2.5L FORD KUGA 2011 1.G Workshop Manual

Fuel Tank and Lines — 2.5L Duratec (147kW/200PS) - VI5 –Component Location
E105870
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2
3
4
5
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10
9
11
Description
Item
Fuel pump and level indicator module,
right-hand side
1
EVAP (evaporative emission) extraction
points
2
Fuel pump and lines for the fuel-fired
booster heater/additional heater
3Description
Item
Fuel-filler pipe
4
EVAP container and lines
5
Vent hose, fuel filler pipe
6
Fuel pump and level indicator module,
left-hand side
7
Fuel tank
8
G1079157en2008.50 Kuga8/2011
310-01- 2
Fuel Tank and Lines
310-01- 2
DESCRIPTION AND OPERATION
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Fuel Tank and Lines — 2.5L Duratec (147kW/200PS) - VI5 –Overview
Fuel tank
The fuel tank is the same on vehicles with FWD
and AWD. The fuel tank is saddle-shaped to accommodate the drive shaft and the exhaust
system. Depending on the design, the volume of
the tank is 56 liters or 66 liters.
Fuel pump and sender unit
E106247
12
Description
Item
Fuel pump and level indicator module,
left-hand side
Comments:Inactive side without separate fuel pump
1
Fuel pump and level indicator module,
right-hand side
2
G1090887en2008.50 Kuga8/2011
310-01-
5
Fuel Tank and Lines
310-01- 5
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Fuel Tank — 2.5L Duratec (147kW/200PS) - VI5
Removal
WARNING: Avoid flames, sparks or lighted
substances.
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).
4x4
2. Refer to: Driveshaft (205-01 Driveshaft,
Removal and Installation).
All vehicles
3. Torque: 48Nm
x2x2
E104225
4.
E104226
5.Torque: 15Nm
E113922
x2
6.Torque: 15Nm
x4x4
E113923
G1175018en2008.50 Kuga8/2011
310-01- 8
Fuel Tank and Lines
310-01- 8
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14.
E104859
x2
15. WARNING: Be prepared to collectescaping fluids.
CAUTION: Use suitable paper to absorb
any escaping fluid.
x2x2
E113946
16.
E104642
x2
Vehicles with fuel fired booster heater
NOTE:This step is only necessary when installing
a new component.
17. WARNING: Be prepared to collect escaping fluids.
CAUTION: Use suitable paper to absorb
any escaping fluid.
Refer to: Quick Release Coupling (310-00 Fuel
System - General Information, General
Procedures).
E113927
All vehicles
NOTE: This step is only necessary when installing
a new component.
18. Refer to: Fuel Pump and Sender Unit - 2.5L
Duratec (147kW/200PS) - VI5 (310-01 Fuel
Tank and Lines, Removal and Installation).
Installation
1. To install, reverse the removal procedure.
G1175018en2008.50 Kuga8/2011
310-01- 10
Fuel Tank and Lines
310-01- 10
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Fuel Level Sensor — 2.5L Duratec (147kW/200PS) - VI5
Removal
1.Refer to: Fuel Pump and Sender Unit - 2.5L
Duratec (147kW/200PS) - VI5 (310-01 Fuel
Tank and Lines, Removal and Installation).
Installation
1. To install, reverse the removal procedure.
G1000788en2008.50 Kuga8/2011
310-01- 11
Fuel Tank and Lines
310-01- 11
REMOVAL AND INSTALLATION
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Fuel Pump and Sender Unit — 2.5L Duratec (147kW/200PS) -VI5
Special Tool(s) / General Equipment
310-210
Wrench, Fuel Tank Sender
Unit
E115757
Special Tool(s) / General Equipment310-211
Wrench, Fuel Tank Sender
Unit
E115758
Fluid Container
Removal
NOTE:Removal steps in this procedure may
contain installation details.
1. Refer to: Fuel Tank - 2.5L Duratec
(147kW/200PS) - VI5 (310-01 Fuel Tank and
Lines, Removal and Installation).
2. Special Tool(s): 310-211
Torque: 1
10Nm
310-211
x2
310-211
x2
E114253
3. CAUTION: Take extra care not to
damage the fuel tank level sensor float
and arm.
E112921
4.
E112922
Vehicles without fuel fired booster heater
5.Refer to: Quick Release Coupling (310-00 Fuel
System - General Information, General
Procedures).
E116270
G1000791en2008.50 Kuga8/2011
310-01- 18
Fuel Tank and Lines
310-01- 18
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SECTION 412-01 Climate Control
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
SPECIFICATIONS
412-01-3
Specifications ........................................................................\
..............................................
DESCRIPTION AND OPERATION 412-01-4
Climate Control (Component Location) ........................................................................\
......
412-01-10
Climate Control (Overview) ........................................................................\
........................
412-01-10
Pollen filter ........................................................................\
..................................................
412-01-10
Heat exchanger ........................................................................\
..........................................
412-01-10
Evaporator assembly ........................................................................\
..................................
412-01-10
Blower motor ........................................................................\
..............................................
412-01-11
Fault Memory Interrogation without diagnostics unit - vehicles with automatic temperature
control ........................................................................\
.......................................................
412-01-11
Switch over from Celsius to Fahrenheit ........................................................................\
......
412-01-12
Climate Control (System Operation and Component Description) .....................................
412-01-12
System Diagram ........................................................................\
.........................................
412-01-19
System Operation ........................................................................\
.......................................
412-01-19
Climate control housing ........................................................................\
..........................
412-01-22
Climate control ........................................................................\
........................................
412-01-24
Component Description ........................................................................\
..............................
412-01-24
Air conditioning compressor ........................................................................\
...................
412-01-24
Pollen filter ........................................................................\
..............................................
412-01-24
Control assembly, climate control - vehicles with manual temperature control ..............
412-01-25
Control assembly, climate control - vehicles with automatic temperature control ...........
412-01-25
Control assembly, climate control - vehicles with DVD navigation system with a touch
screen........................................................................\
................................................... 412-01-25
Climate control module - vehicles with DVD navigation system with a touch screen.....
412-01-25
Sun sensor - vehicles with automatic temperature control .............................................
412-01-26
In-vehicle temperature sensor ........................................................................\
................
412-01-26
Ambient temperature sensor ........................................................................\
..................
412-01-26
Blower motor ........................................................................\
...........................................
412-01-26
Blower control module - vehicles equipped with automatic temperature control ............
REMOVAL AND INSTALLATION 412-01-28
(34 626 4)
Air Conditioning (A/C) Compressor — 2.5L Duratec (147kW/200PS) - VI5 ....
412-01-29
Air Conditioning (A/C) Compressor to Condenser Discharge Line .....................................
412-01-30
Air Conditioning (A/C) Compressor to Condenser Discharge Line — 2.5L Duratec
(147kW/200PS) - VI5 ........................................................................\
................................
412-01-31
Condenser ........................................................................\
..................................................
412-01-35
Clutch and Clutch Field Coil........................................................................\
.......................
412-01-36
Pollen Filter — RHD........................................................................\
...................................
412-01-37
(34

374 0)
Blower Motor — RHD ........................................................................\
.............
412-01-40
(34 382 0)
Blower Motor Resistor — Vehicles With: Manual Temperature Control, RHD .
412-01-41
(34 382 0)
Blower Motor Resistor — Vehicles With: Dual Automatic Temperature
Control ........................................................................\
..................................
412-01- 1
Climate Control
412-01- 1
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412-01-42
Heater Core and Evaporator Core Housing .......................................................................
412-01-45
(34 364 0)
Heater Core — RHD ........................................................................\
...............
412-01-53
Suction Accumulator ........................................................................\
...................................
412-01-56
Suction Accumulator to Air Conditioning (A/C) Compressor Line ......................................
412-01-57
Suction Accumulator to Air Conditioning (A/C) Compressor Line — 2.5L Duratec
(147kW/200PS) - VI5 ........................................................................\
................................
412-01-58
Low-Pressure Cutoff Switch ........................................................................\
.......................
412-01-59
High-Pressure Cutoff Switch ........................................................................\
.......................
412-01-60
Evaporator ........................................................................\
..................................................
412-01-62
Evaporator Outlet Line ........................................................................\
................................
412-01-65
Evaporator Core Orifice ........................................................................\
..............................
412-01-68
Condenser to Evaporator Line........................................................................\
....................
412-01-71
(34 300 0)
Climate Control Assembly — Vehicles With: Manual Temperature Control ....
412-01-72
(34 300 0)
Climate Control Assembly — Vehicles With: Automatic Temperature Control .
412-01-73
(34 485 4)
Footwell Air Discharge Temperature Sensor ..................................................
412-01-74
Center Register Air Discharge Temperature Sensor ..........................................................
412-01-75
In-Vehicle Temperature Sensor ........................................................................\
..................
412-01-76
(34 676 0)
Ambient Air Temperature Sensor ...................................................................
412-01-77
(34 665 0)
Sunload Sensor ........................................................................\
......................
412-01-78
(34 591 0)
Footwell Vent/Duct Blend Door Actuator — RHD ...........................................
412-01-79
(34 606 0)
Air Inlet Blend Door Actuator ........................................................................\
..
412-01-80
(34 608 0)
Driver Side Temperature Blend Door Actuator ...............................................
412-01-81
(34 608 0)
Passenger Side Temperature Blend Door Actuator .......................................
412-01-82
(34 591 0)
Defrost Vent/Register Blend Door Actuator — RHD ......................................
412-01-2
Climate Control
412-01- 2
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A/C compressor
Description
Visteon VS16
A/C compressor (vehicles with 2.0L Duratorq-TDCi (DW 10) engines)
Zexel KC88
A/C compressor (vehicles with 2.5L Duratec-ST (VI5) engine)
G1158274en2008.50 Kuga8/2011
412-01- 3
Climate Control
412-01- 3
SPECIFICATIONS
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Air Conditioning (A/C) Compressor — 2.5L Duratec(147kW/200PS) - VI5(34 626 4)
Materials
Specification
Name
WSH-M1C231-B /
6U7J-M1C231-AA
Compressor Oil - Air
Conditioning
Removal
NOTE:
Removal steps in this procedure may
contain installation details. 1.
Refer to: Air Conditioning (A/C) System
Recovery, Evacuation and Charging (412-00
Climate Control System - General Information,
General Procedures).
2. Refer to: Air Conditioning (A/C) Compressor
Belt (303-05 Accessory Drive - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
3. CAUTION: Make sure that all openings are sealed.
2. Torque: 20Nm
3. Torque: 25Nm
E112667
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3
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Installation
1.To install, reverse the removal procedure.
2. Coat the O-ring seals on the refrigerant lines.
Material: Compressor Oil - Air Conditioning
(WSH-M1C231-B / 6U7J-M1C231-AA)
refrigerant oil
G1158270en2008.50 Kuga8/2011
412-01- 28
Climate Control
412-01- 28
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