clock FORD KUGA 2011 1.G User Guide

SECTION 211-05 Steering Column Switches
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
DESCRIPTION AND OPERATION
211-05-2
Steering Column Switches (Component Location) .............................................................
211-05-3
Steering Column Switches (Overview) ........................................................................\
.......
211-05-3
Switch unit, steering column ........................................................................\
.......................
211-05-3
Clockspring ........................................................................\
.................................................
REMOVAL AND INSTALLATION 211-05-4
Steering Column Lock Module ........................................................................\
...................
211-05-6
Steering Column Multifunction Switch LH ........................................................................\
..
211-05-7
Steering Column Multifunction Switch RH ........................................................................\
..
211-05-1
Steering Column Switches
211-05- 1
.
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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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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.
G1092773en2008.50 Kuga8/2011
303-01-
13
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
13
DESCRIPTION AND OPERATION
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Timing marks
132
45
6
78
E62440
Description
Item
Exhaust camshaft pulley timing mark
1
Engine front cover with timing marks
2
Intake camshaft pulley timing mark
3
Intake camshaft drive gear
4Description
Item
Exhaust camshaft drive gear
5
Crankshaft timing belt pulley timing mark
6
Crankshaft timing belt pulley
7
Crankshaft
8
The front engine cover must always be fitted when
checking and adjusting the valve timing or timing
belt tension, as the timing marks for both camshaft
pulleys are provided on its front end.
Correct timing belt tension is ensured by the
automatic timing belt tensioner.
No direction of movement is specified when using
a new timing belt. If, however, the old timing belt
is reused, the direction of movement must be
marked prior to removal.
Once the timing belt has been correctly tensioned,
the engine must be rotated by hand two turns
clockwise at the crankshaft in order to allow a subsequent check of the timing belt tension and
adjustment.
Cylinder block
The cylinder block consists of three parts. These
are the cylinder block, the lower crankcase and the
sump pan. The cylinder block has five cylinder
liners made of cast iron, which cannot be replaced.
The pistons are made of a homogeneous aluminum
alloy with a graphite coating on the sides. This
coating serves to reduce friction and dampen noise.
The pistons are cooled from below via oil-spray
nozzles screwed into the cylinder block.
G1092773en2008.50 Kuga8/2011
303-01-
14
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
14
DESCRIPTION AND OPERATION
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The engine oil is drawn from the oil pan and routed
to the camshaft oil ducts via the engine oil circuit
before passing from there to the VCT oil control
solenoid and to the locking pin. This releases the
locking pin and separates the positive engagement
between the camshaft pulley and the rotor. Whenthe control unit is being retarded, the chamber (b)
fills with engine oil. The rotor turns clockwise
because of the oil pressure in the chamber (b). The
engine oil returning from the chamber (a) flows via
the oil return duct (D) to the VCT oil control
solenoid and from there back into the oil pan.
E62710
When the VCT control unit is being advanced, the
chamber (a) fills with engine oil. The rotor turns
counter-clockwise because of the oil pressure in
the chamber (a). This completes the advance
adjustment. The engine oil returning from the
chamber (b) flows via the oil return duct (D) to the
VCT oil control solenoid and from there back into
the oil pan.
G1032416en2008.50 Kuga8/2011
303-01-
18
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
18
DESCRIPTION AND OPERATION
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36.
E83911
37. CAUTION: Only rotate the crankshaftclockwise.
Rotate the crankshaft slowly until the crankshaft
stops.
Install the Special Tool(s): 303-1182
E66328
303-1182
38. CAUTION: Make sure that theinstallation marks are aligned.
E113883
G543500en2008.50 Kuga8/2011
303-01- 107
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
107
ASSEMBLY
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All vehicles
42.Torque: 120Nm
E84550
x2
43.Remove the Special Tool(s): 303-1178
E66324
303-1178
44. CAUTION: Only rotate the crankshaft
clockwise.
Rotate the crankshaft slowly until the crankshaft
stops.
Remove the Special Tool(s): 303-1182
E66328
303-1182
45.
E112858
1
x2
2
46. CAUTION: Only rotate the crankshaftclockwise.
Rotate the crankshaft slowly until the crankshaft
stops.
Install the Special Tool(s): 303-1182
E66328
303-1182
47.Install the Special Tool(s): 303-1178
Torque: 10
Nm
E66324
303-1178
G543500en2008.50 Kuga8/2011
303-01- 109
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
109
ASSEMBLY
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Function of the shift solenoids in the gears
S5
S4
S3
S2
S1
Gear
Off
Off
On
On
On
1
Off
Off
On
Off
Off
2
Off
On
On
Off
Off
3
Off
On
Off
Off
Off
4
Off
On
Off
On
Off
5
Overview of the brakes, clutches and
one-way clutches
E112793
1234
5
12
13
Description
Item
Clutch C2: Connects the input shaft with
the sun gear.
1
Clutch C1: Connects the input shaft with
the rear gear.
2
Brake B3: Locks the annulus of the front
planetary gear.
3
One-way clutch F2: Locks the front
annulus in the counterclockwise direction.
4
Brake B2: Prevents the sun gear on the
input shaft from turning counterclockwise.
5Description
Item
Brake B1: Locks the sun gear on the input
shaft.
6
One-way clutch F1: Prevents the sun gear
on the input shaft turning counterclockwise
when B2 is activated.
7
Park System
8
Clutch C3: Connects the sun gear with the
front planetary gear carrier on the output
shaft.
9
Brake band B4: Blocks the the sun gear
on the output shaft.
10
G1163604en2008.50 Kuga8/2011
307-01-
11
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 11
DESCRIPTION AND OPERATION
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E127357
1234
5
12
13
Description
Item
5th gear and reverse gear clutch (C2)
1
1st - 5th gear clutch (C1)
2
Reverse gear brake (B3)
3
1st gear one-way clutch (F2)
4
2nd - 5th gear brake (B2)
5
2nd - 4th gear brake (B1)
6
2nd - 4th gear one-way clutch (F1)
7Description
Item
Parking lock
8
4th and 5th gear clutch (C3)
9
3rd gear brake (B4) (band brake)
10
1st and 2nd gear and reverse gear brake
(B5)
11
Output shaft – transaxle
12
Input shaft – transaxle
13
The transaxle features three clutches, five brakes,
and two one-way clutches.
The clutches are designed as multi-plate clutches.
There are four multi-plate brakes (B1, B2, B3, B5)
and one band brake (B4).
Tasks of clutches and brakes
• 1st-5th gear clutch (C1) : Connects the input
side with the ring gear.
• 5th gear and reverse clutch (C2) : Connects
the input side with the sun gear.
• 4th and 5th gear clutch (C3) : Connects the
sun gear with the front planetary gear carriers
on the output side. •
2nd-4th gear brake (B1) : Locks the sun gear
on the input side.
• 2nd-5th gear brake (B2) : Locks the rotational
movement of the sun gear on the input side in
a counterclockwise direction.
• Reverse gear brake (B3) and 1st gear brake
in select-shift mode : Locks the ring gear on
the input side.
• 3rd gear brake (B4) (band brake) : Locks the
two sun gears on the output side.
• 1st and 2nd gear and reverse gear brake
(B5) : Locks the rear planetary gear carriers on
the output side.
G1163605en2008.50 Kuga8/2011
307-01- 32
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 32
DESCRIPTION AND OPERATION
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•2nd-4th one-way clutch (F1) : Locks the
rotational movement of the sun gear on the input
side in a counterclockwise direction, if 2nd-5th
gear brake (B2) is applied. •
1st gear one-way clutch (F2) : Locks the
rotational movement of the ring gear on the input
side in a counterclockwise direction.
Function of the clutches and brakes in the gears and when shifting gears in automatic mode and
select-shift mode (manual shifting)
F2
F1
B5
B4
B3
B2
B1
C3
C2
C1
Gear
––
0
–––––––
Park
––
0
–0–––0–R
(V<=7)
––
0
–––––––R
(V>7)
––
0
–––––––N
0–
0
–
–*
––––01
0/–
–/0
0
––
–/0
–/0
––01<=>2
–0
0
––00––02
–0
0/–
–/0
–00––02<=>3
–0
–
0–00––03
–0
–
0/–
–00
–/0
–03<=>4
–0
–
––000–04
–
0/–
–
––0
0/–
0
–/0
04<=>5
––
–
––0–0005
• V= Road speed in km/h
• 0= Actuated
• –= Not actuated
• x<=>x = Gear change "up/down"
• *= Actuated in select-shift mode
Position P (park)
G1163605en2008.50 Kuga8/2011
307-01- 33
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 33
DESCRIPTION AND OPERATION
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