2011 FORD KUGA Park

Parking Brake Control(12 664 0)
Removal
1.Refer to: Floor Console (501-12 Instrument
Panel and Console, Removal and Installation).
2. Release the parking brake.
3.
3
33
2
1
4
E93308
Installation
1. Torque: 35Nm2.
3.NOTE: Only tighten the nut finger tight at this
stage.
2
22
3
4
1
E93328
2. Refer to: Parking Brake Cable Adjustment
(206-05 Parking Brake and Actuation, General
Procedures).
3. Refer to: Floor Console (501-12 Instrument
Panel and Console, Removal and Installation).
G1058318en2008.50 Kuga8/2011
206-05- 11
Parking Brake and Actuation
206-05- 11
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Parking Brake Rear Cables
Removal
NOTE:Removal steps in this procedure may
contain installation details.
1. Fully release the parking brake control.
2.
E92650
3. Loosen the parking brake cable adjustment nut
to the end of the parking brake cable thread.
E92651
4.Refer to: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation).
4x4
5. Torque: 25Nm
E101187
x2
x4
1
2
3
4x2
6.Torque: 25Nm
E101189
x4
G1072319en2008.50 Kuga8/2011
206-05- 12
Parking Brake and Actuation
206-05- 12
REMOVAL AND INSTALLATION
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All vehicles
7.Torque: 25Nm1.
2. Torque: 5
Nm
E101191
1
x4
2
3
8.Torque: 5Nm
E101190
x4
9.
E101192
1
2
x2
10.
E70349
2
43
1
11 .Torque: 2Nm
G1072319en2008.50 Kuga8/2011
206-05- 13
Parking Brake and Actuation
206-05- 13
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

E101193
1
x43
2
Installation
1.To install, reverse the removal procedure.
2. Refer to: Parking Brake Cable Adjustment
(206-05 Parking Brake and Actuation, General
Procedures).
G1072319en2008.50 Kuga8/2011
206-05- 14
Parking Brake and Actuation
206-05- 14
REMOVAL AND INSTALLATION
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firmly grasp the road wheel and apply a rocking
motion checking for any free play in the steering
linkage.
E56375
10. Detach the steering gear boot from the steeringgear body and check for free play at the tie-rod
inner ball joint.
11. If there is free play at the tie-rod inner ball joint, install a new tie-rod.
REFER to: Tie Rod(211-03 Steering Linkage,
Removal and Installation).
12. Check the tie-rod end for free play. Install a new tie-rod end if necessary.
REFER to: Tie Rod End (211-03 Steering
Linkage, Removal and Installation).
Turning Effort Test
NOTE: Before carrying out this test, make sure
that the suspension components are serviceable.
NOTE: Before carrying out this test, make sure
that the steering column is serviceable.
NOTE: Before carrying out this test, make sure
that the toe adjustment and tire pressures are
correct.
1. Park the vehicle on a dry, even surface and apply the parking brake.
2. Remove the driver air bag module.
REFER to: Driver Air Bag Module (501-20
Supplemental Restraint System, Removal and
Installation).
3. Connect the air bag simulators to the sub-harnesses in place of the driver air bag
module at the top of the steering column.
4. Start the engine and turn the steering wheel from lock to lock several times until the power
steering fluid has reached normal operating
temperature. 5. Using a suitable torque wrench and socket,
check the steering wheel turning effort.
6. If the steering wheel turning effort is greater than the specification, install a new steering gear.
Steering Column Universal Joint
1.WARNING: Install a new steering column
to steering gear pinion retaining bolt. Failure
to follow this instruction may result in
personal injury.
Detach the steering column from the steering
gear pinion.• Discard the steering column to steering gear pinion retaining bolt.
TIE45919
1
2
2
2. Check for smooth movement of the steeringcolumn universal joint.
1. Hold the steering column universal joint yoke.
2. Articulate the free yoke in a figure of eight movement.
• If the movement is not smooth or resistance is felt, install a new steering column.
REFER to: Steering Column (211-04 Steering
Column, Removal and Installation).
TIE45918
3. Hold both of the steering column universal joint yokes and twist them clockwise and
counterclockwise.
G1059437en2008.50 Kuga8/2011
211-00- 4
Steering System - General Information
211-00- 4
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Engine
Special Tool(s) / General EquipmentSocket, Spark Plug
303-499
ES21202
Compression Test Adapter
303-1056
E42936
Ford diagnostic equipment
Materials
Specification
Name
WSK-M2G349-A7
Adhesive - Loctite 243 1. Verify the customer concern by operating the
system
2. Visually inspect for obvious signs of mechanical or electrical damage.
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, verify the symptom and refer to the Symptom Chart.
Visual Inspection Chart
Electrical
Mechanical
– Fuse(s)
– Loose or corrodedconnector(s)
– Control module
– Damaged or worn switch(es)
– Coolant leaks
– Oil leaks
– Fuel system leaks
– Visibly damaged or
worn parts
– Loose or missing nuts or bolts
Action
Possible Sources
Symptom
• CHECK for evidence of oilleaks on components. Use an
ultraviolet (UV) leak tester if an
oil leak is not evident. INSTALL
new gaskets or components as
required.
• Oil leaks on components that
are either coated in oil them-
selves or on components local
to them.
• Loss of oil
• CHECK the coolant expansiontank for a film of oil on the
coolant surface. INSTALL a
new oil cooler or oil cooler
gasket.
• Internal or external leak at the
oil cooler.
• INSTALL a new crankshaftseal.
• Leak at the crankshaft seal.
• CHECK for cracks in oil-carrying components of the
basic engine by means of a UV
leak test. INSTALL new
components or seals as
necessary.
• Leaks from oil carrying
components or basic engine.
• DETERMINE the last type ofengine oil used and compare
with the specification. Change
the engine oil to the specifica-
tion.
• Use of the wrong type of engine
oil.
• Oil consumption
G1055128en2008.50 Kuga8/2011
303-00-
2
Engine System - General Information
303-00- 2
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Measure the compression pressure
(Engine - 2.5L Duratec-ST (VI5))
TIE44608
1. Remove the central junction box (CJB) cover.
TIE44609
2. Open the CJB and remove the fuel pump relay.
3. NOTE: The engine will start, run for a fewseconds and then stop.
Start the engine.
4. Remove the ignition coil-on-plug.
REFER to: Ignition Coil-On-Plug (303-07 Engine
Ignition - 2.5L Duratec (147kW/200PS) - VI5,
Removal and Installation). 5. Connect the battery ground cable.
REFER to: Battery Disconnect and Connect
(414-01 Battery, Mounting and Cables,
General Procedures).
E68679
x5
6. Using Special Tool 303-499, remove the spark plugs.
E68434
NOTE: Operate the starter motor with wide open
throttle until the pointer on the measuring device
stops rising.
7. Carry out the measurement in accordance with the instructions supplied with the measuring
device on every cylinder using a suitable
compression pressure recorder with a suitable
adapter.
E68680
28 Nm
8. Using Special Tool 303-499, install the sparkplugs.
G1055128en2008.50 Kuga8/2011
303-00- 10
Engine System - General Information
303-00- 10
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

E62857
1
2
3
6
5
4
Description
Item
Camshaft bearings
1
Valve cover
2
Cylinder head
3Description
Item
Spark plug well sealing ring
4
Exhaust camshaft
5
intake camshaft
6
A conventional cylinder head gasket is installed
between the cylinder head and the cylinder block. The gaskets between the other mating faces are
fluid gaskets.
G1092773en2008.50 Kuga8/2011
303-01-
11
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
11
DESCRIPTION AND OPERATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL