2011 FORD KUGA 100

Cooling System Draining and Vacuum Filling
General EquipmentCooling System Vacuum Tester and Refiller
Fluid Container
Materials
Specification
Name
WSS-M97B44-D / 4U7J-
19544-AA2A
Antifreeze Super Plus
Premium
Draining
WARNING: When releasing the cooling
system pressure, cover the coolant
expansion tank cap with a thick cloth.
NOTE: Always follow the manufacturer's
instructions when handling the equipment.
1. Refer to: Engine Cooling System Health and
Safety Precautions (100-00 General
Information, Description and Operation).
2.
Release the cooling system pressure by slowly
turning the coolant expansion tank cap between
2 and 3 turns.
E68577
3. Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
4.
E65299
5.
WARNING: Be prepared to collect
escaping fluid.
Use a suitable coolant hose to drain the coolant.
General Equipment: Fluid Container
Loosen: 4
turn(s)
E97501
6.
E97501
G1034816en2008.50 Kuga8/2011
303-03- 5
Engine Cooling
303-03- 5
GENERAL PROCEDURES
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Radiator Lower Mounting Repair
General Equipment5mmDrillBit
Cable Ties
Flat File
1. General Equipment: Cable Ties
E100039
2.Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
3.
E98183
4.
E98184
5.
E100040
x4
6. General Equipment: Flat File
1.
2. General Equipment: 5 mm Drill Bit
G1062292en2008.50 Kuga8/2011
303-03- 7
Engine Cooling
303-03- 7
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

8.Torque: 25Nm
E100040
x4
9.
E98184
10.
E98183
11 .Remove the cable ties securing the radiator and
condenser assembly.
G1062292en2008.50 Kuga8/2011
303-03- 9
Engine Cooling
303-03- 9
GENERAL PROCEDURES
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Cooling Fan Motor and Shroud — 2.5L Duratec (147kW/200PS)- VI5(24 222 0)
Removal
NOTE: Removal steps in this procedure may
contain installation details.
1. Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
2.
E98183
3.
E98184
4.
E112584
5.
E112335
6. Torque: 25Nm
G1156382en2008.50 Kuga8/2011
303-03- 11
Engine Cooling
303-03- 11
REMOVAL AND INSTALLATION
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Fuel Charging and Controls
E64777
14
5
2
3
G510053en2008.50 Kuga8/2011
303-04A-2
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 2
DESCRIPTION AND OPERATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Description
Item
Fuel Injectors
1
Valve
2
Fuel rail
3
Throttle body
4
Fuel tank to fuel rail fuel supply line
5
G510053en2008.50 Kuga8/2011
303-04A- 3
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 3
DESCRIPTION AND OPERATION
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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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Fuel Rail
Removal
NOTE:Removal steps in this procedure may
contain installation details.
1. Refer to: Petrol and Petrol-Ethanol Fuel
Systems Health and Safety Precautions
(100-00 General Information, Description and
Operation).
2. Refer to: Fuel System Pressure Release
(310-00 Fuel System - General Information,
General Procedures).
3. Refer to: Battery Disconnect and Connect
(414-01 Battery, Mounting and Cables,
General Procedures).
4. Refer to: Air Cleaner (303-12 Intake Air
Distribution and Filtering - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
5. Torque: 10
Nm
x2x2
E92954
6. CAUTION: Make sure that the inside of
the pipe ends are clean and free of oil
residue.
Torque: 4Nm
E63576
7. CAUTION: Make sure that the inside ofthe pipe ends are clean and free of oil
residue.
E64164
8. CAUTION: Make sure that the inside ofthe pipe ends are clean and free of oil
residue.
E64165
G1079057en2008.50 Kuga8/2011
303-04A- 24
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 24
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL