2011 FORD KUGA charging

8.Torque: 24Nm
E112607
4
9. CAUTION: Make sure that the inside of
the pipe ends are clean and free of oil
residue.
10.Torque: 17Nm
E63819
12.
13.General Equipment: Cable Ties
14.Torque: 28Nm
E66825
G1079058en2008.50 Kuga8/2011

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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
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E66726
TIE0014991
1
2
3
11. CAUTION: Make sure that the inside of
the pipe ends are clean and free of oil
residue.
Torque: 4Nm
E63820
303-04B- 12
Fuel Charging and Controls - Turbocharger
—
2.5L Duratec (147kW/200PS) - VI5
303-04B- 12
REMOVAL AND INSTALLATION

15.
E66050
16.Torque: 24Nm
E112254
17. CAUTION: 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
E112253
x2
18. General Equipment: Hose Clamp
Remover/Installer
Torque: 38
Nm
E66826
G1079058en2008.50 Kuga8/2011
303-04B- 13
Fuel Charging and Controls - Turbocharger
—
2.5L Duratec (147kW/200PS) - VI5
303-04B- 13
REMOVAL AND INSTALLATION
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19.Torque: 12Nm
E66829
x2
20.Torque: 24Nm
E112772
x12
1
2
3
Installation
1.To install, reverse the removal procedure.
2. Refer to: Door Window Motor Initialization
(501-11 Glass, Frames and Mechanisms,
General Procedures).
G1079058en2008.50 Kuga8/2011
303-04B- 14
Fuel Charging and Controls - Turbocharger
—
2.5L Duratec (147kW/200PS) - VI5
303-04B- 14
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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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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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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Powertrain Control Module (PCM)
E65160
The PCM communicates with all engine sensors
and the other modules. Communication of the PCM
with the other modules and the system diagnostics
takes place via the CAN (controller area network)
data bus.
The following functions are regulated or controlled
by the PCM:
• Fuel supply to the engine including lambdacontrol
• Ignition setting including knock control
• Idle speed control
• Control of optimum valve timing via the camshaft adjustment for intake and exhaust camshafts
• The refrigerant compressor is controlled by the air conditioning clutch relay and the delivery of
the refrigerant compressor is controlled by a
PWM (pulse width modulation) signal.
• Control of EVAP purge valve
• Boost pressure control
• Control of the cooling fan
• Charging system (Smart Charge)
• Starting system (Smart Start)
If the PCM is isolated from the vehicle electrical
system or the battery is disconnected, the throttle
control unit mustbe initialized.
The PCM is fitted in the engine compartment in the
air filter housing. On right hand drive vehicles a
protective metal plate is also installed to prevent
the plug connector from being pulled off, or make
it harder to pull off, in case of theft. The protective
plate is secured with a shear bolt. The shear bolt
needs to be drilled out in order to remove the
protective plate.
Knock Sensor
E96986
Two KSs are fitted. They are on the cylinder block,
one close to the 2nd cylinder and one close to the
4th cylinder.
When fitting, adhere strictly to the specified
tightening torque, otherwise the KS will not work
properly.
If the signal from one or both KS is implausible or
absent, knock control is deactivated. The PCM
switches to an ignition map that is further away
from the knock limit. As a result, engine damage
caused by combustion knock is avoided. If a fault
occurs, a fault code is stored in the error memory
of the PCM.
Camshaft Position (CMP) Sensor
E89993
If one or both CMP sensors fail, a fault is saved in
the error memory of the PCM and the camshaft
adjustment and knock control are deactivated.
G1021907en2008.50 Kuga8/2011
303-14- 8
Electronic Engine Controls— 2.5L Duratec (147kW/200PS) - VI5303-14-
8
DESCRIPTION AND OPERATION
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Description
Item
Medium speed CAN data bus (MS-CAN)
1
DLC
2
GEM
Comments:Serves as a gateway between the two
CAN databus systems.
3
High speed CAN data bus (HS-CAN)
4
PCMRefertoComponentDescription:(page
8)
5
LIN (local interconnect network) databus
6
Alternator
7
Heating element - broadband HO2S
8
Catalyst monitor sensor heating element
9
Powertrain Control Module relay
10
Starter Relay
11
FPDM
Comments:Refer to: Fuel Tank and Lines - 2.5L
Duratec (147kW/200PS) - VI5 (310-01
Fuel Tank and Lines, Description and
Operation).
12
Fuel pump
13
injectorsRefertoComponentDescription:(page
?)
Comments: 5x
14Description
Item
Air conditioning clutch relay
Comments:Refer to: Climate Control (412-01
Climate Control, Description and
Operation).
15
EVAP valve
Comments:
16
VCT oil control solenoid, exhaust camshaftRefer to Component Description:
solenoids(page26)
17
VCT oil control solenoid, intake camshaftRefer to Component Description:
solenoids(page26)
18
Cooling fan module
Comments:Refer to: Engine Cooling - 2.5L Duratec
(147kW/200PS) - VI5 (303-03 Engine
Cooling, Description and Operation).
19
Wastegate control valve
Comments:Refer to: Turbocharger (303-04 Fuel
Charging and Controls - Turbocharger
- 2.5L Duratec (147kW/200PS) - VI5,
Description and Operation).
20
Ignition coil-on-plugRefertoComponentDescription:(page
10)
Comments: 5x
21
Throttle control unitRefertoComponentDescription:(page
30)
Comments: Actuator motor unit
22
System Operation
The engine is controlled by the PCM. For this
purpose, the PCM uses information from the
sensors, sender units and switches. In addition,
the PCM receives information from other control
modules via the CAN data bus. All the information
is processed in the PCM and is used to control or
regulate the different actuators.
These are:
• the throttle control unit,
• the fuel injectors, • the camshaft adjustment,
• the boost control solenoid valve
• and the ignition coils.
Some values are sent via the CAN databus to other
systems.
The following functions are regulated or controlled
by the PCM:
G1021908en2008.50 Kuga8/2011
303-14-
16
Electronic Engine Controls— 2.5L Duratec (147kW/200PS) - VI5303-14-
16
DESCRIPTION AND OPERATION
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