charging FORD KUGA 2011 1.G Owner's Manual

Electrical consumers are switched off when the
battery voltage is low if the GEM determines (as a
result of the message received from the PCM on
the CAN bus via the instrument cluster) that the
battery voltage has dropped below the threshold
value.
When the threshold for low battery voltage is
reached the GEM switches off the following
consumers in this order at intervals of 5 seconds:
• Heated windscreen
• Heated rear window
• Electric booster Heater
• A/C system
If the battery voltage increases back above the
lower threshold then all of the consumers which
were previously switched off are reactivated by the
GEM.
Once the electric consumers have been reactivated
their status is "switched off", i.e. the consumers
are switched off and await an input signal provided
from the relevant switch via the GEM; this means
that the driver needs to switch these components
back on again.
Electrical consumers are switched on when the
battery voltage is excessively high if the GEM
determines that the battery voltage has increased
above the threshold for overvoltage and the
charging system warning indicator has come on.
When the threshold is reached the GEM switches
on the following consumers in this order at intervals
of 5 seconds:
• Heated windscreen
• Heated rear window
When these components are deactivated again
their status is "switched off". This means that the
consumers are waiting for an input signal provided
from the relevant switch via the GEM.
Ignition overload protection
The ignition overload protection intermittently
disconnects certain circuits in order to restrict the
current being drawn from the battery while the
starter motor is operating.
The position of the ignition switch is broadcast by
the instrument cluster on the medium speed CAN
bus.
The ignition overload protection relay which is
integrated in the battery junction box is activated
by the GEM if the message "ignition switch in
position III" is received from the instrument cluster.
All of the electric consumers controlled by the
ignition overload protection relay are then switched
off.
The following consumers (among others) are
controlled by the ignition overload protection relay:
• Fog lamps
• Windscreen/rear window wash/wipe systems
• Backup lamps
• Heated washer nozzles
• Heating blower motor
• Seat heating
Headlamp switch-off delay
The headlamp switch-off delay utilizes the low
beam together with the peripheral lights (if
equipped) to illuminate the area surrounding the
vehicle. The function is activated by operating the
high beam lever when the ignition switch is in the
"0" position.
After the last door has been closed, the function
remains active for a further 30 seconds and then
switches off automatically.
When a door or the tailgate is open, the switch-off
time is extended to 180 seconds. After the last door
has been closed, the switch-off time is reset to 30
seconds.
The headlamp switch-off delay can be deactivated
prematurely by operating the high beam lever again
or by switching on the ignition.
The switch-off time is adjusted to set values at the
factory and cannot be re-programmed using the
Ford diagnostic unit.
G1030788en
2008.50 Kuga 8/2011 419-10-7
Multifunction Electronic Modules
419-10-7
DESCRIPTION AND OPERATIONTO MODEL INDEX
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• 4 minutes have elapsed since the button for the
heated windshield was pressed.
• The ignition switch is turned to the "I" or "0" position.
• The "Defrost" function is deactivated or the switch for the heated windscreen is pressed
again while the heated windscreen is still
switched on.
• The charging system warning indicator is switched on.
• The battery voltage falls below the threshold value for low battery voltage for more than 20
seconds (power management strategy). Manual
requests for switching on the heated windshield
by pressing the switch are ignored at this time.
• More than 4 minutes have passed since starting
the engine.
Heated rear window and heated external
mirrors
The GEM transmits a request signal via the CAN
bus to the door modules to switch on the heated
exterior mirrors.
The heated rear window and the heated exterior
mirrors are switched on by the GEM under the
following conditions:
• The switch for the heated rear window is pressed and the ignition switch is in the "II"
position.
• The "defrost" function of the air conditioning is activated and the ignition switch is in the position
"II".
• The battery voltage has exceeded 16 V for more
than 20 seconds (power management strategy).
Manual requests to switch off the heated rear
window by pressing the button are ignored at
this time.
• The engine was started at an outside air temperature below 4°C and an engine
temperature below 65°. Manual requests for
switching off the heated rear window by pressing
the switch are accepted.
NOTE: If the battery voltage returns to the normal
range then the disabling of the heated rear window
is cancelled - the heated rear window is then in a
switched-off state.
The GEM transmits a request signal via the CAN
bus to the door modules to switch off the heated
exterior mirrors. The heated rear window and the heated exterior
mirrors are switched off by the GEM under the
following conditions
• 14 minutes have elapsed since the button for
the heated rear window was pressed.
• The ignition switch is turned to the position "0", "I" or "III".
• The switch for the heated rear window is pressed or the "defrost" function of the air
conditioning is deactivated while the heated rear
window is switched on.
• The battery voltage has dropped below 10.3 V for more than 20 seconds (power management
strategy). Manual requests for switching on the
heated rear window by pressing the switch are
ignored at this time.
• More than 14 minutes have passed since starting the engine.
Ambient air temperature
The ambient air temperature sensor is connected
via a cable to the GEM. It measures the outside
air temperature to an accuracy of around ±0.5 °C.
The GEM broadcasts the ambient air temperature
on the medium speed CAN bus, where it can be
evaluated by various systems.
Brake fluid level
The brake fluid level switch is connected via a
cable to the GEM.
The GEM transmits a message on the medium
speed CAN bus. The instrument cluster then
transfers this message to the high speed CAN bus
where it is made available for various other
functions.
Automatic headlamps
Refer to: Exterior Lighting (417-01 Exterior Lighting,
Description and Operation).
Combined rain sensor/light sensor
Refer to: Exterior Lighting (417-01 Exterior Lighting,
Description and Operation). G1030788en
2008.50 Kuga 8/2011 419-10-9
Multifunction Electronic Modules
419-10-9
DESCRIPTION AND OPERATIONTO MODEL INDEX
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Brake Booster — 2.5L Duratec (147kW/200PS) - VI5, RHD4WD/RHD FWD(12 451 0)
Removal
NOTE: Removal steps in this procedure may
contain installation details.
1. Refer to: Brake System Health and Safety
Precautions (100-00 General Information,
Description and Operation).
2. Torque: 24
Nm
E69829
x4
1
2
3.Refer to: Air Conditioning (A/C) System
Recovery, Evacuation and Charging (412-00
Climate Control System - General Information,
General Procedures).
Refer to: Brake Master Cylinder - 2.5L Duratec
(147kW/200PS) - VI5 (206-06 Hydraulic Brake
Actuation, Removal and Installation).
Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
4.
E65299
5. Torque:
• Stage 1: 10
Nm
• Stage 2: 25Nm
E99866
x6
6.
G1185955en2008.50 Kuga8/2011
206-07- 2
Power Brake Actuation
206-07- 2
REMOVAL AND INSTALLATION
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Action
Possible Sources
Symptom
• CHECK if the PCV system isoperating correctly and repair
as necessary. Engine - 2.5L
Duratec-ST (VI5) -
REFER to: Engine Emission
Control (303-08 Engine
Emission Control - 2.5L
Duratec (147kW/200PS) -
VI5, Diagnosis and Testing).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Faulty positive crankcase vent-
ilation (PCV) system.
- Hoses or ventilation orbreather valves are blocked.
This causes excessive
pressure in the crankcase
which causes more oil to
enter the combustion
chamber.
- PCV oil separator is faulty and engine oil can enter the
combustion chamber
through the intake manifold.
• INSTALL a new turbocharger.Engine - 2.5L Duratec-ST (VI5)
-
REFER to: Turbocharger (303-
04 Fuel Charging and
Controls - Turbocharger -
2.5L Duratec (147kW/200PS)
- VI5, Removal and Installa-
tion).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Turbocharger seals.
• CHECK the gaskets and matingsurfaces for damage.
Remove the cylinder head.
CHECK the mating faces, cylinder
head gasket and the evenness of
the cylinder head and engine block
mating faces.
INSTALL new valve seals. Engine
- 2.5L Duratec-ST (VI5) -
REFER to: Valve Stem Seals
(303-01 Engine - 2.5L Duratec
(147kW/200PS) - VI5, Removal
and Installation).
Engine - 2.0L Duratorq-TDCi (DW)
Diesel -
• Damaged gaskets or mating
surfaces.
- Cylinder head gasket isdamaged or mating face are
warped.
- Valve stem seals are worn and engine oil can enter the
combustion chamber
between the valve stem and
the valve stem guide.
• INSTALL new components asnecessary.
• Piston ring or cylinder liner
wear.
• CHECK the running surfacesand clearances of the individual
engine components. INSTALL
new components as necessary.
INSTALL a new cylinder block
if necessary.
• Check the pistons and piston rings.
• Damaged cylinder liners or
excessive clearance of engine
components.
- Pistons.
- Piston rings (clearance ingroove and end gap).
- Cylinder liners.
G1055128en2008.50 Kuga8/2011
303-00- 3
Engine System - General Information
303-00- 3
DIAGNOSIS AND TESTING
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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 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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Action
Possible Sources
Symptom
• 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).
• Fault in ignition system (petrol
engine only).
• CHECK the turbocharger.Engine - 2.5L Duratec-ST (VI5)
-
REFER to: Turbocharger (303-
04 Fuel Charging and
Controls - Turbocharger -
2.5L Duratec (147kW/200PS)
- VI5, Diagnosis and Testing).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Turbocharger.
• CHECK and adjust valvetiming. INSTALL new compon-
ents 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 -
• Incorrect valve timing. Timing
belt/timing sprocket or
pulley/sprocket damaged.
• CHECK the electronic enginecontrols. 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).
• Ignition timing incorrect (petrol
engine only).
• CHECK engine auxiliarycomponents for damage or
looseness. CHECK and adjust
valve timing. 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 -
• Engine auxiliary components
loose or damaged.
• Noisy running
G1055128en2008.50 Kuga8/2011
303-00-
7
Engine System - General Information
303-00- 7
DIAGNOSIS AND TESTING
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Exhaust Manifold(21 187 0)
Removal
1.Refer to: Turbocharger (303-04 Fuel Charging
and Controls - Turbocharger - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
Installation
1. Refer to: Turbocharger (303-04 Fuel Charging
and Controls - Turbocharger - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
G1079021en2008.50 Kuga8/2011
303-01- 49
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
49
REMOVAL AND INSTALLATION
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SECTION 303-04A Fuel Charging and Controls— 2.5L Duratec
(147kW/200PS) - VI5
VEHICLE APPLICATION: 2008.50 Kuga
PA G E
CONTENTS
DESCRIPTION AND OPERATION
303-04A-2
Fuel Charging and Controls ........................................................................\
........................
DIAGNOSIS AND TESTING 303-04A-4
Fuel Charging and Controls ........................................................................\
........................
303-04A-4
Inspection and Verification ........................................................................\
..........................
303-04A-4
Symptom Chart ........................................................................\
...........................................
REMOVAL AND INSTALLATION 303-04A-22
Fuel Injectors ........................................................................\
..............................................
303-04A-23
(23 198 0)
Throttle Body ........................................................................\
..........................
303-04A-24
Fuel Rail ........................................................................\
......................................................
303-04A- 1
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 1
.
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Fuel Charging and Controls
E64777
14
5
2
3
G510053en2008.50 Kuga8/2011
303-04A-2
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 2
DESCRIPTION AND OPERATION
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