all FORD KUGA 2011 1.G Workshop Manual

Transfer Case
Installation
1.Refer to: Transfer Case (307-07 Transfer Case
- Vehicles With: 5-Speed Automatic Transaxle
- AW55 AWD/6-Speed Automatic Transaxle
- 6DCT450, Installation).
G1164998en2008.50 Kuga8/2011
307-07- 19
Transfer Case
— Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450
307-07- 19
INSTALLATION
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SECTION 309-00 Exhaust System— 2.5L Duratec (147kW/200PS) - VI5
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
DESCRIPTION AND OPERATION
309-00-2
Exhaust System (Component Location) ........................................................................\
.....
REMOVAL AND INSTALLATION 309-00-3
Exhaust Flexible Pipe ........................................................................\
.................................
309-00-6
Catalytic Converter ........................................................................\
.....................................
309-00-1
Exhaust System— 2.5L Duratec (147kW/200PS) - VI5309-00-
1
.
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Exhaust Flexible Pipe
General EquipmentCable TiesMaterials
Specification
Name
SA-M1C9107-A / YS5J-
M1C9107-AA
Grease KS-PS
Removal
NOTE:
Removal steps in this procedure may
contain installation details.
1.
E65070
2. CAUTION: Make sure that the inside of the pipe ends are clean and free of oil
residue.
1. Torque: 10Nm
2. Torque: 4Nm
3. Torque: 10Nm
2
1
3
E68504
3.Torque: 20Nm
E112607
1
2
34
4.
E67948
2
1
5. CAUTIONS:
Jointing compound must not be used
forward of the catalytic converter.
G1079152en2008.50 Kuga8/2011
309-00- 3
Exhaust System— 2.5L Duratec (147kW/200PS) - VI5309-00-
3
REMOVAL AND INSTALLATION
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Make sure that the exhaust flexible pipe
is not forcibly bent.
2. Torque: 47
Nm
3. Torque: 28Nm
E112609
x3
1
2
3
6. Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
7.
E65299
8. General Equipment: Cable Ties
TIE0014991
9.
E66050
10.Torque: 30Nm
E112254
G1079152en2008.50 Kuga8/2011
309-00- 4
Exhaust System— 2.5L Duratec (147kW/200PS) - VI5309-00-
4
REMOVAL AND INSTALLATION
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11. CAUTION: Make sure that the exhaustflexible pipe is not forcibly bent.
Torque: 48Nm
E112253
x2
12.Material: Grease KS-PS (SA-M1C9107-A /
YS5J-M1C9107-AA) grease
Torque: 48
Nm
E112608
Installation
1. To install, reverse the removal.
G1079152en2008.50 Kuga8/2011
309-00- 5
Exhaust System— 2.5L Duratec (147kW/200PS) - VI5309-00-
5
REMOVAL AND INSTALLATION
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Catalytic Converter
General EquipmentCable TiesMaterials
Specification
Name
SA-M1C9107-A / YS5J-
M1C9107-AA
Grease KS-PS
Removal
NOTE:
Removal steps in this procedure may
contain installation details.
1. Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
2.
E65299
3. General Equipment: Cable Ties
TIE0014991
4.
E66050
5. CAUTIONS:
Jointing compound must not be used
forward of the catalytic converter.
Make sure that the exhaust flexible pipe
is not forcibly bent.
Material: Grease KS-PS (SA-M1C9107-A / YS5J-M1C9107-AA) grease
Torque: 50
Nm
E66052
x2
G1079153en2008.50 Kuga8/2011
309-00- 6
Exhaust System— 2.5L Duratec (147kW/200PS) - VI5309-00-
6
REMOVAL AND INSTALLATION
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6. CAUTION: Make sure that the exhaustflexible pipe is not forcibly bent.
Material: Grease KS-PS (SA-M1C9107-A /YS5J-M1C9107-AA) grease
Torque: 50
Nm
E112253
x2
7. NOTE: This step is not necessary when
installing a new component.
Torque: 45
Nm
E66051
Installation
1. To install, reverse the removal procedure.
G1079153en2008.50 Kuga8/2011
309-00- 7
Exhaust System— 2.5L Duratec (147kW/200PS) - VI5309-00-
7
REMOVAL AND INSTALLATION
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Fuel System — Vehicles With: Fuel Additive Tank
General EquipmentFord diagnostic equipment
Principles of Operation
WARNINGS:
This procedure involves fuel additive
handling. Be prepared for fuel additive
spillage at all times and always observe
fuel handling precautions. Failure to follow
these instructions may result in personal
injury.
Eye, hand, ear protection and protective
clothing are required to be worn during
any general service or removal and
installation service procedure of fuel
additive system components. Failure to
follow this instruction may result in
personal injury.
In case of fuel additive fluid contact with
the skin or the eyes, flush immediately with
water for a minimum of 15 minutes and
seek prompt medical attention. Failure to
follow these instructions may result in
personal injury.
If fuel additive fluid is swallowed, call a
physician immediately. Rinse mouth
immediately with water, do not induce
vomiting. Failure to follow these
instructions may result in personal injury.
Always provide adequate ventilation when
working on the fuel additive fluid system
or related components. Failure to follow
these instructions may result in personal
injury.
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 may ignite. Failure to follow
these instructions may result in personal
injury.
CAUTION: Make sure the workshop area
in which the vehicle is being worked on is
as clean and as dust free as possible.
Foreign matter from working on clutches,
brakes or from machining or welding
operations can contaminate the fuel
system and may result in later malfunction. The fuel additive system is an on-board system
that allows the injection of an additive at each
refueling operation by the customer. The additive
quantity is proportional to the fuel quantity that has
been added. The fuel additive system module
controls the amount of additive fluid entering the
fuel tank at each refueling, A switch mounted on
the fuel filler flap is used to detect the start of the
refueling event and the fuel gauge that is mounted
within the fuel tank informs the fuel additive tank
module the quantity of actual fuel added.
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of leakage
and mechanical or electrical damage.
Visual Inspection Chart
Electrical
Mechanical
– Fuse(s)
– Fuel filler switch andmagnet
– Wiring harness(s)
– Electrical connector(s)
– Fuel additive system module
– Fuel additive tank module
– Instrument cluster
– Powertrain Control Module (PCM)
– Fuel level sensor
– Fuel additive tank
– Fuel additive tank
line(s)
– Fuel additive tank pipe(s)
– Fuel additive tank connector(s)
– Fuel tank filler cap
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, REFER to the Ford diagnostic equipment.
G1080718en2008.50 Kuga8/2011
310-00- 2
Fuel System - General Information
310-00- 2
DIAGNOSIS AND TESTING
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Fuel System Pressure Release
Release
1.Refer to: Petrol and Petrol-Ethanol Fuel
Systems Health and Safety Precautions
(100-00 General Information, Description and
Operation).
2. Remove the fuel pump and sender unit fuse.
3. Start the engine and allow it to idle until the
engine stalls.
4. Crank the engine for approximately five seconds
to make sure that the fuel rail pressure is
released.
5. Install the fuel pump and sender unit fuse.
G551380en2008.50 Kuga8/2011
310-00- 10
Fuel System - General Information
310-00- 10
GENERAL PROCEDURES
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Fuel Tank Draining
General EquipmentFluid Container
Fuel Tank Draining Equipment
Hose Clamp Remover/Installer
Activation
CAUTION: If the fuel tank has been filled
with the wrong type of fuel, the engine
must not be started.
NOTE: Removal steps in this procedure may
contain installation details.
6. Refer to: Petrol and Petrol-Ethanol Fuel
Systems Health and Safety Precautions
(100-00 General Information, Description and
Operation).
7. Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
8. WARNINGS:
Fuel may still be present in the fuel tank
after draining.
Be prepared to collect escaping fluids.
CAUTION: Use suitable paper to absorb
any escaping fluid. NOTE:
Make sure that a new component is
installed.
• General Equipment: Hose Clamp Remover/Installer
1. Make sure, that the fuel filler pipe is above the fuel level .
2. Drain the reservoir.
General Equipment: Fuel Tank DrainingEquipment
General Equipment: Fluid Container12
E116177
9. Refer to: Fuel Pump and Sender Unit - 2.5L
Duratec (147kW/200PS) - VI5 (310-01 Fuel
Tank and Lines, Removal and Installation).
10. WARNING: Be prepared to collect escaping fluids.
CAUTION: Use suitable paper to absorb
any escaping fluid.
G1165328en2008.50 Kuga8/2011
310-00- 11
Fuel System - General Information
310-00- 11
GENERAL PROCEDURES
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL