2011 FORD KUGA connector

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
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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Spring Lock Couplings
Special Tool(s)310-040
Disconnect Tool, Fuel Line
(5/16")
23041
310-137
Disconnect Tool, Fuel Line
E51255
310-D004
Disconnect Tool, Spring Lock
Coupling (3/8" yellow)
23039
310-D005
Disconnect Tool, Spring Lock
Coupling (1/2" green)
23-040
412-038
Disconnect Tool, Spring Lock
Coupling (5/8" black)
34003
412-069
Disconnect Tool, Spring Lock
Coupling (3/4" white)
34002
Materials
Specification
Name
WSS-M2C153-G
Engine Oil - 5W-30
Disconnect
WARNINGS:
Refer to: Petrol and Petrol-Ethanol Fuel
Systems Health and Safety Precautions
(100-00 General Information, Description
and Operation).
NOTE: Fuel supply line connectors are color coded
white. Fuel return line connectors are color coded
red.
1. Release the fuel system pressure
Refer to: Fuel System Pressure Release
(310-00 Fuel System - General Information,
General Procedures).
2. Special Tool(s): 310-137
E77752
G544275en2008.50 Kuga8/2011
310-00- 3
Fuel System - General Information
310-00- 3
GENERAL PROCEDURES
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Quick Release Coupling
General EquipmentFlat-bladed screwdriver
Disconnect
WARNINGS:
Refer to: Petrol and Petrol-Ethanol Fuel
Systems Health and Safety Precautions
(100-00 General Information, Description
and Operation).
NOTE: Fuel supply line connectors are color coded
white. Fuel return line connectors are color coded
red.
1. Release the fuel system pressure
Refer to: Fuel System Pressure Release
(310-00 Fuel System - General Information,
General Procedures).
2.
E71970
1 2
1
3.
E71971
3
12
4.
E71973
21
1
5.
E53517
1
2
6.
E38209
2
1
G544276en2008.50 Kuga8/2011
310-00- 6
Fuel System - General Information
310-00- 6
GENERAL PROCEDURES
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Changing the right-hand fuel pump and level
indicator module
E113328
If the right-hand fuel pump and level indicator
module needs to be changed on a vehicle with a
booster heater/additional heater, the bore for the
connection to the fuel-fired booster
heater/additional heater must be drilled.
The right-hand fuel pump and level indicator
module contains a demand-switched electric fuel
pump which drives two suction jet pumps. One of
them ensures that fuel is pumped from the left-hand
half of the tank into the right-hand half. On-demand
switching is performed by the fuel pump module.
To remove the right-hand fuel pump and level
indicator module it is necessary to detach theleft-hand fuel pump and level indicator module and
pull it out slightly so that the connecting hose can
be detached and the connector for the left-hand
fuel pump and level indicator module can be
disconnected. The left-hand fuel pump and level
indicator module can be removed without detaching
the right-hand fuel pump and level indicator
module.
The instrument cluster uses the signals from both
fuel fill level sensors to determine the fuel fill level.
The resistor tracks of the fuel fill level sensors
cannot be replaced individually.
The fuel filter is designed to last for the service life
of the vehicle and does not need to be replaced.
The right-hand fuel pump and level indicator
module contains an overpressure limiting valve.
This overpressure limiting valve ensures that the
fuel pressure between the injectors and the
right-hand fuel pump and level indicator module
does not exceed 3.3 bar after the engine is
stopped. This reduces the formation of vapor
bubbles and also prevents dripping from the
injectors.
Fuel filler pipe and tank cap
NOTE:
Any water in the filling area can cause the
mechanism to freeze at temperatures below 0 °C.
In this case the closing mechanism will not open
when the nozzle of the petrol/diesel pump is
inserted.
43
1
2
1
5
43
1
2
1
5
E100648
G1090887en2008.50 Kuga8/2011
310-01- 6
Fuel Tank and Lines
310-01- 6
DESCRIPTION AND OPERATION
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Acceleration Control
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanicalor electrical damage.
Visual Inspection Chart
Electrical
Mechanical
– Wiring harness(s)
– Wiring harnessretaining clips
– Electrical connector(s)
– Accelerator pedal
– Powertrain control module (PCM)
– Electronic throttle body
– Accelerator pedal
– Throttle body
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 diagnostic tab within
the Ford approved diagnostic tool.
G1080719en2008.50 Kuga8/2011
310-02- 2
Acceleration Control
310-02- 2
DIAGNOSIS AND TESTING
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• Parking brake switch.– The parking brake switch is hard-wired to theGEM. The parking brake switch sends a
signal to the GEM when the parking brake is
operated. The GEM activates the parking
brake indicator lamp in the instrument cluster.
If the parking brake indicator lamp is lit,
cruise control cannot be activated.
• Back-up light switch – The backup lamp switch is hard-wired to the GEM. The backup lamp switch sends a signal
to the GEM when reverse gear is engaged.
The GEM activates the reversing lamp.
Cruise control cannot be activated when
reverse gear is engaged.
Component Description
Speed control switches
E103768
3
4
5
1
2
Description
Item
"ON" button
Comments:
1
"OFF" button
2Description
Item
"RES" button
3
"SET+" button
4
"SET-" button
5
The cruise control buttons are non-locking push
buttons. They are connected to the coil spring via
a hard-wired 9-pin plug connection.
The cruise control buttons operate according to
the resistance bridge circuit principle. The buttons
receive a 5 Volt reference voltage. When operated,
each button passes a particular voltage to the
GEM. The GEM measures this voltage and from
it determines which button has been pressed.
The operation of the cruise control buttons can be
checked by a simple measurement of the
resistance between pin 4 and pin 5 at the coil
spring 9-pin connector. A change of resistance
must occur when a button is pressed.
G1044191en2008.50 Kuga8/2011
310-03- 6
Speed Control
310-03- 6
DESCRIPTION AND OPERATION
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Speed Control
Inspection and Verification
1. Verify the customer concern by operating thesystem.
2. Visually inspect for obvious signs of mechanical or electrical damage.
Visual Inspection Chart
Electrical
Mechanical
– Fuse(s)
– Connections
– Wiring harness
– Clockspring
– Loose or corrodedelectrical
connector(s)
– Speed control switch
– Brake pedal position (BPP) deactivation
switch
– Clutch pedal posi- tion (CPP) deactiva-
tion Switch
– Powertrain control module (PCM)
– Central junction box (CJB)
– Brake pedal
– Clutch pedal
3. NOTE: Not all passenger junction box (PJB) variants support the speed control system.
NOTE: If the PJB is configured for speed control
disable, speed control operation is not transmitted,
no Diagnostic Trouble Codes (DTCs) are
generated.
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 diagnostic tab within
the Ford approved diagnostic tool.
G1054908en2008.50 Kuga8/2011
310-03- 7
Speed Control
310-03- 7
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL