Ford Kuga 2008-2012 Service & Repair Workshop Manual
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🏷️ Basic Information Identification Make: Ford Model: Kuga Generation: First Generation (C394) Production Years: 2008-2012 Codes Chassis Code: C394 👋 Introduction Market Position Segment: Compact Crossover SUV Platform: Based on Ford Focus (second generation) platform Competitive Analysis Key Competitors: Nissan Qashqai, Volkswagen Tiguan, Honda CR-V, Toyota RAV4 Key Features Design Philosophy: Kinetic Design language Drivetrain Options: Available in Front-Wheel Drive (FWD) and Intelligent All-Wheel Drive (AWD) 📋 Manual Details Coverage Areas Regions Covered: Global (primarily European market focus for this generation) Page Count Estimated Page Count: High (hundreds of pages) Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English (assumed based on typical factory service manual availability and product description) Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, ignition system, cooling system, exhaust system, lubrication system Transmission: Manual transmission, Automatic transmission (PowerShift) Drivetrain: Front-wheel drive, All-wheel drive (Intelligent AWD) Chassis: Suspension (front and rear), steering system, braking system Electrical: Engine control module (ECM), body control module (BCM), lighting systems, instrument cluster, infotainment, power accessories, charging system, starting system Body: Exterior body panels, interior trim, doors, windows, seats, HVAC system Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and changes Diagnostics: Troubleshooting guides, diagnostic trouble codes (DTCs), fault finding procedures Repair: Component removal and installation, sub-assembly repairs, major system overhauls Technical Specifications: Torque specifications, clearances, alignment settings, electrical schematics Special Tools: Identification of specific tools required for certain procedures Technical Depth Depth: Comprehensive (from basic servicing to complex component rebuilds and diagnostics) 📊 Manual Specifications File Format Format: PDF Searchability: Likely searchable text content (standard for factory PDFs) Print Quality Printability: Printable (single pages or full manual) Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) Licensing Usage Rights: Unlimited use on multiple devices, no expiry ⚙️ Engine Specifications Primary Engine Engine Code Petrol: Duratec Ti-VCT Engine Displacement Petrol: 2.5 Liters (2522 cc) Engine Configuration Petrol: Inline 5-cylinder Engine Type Petrol: Naturally Aspirated Engine Code Diesel: DW10BTED4 (PSA/Ford collaboration) Engine Displacement Diesel: 2.0 Liters (1997 cc) Engine Configuration Diesel: Inline 4-cylinder Engine Type Diesel: Turbocharged Diesel Performance Horsepower Petrol 2.5: 173 PS (171 hp; 127 kW) at 6000 rpm Torque Petrol 2.5: 230 Nm (170 lb-ft) at 4500 rpm Horsepower Diesel 2.0: 136 PS (134 hp; 100 kW) at 4000 rpm Torque Diesel 2.0: 320 Nm (236 lb-ft) at 2000 rpm Fuel System Fuel Injection Petrol: Electronic Fuel Injection (EFI) Fuel Type Petrol: Unleaded Gasoline (Petrol) Fuel Type Diesel: Diesel 🔧 Transmission Standard Type Petrol: 6-Speed Manual (MTX75) Optional Type Automatic: 6-Speed Dual-Clutch Automatic (PowerShift - available on some diesel models) Features AWD System: Haldex-sourced Intelligent All-Wheel Drive system with electronic coupling 📐 Dimensions Exterior Length: Approx. 4444 mm (174.9 in) Width: Approx. 1842 mm (72.5 in) Height: Approx. 1689 mm (66.5 in) Wheelbase: Approx. 2690 mm (105.9 in) Cargo Cargo Volume Seats Up: Approx. 410 liters (14.5 cu ft) Cargo Volume Seats Down: Approx. 1450 liters (51.2 cu ft) Weights Curb Weight Start: Approx. 1500 kg (3307 lb) for FWD models Curb Weight End: Approx. 1650 kg (3638 lb) for AWD models 🛡️ Safety Features Ratings Euro Ncap Rating: 5 Stars (2009) Active Features Braking System: ABS with EBD (Electronic Brakeforce Distribution), ESP (Electronic Stability Program), Traction Control (TCS) Passive Features Airbags: Front airbags, side airbags, curtain airbags Seatbelts: Pre-tensioned seatbelts with load limiters 💡 Technology Features Infotainment Audio System: Ford CD/MP3 player with auxiliary input, optional Sony premium sound system, optional Ford SYNC with Bluetooth and voice control Driver Assistance Cruise Control: Standard on most trims, adaptive cruise control not typically available for this generation. Connectivity Usb Port: Optional, often integrated with SYNC system 🔧 Maintenance Service Intervals Oil Change Interval Petrol: Typically 1 year or 12,500 miles (20,000 km), whichever comes first Oil Change Interval Diesel: Typically 1 year or 10,000 miles (16,000 km), whichever comes first (may vary with DPF fitted) Timing Belt Interval: Timing belt replacement interval for 2.0 TDCi is typically 10 years or 125,000 miles (200,000 km) – verify in manual. Fluid Specifications Engine Oil Petrol 2.5: Ford WSS-M2C913-B or compatible API SL/SM, ACEA A5/B5 (e.g., 5W-30) Engine Oil Diesel 2.0: Ford WSS-M2C913-C or compatible API CF, ACEA A1/B1, A5/B5 (e.g., 5W-30) – verify for DPF compatibility. Coolant Type: Ford Super Plus Premium Coolant (Orange) or equivalent meeting Ford specification WSS-M97B44-D Brake Fluid Type: DOT 4 Transmission Fluid Manual: Ford WSS-M2C200-D2 or compatible manual transmission fluid (e.g., 75W-90) Transmission Fluid Powershift: Ford WSS-M2C200-D3 or compatible transmission fluid (specific PowerShift fluid required) Known Issues Common Problems: Potential issues include power steering pump leaks, HVAC blower motor failures, clutch wear on manual transmissions, and sometimes DPF regeneration issues on diesel models. 📚 Vehicle History Brand Heritage Ford SUV History: Ford has a long history with SUVs, starting with the Bronco...
Suspension (front and rear), steering system, braking system
Electrical:
Engine control module (ECM), body control module (BCM), lighting systems, instrument cluster, infotainment, power accessories, charging system, starting system
Body:
Exterior body panels, interior trim, doors, windows, seats, HVAC system
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and changes
Identification of specific tools required for certain procedures
Technical Depth
Depth:
Comprehensive (from basic servicing to complex component rebuilds and diagnostics)
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Likely searchable text content (standard for factory PDFs)
Print Quality
Printability:
Printable (single pages or full manual)
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
Licensing
Usage Rights:
Unlimited use on multiple devices, no expiry
⚙️ Engine Specifications
Primary Engine
Engine Code Petrol:
Duratec Ti-VCT
Engine Displacement Petrol:
2.5 Liters (2522 cc)
Engine Configuration Petrol:
Inline 5-cylinder
Engine Type Petrol:
Naturally Aspirated
Engine Code Diesel:
DW10BTED4 (PSA/Ford collaboration)
Engine Displacement Diesel:
2.0 Liters (1997 cc)
Engine Configuration Diesel:
Inline 4-cylinder
Engine Type Diesel:
Turbocharged Diesel
Performance
Horsepower Petrol 2.5:
173 PS (171 hp; 127 kW) at 6000 rpm
Torque Petrol 2.5:
230 Nm (170 lb-ft) at 4500 rpm
Horsepower Diesel 2.0:
136 PS (134 hp; 100 kW) at 4000 rpm
Torque Diesel 2.0:
320 Nm (236 lb-ft) at 2000 rpm
Fuel System
Fuel Injection Petrol:
Electronic Fuel Injection (EFI)
Fuel Type Petrol:
Unleaded Gasoline (Petrol)
Fuel Type Diesel:
Diesel
🔧 Transmission
Standard
Type Petrol:
6-Speed Manual (MTX75)
Optional
Type Automatic:
6-Speed Dual-Clutch Automatic (PowerShift - available on some diesel models)
Features
AWD System:
Haldex-sourced Intelligent All-Wheel Drive system with electronic coupling
📐 Dimensions
Exterior
Length:
Approx. 4444 mm (174.9 in)
Width:
Approx. 1842 mm (72.5 in)
Height:
Approx. 1689 mm (66.5 in)
Wheelbase:
Approx. 2690 mm (105.9 in)
Cargo
Cargo Volume Seats Up:
Approx. 410 liters (14.5 cu ft)
Cargo Volume Seats Down:
Approx. 1450 liters (51.2 cu ft)
Weights
Curb Weight Start:
Approx. 1500 kg (3307 lb) for FWD models
Curb Weight End:
Approx. 1650 kg (3638 lb) for AWD models
🛡️ Safety Features
Ratings
Euro Ncap Rating:
5 Stars (2009)
Active Features
Braking System:
ABS with EBD (Electronic Brakeforce Distribution), ESP (Electronic Stability Program), Traction Control (TCS)
Passive Features
Airbags:
Front airbags, side airbags, curtain airbags
Seatbelts:
Pre-tensioned seatbelts with load limiters
💡 Technology Features
Infotainment
Audio System:
Ford CD/MP3 player with auxiliary input, optional Sony premium sound system, optional Ford SYNC with Bluetooth and voice control
Driver Assistance
Cruise Control:
Standard on most trims, adaptive cruise control not typically available for this generation.
Connectivity
Usb Port:
Optional, often integrated with SYNC system
🔧 Maintenance
Service Intervals
Oil Change Interval Petrol:
Typically 1 year or 12,500 miles (20,000 km), whichever comes first
Oil Change Interval Diesel:
Typically 1 year or 10,000 miles (16,000 km), whichever comes first (may vary with DPF fitted)
Timing Belt Interval:
Timing belt replacement interval for 2.0 TDCi is typically 10 years or 125,000 miles (200,000 km) – verify in manual.
Fluid Specifications
Engine Oil Petrol 2.5:
Ford WSS-M2C913-B or compatible API SL/SM, ACEA A5/B5 (e.g., 5W-30)
Engine Oil Diesel 2.0:
Ford WSS-M2C913-C or compatible API CF, ACEA A1/B1, A5/B5 (e.g., 5W-30) – verify for DPF compatibility.
Coolant Type:
Ford Super Plus Premium Coolant (Orange) or equivalent meeting Ford specification WSS-M97B44-D
Brake Fluid Type:
DOT 4
Transmission Fluid Manual:
Ford WSS-M2C200-D2 or compatible manual transmission fluid (e.g., 75W-90)
Transmission Fluid Powershift:
Ford WSS-M2C200-D3 or compatible transmission fluid (specific PowerShift fluid required)
Known Issues
Common Problems:
Potential issues include power steering pump leaks, HVAC blower motor failures, clutch wear on manual transmissions, and sometimes DPF regeneration issues on diesel models.
📚 Vehicle History
Brand Heritage
Ford SUV History:
Ford has a long history with SUVs, starting with the Bronco and Explorer, establishing expertise in this segment.
Model Evolution
Market Introduction:
Launched in 2008 as Ford's first compact SUV specifically developed for the European market, utilizing the C1 platform shared with the Focus and C-Max.
Production
Manufacturing Plant:
Ford's plant in Cologne, Germany
🏆 Awards & Recognition
Recognitions
Safety Award:
Achieved a 5-star safety rating from Euro NCAP.
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