stop start FORD KUGA 2011 1.G User Guide

DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
F2: CHECK FOR BRAKE PEDAL BINDING
1 Check the brake pedal for free operation.
• Did the brake pedal operate freely?
zYe s INSTALL a new brake booster. TEST the
system for normal operation.
zNoINSTALL new brake pedal bushings. TEST
the system for normal operation.
Component Tests
Hydraulic Leak Check
NOTE: There is a common clutch and brake fluid
reservoir, therefore it is possible that a clutch leak
can lead to reduction in the reservoir level.
It is possible that all evidence of fluid leakage may
have washed off if the vehicle has been operated
in rain or snow, as brake fluid is water-soluble.
Refill the system, bleed then apply the brakes
several times. Examine the system to verify that
the reservoir fluid level is actually dropping. Locate
and repair the external leak. If the fluid level drops
and no external leak can be found, check for a
brake master cylinder bore end seal leak.
Brake System Check
Brake Pedal Reserve Check
Where a low brake pedal or the feel of a
bottomed-out condition exists, check for brake
pedal reserve.
1. Operate the engine at idle with the transaxle in the NEUTRAL position.
2. Apply the brake pedal lightly three or four times.
3. Allow 15 seconds for the vacuum to replenish the brake booster.
NOTE: This increased resistance may feel like
something has bottomed out.
4. Apply the brake pedal until it stops moving downward or an increased resistance to the
pedal travel occurs. 5. Hold the brake pedal in the applied position and
raise the engine speed to approximately 2000
rpm.
NOTE: The additional movement of the brake pedal
is the result of the increased engine manifold
vacuum which exerts more force on the brake
booster during engine rundown. This means that
additional stroke is available in the brake master
cylinder and the brake system is not bottoming out.
6. Release the accelerator pedal and observe that the brake pedal moves downward as the engine
returns to idle speed.
Brake Booster Functional Test
Inspect all hoses and connections. All unused
vacuum connectors should be capped. Hoses and
their connections should be correctly secured and
in good condition with no holes and no collapsed
areas. Inspect the check valve on the brake booster
for damage.
Brake Booster Operation Check
1. Check the hydraulic brake system for leaks orlow fluid.
2. With the transaxle in the NEUTRAL position, stop the engine and apply the parking brake.
Apply the brake pedal several times to exhaust
all the vacuum in the system.
3. With the engine turned off and the vacuum in the system exhausted, apply the brake pedal
and hold it down. Start the engine. If the vacuum
system is operating, the brake pedal will tend
to move downward under constant foot
pressure. If no motion is felt, the vacuum
booster system is not functioning.
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Brake System - General Information
206-00- 17
DIAGNOSIS AND TESTING
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Power Steering System Filling
Special Tool(s)211-189
Adapter, Power Steering
Bleeding
13016
416-D001
Hand Vacuum
Pump/Pressure Pump
23036A
Materials
Specification
Name
WSS-M2C204-A2 /
5U7J-M2C204-AA
Hydraulic Fluid DP-PS
1. Fill the power steering fluid reservoir to the MAX
mark.
Material: Hydraulic Fluid DP-PS
(WSS-M2C204-A2 / 5U7J-M2C204-AA)
hydraulic fluid
2. Raise the vehicle until the road wheels are clear
of the floor. Support the vehicle.
Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
3. Slowly turn the steering wheel from lock to lock
and add power steering fluid until the power
steering fluid in the power steering fluid reservoir
stops dropping.
4. Start the engine and slowly turn the steering
wheel from lock to lock and add power steering
fluid until the power steering fluid in the power
steering fluid reservoir stops dropping. 5.
Switch the engine OFF and using the special
tools, create a vacuum of 62cm-Hg - 75cm-Hg
for 30 seconds.
Special Tool(s): 211-189, 416-D001
E73916
211-189
416-D001
6. Observe the vacuum gauge reading.
1.
2. If the vacuum decreases by more than
5cm-Hg in 5 minutes, the system should be
checked for leaks.
7. Remove the special tools. Fill the power steering
fluid reservoir to the MAX mark as necessary.
Material: Hydraulic Fluid DP-PS
(WSS-M2C204-A2 / 5U7J-M2C204-AA)
hydraulic fluid
8. Lower the vehicle.
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Steering System - General Information
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GENERAL PROCEDURES
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Measure the compression pressure
(Engine - 2.5L Duratec-ST (VI5))
TIE44608
1. Remove the central junction box (CJB) cover.
TIE44609
2. Open the CJB and remove the fuel pump relay.
3. NOTE: The engine will start, run for a fewseconds and then stop.
Start the engine.
4. Remove the ignition coil-on-plug.
REFER to: Ignition Coil-On-Plug (303-07 Engine
Ignition - 2.5L Duratec (147kW/200PS) - VI5,
Removal and Installation). 5. Connect the battery ground cable.
REFER to: Battery Disconnect and Connect
(414-01 Battery, Mounting and Cables,
General Procedures).
E68679
x5
6. Using Special Tool 303-499, remove the spark plugs.
E68434
NOTE: Operate the starter motor with wide open
throttle until the pointer on the measuring device
stops rising.
7. Carry out the measurement in accordance with the instructions supplied with the measuring
device on every cylinder using a suitable
compression pressure recorder with a suitable
adapter.
E68680
28 Nm
8. Using Special Tool 303-499, install the sparkplugs.
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Engine System - General Information
303-00- 10
DIAGNOSIS AND TESTING
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18. Install the glow plugs.
CAUTION: Contact of the engine upper
cover with the cowl panel may cause
damage (scratches) on the engine upper
cover. Failure to follow this instruction may
cause the engine upper cover to be
damaged.
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Engine System - General Information
303-00- 13
DIAGNOSIS AND TESTING
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TIE39592TIE39688
E39706
303-1056
TIE39593
3Nm
TIE39594
E50473
3Nm
5Nm 5Nm
14. Remove the glow plugs.
15. Install the special tool and a suitable
compression tester into the glow plug bore.
NOTE: Crank the engine with the starter motor
until the pointer on the compression tester stops
rising.
16. Carry out the measurement on all cylinders, following the measuring equipment
manufacturer's instructions.
17. Detach the compression tester and the special tool.
19. Install the glow plug power supply.
20. Install the EGR valve.
21. Install the EGR cooler.
22. Connect the fuel injector electrical connectors.
23. Apply soap solution to the ball clip mountingsin the engine upper cover.
• Soap solution (maximum concentration of soap in water 1:200).
24.

Description
Item
Exhaust camshaft
1
intake camshaft
2
Valve cover
3
CMP Sensor - intake camshaft
4Description
Item
Intake camshaft reference mark
5
Exhaust camshaft reference mark
6
CMP Sensor - exhaust camshaft
7
CAUTION: Before removal, mark the
camshafts as the intake and exhaust
camshafts can be mixed up.
A reference mark for the CMP sensor is machined
into each camshaft. When the camshafts are set
precisely to the timing marks, the machined mark
on the exhaust camshaft is located roughly at the
5 o'clock position and the machined mark on the
intake camshaft is located at 8 o'clock.
When changing the toothed belts it is not necessary
to dismantle the camshaft adjustment units. A
special tool prevents the VCT control units from
turning during the adjustment process by locking
the two VCT control units to one another.
A further special tool is needed to fix the camshafts
in the adjustment position. The special tool
engages in corresponding recesses for the
reference marks on the CMP sensors. Each camshaft is fixed in place using four bearing
caps and the bearing cap VVT. The bearing caps
must not be changed around and must always be
fitted in their original positions.
The VCT control units for the intake and exhaust
camshafts are moved into the locked base position
when the engine is stopped through the
engagement of a spring-loaded locking pin. The
movement to the locked base position is assisted
by the tensile force of the timing belt for the intake
VCT control unit. With the exhaust VCT control
unit, a spring inside the control unit additionally
assists in reaching the locked base position. The
intake VCT control unit is in the "retarded timing"
position and the exhaust VCT control unit is in the
"advanced timing" position when in the locked base
position. The lock is hydraulically released when
the engine is started depending on the oil pressure.
The mechanical valve tappets are maintenance
free.
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Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
13
DESCRIPTION AND OPERATION
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Action
Possible Sources
Symptom
• REMOVE and visuallyINSPECT the catalytic
converter as necessary.
REFER to: Catalytic Converter
(309-00 Exhaust System -
2.5L Duratec (147kW/200PS)
- VI5, Removal and Installa-
tion).
• Catalytic converter blocked.
• TEST the engine cylindercompression.
REFER to: Engine(303-00
Engine System - General
Information, Diagnosis and
Testing).
• Low cylinder compression.
• INSTALL a new air cleanerelement.
• Air cleaner element blocked.
• Engine starts but immediately
stops
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• CKP sensor.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• CMP sensor.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
•PCM.
• Check the fuel system pres-sure.
• Low fuel system pressure.
• INSPECT the fuel system.INSTALL new components as
necessary. TEST the system
for normal operation.
• Fuel system restriction.
• INSTALL a new fuel filter.
• Fuel filter blocked.
• INSTALL a new air cleanerelement.
• Air cleaner element blocked.
• Poor idling
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303-04A- 7
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 7
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Description
Item
Vehicles with manual transaxle.
A
If equipped with an automatic transaxle.
B
Ignition key
Comments:With transponder for PATS (passive
anti-theft system)
1
PAT S
2
Ignition lock
3
GEM (generic electronic module)
4
PCM (powertrain control module)
5
Battery
6Description
Item
Starter relay
7
Starter motor
8
Stoplight Switch
Comments:If equipped with an automatic transaxle.
9
TCM (transmission control module)
Comments:If equipped with an automatic transaxle.
10
Starting deactivation relay
Comments:If equipped with an automatic transaxle.
11
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Starting System— 2.5L Duratec (147kW/200PS) - VI5303-06-
4
DESCRIPTION AND OPERATION
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Description
Item
Start/stop button
1
CPP (clutch pedal position) switches
Comments:Switches when the clutch pedal is
operated
2
Keyless vehicle module
3
Electronic steering lock with mount -
passive key and PATS transmitter/receiver
unit
Comments:for emergency start function
4Description
Item
Radio frequency receiver
Comments:Signal is only executed in GEM
5
GEM
6
PCM
7
Starter relay
8
Starter motor
9
Battery
10
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Starting System— 2.5L Duratec (147kW/200PS) - VI5303-06-
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Description
Item
Start/stop button
1
Keyless vehicle module
2
Electronic steering lock with mount -
passive key and PATS transmitter/receiver
unit
Comments:for emergency start function
3
Radio frequency receiver
Comments:Signal is only executed in GEM
4Description
Item
GEM
5
Stoplight Switch
6
TCM7
Starting deactivation relay
8
PCM
9
Starter relay
10
Starter motor
11
Battery
12
System Operation
Smart Start
The PCM enables the starting process when a key
providing a valid code is read via the PATS. This
code is then verified in the GEM and compared
with the saved code. If this code is recognized as
correct, synchronization with other modules is
carried out. After successful synchronization, the
engine is cleared to start in the PCM. The PCM
connects earth to the starter relay, which then
connects power to the starter solenoid. As soon
as the engine reaches a certain speed, the PCM
disconnects the starter relay and so turns off the
starter. This protects the starter.
If the engine does not turn or turns only slowly, the
starting process is aborted by the PCM.
The starter is notactivated if:
• the engine is running (i.e. the engine speed is above a particular value),
• the PATS does not permit the engine to be started,
• the clutch pedal is not operated (vehicles with manual transmission),
• the gear selector level is not set to P or N (vehicles with automatic transmission),
• the brake pedal is not operated (vehicles with automatic transmission).
Emergency starting function
If the keyless vehicle system is unable to recognize
the passive key, the vehicle can be started via the
emergency starting function. In this case, there is a passive key mount on the
steering wheel. A PATS transmission/reception
unit is attached to this.
To start the engine, the passive key must be
inserted into the passive key mount. The Start/Stop
button can then be used to turn on the ignition and
start the engine as normal. To deactivate the
PATS, a transponder is fitted in the passive key,
which is read by the transmission/reception unit.
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Starting System— 2.5L Duratec (147kW/200PS) - VI5303-06-
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DESCRIPTION AND OPERATION
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To exactly determine the activation points of the
gear shifts and torque converter lockup on the
basis of the type of driving mode chosen, the TCM
receives the following information:
• Selected transmission range (TR sensor)
• Selected driving mode (normal/sport/select-shift)
• Transmission input shaft speed (TSS sensor)
• Transmission output shaft speed (OSS sensor)
• Transmission fluid temperature (TFT sensor)
• The engine speed and the torque as well as thethrottle plate opening - from the PCM via the
CAN databus
• Actuation of accelerator – from the PCM via the CAN databus
• The coolant temperature – from the PCM via the CAN databus
• Road speed – from the ABS module via the CAN databus
• Actuation of brake pedal – from the PCM via the CAN databus
Gearshift control
Adaptation
The TCM monitors every shift operation in all
driving conditions to make even and smooth gear
shifts possible. This is done by the control module,
which either lowers or increases the hydraulic line
pressure during gearshifts.
The changed pressure values are stored in the
control module memory after the engine is switched
off and retrieved during engine starting. This
improves the shift comfort and extends the service
life.
Full adaptability occurs when the following criteria
are met:
• Throttle plate opening is constant.
• Transmission fluid temperature between 65 °Cand 110 °C.
Shifting from 'P' to another transmission
range
To be able to move the selector lever from 'P' into
another transmission range, the ignition must be
switched on and the brake pedal pressed (stoplamp
switch on). The TCM detects the position of the
brake pedal via the CAN data bus and the engaged
transmission range from the TR sensor. Based on this information, the TCM transmits a
signal to the select-shift switch module. This
activates the brake shift interlock actuator in the
selector lever assembly.
When the brake shift interlock actuator is activated,
the locking pin is retracted so that another
transmission range can be selected.
The brake shift interlock actuator is deactivated
when the ignition is switched off. It is mechanically
locked when the gear selector lever is in 'P'.
Automatic transmission, selector lever in
position "D".
The TCM adapts the shift points to match the
driving conditions. Normally the TCM is in adaptive
mode and gear changes take place adapted to the
driving conditions. If special driving conditions are
detected, the TCM switches to predefined
characteristics.
When driving with normal acceleration, the TCM
uses a preset shift program which is optimized for
economical driving.
This shift program is suitable for "normal" driving
and delivers early upward changes and torque
converter lockup. Furthermore, the transmission
fluid pressure is adapted to make smooth
engagement of the gears possible.
Sport mode, selector lever in position "S"
The transmission switches from automatic
operation into sport mode. In this mode the TCM
switches to another set of characteristic curves.
These characteristic curves for control of the gear
changes are adapted to sporting calculations (e.g.
gear change at higher engine speed).
In the sport mode shift program the shift points are
set so that good performance is offered. Changing
down occurs at lower engine speeds.
Manual gear changes (select-shift mode) can be
made in sport mode by moving the selector lever
in the (+) or (-) direction.
Changing gear in select-shift mode
If you move the selector lever to 'S', the automatic
transaxle remains hydraulically in 'D' position. If
you move the gear selector lever forwards (-), the
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Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 29
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