2011 FORD KUGA air condition

Engine – System Operation and Component Description
System Operation
The variable camshaft timing occurs
electro-hydraulically and individually for both
camshafts.
The camshaft adjusters work according to the vane
cell principle and have an adjustment range of 52°
crank angle on the intake side and 47° crank angle
on the exhaust side. On starting the engine and
during idling, both camshafts are mechanically
locked in their starting positions. The exhaust
camshaft is in the early position and the intake
camshaft is in the late position. The camshaftadjuster on the exhaust side has a torsion spring
which compensates the camshaft drive torque.
This ensures that the assembly can return to the
starting position under all operating conditions and
when the engine is turned off.
Internal exhaust gas recirculation can be realized
through continuous adjustment of the timings. This
results in better fuel consumption and more
favorable combustion temperatures which produce
less pollutants. This means that pollutant level IV
can be adhered to with a 3-way catalytic converter.
The variable timings also make it possible to
optimize performance with wide open throttle.
G1032416en2008.50 Kuga8/2011
303-01-
16
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
16
DESCRIPTION AND OPERATION
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Timing Belt(21 304 0)
Special Tool(s) / General Equipment303-1054
Locking Tool, Timing Belt
Tensioner
3031054
303-1179
Holding Wrench, Crankshaft
E62035
Trolley Jack
Two Leg Puller
Removal
1.Refer to: Air Conditioning (A/C) Compressor
Belt (303-05 Accessory Drive - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
2.
E68741
3. General Equipment: Trolley Jack
E66944
4.
E68472
2
1
5.
E68742
G543492en2008.50 Kuga8/2011
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Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
25
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10.Torque: 115Nm1.
2. Torque: 90
Nm
E68740
1
2
11 .
E68741
12.Refer to: Air Conditioning (A/C) Compressor
Belt (303-05 Accessory Drive - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
G543492en2008.50 Kuga8/2011
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Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
30
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31.Torque:
• Stage 1: 25
Nm
• Stage 2: 60°
E122520
x4
32.Install the following items:
1. Refer to: Air Conditioning (A/C) Compressor
Belt (303-05 Accessory Drive - 2.5L
Duratec (147kW/200PS) - VI5, Removal
and Installation).
2. Refer to: Starter Motor (303-06 Starting
System - 2.5L Duratec (147kW/200PS) -
VI5, Removal and Installation).
G1166799en2008.50 Kuga8/2011
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Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
44
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SECTION 303-05 Accessory Drive— 2.5L Duratec (147kW/200PS) - VI5
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
DESCRIPTION AND OPERATION
303-05-2
Accessory Drive ........................................................................\
..........................................
DIAGNOSIS AND TESTING 303-05-4
Accessory Drive ........................................................................\
..........................................
303-05-4
Inspection and Verification ........................................................................\
..........................
303-05-4
Accessory Drive Belt Concerns ........................................................................\
..................
303-05-6
Symptom Chart ........................................................................\
...........................................
303-05-9
Component Tests ........................................................................\
........................................
REMOVAL AND INSTALLATION 303-05-11
(21 569 0)
Accessory Drive Belt Tensioner ......................................................................
303-05-12
(21 567 0)
Accessory Drive Belt ........................................................................\
..............
303-05-13
(21 567 0)
Air Conditioning (A/C) Compressor Belt .........................................................
303-05-14
Air Conditioning (A/C) Compressor Belt Tensioner ............................................................
303-05-1
Accessory Drive— 2.5L Duratec (147kW/200PS) - VI5303-05-
1
.
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Accessory Drive
2
1
E63663
Description
Item
Accessory drive belt
1
Air conditioning (A/C) compressor belt
2
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303-05- 2
Accessory Drive— 2.5L Duratec (147kW/200PS) - VI5303-05-
2
DESCRIPTION AND OPERATION
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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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Pilling
Pilling is dust that forms in between the ribs of the
accessory drive belt from rubber that is worn off
the accessory drive belt when it is new. There may
also be loose particles left on the accessory drive
belt during the manufacturing process. These are
worn off and form into small balls of rubber that
then get trapped in the grooves of the accessory
drive belt. This condition will usually clear itself
within 4800 km - 8000 km (3000 miles - 5000 miles)
of normal driving.
VUE0037805
3. Check the accessory drive belt for pilling. Thecondition of the accessory drive belt should be
compared against the illustration.
1. Small scattered pills. Not considered a concern. No action required.
2. Small scattered pills. Not considered a concern. No action required.
3. Longer pills up to 50% of the rib height. Possible noise concern. INSTALL a new
accessory drive belt if noise is apparent.
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).
4. Longer pills up to 50% of the rib height. Possible noise concern. INSTALL a new
accessory drive belt if noise is apparent.
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).
5. Heavy deposits in the grooves. Possible noise and stability concern. 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).
6. Heavy deposits in the grooves. Possible noise and stability concern. 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 AccessoryDrive
- 2.5L Duratec (147kW/200PS) - VI5,
Removal and Installation).
Incorrect fitment
Accessory drive belt noise can be generated by
the accessory drive belt being incorrectly fitted on
the pulley as shown in the following illustration.
Make sure that all the V grooves on the accessory
drive belt contact correctly with the pulley.
G1183443en2008.50 Kuga8/2011
303-05- 5
Accessory Drive— 2.5L Duratec (147kW/200PS) - VI5303-05-
5
DIAGNOSIS AND TESTING
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