FORD KUGA 2011 1.G Workshop Manual

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Description
Item
Electric Booster HeaterRefer to Component Description: (page
?)
1
GEM2
Outside temperature sensor
3
Climate control system control assembly
4 Description
Item
Generator and Alternator
5
PCM6
Coolant temperature sensor (ECT sensor)Refer to Component Description: ECT
(page ?)
7
instrument cluster
8 G1066982en
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System Operation
Electric Booster Heater
In diesel vehicles which give off little residual heat,
a booster heater is used to heat the passenger
compartment rapidly in the case of low ambient
temperatures.
If the interior temperature has been set to HI, or if
the heater controls have been switched to the
highest setting, the two-zone air conditioning
system sends an "electric booster heater ON"
request signal to the CAN (controller area network)
via the medium speed GEM bus. If a manual air
conditioning system is installed, the signal is
transmitted via a conventional cable connection.
The GEM switches on the electric booster heater
depending on the following parameters:
• Engine coolant temperature is below 60 °C.
• Ambient air temperature is below 10 °C.
• Sufficient generator capacity is available.
The electric booster heater electronics activate
three output stages as a function of a pulse width
modulated signal PWM (pulse width modulation)
generated by the GEM. The output stages switch
the three heating elements of the electric booster
heater ON or OFF individually, whereby the heating
periods of the individual elements can overlap. Due
to the variable switch-on duration, continuously
variable temperature control is possible. The overall
heating power of the three heating elements is
linearly proportional to the PWM signal. If the PWM
signal is below 10% or above 95%, the electric
booster heater is not activated.
The electric booster heater is switched off when
an engine coolant temperature of 70°C or an
ambient air temperature of 20°C is exceeded.
Fuel-fired heater - function diagram G1066982en
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL12345671205304254481201056820108V58911121112E977670

Description
Item
Glow plug
1
Combustion Air Blower
2
Fuel pump
3
Fuel-fired heater on
4
Fuel-fired heater - large regulating step
5
Fuel-fired heater - small regulating step
6 Description
Item
Fuel-fired heater off
7
Blower motor on
8
Flame detection
9
Blower motor off
10
Large regulating step
11
Small regulating step
12
Boost heat mode
When the engine is running, the booster heater
helps the engine to heat the passenger
compartment at low ambient temperatures.
When the coolant temperature reaches 30 °C, the
control unit transmits a switch-on signal for the
passenger compartment blower via the CAN bus.
When the coolant temperature drops, the blower
remains on until the temperature reaches 20 °C
whereupon it is deactivated.
The fuel tank must be filled to at least 14% for the
system to be switched on. If the fuel level drops
below 8% then the system is switched off.
In boost mode, the fuel fired booster heater is only
switched on if all of the following criteria are met:
• Engine speed above 500 rpm. The fuel fired booster heater is not allowed to start up while
the engine is being cranked; this prevents a
shut-down due to low voltage if the battery
charge is low.
• Ambient temperature below 5 °C.
• Fuel level above 14% of total capacity.
• Function is active on the trip computer menu.
One of the following conditions is sufficient to
switch off the booster heater in boost heat mode:
• Engine speed below 500 rpm.
• Ambient temperature above 11 °C.
• Function is active on the trip computer menu.
• Fuel level below 8% of total capacity.
Programmable fuel fired booster heater
The programmable fuel fired booster heater has
two operating modes:
• Instant start
• Programmed start
The heater status is displayed on the instrument
cluster display. The parking heater mode is controlled via a menu in the message centre. The
fuel fired booster heater can be activated and
deactivated via the message centre. (If set to 'Auto'
the system is activated, if set to 'Off' the system is
completely deactivated)
Immediate start-up of the booster
heater
This function enables the fuel-fired booster heater
to be switched on manually when the engine is not
running. This function is activated via the menu on
the driver information system.
The ignition key must be in the II" position before
this menu can be accessed. The timer function of
the booster heater remains active when the ignition
key is in position "0".
After an immediate start-up of the booster heater
it is switched off again after 30 minutes (or if the
fuel level in the fuel tank drops below 8%). The
booster heater stops within 2 minutes of the engine
starting. This leaves enough time to check whether
the switch-on conditions for boost heat mode have
been met, thus preventing the booster heater from
having to switch off and switch back on again. The
heater can be switched off manually at any time
from the menu.
Programmed start-up of the booster
heater
The driver can use a menu to adjust the time at
which the vehicle is to be pre-heated. The following
options are available:
• Time setting. One or two times can be
programmed for each day of the week. It is
possible to program days either individually or
together in groups (Mon-Sun/Mon-Sat/Mon-Fri).
• Time and data setting
With the first option, the fuel-fired booster heater
will start repeatedly without needing to be G1066982en
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

reprogrammed. However, if the engine hasn't been
run since the last programmed start, the fuel-fired
booster heater will not start up the second time so
as to prevent the battery from being discharged.
The length of time required to pre-heat the vehicle
is calculated in the control unit of the fuel-fired
booster heater and is based on two temperature
values:
• Ambient air temperature: this message is taken
from the GEM via the CAN bus.
• Coolant temperature: this is determined via an internal sensor in the fuel-fired booster heater.
The maximum heating time is 30 minutes at an
outside air temperature of -10 °C or lower. The
heating time decreases proportionally with
increasing ambient temperature until the ambient
temperature is between +15 °C and +20 °C. Then
the minimum heating time is 10 minutes. The
parking heater is deactivated at temperatures
above +20 °C.
The sequence for a programmed start of the
booster heater is as follows:
• Two minutes before the start of the maximum heating time the driver information
system/instrument cluster sends an activation
message to the fuel-fired booster heater via the
CAN bus.
• The fuel-fired booster heater calculates the required heating time and, if necessary, sends
a delay request on the CAN bus.
• At the calculated time, the fuel-fired booster heater starts up. The conditions for start-up are:
engine not running and amount of fuel in the
fuel tank is above 14% of maximum.
• When the coolant temperature reaches +30 °C, the control unit of the fuel-fired booster heater
sends a request to switch on the passenger
compartment blower.
• Eight minutes after the programmed switch-off time, the booster heater stops heating mode
and starts a run-on operation to clean the
system's spark plugs.
• Ten minutes after the switch-off time, the post-cleaning operation is complete. The
additional ten minutes run-on time provides
some leeway in case the driver is late arriving.
After a programmed start-up of the booster heater
it is switched off again after the heating time has
elapsed (or if the fuel level in the fuel tank drops
below 8%). The booster heater stops within 2 minutes of the engine starting. This leaves enough
time to check whether the switch-on conditions for
boost heat mode have been met, thus preventing
the booster heater from having to switch off and
switch back on again. The heater can be switched
off manually at any time from the menu.
Whilst the fuel-fired booster heater is in additional
heating mode and/or parking heating mode, the
instrument cluster receives a fuel consumption
signal; this is used to re-calculate the vehicle's
remaining range and fuel consumption data.
Emergency shutoff
In the event of an accident in which the airbags
are deployed, the control unit of the fuel-fired
booster heater receives a message on the CAN
bus from the restraints control module (RCM).
When this message is received, the booster heater
system switches off immediately.
The booster heater control module deactivates the
system and does not respond to further messages
on the CAN bus. The booster heater control module
needs to be activated with WDS.
Component Description
Electric Booster Heater
The electric booster heater consists of three
individual heating elements, which are incorporated
into a single housing. It is controlled by the generic
electronic module (GEM), taking into account the
following factors:
Detailed illustration of fuel-fired heater
G1066982en
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Description
Item
Cooling sleeve cover
1
Combustion air blower cover
2
Fuel fired additional heater module
3
Combustion Air Blower
4
Cooling sleeve
5
Glow plug
6
Flame sensor
7
Overheat Sensor
8 Description
Item
ECT9
Compression spring
10
'O' Ring
11
Internal wiring harness - fuel fired
additional heater
12
Gasket
13
Gasket
14
Heat exchanger
15 G1066982en
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUALE850351132126791011115144316171518198

Description
Item
Combustion chamber
16
'O' Ring
17 Description
Item
Combustion blower motor cover
18
Glow plug wiring harness
19
Flame sensor
If the flame goes out independently during
operation of the booster heater, a restart is carried
out. If the booster heater does not ignite within 90
seconds of fuel delivery or if the flame goes out
within 15 minutes of starting, a lockout will be
implemented by the flame sensor.
Lockout can be cancelled by switching the booster
heater off then on again, although this may only
be repeated at most 2 times.
Overheat Sensor
The overheating sensor enables the fuel-fired
booster heater module to determine the coolant
temperature, protecting the heater from
overheating. The overheating sensor is installed
next to the coolant temperature sensor under a
cover on the top of the fuel-fired heater.
In the event of overheating (lack of water, poorly
ventilated coolant circuit), the fuel supply to the
heater is interrupted and a lockout occurs. After
the cause of the overheating has been eliminated,
the heater can be restarted by switching it off and
on again, if the coolant temperature is below 70°C.
If the heater overheats ten times in a row, the
control unit is locked.
ECT
The fuel-fired booster heater module uses the
temperature sensor to determine the coolant
temperature, which it then uses to set the starting
and stopping time. The coolant temperature sensor
is installed next to the overheating sensor under a
cover on the top of the fuel-fired heater. Water pump The coolant pump is located on the holder for the
fuel-fired heater on the bulkhead in the rear of the
engine compartment. The coolant pump is driven
by a built-in electric motor and circulates the
coolant in the engine cooling system. The delivery
rate for the pump is 820l/h at a delivery pressure
of 0.1 bar.
Fuel pump
The fuel required for the fuel-fired heater is taken
from the fuel system by a fuel pump fitted in the
fuel tank and is delivered to the heater via a fuel
line.
The fuel pump is an electric piston pump which
meters the corresponding fuel volume for the
fuel-fired heater according to a cycle set by the
fuel-fired heater module.
G1066982en
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUALE97646 E97647

Auxiliary Coolant Flow Pump
General Equipment
Hose Clamp(s) General Equipment
Hose Clamp Remover/Installer
Removal
1. Refer to: Engine Cooling System Health and
Safety Precautions (100-00 General
Information, Description and Operation).
2. Refer to: Jacking(100-02 Jacking and Lifting,
Description and Operation).
3. General Equipment: Hose Clamp(s)
General Equipment: Hose Clamp
Remover/Installer Installation
1.
To install, reverse the removal procedure.
2. Check the coolant level.
Refer to: Cooling System Draining and Vacuum
Filling (303-03 Engine Cooling, General
Procedures). G1163562en
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL11E112651