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Ford Kuga Complete Workshop Service Repair Manual 2012

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🏷️ Basic Information Identification Make: Ford Model: Kuga Year: 2012 Codes Platform Code: C1 / Global C Platform 👋 Introduction Market Position Segment: Compact Crossover SUV Target Audience: DIY enthusiasts, independent repair shops, Ford Kuga owners seeking in-depth maintenance and repair information Competitive Analysis Competitors 2012: Nissan Qashqai, Volkswagen Tiguan, Kia Sportage, Hyundai ix35, Mazda CX-5, Honda CR-V Key Features Value Proposition: Cost savings through self-maintenance and repair, detailed step-by-step instructions with illustrations, comprehensive coverage of all vehicle systems 📋 Manual Details Coverage Areas Model Variants: All engine variants, trim levels, and transmission types Page Count Estimated Pages: Comprehensive (estimated 1500+ pages for a full workshop manual) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, ignition system, exhaust system, cooling system, lubrication system, engine management systems (ECU, sensors, actuators) Transmission: Manual transmission, Automatic transmission (Powershift DCT), clutch, driveline, transfer case (if applicable), drive shafts, differentials Chassis: Suspension (front and rear), steering system, brake system (hydraulic, ABS, ESP), wheel and tire specifications Electrical: Battery, charging system, starting system, lighting systems, instrumentation, audio systems, climate control electricals, power windows/locks/mirrors, airbags, body control modules (BCM) Body: Body structure, interior trim, exterior body panels, doors, hoods, liftgates, bumpers, glass, seals Procedures Included Maintenance: Scheduled maintenance, fluid changes (oil, coolant, brake fluid, transmission fluid), filter replacements (oil, air, fuel, cabin), spark plug replacement, battery checks Repair: Engine overhaul, transmission repair, brake component replacement, suspension and steering component replacement, electrical component diagnosis and replacement, body panel repair and replacement Diagnostics: Troubleshooting guides for common symptoms, diagnostic trouble codes (DTCs) interpretation, testing procedures for sensors and actuators, wiring diagrams, flowcharts Technical Specifications: Torque specifications for all fasteners, component measurements, tolerances, diagnostic data (e.g., sensor voltage/resistance ranges) Technical Depth Depth: Comprehensive (covering basic maintenance to complete engine and transmission rebuilds, advanced electrical diagnostics) 📊 Manual Specifications File Format File Type: PDF Print Quality Readability: High-resolution, clear text and images, designed for easy viewing and printing Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) Searchability Text Search: Fully searchable PDF content ⚙️ Engine Specifications Primary Engine Engine 1: 2.0L Duratorq TDCi Diesel (DW10) Engine 1 Power: 140 PS (138 hp; 103 kW) @ 4000 rpm Engine 1 Torque: 300-340 Nm (221-251 lb-ft) @ 1750-2000 rpm (depending on variant) Engine 2: 1.6L EcoBoost Petrol Engine 2 Power: 150 PS (148 hp; 110 kW) or 180 PS (178 hp; 132 kW) Engine 2 Torque: 240-270 Nm (177-199 lb-ft) Engine 3: 2.0L Duratorq TDCi Diesel (DW10) with AWD Engine 3 Power: 163 PS (161 hp; 120 kW) @ 3750 rpm Engine 3 Torque: 340 Nm (251 lb-ft) @ 1750-2250 rpm Fuel System Fuel Type: Petrol (Unleaded) / Diesel (Common Rail Direct Injection) Engine Management ECU Types: Siemens, Bosch ECUs commonly used 🔧 Transmission Standard Transmission 1: 6-speed Manual Transmission (Getrag MT285, Ford MMT6) Optional Transmission 2: 6-speed Automatic Dual-Clutch Transmission (Ford Powershift 6DCT450) Features Drivetrain Options: Front-Wheel Drive (FWD), Intelligent All-Wheel Drive (iAWD) Fluid Specs Powershift Fluid: WSS-M2C200-D2 (or equivalent) 📐 Dimensions Exterior Length: 4529 mm (178.3 in) Width: 1838 mm (72.4 in) (excluding mirrors) Height: 1686 mm (66.4 in) Cargo Cargo Volume: Approx. 400-450 liters (14.1-15.9 cu ft) (seats up) Weights Curb Weight: Approx. 1500-1700 kg (3300-3750 lbs) depending on configuration Wheelbase Wheelbase: 2690 mm (105.9 in) 🛡️ Safety Features Ratings Euro Ncap Rating: 5 Stars (2011) Active Features ABS: Anti-lock Braking System (ABS) with Electronic Brake-force Distribution (EBD) and Emergency Brake Assist (EBA) Esp: Electronic Stability Program (ESP) with Traction Control (TC) and Roll Stability Control (RSC) Passive Features Airbags: Front airbags (driver & passenger), side airbags, curtain airbags, driver's knee airbag (optional) Seatbelts: Pre-tensioned front seatbelts with load limiters 💡 Technology Features Infotainment Infotainment System: Ford Power Button with Keyless Entry, Ford SYNC (optional with Bluetooth, voice control, USB connectivity) Driver Assistance Parking Assistance: Rear parking sensors (optional), Active Park Assist (optional on some trims) Cruise Control: Standard or optional cruise control Connectivity Usb Aux: USB and AUX input for audio devices 🔧 Maintenance Service Intervals Oil Change Diesel: Every 12,500 miles or 1 year, whichever comes first Oil Change Petrol Ecoboost: Every 10,000 miles or 1 year, whichever comes first Air Filter Replacement: Every 20,000-30,000 miles or 2 years Cabin Filter Replacement: Every 10,000-15,000 miles or 1 year Brake Fluid Change: Every 2 years Fluid Specifications Engine Oil Diesel: Ford WSS-M2C913-D (e.g., Castrol Magnatec Professional A5 5W-30) Engine Oil Petrol Ecoboost: Ford WSS-M2C948-B (0W-20) or WSS-M2C913-D (5W-30) depending on specific engine calibration Coolant Type: Ford Super Plus Premium Antifreeze/Coolant (Yellow) - WSS-M97B44-D2 Known Issues Powershift Transmission: Potential for judder, rough shifting, or clutch wear; requires specialized diagnostic and fluid service Ecoboost Engine: Some early 1.6 EcoBoost models experienced issues with the coolant system, leading to overheating and...
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Ford Kuga Complete Workshop Service Repair Manual 2012
🏷️ Basic Information
Identification
Make:
Ford
Model:
Kuga
Year:
2012
Codes
Platform Code:
C1 / Global C Platform
👋 Introduction
Market Position
Segment:
Compact Crossover SUV
Target Audience:
DIY enthusiasts, independent repair shops, Ford Kuga owners seeking in-depth maintenance and repair information
Competitive Analysis
Competitors 2012:
Nissan Qashqai, Volkswagen Tiguan, Kia Sportage, Hyundai ix35, Mazda CX-5, Honda CR-V
Key Features
Value Proposition:
Cost savings through self-maintenance and repair, detailed step-by-step instructions with illustrations, comprehensive coverage of all vehicle systems
📋 Manual Details
Coverage Areas
Model Variants:
All engine variants, trim levels, and transmission types
Page Count
Estimated Pages:
Comprehensive (estimated 1500+ pages for a full workshop manual)
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel system, ignition system, exhaust system, cooling system, lubrication system, engine management systems (ECU, sensors, actuators)
Transmission:
Manual transmission, Automatic transmission (Powershift DCT), clutch, driveline, transfer case (if applicable), drive shafts, differentials
Chassis:
Suspension (front and rear), steering system, brake system (hydraulic, ABS, ESP), wheel and tire specifications
Electrical:
Battery, charging system, starting system, lighting systems, instrumentation, audio systems, climate control electricals, power windows/locks/mirrors, airbags, body control modules (BCM)
Body:
Body structure, interior trim, exterior body panels, doors, hoods, liftgates, bumpers, glass, seals
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes (oil, coolant, brake fluid, transmission fluid), filter replacements (oil, air, fuel, cabin), spark plug replacement, battery checks
Repair:
Engine overhaul, transmission repair, brake component replacement, suspension and steering component replacement, electrical component diagnosis and replacement, body panel repair and replacement
Diagnostics:
Troubleshooting guides for common symptoms, diagnostic trouble codes (DTCs) interpretation, testing procedures for sensors and actuators, wiring diagrams, flowcharts
Technical Specifications:
Torque specifications for all fasteners, component measurements, tolerances, diagnostic data (e.g., sensor voltage/resistance ranges)
Technical Depth
Depth:
Comprehensive (covering basic maintenance to complete engine and transmission rebuilds, advanced electrical diagnostics)
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Readability:
High-resolution, clear text and images, designed for easy viewing and printing
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
Searchability
Text Search:
Fully searchable PDF content
⚙️ Engine Specifications
Primary Engine
Engine 1:
2.0L Duratorq TDCi Diesel (DW10)
Engine 1 Power:
140 PS (138 hp; 103 kW) @ 4000 rpm
Engine 1 Torque:
300-340 Nm (221-251 lb-ft) @ 1750-2000 rpm (depending on variant)
Engine 2:
1.6L EcoBoost Petrol
Engine 2 Power:
150 PS (148 hp; 110 kW) or 180 PS (178 hp; 132 kW)
Engine 2 Torque:
240-270 Nm (177-199 lb-ft)
Engine 3:
2.0L Duratorq TDCi Diesel (DW10) with AWD
Engine 3 Power:
163 PS (161 hp; 120 kW) @ 3750 rpm
Engine 3 Torque:
340 Nm (251 lb-ft) @ 1750-2250 rpm
Fuel System
Fuel Type:
Petrol (Unleaded) / Diesel (Common Rail Direct Injection)
Engine Management
ECU Types:
Siemens, Bosch ECUs commonly used
🔧 Transmission
Standard
Transmission 1:
6-speed Manual Transmission (Getrag MT285, Ford MMT6)
Optional
Transmission 2:
6-speed Automatic Dual-Clutch Transmission (Ford Powershift 6DCT450)
Features
Drivetrain Options:
Front-Wheel Drive (FWD), Intelligent All-Wheel Drive (iAWD)
Fluid Specs
Powershift Fluid:
WSS-M2C200-D2 (or equivalent)
📐 Dimensions
Exterior
Length:
4529 mm (178.3 in)
Width:
1838 mm (72.4 in) (excluding mirrors)
Height:
1686 mm (66.4 in)
Cargo
Cargo Volume:
Approx. 400-450 liters (14.1-15.9 cu ft) (seats up)
Weights
Curb Weight:
Approx. 1500-1700 kg (3300-3750 lbs) depending on configuration
Wheelbase
Wheelbase:
2690 mm (105.9 in)
🛡️ Safety Features
Ratings
Euro Ncap Rating:
5 Stars (2011)
Active Features
ABS:
Anti-lock Braking System (ABS) with Electronic Brake-force Distribution (EBD) and Emergency Brake Assist (EBA)
Esp:
Electronic Stability Program (ESP) with Traction Control (TC) and Roll Stability Control (RSC)
Passive Features
Airbags:
Front airbags (driver & passenger), side airbags, curtain airbags, driver's knee airbag (optional)
Seatbelts:
Pre-tensioned front seatbelts with load limiters
💡 Technology Features
Infotainment
Infotainment System:
Ford Power Button with Keyless Entry, Ford SYNC (optional with Bluetooth, voice control, USB connectivity)
Driver Assistance
Parking Assistance:
Rear parking sensors (optional), Active Park Assist (optional on some trims)
Cruise Control:
Standard or optional cruise control
Connectivity
Usb Aux:
USB and AUX input for audio devices
🔧 Maintenance
Service Intervals
Oil Change Diesel:
Every 12,500 miles or 1 year, whichever comes first
Oil Change Petrol Ecoboost:
Every 10,000 miles or 1 year, whichever comes first
Air Filter Replacement:
Every 20,000-30,000 miles or 2 years
Cabin Filter Replacement:
Every 10,000-15,000 miles or 1 year
Brake Fluid Change:
Every 2 years
Fluid Specifications
Engine Oil Diesel:
Ford WSS-M2C913-D (e.g., Castrol Magnatec Professional A5 5W-30)
Engine Oil Petrol Ecoboost:
Ford WSS-M2C948-B (0W-20) or WSS-M2C913-D (5W-30) depending on specific engine calibration
Coolant Type:
Ford Super Plus Premium Antifreeze/Coolant (Yellow) - WSS-M97B44-D2
Known Issues
Powershift Transmission:
Potential for judder, rough shifting, or clutch wear; requires specialized diagnostic and fluid service
Ecoboost Engine:
Some early 1.6 EcoBoost models experienced issues with the coolant system, leading to overheating and potential engine damage (e.g., cracked cylinder heads). Regular coolant level checks are crucial.
Dpf Issues Diesel:
Diesel Particulate Filter (DPF) regeneration issues if not driven regularly on longer journeys; potential for clogging.
Electrical Gremlins:
Reports of intermittent electrical faults, particularly with door modules or interior lighting.
📚 Vehicle History
Brand Heritage
Ford SUV Lineage:
Builds on Ford's extensive history in producing popular SUVs and Crossovers like the Ford Explorer and Ford Escape/Maverick
Model Evolution
Generation 1 Codename:
C394
Platform Shared With:
Ford Focus Mk2, Ford C-MAX/Grand C-MAX
Production
Manufacturing Plant:
Ford-Werke GmbH, Saarlouis, Germany
🏆 Awards & Recognition
Recognitions
Safety Award:
5-star Euro NCAP safety rating
Ratings
Green Car Awards:
Fuel-efficient EcoBoost and TDCi diesel models often recognized for economy
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