power FORD KUGA 2011 1.G Workshop Manual

E74168
1
23456
Description
Item
Stop screw
1
Toothed segment
2
Throttle flap spindle
3
Throttle flap return spring
4
Joint shaft
5
Electric motor with pinion
6
CAUTION: The throttle control unit must
not be repaired or adjusted. The stop of
the throttle valve must on no account be
adjusted.
If there is a fault, the throttle is returned to its
original position by means of the throttle valve
return spring. In this position, the throttle valve is
still slightly open. As a result, a higher idle speed
is set, enabling the vehicle to be driven, though
within narrow limits.
ECT sensor
E94804
The ECT sensor is designed as an NTC resistor.
A voltage of 5V is applied to the ECT sensor by
the PCM. The PCM is able to determine the coolant
temperature from the temperature-dependent
voltage drop at the sensor.
Cooling fan module
E94806
The cooling fan module is directly supplied with
battery power via a 60A fuse in the BJB. The
radiator fan speed is controlled by the PWM via a
PCM signal.
G1021908en2008.50 Kuga8/2011
303-14- 31
Electronic Engine Controls— 2.5L Duratec (147kW/200PS) - VI5303-14-
31
DESCRIPTION AND OPERATION
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Description
Item
Coil-on-plug ignition coil
1
Spark plug connector
2
Low-voltage connection
3
Laminated soft-iron core
4Description
Item
Primary winding
5
Secondary winding
6
Spark plug
7
High-voltage connection via spring contact
8
In an ignition system with coil-on-plug ignition coils,
each cylinder is actuated individually and only once
per cycle (working stroke). The coil-on-plug ignition
coils are mounted directly on the spark plugs,
therefore no ignition cables are required between
the ignition coils and the spark plugs.
Each individual ignition coil is actuated on the
low-voltage side by the PCM. The power
end-stages are incorporated into the coil-on-plug
ignition coils. Only the actuating current for these
power end-stages is controlled by the PCM.
Fuel pressure/fuel temperature sensor
E73531
The fuel pressure/fuel temperature sensor is a
combination of two sensors, one for the fuel
absolute pressure and one for the fuel temperature.
The sensors register the fuel values in the fuel
injection supply manifold. The sensor is supplied
with a 5V voltage by the PCM.
The fuel pressure sensor is a piezoresistor and
works using an analog signal. The change in output
voltage mirrors the change in pressure in the fuel
rail. If the pressure is low, the output voltage is also
low.
The fuel temperature sensor is an NTC resistor.
When the fuel pressure/fuel temperature sensor is
disconnected, the resistance of the fuel
temperature sensor between connections 1 and 2
of the sensor can be measured.
Resistor
Temperature
5896 Ohm
0° C
3792 Ohm
10° C
2500 Ohm
20° C
1707 Ohm
30° C
1175 Ohm
40° C
The values of the fuel pressure/fuel temperature
sensor can be read out with IDS. The displayed
values are absolute values (fuel pressure +
atmospheric pressure).
Wastegate control valve
E73539
The boost control solenoid valve is a 2/3-way valve
that is actuated with a PWM signal. This allows the
valve opening to be steplessly adjusted.
Power (battery voltage) is supplied via the
Powertrain Control Module relay in the BJB. The
solenoid coil resistance is around 23 ohms at 20°
C.
G1021908en2008.50 Kuga8/2011
303-14- 33
Electronic Engine Controls— 2.5L Duratec (147kW/200PS) - VI5303-14-
33
DESCRIPTION AND OPERATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Electronic Engine Controls
General EquipmentFord diagnostic equipment
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical or electrical damage.
Visual Inspection Chart
Electrical
– Fuse(s)
– Wiring harness
– Electrical connector(s)
– Relay(s)
– Sensor(s)
– Switch(es)
– Powertrain control module (PCM)
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 Ford diagnostic
equipment to diagnose the system.
G165604en2008.50 Kuga8/2011
303-14- 35
Electronic Engine Controls— 2.5L Duratec (147kW/200PS) - VI5303-14-
35
DIAGNOSIS AND TESTING
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Powertrain Control Module (PCM)(29 200 0)
General Equipment3.5 mm Drill Bit
Center Punch
Ford Diagnostic Equipment
Removal
NOTE: Removal steps in this procedure may
contain installation details.
1. NOTE: This step is only necessary when
installing a new component.
Download the PCM and throttle body
configuration information into the diagnostic tool,
using the Programmable Modules Installation
routine.
General Equipment: Ford Diagnostic Equipment
2. Refer to: Battery Disconnect and Connect
(414-01 Battery, Mounting and Cables,
General Procedures).
Vehicles without PCM security shield
3.
E63329
4.
E93509
5.
E65856
6. Torque: 7Nm
E66285
Vehicles with PCM security shield
7.Refer to: Air Cleaner (303-12 Intake Air
Distribution and Filtering - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
8. General Equipment: Center Punch
1.
2. General Equipment: 3.5 mm Drill Bit
G1079137en2008.50 Kuga8/2011
303-14- 43
Electronic Engine Controls— 2.5L Duratec (147kW/200PS) - VI5303-14-
43
REMOVAL AND INSTALLATION
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307-01-29
Automatic transmission, selector lever in position "D". ...................................................
307-01-29
Sport mode, selector lever in position "S" .......................................................................
307-01-29
Changing gear in select-shift mode........................................................................\
........
307-01-30
Selector lever from 'N' to 'R' position ........................................................................\
......
307-01-30
Self-test and Diagnosis ........................................................................\
...........................
307-01-30
Temperature controlled torque converter lockup ............................................................
307-01-30
Slip locking ........................................................................\
..............................................
307-01-30
Hill climbing ........................................................................\
.............................................
307-01-31
Downhill driving ........................................................................\
.......................................
307-01-31
Hill-hold function ........................................................................\
.....................................
307-01-31
Altitude correction ........................................................................\
...................................
307-01-31
Selector lever lock ........................................................................\
..................................
307-01-31
Shifting from P into another transmission range .............................................................
307-01-31
Shifting from N into another transmission range .............................................................
307-01-31
Power flow through the transmission ........................................................................\
......
307-01-31
Clutches and brakes ........................................................................\
...............................
307-01-33
Position P (park) ........................................................................\
.....................................
307-01-34
Position N (neutral) ........................................................................\
.................................
307-01-35
Position D, 1st gear........................................................................\
................................
307-01-36
Position D, 2nd gear ........................................................................\
...............................
307-01-37
Position D, 3rd gear ........................................................................\
................................
307-01-38
Position D, 4th gear ........................................................................\
................................
307-01-39
Position D, 5th gear ........................................................................\
................................
307-01-40
Position R (reverse) ........................................................................\
................................
307-01-41
Service instructions ........................................................................\
.................................
307-01-41
Towing procedure ........................................................................\
...................................
307-01-42
Reset adaptation data ........................................................................\
.............................
307-01-42
Limp home mode ........................................................................\
....................................
307-01-42
Component Description ........................................................................\
..............................
Tasks of the electronic components ........................................................................\
........
307-01-44
Input signals ........................................................................\
............................................
307-01-45
Output signals ........................................................................\
.........................................
Control valve assembly ........................................................................\
...........................
Shift solenoids S1 - S5 ........................................................................\
...........................
PWM-

solenoid valve – TCC (SLU) ........................................................................\
........
PWM solenoid valve – shift pressure (SLS) ...................................................................
PWM solenoid valve for main line pressure (SLT) ..........................................................
307-01-52
Installation position ........................................................................\
.................................
Operation ........................................................................\
................................................
Selector lever with integrated select-shift switch module ...............................................
Oil pump ........................................................................\
..................................................
Torque converter with TCC ........................................................................\
.....................
The TSS sensor ........................................................................\
......................................
The OSS sensor ........................................................................\
.....................................
The TFT sensor ........................................................................\
......................................
The TR sensor ........................................................................\
........................................
GENERAL PROCEDURES
T ransmission Fluid Level Check ........................................................................\
.................
307-01-63
T ransmission Fluid Drain and Refill ........................................................................\
............
REMOVAL AND INSTALLATION 307-01-67
Halfshaft Seal LH ........................................................................\
........................................
307-01-68
Halfshaft Seal RH........................................................................\
.......................................
307-01-69
Main Control Valve Body ........................................................................\
............................
307-01-2
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 2
.
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307-01-42
307-01-49
307-01-52 307-01-47
307-01-45
307-01-50
307-01-51
307-01-53
307-01-55
307-01-54
307-01-56
307-01-57
307-01-58
307-01-61 307-01-60
PAGE 2 OF 3 FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

E112805
59
13
2
6
10
14
3
7
11
15
4
8
12
16
17
19202118
1
Description
Item
TCM1
GEM (generic electronic module)
2Description
Item
Instrument Cluster
3
PCM (powertrain control module)
4
G1163604en2008.50 Kuga8/2011
307-01- 13
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 13
DESCRIPTION AND OPERATION
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The TCM detects uphill driving by comparing the
engine load transmitted by the PCM with the engine
speed. If the engine load increases and the engine
speed falls, then the TCM causes the transaxle to
shift to a lower transmission range in order to
increase the traction force.
Downhill driving
The TCM detects downhill driving by comparing
the engine load and engine speed values
transmitted by the PCM with the OSS sensor
signal. In order to prevent overloading of the
vehicle brakes, the TCM causes the transaxle to
shift to a lower transmission range.
Hill-hold function
If the vehicle is stopped on an uphill incline, the
TCM detects this through the faster drop in engine
speed compared with the drop in engine speed
when stopping on the flat. In this situation, the
hydraulics are actuated by the TCM in such a way
that the vehicle is prevented from rolling back. This
function is not used on steep inclines.
If the vehicle is parked on an uphill incline (ignition
switched off), the hill-hold function is not active
when pulling away.
Altitude correction
Lower air density results in reduced engine
performance. In order to compensate for this
operating situation, the TCM changes the shift
points.
Selector lever lock
To prevent the selector lever being accidentally
moved from the P or N position, the vehicle also
has an electrically operated selector lever lock.
This blocks the locking pin in the locking segment
and thus locks the selector lever in the P or N
position.
Shifting from P into 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 must be
depressed (stop light 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.
The signal is then transferred from the TCM to the
select-shift switch module in order to activate the
solenoid valve in the selector mechanism
assembly.
In position P, the solenoid valve is activated and
the locking pin is pulled in so that the lock button
on the selector lever can be pressed as usual to
engage another transmission range.
In the selector mechanism assembly there is a Hall
sensor which is affected by a permanent magnet
on the gate of the selector mechanism assembly.
If the selector lever is moved from the P position,
both the Hall sensor and the selector lever lock
solenoid are simultaneously deactivated, to prevent
the selector from being kept in the N position.
If the ignition is set to "I" or "0" the solenoid valve
is deactivated. When the selector lever is in the P
position, it is mechanically locked because it has
no voltage.
Shifting from N into another transmission
range
The conditions are the same as for shifting from P
into another transmission range.
However, the lock button on the selector lever must
be pressed to be able to select R or P.
Power flow through the transmission
Clutches and brakes
G1163605en2008.50 Kuga8/2011
307-01-31
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 31
DESCRIPTION AND OPERATION
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E125575
1
2
Description
Item
Parking lock
1
1st and 2nd gear and reverse gear brake
(B5)
2
The transmission input shaft rotates in the
clockwise direction. All clutches and brakes on the
input side are deactivated and no power is
transmitted to the planetary gear sets.
No force is transferred to the output shaft. The
brake B5 (2) locks the rear planetary gear carrier
on the output side. The parking lock (1) is not
activated. Since the transaxle input shaft is not
positively connected with the input side, the vehicle
will start to roll away if it is on an incline. The brake B5 is activated both in 'P' and in 'N'
position to reduce the cut-in pressure that
otherwise occurs if several brakes and clutches
are activated simultaneously when the selector
lever is moved to 'D' or 'R' position. Since the brake
B5 is activated both in first and second as well as
in reverse gear, this method reduces the total
number of transient effects.
Position D, 1st gear
G1163605en2008.50 Kuga8/2011
307-01-
35
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 35
DESCRIPTION AND OPERATION
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E127358
21
3
Input shaft:
The transmission input shaft rotates in the
clockwise direction. Clutch C1 (1) joins the
transaxle input shaft with the ring gear, which
rotates in clockwise direction. The rear planetary
gear set rotates in the clockwise direction. The
front larger planetary gear set rotates clockwise
with the rear planetary gear set as a single unit.
The front smaller planetary gear set rotates in the
clockwise direction. The front annular gear rotates
counterclockwise. One-way clutch F2 (2) blocks
the front annular gear clockwise rotation.
The front and rear planetary gear carriers are
turned clockwise because of the reactive forces
from the small gear. The primary idler gear rotates
clockwise with the front and rear planetary gear
carriers as one unit.
Output shaft:
The secondary idler gear rotates counterclockwise.
The front annular gear rotates counterclockwise
with the secondary idler gear as a single unit.The front planetary gear set rotates in the clockwise
direction. The sun gear rotates clockwise.
The rear planetary gear set rotates
counterclockwise. Brake B5 (3) prevents rotation
of the rear planetary gear carrier. The rear annular
gear rotates counterclockwise. The front planetary
gear carrier and the final drive pinion rotate
counterclockwise with the rear annular gear as one
unit. The final drive rotates in the clockwise
direction.
Engine braking:
The 1st gear has no engine braking function
because the power flow is interrupted by the
one-way clutch F2 rotating against the locking
direction.
The brake B3 is additionally activated in select-shift
mode to guarantee engine braking.
Position D, 2nd gear
G1163605en2008.50 Kuga8/2011
307-01-
36
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 36
DESCRIPTION AND OPERATION
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E127359
1
2
3
4
5
Input shaft:
The transmission input shaft rotates in the
clockwise direction. The clutch C1 (1) joins the
transaxle input shaft and the ring gear. The ring
gear rotates in clockwise direction. The planetary
gear set rotates in clockwise direction.
The front larger planet gear rotates clockwise with
the rear planet gear as a single unit. Brakes B2
(2), brake B1 (3) and the one-way clutch F1 (4)
prevent rotation of the sun gear.
The front and rear planetary gear carriers are
turned clockwise by the front larger gear. The
primary idler gear rotates clockwise with the front
and rear planetary gear carriers as one unit.
Output shaft:
The secondary idler gear rotates counterclockwise.
The front annular gear rotates counterclockwisewith the secondary idler gear as a single unit. The
front planetary gear set rotates in the clockwise
direction.
The sun gear rotates clockwise. The rear planetary
gear set rotates counterclockwise. Brake B5 (5)
prevents rotation of the rear planetary gear carrier.
The rear annular gear rotates counterclockwise.
The front planetary gear carrier and the shaft drive
pinion rotate in counterclockwise direction with the
rear ring gear as one unit. The final drive rotates
in the clockwise direction.
Engine braking:
The power is transferred directly to the
transmission input shaft without one-way clutch
involvement. Engine braking is thus applied.
Position D, 3rd gear
G1163605en2008.50 Kuga8/2011
307-01-
37
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 37
DESCRIPTION AND OPERATION
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