2.5L FORD KUGA 2011 1.G Workshop Manual

Knock Sensor (KS)(29 222 0)
Removal
NOTE:Removal steps in this procedure may
contain installation details.
1. Refer to: Air Cleaner (303-12 Intake Air
Distribution and Filtering - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
2. NOTE: Make sure that the sensor is installed in
the same location as when removed.
Torque: 20
Nm
E65542
Installation
1. To install, reverse the removal procedure.
G965267en2008.50 Kuga8/2011
303-14- 41
Electronic Engine Controls— 2.5L Duratec (147kW/200PS) - VI5303-14-
41
REMOVAL AND INSTALLATION
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Mass Air Flow (MAF) Sensor(29 226 0)
Removal
NOTE:Removal steps in this procedure may
contain installation details.
1. Torque: 10
Nm
E106250
x2
Installation
1.To install, reverse the removal.
G1079138en2008.50 Kuga8/2011
303-14- 42
Electronic Engine Controls— 2.5L Duratec (147kW/200PS) - VI5303-14-
42
REMOVAL AND INSTALLATION
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Powertrain Control Module (PCM)(29 200 0)
General Equipment3.5 mm Drill Bit
Center Punch
Ford Diagnostic Equipment
Removal
NOTE: Removal steps in this procedure may
contain installation details.
1. NOTE: This step is only necessary when
installing a new component.
Download the PCM and throttle body
configuration information into the diagnostic tool,
using the Programmable Modules Installation
routine.
General Equipment: Ford Diagnostic Equipment
2. Refer to: Battery Disconnect and Connect
(414-01 Battery, Mounting and Cables,
General Procedures).
Vehicles without PCM security shield
3.
E63329
4.
E93509
5.
E65856
6. Torque: 7Nm
E66285
Vehicles with PCM security shield
7.Refer to: Air Cleaner (303-12 Intake Air
Distribution and Filtering - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
8. General Equipment: Center Punch
1.
2. General Equipment: 3.5 mm Drill Bit
G1079137en2008.50 Kuga8/2011
303-14- 43
Electronic Engine Controls— 2.5L Duratec (147kW/200PS) - VI5303-14-
43
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

E923483
1
2
4
x2
9.
E65361
Installation
1.To install, reverse the removal.
Vehicles with PCM security shield
2.Tighten the shear bolt until the shear bolt head
is sheared off.
E92350
All vehicles
3. NOTE: This step is only necessary when
installing a new component.
Upload the PCM and throttle body configuration
information into the PCM, using the
Programmable Modules Installation routine.
General Equipment: Ford Diagnostic Equipment
G1079137en2008.50 Kuga8/2011
303-14- 44
Electronic Engine Controls— 2.5L Duratec (147kW/200PS) - VI5303-14-
44
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Variable Valve Timing (VVT) Oil Control Solenoid(29 233 0)
Removal
NOTE:Removal steps in this procedure may
contain installation details.
1. Torque: 10
Nm
x2x2
E92954
2.Torque: 10Nm
E67949
Installation
1.To install, reverse the removal procedure.
G970800en2008.50 Kuga8/2011
303-14- 45
Electronic Engine Controls— 2.5L Duratec (147kW/200PS) - VI5303-14-
45
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Brake Pedal Position (BPP) Switch(33 502 0)
Removal
1. CAUTION: Make sure that the brakepedal remains in the rest position.
E101878
Installation
1.CAUTION: Make sure that the brake
pedal remains in the rest position.
To install, reverse the removal procedure.
G1065472en2008.50 Kuga8/2011
303-14- 46
Electronic Engine Controls— 2.5L Duratec (147kW/200PS) - VI5303-14-
46
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Clutch Pedal Position (CPP) Switch(33 503 0)
Removal
1. CAUTION: Make sure that the clutchpedal remains in the rest position.
2
451
E101866
Installation
1.CAUTION: Make sure that the clutch
pedal remains in the rest position.
To install, reverse the removal procedure.
G1065474en2008.50 Kuga8/2011
303-14- 47
Electronic Engine Controls— 2.5L Duratec (147kW/200PS) - VI5303-14-
47
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

4.On both sides.
Loosen: 3
turn(s)
E99147
x3
5.Refer to: Battery(414-01 Battery, Mounting and
Cables, Removal and Installation).
6.
E101006
7. Refer to: Air Cleaner (303-12 Intake Air
Distribution and Filtering - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
8. NOTE: Only tighten the bolts finger tight at this
stage.
E114727
9.
G1163644en2008.50 Kuga8/2011
307-01- 83
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 83
REMOVAL
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

40.Torque: 10Nm
E101006
41.Refer to: Battery(414-01 Battery, Mounting and
Cables, Removal and Installation).
42. On both sides.
Torque: 35
Nm
E99147
x3
43.Refer to: Air Cleaner (303-12 Intake Air
Distribution and Filtering - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
44.
E114689
45. Refer to: Cowl Panel Grille (501-02 Front End
Body Panels, Removal and Installation).
Refer to: Transmission Fluid Level Check
(307-01 Automatic Transmission/Transaxle -
Vehicles With: 5-Speed Automatic Transaxle
- AW55 AWD, General Procedures).
G1163646en2008.50 Kuga8/2011
307-01- 100
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 100
INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

SECTION 309-00 Exhaust System— 2.5L Duratec (147kW/200PS) - VI5
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
DESCRIPTION AND OPERATION
309-00-2
Exhaust System (Component Location) ........................................................................\
.....
REMOVAL AND INSTALLATION 309-00-3
Exhaust Flexible Pipe ........................................................................\
.................................
309-00-6
Catalytic Converter ........................................................................\
.....................................
309-00-1
Exhaust System— 2.5L Duratec (147kW/200PS) - VI5309-00-
1
.
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL