Scr FORD KUGA 2011 1.G Workshop Manual

Spring Lock Coupling
Special Tool(s)412-026
Disconnect Tool, Spring Lock
Coupling (3/8" red)
23023A
412-027
Disconnect Tool, Spring Lock
Coupling (1/2" blue)
34001
412-038
Disconnect Tool, Spring Lock
Coupling (5/8" black)
34003
412-069
Disconnect Tool, Spring Lock
Coupling (3/4" white)
34002
Materials
Specification
Name
WSH-M1C231-B /
6U7J-M1C231-AA
Compressor Oil - Air
Conditioning 1.
Refer to: Air Conditioning (A/C) System Health
and Safety Precautions (100-00 General
Information, Description and Operation).
2. NOTE: Choose the special tool according to the
line diameter.
Special Tool(s): 412-026, 412-027, 412-038,
412-069
E68499
3.
E68500
4. CAUTION: Make sure that all openings are sealed.
E68501
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Climate Control System - General Information
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Air Conditioning (A/C) Clutch Air Gap Adjustment
1.Check the gap A (measure the difference
between the engaged and disengaged positions
of the air conditioning clutch) at 60° intervals
around the circumference of the pulley. Operate
the air conditioning clutch several times with the
aid of a 5 A fused cable. Refer to the relevant
wiring diagram for the correct electrical
connection.
Refer to: Specifications (412-00 Climate Control
System - General Information, Specifications).
E92144
A
2.
E68442
3. If necessary correct the gap A using spacer
washers.
E68470
4.Refer to: Specifications (412-00 Climate Control
System - General Information, Specifications).
E68442
5. Check the gap A as described in step 1. If
necessary, repeat steps 2-5.
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Climate Control System - General Information
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Electronic Leak Detection
1.Refer to: Air Conditioning (A/C) System Health
and Safety Precautions (100-00 General
Information, Description and Operation).
2. WARNINGS:
Before starting leak detection, make
sure that the area where it is to be done
is well ventilated. If the surrounding air
is contaminated with refrigerant gas, the
leak detector will indicate this gas all
the time. Odors from other chemicals
such as antifreeze, diesel fuel, disc
brake cleaner, or other cleaning
solvents can cause the same problem.
Prevent air movement while performing
leak detection.
The refrigerant identification equipment
must be used before attaching the
manifold gauge set. Otherwise the
manifold gauge set may become
contaminated. Contaminated refrigerant
must be disposed of as special waste.
Follow the manufacturer's instructions
when working with the service unit.
NOTE: At 24°C with the engine switched off,
both manifold gauges should show 4.1 to 5.5
bar.
Attach the manifold gauge set to the service
gauge port valves.
3. For the leak test, close the manual valves on
the gauge set.
4. If little or no pressure is indicated, charge the
system with approx. 300g of refrigerant. Refer
to: Air Conditioning System - Evacuate and
Refill.
5. Use the R-134a Automatic Calibration Halogen
Leak Detector to leak test the refrigerant system.
Follow the instructions included with leak
detector for handling and operation techniques.
6. If any leak is found, extract the refrigerant under
suction. Refer to: Air Conditioning System -
Evacuate and Refill.
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Climate Control System - General Information
412-00- 14
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Fluorescent Dye Leak Detection
General EquipmentUV Leak Detector
1. Refer to: Air Conditioning (A/C) System Health
and Safety Precautions (100-00 General
Information, Description and Operation).
2. NOTE: Some vehicles may have signs of
refrigerant oil at the spring lock couplers. The
cause of this may be a procedure used in
production before installation of the fittings in
order to assist their assembly. When a spring
lock coupler is suspected of leaking, always
wipe the fitting clean and verify the leak with
R-134a Automatic Calibration Halogen Leak
Detector.
NOTE: The exact location of leaks can be
pinpointed by the bright yellow - green glow of
the tracer dye. Since more than one leak can
exist, always inspect each component.
• Locate the leaks. Check all components, fittings and lines of the A/C system for leaks.
General Equipment: UV Leak Detector
3. After the leak is found and rectified, remove any
traces of dye with a general purpose solvent.
4. Check the repair by operating the system for
some minutes and inspecting with the UV lamp
again.
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Climate Control System - General Information
412-00- 15
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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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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)
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Climate Control
412-01- 3
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Climate Control – Component Location
Air distribution, instrument cluster
3
3
3
1
1
2
2
4
6
6
5
E97259
Description
Item
Air passages - side window defroster vents
1
Air passages - side vents (adjustable)
2
Air passages – defroster vents
3Description
Item
Air passages - center vents
4
Air ducts, rear footwell
5
Air ducts, front footwell
6
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Climate Control
412-01- 4
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Air distribution, passenger compartment
E97260
14
2
2
3
4
Description
Item
Air duct, demister vents
1
Air ducts, front footwell
2Description
Item
Air ducts, rear footwell
3
Air passages - center vents
4
Control assembly, climate control - vehicles with
manual temperature control
E97585
Control assembly, climate control - vehicles with
automatic temperature control
E97586
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412-01- 5
Climate Control
412-01- 5
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Control assembly, climate control - vehicles with
DVD navigation system with a touch screen
E97587
Climate control module - vehicles with DVD
navigation system with a touch screen
E68600
Sun sensor - vehicles with automatic temperature
control
E97590
Blower control module - vehicles equipped with
automatic temperature control
E78221
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412-01-6
Climate Control
412-01- 6
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Climate control
32
1
4
5
6
789
E97591
Description
Item
Condenser
1
Air conditioning compressor
2
High pressure filling connection
3
Refrigerant drier
4Description
Item
Dual pressure switch
5
Low pressure filling connection
6
Low pressure limiting switch
7
Evaporator Core Orifice Tube
8
Evaporator assembly
9
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412-01- 7
Climate Control
412-01- 7
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