2011 FORD KUGA case

1.Refer to: Health and Safety Precautions (100-00
General Information, Description and
Operation).
Refer to: Transfer Case (307-07 Transfer Case
- Vehicles With: 5-Speed Automatic Transaxle
- AW55 AWD/6-Speed Automatic Transaxle
- 6DCT450, Removal).
2. Special Tool(s): 303-293
303-293303-293
E115696
Installation
1. Install the Special Tool(s): 308-788
1.
3. Special Tool(s): 204-351
2308-788
1
204-351/1
3
204-351/2
3
2308-788
1
204-351/1
3
204-351/2
3
E115697
2. Remove the Special Tool(s): 308-788
3. Refer to: Transfer Case (307-07 Transfer Case
- Vehicles With: 5-Speed Automatic Transaxle
- AW55 AWD/6-Speed Automatic Transaxle
- 6DCT450, Installation).
Refer to: Transfer Case Fluid Level Check
(307-07 Transfer Case - Vehicles With:
5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle -
6DCT450, General Procedures).
G1164993en2008.50 Kuga8/2011
307-07- 16
Transfer Case
— Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450
307-07- 16
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Transfer Case Seal RH
Removal
1.Refer to: Transfer Case Seal RH (307-07
Transfer Case - Vehicles With: 5-Speed
Automatic Transaxle - AW55 AWD/6-Speed
Automatic Transaxle - 6DCT450, Removal
and Installation).
Installation
1. Refer to: Transfer Case Seal RH (307-07
Transfer Case - Vehicles With: 5-Speed
Automatic Transaxle - AW55 AWD/6-Speed
Automatic Transaxle - 6DCT450, Removal
and Installation).
G1164994en2008.50 Kuga8/2011
307-07- 17
Transfer Case
— Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450
307-07- 17
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Transfer Case
Removal
1.Refer to: Transfer Case (307-07 Transfer Case
- Vehicles With: 5-Speed Automatic Transaxle
- AW55 AWD/6-Speed Automatic Transaxle
- 6DCT450, Removal).
G1164996en2008.50 Kuga8/2011
307-07- 18
Transfer Case
— Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450
307-07- 18
REMOVAL
TO MODEL INDEX
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Transfer Case
Installation
1.Refer to: Transfer Case (307-07 Transfer Case
- Vehicles With: 5-Speed Automatic Transaxle
- AW55 AWD/6-Speed Automatic Transaxle
- 6DCT450, Installation).
G1164998en2008.50 Kuga8/2011
307-07- 19
Transfer Case
— Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450
307-07- 19
INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Fuel System — Vehicles With: Fuel Additive Tank
General EquipmentFord diagnostic equipment
Principles of Operation
WARNINGS:
This procedure involves fuel additive
handling. Be prepared for fuel additive
spillage at all times and always observe
fuel handling precautions. Failure to follow
these instructions may result in personal
injury.
Eye, hand, ear protection and protective
clothing are required to be worn during
any general service or removal and
installation service procedure of fuel
additive system components. Failure to
follow this instruction may result in
personal injury.
In case of fuel additive fluid contact with
the skin or the eyes, flush immediately with
water for a minimum of 15 minutes and
seek prompt medical attention. Failure to
follow these instructions may result in
personal injury.
If fuel additive fluid is swallowed, call a
physician immediately. Rinse mouth
immediately with water, do not induce
vomiting. Failure to follow these
instructions may result in personal injury.
Always provide adequate ventilation when
working on the fuel additive fluid system
or related components. Failure to follow
these instructions may result in personal
injury.
Do not smoke or carry lighted tobacco or
open flame of any type when working on
or near any fuel related components.
Highly flammable vapors are always
present and may ignite. Failure to follow
these instructions may result in personal
injury.
CAUTION: Make sure the workshop area
in which the vehicle is being worked on is
as clean and as dust free as possible.
Foreign matter from working on clutches,
brakes or from machining or welding
operations can contaminate the fuel
system and may result in later malfunction. The fuel additive system is an on-board system
that allows the injection of an additive at each
refueling operation by the customer. The additive
quantity is proportional to the fuel quantity that has
been added. The fuel additive system module
controls the amount of additive fluid entering the
fuel tank at each refueling, A switch mounted on
the fuel filler flap is used to detect the start of the
refueling event and the fuel gauge that is mounted
within the fuel tank informs the fuel additive tank
module the quantity of actual fuel added.
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of leakage
and mechanical or electrical damage.
Visual Inspection Chart
Electrical
Mechanical
– Fuse(s)
– Fuel filler switch andmagnet
– Wiring harness(s)
– Electrical connector(s)
– Fuel additive system module
– Fuel additive tank module
– Instrument cluster
– Powertrain Control Module (PCM)
– Fuel level sensor
– Fuel additive tank
– Fuel additive tank
line(s)
– Fuel additive tank pipe(s)
– Fuel additive tank connector(s)
– Fuel tank filler cap
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, REFER to the Ford diagnostic equipment.
G1080718en2008.50 Kuga8/2011
310-00- 2
Fuel System - General Information
310-00- 2
DIAGNOSIS AND TESTING
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Changing the right-hand fuel pump and level
indicator module
E113328
If the right-hand fuel pump and level indicator
module needs to be changed on a vehicle with a
booster heater/additional heater, the bore for the
connection to the fuel-fired booster
heater/additional heater must be drilled.
The right-hand fuel pump and level indicator
module contains a demand-switched electric fuel
pump which drives two suction jet pumps. One of
them ensures that fuel is pumped from the left-hand
half of the tank into the right-hand half. On-demand
switching is performed by the fuel pump module.
To remove the right-hand fuel pump and level
indicator module it is necessary to detach theleft-hand fuel pump and level indicator module and
pull it out slightly so that the connecting hose can
be detached and the connector for the left-hand
fuel pump and level indicator module can be
disconnected. The left-hand fuel pump and level
indicator module can be removed without detaching
the right-hand fuel pump and level indicator
module.
The instrument cluster uses the signals from both
fuel fill level sensors to determine the fuel fill level.
The resistor tracks of the fuel fill level sensors
cannot be replaced individually.
The fuel filter is designed to last for the service life
of the vehicle and does not need to be replaced.
The right-hand fuel pump and level indicator
module contains an overpressure limiting valve.
This overpressure limiting valve ensures that the
fuel pressure between the injectors and the
right-hand fuel pump and level indicator module
does not exceed 3.3 bar after the engine is
stopped. This reduces the formation of vapor
bubbles and also prevents dripping from the
injectors.
Fuel filler pipe and tank cap
NOTE:
Any water in the filling area can cause the
mechanism to freeze at temperatures below 0 °C.
In this case the closing mechanism will not open
when the nozzle of the petrol/diesel pump is
inserted.
43
1
2
1
5
43
1
2
1
5
E100648
G1090887en2008.50 Kuga8/2011
310-01- 6
Fuel Tank and Lines
310-01- 6
DESCRIPTION AND OPERATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL