2008-2013 Ford Kuga Service and Repair Manual

This 2008-2013 Ford Kuga Service and Repair Manual Covers

Engine and Drivetrain

• Complete repair procedures for the 2.0L Duratorq TDCi diesel engine and the 2.5L Duratec turbocharged inline-5 petrol engine
• Fuel injection system diagnostics, common rail diesel system priming, high-pressure pump servicing, and petrol fuel rail repairs
• Engine cooling system service specifications, electric cooling fan relays, and water pump replacement
• Exhaust and emissions control system repairs, Diesel Particulate Filter (DPF) regeneration, vaporizers, and EGR valve cleaning
• Transmission overhaul, fluid replacement, and adaptation procedures for the 6-speed manual, Durashift 5-speed automatic, and PowerShift MPS6 6-speed dual-clutch transmissions
• Haldex Generation 3 and Generation 4 All-Wheel Drive (AWD) coupling servicing, differential fluid flushes, and front/rear CV axle shafts

Chassis and Suspension

• Front suspension repair procedures specific to the C1 crossover platform, featuring MacPherson struts and reinforced lower control arms
• Rear suspension repair procedures specific to the C1 crossover platform, featuring an independent “Control Blade” multi-link design
• Electro-Hydraulic Power Assisted Steering (EHPAS) pump replacement, fluid bleeding, and software settings
• Factory wheel alignment specifications and cross-member geometric alignment instructions
• High-load wheel bearing and hub assembly replacement procedures
• Suspension trailing arms, anti-roll bar links, and shock absorber troubleshooting

Braking Systems

• Anti-lock Braking System (ABS) and Electronic Stability Program (ESP) module diagnostics
• Brake master cylinder, vacuum booster, and standard piston caliper service specifications
• Electronic Brake Assist (EBA) and Electronic Brake-force Distribution (EBD) calibration
• Mechanical handbrake lever assembly, cable tension adjustment, and rear brake shoe/caliper servicing
• Front ventilated brake disc and rear solid disc inspection, thickness limits, and replacement procedures

Electrical and Wiring

• Complete factory wiring diagrams including Powertrain Control Module (PCM) and Medium/High-Speed CAN-Bus communication layouts
• Smart Charging alternator diagnostics, 12V battery management, and glow plug control module circuits
• Body Control Module (BCM/GEM) diagnostics, fuse replacement, and module programming procedures
• Engine bay junction box and passenger compartment central fuse box schematics
• Halogen and optional High-Intensity Discharge (HID) bi-xenon headlamp assembly and cornering lamp diagnostics
• Ford 6000CD audio, Sony premium head units, Bluetooth Voice Control module (VCU), and travel pilot navigation troubleshooting

Air Conditioning and HVAC

• Manual AC and Dual-Zone Electronic Automatic Temperature Control (DEATC) system diagnostics
• HVAC blower motor resistor, air blend door actuators, and matrix heater core replacement
• R-134a refrigerant capacities, PAG compressor oil specifications, and full system evacuation/recharging steps
• Pollen/cabin air filter access, housing replacement, and air distribution troubleshooting

Body and Interior

• Front and rear seat frames, ISOFIX anchor points, and interior door trim panel removal/installation
• Exterior body panels, split-tailgate mechanism diagnostics, roof rails, and panoramic glass roof sealing
• Power door lock actuators, keyless entry/start (Ford Power button), and global window closure troubleshooting
• Supplemental Restraint System (SRS), side curtains, front impact sensors, and Restraints Control Module (RCM) servicing

Diagnostics and Troubleshooting

• Diagnostic Trouble Code (DTC) lookup procedures for Ford global standard OBD-II protocols
• Ford Integrated Diagnostic System (IDS) scan tool connection, module coding, and live data logger procedures
• Engine sensor pin-out reference values, resistance charts, and oscillograph sensor waveform targets
• Step-by-step troubleshooting workflows for PowerShift transmission judder, AWD fault messages, and DPF clogging
• Diesel injector coding (IMA codes) and adaptation reset procedures

Common Error Codes Covered

• P2002: Diesel Particulate Filter (DPF) Efficiency Below Threshold (Bank 1)
• P24A4: Diesel Particulate Filter Particulate Matter Regeneration Restriction – Too Accumulation
• P0234: Turbocharger/Supercharger Overboost Condition
• P0087: Fuel Rail/System Pressure – Too Low
• P0380: Glow Plug/Heater Circuit “A” Malfunction

Transmission Codes

• P0715: Input/Turbine Speed Sensor “A” Circuit Malfunction
• P2849: Shift Fork “A” Stuck
• P0700: Transmission Control System Malfunction

ABS and Chassis Codes

• C0034: Right Front Wheel Speed Sensor
• C1A14: AWD Clutch Control Circuit Malfunction
• C1277: Steering Wheel Angle Sensor Circuit 1 and 2 Signal Fault

Network Communication Codes

• U0073: Control Module Communication Bus “A” Off
• U0100: Lost Communication With PCM
• U0140: Lost Communication With Body Control Module

Body Control Codes

• B10A2: Crash Input
• B1318: Battery Voltage Low

This manual is ideal for:

• Professional automotive workshops
• Independent repair garages
• Mobile mechanics
• Automotive technicians
• Vehicle owners performing DIY repairs
• Automotive training institutions