2011 FORD KUGA fluid

Action
Possible Sources
Symptom
• Check the fuel system pres-sure.
• Low fuel system pressure.
• Poor starting
• CHECK the system for fuelleak(s). REPAIR the system as
necessary.
• Fuel system leak.
• INSPECT the fuel system.INSTALL new components as
necessary. TEST the system
for normal operation.
• Fuel system restriction.
• INSTALL a new fuel filter.
• Fuel filter blocked.
• INSTALL a new air cleanerelement.
• Air cleaner element blocked.
• INSTALL a new engine oil filterand engine oil.
• Incorrect engine oil.
• DRAIN and REFILL the powersteering system with the correct
fluid.
REFER to: Power Steering
System Filling (211-00
Steering System - General
Information, General Proced-
ures).
• Incorrect power steering fluid.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• CKP sensor.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• Engine coolant temperature
(ECT) sensor.
• INSPECT the fuel injectors.CLEAN the fuel injectors or
INSTALL a new set of injectors
as required only after the
checks have been carried out.
REFER to: Fuel Injectors (303-
04 Fuel Charging and
Controls - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
• Fuel injector(s).
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• Fuel rail fuel pressure sensor.
G1183441en2008.50 Kuga8/2011
303-04A-
6
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 6
DIAGNOSIS AND TESTING
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

9.Torque: 10Nm
E64166
10. To r q u e : 2Nm1.
4.
WARNING: Be prepared to collect
escaping fluid.
Torque: 10
Nm
x5
x24
2
3
1
E93083
Installation
1. To install, reverse the removal procedure.
2. Refer to: Door Window Motor Initialization
(501-11 Glass, Frames and Mechanisms,
General Procedures).
G1079057en2008.50 Kuga8/2011
303-04A- 25
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 25
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Air conditioning (A/C) pressure sensor
E74157
The A/C pressure sensor is installed on the
high-pressure side of the A/C. The input voltage is
5V, the output voltage is between 0.5V and 4.5V
depending on the cryogenic fluid pressure. When
the cryogenic fluid pressure is low, the output
voltage is also low.
Voltage (Volts)
Pressure (bar)
3.9 - 4.0
Approx. 30
3.3 - 3.4
Approx. 25
2.7 - 2.8
Approx. 20
2.1 - 2.2
Approx. 15
1.6 - 1.7
Approx. 10
1.0 - 1.1
Approx. 5
0.5 - 0.7
Approx. 1
Throttle control unit
E74167
1
2
Description
Item
TP sensor
1
Electric motor
2
G1021908en2008.50 Kuga8/2011
303-14- 30
Electronic Engine Controls— 2.5L Duratec (147kW/200PS) - VI5303-14-
30
DESCRIPTION AND OPERATION
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SECTION 307-01 Automatic Transmission/Transaxle
— Vehicles With: 5-Speed Automatic Transaxle - AW55 AWD
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
SPECIFICATIONS
307-01-4
Specifications ........................................................................\
..............................................
DESCRIPTION AND OPERATION 307-01-5
Transmission Description (Component Location) ...............................................................
307-01-6
Transmission Description (Overview) ........................................................................\
.........
307-01-6
Components of the AW55 automatic transaxle ..................................................................
307-01-6
General overview ........................................................................\
....................................
307-01-8
Transaxle cooling ........................................................................\
....................................
307-01-8
External shift mechanism ........................................................................\
........................
307-01-9
Components of the electronic control ........................................................................\
.....
307-01-11
Overview of the brakes, clutches and one-way clutches ................................................
307-01-12
Input and output signals at the TCM ........................................................................\
.......
307-01-14
Knowing and Understanding Customer Concerns ..........................................................
307-01-14
Testing Possible Causes of Transmission Control Faults ...............................................
307-01-14
IDS Diagnosis ........................................................................\
.........................................
307-01-14
visual inspection ........................................................................\
.....................................
307-01-15
Towing the vehicle ........................................................................\
..................................
307-01-15
Push-starting the Vehicle ........................................................................\
........................
307-01-15
Jump-starting the Vehicle ........................................................................\
.......................
307-01-15
Selector Lever Emergency Release ........................................................................\
.......
307-01-16
Adjusting the Selector Lever Cable ........................................................................\
........
307-01-17
Transmission Fluid Level Check ........................................................................\
.............
307-01-17
Changing the Transmission Fluid ........................................................................\
...........
307-01-18
Diagnosis with IDS ........................................................................\
..................................
307-01-19
Resetting the counter for fluid change intervals. .............................................................
307-01-19
Programming the 'N' position of the TR sensor..............................................................
307-01-19
Resetting the values learned by the TCM .......................................................................
307-01-21
Transmission Description (System Operation and Component Description) .....................
307-01-21
System Operation ........................................................................\
.......................................
307-01-22
Functionality overview ........................................................................\
............................
307-01-24
Electronic Control System ........................................................................\
......................
307-01-24
Hydraulic Control System ........................................................................\
.......................
307-01-24
Type plate ........................................................................\
...............................................
307-01-25
Serial number of the transmission ........................................................................\
..........
307-01-25
Markings on the TCM ........................................................................\
.............................
307-01-25
Serial

number of the TCM ........................................................................\
.......................
307-01-25
Transmission Control ........................................................................\
..............................
307-01-27
Pin assignment for TCM connector 'C' (connection to transaxle) ...................................
307-01-28
Operation ........................................................................\
................................................
307-01-29
Gearshift control ........................................................................\
......................................
307-01-29
Adaptation ........................................................................\
...............................................
307-01-29
Shifting from 'P' to another transmission range ..............................................................
307-01-1
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 1
.
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PAGE 1 OF 3 FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

307-01-29
Automatic transmission, selector lever in position "D". ...................................................
307-01-29
Sport mode, selector lever in position "S" .......................................................................
307-01-29
Changing gear in select-shift mode........................................................................\
........
307-01-30
Selector lever from 'N' to 'R' position ........................................................................\
......
307-01-30
Self-test and Diagnosis ........................................................................\
...........................
307-01-30
Temperature controlled torque converter lockup ............................................................
307-01-30
Slip locking ........................................................................\
..............................................
307-01-30
Hill climbing ........................................................................\
.............................................
307-01-31
Downhill driving ........................................................................\
.......................................
307-01-31
Hill-hold function ........................................................................\
.....................................
307-01-31
Altitude correction ........................................................................\
...................................
307-01-31
Selector lever lock ........................................................................\
..................................
307-01-31
Shifting from P into another transmission range .............................................................
307-01-31
Shifting from N into another transmission range .............................................................
307-01-31
Power flow through the transmission ........................................................................\
......
307-01-31
Clutches and brakes ........................................................................\
...............................
307-01-33
Position P (park) ........................................................................\
.....................................
307-01-34
Position N (neutral) ........................................................................\
.................................
307-01-35
Position D, 1st gear........................................................................\
................................
307-01-36
Position D, 2nd gear ........................................................................\
...............................
307-01-37
Position D, 3rd gear ........................................................................\
................................
307-01-38
Position D, 4th gear ........................................................................\
................................
307-01-39
Position D, 5th gear ........................................................................\
................................
307-01-40
Position R (reverse) ........................................................................\
................................
307-01-41
Service instructions ........................................................................\
.................................
307-01-41
Towing procedure ........................................................................\
...................................
307-01-42
Reset adaptation data ........................................................................\
.............................
307-01-42
Limp home mode ........................................................................\
....................................
307-01-42
Component Description ........................................................................\
..............................
Tasks of the electronic components ........................................................................\
........
307-01-44
Input signals ........................................................................\
............................................
307-01-45
Output signals ........................................................................\
.........................................
Control valve assembly ........................................................................\
...........................
Shift solenoids S1 - S5 ........................................................................\
...........................
PWM-

solenoid valve – TCC (SLU) ........................................................................\
........
PWM solenoid valve – shift pressure (SLS) ...................................................................
PWM solenoid valve for main line pressure (SLT) ..........................................................
307-01-52
Installation position ........................................................................\
.................................
Operation ........................................................................\
................................................
Selector lever with integrated select-shift switch module ...............................................
Oil pump ........................................................................\
..................................................
Torque converter with TCC ........................................................................\
.....................
The TSS sensor ........................................................................\
......................................
The OSS sensor ........................................................................\
.....................................
The TFT sensor ........................................................................\
......................................
The TR sensor ........................................................................\
........................................
GENERAL PROCEDURES
T ransmission Fluid Level Check ........................................................................\
.................
307-01-63
T ransmission Fluid Drain and Refill ........................................................................\
............
REMOVAL AND INSTALLATION 307-01-67
Halfshaft Seal LH ........................................................................\
........................................
307-01-68
Halfshaft Seal RH........................................................................\
.......................................
307-01-69
Main Control Valve Body ........................................................................\
............................
307-01-2
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 2
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307-01-42
307-01-49
307-01-52 307-01-47
307-01-45
307-01-50
307-01-51
307-01-53
307-01-55
307-01-54
307-01-56
307-01-57
307-01-58
307-01-61 307-01-60
PAGE 2 OF 3 FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

307-01-72
Output Shaft Speed (OSS) Sensor ........................................................................\
.............
307-01-73
Torque Converter Seal ........................................................................\
................................
307-01-75
Transmission Fluid Pan ........................................................................\
..............................
307-01-77
Transmission Range (TR) Sensor ........................................................................\
..............
307-01-81
Turbine Shaft Speed (TSS) Sensor ........................................................................\
............
REMOVAL 307-01-82
Transmission ........................................................................\
..............................................
INSTALLATION 307-01-91
Transmission ........................................................................\
..............................................
307-01-3
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 3
.
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Lubricants, Fluids, Sealers and Adhesives
Specification
Item
WSS-M2C924-A
Automatic transmission fluid
Capacities
Litres
7.7±0.2
Automatic transmission fluid (including cooler an cooler hoses)
Gear Ratio
Gear Ratio 4.576
1st gear
2.980
2nd gear
1.948
3rd gear
1.318
4th gear
1.000
5th gear
5.024
Reverse gear
1.018
Counter gear
2.652
Differential gear
Line Pressure Chart
Stall (psi)
Stall (kPa)
Stall (bar)
Idle (psi)
Idle (kPa)
Idle (bar)
Transmis-
sion
Range
248 - 289
1710 - 1990
17,1 - 19,9
71 - 88
490 - 610
4,9 - 6,1
R
187 - 205
1290 - 1410
12,9 - 14,1
48 - 57
330 - 390
3,3 - 3,9
D
G1163602en2008.50 Kuga8/2011
307-01- 4
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 4
SPECIFICATIONS
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Transaxle cooling
1
2
3
4
E112583
Description
Item
The transmission fluid cooler.
1
Quick-release couplings
2Description
Item
From transmission fluid cooler to
transmission
3
From transmission to transmission fluid
cooler
4
The transmission fluid cooler is mounted on the
radiator. The transmission fluid cooler and the
automatic transaxle are connected via two hose
lines, which are equipped with quick-release
couplings. The transmission fluid cooler operates according
to the heat exchanger principle. The ram air
passing through the radiator withdraws heat from
the transmission fluid.
External shift mechanism
G1163604en2008.50 Kuga8/2011
307-01-
8
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 8
DESCRIPTION AND OPERATION
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