2011 FORD KUGA general procedures

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:This step is only necessary when installing
a new component.
17. WARNING: Be prepared to collect escaping fluids.
CAUTION: Use suitable paper to absorb
any escaping fluid.
Refer to: Quick Release Coupling (310-00 Fuel
System - General Information, General
Procedures).
E113927
All vehicles
NOTE: This step is only necessary when installing
a new component.
18. Refer to: Fuel Pump and Sender Unit - 2.5L
Duratec (147kW/200PS) - VI5 (310-01 Fuel
Tank and Lines, Removal and Installation).
Installation
1. To install, reverse the removal procedure.
G1175018en2008.50 Kuga8/2011
310-01- 10
Fuel Tank and Lines
310-01- 10
REMOVAL AND INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Fuel Pump and Sender Unit — 2.5L Duratec (147kW/200PS) -VI5
Special Tool(s) / General Equipment
310-210
Wrench, Fuel Tank Sender
Unit
E115757
Special Tool(s) / General Equipment310-211
Wrench, Fuel Tank Sender
Unit
E115758
Fluid Container
Removal
NOTE:Removal steps in this procedure may
contain installation details.
1. Refer to: Fuel Tank - 2.5L Duratec
(147kW/200PS) - VI5 (310-01 Fuel Tank and
Lines, Removal and Installation).
2. Special Tool(s): 310-211
Torque: 1
10Nm
310-211
x2
310-211
x2
E114253
3. CAUTION: Take extra care not to
damage the fuel tank level sensor float
and arm.
E112921
4.
E112922
Vehicles without fuel fired booster heater
5.Refer to: Quick Release Coupling (310-00 Fuel
System - General Information, General
Procedures).
E116270
G1000791en2008.50 Kuga8/2011
310-01- 18
Fuel Tank and Lines
310-01- 18
REMOVAL AND INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

6.Special Tool(s): 310-210
Torque: 1
10Nm
310-210
x2
310-210
x2
E116489
Vehicles with fuel fired booster heater
7.Refer to: Quick Release Coupling (310-00 Fuel
System - General Information, General
Procedures).
E112978
8. CAUTION: Take extra care when handling the component terminals.
Special Tool(s): 310-210
Torque: 1
10Nm
310-210
x2
310-210
x2
E116490
1
All vehicles
9. CAUTION: Take extra care not todamage the fuel tank level sensor float
and arm.
E112979
10. WARNING: Be prepared to collectescaping fluid.
CAUTION: Use suitable paper to absorb
any escaping fluid.
Drain ther reservoir.
General Equipment: Fluid Container
E114482
Vehicles with fuel fired booster heater
NOTE: This step is only necessary when installing
a new component.
G1000791en2008.50 Kuga8/2011
310-01- 19
Fuel Tank and Lines
310-01- 19
REMOVAL AND INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

SECTION 412-00 Climate Control System - General
Information
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
SPECIFICATIONS
412-00-2
Specifications ........................................................................\
..............................................
DIAGNOSIS AND TESTING 412-00-3
Climate Control System ........................................................................\
..............................
412-00-3
Inspection and Checking ........................................................................\
............................
412-00-3
Refrigerant Circuit - Quick Check ........................................................................\
...............
412-00-4
Sequence of A/C Request Signal ........................................................................\
...............
GENERAL PROCEDURES 412-00-6
Air Conditioning (A/C) System Flushing ........................................................................\
.....
412-00-7
Air Conditioning (A/C) System Recovery, Evacuation and Charging .................................
412-00-9
Spring Lock Coupling ........................................................................\
..................................
412-00-11
Air Conditioning (A/C) Clutch Air Gap Adjustment .............................................................
412-00-12
Refrigerant Oil Adding ........................................................................\
................................
412-00-13
Contaminated Refrigerant Handling ........................................................................\
...........
412-00-14
Electronic Leak Detection ........................................................................\
...........................
412-00-15
Fluorescent Dye Leak Detection ........................................................................\
................
412-00-16
Vacuum Leak Detection ........................................................................\
..............................
412-00-1
Climate Control System - General Information
412-00- 1
.
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Climate Control System
Refer to Wiring Diagrams Section 412-00, for
schematic and connector information.
Special Tool(s) / General EquipmentTerminal Probe Kit
418-S035
29011A
Digital Multimeter (compatible with K-type
thermocouple)
The Ford approved diagnostic tool
Refrigerant center
Thermometer - Fluke 80 PK-8 (FSE number 260
4102 001 07)
Inspection and Checking
NOTE:The electronic automatic temperature
control (EATC) module is integrated into the air
conditioning control assembly.
1. VERIFY customer concern.
2. Visually CHECK for any obvious mechanical or electrical damage.
NOTE: Ensure correct locking of the wiring harness
connector.
Visual Inspection
Electrical
Mechanical
• Fuses
• Wiring harness
• Connector
• Refrigerant lines
• Condenser core
• Coolant level
• Drive belt
• A/C compressor
3. RECTIFY any obvious causes for a concern found during the visual inspection before
performing any further tests. CHECK the
operation of the system.
4. If the concern is still present after the visual inspection, perform fault diagnosis on the
electronic engine management, the charging
system, the generic electronic module (GEM)
and the instrument cluster (vehicles with EATC:
read out the EATC fault memory as well) using the Ford approved diagnostic tool and RECTIFY
the fault(s) displayed in accordance with the
fault description. CHECK the operation of the
system.
5. For vehicles with no stored fault(s), PROCEED in accordance with the Symptom Chart
according to the fault symptom.
6. Following checking or elimination of the fault(s) and after completion of operations, the fault
memories of all vehicle modules must be READ
OUT and any stored faults must be DELETED.
Refrigerant Circuit - Quick Check
WARNING: The air conditioning system is
filled with refrigerant R134a. Observe
"Health and Safety Precautions". For
further information
REFER to: Air Conditioning (A/C) System
Recovery, Evacuation and Charging
(412-00 Climate Control System - General
Information, General Procedures).
Refrigerant circuit check
WARNING: Under certain circumstances,
refrigerant lines and A/C components may
be extremely hot or cold. Exercising care,
touch the refrigerant lines or A/C
components in order to check this. Failure
to follow these instructions may result in
personal injury.
When the A/C system is operating, the following
conditions should apply:
• The refrigerant line from the refrigerant compressor to the condenser must be hot.
• The refrigerant line from the A/C condenser to the fixed orifice tube must be warm, but not so
hot as the refrigerant line mentioned above.
• Determine the difference in temperature upstream and downstream of the A/C condenser
by measuring the temperatures at the refrigerant
lines. The temperature difference should be
more than 20° C, depending on the ambient
temperature. If the temperature difference is
less, check the condenser for contamination or
damage to the fins as well as operation of the
radiator fans.
G1055878en2008.50 Kuga8/2011
412-00- 3
Climate Control System - General Information
412-00- 3
DIAGNOSIS AND TESTING
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

• The refrigerant line between the fixed orificetube and the evaporator must be cold from the
point where the fixed orifice tube is installed.
Depending on the weather, the refrigerant line
may also have ice on its surface.
• The refrigerant line between the evaporator and the A/C compressor including the dehydrator
must be cold.
Evaporator outlet line temperature test
To test the power of the A/C system, the
temperature at the evaporator outlet line must be
measured. To do this, the following preconditions
must be met:
• Open all windows.
• Set the air distribution to the defrost/dashboardposition and open all the ventilation nozzles.
• DO NOT switch on recirculated air.
• Select lowest blower switch setting.
• Select lowest temperature setting.
NOTE: The temperature measurement cannot be
done with a thermometer which makes no contact.
The surface reflection from the metal line may
cause incorrect readings.
Connect the temperature sensor (Fluke 80 PK-8)
to the outlet line of the evaporator. Locate the
temperature sensor as close as possible to the
evaporator. Connect the temperature sensor to the
multimeter.
Start the engine and allow it to run at idle speed
for several minutes.
Switch on the A/C.
After three minutes, measure the surface
temperature of the evaporator outlet line.
If the temperature measured is 4° C or lower, the
A/C system is OK. If the temperature is higher, the
A/C system may be under-filled. For further
information, refer to
REFER to: Air Conditioning (A/C) System
Recovery, Evacuation and Charging (412-00
Climate Control System - General Information,
General Procedures).
Frequent faults and their causes
If the cooling power of the A/C system is not
adequate, make certain that the temperature
control flap(s) is/are operating correctly. • No or poor cooling performance:
– Blockage or narrowing of a refrigerant line orin the dehydrator. The location of the
blockage or narrowing can easily be located
by temperature comparisons at the
refrigerant lines and the dehydrator. The
blockage or restriction is located at the point
where the temperature difference is
identified. Note: A temperature difference
in the area of the fixed orifice tube is
normal. If the location of the blockage or
narrowing is found, check the corresponding
component and renew as applicable.
• Sudden drop in cooling performance (after the air conditioning has been switched off for
approx. 5 minutes, the cooling performance
returns to normal):
– The cause is an iced-up fixed orifice tubebecause of moisture in the refrigerant circuit.
In order to ensure that moisture is completely
removed from the refrigerant circuit, the
dehydrator should be renewed and the
evacuation time should be extended to 2-3
hours. For further information
REFER to: Air Conditioning (A/C) System
Recovery, Evacuation and Charging
(412-00 Climate Control System - General
Information, General Procedures).
Sequence of A/C Request Signal
NOTE: The electronic automatic temperature
control (EATC) module is integrated into the air
conditioning control assembly.
NOTE: The generic electronic module (GEM) is
an integral part of the central junction box (CJB).
After actuating the A/C ON/OFF switch integrated
into the A/C control assembly, an A/C request
signal is sent from the A/C control assembly
(vehicles with EATC: EATC module) to the GEM.
From there, the signal is sent to the instrument
cluster via the MS-CAN bus. A gateway is installed
in the instrument cluster, which establishes the
connection between the MS-CAN bus and the
HS-CAN bus.
After the signal has been converted in the gateway,
it is relayed to the powertrain control module (PCM)
via the HS-CAN bus. Once all the required
parameters have been met, the PCM switches on
the refrigerant compressor and thus the A/C system
via the A/C clutch relay.
G1055878en2008.50 Kuga8/2011
412-00- 4
Climate Control System - General Information
412-00- 4
DIAGNOSIS AND TESTING
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Air Conditioning (A/C) System Flushing
9. Information not available at this time.
G1438314en2008.50 Kuga8/2011
412-00-6
Climate Control System - General Information
412-00- 6
GENERAL PROCEDURES
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Air Conditioning (A/C) System Recovery, Evacuation and Charging
General EquipmentAir Conditioning Service Unit
Automatic Calibration Halogen Leak Detector
Electronic Leak Detector
Refrigerant Identification Equipment
UV Leak Detector
1. Refer to: Air Conditioning (A/C) System Health
and Safety Precautions (100-00 General
Information, Description and Operation).
2.
E100846
x4
3. CAUTION: The refrigerant analyzer must be used before recovery, otherwise the
refrigerant center may become
contaminated. Contaminated refrigerant
must be disposed of as hazardous
waste. Always follow the manufacturer's
instructions when using the refrigerant
center and the refrigerant analyzer.
Unscrew and remove the protective caps from
the A/C charging connections.
General Equipment: Air Conditioning Service Unit
General Equipment: Refrigerant Identification Equipment 4.
Low-pressure connection
1.
2. High-pressure connection
2
E51608
1
5. Connect the service unit lines to the filling
connection of the air conditioning system.
VFE0031288
6.Drain the air conditioning system via the
low-pressure port in accordance with the service
unit manufacturer instructions.
7. CAUTION: Make sure that the specified amount of refrigerant oil is added.
NOTE:This step is only required when installing
a new component.
Fill up with refrigerant oil.
Refer to: Specifications (412-00 Climate Control
System - General Information, Specifications).
Refer to: Refrigerant Oil Adding (412-00 Climate
Control System - General Information, General
Procedures).
8. Evacuate the air conditioning system in
accordance with the service unit manufacturer
instructions.
9. NOTE: The system is leak-tight if the pressure
increase does not exceed 20 mbar.
G1022208en2008.50 Kuga8/2011
412-00- 7
Climate Control System - General Information
412-00- 7
GENERAL PROCEDURES
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL