2011 FORD KUGA engine control

SECTION 303-08B Engine Emission Control— 2.0L Duratorq-TDCi
(100kW/136PS) - DW, Emission Requirements: Stage IV, 2.0L Duratorq-TDCi (DW) Diesel
VEHICLE APPLICATION: 2011.0 Kuga
PA G E
CONTENTS
ELECTRICAL CONNECTORS
303-08B-2
Exhaust Gas Recirculation (EGR) Cooler Bypass Valve — A ............................................
303-08B-2
Exhaust Gas Recirculation (EGR) Cooler Bypass Valve Position Sensor — C .................
303-08B-2
Exhaust Gas Recirculation (EGR) Vacuum Regulator Valve ..............................................
303-08B-2
Exhaust Gas Recirculation (EGR) Valve — B ....................................................................
303-08B-3
Exhaust Gas Recirculation (EGR) Valve Position Sensor ..................................................
303-08B-3
Positive Crankcase Ventilation (PCV) Valve .......................................................................
303-08B-1
Engine Emission Control
— 2.0L Duratorq-TDCi (100kW/136PS) -
DW, Emission Requirements: Stage IV, 2.0L Duratorq-TDCi (DW) Diesel
303-08B- 1
.
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Exhaust Gas Recirculation (EGR) Cooler Bypass Valve—A (G1336766)
Exhaust Gas Recirculation (EGR) Cooler Bypass Valve Position Sensor—C (G1336764)
123
6M5T-14A464-FCA
HARNESS 12A690 TO EGR BYPASS POSITION SENSOR C1E756-C G0.50WK
BN-WH
LE139AB
G0.50WK
BN-WH
RE139AB
G0.50WK
WH-OG
VE721AB
Exhaust Gas Recirculation (EGR) Vacuum Regulator Valve (G1230348)
123456
6M5T-14A464-DFA
HARNESS 12A690 TO EGR VALVE (HEAT EXCHANGER) C833 G
0.50
WKBN-GN9-RL7
G
0.75WKBK-GN91S-RL7G
0.75WKGN-BK15S-RL7G
0.50WKYE-GN7-RL7G
0.50WKWH-GN8-RL7
Exhaust Gas Recirculation (EGR) Valve—B (G1336763)
1
5
234
5M5T-14A464-EAA
HARNESS 12A690 TO EGR VALVE C1E139-B G0.75WK
WH-VT
CE101A
G0.50WK
BN-WH
LE139A G0.75WK
YE-BU
CE102A
G0.50WK
WH-OG
VE721A
G0.50WK
GY-OG
RE139A
201

1.0 Kuga
303-08B- 2
Engine Emission Control
— 2.0L Duratorq-TDCi (100kW/136PS) -
DW, Emission Requirements: Stage IV, 2.0L Duratorq-TDCi (DW) Diesel
303-08B-2
.
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Exhaust Gas Recirculation (EGR) Valve Position Sensor (G1230349)
12
6M5T-14A464-GBA
HARNESS 12A690 TO EGR THROTTLE POSITION (CONTROL) C860 G0.75
WKGN-BK15S-RJ37G
0.75WKGN-BK15-RJ37
Positive Crankcase Ventilation (PCV) Valve (G1230350)
12
6M5T-14A464-JBA
HARNESS 12A690 FUEL PRESSURE REGULATOR C859 G1.0
WKGN-BU15S-RL42G1.0WKBK-BU91S-RL42
303-08B-
3
Engine Emission Control
— 2.0L Duratorq-TDCi (100kW/136PS) -
DW, Emission Requirements: Stage IV, 2.0L Duratorq-TDCi (DW) Diesel
303-08B-3
.
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SECTION 303-14A Electronic Engine Controls— 2.5L Duratec
(147kW/200PS) - VI5
VEHICLE APPLICATION: 2011.0 Kuga
PA G E
CONTENTS
ELECTRICAL SCHEMATICS
303-14A-2
Engine Control — Vehicles With: 6-Speed Manual Transaxle - M66 AWD, LHD 4WD ......
303-14A-8
Engine Control — Vehicles With: 5-Speed Automatic Transaxle - AW55 AWD, LHD 4WD .
303-14A-14
Engine Control — Vehicles With: 6-Speed Manual Transaxle - M66 AWD, RHD 4WD .....
303-14A-20
Engine Control — Vehicles With: 5-Speed Automatic Transaxle - AW55 AWD, RHD 4WD .
ELECTRICAL CONNECTORS 303-14A-26
Accelerator Pedal Position (APP) Sensor ........................................................................\
..
303-14A-26
Brake Pedal Position (BPP) Switch ........................................................................\
............
303-14A-26
Catalyst Monitor Sensor ........................................................................\
.............................
303-14A-26
Clutch Pedal Position (CPP) Switch ........................................................................\
...........
303-14A-27
Clutch Pedal Position (CPP) Switch ........................................................................\
...........
303-14A-27
Clutch Pedal Position (CPP) Switch ........................................................................\
...........
303-14A-27
Crankshaft Position (CKP) Sensor ........................................................................\
.............
303-14A-27
Engine Coolant Temperature (ECT) Sensor .......................................................................
303-14A-28
Exhaust Camshaft Position (CMP) Sensor ........................................................................\
.
303-14A-28
Exhaust Variable Valve Timing (VVT) Oil Control Solenoid ................................................
303-14A-28
Fuel Rail Pressure (FRP) Sensor ........................................................................\
...............
303-14A-28
Fuel Rail Temperature Sensor ........................................................................\
....................
303-14A-29
Fuel Rail Pressure and Temperature Sensor .....................................................................
303-14A-29
Heated Oxygen Sensor (HO2S) ........................................................................\
.................
303-14A-29
Intake Camshaft Position (CMP) Sensor ........................................................................\
....
303-14A-29
Intake Variable Valve Timing (VVT) Oil Control Solenoid ...................................................
303-14A-30
Knock Sensor (KS) ........................................................................\
.....................................
303-14A-30
Manifold Absolute Pressure and Temperature (MAPT) Sensor ..........................................
303-14A-30
Mass Air Flow (MAF) Sensor ........................................................................\
......................
303-14A-31
Powertrain Control Module (PCM) ........................................................................\
..............
303-14A-32
Powertrain Control Module (PCM) ........................................................................\
..............
303-14A-1
Electronic Engine Controls— 2.5L Duratec (147kW/200PS) - VI5303-14A-
1
.
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.
TO TURBO I5 PCM
6.0
WA
BK
31-PA1
C281
4
0.50
WA
BU
49-PA6
A4
PWM
A2
GND
PWR A1
INCLUDING
COOLING FAN MOTORM
EC01.
25.0
FWK
RD
30-DA25
PM
(+) (-)
.
B+11B-
GROUND
ENGINE
G8
G1
BATTERY
GROUND
25.0
FLR9
BK
31-BA11A25.0
FLR9
BK
31-BA11
BB03 .
+40AF1
GROUND LEFT FRONT
G37
C90_34
C281
1
C281
2
49-PA6 BU R2 0.50
S
C681
8
R14
.
EC05
15-PA41 GN-BK WA 1.030-PA1 RD WA 6.0
60
WA
RD
30-PA10.50
WA
BK
31-PA41
S1201.0
WA
GN-RD
15-RH10A
+
F9 20A
30-RH10 RD WA 1.0
GROUND
LEFT FRONT G37
2.5
WA
BK
31-DA3
S121
.Cooling Fan Motor
Battery
GROUNDGGROUNDGGGROUNDSUPPORTGROUNDGROUNDGROUNDSUPPORTEJB
GROUNDGGROUNDGGGROUNDFENDER
.Cooling Fan Relay
GROUNDGGROUNDGGGROUNDFENDER
303-14A-2 Engine Control—Vehicles With: 6-Speed Manual Transaxle - M66 AWD, LHD 4WD
2011.0 Kuga (G1313076)
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FJB(PARTIAL)
R6.
E612
91S-RH9 BK-BU WA 0.50
30-RH9 RD WA 1.0
C90_21
.Powertrain Control Module (PCM) Relay
303-14A-3 Engine Control—Vehicles With: 6-Speed Manual Transaxle - M66 AWD, LHD 4WD
201 1.0 Kuga (G1313076)
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.CAN LOW
.START LOCK RLY (-)
.TO 150A ALT (LIN)
.A/C CYCLING SWITCH.STOP LAMP SWITCH
.FUEL PUMP RLY CTRL.
.START LOCK RELAY PWR
.FJB (F34 10A)
.FJB (F30 3A)
.FJB (F35 15A)
.CAN HIGH
.KVM (CRANK SIGNAL)
.A/C RELAY COIL
.A/C RELAY PWR
.A/C PRESSURE SNS
.A/C PRESSURE SNS +
.A/C PRESSURE SNS GND
.ENGINE MGT. RLY. COIL
.DECOS (PWM)
.ACCEL. PEDAL SNS
.START LOCK RLY +
.COOLING FAN MODULE
.FJB (F32 10A)
.PJB (F138 10A)
.FJB (F33 10A)
.FJB (F36 10A)
.STARTER MOTOR VIA INLINE TO 14A280
.COOL. AFTER RUN RELAY
.BOTTOM CLUTCH SW.(KV)
CG
2C6431.
E7119-RJ4
BN-RD R2 0.758-RJ4WH-RD R2 0.757753
46
2.5R2
BK-YE
91-RE8B2.5R2
BK-YE
91-RE8A
2
16
21C902+.
E135
31S-RL2 BK-OG R2 0.7550
MAF.
E807
1
3
C840
2
45C591
3
215-RJ22 GN-BU R2 0.75
6118
87
9-RJ22 BN-BU R2 0.758-RJ21 WH-RD R2 0.75
8-RJ20 WH-GN R2 0.75
9-RJ21 BN-RD R2 0.7563
38
73
1.0R2
GN-YE
15-RJ1415-RJ15 GN-BU WE 1.0
49
0.75WE
GY
91S-RJ153C936
1
2
4C9360.75WE
BK-GN
8-RJ15
95
0.75WE
GY
9-RJ15
90
0.50R2
BK-BU
91S-RH927
26
E801
.21
4C644
3
7
79
8-RJ18 WH-BK R2 0.759-RJ18 BN-YE R2 0.75
8-RJ19 WH-RD R2 0.759-RJ19 BN-RD R2 0.75
30
15
55
31
43
15-RN2 GN-BU R2 1.5
VREFVOUTVGRD.
.
E803
486
C92921510.75WE
GY
91-RL22
0.75R2
GY
7-RJ20A
3
10-RJ30 GY R2 0.50
91-RE8C BK-YE R2 2.5
0.75R2
GN-BU
15-RL2
1.5R2
GN-YE
15-RN1
1.0R2
GN-BU
15-RE8A
1.5R2
GN-BU
15-RR4
+.
E731
916892
67+E735
.
0.75R2
BK-YE
91S-RJ14
WH R2 0.75
8-RJ149-RJ14 0.75R2
BNGN-RD R2 0.75
15S-RJ25BK-OG R2 0.75
91S-RJ25
3
4
1C935
5
C935
62
+
E435
.
0.75R2
BK-GN
8-RJ20B9-RJ20 BN R2 0.75
15-RL22 BU WE 0.75
91S-RH5 BK-BU R2 0.50
49-PA6 BU R2 0.508
30-RE8 RD R2 0.50
0.75R2
GN-WH
15S-LG23
5
S54
27
54
41
9
0.50R2
BK-YE
31S-FA1110
5-EC7H BU-RD R2 0.50
4-EC7H GY-RD R2 0.50
31S-BB16 BK-RD R2 0.50
49-RE31 BU-YE R2 0.7521
1.0R2
GN-BU
15-RE8
1.0R2
GN-YE
15S-FA6
H302
S53
6.0R2
BK
91-RN2A
C9521
0.50R2
YE-VT
7-FA8831
0.50R2
WH-VT
8-FA88
0.50R2
BN-WH
9-FA88
51
53
250.50R2
GN-OG
15S-FA17
E801
.
0.50R2
GN-BU
50-RE817
R2
GY
50-BB12A 2.5C1201
118 REF. SUPPLY VOLTAGE 2
GND
204
227 ENG. MANAGEMENT REL.
251 A/C LINEAR SNS HIGH PRESSURE
151 TURBO CTRL. VALVE (PWM)
FUEL PRESSURE SNS (DECOS) 189115GND
CAM SNS 1, INTAKE 183136GND
163 MAF / HFM5
INLET AIR TEMP. SNS (TMAP)
187
213 P/N POSITION (AT) / CLUTCH SWITCH (MT)
208 ENGINE COOLANT FAN (PWM)
B+ PWR
216
138 GND
131 KNOCK SNS 2 -KNOCK SNS 2 +
179
FLYWHEEL SNS +
177
VVT SOL. 1 INTAKE (PWM) 172
FLYWHEEL SNS -
153
STARTER REL. LOW-SIDE DRIVER
209
MANIFOLD AIR PRESSURE SNS 1
186
REF. SUPPLY VOLTAGE 2 144
FUEL PUMP RELAY
127
221 FUEL PUMP CTRL. (DECOS, PWM)
146 LIN
141
FUEL TEMP SNS (DECOS)
101
INJECTOR VALVE A
206 GND
THROTTLE VALVE DC MOTOR - 175
109
OIL PRESSURE SWITCH
203 PCM PWR (IGN)
161 GND
GND
202
150 EVAP. PURGE CTRL. VALVE (PWM)
KNOCK SNS 1 -
155KNOCK SNS 1 +
107
REF. SUPPLY VOLTAGE 2
143OXYGEN SNS 1 HEATING
149
195 OXYGEN SNS HEATINGOXYGEN SNS 1 SIGNAL +
190
OXYGEN SNS 1 HEATING
173192 OXYGEN SNS TRIM. CURRENT168 OXYGEN SNS PUMP CURRENT191 OXYGEN SNS SIGNAL -167 OXYGEN SNS SIGNAL +
210 A/C REL.
215 IGN (FROM IGN2 REL. / KEYLESS GO)
217 CRANK SIGNAL (50-) (FROM KVM)
241 HS CAN LOW
254 HS CAN HIGH
A/C PRESSURE SNS GND
253
REF. SUPPLY VOLTAGE 2
231
A/C LOW PRESSURE CYCLING SW.
225
STOP LAMP SWITCH
230
226 ACCEL. PEDAL SNS (PWM)
PCM PWR (IGN)
205
125
INJECTOR VALVE B
102
INJECTOR VALVE C
126
INJECTOR VALVE D
103
INJECTOR VALVE E
IGNITION PWR A 181
IGNITION PWR B 157
IGNITION PWR C 182
IGNITION PWR D 158
IGNITION PWR E 134
VVT SOL. 2 EXHAUST (PWM) 196
REF. SUPPLY VOLTAGE 3 116
117
REF. SUPPLY VOLTAGE 3CAM SNS 2, EXHAUST 159137GND
GND 114REF. SUPPLY VOLTAGE 1 119THROTTLE VALVE DC MOTOR + 174188
THROTTLE VALVE POS. SNS 2THROTTLE VALVE POS. SNS 1 165
ENGINE COOLANT TEMP SNS 1 142112GND
STARTER REL. HIGH-SIDE DRIVER
211
257 HS CAN HIGH
244 HS CAN LOW
105 BACKUP LAMP RELAY (AT)
COOL AFTER RUN CTRL.
245
CAN
ENGINE CONTROL MODULE PCM HAS TWO CONNECTORS
NUMBERS STARTING WITH:
1XX REFLECT C680
2XX REFLECT C681
E108 .
0.50WE
WH-RD
8-EE11
C87346
110.50R2
GY-VT
50-BB13
1
C90
C90 4
C905
C908
C90 9
C9011
C9012
C9013
14
C90
C90 15
C9016
17
C90
18
C90
19
C90
C90 29
C9032
C90 21
C9024
C9028
31
C90
C90 34
C9036
C90 37
C9040
C9041
G57C
LEFT FRONT
GROUND
15-RE17 GN-YE R2 0.50
45C90
70.50R2
BK-RD
91S-FC14
1391S-PG17 BK-BU R2 0.50C90 6
.Crankshaft Position (CKP) Sensor
.Evaporative Emission Canister Purge Valve
RJBN BUR.Mass Air Flow (MAF) Sensor
.Knock Sensor (KS)
28RJ28RJ2RJVREF7RVREFEF.
Manifold Absolute Pressure (MAP) Sensor
2.Catalyst Monitor Sensor
.
Heated Oxygen Sensor (HO2S)
.
Wastegate Control Valve
Clutch and Clutch Field Coil
.Knock Sensor (KS)
.Powertrain Control Module (PCM)GROUNDGGROUNDGGGROUNDFENDER 2
303-14A-4 Engine Control—Vehicles With: 6-Speed Manual Transaxle - M66 AWD, LHD 4WD
2011.0 Kuga (G1313076)
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TO MODEL INDEXFORD KUGA 2011.0MY WIRING DIAGRAMS

.PJB (F141 10A)
.PJB (BACKUP LAMPS)
ENGINE GND
ENGINE GND
M66 MT
1.0R2
GN-YE
15-RL14
+E205 .
+.
E206
+E208 .
+.
E209
91S-RL10 BK-WH R2 0.75
91S-RL11 BK-YE R2 0.75
91S-RL12 BK-BU R2 0.75
91S-RL13 BK-OG R2 0.75
8-RJ3 WH-VT R2 0.5
C7711
C7721
1C775
1C773
2
2
2
2
4
C847
1
0.75WE
WH-BU
8-RJ119-RJ12 BN-BU R2 0.75
1
25
2
26
8336
8915
+1E422
.2C5881
15-RL26 GN-BU R2 0.75
91S-RL26 BK-WH R2 0.7596
1.0R2
GN-YE
15-RL10
31S-GC21 BK-GN R2 0.75
C9541
1
2
1ET46
.
9
91S-RL14 BK-GN R2 0.75+.
E2071C774231.0R2
GN-YE
15-RL13
16
13
C8042
1VREFVOUTVGRD.
E70632C803
VREFVOUTVGRD.
E7079-RJ2
BN-YE R2 0.50
7-RJ2YE-BK R2 0.50
598-RJ2WH-BK R2 0.50
E303
.
E304.
E306 .
E307
.
E305
.
4
13C581
4
13C582
C58331
4
4
13C584
3C5851
4
82
58
34
57
818-RR5 WH R2 0.75
8-RR6 WH-RD R2 0.75
15-RR7 GN-BU R2 1.5
8-RR7 WH-BU R2 0.75
8-RR8 WH-GN R2 0.75
8-RR9 WH-BK R2 0.75
1.5R2
GN-BU
15-RR9
S98
15-RL27 GN-BU R2 0.75
721C5872+E421
.91S-RL27 BK-RD R2 0.75
.
E810
C926218-RJ17 WH-VT R2 0.7512429-RJ17 BN-WH R2 0.75
ETA
M.
E137
G
3G
2
G
5G
6C589
G
4
G
175141974886533-RG3 YE-BU R2 0.7532-RG3 WH-BU R2 0.759-RG3 BN-BU R2 0.758-RG3 WH-BU R2 0.7591S-RG3 BK-OG R2 0.7515S-RG3 GN-RD R2 0.75
37
0.5R2
BN-WH
9-RJ3
3
7-RJ3 YE-RD R2 0.5
1.5R2
GN-BU
15-RR5
S103
15-RR6 GN-BU 1.5R2
15-RR8 GN-BU R2 1.5
1.0R2
GN-YE
15-RL12
2.5R2
BK
91-RR8
2.5R2
BK
91-RR9
2.5R2
BK
91-RR7
2.5R2
BK
91-RR5
91-RR6 BK R2 2.5
8-RJ12 GN-RD WE 0.75412
1E745
.
ENG1
17
0.75R2
YE-BU
7-RJ1244
15-RD21 0.75R2
GN-WH
91-RD21 0.75R2
BK-WH
+E321
.
,
2C550
1C550
ENG2
15-RL11 GN-YE R2 1.0
1C864
G2GC86C86
1
2
ET47
31-LG28 BK R2 0.75
0.75R2
GN-YE
15S-LG3C90 10
39
C90
.Fuel Injector 1
.Fuel Injector 2
.Fuel Injector 4
.Fuel Injector
.Exhaust Variable Valve Timing (VVT) Oil Control Solenoid
.Engine Oil Pressure (EOP) Switch
.Fuel Injector 3
.Intake Camshaft Position (CMP) Sensor
.Exhaust Camshaft Position (CMP) Sensor
.Ignition Coil-On-Plug 1
.Ignition Coil-On-Plug 2
.Ignition Coil-On-Plug 4
.Ignition Coil-On-Plug 5
.Ignition Coil-On-Plug 3
.Variable Camshaft Timing (VCT) Oil Control Solenoid
.Engine Coolant Temperature (ECT) Sensor
.Throttle Body
.T
Positive Crankcase Ventilation (PCV) Valve Heater Eleme
Reversing Lamp Switch
303-14A-5 Engine Control—Vehicles With: 6-Speed Manual Transaxle - M66 AWD, LHD 4WD
2011.0 Kuga (G1313076)
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