belt FORD KUGA 2011 1.G Service Manual

Action
Possible Sources
Symptom
• INSPECT the fuel lines.INSTALL new components as
necessary. TEST the system
for normal operation.
• Fuel lines damaged or blocked.
• INSTALL a new fuel filter.
• Fuel filter blocked.
• REFER to:Fuel Pump and
Sender Unit - 2.5L Duratec
(147kW/200PS) - VI5 (310-01
Fuel Tank and Lines,
Removal and Installation).
• Fuel pump and sender unit.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• Crankshaft position (CKP)
sensor.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• Camshaft position (CMP)
sensor.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
•PCM.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• Fuel rail fuel pressure sensor.
• INSPECT the fuel injectors.CLEAN the fuel injectors or
INSTALL a new set of injectors
as required only after the
checks have been carried out.
REFER to: Fuel Injectors (303-
04 Fuel Charging and
Controls - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
• Fuel injectors.
• CHECK the valve timing.REFER to: Timing Belt (303-01
Engine - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
• Incorrect valve timing.
• TEST the cylinder compres-sion.
REFER to: Engine(303-00
Engine System - General
Information, Diagnosis and
Testing).
• Low cylinder compression.
G1183441en2008.50 Kuga8/2011
303-04A-
5
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 5
DIAGNOSIS AND TESTING
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Action
Possible Sources
Symptom
• CHECK for signs of contamina-tion such as strange odors from
the fuel tank.
• If contaminated fuel is found, DRAIN the complete fuel
system. FLUSH the fuel system
through with clean gasoline.
REFER to: Fuel Tank Draining
(310-00 Fuel System -
General Information, General
Procedures).
INSTALL a new fuel filter.
• INSPECT the fuel injectors. CLEAN the fuel injectors or
INSTALL a new set of injectors
as required only after the
checks have been carried out.
• INSTALL a new fuel rail.
REFER to: Fuel Rail(303-04
Fuel Charging and Controls -
2.5L Duratec (147kW/200PS)
- VI5, Removal and Installa-
tion).
• Incorrect or contaminated fuel.
• INSTALL a new fuel filter.
• Fuel filter blocked.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• ECT sensor.
• INSPECT the fuel injectors.CLEAN the fuel injectors or
INSTALL a new set of injectors
as required only after the
checks have been carried out.
REFER to: Fuel Injectors (303-
04 Fuel Charging and
Controls - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
• Fuel injectors.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• Fuel rail fuel pressure sensor.
• CHECK the valve timing.REFER to: Timing Belt (303-01
Engine - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
• Incorrect valve timing.
G1183441en2008.50 Kuga8/2011
303-04A-
10
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 10
DIAGNOSIS AND TESTING
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Action
Possible Sources
Symptom
• CHECK the valve timing.REFER to: Timing Belt (303-01
Engine - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
• Incorrect valve timing.
• INSTALL a new air cleanerelement as necessary.
• Air cleaner element blocked.
• Excessive black smoke during
acceleration
• CHECK for signs of contamina-tion such as strange odors from
the fuel tank.
• If contaminated fuel is found, DRAIN the complete fuel
system. FLUSH the fuel system
through with clean gasoline.
REFER to: Fuel Tank Draining
(310-00 Fuel System -
General Information, General
Procedures).
INSTALL a new fuel filter.
• INSPECT the fuel injectors. CLEAN the fuel injectors or
INSTALL a new set of injectors
as required only after the
checks have been carried out.
• INSTALL a new fuel rail.
REFER to: Fuel Rail(303-04
Fuel Charging and Controls -
2.5L Duratec (147kW/200PS)
- VI5, Removal and Installa-
tion).
• Incorrect or contaminated fuel.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• CKP sensor.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• KS.
• INSPECT the fuel injectors.CLEAN the fuel injectors or
INSTALL a new set of injectors
as required only after the
checks have been carried out.
REFER to: Fuel Injectors (303-
04 Fuel Charging and
Controls - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
• Fuel injectors.
G1183441en2008.50 Kuga8/2011
303-04A-
12
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 12
DIAGNOSIS AND TESTING
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Action
Possible Sources
Symptom
• CHECK the valve timing.REFER to: Timing Belt (303-01
Engine - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
• Incorrect valve timing.
• REMOVE the cylinder head.INSPECT the cylinder head
and pistons for signs carbon
build up.
REFER to: Cylinder Head (303-
01 Engine - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
• Excessive carbon build up.
• INSPECT the engine compon-ents.
• Worn or damaged oil pump.
• Worn or damaged timing chain
or sprocket.
• Major mechanical engine failure.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• KS.
• Engine knock during accelera-
tion
• INSPECT the fuel injectors.CLEAN the fuel injectors or
INSTALL a new set of injectors
as required only after the
checks have been carried out.
REFER to: Fuel Injectors (303-
04 Fuel Charging and
Controls - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
• Fuel injectors.
• REFER to:Engine(303-00
Engine System - General
Information, Diagnosis and
Testing).
• Major mechanical engine
failure.
• CHECK the braking system.REFER to: Brake System (206-
00 Brake System - General
Information, Diagnosis and
Testing).
• Brakes binding.
• Excessive fuel consumption
• ADVISE the customer aboutthe effects of overloading the
vehicle and wind resistance on
the fuel consumption.
• Vehicle overloaded, or
excessive wind resistance (roof
racks, towing etc).
• INSTALL a new air cleanerelement.
• Air cleaner element blocked.
G1183441en2008.50 Kuga8/2011
303-04A-
19
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 19
DIAGNOSIS AND TESTING
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Action
Possible Sources
Symptom
• CHECK the system for fuelleak(s). REPAIR or INSTALL
new parts as necessary.
• Fuel system leak(s).
• INSTALL a new fuel filter.
• Fuel filter blocked.
• INSTALL a new oil filter andengine oil.
• Incorrect engine oil.
• REFER to the Ford diagnosticequipment.
• Generator.
•
• Slipping clutch.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• ECT sensor.
• INSPECT the fuel injectors.CLEAN the fuel injectors or
INSTALL a new set of injectors
as required only after the
checks have been carried out.
REFER to: Fuel Injectors (303-
04 Fuel Charging and
Controls - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
• Fuel injectors.
• Using the Ford diagnosticequipment, CHECK for the
availability of a calibration
update.
• PCM calibration.
• CHECK the valve timing.REFER to: Timing Belt (303-01
Engine - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
• Incorrect valve timing.
• CHECK the engine compres-sion.
REFER to: Engine(303-00
Engine System - General
Information, Diagnosis and
Testing).
• Low cylinder compression.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• CMP sensor.
• Engine cuts out during hard
acceleration
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• CKP sensor.
G1183441en2008.50 Kuga8/2011
303-04A-
20
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 20
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
DESCRIPTION AND OPERATION
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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
DESCRIPTION AND OPERATION
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Accessory Drive
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanicaldamage.
Visual Inspection Chart
Mechanical
– Damaged or contaminated accessory drive belt or air conditioning (A/C) compressor belt
– Damaged or contaminated pulley(s)
– Incorrect accessory drive belt or A/C compressor belt
– Incorrect fitment of the accessory drive belt or A/C compressor belt
– Accessory drive belt tensioner
– Accessory drive belt idler pulley
– Generator
– A/C compressor
– A/C compressor belt tensioner
– Pulley(s)
– Loose hardware
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible)
before proceeding to the next step.
Accessory Drive Belt Concerns
CAUTION: Do not lubricate the accessory
drive belt, accessory drive belt tensioner(s)
or idler pulley(s) as potential damage to
the accessory drive belt material
construction, accessory drive belt
tensioner damping mechanism, accessory
drive belt tensioner pulley bearing and idler
pulley(s) bearing may occur.
NOTE: All the diagnosis and testing information
contained within this procedure can be used for
the accessory drive belt and the A/C compressor
belt.
Cracking
Accessory drive belts are made from rubber which
hardens with time and can develop cracks. As the
accessory drive belt runs on the back of some of
the pulleys, the cracks are opened up. Small cracks
are not considered to be a failure of the accessory drive belt. Only if the crack is deep enough to reach
the bottom of the groove to expose the cord or any
chunks are found to be missing from the accessory
drive belt, is the accessory drive belt condition
considered to be unacceptable.
1. Check the accessory drive belt for cracks. If the
damage exceeds the acceptable limit, 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
Installation).
Chunking
Chunking describes the condition where long
lengths of rubber become detached from the ribs
of the accessory drive belt. This is considered to
be a failure of the accessory drive belt.
MPZ9632071
2. Check the accessory drive belt for damage. If any chunks are found to be missing, 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
Installation).
G1183443en2008.50 Kuga8/2011
303-05- 4
Accessory Drive— 2.5L Duratec (147kW/200PS) - VI5303-05-
4
DIAGNOSIS AND TESTING
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Pilling
Pilling is dust that forms in between the ribs of the
accessory drive belt from rubber that is worn off
the accessory drive belt when it is new. There may
also be loose particles left on the accessory drive
belt during the manufacturing process. These are
worn off and form into small balls of rubber that
then get trapped in the grooves of the accessory
drive belt. This condition will usually clear itself
within 4800 km - 8000 km (3000 miles - 5000 miles)
of normal driving.
VUE0037805
3. Check the accessory drive belt for pilling. Thecondition of the accessory drive belt should be
compared against the illustration.
1. Small scattered pills. Not considered a concern. No action required.
2. Small scattered pills. Not considered a concern. No action required.
3. Longer pills up to 50% of the rib height. Possible noise concern. INSTALL a new
accessory drive belt if noise is apparent.
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 Installation).
4. Longer pills up to 50% of the rib height. Possible noise concern. INSTALL a new
accessory drive belt if noise is apparent.
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 Installation).
5. Heavy deposits in the grooves. Possible noise and stability concern. 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 Installation).
6. Heavy deposits in the grooves. Possible noise and stability concern. 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 AccessoryDrive
- 2.5L Duratec (147kW/200PS) - VI5,
Removal and Installation).
Incorrect fitment
Accessory drive belt noise can be generated by
the accessory drive belt being incorrectly fitted on
the pulley as shown in the following illustration.
Make sure that all the V grooves on the accessory
drive belt contact correctly with the pulley.
G1183443en2008.50 Kuga8/2011
303-05- 5
Accessory Drive— 2.5L Duratec (147kW/200PS) - VI5303-05-
5
DIAGNOSIS AND TESTING
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL