length FORD KUGA 2011 1.G Workshop Manual

Description
Item
Measure the current using a digital
multimeter
1
Measure the voltage using a digital
multimeter
2
Measure the resistance using a digital
multimeter
3
Measure the length/distance
4
Check that the specified pressure is
available using a suitable pressure gauge
5
Measure the pressure at the specified port
using a suitable pressure gauge
6
Measure the time using a suitable
stopwatch
7
Wait for the specified period of time
8
The specified task requires the specified
minimum temperature
9Description
Item
The specified task requires the specified
maximum temperature not to be exceeded
10
The specified task requires the specified
temperature range
11
The specified task requires the specified
temperature
12
Measure and check for the specified value
using a dial indicator gauge
13
Measure and check for the specified MAX
value using a dial indicator gauge
14
Measure and check for the specified MIN
value using a dial indicator gauge
15
General equipment symbols
The general equipment symbols are used to show
where to use which type of general equipment to
carry out a procedure step.
G955392en2008.50 Kuga8/2011
100-00-
32
General Information
100-00- 32
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reprogrammed. However, if the engine hasn't been
run since the last programmed start, the fuel-fired
booster heater will not start up the second time so
as to prevent the battery from being discharged.
The length of time required to pre-heat the vehicle
is calculated in the control unit of the fuel-fired
booster heater and is based on two temperature
values:
• Ambient air temperature: this message is taken
from the GEM via the CAN bus.
• Coolant temperature: this is determined via an internal sensor in the fuel-fired booster heater.
The maximum heating time is 30 minutes at an
outside air temperature of -10 °C or lower. The
heating time decreases proportionally with
increasing ambient temperature until the ambient
temperature is between +15 °C and +20 °C. Then
the minimum heating time is 10 minutes. The
parking heater is deactivated at temperatures
above +20 °C.
The sequence for a programmed start of the
booster heater is as follows:
• Two minutes before the start of the maximum heating time the driver information
system/instrument cluster sends an activation
message to the fuel-fired booster heater via the
CAN bus.
• The fuel-fired booster heater calculates the required heating time and, if necessary, sends
a delay request on the CAN bus.
• At the calculated time, the fuel-fired booster heater starts up. The conditions for start-up are:
engine not running and amount of fuel in the
fuel tank is above 14% of maximum.
• When the coolant temperature reaches +30 °C, the control unit of the fuel-fired booster heater
sends a request to switch on the passenger
compartment blower.
• Eight minutes after the programmed switch-off time, the booster heater stops heating mode
and starts a run-on operation to clean the
system's spark plugs.
• Ten minutes after the switch-off time, the post-cleaning operation is complete. The
additional ten minutes run-on time provides
some leeway in case the driver is late arriving.
After a programmed start-up of the booster heater
it is switched off again after the heating time has
elapsed (or if the fuel level in the fuel tank drops
below 8%). The booster heater stops within 2 minutes of the engine starting. This leaves enough
time to check whether the switch-on conditions for
boost heat mode have been met, thus preventing
the booster heater from having to switch off and
switch back on again. The heater can be switched
off manually at any time from the menu.
Whilst the fuel-fired booster heater is in additional
heating mode and/or parking heating mode, the
instrument cluster receives a fuel consumption
signal; this is used to re-calculate the vehicle's
remaining range and fuel consumption data.
Emergency shutoff
In the event of an accident in which the airbags
are deployed, the control unit of the fuel-fired
booster heater receives a message on the CAN
bus from the restraints control module (RCM).
When this message is received, the booster heater
system switches off immediately.
The booster heater control module deactivates the
system and does not respond to further messages
on the CAN bus. The booster heater control module
needs to be activated with WDS.
Component Description
Electric Booster Heater
The electric booster heater consists of three
individual heating elements, which are incorporated
into a single housing. It is controlled by the generic
electronic module (GEM), taking into account the
following factors:
Detailed illustration of fuel-fired heater
G1066982en
2008.50 Kuga 8/2011 412-02-14
Auxiliary Climate Control
412-02-14
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUALE97621

Parking Aid Camera
For vehicles with a DVD navigation system with a
touch screen, the parking aid camera is supplied
as standard. For vehicles with a standard
navigation system, the camera can be ordered as
an optional extra. The system essentially consists
of a camera with a wide angle lens, a control unit
and a wiring harness which is not integrated in the
vehicle wiring harness.
On the navigation display screen, the drivers sees
a video image of the area behind the vehicle.
Guides integrated in the camera images by the
parking aid camera module and displayed on the
screen help the driver to find out about the steering
angle, vehicle width, cornering and driving straight
ahead. The system generates these guides using:
• Vehicle parameters (length, width)
• Steering Angle
• Vehicle position during the parking maneuverDescription
Item
Monitoring angle
1
If the vehicle is also fitted with a rear parking aid,
the distances to the obstacle are displayed as a
3D illustration. G1034399en
2008.50 Kuga 8/2011 413-13-13
Parking Aid
413-13-13
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL0,3m120,11E97904 E97905

Battery Disconnect and Connect
Disconnect
WARNINGS:
Batteries normally produce explosive
gases which may cause personal injury,
therefore do not allow flames, sparks or
lighted substances to come near the
battery. When charging or working near
the battery always shield your face and
protect your eyes. Always provide
adequate ventilation. Failure to follow
these instructions may result in personal
injury.
The supplemental restraint system (SRS)
is active for a certain length of time after
the power supply has been disconnected.
Wait for a minimum of 3 minutes before
disconnecting or removing any SRS
components.
Audio unit key code saving devices must
not be used when working on
supplemental restraint or fuel systems.
When using these devices the vehicle
electrical system is still live but with a
reduced current flow. Failure to follow this
instruction may result in personal injury.
CAUTION: Make sure the engine is not
running before disconnecting the battery
ground cable to avoid damage to the
vehicle electrical system.
NOTE: Disconnecting the battery will erase fault
codes, drive values and customer data stored in
the modules.
NOTE: This procedure should be used to
disconnect the battery while carrying out repairs
that refer to the battery being disconnected.
1. Refer to: Battery and Battery Charging Health
and Safety Precautions (100-00 General
Information, Description and Operation).
2. Obtain and record the audio unit keycode and
preset radio frequencies. 3.
G1062389en
2008.50 Kuga 8/2011 414-01-2
Battery, Mounting and Cables
414-01-2
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUALE103137

Steering Column(13 542 0)
Removal
WARNINGS:
The supplemental restraint system (SRS)
is active for a certain length of time after
the power supply has been disconnected.
Wait for a minimum of 3 minutes before
disconnecting or removing any SRS
components.
Make sure that the vehicle electrical
system is fully depowered and no other
power source is connected.
NOTE: Removal steps in this procedure may
contain installation details.
1. NOTE: Make sure that the road wheels are in
the straight ahead position.
E99259
2. CAUTION: Make sure that the steering wheel lock is engaged.
Refer to: Battery Disconnect and Connect
(414-01 Battery, Mounting and Cables,
General Procedures).
3. If equipped.
E100834
4.
E95563
5.
E99639
1
2
6.
E99720
G1058718en2008.50 Kuga8/2011
211-04- 5
Steering Column
211-04- 5
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Steering Column Shaft
Removal
WARNINGS:
The supplemental restraint system (SRS)
is active for a certain length of time after
the power supply has been disconnected.
Wait for a minimum of 3 minutes before
disconnecting or removing any SRS
components.
Make sure that the vehicle electrical
system is fully depowered and no other
power source is connected.
NOTE: Removal steps in this procedure may
contain installation details.
1. Refer to: Clockspring (501-20 Supplemental
Restraint System, Removal and Installation).
Refer to: Steering Column Multifunction Switch
LH (211-05 Steering Column Switches,
Removal and Installation).
Refer to: Steering Column Multifunction Switch
RH (211-05 Steering Column Switches,
Removal and Installation).
Refer to: Steering Column Lock Module (211-05
Steering Column Switches, Removal and
Installation).
2. Torque: 30
Nm
E66155
3.Torque: 5Nm
E99641
4.
E99640
5.Torque: 24Nm
E99642
Installation
1.To install, reverse the removal procedure.
G1073504en2008.50 Kuga8/2011
211-04- 7
Steering Column
211-04- 7
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Bar
Description
4.8
Oil pressure relief valve opening pressure
Valve Clearance
mm
Description
0.17 - 0.23
Valve clearance (engine cold), intake
0.36 - 0.43
Valve clearance (engine cold), exhaust
Valves
mm
Description
101.93 - 102.07
Intake valve lenght
5.87 - 6.01
Intake valve shaft diameter
0.05 - 0.07
Intake valve guide clearance
101.43 - 101.57
Exhaust valve lenght
5.87 - 6.01
Exhaust valve shaft diameter
0.05 - 0.07
Exhaust valve guide clearance
Valve Seats
degree
Description
45.33 - 45.67
Intake valve seat angle
45.33 - 45.67
Exhaust valve seat angle
Cylinder Head
mm
Description
149.25 - 149.55
Cylinder head height
0.05
Maximum mating face distortion (lengthwise)
0.02
Maximum mating face distortion (crosswise)
0.30
Maximum face milling
Camshafts
mm
Description
8.68
Intake camshaft lobe lift
9.05
Exhaust camshaft lobe lift
Crankshaft
mm
Description
0.08 - 0.19
Crankshaft axial clearance
Crankshaft Main Bearing Selection
Code - Cylinder block
Code - Cylinder block
Code - Cylinder block
C
B
A
Crankshaft
main bearing carrier
Cylinder
block
Crankshaft
main bearing carrier
Cylinder
block
Crankshaft
main bearing carrier
Cylinder
block
Crankshaft
main bearing
for:
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4
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
4
SPECIFICATIONS
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Accessory Drive
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanicaldamage.
Visual Inspection Chart
Mechanical
– Damaged or contaminated accessory drive belt or air conditioning (A/C) compressor belt
– Damaged or contaminated pulley(s)
– Incorrect accessory drive belt or A/C compressor belt
– Incorrect fitment of the accessory drive belt or A/C compressor belt
– Accessory drive belt tensioner
– Accessory drive belt idler pulley
– Generator
– A/C compressor
– A/C compressor belt tensioner
– Pulley(s)
– Loose hardware
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible)
before proceeding to the next step.
Accessory Drive Belt Concerns
CAUTION: Do not lubricate the accessory
drive belt, accessory drive belt tensioner(s)
or idler pulley(s) as potential damage to
the accessory drive belt material
construction, accessory drive belt
tensioner damping mechanism, accessory
drive belt tensioner pulley bearing and idler
pulley(s) bearing may occur.
NOTE: All the diagnosis and testing information
contained within this procedure can be used for
the accessory drive belt and the A/C compressor
belt.
Cracking
Accessory drive belts are made from rubber which
hardens with time and can develop cracks. As the
accessory drive belt runs on the back of some of
the pulleys, the cracks are opened up. Small cracks
are not considered to be a failure of the accessory drive belt. Only if the crack is deep enough to reach
the bottom of the groove to expose the cord or any
chunks are found to be missing from the accessory
drive belt, is the accessory drive belt condition
considered to be unacceptable.
1. Check the accessory drive belt for cracks. If the
damage exceeds the acceptable limit, install a
new accessory drive belt.
REFER to: Accessory Drive Belt (303-05
Accessory Drive - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
and/or
REFER to: Air Conditioning (A/C) Compressor
Belt (303-05 Accessory Drive - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
Chunking
Chunking describes the condition where long
lengths of rubber become detached from the ribs
of the accessory drive belt. This is considered to
be a failure of the accessory drive belt.
MPZ9632071
2. Check the accessory drive belt for damage. If any chunks are found to be missing, install a
new accessory drive belt.
REFER to: Accessory Drive Belt (303-05
Accessory Drive - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
and/or
REFER to: Air Conditioning (A/C) Compressor
Belt (303-05 Accessory Drive - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
G1183443en2008.50 Kuga8/2011
303-05- 4
Accessory Drive— 2.5L Duratec (147kW/200PS) - VI5303-05-
4
DIAGNOSIS AND TESTING
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Main Control Valve Body
Removal
1.Refer to: Transmission Fluid Pan (307-01
Automatic Transmission/Transaxle - Vehicles
With: 5-Speed Automatic Transaxle - AW55
AWD, Removal and Installation).
2. NOTE: Note the position of the electrical
connectors.
E115690
3. CAUTION: Make sure that no component falls off during removal.
NOTE: Note the different lengths of the bolts.
E115691
x2
4.
E115692
G1163642en2008.50 Kuga8/2011
307-01- 69
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 69
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