2011 FORD KUGA AIR CON

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
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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
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Charge Air Cooler(23 620 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
E98184
4. Torque: 5Nm
E99948
Installation
1.To install, reverse the removal.
G1079096en2008.50 Kuga8/2011
303-12- 8
Intake Air Distribution and Filtering
— 2.5L Duratec
(147kW/200PS) - VI5
303-12- 8
REMOVAL AND INSTALLATION
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
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3.

SECTION 303-13 Evaporative Emissions
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
DIAGNOSIS AND TESTING
303-13-2
Evaporative Emissions ........................................................................\
...............................
303-13-2
Inspection and Verification ........................................................................\
..........................
303-13-1
Evaporative Emissions
303-13- 1
.
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Evaporative Emissions
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)
– Vacuum line(s)
– Evaporative emis-
sion canister
– Evaporative emis- sion system hose(s)
– Evaporative emis- sion canister purge
valve
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.
G165592en2008.50 Kuga8/2011
303-13- 2
Evaporative Emissions
303-13- 2
DIAGNOSIS AND TESTING
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

SECTION 303-14 Electronic Engine Controls— 2.5L Duratec
(147kW/200PS) - VI5
VEHICLE APPLICATION: 2008.50 Kuga
PA G E
CONTENTS
DESCRIPTION AND OPERATION
303-14-3
Electronic Engine Controls (Component Location) .............................................................
303-14-7
Electronic Engine Controls (Overview) ........................................................................\
.......
303-14-7
General overview ........................................................................\
........................................
303-14-8
Powertrain Control Module (PCM) ........................................................................\
..............
303-14-8
Knock Sensor ........................................................................\
.............................................
303-14-8
Camshaft Position (CMP) Sensor ........................................................................\
...............
303-14-9
Crankshaft Position (CKP) sensor ........................................................................\
..............
303-14-9
Camshaft adjuster solenoid valve........................................................................\
...............
303-14-9
Manifold absolute pressure and temperature sensor .........................................................
303-14-9
Accelerator pedal position (APP) sensor ........................................................................\
....
303-14-10
Throttle control unit ........................................................................\
.....................................
303-14-10
Engine Coolant Temperature (ECT) sensor.......................................................................
303-14-10
Ignition coil-on-plug ........................................................................\
....................................
303-14-12
Electronic Engine Controls (System Operation and Component Description) ...................
303-14-12
System Diagram ........................................................................\
.........................................
303-14-16
System Operation ........................................................................\
.......................................
303-14-18
Speed and TDC recording ........................................................................\
......................
303-14-19
Calculation of the ignition angle ........................................................................\
..............
303-14-20
Engine fueling ........................................................................\
.........................................
303-14-22
Engine speed control ........................................................................\
..............................
303-14-22
Oil monitoring ........................................................................\
..........................................
303-14-23
Calculation of valve timing adjustment angle..................................................................
303-14-23
Boost pressure control ........................................................................\
............................
303-14-24
Starting process ........................................................................\
......................................
303-14-24
Alternator control (Smart Charge) ........................................................................\
...........
303-14-24
Component Description ........................................................................\
..............................
303-14-24

CKP sensor ........................................................................\
.............................................
303-14-25

Broadband HO2S ........................................................................\
...................................
303-14-26

VCT (variable camshaft timing) solenoids ......................................................................
303-14-27

MAF sensor ........................................................................\
.............................................
303-14-28

APP sensor ........................................................................\
.............................................
303-14-29

CPP sensor ........................................................................\
.............................................
303-14-29

BPP switches ........................................................................\
..........................................
303-14-30

Air conditioning (A/C) pressure sensor ........................................................................\
...
303-14-30

Throttle
control unit ........................................................................\
.................................
303-14-31

ECT sensor ........................................................................\
.............................................
303-14-31

Cooling fan module ........................................................................\
.................................
303-14-32

injectors........................................................................\
...................................................
303-14-32

Ignition coil-on-plug ........................................................................\
.................................
303-14-33

Fuel pressure/fuel temperature sensor ........................................................................\
...
303-14-33

Wastegate control valve ........................................................................\
..........................
303-14-34

Engine oil level, temperature and quality sensor ............................................................
303-14-1
Electronic Engine Controls— 2.5L Duratec (147kW/200PS) - VI5303-14-
1
.
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