2011 FORD KUGA Workshop Manual

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Page 1985 of 2057

FORD KUGA 2011 1.G Workshop Manual Fuel Tank and Lines — 2.5L Duratec (147kW/200PS) - VI5 –Overview
Fuel tank
The fuel tank is the same on vehicles with FWD
and AWD. The fuel tank is saddle-shaped to accommodate the drive shaft and

Page 1986 of 2057

FORD KUGA 2011 1.G Workshop Manual Changing the right-hand fuel pump and level
indicator module
E113328
If the right-hand fuel pump and level indicator
module needs to be changed on a vehicle with a
booster heater/additional heater, th

Changing the right-hand fuel pump and level
indicator module
E113328
If the right-hand fuel pump and level indicator
module needs to be changed on a vehicle with a
booster heater/additional heater, the bore for the
connection to the fuel-fired booster
heater/additional heater must be drilled.
The right-hand fuel pump and level indicator
module contains a demand-switched electric fuel
pump which drives two suction jet pumps. One of
them ensures that fuel is pumped from the left-hand
half of the tank into the right-hand half. On-demand
switching is performed by the fuel pump module.
To remove the right-hand fuel pump and level
indicator module it is necessary to detach theleft-hand fuel pump and level indicator module and
pull it out slightly so that the connecting hose can
be detached and the connector for the left-hand
fuel pump and level indicator module can be
disconnected. The left-hand fuel pump and level
indicator module can be removed without detaching
the right-hand fuel pump and level indicator
module.
The instrument cluster uses the signals from both
fuel fill level sensors to determine the fuel fill level.
The resistor tracks of the fuel fill level sensors
cannot be replaced individually.
The fuel filter is designed to last for the service life
of the vehicle and does not need to be replaced.
The right-hand fuel pump and level indicator
module contains an overpressure limiting valve.
This overpressure limiting valve ensures that the
fuel pressure between the injectors and the
right-hand fuel pump and level indicator module
does not exceed 3.3 bar after the engine is
stopped. This reduces the formation of vapor
bubbles and also prevents dripping from the
injectors.
Fuel filler pipe and tank cap
NOTE:
Any water in the filling area can cause the
mechanism to freeze at temperatures below 0 °C.
In this case the closing mechanism will not open
when the nozzle of the petrol/diesel pump is
inserted.
43
1
2
1
5
43
1
2
1
5
E100648
G1090887en2008.50 Kuga8/2011
310-01- 6
Fuel Tank and Lines
310-01- 6
DESCRIPTION AND OPERATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Page 1987 of 2057

FORD KUGA 2011 1.G Workshop Manual Description
Item
Latch mechanism
1
Housing, capless fuel filler pipe
2
Overflow
3Description
Item
Gasket
4
Filler nozzle
5
A spring-loaded fuel filler door closes off the upper
end of the fuel tank fi

Page 1988 of 2057

FORD KUGA 2011 1.G Workshop Manual Fuel Tank — 2.5L Duratec (147kW/200PS) - VI5
Removal
WARNING: Avoid flames, sparks or lighted
substances.
NOTE: Removal steps in this procedure may
contain installation details.
1. Refer to: Battery

Page 1989 of 2057

FORD KUGA 2011 1.G Workshop Manual 7.Torque: 15Nm
x4x4
E104227
8.Refer to: Fuel Tank Draining (310-00 Fuel
System - General Information, General
Procedures).
Vehicles with fuel fired booster heater
9.
E113924
10.
E113925
11. WARNING: B

Page 1990 of 2057

FORD KUGA 2011 1.G Workshop Manual 14.
E104859
x2
15. WARNING: Be prepared to collectescaping fluids.
CAUTION: Use suitable paper to absorb
any escaping fluid.
x2x2
E113946
16.
E104642
x2
Vehicles with fuel fired booster heater
NOTE:Th

Page 1991 of 2057

FORD KUGA 2011 1.G Workshop Manual Fuel Level Sensor — 2.5L Duratec (147kW/200PS) - VI5
Removal
1.Refer to: Fuel Pump and Sender Unit - 2.5L
Duratec (147kW/200PS) - VI5 (310-01 Fuel
Tank and Lines, Removal and Installation).
Installa

Page 1992 of 2057

FORD KUGA 2011 1.G Workshop Manual Fuel Tank Filler Pipe
General EquipmentFluid ContainerGeneral EquipmentFuel Tank Draining Equipment
Hose Clamp Remover/Installer
Removal
WARNING: Make sure that the fuel tank is
no more than 3/4 full.

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