Battery Disconnect and Connect
(414-01 Battery, Mounting and Cables,
General Procedures).
2. Refer to: Cooling System Draining and Vacuum
Filling (303-03 Engine Cooling, General
Procedures).
3. Refer to: Cowl Panel Grille (501-02 Front End
Body Panels, Removal and Installation).
4.
E65070
5. CAUTION: Make sure that the inside of the pipe ends are clean and free of oil
residue.
1. Torque: 10Nm
2. Torque: 4Nm
3. Torque: 10Nm
2
1
3
E68504
6.
E67948
2
1
7.Torque: 26Nm1.
2. Torque: 26
Nm
3. Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
Torque: 38
Nm
E112143
3
2
1
G1079058en2008.50 Kuga8/2011
303-04B- 11
Fuel Charging and Controls - Turbocharger
—
2.5L Duratec (147kW/200PS) - VI5
303-04B- 11
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VUE0037806
4. If the cause is not visually evident, verify thesymptom and refer to the Symptom Chart.
Symptom Chart
Action
Possible Sources
Symptom
• CHECK the system with theengine running and the
accessory drive belt removed
(only run the engine for a very
short period). If a noise is
apparent, the cause is not the
accessory drive system. If a
noise is not apparent, the
cause is the accessory drive
system. CHECK where the
noise is coming from. Use a
stethoscope or other listening
device to determine the source
of the noise. INSTALL new
components as necessary.
TEST the system for normal
operation.
• Accessory drive system
• Accessory drive belt noise
• CHECK the accessory drivebelt is correctly installed in the
pulley grooves. INSTALL a new
accessory drive belt as neces-
sary.
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.
• Accessory drive belt incorrectly
installed.
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303-05- 6
Accessory Drive— 2.5L Duratec (147kW/200PS) - VI5303-05-
6
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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
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Accessory Drive— 2.5L Duratec (147kW/200PS) - VI5303-05-
7
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Action
Possible Sources
Symptom
• REMOVE the accessory drivebelt.
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).
INSPECT the idler pulley(s) for
surface finish. INSTALL a new
idler pulley(s) as necessary.
TEST the system for normal
operation.
• Poor surface finish on
accessory drive belt idler pulley
flat surface(s).
NOTE:
Whine is defined as a
continuous noise at the same
frequency, generally associated
with plastic pulleys.
• Accessory drive belt whine
• REMOVE the accessory drivebelt.
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).
INSPECT the idler pulley(s) for
smooth rotation. INSTALL a
new idler pulley(s) as neces-
sary. TEST the system for
normal operation.
• Accessory drive belt idler pulley
bearing failure.
• CHECK that the accessorydrive belt is running centrally
on the flat pulleys. TEST the
system for normal operation.
• CHECK the pulleys for excessive end float and bent
flanges.
• With the engine running at idle, use a stethoscope to identify
the source of the noise.
INSTALL new components as
necessary. TEST the system
for normal operation.
• Pulley misalignment (usually
evident at idle).
NOTE:
Chirp is defined as a twit-
tering noise, often intermittent
• Accessory drive belt chirp
G1183443en2008.50 Kuga8/2011
303-05- 8
Accessory Drive— 2.5L Duratec (147kW/200PS) - VI5303-05-
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