2011 FORD KUGA Engine

Turbocharger(23 612 0)
General EquipmentCable Ties
Hose Clamp Remover/Installer
Materials
Specification
Name
SA-M1C9107-A / YS5J-
M1C9107-AA
Grease KS-PS
Removal
NOTE:
Removal steps in this procedure may
contain installation details.
1. Refer to: Battery Disconnect and Connect
(414-01 Battery, Mounting and Cables,
General Procedures).
2. Refer to: Cooling System Draining and Vacuum
Filling (303-03 Engine Cooling, General
Procedures).
3. Refer to: Cowl Panel Grille (501-02 Front End
Body Panels, Removal and Installation).
4.
E65070
5. CAUTION: Make sure that the inside of the pipe ends are clean and free of oil
residue.
1. Torque: 10Nm
2. Torque: 4Nm
3. Torque: 10Nm
2
1
3
E68504
6.
E67948
2
1
7.Torque: 26Nm1.
2. Torque: 26
Nm
3. Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
Torque: 38
Nm
E112143
3
2
1
G1079058en2008.50 Kuga8/2011
303-04B- 11
Fuel Charging and Controls - Turbocharger
—
2.5L Duratec (147kW/200PS) - VI5
303-04B- 11
REMOVAL AND INSTALLATION
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VUE0037806
4. If the cause is not visually evident, verify thesymptom and refer to the Symptom Chart.
Symptom Chart
Action
Possible Sources
Symptom
• CHECK the system with theengine running and the
accessory drive belt removed
(only run the engine for a very
short period). If a noise is
apparent, the cause is not the
accessory drive system. If a
noise is not apparent, the
cause is the accessory drive
system. CHECK where the
noise is coming from. Use a
stethoscope or other listening
device to determine the source
of the noise. INSTALL new
components as necessary.
TEST the system for normal
operation.
• Accessory drive system
• Accessory drive belt noise
• CHECK the accessory drivebelt is correctly installed in the
pulley grooves. INSTALL a new
accessory drive belt as neces-
sary.
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 Installa-
tion).
TEST the system for normal
operation.
• Accessory drive belt incorrectly
installed.
G1183443en2008.50 Kuga8/2011
303-05- 6
Accessory Drive— 2.5L Duratec (147kW/200PS) - VI5303-05-
6
DIAGNOSIS AND TESTING
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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.
• Pulley(s).
• CHECK the accessory drivebelt for contamination or
damage. RECTIFY the source
of the leak and INSTALL 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 Installa-
tion).
TEST the system for normal
operation.
• Lubricant or other contamina-
tion.
• CHECK the accessory drivebelt tensioner for correct opera-
tion, damage or contamination.
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
worn, damaged or contamin-
ated with oil.
NOTE:
Squeal is defined as a
continuous shriek, most noticeable
when the engine is being acceler-
ated or with electrical load.
• Accessory drive belt squeal
G1183443en2008.50 Kuga8/2011
303-05- 7
Accessory Drive— 2.5L Duratec (147kW/200PS) - VI5303-05-
7
DIAGNOSIS AND TESTING
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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 to: Air Conditioning
(A/C) Compressor Belt (303-
05 Accessory Drive - 2.5L
Duratec (147kW/200PS) -
VI5, Removal and Installa-
tion).
INSPECT the idler pulley(s) for
surface finish. INSTALL a new
idler pulley(s) as necessary.
TEST the system for normal
operation.
• Poor surface finish on
accessory drive belt idler pulley
flat surface(s).
NOTE:
Whine is defined as a
continuous noise at the same
frequency, generally associated
with plastic pulleys.
• Accessory drive belt whine
• 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 to: Air Conditioning
(A/C) Compressor Belt (303-
05 Accessory Drive - 2.5L
Duratec (147kW/200PS) -
VI5, Removal and Installa-
tion).
INSPECT the idler pulley(s) for
smooth rotation. INSTALL a
new idler pulley(s) as neces-
sary. TEST the system for
normal operation.
• Accessory drive belt idler pulley
bearing failure.
• CHECK that the accessorydrive belt is running centrally
on the flat pulleys. TEST the
system for normal operation.
• CHECK the pulleys for excessive end float and bent
flanges.
• With the engine running at idle, use a stethoscope to identify
the source of the noise.
INSTALL new components as
necessary. TEST the system
for normal operation.
• Pulley misalignment (usually
evident at idle).
NOTE:
Chirp is defined as a twit-
tering noise, often intermittent
• Accessory drive belt chirp
G1183443en2008.50 Kuga8/2011
303-05- 8
Accessory Drive— 2.5L Duratec (147kW/200PS) - VI5303-05-
8
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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
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Description
Item
Start/stop button
1
Keyless vehicle module
2
Electronic steering lock with mount -
passive key and PATS transmitter/receiver
unit
Comments:for emergency start function
3
Radio frequency receiver
Comments:Signal is only executed in GEM
4Description
Item
GEM
5
Stoplight Switch
6
TCM7
Starting deactivation relay
8
PCM
9
Starter relay
10
Starter motor
11
Battery
12
System Operation
Smart Start
The PCM enables the starting process when a key
providing a valid code is read via the PATS. This
code is then verified in the GEM and compared
with the saved code. If this code is recognized as
correct, synchronization with other modules is
carried out. After successful synchronization, the
engine is cleared to start in the PCM. The PCM
connects earth to the starter relay, which then
connects power to the starter solenoid. As soon
as the engine reaches a certain speed, the PCM
disconnects the starter relay and so turns off the
starter. This protects the starter.
If the engine does not turn or turns only slowly, the
starting process is aborted by the PCM.
The starter is notactivated if:
• the engine is running (i.e. the engine speed is above a particular value),
• the PATS does not permit the engine to be started,
• the clutch pedal is not operated (vehicles with manual transmission),
• the gear selector level is not set to P or N (vehicles with automatic transmission),
• the brake pedal is not operated (vehicles with automatic transmission).
Emergency starting function
If the keyless vehicle system is unable to recognize
the passive key, the vehicle can be started via the
emergency starting function. In this case, there is a passive key mount on the
steering wheel. A PATS transmission/reception
unit is attached to this.
To start the engine, the passive key must be
inserted into the passive key mount. The Start/Stop
button can then be used to turn on the ignition and
start the engine as normal. To deactivate the
PATS, a transponder is fitted in the passive key,
which is read by the transmission/reception unit.
G1032961en2008.50 Kuga8/2011
303-06-
8
Starting System— 2.5L Duratec (147kW/200PS) - VI5303-06-
8
DESCRIPTION AND OPERATION
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Starting System
Refer toWiring Diagrams Section 303-06, for
schematic and connector information.
General Equipment
Ford diagnostic equipment
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of electrical damage.
Visual Inspection Chart
Electrical
• Fuse(s)
• Wiring harness
• Electrical connector(s)
• Relay
• Switch(es)
• Battery junction box (BJB)
• Engine junction box (EJB)
• Central junction box (CJB)
• Keyless vehicle module (KVM) (if equipped)
• Battery
• Starter motor
• Powertrain Control Module (PCM)
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible)
before proceeding to the next step.
4. If the cause is not visually evident, verify the symptom and refer to the diagnostictab within
the Ford diagnostic equipment .
G1183444en2008.50 Kuga8/2011
303-06-9
Starting System— 2.5L Duratec (147kW/200PS) - VI5303-06-
9
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SECTION 303-07 Engine Ignition— 2.5L Duratec (147kW/200PS) - VI5
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
SPECIFICATIONS
303-07-2
Specifications ........................................................................\
..............................................
303-07-2
Spark plugs ........................................................................\
.............................................
DIAGNOSIS AND TESTING 303-07-3
Engine Ignition ........................................................................\
............................................
303-07-3
Inspection and Verification ........................................................................\
..........................
303-07-3
Symptom Chart ........................................................................\
...........................................
REMOVAL AND INSTALLATION 303-07-4
(22 414 0)
Ignition Coil-On-Plug ........................................................................\
..............
303-07-1
Engine Ignition— 2.5L Duratec (147kW/200PS) - VI5303-07-
1
.
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