2011 FORD KUGA filter

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

Starter Motor(26 204 0)
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: Air Cleaner (303-12 Intake Air
Distribution and Filtering - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
3.
E63784
4. Torque: 10Nm
E63785
5.Torque: 12Nm
E64737
6.Torque: 50Nm
E64738
x2
Installation
1.To install, reverse the removal procedure.
2. Refer to: Door Window Motor Initialization
(501-11 Glass, Frames and Mechanisms,
General Procedures).
G962446en2008.50 Kuga8/2011
303-06- 10
Starting System— 2.5L Duratec (147kW/200PS) - VI5303-06-
10
REMOVAL AND INSTALLATION
TO MODEL INDEX
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

SECTION 303-12 Intake Air Distribution and Filtering
— 2.5L Duratec (147kW/200PS) - VI5
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
DESCRIPTION AND OPERATION
303-12-2
Intake Air Distribution and Filtering (Component Location) ................................................
DIAGNOSIS AND TESTING 303-12-4
Intake Air Distribution and Filtering ........................................................................\
.............
303-12-4
Inspection and Verification ........................................................................\
..........................
303-12-4
Symptom Chart ........................................................................\
...........................................
REMOVAL AND INSTALLATION 303-12-6
(23 174 0)
Air Cleaner ........................................................................\
..............................
303-12-8
(23 620 0)
Charge Air Cooler ........................................................................\
...................
303-12-1
Intake Air Distribution and Filtering
— 2.5L Duratec
(147kW/200PS) - VI5
303-12- 1
.
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Intake Air Distribution and Filtering – Component Location
E105576
1
2
34
5
6
7
8
9
Description
Item
Intake manifold
1
Air cleaner
2
The MAF (mass air flow) sensor
3
Pipe, air filter to turbocharger
4Description
Item
Turbocharger
5
Pipe, turbocharger to intercooler
6
Charge air cooler
7
Pipe, intercooler to intake manifold
8
Air Intake manifold
9
G1079094en2008.50 Kuga8/2011
303-12- 2
Intake Air Distribution and Filtering
— 2.5L Duratec
(147kW/200PS) - VI5
303-12- 2
DESCRIPTION AND OPERATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

E105848
1
2
3
Description
Item
Throttle body mechanism
Comments:Incorporates the TP (throttle position)
sensor
1
PCM (powertrain control module) cover
2
The MAPT (manifold absolute pressure
and temperature) sensor
3
G1079094en2008.50 Kuga8/2011
303-12-
3
Intake Air Distribution and Filtering
— 2.5L Duratec
(147kW/200PS) - VI5
303-12- 3
DESCRIPTION AND OPERATION
TO MODEL INDEX
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Intake Air Distribution and Filtering
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanicalor electrical damage.
Visual Inspection Chart
Electrical
Mechanical
– Mass air flow (MAF)sensor
– Manifold absolute pressure (MAP)
sensor
– Electrical connector(s)
– Air cleaner element
– Air cleaner intake
pipe
– Air cleaner outlet pipe
– Charge air cooler
– Charge air cooler intake pipe
– Charge air cooler outlet pipe 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.
Symptom Chart
Action
Possible Sources
Symptom
• CHECK the pipe(s) for securityand leaks to atmosphere.
INSTALL new intake air
components as necessary.
TEST the system for normal
operation.
• Detached air cleaner pipe(s).
• Detached turbocharger pipe(s).
• Detached charge air cooler
pipe(s).
• Excessive intake air noise
• REFER to:Engine Emission
Control (303-08 Engine
Emission Control - 2.5L
Duratec (147kW/200PS) -
VI5, Diagnosis and Testing).
• Blocked or damaged PCV
pipe(s)/hose(s).
• Blocked or damaged crankcase vent oil separator.
• Oil in the air intake system
• REFER to:Turbocharger(303-
04 Fuel Charging and
Controls - Turbocharger -
2.5L Duratec (147kW/200PS)
- VI5, Diagnosis and Testing).
• Turbocharger.
• CHECK the air intake pipesplash shield for correct install-
ation and alignment.
REPAIR/INSTALL the air intake
pipe splash shield as neces-
sary. TEST the system for
normal operation.
• Air intake pipe splash shield.
• Water in the air cleaner
G1183447en2008.50 Kuga8/2011
303-12- 4
Intake Air Distribution and Filtering
— 2.5L Duratec
(147kW/200PS) - VI5
303-12- 4
DIAGNOSIS AND TESTING
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Action
Possible Sources
Symptom
• CHECK the air cleaner drainfor blockage. TEST the system
for normal operation.
• Blocked air cleaner drain.
• INSPECT the air cleaner forsigns of blockage. INSTALL a
new air cleaner element as
necessary.
• Air cleaner element blocked.
• Engine lacks power
• INSPECT the charge air coolerpipes for damage. INSTALL a
new charge air cooler pipe(s)
as necessary.
• Charge air cooler pipe(s).
• INSPECT the charge air coolerfor blockage. INSTALL a new
charge air cooler as necessary.
REFER to: Charge Air Cooler
(303-12 Intake Air Distribution
and Filtering - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
• Charge air cooler blocked.
• REFER to:Fuel Charging and
Controls (303-04 Fuel Char-
ging and Controls - 2.5L
Duratec (147kW/200PS) -
VI5, Diagnosis and Testing).
• Fuel charging and controls.
• REFER to:Turbocharger(303-
04 Fuel Charging and
Controls - Turbocharger -
2.5L Duratec (147kW/200PS)
- VI5, Diagnosis and Testing).
• Turbocharger.
• REFER to:Engine(303-00
Engine System - General
Information, Diagnosis and
Testing).
• Engine.
G1183447en2008.50 Kuga8/2011
303-12-
5
Intake Air Distribution and Filtering
— 2.5L Duratec
(147kW/200PS) - VI5
303-12- 5
DIAGNOSIS AND TESTING
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Air Cleaner(23 174 0)
General EquipmentRetaining Strap
Trolley Jack
Removal
NOTE: Removal steps in this procedure may
contain installation details.
1.
E106249
2.
E63329
3.
E112307
4. CAUTION: Make sure that no components catch.
General Equipment: Retaining Strap
General Equipment: Trolley Jack
Torque: 90
Nm
E112303
15 mm
G1079095en2008.50 Kuga8/2011
303-12- 6
Intake Air Distribution and Filtering
— 2.5L Duratec
(147kW/200PS) - VI5
303-12- 6
REMOVAL AND INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL