AIR CON FORD KUGA 2011 1.G Workshop Manual

Action
Possible Sources
Symptom
• CHECK the air cleaner drainfor blockage. TEST the system
for normal operation.
• Blocked air cleaner drain.
• INSPECT the air cleaner forsigns of blockage. INSTALL a
new air cleaner element as
necessary.
• Air cleaner element blocked.
• Engine lacks power
• INSPECT the charge air coolerpipes for damage. INSTALL a
new charge air cooler pipe(s)
as necessary.
• Charge air cooler pipe(s).
• INSPECT the charge air coolerfor blockage. INSTALL a new
charge air cooler as necessary.
REFER to: Charge Air Cooler
(303-12 Intake Air Distribution
and Filtering - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
• Charge air cooler blocked.
• REFER to:Fuel Charging and
Controls (303-04 Fuel Char-
ging and Controls - 2.5L
Duratec (147kW/200PS) -
VI5, Diagnosis and Testing).
• Fuel charging and controls.
• REFER to:Turbocharger(303-
04 Fuel Charging and
Controls - Turbocharger -
2.5L Duratec (147kW/200PS)
- VI5, Diagnosis and Testing).
• Turbocharger.
• REFER to:Engine(303-00
Engine System - General
Information, Diagnosis and
Testing).
• Engine.
G1183447en2008.50 Kuga8/2011
303-12-
5
Intake Air Distribution and Filtering
— 2.5L Duratec
(147kW/200PS) - VI5
303-12- 5
DIAGNOSIS AND TESTING
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Air Cleaner(23 174 0)
General EquipmentRetaining Strap
Trolley Jack
Removal
NOTE: Removal steps in this procedure may
contain installation details.
1.
E106249
2.
E63329
3.
E112307
4. CAUTION: Make sure that no components catch.
General Equipment: Retaining Strap
General Equipment: Trolley Jack
Torque: 90
Nm
E112303
15 mm
G1079095en2008.50 Kuga8/2011
303-12- 6
Intake Air Distribution and Filtering
— 2.5L Duratec
(147kW/200PS) - VI5
303-12- 6
REMOVAL AND INSTALLATION
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Charge Air Cooler(23 620 0)
Removal
NOTE:Removal steps in this procedure may
contain installation details.
1. Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
2.
E98183
E98184
4. Torque: 5Nm
E99948
Installation
1.To install, reverse the removal.
G1079096en2008.50 Kuga8/2011
303-12- 8
Intake Air Distribution and Filtering
— 2.5L Duratec
(147kW/200PS) - VI5
303-12- 8
REMOVAL AND INSTALLATION
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3.

SECTION 303-13 Evaporative Emissions
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
DIAGNOSIS AND TESTING
303-13-2
Evaporative Emissions ........................................................................\
...............................
303-13-2
Inspection and Verification ........................................................................\
..........................
303-13-1
Evaporative Emissions
303-13- 1
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Evaporative Emissions
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanicalor electrical damage.
Visual Inspection Chart
Electrical
Mechanical
– Fuse(s)
– Wiring harness
– Electricalconnector(s)
– Vacuum line(s)
– Evaporative emis-
sion canister
– Evaporative emis- sion system hose(s)
– Evaporative emis- sion canister purge
valve
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 diagnostic tab within
the Ford approved diagnostic tool.
G165592en2008.50 Kuga8/2011
303-13- 2
Evaporative Emissions
303-13- 2
DIAGNOSIS AND TESTING
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SECTION 303-14 Electronic Engine Controls— 2.5L Duratec
(147kW/200PS) - VI5
VEHICLE APPLICATION: 2008.50 Kuga
PA G E
CONTENTS
DESCRIPTION AND OPERATION
303-14-3
Electronic Engine Controls (Component Location) .............................................................
303-14-7
Electronic Engine Controls (Overview) ........................................................................\
.......
303-14-7
General overview ........................................................................\
........................................
303-14-8
Powertrain Control Module (PCM) ........................................................................\
..............
303-14-8
Knock Sensor ........................................................................\
.............................................
303-14-8
Camshaft Position (CMP) Sensor ........................................................................\
...............
303-14-9
Crankshaft Position (CKP) sensor ........................................................................\
..............
303-14-9
Camshaft adjuster solenoid valve........................................................................\
...............
303-14-9
Manifold absolute pressure and temperature sensor .........................................................
303-14-9
Accelerator pedal position (APP) sensor ........................................................................\
....
303-14-10
Throttle control unit ........................................................................\
.....................................
303-14-10
Engine Coolant Temperature (ECT) sensor.......................................................................
303-14-10
Ignition coil-on-plug ........................................................................\
....................................
303-14-12
Electronic Engine Controls (System Operation and Component Description) ...................
303-14-12
System Diagram ........................................................................\
.........................................
303-14-16
System Operation ........................................................................\
.......................................
303-14-18
Speed and TDC recording ........................................................................\
......................
303-14-19
Calculation of the ignition angle ........................................................................\
..............
303-14-20
Engine fueling ........................................................................\
.........................................
303-14-22
Engine speed control ........................................................................\
..............................
303-14-22
Oil monitoring ........................................................................\
..........................................
303-14-23
Calculation of valve timing adjustment angle..................................................................
303-14-23
Boost pressure control ........................................................................\
............................
303-14-24
Starting process ........................................................................\
......................................
303-14-24
Alternator control (Smart Charge) ........................................................................\
...........
303-14-24
Component Description ........................................................................\
..............................
303-14-24

CKP sensor ........................................................................\
.............................................
303-14-25

Broadband HO2S ........................................................................\
...................................
303-14-26

VCT (variable camshaft timing) solenoids ......................................................................
303-14-27

MAF sensor ........................................................................\
.............................................
303-14-28

APP sensor ........................................................................\
.............................................
303-14-29

CPP sensor ........................................................................\
.............................................
303-14-29

BPP switches ........................................................................\
..........................................
303-14-30

Air conditioning (A/C) pressure sensor ........................................................................\
...
303-14-30

Throttle
control unit ........................................................................\
.................................
303-14-31

ECT sensor ........................................................................\
.............................................
303-14-31

Cooling fan module ........................................................................\
.................................
303-14-32

injectors........................................................................\
...................................................
303-14-32

Ignition coil-on-plug ........................................................................\
.................................
303-14-33

Fuel pressure/fuel temperature sensor ........................................................................\
...
303-14-33

Wastegate control valve ........................................................................\
..........................
303-14-34

Engine oil level, temperature and quality sensor ............................................................
303-14-1
Electronic Engine Controls— 2.5L Duratec (147kW/200PS) - VI5303-14-
1
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303-14-34
Exterior aor temperature sensor ........................................................................\
.............
DIAGNOSIS AND TESTING 303-14-35
Electronic Engine Controls ........................................................................\
.........................
303-14-35
Inspection and Verification ........................................................................\
..........................
REMOVAL AND INSTALLATION 303-14-36
(29 232 0)
Camshaft Position (CMP) Sensor ...................................................................
303-14-37
(29 219 0)
Catalyst Monitor Sensor ........................................................................\
.........
303-14-38
(29 230 0)
Crankshaft Position (CKP) Sensor .................................................................
303-14-40
(29 220 0)
Heated Oxygen Sensor (HO2S) .....................................................................
303-14-41
(29 222 0)
Knock Sensor (KS) ........................................................................\
.................
303-14-42
(29 226 0)
Mass Air Flow (MAF) Sensor ........................................................................\
..
303-14-43
(29 200 0)
Powertrain Control Module (PCM) .................................................................
303-14-45
(29 233 0)
Variable Valve Timing (VVT) Oil Control Solenoid ..........................................
303-14-46
(33 502 0)
Brake Pedal Position (BPP) Switch ................................................................
303-14-47
(33 503 0)
Clutch Pedal Position (CPP) Switch ...............................................................
303-14-2
Electronic Engine Controls— 2.5L Duratec (147kW/200PS) - VI5303-14-
2
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Electronic Engine Controls – Component Location
E96941
1
12
2
3
4
5
6
7
8
9
10
11
Description
Item
Throttle control unit
1
injectors
Comments:One injector for each cylinder
2
Fuel pressure/fuel temperature sensor
3Description
Item
VVT (variable valve timing) - exhaust
camshaft solenoid
Comments:One each for the inlet and outlet
camshaft
4
Ignition coil-on-plug
Comments:One injection coil for each cylinder
5
G1021906en2008.50 Kuga8/2011
303-14-
3
Electronic Engine Controls— 2.5L Duratec (147kW/200PS) - VI5303-14-
3
DESCRIPTION AND OPERATION
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Description
Item
CMP (camshaft position) sensor
Comments:One each for the inlet and outlet
camshaft
6
EVAP (evaporative emission) valve
7
CKP (crankshaft position) sensor
8Description
Item
MAF (mass air flow) sensor
9
PCM (powertrain control module)
10
Fan control module
11
MAPT (manifold absolute pressure and
temperature) sensor
12
E96950
1
23
4
56
G1021906en2008.50 Kuga8/2011
303-14-
4
Electronic Engine Controls— 2.5L Duratec (147kW/200PS) - VI5303-14-
4
DESCRIPTION AND OPERATION
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Description
Item
Catalyst monitor sensor
1
Fuel pressure/fuel temperature sensor
2
Throttle control unit
3
Ambient air temperature sensor
4Description
Item
MAPT sensor
5
KS (knock sensor)
Comments:Two, on 2nd and 4th cylinder
6
E96980
1
234
Description
Item
EVAP valve
1
Wastegate control valve
2Description
Item
Turbo boost pressure controller
3
HO2S (heated oxygen sensor)
4
G1021906en2008.50 Kuga8/2011
303-14- 5
Electronic Engine Controls— 2.5L Duratec (147kW/200PS) - VI5303-14-
5
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