Ford Kuga Complete Workshop Service Repair Manual 2016
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🏷️ Basic Information Identification Make: Ford Model: Kuga Year: 2016 Generation Generation Identifier: Second Generation (C520) Codes Chassis Code: C520 Platform: Ford Global C platform 👋 Introduction Market Position Segment: Compact Crossover SUV Target Audience: Families, individuals seeking a versatile and practical vehicle. Competitive Analysis Key Competitors: Nissan Qashqai, Volkswagen Tiguan, Kia Sportage, Hyundai Tucson, Mazda CX-5, Peugeot 3008. Key Features Design Philosophy: Kinetic Design language, emphasizing sportiness and dynamism. Drivetrain Options: Available in Front-Wheel Drive (FWD) and Intelligent All-Wheel Drive (iAWD). 📋 Manual Details Coverage Areas Countries Of Operation: Global (with regional variations noted) Model Variants Covered: All Ford Kuga models, engines, trim levels, and transmission types for the 2016 model year. Page Count Estimated Page Count: Extensive (typically 1000+ pages for a complete workshop manual) Manual Type Type: Workshop Service and Repair Manual Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, engine management, fuel system, cooling system, lubrication system, exhaust system, ignition system. Transmission Drivetrain: Manual transmission, automatic transmission (Powershift and conventional), all-wheel-drive (AWD) system, front-wheel-drive (FWD), transfer case, driveshafts, differentials. Chassis: Suspension (front and rear), steering system, braking system (hydraulic, ABS, ESP), wheels and tires. Electrical Electronics: Battery, charging system, starter motor, lighting system (interior and exterior), instrument cluster, power distribution, body control modules (BCM), engine control module (ECM), transmission control module (TCM), infotainment, sensors, actuators. Body Interior: Body construction, body panels, doors, windows, sunroof, interior trim, seating, HVAC system, safety systems (airbags, seat belts). Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and top-ups, spark plug replacement, brake pad replacement. Diagnostics: Troubleshooting guides, fault code interpretation (OBD-II), symptom-based diagnostics, wiring diagrams, diagnostic connector locations. Repair Overhaul: Engine rebuilds, transmission overhaul, brake caliper replacement, suspension component replacement, electrical component repair, body panel repair. Installation Adjustment: Component installation and removal, component adjustments, alignment procedures, recalibration of sensors. Technical Depth Depth: Comprehensive, covering basic maintenance to advanced engine and transmission rebuilds, including detailed diagnostic procedures and schematics. 📊 Manual Specifications File Format Format: PDF (Portable Document Format) Searchability: Likely searchable text for keywords, depending on PDF source quality. Print Quality Resolution: High quality, suitable for printing individual pages or chapters. Binding Type Binding: Digital download - no physical binding. Paper Type Paper: N/A (Digital format) ⚙️ Engine Specifications Primary Engine Engine Family: EcoBoost Engine Configuration: Inline-4 Cylinder (various displacements) Engine Displacement: 1.5L EcoBoost, 1.6L EcoBoost, 2.0L EcoBoost, 2.0L TDCi Diesel (examples) Performance Horsepower Range: Approximately 120 PS (diesel) to 240 PS (EcoBoost gasoline). Torque Range: Approximately 270 Nm (diesel) to 340 Nm (EcoBoost gasoline). Fuel System Fuel Delivery Gasoline: Direct Injection (EcoBoost) Fuel Delivery Diesel: Common Rail Direct Injection Emission Control Catalytic Converter: Yes (Gasoline engines) Diesel Particulate Filter: Yes (TDCi diesel engines) 🔧 Transmission Standard Transmission Type Gasoline: 6-speed Manual Transmission Type Diesel: 6-speed Manual Optional Transmission Type Gasoline Optional: 6-speed Ford Powershift Automatic (Dual-Clutch) Transmission Type Diesel Optional: 6-speed Ford Powershift Automatic (Dual-Clutch) Features AWD Integration: Intelligent AWD system seamlessly integrates with transmission for optimal traction. 📐 Dimensions Exterior Length: Approx. 4556 mm (depending on specific variant) Width: Approx. 1838 mm (excluding mirrors) Height: Approx. 1689 mm (depending on roof rails) Cargo Luggage Capacity Seats Up: Approx. 450 - 480 liters (depending on configuration) Luggage Capacity Seats Down: Approx. 1500 - 1600 liters (depending on configuration) Weights Curb Weight: Approx. 1500 - 1700 kg (depending on engine and drivetrain) Gross Vehicle Weight: Typically around 2100-2300 kg 🛡️ Safety Features Ratings Euro Ncap Rating: 5 Stars (for most configurations of the second generation Kuga) IIHS Rating: Good (typically for models tested by IIHS) Active Features Electronic Stability Control: Standard (ESP/ESC) Anti Lock Braking System: Standard (ABS) Traction Control System: Standard (TCS) Brake Assist: Standard Passive Features Airbags: Driver, passenger, side curtain, front side airbags (standard on most trims). Seat Belts: 3-point seat belts with pretensioners for all seating positions. Child Seat Anchors: ISOFIX mounting points 💡 Technology Features Infotainment Sync System: Ford SYNC 2 or SYNC 3 infotainment system with touchscreen interface. Connectivity Options: Bluetooth, USB connectivity, optional satellite navigation, Apple CarPlay/Android Auto compatibility (depending on SYNC version). Driver Assistance Adaptive Cruise Control: Optional Blind Spot Monitoring: Optional Lane Keeping Aid: Optional Parking Assist: Optional (e.g., Active Park Assist) Connectivity Ford Applink: Allows voice-controlled access to smartphone apps. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 15,000 miles (24,000 km) or 12 months, whichever comes first (for gasoline engines, consult manual for diesel). Air Filter Replacement: Typically every 30,000 miles (48,000 km) or as needed based on driving conditions. Spark Plug Replacement: Around 60,000 - 100,000 miles (96,000 - 160,000 km) for iridium spark plugs (consult manual for specific engine). Fluid Specifications Engine Oil Type: Ford WSS-M2C948-B (for 1.0L and 1.5L EcoBoost) or Ford WSS-M2C913-D (for 1.6L EcoBoost and 2.0L TDCi). Consult manual for specific engine. Coolant...
Manual transmission, automatic transmission (Powershift and conventional), all-wheel-drive (AWD) system, front-wheel-drive (FWD), transfer case, driveshafts, differentials.
Chassis:
Suspension (front and rear), steering system, braking system (hydraulic, ABS, ESP), wheels and tires.
Electrical Electronics:
Battery, charging system, starter motor, lighting system (interior and exterior), instrument cluster, power distribution, body control modules (BCM), engine control module (ECM), transmission control module (TCM), infotainment, sensors, actuators.
Body Interior:
Body construction, body panels, doors, windows, sunroof, interior trim, seating, HVAC system, safety systems (airbags, seat belts).
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and top-ups, spark plug replacement, brake pad replacement.
Approximately 120 PS (diesel) to 240 PS (EcoBoost gasoline).
Torque Range:
Approximately 270 Nm (diesel) to 340 Nm (EcoBoost gasoline).
Fuel System
Fuel Delivery Gasoline:
Direct Injection (EcoBoost)
Fuel Delivery Diesel:
Common Rail Direct Injection
Emission Control
Catalytic Converter:
Yes (Gasoline engines)
Diesel Particulate Filter:
Yes (TDCi diesel engines)
🔧 Transmission
Standard
Transmission Type Gasoline:
6-speed Manual
Transmission Type Diesel:
6-speed Manual
Optional
Transmission Type Gasoline Optional:
6-speed Ford Powershift Automatic (Dual-Clutch)
Transmission Type Diesel Optional:
6-speed Ford Powershift Automatic (Dual-Clutch)
Features
AWD Integration:
Intelligent AWD system seamlessly integrates with transmission for optimal traction.
📐 Dimensions
Exterior
Length:
Approx. 4556 mm (depending on specific variant)
Width:
Approx. 1838 mm (excluding mirrors)
Height:
Approx. 1689 mm (depending on roof rails)
Cargo
Luggage Capacity Seats Up:
Approx. 450 - 480 liters (depending on configuration)
Luggage Capacity Seats Down:
Approx. 1500 - 1600 liters (depending on configuration)
Weights
Curb Weight:
Approx. 1500 - 1700 kg (depending on engine and drivetrain)
Gross Vehicle Weight:
Typically around 2100-2300 kg
🛡️ Safety Features
Ratings
Euro Ncap Rating:
5 Stars (for most configurations of the second generation Kuga)
IIHS Rating:
Good (typically for models tested by IIHS)
Active Features
Electronic Stability Control:
Standard (ESP/ESC)
Anti Lock Braking System:
Standard (ABS)
Traction Control System:
Standard (TCS)
Brake Assist:
Standard
Passive Features
Airbags:
Driver, passenger, side curtain, front side airbags (standard on most trims).
Seat Belts:
3-point seat belts with pretensioners for all seating positions.
Child Seat Anchors:
ISOFIX mounting points
💡 Technology Features
Infotainment
Sync System:
Ford SYNC 2 or SYNC 3 infotainment system with touchscreen interface.
Connectivity Options:
Bluetooth, USB connectivity, optional satellite navigation, Apple CarPlay/Android Auto compatibility (depending on SYNC version).
Driver Assistance
Adaptive Cruise Control:
Optional
Blind Spot Monitoring:
Optional
Lane Keeping Aid:
Optional
Parking Assist:
Optional (e.g., Active Park Assist)
Connectivity
Ford Applink:
Allows voice-controlled access to smartphone apps.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 15,000 miles (24,000 km) or 12 months, whichever comes first (for gasoline engines, consult manual for diesel).
Air Filter Replacement:
Typically every 30,000 miles (48,000 km) or as needed based on driving conditions.
Spark Plug Replacement:
Around 60,000 - 100,000 miles (96,000 - 160,000 km) for iridium spark plugs (consult manual for specific engine).
Fluid Specifications
Engine Oil Type:
Ford WSS-M2C948-B (for 1.0L and 1.5L EcoBoost) or Ford WSS-M2C913-D (for 1.6L EcoBoost and 2.0L TDCi). Consult manual for specific engine.
Coolant Type:
Ford Super Plus Premium Antifreeze/Coolant (Yellow) - Meets Ford WSS-M97B44-D.
Brake Fluid Type:
DOT 4
Transmission Fluid Automatic:
Ford WSS-M2C200-D2 for Powershift, consult manual for conventional automatic or manual transmission.
Known Issues
Powershift Transmission:
Some reports of judder or rough shifting in early Powershift transmissions, often related to clutch pack wear or mechatronic unit issues.
Ecoboost Engine Minor Issues:
Occasional reports of coolant leaks from the water pump or hoses, potential for carbon build-up in direct-injection engines.
Diesel Engine Dpf:
Diesel Particulate Filter (DPF) regeneration issues can occur with consistent short-journey driving.
📚 Vehicle History
Brand Heritage
Ford SUV History:
Ford has a long history in SUV production, dating back to the Bronco and Explorer. The Kuga was developed to compete in the growing compact SUV segment.
Model Evolution
First Generation:
Launched in 2008, based on the Ford Focus platform.
Second Generation:
Launched in 2012 (as a 2013 model year in many markets), based on the Ford Global C platform and rebadged as the 'Escape' in North America.
2016 Model Year Updates:
Refined styling, updated powertrains (especially EcoBoost engines), improved interior materials, and enhanced technology features compared to earlier models in the generation.
Production
Manufacturing Locations:
Primary production for Europe and other global markets at Ford's assembly plant in Valencia, Spain. North American 'Escape' version produced in North America.
🏆 Awards & Recognition
Recognitions
Safety Awards:
Multiple 5-star Euro NCAP ratings for various configurations.
Engine Awards:
Ford EcoBoost engines have received multiple 'International Engine of the Year' awards for their technology and efficiency.
Ratings
Consumer Ratings:
Generally positive consumer ratings for practicality, comfort, and driving dynamics, with variations based on engine and specification.
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