Engine control FORD KUGA 2011 1.G Workshop Manual

Solvent-based Adhesives/Sealers - See
Solvents
Follow manufacturers instructions.
Water-based Adhesives/Sealers
Those based on polymer emulsions and rubber
latexes may contain small amounts of volatile toxic
and harmful chemicals. Skin and eye contact
should be avoided and adequate ventilation
provided during use.
Hot Melt Adhesives
In the solid state, they are safe. In the molten state
they may cause burns and health hazards may
arise from the inhalation of toxic fumes.
Use appropriate protective clothing and a
thermostatically controlled heater with a thermal
cut-out and adequate extraction.
Resin-based Adhesives/Sealers, for
example Epoxide and Formaldehyde
Resin-based
Mixing should be carried out in well ventilated
areas, as harmful or toxic volatile chemicals may
be released.
Skin contact with uncured resins and hardeners
can result in irritation, dermatitis, and absorption
of toxic or harmful chemicals through the skin.
Splashes can damage the eyes.
Provide adequate ventilation and avoid skin and
eye contact.
Anaerobic, Cyanoacrylate (super-glues)
and other Acrylic Adhesives
Many are irritant, sensitizing or harmful to the skin
and respiratory tract. Some are eye irritants.
Skin and eye contact should be avoided and the
manufacturers instructions followed.
Cyanoacrylate adhesives (super-glues) MUST NOT
contact the skin or eyes. If skin or eye tissue is
bonded, cover with a clean moist pad and SEEK
IMMEDIATE MEDICAL ATTENTION. Do not
attempt to pull tissue apart. Use in well ventilated
areas as vapors can cause irritation to the nose
and eyes.For two-pack systems see Resin-based and
Isocyanate Adhesives/Sealers.
Isocyanate (Polyurethane)
Adhesives/Sealers
See also
Resin-based Adhesives.
Individuals suffering from asthma or respiratory
allergies should not work with or near these
materials as sensitivity reactions can occur.
Over exposure is irritating to the eyes and
respiratory system. Excessive concentrations may
produce effects on the nervous system including
drowsiness. In extreme cases, loss of
consciousness may result. Long term exposure to
vapor concentrations may result in adverse health
effects.
Prolonged contact with the skin may have a
defatting effect which may lead to skin irritation
and in some cases, dermatitis.
Splashes entering the eye will cause discomfort
and possible damage.
Any spraying should preferably be carried out in
exhaust ventilated booths, removing vapors and
spray droplets from the breathing zone.
Wear appropriate gloves, eye and respiratory
protection.
Antifreeze
See also Fire, Solvents.
For example isopropanol, ethylene glycol,
methanol.
Highly flammable, flammable, combustible.
Used in vehicle coolant systems, brake air pressure
systems, screenwash solutions.
For additional information, refer to: Engine Cooling
System Health and Safety Precautions (100-00
General Information, Description and Operation).
Asbestos
See also Warning Symbols on Vehicles at the end
of this subsection.
Breathing asbestos dust may cause lung damage
or, in some cases, cancer.
Used in brake and clutch linings, transmission
brake bands and gaskets.
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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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sometimes noticed in the steering wheel/column,
seats, front floor panel, front door trim panel or
front end sheet metal. It is a low frequency
vibration (around 9-15 cycles per second). It
may or may not be increased by applying the
brakes lightly. REFER to Idle
Boom/Shake/Vibration in the Driveline Noise
and Vibration Symptom Chart.
3. High Speed: A vibration is felt in the front floor panel or seats with no visible shake, but with
an accompanying sound or rumble, buzz, hum,
drone or booming noise. Coast with the clutch
pedal depressed (manual transmission) or shift
control selector lever in "N" (NEUTRAL)
(automatic transmission) and engine idling. If
vibration is still evident, it may be related to
wheels, tires, front brake discs, wheel hubs or
front wheel bearings. REFER to Shake and
Vibration While Driving in the Driveline Noise
and Vibration Symptom Chart.
4. Engine rpm Sensitive: A vibration is felt whenever the engine reaches a particular rpm.
It will disappear in neutral coasts. The vibration
can be duplicated by operating the engine at
the problem rpm while the vehicle is stationary.
It can be caused by any component, from the
accessory drive belt to the clutch or torque
converter which turns at engine speed when the
vehicle is stopped. REFER to Shake and
Vibration While Driving in the Driveline Noise
and Vibration Symptom Chart.
5. Noise and Vibration While Turning: Clicking, popping or grinding noises may be due to the
following:
• worn, damaged or incorrectly installed front wheel bearing.
• damaged powertrain/drivetrain mounts.
Road Conditions
An experienced technician will always establish a
route that will be used for all NVH diagnosis road
tests. The road selected should be reasonably
smooth, level and free of undulations (unless a
particular condition needs to be identified). A
smooth asphalt road that allows driving over a
range of speeds is best. Gravel or bumpy roads
are unsuitable because of the additional road noise
produced. Once the route is established and consistently used, the road noise variable is
eliminated from the test results.
NOTE:
Some concerns may be apparent only on
smooth asphalt roads.
If a customer complains of a noise or vibration on
a particular road and only on a particular road, the
source of the concern may be the road surface. If
possible, try to test the vehicle on the same type
of road.
Vehicle Preparation
Carry out a thorough visual inspection of the
vehicle before carrying out the road test. Note
anything which is unusual. Do not repair or adjust
any condition until the road test is carried out,
unless the vehicle is inoperative or the condition
could pose a hazard to the technician. After
verifying that the condition has been corrected,
make sure all components removed have been
installed.
Power Steering Conditions
Check for the noise in the following conditions to
verify the customer concern.
• Check for the noise in several temperature conditions.
• Is the noise from when the vehicle was new?
• Can the noise be repeated constantly or is it random?
• Check the condition of the vehicle age, mileage and service record.
• Interview the customer to find the operating condition in which the noise will occur. Test the
vehicle based on the detail(s) from the customer
interview.
• Follow the power steering operation noise condition tables below, to find which condition
the noise will occur.
Power Steering Operation Noise Check
Step 1: Check for NVH concerns from non-steering
components, which may sound like noises coming
from the steering system.
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DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
B4: CHECK THE POWERTRAIN/DRIVETRAIN MOUNTS
1 Carry out the powertrain/drivetrain mount neut-
ralizing procedure
• Are the powertrain/drivetrain mounts OK?
zYe s Vehicle condition corrected. ROAD TEST as
necessary.
zNoINSTALL new powertrain/drivetrain mounts
as necessary. ROAD TEST as necessary.
PINPOINT TEST C : IDLE BOOM/SHAKE/VIBRATION/SHUDDER
DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
C1: CHECK THE CABLE/HOSES
1 Check the engine compartment for any
component that may have a touch condition
between the engine and body or chassis. For
example: control cable, air conditioning (A/C)
hoses, acceleration cable.
• Are the components OK?
zYe s GO to C2 .
zNo
REPAIR or INSTALL new components as
necessary. ROAD TEST as necessary.
C2: CHECK THE ENGINE COOLING RADIATOR
1 Check the engine cooling radiator mountings
and bushings for security and condition. Check
the radiator installation for any component that
may have a touch condition.
• Is the installation and bushings OK?
zYe s GO to C3 .
zNo
REPAIR or INSTALL new components as
necessary. ROAD TEST as necessary.
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Blower Motor — RHD(34 374 0)
Special Tool(s)412-131
Remover/Installer, Blower
Engine
E42948
Removal
NOTE:Removal steps in this procedure may
contain installation details.
1. Refer to: Cowl Panel Grille (501-02 Front End
Body Panels, Removal and Installation).
2. Torque: 25
Nm
E101389
3.Refer to: Steering Column (211-04 Steering
Column, Removal and Installation).
4. Refer to: Floor Console Extension - Vehicles
With: Center Armrest (501-12 Instrument
Panel and Console, Removal and Installation).
5.
E102293
6. Torque: 25Nm
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Climate Control
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Description
Item
Electric Booster HeaterRefer to Component Description: (page
?)
1
GEM (generic electronic module)
2
Outside temperature sensor
3
Climate control system control assembly
4 Description
Item
Generator and Alternator
5
PCM (powertrain control module)
6
Coolant temperature sensor (ECT (engine
coolant temperature) sensor)Refer to Component Description: ECT
(page ?)
7
instrument cluster
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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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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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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
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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.
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