Accelerator FORD KUGA 2011 1.G Workshop Manual

Road/Roller Testing
Road or roller testing may be carried out for various
reasons and a procedure detailing pre-test checks,
engine starting and stopping, pre-driving checks,
on-test checks and final checks to be completed
on completion of the test is given below.
Unless complete vehicle performance is being
checked, the full road test procedure need not be
carried out. Instead, those items particularly
relevant to the system(s) being checked can be
extracted.
Pre-Test Checks
WARNING: If the brake system hydraulic
fluid level is low, pedal travel is excessive
or a hydraulic leak is found, do not attempt
to road test the vehicle until the reason for
the low fluid level, excessive pedal travel
or hydraulic leak is found and rectified.
It is suggested that pre-test checks and functional
tests of those systems and circuits which affect the
safe and legal operations of the vehicle, such as
brakes, lights and steering, should always be
carried out before the road or roller test.
With the ignition switched off, check:
– the engine oil level.
– the engine coolant level.
– the tires, for correct pressure, compatible types and tread patterns, and wear within limits.
– that there is sufficient fuel in the tank to complete the test.
– all around the engine, transmission and under the vehicle for oil, coolant, hydraulic and fuel
leaks. Make a note of any apparent leaks and
wipe off the surrounding areas to make it easier
to identify the extent of the leak on completion
of the test.
Starting the Engine
NOTE: On initial drive away from cold and within
the first 1.5 km (1 mile), do not depress the
accelerator pedal beyond half travel until the
vehicle has attained a minimum speed of 25 km/h
(15 miles/h). Never operate at high engine speed
or with the accelerator pedal at full travel whilst the
engine is cold.
With the ignition switched off, check: – that the parking brake is applied.
– that the gear lever is in the neutral position.
– that all instrument gauges (except fuel gauge)
read zero.
With the ignition switched on, check:
– that the ignition controlled warning lamps are illuminated.
– that the engine temperature gauge registers a reading compatible with the engine temperature.
– that the fuel gauge registers a reading appropriate to the fuel level in the tank.
– the operation of the parking brake warning lamp and fluid level warning indicator.
Road or Roller Testing
CAUTION: If road testing, check the brake
operation while still traveling at low speed
before continuing with the test. If the
brakes pull to one side, or appear to be
otherwise faulty, do not continue with the
road test until the fault has been found and
rectified.
During the road or roller test, check:
– that the clutch pedal operation is not stiff or heavy.
– that the initial gear engagement is smooth and there is no evidence of clutch drag.
– that the parking brake control operates smoothly and releases quickly and completely.
– that the clutch takes up the drive smoothly, without slip or judder.
– that gear changing is smooth with no abnormal noises or vibrations from the transmission.
– the engine power output is satisfactory, full power is achieved, acceleration is smooth and
pedal operation is not stiff or heavy, and engine
speed returns to idle correctly.
– there is no excessive or abnormally colored smoke from the engine under normal driving,
heavy load or overrun conditions.
– that steering operation, including power steering (if equipped), is smooth, accurate, not
excessively heavy or with excessive free play
or vibration.
– that the steering does not pull to one side and self centers smoothly after cornering.
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General Information
100-00- 58
DESCRIPTION AND OPERATION
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Description
Item
Instrument Cluster
1
PCM (powertrain control module)
2
EHPS (electro-hydraulic power steering)
control module
3
Audio unit
4
GEM (generic electronic module)
5
RCM (restraints control module)
6
PATS transceiver
7 Description
Item
Steering wheel lock module
8
Left-hand steering column switch
9
Fuel level sensor
10
Washer water level warning lamp switch
11
Accelerator pedal position sensor
12
CPP (clutch pedal position) sensor/BPP
(brake pedal position) sensor
13
Lighting control switch
14
System Operation
Instrument Cluster
The instrument cluster contains analog displays
as well as warning and control lamps for displaying
the system status; in addiiton, there is an LCD
indicator field for driver information.
The instrument cluster receives the following
signals from the PCM via the high speed CAN
(controller area network) Bus (HS-CAN):
• Vehicle speed – The PCM receives the necessary signalsfrom the ABS (anti-lock brake system) wheel
sensors from the ABS control unit on the
HS-CAN.
• Engine Coolant Temperature
• Engine oil pressure.
• Engine speed
The instrument cluster receives the following
signals from the GEM via the medium speed CAN
Bus (MS-CAN):
• Ambient temperature
• Brake fluid level
• Handbrake control
• Door latch control
• Liftgate latch control
• High beam control
• Headlamp flasher control
• Direction indicator control
The fuel level signal is sent by the two fuel level
sensors in the fuel pumps in the semitrailer tank,
which is wired to the instrument cluster. The
sensors are connected in series, and the total
resistance is determined from the two individual resistors. The instrument cluster converts the raw
fuel level signal into a damped fuel level value.
The odometer shows the total distance travelled
by the vehicle and is based on the same signal as
is processed for the daily mileage counter. The
value is recorded by the instrument cluster and
stored in a protected EEPROM (Electronically
Erasable Programmable Read Only Memory) area.
This area is a memory protected against
manipulation. If the instrument cluster detects an
error in this memory area, e.g. through damage,
the driver is notified with the "Odometer error"
message.
Message center
The message center is operated using the left-hand
switch on the steering column.
The SET/RESET button is activated to select a
submenu and change the settings. If signal tones
have been activated, a short acoustic signal will
sound each time a button is pressed.
By turning the rotary switch, the different menu
displays can be scrolled through or a setting
selected.
In this display, the navigation system can also
display direction and distance information.
In addition, safety and warning messages can be
displayed in this system, such as "Coolant
overheating", "Engine system error" or "Washer
fluid level too low". In addition to a safety message,
a general warning light (red/yellow) lights up.
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Instrument Cluster
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Oil Change Indicator Reset
1.
Turn the ignition key to position II without
cranking the engine.
2. Simultaneously press and hold the accelerator
pedal and the brake pedal for approximately 15
seconds until the oil change reminder indicator
starts to flash or the "Service Oil Reset
Complete" message appears in the information
and message center (if equipped).
3. Release the pedals.
4. Check that the oil change reminder indicator
has turned off or that there is no "Service Oil"
message in the information and message center
(if equipped). If the oil change reminder indicator
is still illuminated or the "Service Oil" message
is still displayed, turn the ignition key to position
0 and repeat the procedure from Step 1. If it has
turned off or the "Service Oil" message has
disappeared, proceed to Step 5.
5. Turn the ignition key to position 0 and leave it
there for at least 2 minutes so that the
powertrain control module (PCM) fully powers
down and updates the non-volatile memory
(NVM) in the PCM.
6. Turn the ignition key to position II without
cranking the engine and check that the oil
change reminder indicator is not illuminated or
that there is no "Service Oil" message displayed.
7. Turn the ignition key to position 0. G898940en
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Warning Devices
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DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
D2: CHECK THE BRAKE BOOSTER FOR LEAKS
1 Run the engine at approximately 1000 rpm,
release the accelerator pedal and turn the
engine off. Wait 90 seconds and apply the
brakes. Two or more brake applications should
be power assisted.
• Does the brake booster work?
zYe s VERIFY the customer concern.
zNoGO to D4 .
D3: CHECK THE BRAKE PEDAL LINKAGE
1 Disconnect the actuator rod from the pedal pin
and fully depress the brake pedal.
• Did the pedal move freely?
zYe s VERIFY the customer concern.
zNoINSTALL new brake pedal bushings. TEST
the system for normal operation.
D4: CHECK THE BRAKE BOOSTER CHECK VALVE
1 Disconnect the brake booster check valve
vacuum hose at the manifold.
2Blow into the hose attached to the brake booster
check valve.
• Does air pass through the valve?
zYe s INSTALL a new brake booster check valve.
TEST the system for normal operation.
zNoGO to D5 .
D5: CHECK THE BRAKE BOOSTER CHECK VALVE VACUUM
1 Run the engine at idle.
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Brake System - General Information
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DIAGNOSIS AND TESTING
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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
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DIAGNOSIS AND TESTING
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Recirculated air valve
E97052
43
2
1
Description
Item
Recirculated air valve
1
Vacuum hose to intake manifold
2
Air ingress
3
Air discharge
4
If the throttle valve is closed quickly, the moving
air column hits the throttle valve. The air column
is reversed, flows back onto the rotating impeller
of the TC and powerfully decelerates it. A
recirculated air valve is installed to prevent this
deceleration of the impeller and thus allow the TC
to respond faster. The recirculated air valve is
controlled via a vacuum line which is connected to
the intake manifold. When the throttle valve is
suddenly closed, a high vacuum occurs in the
intake manifold. This opens the recirculated air
valve and the compressed air is returned to a point
before the compressor. This causes the speed of
the turbocharger to drop less rapidly and the boost
pressure can build up more rapidly when the
accelerator pedal is pressed again.
Component Description
Wastegate control valve
1
2
3
E98852
Description
Item
from turbocharger (boost pressure)
1
from turbocharger (atmospheric pressure)
2
to boost pressure regulator (control
pressure)
3
The wastegate control valve operates as a cycle
valve. The pressure acting on the membrane in
the boost pressure regulator is controlled by
appropriate pulsing of the wastegate control valve.
The pressure acting on the membrane in the boost
pressure regulator is reduced when the wastegate
control valve opens.
The operating voltage of the wastegate control
valve is 12V.
The internal resistance of the wastegate control
valve is 28.5 ± 1.5 Ohms.
The operating states are:
• De-energised: gate open between 1 and 3 – Boost pressure high > wastegate controlvalve closed > boost pressure regulator open
> turbine receives restricted exhaust gas
flow.
• Energised: gate open between 2 and 3 – Boost pressure low > wastegate control valveopen > boost pressure regulator closed >
turbine receives full exhaust gas flow.
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Fuel Charging and Controls - Turbocharger
—
2.5L Duratec (147kW/200PS) - VI5
303-04B- 7
DESCRIPTION AND OPERATION
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SECTION 303-14 Electronic Engine Controls— 2.5L Duratec
(147kW/200PS) - VI5
VEHICLE APPLICATION: 2008.50 Kuga
PA G E
CONTENTS
DESCRIPTION AND OPERATION
303-14-3
Electronic Engine Controls (Component Location) .............................................................
303-14-7
Electronic Engine Controls (Overview) ........................................................................\
.......
303-14-7
General overview ........................................................................\
........................................
303-14-8
Powertrain Control Module (PCM) ........................................................................\
..............
303-14-8
Knock Sensor ........................................................................\
.............................................
303-14-8
Camshaft Position (CMP) Sensor ........................................................................\
...............
303-14-9
Crankshaft Position (CKP) sensor ........................................................................\
..............
303-14-9
Camshaft adjuster solenoid valve........................................................................\
...............
303-14-9
Manifold absolute pressure and temperature sensor .........................................................
303-14-9
Accelerator pedal position (APP) sensor ........................................................................\
....
303-14-10
Throttle control unit ........................................................................\
.....................................
303-14-10
Engine Coolant Temperature (ECT) sensor.......................................................................
303-14-10
Ignition coil-on-plug ........................................................................\
....................................
303-14-12
Electronic Engine Controls (System Operation and Component Description) ...................
303-14-12
System Diagram ........................................................................\
.........................................
303-14-16
System Operation ........................................................................\
.......................................
303-14-18
Speed and TDC recording ........................................................................\
......................
303-14-19
Calculation of the ignition angle ........................................................................\
..............
303-14-20
Engine fueling ........................................................................\
.........................................
303-14-22
Engine speed control ........................................................................\
..............................
303-14-22
Oil monitoring ........................................................................\
..........................................
303-14-23
Calculation of valve timing adjustment angle..................................................................
303-14-23
Boost pressure control ........................................................................\
............................
303-14-24
Starting process ........................................................................\
......................................
303-14-24
Alternator control (Smart Charge) ........................................................................\
...........
303-14-24
Component Description ........................................................................\
..............................
303-14-24

CKP sensor ........................................................................\
.............................................
303-14-25

Broadband HO2S ........................................................................\
...................................
303-14-26

VCT (variable camshaft timing) solenoids ......................................................................
303-14-27

MAF sensor ........................................................................\
.............................................
303-14-28

APP sensor ........................................................................\
.............................................
303-14-29

CPP sensor ........................................................................\
.............................................
303-14-29

BPP switches ........................................................................\
..........................................
303-14-30

Air conditioning (A/C) pressure sensor ........................................................................\
...
303-14-30

Throttle
control unit ........................................................................\
.................................
303-14-31

ECT sensor ........................................................................\
.............................................
303-14-31

Cooling fan module ........................................................................\
.................................
303-14-32

injectors........................................................................\
...................................................
303-14-32

Ignition coil-on-plug ........................................................................\
.................................
303-14-33

Fuel pressure/fuel temperature sensor ........................................................................\
...
303-14-33

Wastegate control valve ........................................................................\
..........................
303-14-34

Engine oil level, temperature and quality sensor ............................................................
303-14-1
Electronic Engine Controls— 2.5L Duratec (147kW/200PS) - VI5303-14-
1
.
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Electronic Engine Controls – Overview
General overview
Engine Management System
• Bosch ME 9.0 engine management system
• Knock control with two knock sensors
• Electronic Throttle Control Unit.
• Electronic accelerator pedal
• Variable camshaft timing for intake and exhaustcamshafts • Fuel injection supply manifold with combined
fuel pressure and temperature sensor
• Sequential multi-port fuel injection
• Camshaft position (CMP) sensors for intake and exhaust camshafts.
• satisfies the European exhaust emissions standard IV
• EOBD (European On-board Diagnostic) for the monitoring of emissions-related components.
Engine power output and engine speed
2
E62614
1
Description
Item
Torque
1
Power output
2
The engine is controlled by the PCM.
The PCM uses various sensors to calculate the
optimum ignition timing, the optimum injection
quantity and injection time and the position of the
throttle. In addition, various corrections are carried
out, including adjustment of the ignition timing using
the KS and adjustment of the fuel quantity by the Lambda control. Boost pressure control and fuel
pressure control are also performed by the PCM.
For all work on the engine electronics, it is
essential to ensure that the connectorsare
seated and locked properly.
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Crankshaft Position (CKP) sensor
E89994
The CKP sensor can be checked during starting
by measuring the resistance and/or voltage with
the oscilloscope.
The engine cannot work without the CKP signal.
A limp-home mode is therefore not possible. The
engine is switched off or the engine will not start
and a fault is stored in the error memory of the
PCM.
Camshaft adjuster solenoid valve
E96870
For work on the camshaft adjuster solenoids,
extreme cleanliness must be ensured as even
slight impurities can result in failure. The camshaft
adjustment solenoids for the intake and exhaust
camshafts differ only in terms of the position of the
fastening point by which they are fixed to the
cylinder head cover.
If a fault is detected in the camshaft adjustment
solenoids, the solenoids are no longer actuated.
Manifold absolute pressure and
temperature sensor
E96146
During installation of the MAPT sensor, correct
sealing must be ensured to ensure that no
infiltrated air can penetrate into the intake manifold
from outside.
If the MAP (manifold absolute pressure) sensor
fails, the PCM operates with a substitute value.
Accelerator pedal position (APP)
sensor
E74146
The APP (accelerator pedal position) sensor
comprises two separate sensors.
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Electronic Engine Controls— 2.5L Duratec (147kW/200PS) - VI5303-14-
9
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If one of the two APP sensors fails, then only a
proportion of the engine's power will be available
when accelerating. Top speed can nevertheless
be achieved.
If both of the APP sensors fail, the engine is
regulated to a defined speed following a plausibility
check after the BPP (brake pedal position) switch
and brake light switch have been actuated once.
The vehicle can then only be accelerated to a
defined speed.
In either case, a fault is saved in the error memory
of the PCM.
Throttle control unit
E74167
1
2
Description
Item
TP (throttle position) sensor
1
Electric motor
2
CAUTION: The throttle control unit must
not be repaired or adjusted. The stop of
the throttle valve must on no account be
adjusted.
After disconnecting the battery or replacing the
throttle control unit or the PCM, initialization is
necessary. • engine off
• Accelerator pedal not pressed
• Battery voltage 11 ... 14 V
• Ignition key in ON position
• Wait approximately 30 seconds until initialization
is complete.
Engine Coolant Temperature (ECT)
sensor
E94804
The ECT (engine coolant temperature) sensor is
designed as an NTC (negative temperature
coefficient) resistor.
If the signal from the ECT sensor fails, the cooling
fan is on all the time and the A/C (air conditioning)
is turned off. When the ignition is switched on, the
value from the IAT (intake air temperature) sensor
is read. When the engine is running, the
temperature is calculated using a temperature map
stored in the PCM according to how long the
engine has been running. This substitute value is
then used as the basis for calculating the injected
fuel quantity and the ignition timing.
Ignition coil-on-plug
E73540
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Electronic Engine Controls— 2.5L Duratec (147kW/200PS) - VI5303-14-
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