2011 FORD KUGA Workshop Manual

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Page 1737 of 2057

FORD KUGA 2011 1.G Workshop Manual Action
Possible Sources
Symptom
• CHECK the pulley(s) fordamage, freedom of rotation,
stone entrapment and align-
ment. INSTALL new compon-
ents as necessary. TEST the
system for normal operation.
�

Page 1738 of 2057

FORD KUGA 2011 1.G Workshop Manual Action
Possible Sources
Symptom
• REMOVE the accessory drivebelt.
REFER to: Accessory Drive
Belt (303-05 Accessory Drive
- 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
and/or
REFER t

Page 1739 of 2057

FORD KUGA 2011 1.G Workshop Manual Action
Possible Sources
Symptom
• CHECK the accessory drivebelt tensioner for correct opera-
tion or damage. REFER to the
Accessory Drive Belt Tensioner
Component Test in this
procedure. INSTALL a n

Action
Possible Sources
Symptom
• CHECK the accessory drivebelt tensioner for correct opera-
tion or damage. REFER to the
Accessory Drive Belt Tensioner
Component Test in this
procedure. INSTALL a new
accessory drive belt tensioner
as necessary.
REFER to: Accessory Drive
Belt Tensioner (303-05
Accessory Drive - 2.5L
Duratec (147kW/200PS) -
VI5, Removal and Installa-
tion).
or
REFER to: Air Conditioning
(A/C) Compressor Belt
Tensioner (303-05 Accessory
Drive - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
TEST the system for normal
operation.
• Accessory drive belt tensioner
hitting the end stops.
NOTE:
Rattle is defined as a
metallic knocking noise
• Accessory drive belt rattle
• CHECK the components orhardware for correct installation
and tighten as necessary.
TEST the system for normal
operation.
• Loose components or hard-
ware.
Component Tests
Accessory Drive Belt Tensioner - Static
Check
The accessory drive belt tensioner may be checked
statically as follows:
1. Inspect the area surrounding the accessorydrive belt tensioner for lubricant or other
contamination. Rectify any leaks before
installing a new accessory drive belt tensioner.
If the accessory drive belt tensioner is
contaminated, do not attempt to clean it as the
damping mechanism inside may be damaged.
INSTALL a new accessory drive belt tensioner
as necessary.
REFER to: Accessory Drive Belt Tensioner
(303-05 Accessory Drive - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation). or
REFER to:
Air Conditioning (A/C) Compressor
Belt Tensioner (303-05 Accessory Drive - 2.5L
Duratec (147kW/200PS) - VI5, Removal and
Installation).
TEST the system for normal operation.
2. Detach the accessory drive belt in the area of the accessory drive belt tensioner.
3. NOTE: The accessory drive belt tensioner has a damping feature, which is usually a
friction device, therefore some friction within
the system is normal.
Using the correct tool, move the accessory drive
belt tensioner from its relaxed position through
its full stroke and back to the relaxed position
to make sure there is no excessive stick, grab
or bind, and to make sure there is tension on
the accessory drive belt tensioner spring.
4. Rotate the accessory drive belt tensioner pulley and check for damage, freedom of rotation and
G1183443en2008.50 Kuga8/2011
303-05- 9
Accessory Drive— 2.5L Duratec (147kW/200PS) - VI5303-05-
9
DIAGNOSIS AND TESTING
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Page 1740 of 2057

FORD KUGA 2011 1.G Workshop Manual alignment. INSTALL a new accessory drive belt
tensioner as necessary.
REFER to:Accessory Drive Belt Tensioner
(303-05 Accessory Drive - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
or

alignment. INSTALL a new accessory drive belt
tensioner as necessary.
REFER to:Accessory Drive Belt Tensioner
(303-05 Accessory Drive - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
or
REFER to: Air Conditioning (A/C) Compressor
Belt Tensioner (303-05 Accessory Drive - 2.5L
Duratec (147kW/200PS) - VI5, Removal and
Installation).
TEST the system for normal operation.
5. If the accessory drive belt tensioner meets the above criteria, proceed to test the accessory
drive belt tensioner dynamically. If the accessory
drive belt tensioner does not meet the above
criteria, INSTALL a new accessory drive belt
tensioner.
REFER to: Accessory Drive Belt Tensioner
(303-05 Accessory Drive - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
or
REFER to: Air Conditioning (A/C) Compressor
Belt Tensioner (303-05 Accessory Drive - 2.5L
Duratec (147kW/200PS) - VI5, Removal and
Installation).
TEST the system for normal operation.
Accessory Drive Belt Tensioner - Dynamic
Check
The accessory drive belt tensioner may be checked
dynamically as follows:
1. With the engine running, observe the accessory drive belt tensioner movement. The accessory
drive belt tensioner should move (respond)
when the engine is accelerated rapidly or when
the A/C clutch cycles ON and OFF (the degree
of movement can be up to 4 mm). If the
accessory drive belt tensioner movement is not
constant without engine acceleration or A/C
clutch cycling, a pulley or shaft is possibly bent,
out of round, or the damping mechanism inside
the accessory drive belt tensioner may be
damaged. INSTALL a new accessory drive belt
tensioner as necessary.
REFER to: Accessory Drive Belt Tensioner
(303-05 Accessory Drive - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation). or
REFER to:
Air Conditioning (A/C) Compressor
Belt Tensioner (303-05 Accessory Drive - 2.5L
Duratec (147kW/200PS) - VI5, Removal and
Installation).
TEST the system for normal operation.
2. Excessive accessory drive belt rideout (uneven depth of grooves in the accessory drive belt)
may cause excessive accessory drive belt
tensioner movement. Check the condition by
installing 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).
TEST the system for normal operation.
G1183443en2008.50 Kuga8/2011
303-05- 10
Accessory Drive— 2.5L Duratec (147kW/200PS) - VI5303-05-
10
DIAGNOSIS AND TESTING
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Page 1741 of 2057

FORD KUGA 2011 1.G Workshop Manual Accessory Drive Belt Tensioner(21 569 0)
Removal
NOTE:Removal steps in this procedure may
contain installation details.
1. Remove the air conditioning (A/C) compressor
belt tensioner.
Refer to: Air Co

Page 1742 of 2057

FORD KUGA 2011 1.G Workshop Manual Accessory Drive Belt(21 567 0)
Removal
1.Remove the air conditioning (A/C) compressor
belt.
Refer to: Air Conditioning (A/C) Compressor
Belt (303-05 Accessory Drive - 2.5L Duratec
(147kW/200PS) - VI5,

Page 1743 of 2057

FORD KUGA 2011 1.G Workshop Manual Air Conditioning (A/C) Compressor Belt(21 567 0)
Removal
1.Remove the right-hand front wheel and tire.
Refer to: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation).
2.
E65955
3.
E64285

Page 1744 of 2057

FORD KUGA 2011 1.G Workshop Manual Air Conditioning (A/C) Compressor Belt Tensioner
Removal
NOTE:Removal steps in this procedure may
contain installation details.
1. Remove AC compressor belt.
Refer to: Air Conditioning (A/C) Compresso

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