2011 FORD KUGA Cooling system

Action
Possible Sources
Symptom
• Check the cooling systemcomponents. Engine - 2.5L
Duratec-ST (VI5) -
REFER to: Engine Cooling
(303-03 Engine Cooling,
Diagnosis and Testing).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
REFER to: Engine Cooling
(303-03 Engine Cooling,
Diagnosis and Testing).
• Cooling system components.
• Coolant consumption
• INSTALL a new oil cooler.
• Oil cooler.
• CHECK the cylinder headgasket for damage. CHECK the
cylinder head for distortion.
• Damaged gaskets or warped
mating faces.
• DETERMINE the damagedengine component(s) and
install new component(s) as
necessary.
• Cracks or fractures in engine
components surrounded by
coolant, such as cylinder liners
and cylinder head combustion
chamber.
• CHECK the battery and cables.REFER to: Charging System
(414-00 Charging System -
General Information,
Diagnosis and Testing).
• Battery or cables.
• Engine will not crank
• CHECK the starting system.Engine - 2.5L Duratec-ST (VI5)
-
REFER to: Starting System
(303-06 Starting System -
2.5L Duratec (147kW/200PS)
- VI5, Diagnosis and Testing).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Starter motor or cables.
• CHECK the fuel level.
• Fuel tank is empty.
• Engine cranks but will not start
• Drain the water from the fuelsystem.
• Water in fuel (diesel engine
only).
• INSTALL a new fuel filter.Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Fuel filter blocked.
G1055128en2008.50 Kuga8/2011
303-00-
4
Engine System - General Information
303-00- 4
DIAGNOSIS AND TESTING
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Cylinder Head(21 163 0)
General EquipmentFluid Container
Tire Lever
Materials
Specification
Name
WSS-M2C913-C
Engine Oil - 5W-30
SA-M1C9107-A / YS5J-
M1C9107-AA
Grease KS-PS
Removal
NOTE:
Removal steps in this procedure may
contain installation details.
1. Refer to: Cooling System Draining and Vacuum
Filling (303-03 Engine Cooling, General
Procedures).
2. Refer to: Fuel System Pressure Release
(310-00 Fuel System - General Information,
General Procedures).
3. Refer to: Battery Disconnect and Connect
(414-01 Battery, Mounting and Cables,
General Procedures).
4. Refer to: Air Cleaner (303-12 Intake Air
Distribution and Filtering - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
5.
E98184
6. Torque: 24Nm
E68748
7. Torque: 48Nm1.
2. Torque: 80
Nm
E65766
1
2
8. CAUTION: Make sure that the exhaust
flexible pipe is not forcibly bent.
General Equipment: Tire Lever
Material: Grease KS-PS (SA-M1C9107-A /YS5J-M1C9107-AA) grease
Torque: 50
Nm
E66052
x2
G1079022en2008.50 Kuga8/2011
303-01- 50
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
50
REMOVAL AND INSTALLATION
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Oil Cooler(21 764 0)
General EquipmentFluid Container
Hose Clamp(s)
Materials
Specification
Name
WSS-M2C913-C
Engine Oil - 5W-30
Removal
NOTE: Removal steps in the procedure may
contain installation details.
1.
E65299
2.
WARNING: Be prepared to collect
escaping fluid.
General Equipment: Fluid Container
Torque: 38
Nm
E92766
3.
WARNING: Be prepared to collect
escaping fluids.
1. General Equipment: Fluid Container General Equipment: Hose Clamp(s)
2. Torque: 3
Nm
3. Torque: 17Nm
E74103
x4
x2
2
3
1
Installation
1. To install, reverse the removal procedure.
2. CAUTION: Make sure that fluid level is to the MAX mark.
Refer to: Specifications (303-01 Engine - 2.5L
Duratec (147kW/200PS) - VI5, Specifications).
Material: Engine Oil - 5W-30 (WSS-M2C913-C) engine oil
3. Refer to: Cooling System Draining and Vacuum
Filling (303-03 Engine Cooling, General
Procedures).
G834604en2008.50 Kuga8/2011
303-01- 58
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
58
REMOVAL AND INSTALLATION
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25.Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
26. Refer to: Cooling System Draining and Vacuum
Filling (303-03 Engine Cooling, General
Procedures).
27.
E98184
28.
E112511
29. On both sides.
E99722
30mm1
30.
G1191240en2008.50 Kuga8/2011
303-01- 65
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
65
REMOVAL
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67.Install the following items:
1. Refer to: Battery(414-01 Battery, Mounting
and Cables, Removal and Installation).
2. Refer to: Cowl Panel Grille (501-02 Front
End Body Panels, Removal and
Installation).
68.
E79327
69. Refer to: Cooling System Draining and Vacuum
Filling (303-03 Engine Cooling, General
Procedures).
70. Refer to: Power Steering System Filling (211-00
Steering System - General Information,
General Procedures).
71. Refer to: Door Window Motor Initialization
(501-11 Glass, Frames and Mechanisms,
General Procedures).
G1191241en2008.50 Kuga8/2011
303-01- 138
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
138
INSTALLATION
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SECTION 303-03 Engine Cooling
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
DESCRIPTION AND OPERATION
303-03-2
Engine Cooling — 2.5L Duratec (147kW/200PS) - VI5 (Component Location) .................
303-03-3
Engine Cooling — 2.5L Duratec (147kW/200PS) - VI5 (Overview) ....................................
303-03-3
Auxiliary coolant pump ........................................................................\
...............................
DIAGNOSIS AND TESTING 303-03-4
Engine Cooling ........................................................................\
...........................................
303-03-4
Inspection and Verification ........................................................................\
..........................
GENERAL PROCEDURES 303-03-5
Cooling System Draining and Vacuum Filling .....................................................................
303-03-5
Draining ........................................................................\
......................................................
303-03-6
Evacuating and Filling ........................................................................\
................................
303-03-7
Radiator Lower Mounting Repair ........................................................................\
................
REMOVAL AND INSTALLATION 303-03-10
(24 404 0)
Coolant Pump — 2.5L Duratec (147kW/200PS) - VI5 ...................................
303-03-11
(24 222 0)
Cooling Fan Motor and Shroud — 2.5L Duratec (147kW/200PS) - VI5 .........
303-03-14
(24 254 0)
Radiator — 2.5L Duratec (147kW/200PS) - VI5 .............................................
303-03-19
(24 454 0)
Thermostat — 2.5L Duratec (147kW/200PS) - VI5 ........................................
303-03-20
(24 001 0)
Thermostat Housing — 2.5L Duratec (147kW/200PS) - VI5 ..........................
303-03-1
Engine Cooling
303-03- 1
.
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Engine Cooling
Special Tool(s) / General EquipmentPressure Tester, Cooling
System
303-396 (24-001 A)
IA24001A
Adaptor for 303-396
303-396-09
E55030
Ford approved diagnostic tool
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanicalor electrical damage.
Visual Inspection Chart
Electrical
Mechanical
– Fuse(s)
– Wiring harness
– Electricalconnector(s)
– Engine coolant temperature (ECT)
sensor
– Cooling fan motor
– Cooling fan module
– Powertrain control module (PCM)
– Coolant shut off valve
– Coolant degas shut off valve
– Coolant leaks
– Gaskets/seals
– Core plug(s)
– Hose(s)/hose joints
– Coolant expansion
tank cap and seal(s)
– Coolant expansion tank
– Radiator
– Coolant pump
– Thermostat
– Heater core
– Exhaust gas recircu- lation (EGR) cooler
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.
G1058974en2008.50 Kuga8/2011
303-03- 4
Engine Cooling
303-03- 4
DIAGNOSIS AND TESTING
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Cooling System Draining and Vacuum Filling
General EquipmentCooling System Vacuum Tester and Refiller
Fluid Container
Materials
Specification
Name
WSS-M97B44-D / 4U7J-
19544-AA2A
Antifreeze Super Plus
Premium
Draining
WARNING: When releasing the cooling
system pressure, cover the coolant
expansion tank cap with a thick cloth.
NOTE: Always follow the manufacturer's
instructions when handling the equipment.
1. Refer to: Engine Cooling System Health and
Safety Precautions (100-00 General
Information, Description and Operation).
2.
Release the cooling system pressure by slowly
turning the coolant expansion tank cap between
2 and 3 turns.
E68577
3. Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
4.
E65299
5.
WARNING: Be prepared to collect
escaping fluid.
Use a suitable coolant hose to drain the coolant.
General Equipment: Fluid Container
Loosen: 4
turn(s)
E97501
6.
E97501
G1034816en2008.50 Kuga8/2011
303-03- 5
Engine Cooling
303-03- 5
GENERAL PROCEDURES
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