2011 FORD KUGA ALL

Start Inhibit Switch
Removal
1. CAUTION: Make sure that the clutchpedal remains in the rest position.
1
2
3E101868
Installation
1.CAUTION: Make sure that the clutch
pedal remains in the rest position.
To install, reverse the removal procedure.
G1264759en2008.50 Kuga8/2011
303-06- 11
Starting System— 2.5L Duratec (147kW/200PS) - VI5303-06-
11
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

SECTION 303-07 Engine Ignition— 2.5L Duratec (147kW/200PS) - VI5
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
SPECIFICATIONS
303-07-2
Specifications ........................................................................\
..............................................
303-07-2
Spark plugs ........................................................................\
.............................................
DIAGNOSIS AND TESTING 303-07-3
Engine Ignition ........................................................................\
............................................
303-07-3
Inspection and Verification ........................................................................\
..........................
303-07-3
Symptom Chart ........................................................................\
...........................................
REMOVAL AND INSTALLATION 303-07-4
(22 414 0)
Ignition Coil-On-Plug ........................................................................\
..............
303-07-1
Engine Ignition— 2.5L Duratec (147kW/200PS) - VI5303-07-
1
.
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Engine Ignition
General EquipmentFord diagnostic equipment
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of electrical damage. Visual Inspection Chart
Electrical
• Circuit(s)
• Wiring harness
• Electrical connector(s)
• Spark plug(s)
• Ignition coil-on-plug(s)
• Powertrain control module (PCM)
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
• CARRY OUT a KV test usingthe Ford diagnostic equipment.
• Spark plug(s).
• Engine misfire
• REFER to the Ford diagnosticequipment.
• Circuit(s).
• Ignition coil-on-plug(s).
•PCM.
• PCM calibration.
• CARRY OUT a KV test usingthe Ford diagnostic equipment.
• Spark plug(s).
• Engine stumbling
• REFER to the Ford diagnosticequipment.
• Circuit(s).
• Ignition coil-on-plug(s).
•PCM.
• PCM calibration.
• CARRY OUT a KV test usingthe Ford diagnostic equipment.
• Spark plug(s).
• Engine lacks power
• REFER to the Ford diagnosticequipment.
• Circuit(s).
• Ignition coil-on-plug(s).
G323557en2008.50 Kuga8/2011
303-07-
3
Engine Ignition— 2.5L Duratec (147kW/200PS) - VI5303-07-
3
DIAGNOSIS AND TESTING
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Ignition Coil-On-Plug(22 414 0)
Removal
NOTE:Removal steps in this procedure may
contain installation details.
1. CAUTION: Make sure that the inside of the pipe ends are clean and free of oil
residue.
E65070
2. CAUTION: Make sure that the inside ofthe pipe ends are clean and free of oil
residue.
1. Torque: 10Nm
2. Torque: 4Nm
3. Torque: 10Nm
2
1
3
E68504
3.Torque: 10Nm
E113004
x8
4. Torque: 10Nm2.
1
22
E65075
Installation
1.To install, reverse the removal procedure.
G1165594en2008.50 Kuga8/2011
303-07- 4
Engine Ignition— 2.5L Duratec (147kW/200PS) - VI5303-07-
4
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Engine Emission Control
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanicaldamage.
Visual Inspection Chart
Electrical
Mechanical
– Electricalconnector(s)
– Wiring harness
– Fuse(s)
– Relay
– Powertain control module (PCM)
– Hose(s)/hose joints
– Gasket(s)
– Positive crankcase
ventilation (PCV)
valve
– PCV crankcase vent oil separator
– Turbocharger 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
• CLEAN or INSTALL new PCVcomponents as necessary.
TEST the system for normal
operation.
• Blocked PCV crankcase vent
oil separator.
• Blocked PCV hose.
• Excessive crankcase pressure
• Worn or damaged enginecomponents.
REFER to: Engine(303-00
Engine System - General
Information, Diagnosis and
Testing).
• Engine.
• CLEAN or INSTALL a newcrankcase vent oil separator.
TEST the system for normal
operation.
• Crankcase vent oil separator.
• Oil in the air intake system
• Worn or damagedturbocharger.
REFER to: Turbocharger (303-
04 Fuel Charging and
Controls - Turbocharger -
2.5L Duratec (147kW/200PS)
- VI5, Diagnosis and Testing).
• Turbocharger.
G1183446en2008.50 Kuga8/2011
303-08-
4
Engine Emission Control— 2.5L Duratec (147kW/200PS) - VI5303-08-
4
DIAGNOSIS AND TESTING
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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
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