2011 FORD KUGA 2.5L

Exhaust System – Component Location
E106894
1
2
3
4
5
6
7
8
Description
Item
Exhaust flexible pipe gasket
1
HO2S (heated oxygen sensor)
2
Exhaust flexible pipe
3
Front gasket, catalytic converter
4Description
Item
Exhaust catalytic convertor
5
Rear gasket, catalytic converter
6
Rear Muffler
7
Catalyst monitor sensor
8
G1079149en2008.50 Kuga8/2011
309-00- 2
Exhaust System— 2.5L Duratec (147kW/200PS) - VI5309-00-
2
DESCRIPTION AND OPERATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Exhaust Flexible Pipe
General EquipmentCable TiesMaterials
Specification
Name
SA-M1C9107-A / YS5J-
M1C9107-AA
Grease KS-PS
Removal
NOTE:
Removal steps in this procedure may
contain installation details.
1.
E65070
2. 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
3.Torque: 20Nm
E112607
1
2
34
4.
E67948
2
1
5. CAUTIONS:
Jointing compound must not be used
forward of the catalytic converter.
G1079152en2008.50 Kuga8/2011
309-00- 3
Exhaust System— 2.5L Duratec (147kW/200PS) - VI5309-00-
3
REMOVAL AND INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Make sure that the exhaust flexible pipe
is not forcibly bent.
2. Torque: 47
Nm
3. Torque: 28Nm
E112609
x3
1
2
3
6. Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
7.
E65299
8. General Equipment: Cable Ties
TIE0014991
9.
E66050
10.Torque: 30Nm
E112254
G1079152en2008.50 Kuga8/2011
309-00- 4
Exhaust System— 2.5L Duratec (147kW/200PS) - VI5309-00-
4
REMOVAL AND INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

11. CAUTION: Make sure that the exhaustflexible pipe is not forcibly bent.
Torque: 48Nm
E112253
x2
12.Material: Grease KS-PS (SA-M1C9107-A /
YS5J-M1C9107-AA) grease
Torque: 48
Nm
E112608
Installation
1. To install, reverse the removal.
G1079152en2008.50 Kuga8/2011
309-00- 5
Exhaust System— 2.5L Duratec (147kW/200PS) - VI5309-00-
5
REMOVAL AND INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Catalytic Converter
General EquipmentCable TiesMaterials
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: Lifting(100-02 Jacking and Lifting,
Description and Operation).
2.
E65299
3. General Equipment: Cable Ties
TIE0014991
4.
E66050
5. CAUTIONS:
Jointing compound must not be used
forward of the catalytic converter.
Make sure that the exhaust flexible pipe
is not forcibly bent.
Material: Grease KS-PS (SA-M1C9107-A / YS5J-M1C9107-AA) grease
Torque: 50
Nm
E66052
x2
G1079153en2008.50 Kuga8/2011
309-00- 6
Exhaust System— 2.5L Duratec (147kW/200PS) - VI5309-00-
6
REMOVAL AND INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

6. CAUTION: Make sure that the exhaustflexible pipe is not forcibly bent.
Material: Grease KS-PS (SA-M1C9107-A /YS5J-M1C9107-AA) grease
Torque: 50
Nm
E112253
x2
7. NOTE: This step is not necessary when
installing a new component.
Torque: 45
Nm
E66051
Installation
1. To install, reverse the removal procedure.
G1079153en2008.50 Kuga8/2011
309-00- 7
Exhaust System— 2.5L Duratec (147kW/200PS) - VI5309-00-
7
REMOVAL AND INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

SECTION 310-00 Fuel System - General Information
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
DIAGNOSIS AND TESTING
310-00-2
Fuel System — Vehicles With: Fuel Additive Tank .............................................................
310-00-2
Principles of Operation ........................................................................\
...............................
310-00-2
Inspection and Verification ........................................................................\
..........................
GENERAL PROCEDURES 310-00-3
Spring Lock Couplings ........................................................................\
................................
310-00-3
Disconnect ........................................................................\
..................................................
310-00-5
Connect ........................................................................\
......................................................
310-00-6
Quick Release Coupling ........................................................................\
.............................
310-00-6
Disconnect ........................................................................\
..................................................
310-00-7
Connect ........................................................................\
......................................................
310-00-8
Fuel System Pressure Check — 2.5L Duratec (162kW/220PS) - VI5 ................................
310-00-10
Fuel System Pressure Release ........................................................................\
..................
310-00-10
Release ........................................................................\
......................................................
310-00-11
Fuel Tank Draining ........................................................................\
......................................
310-00-1
Fuel System - General Information
310-00- 1
.
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Fuel System Pressure Check — 2.5L Duratec (162kW/220PS) -VI5
General Equipment
Adapter Pressure Vacuum Transducer (C219)
Ford Diagnostic Equipment
Pressure Vacuum Transducer (C407)
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. General Equipment: Adapter Pressure
Vacuum Transducer (C219)
•
E118166
1
2
C 219
4.
Connect the following items:
• General Equipment: Adapter Pressure Vacuum Transducer (C219)
• General Equipment: Pressure Vacuum Transducer (C407)
E107164
C 407
C219
5.Using the digital multi-meter function, measure
the fuel system pressure.
General Equipment: Ford Diagnostic Equipment
6. General Equipment: Ford Diagnostic Equipment
650 - 7503.6 - 4 bar650 - 7503.2 - 3.4 bar
123
E118167
7.General Equipment: Ford Diagnostic Equipment
2 bar2 bar
E107203
123
G544278en2008.50 Kuga8/2011
310-00- 8
Fuel System - General Information
310-00- 8
GENERAL PROCEDURES
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL