check engine FORD KUGA 2011 1.G Service Manual

Action
Possible Sources
Symptom
• CHECK the ignition system.Engine - 2.5L Duratec-ST (VI5)
-
REFER to: Engine Ignition
(303-07 Engine Ignition - 2.5L
Duratec (147kW/200PS) -
VI5, Diagnosis and Testing).
• Fault in ignition system (petrol
engine only).
• CHECK the turbocharger.Engine - 2.5L Duratec-ST (VI5)
-
REFER to: Turbocharger (303-
04 Fuel Charging and
Controls - Turbocharger -
2.5L Duratec (147kW/200PS)
- VI5, Diagnosis and Testing).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Turbocharger.
• CHECK and adjust valvetiming. INSTALL new compon-
ents as necessary. Engine -
2.5L Duratec-ST (VI5) -
REFER to: Timing Belt (303-01
Engine - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Incorrect valve timing. Timing
belt/timing sprocket or
pulley/sprocket damaged.
• CHECK the electronic enginecontrols. Engine - 2.5L Duratec-
ST (VI5) -
REFER to: Electronic Engine
Controls (303-14 Electronic
Engine Controls - 2.5L
Duratec (147kW/200PS) -
VI5, Diagnosis and Testing).
• Ignition timing incorrect (petrol
engine only).
• CHECK engine auxiliarycomponents for damage or
looseness. CHECK and adjust
valve timing. INSTALL new
components as necessary.
Engine - 2.5L Duratec-ST (VI5)
-
REFER to: Timing Belt (303-01
Engine - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Engine auxiliary components
loose or damaged.
• Noisy running
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Engine System - General Information
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Action
Possible Sources
Symptom
• DETERMINE which type of fuelwas last put into the fuel tank
(note the country specific fuel
specifications).
• Incorrect fuel
• Noisy running, misfiring, back-
firing or knocking
• CHECK the fuel system forwater or other contamination.
• Water in fuel or fuel contamin-
ated.
• CHECK and adjust valvetiming. INSTALL new compon-
ents as necessary. Engine -
2.5L Duratec-ST (VI5) -
REFER to: Timing Belt (303-01
Engine - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Valve timing incorrect, timing
belt/chain or pulley/sprocket
damaged.
• INSTALL new hydraulic lashadjusters or adjust the valve
clearance. Engine - 2.5L
Duratec-ST (VI5) -
REFER to: Valve Clearance
Adjustment (303-01 Engine -
2.5L Duratec (147kW/200PS)
- VI5, General Procedures).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Valve clearance too large due
to faulty valve tappets or worn
valve train components.
• Noisy running or valve train
noise
• INSTALL a new timing belt ortiming chain. Engine - 2.5L
Duratec-ST (VI5) -
REFER to: Timing Belt (303-01
Engine - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Timing belt or timing chain
damaged.
• CHECK the timing belt tension.INSTALL a new timing belt or
timing chain as necessary.
Engine - 2.5L Duratec-ST (VI5)
-
REFER to: Timing Belt (303-01
Engine - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Timing belt or timing chain
incorrectly tensioned.
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Action
Possible Sources
Symptom
• CHECK the engine compon-ents for wear or damage. Make
sure that all components are
within specification. INSTALL
new components as necessary.
Engine - 2.5L Duratec-ST (VI5)
-
REFER to: Specifications (303-
01 Engine - 2.5L Duratec
(147kW/200PS) - VI5,
Specifications).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Engine components
- Pistons.
- Piston rings.
- Connecting rod big end,main bearing or thrust
bearing journals.
- Connecting rods bent or damaged.
• Noisy running or engine noise
Engine - Oil Leaks
NOTE:
Before installing new gaskets or oil seals,
make sure that the fault is clearly established.
If the oil leak cannot be identified clearly by a visual
inspection, carry out an ultraviolet (UV) test:
Ultraviolet (UV) Testing
1. Clean the engine and transmission with a suitable cleaning fluid.
2. Pour the UV-test fluid in accordance with the quantity specified by the manufacturer through
the oil filler neck into the engine and install the
oil filler cap.
WARNING: Vehicles with manual transaxle,
shift the transaxle into Neutral. Failure to
follow this instruction may result in
personal injury.
3. Start the engine and let it run for about five minutes.
4. Switch off the engine.
NOTE: If no leak can be found, road test the
vehicle under various loads and check the engine
for leaks again.
5. Check the engine for oil leaks using a suitable UV lamp.
6. Rectify any leaks found and check the engine for oil leaks.
Measure the compression pressure
NOTE: The powertrain control module (PCM)
receives an error message when the fuel pump
relay is removed or electrical components are disconnected. This error message must be deleted
from the fault memory using the Ford diagnostic
equipment after completing the compression test.
NOTE:
Valve clearance must be set correctly
before performing a compression test. Make sure
the engine is at the normal operating temperature.
NOTE: The varying design of compression
checking devices and fluctuating starter motor
speeds normally only allows for a comparison to
be made of the compression pressures in all
cylinders.
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9. Install the ignition coil-on-plug.REFER to: Ignition Coil-On-Plug (303-07 Engine
Ignition - 2.5L Duratec (147kW/200PS) - VI5,
Removal and Installation).
TIE44609
10. Install the fuel pump relay and close the CJB.
TIE44608
11. Install the CJB cover.
Measure the compression pressure
(Engine - 2.0L Duratorq-TDCi (DW)
Diesel)
WARNINGS:
Do not smoke or carry lighted tobacco or
open flame of any type when working on or near any fuel related components.
Highly flammable vapors are always
present and can ignite. Failure to follow
these instructions may result in personal
injury.
Do not carry out any repairs to the fuel
injection system without checking that the
fuel pressure has dropped to zero and that
the fuel temperature has either reached
ambient temperature or is below 30°C,
whichever is the greater. Failure to follow
these instructions may result in personal
injury.
1. Using datalogger in the Ford diagnostic
equipment , check that the fuel pressure has
dropped to zero and that the fuel temperature
has either reached ambient temperature or is
below 30°C, whichever is the greater.
2. Raise and support the vehicle.
REFER to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
VFE0035742
3. Remove the engine undershield.
VFE0035752
4. Remove the radiator undershield.
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E65955
13. Install the engine undershield.
14. Lower the vehicle.
Measure the oil pressure (Engine - 2.0L
Duratorq-TDCi (DW) Diesel)
1. Raise and support the vehicle.REFER to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
TIE40578
2. Remove the engine under shield.
TIE39595
3. Disconnect the oil pressure switch electrical connector.
TIE39596
4. Remove the oil pressure switch.
TIE39705
5. Attach the oil pressure gauge with the oilpressure gauge connector.
6. NOTE: Measure the oil pressure at the specified engine speed. Measure the oil
pressure at an oil temperature of 80° C.
NOTE: Measure the oil pressure at 2000 rpm and
at 4000 rpm.
NOTE: Oil pressure at 2000 rpm: 2.0 bar.
NOTE: Oil pressure at 4000 rpm: 4.0 bar.
Check the oil pressure.
TIE39705
7. Detach the oil pressure gauge and the oil pressure gauge connector.
8. Coat the oil pressure switch with adhesive.
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TIE39704
35 Nm
9. Install the oil pressure switch.
TIE39595
10. Connect the oil pressure switch electricalconnector.
VFE0035742
11. Install the engine under shield.
12. Lower the vehicle.
Valve train analysis - static (engine off)
Remove the valve cover.
Check all valve train components for damage and
wear. Make sure that only original components are
installed and that all bolts and nuts have been
tightened to the correct tightening torque.
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Timing marks
132
45
6
78
E62440
Description
Item
Exhaust camshaft pulley timing mark
1
Engine front cover with timing marks
2
Intake camshaft pulley timing mark
3
Intake camshaft drive gear
4Description
Item
Exhaust camshaft drive gear
5
Crankshaft timing belt pulley timing mark
6
Crankshaft timing belt pulley
7
Crankshaft
8
The front engine cover must always be fitted when
checking and adjusting the valve timing or timing
belt tension, as the timing marks for both camshaft
pulleys are provided on its front end.
Correct timing belt tension is ensured by the
automatic timing belt tensioner.
No direction of movement is specified when using
a new timing belt. If, however, the old timing belt
is reused, the direction of movement must be
marked prior to removal.
Once the timing belt has been correctly tensioned,
the engine must be rotated by hand two turns
clockwise at the crankshaft in order to allow a subsequent check of the timing belt tension and
adjustment.
Cylinder block
The cylinder block consists of three parts. These
are the cylinder block, the lower crankcase and the
sump pan. The cylinder block has five cylinder
liners made of cast iron, which cannot be replaced.
The pistons are made of a homogeneous aluminum
alloy with a graphite coating on the sides. This
coating serves to reduce friction and dampen noise.
The pistons are cooled from below via oil-spray
nozzles screwed into the cylinder block.
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Fuel Charging and Controls
General EquipmentFord diagnostic equipment
Inspection and Verification
1. Verify the customer concern by operating the system.
2. Visually inspect for obvious signs of mechanical or electrical damage. Visual Inspection Chart
Electrical
Mechanical
– Loose or corrodedconnector(s)
– Wiring harness
– Fuel injector(s)
– Fuel leaks
– Blocked or contamin-
ated fuel filter
– Damaged fuel supply manifold
– Damaged fuel line connections
– Damaged vacuum hoses
– Fuel rail pressure sensor
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 concern is not visually evident, verify the symptom and refer to the Ford diagnostic
equipment .
Symptom Chart
Action
Possible Sources
Symptom
• CHECK the PATS LED extin-guishes within 3 seconds when
the ignition is turned on.
REFER to: Anti-Theft - Passive
(419-01 Anti-Theft - Passive,
Diagnosis and Testing).
• PAT S .
• Engine does not crank
• REFER to:Starting System
(303-06 Starting System -
2.5L Duratec (147kW/200PS)
- VI5, Diagnosis and Testing).
• Starting system.
• REFER to the Wiring Diagrams.
• Ignition switch.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• Powertrain control module
(PCM).
• RESET the IFS switch.
• Inertia fuel shutoff (IFS) switch.
• Engine cranks but does not
start
• Check the fuel system pres-sure.
• Low fuel system pressure.
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Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 4
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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.
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— 2.5L Duratec (147kW/200PS) -
VI5
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Action
Possible Sources
Symptom
• Check the fuel system pres-sure.
• Low fuel system pressure.
• Poor starting
• CHECK the system for fuelleak(s). REPAIR the system as
necessary.
• Fuel system leak.
• INSPECT the fuel system.INSTALL new components as
necessary. TEST the system
for normal operation.
• Fuel system restriction.
• INSTALL a new fuel filter.
• Fuel filter blocked.
• INSTALL a new air cleanerelement.
• Air cleaner element blocked.
• INSTALL a new engine oil filterand engine oil.
• Incorrect engine oil.
• DRAIN and REFILL the powersteering system with the correct
fluid.
REFER to: Power Steering
System Filling (211-00
Steering System - General
Information, General Proced-
ures).
• Incorrect power steering fluid.
• 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.
• Engine coolant temperature
(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 injector(s).
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• Fuel rail fuel pressure sensor.
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Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 6
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