2011 FORD KUGA FORD KUGA PCM

Engine Cooling
Special Tool(s) / General EquipmentPressure Tester, Cooling
System
303-396 (24-001 A)
IA24001A
Adaptor for 303-396
303-396-09
E55030
Ford approved diagnostic tool
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanicalor electrical damage.
Visual Inspection Chart
Electrical
Mechanical
– Fuse(s)
– Wiring harness
– Electricalconnector(s)
– Engine coolant temperature (ECT)
sensor
– Cooling fan motor
– Cooling fan module
– Powertrain control module (PCM)
– Coolant shut off valve
– Coolant degas shut off valve
– Coolant leaks
– Gaskets/seals
– Core plug(s)
– Hose(s)/hose joints
– Coolant expansion
tank cap and seal(s)
– Coolant expansion tank
– Radiator
– Coolant pump
– Thermostat
– Heater core
– Exhaust gas recircu- lation (EGR) cooler
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 diagnostic tab within
the Ford approved diagnostic tool.
G1058974en2008.50 Kuga8/2011
303-03- 4
Engine Cooling
303-03- 4
DIAGNOSIS AND TESTING
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Fuel Charging and Controls
General EquipmentFord diagnostic equipment
Inspection and Verification
1. Verify the customer concern by operating the system.
2. Visually inspect for obvious signs of mechanical or electrical damage. Visual Inspection Chart
Electrical
Mechanical
– Loose or corrodedconnector(s)
– Wiring harness
– Fuel injector(s)
– Fuel leaks
– Blocked or contamin-
ated fuel filter
– Damaged fuel supply manifold
– Damaged fuel line connections
– Damaged vacuum hoses
– Fuel rail pressure sensor
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 concern is not visually evident, verify the symptom and refer to the Ford diagnostic
equipment .
Symptom Chart
Action
Possible Sources
Symptom
• CHECK the PATS LED extin-guishes within 3 seconds when
the ignition is turned on.
REFER to: Anti-Theft - Passive
(419-01 Anti-Theft - Passive,
Diagnosis and Testing).
• PAT S .
• Engine does not crank
• REFER to:Starting System
(303-06 Starting System -
2.5L Duratec (147kW/200PS)
- VI5, Diagnosis and Testing).
• Starting system.
• REFER to the Wiring Diagrams.
• Ignition switch.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• Powertrain control module
(PCM).
• RESET the IFS switch.
• Inertia fuel shutoff (IFS) switch.
• Engine cranks but does not
start
• Check the fuel system pres-sure.
• Low fuel system pressure.
G1183441en2008.50 Kuga8/2011
303-04A-
4
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 4
DIAGNOSIS AND TESTING
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Action
Possible Sources
Symptom
• INSPECT the fuel lines.INSTALL new components as
necessary. TEST the system
for normal operation.
• Fuel lines damaged or blocked.
• INSTALL a new fuel filter.
• Fuel filter blocked.
• REFER to:Fuel Pump and
Sender Unit - 2.5L Duratec
(147kW/200PS) - VI5 (310-01
Fuel Tank and Lines,
Removal and Installation).
• Fuel pump and sender unit.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• Crankshaft position (CKP)
sensor.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• Camshaft position (CMP)
sensor.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
•PCM.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• Fuel rail fuel pressure 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.
• CHECK the valve timing.REFER to: Timing Belt (303-01
Engine - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
• Incorrect valve timing.
• TEST the cylinder compres-sion.
REFER to: Engine(303-00
Engine System - General
Information, Diagnosis and
Testing).
• Low cylinder compression.
G1183441en2008.50 Kuga8/2011
303-04A-
5
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 5
DIAGNOSIS AND TESTING
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Action
Possible Sources
Symptom
• REMOVE and visuallyINSPECT the 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.
• TEST the engine cylindercompression.
REFER to: Engine(303-00
Engine System - General
Information, Diagnosis and
Testing).
• Low cylinder compression.
• INSTALL a new air cleanerelement.
• Air cleaner element blocked.
• Engine starts but immediately
stops
• 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.
•PCM.
• Check the fuel system pres-sure.
• Low fuel system pressure.
• INSPECT the fuel system.INSTALL new components as
necessary. TEST the system
for normal operation.
• Fuel system restriction.
• INSTALL a new fuel filter.
• Fuel filter blocked.
• INSTALL a new air cleanerelement.
• Air cleaner element blocked.
• Poor idling
G1183441en2008.50 Kuga8/2011
303-04A- 7
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 7
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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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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Turbocharger
Special Tool(s) / General EquipmentHand Vacuum/Pressure
Pump
416 - D001 (23 - 036A)
23036A
Fuel Pressure Gauge
310-053 (23-046)
23046
Ford diagnostic equipment
Inspection and Verification
NOTE:It is normal for a small amount of
combustion gas to pass into the crankcase. This
gas is scavenged into the air intake system through
the positive crankcase ventilation (PCV) system,
which incorporates an crankcase vent oil separator.
Some engine oil, in the form of a vapor is carried
into the air intake system with the blow-by gases
(this engine oil also contributes to valve seat
durability). This means that oil will collect inside
the air intake components and the turbocharger.
This is not an indication that the turbocharger oil
seal has failed. The turbocharger oil seal will not
fail unless the bearings fail first, which will cause
the turbocharger to become noisy or seize. Do not
install a new turbocharger due to oil inside the
turbocharger or the air intake components. If a leak
is detected in the oil supply or return tubes or connections, locate and rectify the source. Do not
install a new turbocharger due to an oil leak.
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical
or electrical damage.
Visual Inspection Chart
Electrical
Mechanical
• Wiring harness
• Boost controlsolenoid valve
• Powertrain control module (PCM)
• Oil leak(s)
• Air cleaner element
• Air cleaner outlet
pipe
• Air cleaner intake pipe
• Turbocharger oil supply or oil return
tube
• Turbocharger intake pipe
• Turbocharger vacuum diaphragm
unit
• Turbocharger housing
• Charge air cooler
• Charge air cooler intake pipe and
hose(s)
• Charge air cooler outlet pipe and
hose(s)
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 Symptom Chart.
NOTE: The vacuum diaphragm unit is a fixed part of the turbocharger and cannot be adjusted or renewed.
G1183442en2008.50 Kuga8/2011
303-04B- 9
Fuel Charging and Controls - Turbocharger
—
2.5L Duratec (147kW/200PS) - VI5
303-04B- 9
DIAGNOSIS AND TESTING
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Description
Item
Vehicles with manual transaxle.
A
If equipped with an automatic transaxle.
B
Ignition key
Comments:With transponder for PATS (passive
anti-theft system)
1
PAT S
2
Ignition lock
3
GEM (generic electronic module)
4
PCM (powertrain control module)
5
Battery
6Description
Item
Starter relay
7
Starter motor
8
Stoplight Switch
Comments:If equipped with an automatic transaxle.
9
TCM (transmission control module)
Comments:If equipped with an automatic transaxle.
10
Starting deactivation relay
Comments:If equipped with an automatic transaxle.
11
G1032961en2008.50 Kuga8/2011
303-06-
4
Starting System— 2.5L Duratec (147kW/200PS) - VI5303-06-
4
DESCRIPTION AND OPERATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL