fuel FORD KUGA 2011 1.G Manual PDF

Action
Possible Sources
Symptom
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• Fuel rail fuel pressure sensor.
• Check the fuel system pres-sure.
• Low fuel system pressure.
G1183441en2008.50 Kuga8/2011
303-04A-
21
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 21
DIAGNOSIS AND TESTING
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Fuel Injectors
MaterialsSpecification
Name
WSS-M2C911-A
Engine Oil - 5W-30
Removal
NOTE: Removal steps in this procedure may
contain installation details.
1. Refer to: Fuel Rail (303-04 Fuel Charging and
Controls - 2.5L Duratec (147kW/200PS) - VI5,
Removal and Installation).
2. Torque: 10
Nm1.
4. Material: Engine Oil - 5W-30
(WSS-M2C911-A) engine oil
E64170
1
243
Installation
1.To install, reverse the removal procedure.
G544636en2008.50 Kuga8/2011
303-04A- 22
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 22
REMOVAL AND INSTALLATION
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Throttle Body(23 198 0)
Removal
NOTE:Removal steps in this procedure may
contain installation details.
1. Remove the right-hand side headlamp
assembly.
2.
E74132
3. NOTE: The gasket is to be reused unless
damaged.
Torque: 10
Nm
E74133
x4
Installation
1. To install, reverse the removal procedure.
2. NOTE: Make sure that the pedals remain in the
rest position.
Turn the ignition key to position II and wait for
one minute to initialize the throttle body. 3.
E101067
G1079056en2008.50 Kuga8/2011
303-04A-
23
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 23
REMOVAL AND INSTALLATION
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Fuel Rail
Removal
NOTE:Removal steps in this procedure may
contain installation details.
1. Refer to: Petrol and Petrol-Ethanol Fuel
Systems Health and Safety Precautions
(100-00 General Information, Description and
Operation).
2. Refer to: Fuel System Pressure Release
(310-00 Fuel System - General Information,
General Procedures).
3. Refer to: Battery Disconnect and Connect
(414-01 Battery, Mounting and Cables,
General Procedures).
4. Refer to: Air Cleaner (303-12 Intake Air
Distribution and Filtering - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
5. Torque: 10
Nm
x2x2
E92954
6. CAUTION: Make sure that the inside of
the pipe ends are clean and free of oil
residue.
Torque: 4Nm
E63576
7. CAUTION: Make sure that the inside ofthe pipe ends are clean and free of oil
residue.
E64164
8. CAUTION: Make sure that the inside ofthe pipe ends are clean and free of oil
residue.
E64165
G1079057en2008.50 Kuga8/2011
303-04A- 24
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 24
REMOVAL AND INSTALLATION
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9.Torque: 10Nm
E64166
10. To r q u e : 2Nm1.
4.
WARNING: Be prepared to collect
escaping fluid.
Torque: 10
Nm
x5
x24
2
3
1
E93083
Installation
1. To install, reverse the removal procedure.
2. Refer to: Door Window Motor Initialization
(501-11 Glass, Frames and Mechanisms,
General Procedures).
G1079057en2008.50 Kuga8/2011
303-04A- 25
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 25
REMOVAL AND INSTALLATION
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SECTION 303-04B Fuel Charging and Controls -
Turbocharger
— 2.5L Duratec (147kW/200PS) - VI5
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
DESCRIPTION AND OPERATION
303-04B-2
Turbocharger (Component Location) ........................................................................\
..........
303-04B-4
Turbocharger (Overview) ........................................................................\
............................
303-04B-4
Turbocharger(s) ........................................................................\
..........................................
303-04B-5
Turbocharger (System Operation and Component Description) ........................................
303-04B-5
System Diagram ........................................................................\
.........................................
303-04B-6
System Operation ........................................................................\
.......................................
303-04B-6
Turbocharger(s) ........................................................................\
......................................
303-04B-6
Turbocharger boost pressure control ........................................................................\
......
303-04B-7
Recirculated air valve ........................................................................\
.............................
303-04B-7
Component Description ........................................................................\
..............................
303-04B-7
Wastegate control valve ........................................................................\
..........................
303-04B-7
Recirculated air valve ........................................................................\
.............................
DIAGNOSIS AND TESTING 303-04B-9
Turbocharger ........................................................................\
..............................................
303-04B-9
Inspection and Verification ........................................................................\
..........................
REMOVAL AND INSTALLATION 303-04B-11
(23 612 0)
Turbocharger ........................................................................\
..........................
303-04B-1
Fuel Charging and Controls - Turbocharger
—
2.5L Duratec (147kW/200PS) - VI5
303-04B- 1
.
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Turbocharger – Component Location
E97600
12
34
5
Description
Item
Turbocharger heat shield
1
from air filter
2Description
Item
TC (turbocharger)
3
to intercooler
4
Exhaust manifold
5
G1032424en2008.50 Kuga8/2011
303-04B- 2
Fuel Charging and Controls - Turbocharger
—
2.5L Duratec (147kW/200PS) - VI5
303-04B- 2
DESCRIPTION AND OPERATION
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6
79108
123
4
5
6
79108
E97592
Description
Item
Exhaust manifold
1
PCV (positive crankcase ventilation)- hose
Comments:to cylinder head
2
Vacuum line - recirculated air valve
Comments:to intake manifold
3
Coolant return pipe
4Description
Item
Turbo boost pressure controller
5
Oil supply pipe - TC
6
Wastegate control valve
7
TC
Comments:Contains the recirculated air valve
8
Coolant supply pipe
9
Oil return pipe - TC
10
G1032424en2008.50 Kuga8/2011
303-04B- 3
Fuel Charging and Controls - Turbocharger
—
2.5L Duratec (147kW/200PS) - VI5
303-04B- 3
DESCRIPTION AND OPERATION
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Turbocharger – Overview
Turbocharger(s)
CAUTION: Do not switch off the engine
while it is running at high speed. If the
engine is switched off while it is running
at high speed, the turbocharger will
continue to run after the engine oil
pressure has already dropped to zero. This
will cause premature wear in the
turbocharger bearings.
A TC consists of an exhaust turbine located in the
exhaust gas flow, this turbine is connected to a
compressor by a shaft. The turbine is made to
rotate by the exhaust gas flow from the engine and
thus drives the compressor. The compressor
increases the pressure in the engine intake tract
so that a greater mass of air enters the cylinder
during the intake stroke.
The turbine housing of the TC is integrated into the
exhaust manifold. This construction offers
thermodynamic advantages compared with the
usual construction, the maximum exhaust
temperature is up to 1050°C.
The maximum boost pressure is 0.65 bar.
The exhaust manifold is secured to the exhaust
side of the cylinder head with 12 self-locking nuts.
The exhaust manifold gasket is a multi-layer steel
gasket and cannot be reused. In order to
compensate for the thermal expansion of the
exhaust manifold, the flange of the TC is provided
with two grooves.
The TC and the exhaust manifold are joined by a
hose clip. The hose clip must not be loosened or
removed. The TC and the exhaust manifold are
not available as separate replacement parts,
exchange is only possible as a complete unit.
The turbocharger heat shield is secured to the
exhaust manifold by four bolts. Two of the bolts
have spring washers underneath their heads.
During removal, make a note of the installation
location of the spring washers to refer to during
installation.
The recirculated air valve is built into the TC
housing and cannot be changed.
The Ford diagnostic unit can test the operation of
the wastegate control valve using actuator
diagnosis.
The boost pressure regulator is set in the factory.
Adjustments to the boost pressure regulator must never be attempted. A red colored seal is applied
to the adjustment nut of the operating rod, in order
to monitor the factory setting of the boost pressure.
The bearings of the TC are lubricated with engine
oil. The engine oil passes from the cylinder block
through the oil supply pipe to the TC. The oil is
returned to the oil pan through the oil return pipe,
The TC is cooled by the engine coolant circuit.
When installing hoses and lines, make certain that
their ends are free of oil residues and dirt.
G1032425en2008.50 Kuga8/2011
303-04B-
4
Fuel Charging and Controls - Turbocharger
—
2.5L Duratec (147kW/200PS) - VI5
303-04B- 4
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Turbocharger – System Operation and Component Description
System Diagram
346
7
8
10
11
12
1415
25
13
7
9
1346
7
8
10
11
12
1415
25
13
7
9
E98961
Description
Item
Turbo boost pressure controller
1
from exhaust manifold
2
Pilot pressure
3Description
Item
Wastegate control valveRefertoComponentDescription:(page
7)
Comments: closed when de-energised
4
G1032426en2008.50 Kuga8/2011
303-04B-
5
Fuel Charging and Controls - Turbocharger
—
2.5L Duratec (147kW/200PS) - VI5
303-04B- 5
DESCRIPTION AND OPERATION
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