all FORD KUGA 2011 1.G Manual PDF

Evaporator Core Orifice
Special Tool(s)
412-027
Disconnect Tool, Spring Lock
Coupling (1/2" blue) 412-034
Remover/Installer, Evaporator
Core Orifice Special Tool(s)
412-034-01
Adapter for 412-034 412-035
Remover, Damaged
Evaporator Core Orifice
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: Cowl Panel Grille (501-02 Front End
Body Panels, Removal and Installation).
3. G1071472en
2008.50 Kuga 8/2011 412-01-65
Climate Control
412-01-65
REMOVAL AND INSTALLATIONTO MODEL INDEX
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL34001 34004 E129004 34005

Using the special tools, remove the broken fixed
orifice tube.
Special Tool(s): 412-034, 412-035
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 G1071472en
2008.50 Kuga 8/2011 412-01-67
Climate Control
412-01-67
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUALVFV9510034412-034412-035

4. CAUTION: Make sure that all openings
are sealed. Use new blanking caps. Special Tool(s): 412-027
Torque: 25
Nm 5.
6. CAUTION: Make sure that all openings
are sealed. Use new blanking caps. Torque: 8 Nm
G1065547en
2008.50 Kuga 8/2011 412-01-69
Climate Control
412-01-69
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In-Vehicle Temperature Sensor
Removal
1.
2.
3. 4.
Installation
1.
To install, reverse the removal procedure. G1158232en
2008.50 Kuga 8/2011 412-01-75
Climate Control
412-01-75
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUALE100834 E95563 E9963912 E112941

Ambient Air Temperature Sensor(34 676 0)
Removal
1.
2.
Installation
1.
To install, reverse the removal procedure. G1158234en
2008.50 Kuga 8/2011 412-01-76
Climate Control
412-01-76
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUALE112925x4 E112926

Footwell Vent/Duct Blend Door Actuator — RHD(34 591 0)
Removal
1.
Refer to: Floor Console Extension - Vehicles
With: Center Armrest (501-12 Instrument
Panel and Console, Removal and Installation).
2. 3.
Installation
1.
To install, reverse the removal procedure. G1065565en
2008.50 Kuga 8/2011 412-01-78
Climate Control
412-01-78
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUALE102293 E101545x2x3

Air Inlet Blend Door Actuator(34 606 0)
Removal
1.
Refer to: Floor Console Extension - Vehicles
With: Center Armrest (501-12 Instrument
Panel and Console, Removal and Installation).
2. 3.
Installation
1.
To install, reverse the removal procedure. G1065557en
2008.50 Kuga 8/2011 412-01-79
Climate Control
412-01-79
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUALE102293 E100655x3

5.
Installation
1.
To install, reverse the removal procedure. G1065563en
2008.50 Kuga 8/2011 412-01-83
Climate Control
412-01-83
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUALE100671x3

SECTION 412-02 Auxiliary Climate Control
VEHICLE APPLICATION:
2008.50 Kuga
PAGE
CONTENTS
DESCRIPTION AND OPERATION
412-02-2
Auxiliary Climate Control (Component Location) ................................................................
412-02-4
Auxiliary Climate Control (Overview) ..................................................................................
412-02-4
Initial start-up of the fuel-fired booster heater .....................................................................
412-02-4
Lockout ...............................................................................................................................
412-02-4
Unlocking the control unit ...................................................................................................
412-02-5
Auxiliary Climate Control (System Operation and Component Description) ......................
412-02-5
System Diagram.................................................................................................................
412-02-12
System Operation ...............................................................................................................
412-02-12
Electric Booster Heater ...................................................................................................
412-02-12
Fuel-fired heater - function diagram................................................................................
412-02-13
Boost heat mode.............................................................................................................
412-02-13
Programmable fuel fired booster heater .........................................................................
412-02-13
Immediate start-up of the booster heater ........................................................................
412-02-13
Programmed start-up of the booster heater ....................................................................
412-02-14
Emergency shutoff ..........................................................................................................
412-02-14
Component Description ......................................................................................................412-02-14Electric Booster Heater...................................................................................................
412-02-14Detailed illustration of fuel-fired heater ...........................................................................
412-02-16Flame sensor..................................................................................................................
412-02-16Overheat Sensor.............................................................................................................
412-02-16ECT.................................................................................................................................
412-02-16Water pump....................................................................................................................
412-02-16Fuel pump.......................................................................................................................
REMOVAL AND INSTALLATION 412-02-17
Auxiliary Coolant Flow Pump ..............................................................................................
412-02-18
Electric Booster Heater .......................................................................................................
412-02-21
Fuel Fired Booster Heater — 2.5L Duratec (147kW/200PS) - VI5 .....................................
412-02-25
Fuel Fired Booster Heater Fuel Pump ................................................................................
DISASSEMBLY AND ASSEMBLY 412-02-26
Fuel Fired Booster Heater .................................................................................................. 412-02-1
Auxiliary Climate Control
412-02-1
.
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

System Operation
Electric Booster Heater
In diesel vehicles which give off little residual heat,
a booster heater is used to heat the passenger
compartment rapidly in the case of low ambient
temperatures.
If the interior temperature has been set to HI, or if
the heater controls have been switched to the
highest setting, the two-zone air conditioning
system sends an "electric booster heater ON"
request signal to the CAN (controller area network)
via the medium speed GEM bus. If a manual air
conditioning system is installed, the signal is
transmitted via a conventional cable connection.
The GEM switches on the electric booster heater
depending on the following parameters:
• Engine coolant temperature is below 60 °C.
• Ambient air temperature is below 10 °C.
• Sufficient generator capacity is available.
The electric booster heater electronics activate
three output stages as a function of a pulse width
modulated signal PWM (pulse width modulation)
generated by the GEM. The output stages switch
the three heating elements of the electric booster
heater ON or OFF individually, whereby the heating
periods of the individual elements can overlap. Due
to the variable switch-on duration, continuously
variable temperature control is possible. The overall
heating power of the three heating elements is
linearly proportional to the PWM signal. If the PWM
signal is below 10% or above 95%, the electric
booster heater is not activated.
The electric booster heater is switched off when
an engine coolant temperature of 70°C or an
ambient air temperature of 20°C is exceeded.
Fuel-fired heater - function diagram G1066982en
2008.50 Kuga 8/2011 412-02-12
Auxiliary Climate Control
412-02-12
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