2011 FORD KUGA start

External Controls – Overview
Transmission range selector
E112313
The transmission range selector is located on the
center console and is mechanically connected to
the transmission by a cable for operation of the
gear selector shaft and the TR (transmission range)
sensor.
As well as the positions P/R/N/D, the transmission
range selector provides a position for the sport and
select-shift mode (S). The manual gear position
can be selected at any time while driving. The gear
selected is locked until the driver selects another
gear.
The engine can only be started in positions P or
N.
The selector cable adjustment mechanism is at the
transmission end of the selector cable.
NOTE:Details of the exact procedure and
specifications can be found in the current service
literature.
Transmission range selector lever
emergency release
E114512
1
2
3
4
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307-05-
4
Automatic Transmission/Transaxle External
Controls
— Vehicles With: 5-Speed Automatic Transaxle - AW55 AWD/6-Speed
Automatic Transaxle - 6DCT450
307-05-4
.

Selector Lever Cable Adjustment — Vehicles With: 5-SpeedAutomatic Transaxle - AW55 AWD
Adjustment
1.
E114413
2.
E114414
3.
E114415
4.
E114416
5.Start the engine and move the selector lever
through all the gear positions. Wait until each
gear engages when moving through the gear
positions.
6. Check that the selector lever position indicator
corresponds to the position of the selector lever,
repeat the adjustment procedure if necessary.
7.
E108427
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6
Automatic Transmission/Transaxle External
Controls
— Vehicles With: 5-Speed Automatic Transaxle - AW55 AWD/6-Speed
Automatic Transaxle - 6DCT450
307-05-6
.

Transfer Case – System Operation and Component Description
System Operation
1
2
3
E103728
Description
Item
Hollow shaft
1
Output shaft
2
Output drive flange
3
NOTE: From the start of series production, the
transfer box will be subject to a "Black Box Phase"
and will therefore not be repaired.
To realise the all-wheel drive, a transfer box has
been flange-mounted to the manual transaxle. The
transfer box is designed as an angular gear to
transfer the torque from the transaxle to the rear
axle. The hollow shaft of the transfer box is inserted
in a tooth on the gear case. From the hollow shaft,
torque is transferred to the driveshaft through the
output shaft/output flange via crown gear and
differential pinion gear.
G1164987en2008.50 Kuga8/2011
307-07- 8
Transfer Case
— Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450
307-07- 8
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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.
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310-00- 2
Fuel System - General Information
310-00- 2
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Fuel System Pressure Release
Release
1.Refer to: Petrol and Petrol-Ethanol Fuel
Systems Health and Safety Precautions
(100-00 General Information, Description and
Operation).
2. Remove the fuel pump and sender unit fuse.
3. Start the engine and allow it to idle until the
engine stalls.
4. Crank the engine for approximately five seconds
to make sure that the fuel rail pressure is
released.
5. Install the fuel pump and sender unit fuse.
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310-00- 10
Fuel System - General Information
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Fuel Tank Draining
General EquipmentFluid Container
Fuel Tank Draining Equipment
Hose Clamp Remover/Installer
Activation
CAUTION: If the fuel tank has been filled
with the wrong type of fuel, the engine
must not be started.
NOTE: Removal steps in this procedure may
contain installation details.
6. Refer to: Petrol and Petrol-Ethanol Fuel
Systems Health and Safety Precautions
(100-00 General Information, Description and
Operation).
7. Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
8. WARNINGS:
Fuel may still be present in the fuel tank
after draining.
Be prepared to collect escaping fluids.
CAUTION: Use suitable paper to absorb
any escaping fluid. NOTE:
Make sure that a new component is
installed.
• General Equipment: Hose Clamp Remover/Installer
1. Make sure, that the fuel filler pipe is above the fuel level .
2. Drain the reservoir.
General Equipment: Fuel Tank DrainingEquipment
General Equipment: Fluid Container12
E116177
9. Refer to: Fuel Pump and Sender Unit - 2.5L
Duratec (147kW/200PS) - VI5 (310-01 Fuel
Tank and Lines, Removal and Installation).
10. WARNING: Be prepared to collect escaping fluids.
CAUTION: Use suitable paper to absorb
any escaping fluid.
G1165328en2008.50 Kuga8/2011
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Fuel System - General Information
310-00- 11
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Description
Item
PCM
8
Throttle body
Comments:Contains the TP (throttle position) sensor
9
The APP (accelerator pedal position)
sensor.
10Description
Item
CPP (clutch pedal position) switch
Comments:Vehicles with manual transaxle.
11
BPP (brake pedal position) switch
12
Reverse gear solenoid
Comments:Vehicles with manual transaxle.
13
System Operation
Speed Control
Cruise control is integrated into PCM and
intervenes in engine management to automatically
keep to the target speed selected by the driver.
When the system is active, the vehicle can be
accelerated or decelerated without the accelerator
pedal being pressed. Cruise control is operated
using the control switch units on the steering wheel.
The PCM controls the throttle to achieve this. The
ABS module supplies the VSS signal for this.
On vehicles with automatic transmission, the TCM
receives a notification via the CAN (controller area
network) bus that cruise control is active. The TCM
then controls the transmission based on special
engine maps.
Cruise control recognizes three operating modes:
• "OFF": Control is switched off.
• "STANDBY": Control is switched on but not
active. The speed of the vehicle is not regulated
by the cruise control.
• "ACTIVE": Control is switched on and active. Cruise control adjusts the vehicle speed to the
stored or desired target speed.
Every time the engine is started, cruise control is
in the "OFF" mode. In this mode, only the "ON"
button is operable.
Cruise control is initially set to "STANDBY" mode
when the "ON" button is pressed. The green cruise
control indicator lamp in the instrument cluster
lights up. There is no target speed saved.
Cruise control can only be set to "STANDBY" mode
under the following conditions:
• Engine speed is between idle speed and maximum permissible speed. Cruise control can only be changed into "ACTIVE"
mode under the following conditions:
• 2nd - 6th gear engaged.
• Engine speed between idle speed and maximum
permissible speed.
• Vehicle speed at least 40 km/h.
Pressing the "SET+" or "SET-" button activates
cruise control ("ACTIVE" mode). The green "Cruise
control" indicator lamp in the instrument cluster
lights up. The current vehicle speed is saved as
the target.
In "ACTIVE" mode the "OFF", "SET+", "SET-" and
"RES" buttons are active. If the "RES" button is
pressed again, control is suspended. The "RES"
button has a dual function and is used to resume
and suspend the cruise control.
Tapping the "SET+" button (for less than 640 ms)
increases the target speed by 1 km/h at a time.
Holding down the "SET+" button (for longer than
640 ms) increases the target speed until the button
is released. If the button is not released, cruise
control accelerates the vehicle up to the maximum
permissible vehicle speed (200 km/h) or up to the
vehicle's maximum speed (whichever speed is
lower). Tapping the "SET-" button (for less than
640 ms) reduces the target speed by 1 km/h at a
time. When the the "SET-" button is held down, the
control reduces the target speed until the button is
released. If the "SET-" button is held down until
the minimum speed of 40 km/h is reached, cruise
control switches to "STANDBY" mode.
Cruise control is put into "STANDBY" mode when
the "RES" button is pressed. Control to the stored
target speed can be started again by pressing the
"RES" button again. If the "SET+" or "SET-" button
is pressed while the "RES" function is being
performed (control to saved target speed), cruise
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310-03- 4
Speed Control
310-03- 4
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• The refrigerant line between the fixed orificetube and the evaporator must be cold from the
point where the fixed orifice tube is installed.
Depending on the weather, the refrigerant line
may also have ice on its surface.
• The refrigerant line between the evaporator and the A/C compressor including the dehydrator
must be cold.
Evaporator outlet line temperature test
To test the power of the A/C system, the
temperature at the evaporator outlet line must be
measured. To do this, the following preconditions
must be met:
• Open all windows.
• Set the air distribution to the defrost/dashboardposition and open all the ventilation nozzles.
• DO NOT switch on recirculated air.
• Select lowest blower switch setting.
• Select lowest temperature setting.
NOTE: The temperature measurement cannot be
done with a thermometer which makes no contact.
The surface reflection from the metal line may
cause incorrect readings.
Connect the temperature sensor (Fluke 80 PK-8)
to the outlet line of the evaporator. Locate the
temperature sensor as close as possible to the
evaporator. Connect the temperature sensor to the
multimeter.
Start the engine and allow it to run at idle speed
for several minutes.
Switch on the A/C.
After three minutes, measure the surface
temperature of the evaporator outlet line.
If the temperature measured is 4° C or lower, the
A/C system is OK. If the temperature is higher, the
A/C system may be under-filled. For further
information, refer to
REFER to: Air Conditioning (A/C) System
Recovery, Evacuation and Charging (412-00
Climate Control System - General Information,
General Procedures).
Frequent faults and their causes
If the cooling power of the A/C system is not
adequate, make certain that the temperature
control flap(s) is/are operating correctly. • No or poor cooling performance:
– Blockage or narrowing of a refrigerant line orin the dehydrator. The location of the
blockage or narrowing can easily be located
by temperature comparisons at the
refrigerant lines and the dehydrator. The
blockage or restriction is located at the point
where the temperature difference is
identified. Note: A temperature difference
in the area of the fixed orifice tube is
normal. If the location of the blockage or
narrowing is found, check the corresponding
component and renew as applicable.
• Sudden drop in cooling performance (after the air conditioning has been switched off for
approx. 5 minutes, the cooling performance
returns to normal):
– The cause is an iced-up fixed orifice tubebecause of moisture in the refrigerant circuit.
In order to ensure that moisture is completely
removed from the refrigerant circuit, the
dehydrator should be renewed and the
evacuation time should be extended to 2-3
hours. For further information
REFER to: Air Conditioning (A/C) System
Recovery, Evacuation and Charging
(412-00 Climate Control System - General
Information, General Procedures).
Sequence of A/C Request Signal
NOTE: The electronic automatic temperature
control (EATC) module is integrated into the air
conditioning control assembly.
NOTE: The generic electronic module (GEM) is
an integral part of the central junction box (CJB).
After actuating the A/C ON/OFF switch integrated
into the A/C control assembly, an A/C request
signal is sent from the A/C control assembly
(vehicles with EATC: EATC module) to the GEM.
From there, the signal is sent to the instrument
cluster via the MS-CAN bus. A gateway is installed
in the instrument cluster, which establishes the
connection between the MS-CAN bus and the
HS-CAN bus.
After the signal has been converted in the gateway,
it is relayed to the powertrain control module (PCM)
via the HS-CAN bus. Once all the required
parameters have been met, the PCM switches on
the refrigerant compressor and thus the A/C system
via the A/C clutch relay.
G1055878en2008.50 Kuga8/2011
412-00- 4
Climate Control System - General Information
412-00- 4
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