filter FORD KUGA 2011 1.G User Guide

E100664
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3
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Description
Item
Multiplate clutch
1
Ring piston pump
2
All-wheel drive control unit
3
Pressure relief valve (high pressure)
4
Input shaft
5Description
Item
Electric feed pump
6
Fluid filter
7
Pressure accumulator
8
Pressure relief valve (low pressure)
9
Preload valve
10
High-pressure valves
11
G1076981en2008.50 Kuga8/2011
205-02- 8
Rear Drive Axle/Differential
205-02- 8
DESCRIPTION AND OPERATION
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The Haldex clutch is based on the principle of a
simple wet clutch that distributes the torque variably
between the front and rear axles.
Three components are linked within the Haldex
clutch:• A mechanical component, comprising input and
output shafts, the plate assembly (clutch) as
well as the cam plate and the roller bearing.
• A hydraulic component, essentially comprising pressure valves, a pressure accumulator, the
control valve, the ring pistons and a fluid filter.
• The electronic control comprises the electric fluid pump and the all-wheel drive control unit
with integrated pressure/temperature sensor
and an actuator motor for the control valve.
Design of the multi-plate clutch
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10911
13
A
B12
5
E100662
Description
Item
Pump plunger assembly
A
Working piston assembly
B
Output shaft
1
Inner plates
2
Outer plates
3
Disc drum
4
Contact plate
5Description
Item
Input shaft
6
Cam disc
7
Springs
8
Pump plunger roller
9
Pump plunger roller
10
Pump plunger
11
Working piston roller
12
Working piston
13
G1076981en2008.50 Kuga8/2011
205-02- 9
Rear Drive Axle/Differential
205-02- 9
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E100539
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2
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6
5A
B
C
D
Description
Item
Barometric Pressure
A
Base pressure
B
Increased base pressure (preload)
C
Operating pressure
Drive
Plate assembly and ring piston pump
1
High-pressure valves
2
Pressure Sensor
3Description
Item
Control valve
4
Pressure accumulator
5
Electric feed pump
6
Filters7
Preload valve
8
Pressure relief valve (low pressure)
9
Pressure relief valve (high pressure)
10
Base pressure
G1076981en2008.50 Kuga8/2011
205-02- 11
Rear Drive Axle/Differential
205-02- 11
DESCRIPTION AND OPERATION
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E100540
Description
Item
Barometric Pressure
A
Base pressure
BDescription
Item
Increased base pressure (preload)
C
Operating pressure
Drive
The hydraulic fluid is drawn from the sump of the
hydraulic system and directed through a filter. The
feed pump pressurises the system and pumps
hydraulic fluid into the pump plungers. This base
pressure of 4 bar presses the rollers for the pump
plungers against the cam disc. At the same time,
hydraulic fluid flows into the working piston. This
eliminates the play in the clutch plates. The Haldex
clutch can respond quickly and distribute the torque
within fractions of a second. The spring force in
the pressure accumulator determines the base pressure of 4 bar and compensates pressure
fluctuations. A compensating spring works in the
opposite direction and prevents the plate discs
becoming blocked by the force of the working
piston. This restricts the transferable torque to
approx. 7 Nm. This value can, however, deviate
slightly due to temperature and/or the difference
in speed between the input and output shafts.
Increased base pressure (preload)
G1076981en2008.50 Kuga8/2011
205-02-
12
Rear Drive Axle/Differential
205-02- 12
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1
2
3
4
E115887
Description
Item
Fluid filter
1
All-wheel drive control unit
2Description
Item
Electric feed pump
3
Pressure accumulator
4
The electric feed pump is an axial piston pump
which is more robustly designed than the gerotor
pump in the 3rd generation Haldex. The higher
feed pressure means that the ring piston pump at
the clutch plate assembly, the pressure relief
valves, preload valve and the high pressure valves
are no longer necessary.
The pressure accumulator on the 4th generation
Haldex is larger and is designed for the higher
pressure. The 4th generation Haldex has a larger fluid filter
which contains a non-return valve.
The all-wheel drive control unit no longer contains
a pressure sensor in the 4th generation Haldex.
Pressure control - 4th generation Haldex
clutch
G1076981en2008.50 Kuga8/2011
205-02-
15
Rear Drive Axle/Differential
205-02- 15
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6
7
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9
10
11
1
2
3
4
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9
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11
E114914
Description
Item
Haldex clutch fluid
1
Inlet filter
2
Electric feed pump
3
Filters4
Pressure accumulator
5Description
Item
Control valve
6
Dished washer
7
Ring piston
8
Clutch plate pack
9
Return pressure accumulator
10
Return control valve
11
Full torque is available at any time on the 4th
generation Haldex clutch because the pressure is
not dependent on the difference in the speeds of
rotation. This is used for instance to activate the
Haldex clutch for better traction when moving off.
On the 4th generation Haldex clutch, the preload
function which applied 80 Nm to the plates in the
3rd generation is no longer required.
On request from the control unit and at engine
speeds above 400 rpm, the electric feed pump runs
and maintains the storage pressure at about 30
bar.
A pressure reducing valve acts as a control valve,
allowing the all-wheel drive control unit to control
the pressure with much greater precision. The
all-wheel drive control unit monitors the position and function of the control valve. The control valve
distributes the pressure, depending on the
requirements, across its three outlet openings
(storage pressure, working pressure, return).
From the storage pressure (30 bar) and depending
on the requirements, the control valve regulates a
working pressure of 0 - 17 bar, which is applied to
the ring piston. At 17 bar working pressure, the
maximum torque of 1000 Nm is transferred to the
rear wheels. The all-wheel drive control unit
ensures the best possible performance under all
driving conditions, for all road conditions and
independent of the speed.
G1076981en2008.50 Kuga8/2011
205-02-
16
Rear Drive Axle/Differential
205-02- 16
DESCRIPTION AND OPERATION
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Action
Possible Sources
Symptom
• Check the cooling systemcomponents. Engine - 2.5L
Duratec-ST (VI5) -
REFER to: Engine Cooling
(303-03 Engine Cooling,
Diagnosis and Testing).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
REFER to: Engine Cooling
(303-03 Engine Cooling,
Diagnosis and Testing).
• Cooling system components.
• Coolant consumption
• INSTALL a new oil cooler.
• Oil cooler.
• CHECK the cylinder headgasket for damage. CHECK the
cylinder head for distortion.
• Damaged gaskets or warped
mating faces.
• DETERMINE the damagedengine component(s) and
install new component(s) as
necessary.
• Cracks or fractures in engine
components surrounded by
coolant, such as cylinder liners
and cylinder head combustion
chamber.
• CHECK the battery and cables.REFER to: Charging System
(414-00 Charging System -
General Information,
Diagnosis and Testing).
• Battery or cables.
• Engine will not crank
• CHECK the starting system.Engine - 2.5L Duratec-ST (VI5)
-
REFER to: Starting System
(303-06 Starting System -
2.5L Duratec (147kW/200PS)
- VI5, Diagnosis and Testing).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Starter motor or cables.
• CHECK the fuel level.
• Fuel tank is empty.
• Engine cranks but will not start
• Drain the water from the fuelsystem.
• Water in fuel (diesel engine
only).
• INSTALL a new fuel filter.Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Fuel filter blocked.
G1055128en2008.50 Kuga8/2011
303-00-
4
Engine System - General Information
303-00- 4
DIAGNOSIS AND TESTING
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Action
Possible Sources
Symptom
• CHECK the intake air system.Engine - 2.5L Duratec-ST (VI5)
-
REFER to: Intake Air Distribu-
tion and Filtering (303-12
Intake Air Distribution and
Filtering - 2.5L Duratec
(147kW/200PS) - VI5,
Diagnosis and Testing).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Engine intake air system.
• CHECK the glow plugs.INSTALL new glow plugs as
necessary.
• Glow plug faulty (diesel engine
only).
• CHECK the engine manage-ment system. Engine - 2.5L
Duratec-ST (VI5) -
REFER to: Electronic Engine
Controls (303-14 Electronic
Engine Controls - 2.5L
Duratec (147kW/200PS) -
VI5, Diagnosis and Testing).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Engine management system.
• CHECK the ignition system.Engine - 2.5L Duratec-ST (VI5)
-
REFER to: Engine Ignition
(303-07 Engine Ignition - 2.5L
Duratec (147kW/200PS) -
VI5, Diagnosis and Testing).
• Ignition system (petrol engine
only).
• CHECK and adjust the valvetiming. Engine - 2.5L Duratec-
ST (VI5) -
REFER to: Timing Belt (303-01
Engine - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Incorrect valve timing.
G1055128en2008.50 Kuga8/2011
303-00-
5
Engine System - General Information
303-00- 5
DIAGNOSIS AND TESTING
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Action
Possible Sources
Symptom
• CHECK the timing belt/timingchain and sprockets/pulleys.
INSTALL new components as
necessary. Engine - 2.5L
Duratec-ST (VI5) -
REFER to: Timing Belt (303-01
Engine - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Broken or damaged timing
belt/timing chain or
pulley/sprocket.
• CHECK the fuel system.Engine - 2.5L Duratec-ST (VI5)
-
REFER to: Fuel Charging and
Controls (303-04 Fuel Char-
ging and Controls - 2.5L
Duratec (147kW/200PS) -
VI5, Diagnosis and Testing).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Fuel system.
• Very poor power output or fuel
consumption too high or engine
running rough.
• CHECK the intake air system.Engine - 2.5L Duratec-ST (VI5)
-
REFER to: Intake Air Distribu-
tion and Filtering (303-12
Intake Air Distribution and
Filtering - 2.5L Duratec
(147kW/200PS) - VI5,
Diagnosis and Testing).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Engine intake air system.
• CHECK the exhaust system.
• Exhaust system blocked.
• CHECK the engine manage-ment system. Engine - 2.5L
Duratec-ST (VI5) -
REFER to: Electronic Engine
Controls (303-14 Electronic
Engine Controls - 2.5L
Duratec (147kW/200PS) -
VI5, Diagnosis and Testing).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Engine management system.
G1055128en2008.50 Kuga8/2011
303-00-
6
Engine System - General Information
303-00- 6
DIAGNOSIS AND TESTING
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Put the engine cover into installation position
and clip it in place by pressing at the places
shown.• Make sure that the engine upper cover is fully engaged in the area of the fuel filter, if
necessary apply more pressure in the areas
shown.
25. Install the cowl panel grille.
REFER to: Cowl Panel Grille (501-02 Front End
Body Panels, Removal and Installation).
26. Raise and support the vehicle.
REFER to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
TIE44583
27. Install the glow plug relay.
VFE0035752
28. Install the radiator undershield.
VFE0035742
29. Install the engine undershield.
30. Lower the vehicle.
31. Reset the PCM fault memory.
Measure the oil pressure (21 113 0)
The oil pressure depends on various factors
(engine speed, oil temperature, oil viscosity,
amount of oil filter contamination etc.).
Measure the oil pressure (Engine - 2.5L
Duratec-ST (VI5))
1. Raise and support the vehicle.
REFER to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
E65955
2. Remove the engine undershield.
E68443
3. Disconnect the oil pressure switch electrical connector.
G1055128en2008.50 Kuga8/2011
303-00- 14
Engine System - General Information
303-00- 14
DIAGNOSIS AND TESTING
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