2011 FORD KUGA tow

Action
Possible Sources
Symptom
• CHECK ride height, VERIFYcorrect spring rate and CHECK
items under Halfshaft Joint
Pullout. REPAIR or INSTALL
new as necessary.
• Excessively high CV joint oper-
ating angles caused by incor-
rect ride height.
• Shudder Vibration During
Acceleration.
• INSPECT and INSTALL newas necessary.
• Excessively worn or damaged
inboard front wheel driveshaft
joint or outboard front wheel
driveshaft joint.
• INSPECT and REPAIR orINSTALL new as necessary.
• Inboard driveshaft bearing
retainer circlip missing or not
correctly seated in differential
side gear.
• Halfshaft Joint Pullout
• CHECK engine mounts fordamage or wear. REPAIR or
INSTALL new as necessary.
• Engine/transaxle assembly
mispositioned.
• CHECK underbody dimensions.REFER to REFER to
Section 501-00 [Body System
-General Information] .
• Frame rail or strut tower out of
position or damaged.
• CHECK for worn bushings orbent components (front stabil-
izer bar, front suspension lower
arm). REPAIR or INSTALL new
as necessary.
• Front suspension components
worn or damaged.
G17442en2008.50 Kuga8/2011
205-04- 4
Front Drive Halfshafts
205-04- 4
DIAGNOSIS AND TESTING
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Hydraulic principle of operation
E96442
3
4
5
7
8
6
1
2
Description
Item
Reservoir
1
Valve unit
2
Steering rack and pinion
3
Flow control/pressure relief - return
4
Flow control/pressure relief valve
5Description
Item
Outlet of the power steering pump
6
Electro-hydraulic power steering pumpRefertoComponentDescription:(page
5)
7
Low pressure suction line
8
When the engine is started, the electro-hydraulic
power steering pump sucks in power steering fluid
from the reservoir. The fluid flows through the pump
and is discharged under high pressure from the
outlet. The high-pressure line carries the power
steering fluid to the servo valve.
If no steering effort is applied, there is no resistance
to the circulation of power steering fluid and the
supply pressure from the pump is very low. Only
minimal pressure is applied by the servo valve to
the two sides of the piston in the working cylinder.
When the steering wheel is turned in either
direction, the return flow of fluid to the reservoir is restricted by the servo valve, causing the pressure
to increase on the supply side. The power steering
fluid is directed by the servo valve to the
corresponding side of the piston in the working
cylinder, providing the power assistance required
to reduce the steering effort. The power steering
fluid which is displaced towards the low-pressure
side of the cylinder flows through the servo valve
and the return line back to the reservoir.
Component Description
Electro-hydraulic power steering pump
G1001270en2008.50 Kuga8/2011
211-02-
9
Power Steering
211-02- 9
DESCRIPTION AND OPERATION
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Engine Cooling — 2.5L Duratec (147kW/200PS) - VI5 – Overview
Auxiliary coolant pump
An electrically operated auxiliary coolant pump is
installed on vehicles with a trailer coupling and/or
additional heating. The auxiliary coolant pump
ensures that the coolant is circulated when the
coolant pump (which is driven by the engine) is not
running.
The additional heating uses the auxiliary coolant
pump to circulate hot coolant through the heat
exchanger and the engine.
On vehicles with a trailer coupling the auxiliary
coolant pump is switched on for 6 minutes by the
PCM (powertrain control module) if the coolant
temperature exceeds 106°C when the engine is
switched off. This prevents the coolant circuit from
overheating. This could happen particularly if the
engine is switched off after towing a heavy trailer
up a steep hill before there has been sufficient time
for cooling.
G1088220en2008.50 Kuga8/2011
303-03-3
Engine Cooling
303-03- 3
DESCRIPTION AND OPERATION
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Action
Possible Sources
Symptom
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• Fuel injection supply manifold
fuel pressure sensor.
• REFER to:Engine Ignition
(303-07 Engine Ignition - 2.5L
Duratec (147kW/200PS) -
VI5, Diagnosis and Testing).
• Engine ignition.
• Engine stumbling
• 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 injectors.
• Check the fuel system pres-sure.
• Low fuel system pressure.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• Fuel rail fuel pressure sensor.
• REFER to:Engine Ignition
(303-07 Engine Ignition - 2.5L
Duratec (147kW/200PS) -
VI5, Diagnosis and Testing).
• Engine ignition.
• Engine lacks power
• CHECK the braking system.REFER to: Brake System (206-
00 Brake System - General
Information, Diagnosis and
Testing).
• Brakes binding.
• ADVISE the customer aboutthe effects of overloading the
vehicle and wind resistance on
the fuel consumption.
• Vehicle overloaded, or
excessive wind resistance (roof
racks, towing etc).
• INSTALL a new air cleanerelement as necessary.
• Air cleaner element blocked.
• Check the fuel system pres-sure.
• Low fuel system pressure.
• INSPECT the fuel lines.INSTALL new components as
necessary. TEST the system
for normal operation.
• Kinked or restricted fuel lines.
G1183441en2008.50 Kuga8/2011
303-04A-
9
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 9
DIAGNOSIS AND TESTING
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Action
Possible Sources
Symptom
• CHECK the valve timing.REFER to: Timing Belt (303-01
Engine - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
• Incorrect valve timing.
• REMOVE the cylinder head.INSPECT the cylinder head
and pistons for signs carbon
build up.
REFER to: Cylinder Head (303-
01 Engine - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
• Excessive carbon build up.
• INSPECT the engine compon-ents.
• Worn or damaged oil pump.
• Worn or damaged timing chain
or sprocket.
• Major mechanical engine failure.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• KS.
• Engine knock during accelera-
tion
• 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 injectors.
• REFER to:Engine(303-00
Engine System - General
Information, Diagnosis and
Testing).
• Major mechanical engine
failure.
• CHECK the braking system.REFER to: Brake System (206-
00 Brake System - General
Information, Diagnosis and
Testing).
• Brakes binding.
• Excessive fuel consumption
• ADVISE the customer aboutthe effects of overloading the
vehicle and wind resistance on
the fuel consumption.
• Vehicle overloaded, or
excessive wind resistance (roof
racks, towing etc).
• INSTALL a new air cleanerelement.
• Air cleaner element blocked.
G1183441en2008.50 Kuga8/2011
303-04A-
19
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 19
DIAGNOSIS AND TESTING
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Starting System
Refer toWiring Diagrams Section 303-06, for
schematic and connector information.
General Equipment
Ford diagnostic equipment
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of electrical damage.
Visual Inspection Chart
Electrical
• Fuse(s)
• Wiring harness
• Electrical connector(s)
• Relay
• Switch(es)
• Battery junction box (BJB)
• Engine junction box (EJB)
• Central junction box (CJB)
• Keyless vehicle module (KVM) (if equipped)
• Battery
• Starter motor
• Powertrain Control Module (PCM)
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 diagnostictab within
the Ford diagnostic equipment .
G1183444en2008.50 Kuga8/2011
303-06-9
Starting System— 2.5L Duratec (147kW/200PS) - VI5303-06-
9
DIAGNOSIS AND TESTING
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than to a change in the throttle valve position. The
ignition timing also changes much more quickly.
To keep the ignition point as close as possible to
the knock limit and so optimize the efficiency of the
engine, two KS are installed in the engine, which
pick up the mechanical vibrations of the engine
and convert them into an electrical signal for the
PCM.
TIE42093
1
2
A
B1
2
Description
Item
Normal combustion
A
Knocking combustion
B
Pressure characteristic in cylinder
1
Output signal from KS
2
The term "knocking" is used to describe
combustion processes in which the flame front
propagation speed reaches the speed of sound.
This can happen towards the end of combustion
in particular, when unburnt air/fuel mixture on the
combustion chamber walls self-ignites due to the
increase in pressure following initiation of regular
combustion. The resulting pressure peaks damage
the pistons, cylinder head gasket and cylinder
head.
The cylinder in which combustion knock is
occurring is identified from the camshaft position (CMP sensors) and crankshaft position (CKP
sensor) information.
If the PCM detects combustion knock, the ignition
timing for the cylinder in question is gradually
retarded for a few crankshaft revolutions until
combustion knock stops. After that the ignition point
is slowly returned to the calculated value. This
facilitates individual cylinder ignition, which makes
it possible for the engine to operate at optimum
efficiency at the knock limit.
Engine fueling
Fuel is supplied by a non-return fuel system.
Fuel pressure and fuel delivery rate are regulated
by the PCM with the aid of the FPDM. The fuel
pump is supplied with a cycled voltage by the
FPDM. By cycling the voltage, the fuel pump output
can be steplessly adjusted. The fuel pressure can
be steplessly regulated between 3 and 5 bar.
Adjusting the fuel pump output has the following
advantages:
• The fuel pump's power consumption is reduced,
thereby reducing the load on the vehicle's power
supply system.
• The fuel pump's service life is increased.
• Fuel pump noise is reduced.
Fuel pressure regulator
The PCM calculates the required fuel pressure
based on the operating conditions. The PCM
transmits a corresponding PWM signal to the
FPDM. With the aid of this signal, the FPDM
actuates the pump by sending, in turn, a PWM
signal to the ground connection of the fuel pump.
The fuel pump can be steplessly regulated by
varying the pulse width of the PWM signal.
The PCM continuously monitors the fuel pressure
in the fuel rail by means of the fuel temperature/fuel
pressure sensor. If the pressure deviates from the
calculated value, the PCM adapts the PWM signal
to the FPDM accordingly. Thus the fuel pressure
levels out at approx. 4 bar.
For safety reasons, the PCM switches off fuel
delivery if the SRS (supplemental restraint system)
module detects a crash.
Regulation of injected fuel quantity
The electromagnetically controlled injectors dose
and atomize the fuel. The quantity of injected fuel
is regulated by the duration of actuation of the fuel
injectors. The fuel injectors are either closed (not
G1021908en2008.50 Kuga8/2011
303-14- 20
Electronic Engine Controls— 2.5L Duratec (147kW/200PS) - VI5303-14-
20
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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