2011 FORD KUGA fuel sensor

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.
• INSTALL a new air cleanerelement as necessary.
• Air cleaner element blocked.
• Excessive black smoke during
acceleration
• CHECK for signs of contamina-tion such as strange odors from
the fuel tank.
• If contaminated fuel is found, DRAIN the complete fuel
system. FLUSH the fuel system
through with clean gasoline.
REFER to: Fuel Tank Draining
(310-00 Fuel System -
General Information, General
Procedures).
INSTALL a new fuel filter.
• 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.
• INSTALL a new fuel rail.
REFER to: Fuel Rail(303-04
Fuel Charging and Controls -
2.5L Duratec (147kW/200PS)
- VI5, Removal and Installa-
tion).
• Incorrect or contaminated fuel.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• CKP sensor.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• KS.
• 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.
G1183441en2008.50 Kuga8/2011
303-04A-
12
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 12
DIAGNOSIS AND TESTING
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Action
Possible Sources
Symptom
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• Fuel rail fuel pressure sensor.
• REMOVE and visuallyINSPECT the catalytic
converter for damage. INSTALL
a new catalytic converter as
necessary.
REFER to: Catalytic Converter
(309-00 Exhaust System -
2.5L Duratec (147kW/200PS)
- VI5, Removal and Installa-
tion).
• Catalytic converter blocked.
• INSTALL a new air cleanerelement.
• Air cleaner element blocked.
• Black smoke at cruising speeds
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• ECT sensor.
• 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.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• Fuel rail fuel pressure sensor.
• REMOVE and visuallyINSPECT the catalytic
converter for damage. INSTALL
a new catalytic converter as
necessary.
REFER to: Catalytic Converter
(309-00 Exhaust System -
2.5L Duratec (147kW/200PS)
- VI5, Removal and Installa-
tion).
• Catalytic converter blocked.
• CARRY OUT a controlled oilconsumption test over 1000 km
(600 miles). CONFIRM that the
oil consumption is less than 0.1
litre per 1000 km (600 miles).
• Engine burning oil.
• Blue smoke
G1183441en2008.50 Kuga8/2011
303-04A- 13
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 13
DIAGNOSIS AND TESTING
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Action
Possible Sources
Symptom
• REFER to:Engine Ignition
(303-07 Engine Ignition - 2.5L
Duratec (147kW/200PS) -
VI5, Diagnosis and Testing).
• Engine ignition.
• Engine misfire
• CHECK for signs of contamina-tion such as strange odors from
the fuel tank.
• If contaminated fuel is found, DRAIN the complete fuel
system. FLUSH the fuel system
through with clean gasoline.
REFER to: Fuel Tank Draining
(310-00 Fuel System -
General Information, General
Procedures).
INSTALL a new fuel filter.
• 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.
• INSTALL a new fuel rail.
REFER to: Fuel Rail(303-04
Fuel Charging and Controls -
2.5L Duratec (147kW/200PS)
- VI5, Removal and Installa-
tion).
• Incorrect or contaminated fuel.
• Check the fuel system pres-sure.
• Low fuel system pressure.
• REFER to:Engine Cooling
(303-03 Engine Cooling,
Diagnosis and Testing).
• Engine operating temperature
too high.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• ECT sensor.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• CKP sensor.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• CMP sensor.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• KS.
G1183441en2008.50 Kuga8/2011
303-04A-
16
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 16
DIAGNOSIS AND TESTING
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Action
Possible Sources
Symptom
• 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.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• Fuel rail fuel pressure sensor.
• CHECK the engine compres-sion.
REFER to: Engine(303-00
Engine System - General
Information, Diagnosis and
Testing).
• Low cylinder compression.
• REMOVE the cylinder head.INSPECT the cylinder head,
valves, tappets and camshafts
for signs of wear or damage.
REFER to: Cylinder Head (303-
01 Engine - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
• Worn or damaged valve(s),
tappet(s) or camshaft(s).
• REMOVE the cylinder head.INSPECT the cylinder head
gasket and cylinder bores for
wear or damage.
REFER to: Cylinder Head (303-
01 Engine - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
• Damaged cylinder head gasket.
• CHECK the engine oil level.REFILL as necessary.
• Low engine oil level.
• Engine knock at idle
G1183441en2008.50 Kuga8/2011
303-04A- 17
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 17
DIAGNOSIS AND TESTING
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Action
Possible Sources
Symptom
• CHECK for signs of contamina-tion such as strange odors from
the fuel tank.
• If contaminated fuel is found, DRAIN the complete fuel
system. FLUSH the fuel system
through with clean gasoline.
REFER to: Fuel Tank Draining
(310-00 Fuel System -
General Information, General
Procedures).
INSTALL a new fuel filter.
• 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).
• INSTALL a new fuel rail.
REFER to: Fuel Rail(303-04
Fuel Charging and Controls -
2.5L Duratec (147kW/200PS)
- VI5, Removal and Installa-
tion).
• Incorrect or contaminated fuel.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• KS.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• CKP sensor.
• 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 injector(s).
G1183441en2008.50 Kuga8/2011
303-04A-
18
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 18
DIAGNOSIS AND TESTING
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Action
Possible Sources
Symptom
• CHECK the system for fuelleak(s). REPAIR or INSTALL
new parts as necessary.
• Fuel system leak(s).
• INSTALL a new fuel filter.
• Fuel filter blocked.
• INSTALL a new oil filter andengine oil.
• Incorrect engine oil.
• REFER to the Ford diagnosticequipment.
• Generator.
•
• Slipping clutch.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• ECT sensor.
• 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.
• Using the Ford diagnosticequipment, CHECK for the
availability of a calibration
update.
• PCM calibration.
• CHECK the valve timing.REFER to: Timing Belt (303-01
Engine - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
• Incorrect valve timing.
• CHECK the engine compres-sion.
REFER to: Engine(303-00
Engine System - General
Information, Diagnosis and
Testing).
• Low cylinder compression.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• CMP sensor.
• Engine cuts out during hard
acceleration
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• CKP sensor.
G1183441en2008.50 Kuga8/2011
303-04A-
20
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 20
DIAGNOSIS AND TESTING
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Action
Possible Sources
Symptom
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• Fuel rail fuel pressure sensor.
• Check the fuel system pres-sure.
• Low fuel system pressure.
G1183441en2008.50 Kuga8/2011
303-04A-
21
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 21
DIAGNOSIS AND TESTING
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Description
Item
PWM (pulse width modulation) signal
Comments:from PCM (powertrain control module)
5
Atmospheric pressure
6
Turbocharger boost pressure.
7
from air filter
8
Intake air
9Description
Item
Recirculated air valveRefertoComponentDescription:(page
7)
10
Vacuum line, recirculated air valve
11
to intake manifold
12
Throttle plate
13
Compressor
14
Turbine
15
System Operation
Turbocharger(s)
The TC consists of a turbine and a compressor.
The turbine is driven by the exhaust gas flow. A
common shaft drives the compressor and this then
compresses the intake air.
Turbocharger boost pressure control
E98942
1
2
3
4
Description
Item
Atmospheric pressure
1
Turbocharger boost pressure.
2
Wastegate control valve
3
Pilot pressure
4
The size of the TC is designed to produce a charge
effect even at medium engine speeds and lower
exhaust gas flows. This means that, when the engine speed is high and there is a large amount
of exhaust gas, either the boost pressure of the
TC will become too high or its speed will be too
high. The TC must therefore be regulated. The
best regulation is achieved by an electronically
controlled wastegate control valve. The wastegate
control valve controls the pressure on the
membrane in the boost pressure regulator.
The wastegate control valve is actuated by the
PCM with a PWM signal according to a map. The
boost pressure is applied to the wastegate control
valve via the pressure line from the compressor.
This pressure is passed to the boost pressure
regulator via the wastegate control valve. This
opens the bypass valve using a linkage. This
channels a portion of the exhaust gases around
the turbine. If the wastegate control valve is
actuated by the PCM, a bypass is opened in the
wastegate control valve. This causes the pressure
which can act on the membrane in the boost
pressure regulator to be reduced. This occurs until
the boost pressure has reached a set value. By
actuation with a PWM signal, it is also possible to
partially open or close the wastegate control valve.
This results in a constant boost pressure and
therefore high torque over a wide range of engine
speeds.
Because the PCM calculates the boost pressure
using the signal from the boost pressure sensor
and the IAT (intake air temperature) sensor, the
atmospheric pressure and the temperature are
automatically compensated for. Because of this
compensation, the engine power is not noticeably
affected by variations in atmospheric temperature
or pressure.
G1032426en2008.50 Kuga8/2011
303-04B-
6
Fuel Charging and Controls - Turbocharger
—
2.5L Duratec (147kW/200PS) - VI5
303-04B- 6
DESCRIPTION AND OPERATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL