Electric FORD KUGA 2011 1.G Owners Manual

The opto-electronic steering wheel rotation sensors
use light barriers for contactless scanning of a
segment disk which is connected fixedly to the
steering shaft.
E54014
1
23
4
Description
Item
Segment disk
1
Photoelectric barrier
2
Electronics
3
Electrical connection
4
Use is made of opto-electronic types of sensors
with relative and absolute steering angle sensing.
For relative steering angle sensing, changes in the
steering angle are measured exclusively by the
sensor and transmitted to the ABS/ESP module.
With the aid of other vehicle status signals (e.g.
wheel speed sensors) the module calculates the
straight ahead position of the steering. For absolute
steering angle sensing, the sensor transmits a
specific signal to the module for each steering
angle position (in relation to one turn of the steering
wheel). The straight ahead position of the steering
is therefore defined in the sensor. On an absolute
steering angle sensor, several photoelectric barrier
modules are distributed around the segment disk
at varying distances. The gaps between segments
of the segment disk are also unequal. For each specific steering angle there is therefore a specific
switch status of all photoelectric barriers.
ABS/ESP module or hydraulic control unit
(HCU)
E97648
1
2
3
Description
Item
ABS Pump Motor
1
Valve block (with low-pressure
accumulators)
2
ABS module
3
The HCU comprises the ABS module, the valve
block (with low-pressure accumulators) and the
ABS pump.
The valve block combines all of the brake pressure
control valves in one unit. Depending on the
system, either simple changeover valves or
proportioning valves (e.g. on EBD (electronic brake
force distribution) systems) are installed. The
low-pressure accumulators store the brake fluid
that is returned from the wheel brakes during the
pressure reduction phase until it is drawn back into
the system by the ABS pump.
The ABS pump is designed as a dual piston pump.
This means that two separate pump elements
assure an increase in brake pressure during control
interventions. A direct current motor drives the
pump pistons via an eccentric shaft.
The ABS/ESP module monitors the input signals
of all sensors and actuates the electro-magnetic
brake pressure valves and the ABS pump as
required. For reasons of safety, the module is of
the redundant type, whereby processing of the
signals is carried out via two separate processors
that also monitor each other.
G1001304en2008.50 Kuga8/2011
206-09B- 12
Anti-Lock Control - Stability Assist
206-09B- 12
DESCRIPTION AND OPERATION
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Steering System
Special Tool(s) / General EquipmentAlignment Pins, Subframe
205-316 (15-097A)
15097
Simulator, Driver and
Passenger Air Bags and Side
Air Curtains
501-073 (40-016)
501073
The Ford approved diagnostic tool
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanicalor electrical damage.
Visual Inspection Chart
Electrical
Mechanical
• Battery
• Battery cables
• Steering anglesensor electrical
connector
• Power steering pump control
module electrical
connectors
• Power steering pump control
module ground
cable
• Power steering pump control
module ground
cable retaining
screw
• Steering angle sensor warning
indicator
• Fuse(s)
• Tire pressure(s)
• Loose tie-rod end(s)
• Loose strut and
spring assemblies or
ball joints
• Loose pinch bolts on steering column
shaft flexible coup-
ling
• Wheels and tires
• Power steering line fluid leaks
• Steering gear bellows 3. If an obvious cause for an observed or reported
concern is found, correct the cause (if possible)
before proceeding to the next step.
4. If the cause is not visually evident, verify the symptom and refer to the diagnostic tab within
the Ford approved diagnostic tool.
Components Tests
Steering Linkage
1. Grasp the steering wheel firmly and move it upand down and to the left and right without
turning the steering wheel to check the steering
column bearing for wear, steering column shaft
for wear, steering wheel for looseness and
steering column for looseness. If the steering
column bearing or the steering column shaft is
worn install a new steering column. If the
steering wheel or the steering column is loose,
tighten the steering wheel or the steering column
retaining bolts.
2. With the road wheels in the straight ahead position, gently turn the steering wheel to the
left and the right to check for free play in the
steering linkage.
3. There should be no excessive free play at the steering wheel rim. If there is excessive free
play, CHECK the tie-rod inner and outer ball
joints, REFER to Tie-Rod Component Test in
this procedure. CHECK the steering column
universal joint, REFER to Steering Column
Universal Joint Component Test in this
procedure. If there is no free play in the tie-rod
and the steering column, install a new steering
gear.
Tie-Rod
CAUTION: Steering gear boots must be
handled carefully to avoid damage. Use
new steering boot clamps when installing
the steering gear boots.
NOTE: Noises such as knocks, which may appear
to originate from the steering linkage, may also be
generated by front suspension components.
REFER to: Noise, Vibration and Harshness (NVH)
(100-04 Noise, Vibration and Harshness,
Diagnosis and Testing).
G1059437en2008.50 Kuga8/2011
211-00- 2
Steering System - General Information
211-00- 2
DIAGNOSIS AND TESTING
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Power Steering – Overview
Power Steering
E96186
1
2
3
4
5
6
Description
Item
Reservoir
1
Electro-hydraulic power steering pump
2
power steering return hose
3Description
Item
Power steering fluid pressure line
4
Heat shield
5
Steering gear
6
The EHPS system uses an electrically driven
hydraulic pump and a conventional rack and pinion
steering gear. This ensures precise steering operation and steering assistance with minimum
energy consumption.
G1001269en2008.50 Kuga8/2011
211-02-
3
Power Steering
211-02- 3
DESCRIPTION AND OPERATION
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Steering wheel
E98657
During removal and installation or renewal of the
steering wheel, pay attention to the following:
• Make sure that the vehicle electrical system isfully depowered and no other power source is
connected.
• The clockspring rotor must not be turned during removal or installation of the steering wheel.
• Secure the clockspring rotor with adhesive tape to the clockspring outer.
• Make sure that the pins of the clockspring are not bent or damaged during installation.
Extension, steering shaft
E98647
1
2
Description
Item
Extension, steering shaft
1
Bolt, steering shaft extension
2
During removal and installation or renewal of
components of the steering shaft extension, pay
attention to the following:
• Make certain that a new steering shaft extension bolt is installed.
• Make sure a new steering column flexible coupling bolt is installed.
Steering Column
E98646
1
2
Description
Item
Steering Column
1
Bolt, steering shaft flexible coupling
2
The following components may be renewed:
• Steering Column
During removal and installation or renewal of
components of the steering column, pay attention
to the following:
• Make sure that the vehicle electrical system is fully depowered and no other power source is
connected.
• Make sure a new steering column flexible coupling bolt is installed.
• Secure the clockspring rotor with adhesive tape to the clockspring outer.
• The clockspring rotor must not be turned during removal or installation of the steering wheel or
the steering column switch unit.
G1030751en2008.50 Kuga8/2011
211-04- 3
Steering Column
211-04- 3
DESCRIPTION AND OPERATION
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Steering Column(13 542 0)
Removal
WARNINGS:
The supplemental restraint system (SRS)
is active for a certain length of time after
the power supply has been disconnected.
Wait for a minimum of 3 minutes before
disconnecting or removing any SRS
components.
Make sure that the vehicle electrical
system is fully depowered and no other
power source is connected.
NOTE: Removal steps in this procedure may
contain installation details.
1. NOTE: Make sure that the road wheels are in
the straight ahead position.
E99259
2. CAUTION: Make sure that the steering wheel lock is engaged.
Refer to: Battery Disconnect and Connect
(414-01 Battery, Mounting and Cables,
General Procedures).
3. If equipped.
E100834
4.
E95563
5.
E99639
1
2
6.
E99720
G1058718en2008.50 Kuga8/2011
211-04- 5
Steering Column
211-04- 5
REMOVAL AND INSTALLATION
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Steering Column Shaft
Removal
WARNINGS:
The supplemental restraint system (SRS)
is active for a certain length of time after
the power supply has been disconnected.
Wait for a minimum of 3 minutes before
disconnecting or removing any SRS
components.
Make sure that the vehicle electrical
system is fully depowered and no other
power source is connected.
NOTE: Removal steps in this procedure may
contain installation details.
1. Refer to: Clockspring (501-20 Supplemental
Restraint System, Removal and Installation).
Refer to: Steering Column Multifunction Switch
LH (211-05 Steering Column Switches,
Removal and Installation).
Refer to: Steering Column Multifunction Switch
RH (211-05 Steering Column Switches,
Removal and Installation).
Refer to: Steering Column Lock Module (211-05
Steering Column Switches, Removal and
Installation).
2. Torque: 30
Nm
E66155
3.Torque: 5Nm
E99641
4.
E99640
5.Torque: 24Nm
E99642
Installation
1.To install, reverse the removal procedure.
G1073504en2008.50 Kuga8/2011
211-04- 7
Steering Column
211-04- 7
REMOVAL AND INSTALLATION
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Steering Column Switches – Overview
Switch unit, steering column
E98629
1
2
3
4
5
Description
Item
Left-hand switch, steering column
1
Switch unit carrier, steering column
2
Right-hand switch, steering column
3Description
Item
Steering wheel rotation sensor
Refer to: Anti-Lock Control - Stability
Assist (206-09 Anti-Lock Control -
Stability Assist, Description and
Operation).
4
Clockspring
5
Clockspring
The clockspring is designed to carry signals
between the RCM and the driver air bag module.
The clockspring is installed on the steering column,
and consists of fixed and moving parts connected
by a coiled Mylar tape with internal conducting
tracks. The Mylar tape is able to 'wind up' and
'unwind' as the steering wheel is rotated,
maintaining electrical contact at all times between
the RCM and the driver air bag module. During removal and installation or renewal of the
clockspring, pay attention to the following:
• Before installation of the clockspring, it must be
aligned according to the installation instructions.
• Make sure that the vehicle electrical system is fully depowered and no other power source is
connected.
• Secure the clockspring rotor with adhesive tape to the clockspring outer.
• The clockspring rotor must not be turned during removal or installation of the steering wheel or
the steering column switch unit.
G1030755en2008.50 Kuga8/2011
211-05- 3
Steering Column Switches
211-05- 3
DESCRIPTION AND OPERATION
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Engine
Special Tool(s) / General EquipmentSocket, Spark Plug
303-499
ES21202
Compression Test Adapter
303-1056
E42936
Ford diagnostic equipment
Materials
Specification
Name
WSK-M2G349-A7
Adhesive - Loctite 243 1. Verify the customer concern by operating the
system
2. Visually inspect for obvious signs of mechanical or electrical damage.
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible)
before proceeding to the next step.
4. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart.
Visual Inspection Chart
Electrical
Mechanical
– Fuse(s)
– Loose or corrodedconnector(s)
– Control module
– Damaged or worn switch(es)
– Coolant leaks
– Oil leaks
– Fuel system leaks
– Visibly damaged or
worn parts
– Loose or missing nuts or bolts
Action
Possible Sources
Symptom
• CHECK for evidence of oilleaks on components. Use an
ultraviolet (UV) leak tester if an
oil leak is not evident. INSTALL
new gaskets or components as
required.
• Oil leaks on components that
are either coated in oil them-
selves or on components local
to them.
• Loss of oil
• CHECK the coolant expansiontank for a film of oil on the
coolant surface. INSTALL a
new oil cooler or oil cooler
gasket.
• Internal or external leak at the
oil cooler.
• INSTALL a new crankshaftseal.
• Leak at the crankshaft seal.
• CHECK for cracks in oil-carrying components of the
basic engine by means of a UV
leak test. INSTALL new
components or seals as
necessary.
• Leaks from oil carrying
components or basic engine.
• DETERMINE the last type ofengine oil used and compare
with the specification. Change
the engine oil to the specifica-
tion.
• Use of the wrong type of engine
oil.
• Oil consumption
G1055128en2008.50 Kuga8/2011
303-00-
2
Engine System - General Information
303-00- 2
DIAGNOSIS AND TESTING
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Action
Possible Sources
Symptom
• CHECK the engine compon-ents for wear or damage. Make
sure that all components are
within specification. INSTALL
new components as necessary.
Engine - 2.5L Duratec-ST (VI5)
-
REFER to: Specifications (303-
01 Engine - 2.5L Duratec
(147kW/200PS) - VI5,
Specifications).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Engine components
- Pistons.
- Piston rings.
- Connecting rod big end,main bearing or thrust
bearing journals.
- Connecting rods bent or damaged.
• Noisy running or engine noise
Engine - Oil Leaks
NOTE:
Before installing new gaskets or oil seals,
make sure that the fault is clearly established.
If the oil leak cannot be identified clearly by a visual
inspection, carry out an ultraviolet (UV) test:
Ultraviolet (UV) Testing
1. Clean the engine and transmission with a suitable cleaning fluid.
2. Pour the UV-test fluid in accordance with the quantity specified by the manufacturer through
the oil filler neck into the engine and install the
oil filler cap.
WARNING: Vehicles with manual transaxle,
shift the transaxle into Neutral. Failure to
follow this instruction may result in
personal injury.
3. Start the engine and let it run for about five minutes.
4. Switch off the engine.
NOTE: If no leak can be found, road test the
vehicle under various loads and check the engine
for leaks again.
5. Check the engine for oil leaks using a suitable UV lamp.
6. Rectify any leaks found and check the engine for oil leaks.
Measure the compression pressure
NOTE: The powertrain control module (PCM)
receives an error message when the fuel pump
relay is removed or electrical components are disconnected. This error message must be deleted
from the fault memory using the Ford diagnostic
equipment after completing the compression test.
NOTE:
Valve clearance must be set correctly
before performing a compression test. Make sure
the engine is at the normal operating temperature.
NOTE: The varying design of compression
checking devices and fluctuating starter motor
speeds normally only allows for a comparison to
be made of the compression pressures in all
cylinders.
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303-00- 9
Engine System - General Information
303-00- 9
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TIE44583
5. Remove the glow plug relay.
6. Lower the vehicle.
7. Remove the cowl panel grille.REFER to: Cowl Panel Grille (501-02 Front End
Body Panels, Removal and Installation).
E50527
8. NOTE: The engine upper cover is held in place by 3 ball clips. The ball clips are not
vertical, but are angled backwards by
approximately 20 degrees.
Location of the engine upper cover ball clips.
E50472
2
1
3
4
9.CAUTION: Contact of the engine upper
cover with the cowl panel may cause damage
(scratches) on the engine upper cover. If the
ambient temperature is below 0°C, detach
the engine upper cover with extreme caution. Failure to follow this instruction may cause
the engine upper cover to be damaged.
NOTE: Only remove and install the engine upper
cover in the sequence shown.
Remove the engine upper cover.• Detach the engine upper cover ball clips in the sequence shown.
TIE39594
10.CAUTION: Do not disconnect the fuel
injection pump electrical connectors and
crank the engine.
Disconnect the fuel injector electrical
connectors.
11. Remove the exhaust gas recirculation (EGR) cooler.
12. Remove the EGR valve.
TIE39687
13. Remove the glow plug power supply.
G1055128en2008.50 Kuga8/2011
303-00- 12
Engine System - General Information
303-00- 12
DIAGNOSIS AND TESTING
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