Manual Temperature Control FORD KUGA 2011 1.G Owner's Guide

Turbocharger – Overview
Turbocharger(s)
CAUTION: Do not switch off the engine
while it is running at high speed. If the
engine is switched off while it is running
at high speed, the turbocharger will
continue to run after the engine oil
pressure has already dropped to zero. This
will cause premature wear in the
turbocharger bearings.
A TC consists of an exhaust turbine located in the
exhaust gas flow, this turbine is connected to a
compressor by a shaft. The turbine is made to
rotate by the exhaust gas flow from the engine and
thus drives the compressor. The compressor
increases the pressure in the engine intake tract
so that a greater mass of air enters the cylinder
during the intake stroke.
The turbine housing of the TC is integrated into the
exhaust manifold. This construction offers
thermodynamic advantages compared with the
usual construction, the maximum exhaust
temperature is up to 1050°C.
The maximum boost pressure is 0.65 bar.
The exhaust manifold is secured to the exhaust
side of the cylinder head with 12 self-locking nuts.
The exhaust manifold gasket is a multi-layer steel
gasket and cannot be reused. In order to
compensate for the thermal expansion of the
exhaust manifold, the flange of the TC is provided
with two grooves.
The TC and the exhaust manifold are joined by a
hose clip. The hose clip must not be loosened or
removed. The TC and the exhaust manifold are
not available as separate replacement parts,
exchange is only possible as a complete unit.
The turbocharger heat shield is secured to the
exhaust manifold by four bolts. Two of the bolts
have spring washers underneath their heads.
During removal, make a note of the installation
location of the spring washers to refer to during
installation.
The recirculated air valve is built into the TC
housing and cannot be changed.
The Ford diagnostic unit can test the operation of
the wastegate control valve using actuator
diagnosis.
The boost pressure regulator is set in the factory.
Adjustments to the boost pressure regulator must never be attempted. A red colored seal is applied
to the adjustment nut of the operating rod, in order
to monitor the factory setting of the boost pressure.
The bearings of the TC are lubricated with engine
oil. The engine oil passes from the cylinder block
through the oil supply pipe to the TC. The oil is
returned to the oil pan through the oil return pipe,
The TC is cooled by the engine coolant circuit.
When installing hoses and lines, make certain that
their ends are free of oil residues and dirt.
G1032425en2008.50 Kuga8/2011
303-04B-
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Fuel Charging and Controls - Turbocharger
—
2.5L Duratec (147kW/200PS) - VI5
303-04B- 4
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Description
Item
PWM (pulse width modulation) signal
Comments:from PCM (powertrain control module)
5
Atmospheric pressure
6
Turbocharger boost pressure.
7
from air filter
8
Intake air
9Description
Item
Recirculated air valveRefertoComponentDescription:(page
7)
10
Vacuum line, recirculated air valve
11
to intake manifold
12
Throttle plate
13
Compressor
14
Turbine
15
System Operation
Turbocharger(s)
The TC consists of a turbine and a compressor.
The turbine is driven by the exhaust gas flow. A
common shaft drives the compressor and this then
compresses the intake air.
Turbocharger boost pressure control
E98942
1
2
3
4
Description
Item
Atmospheric pressure
1
Turbocharger boost pressure.
2
Wastegate control valve
3
Pilot pressure
4
The size of the TC is designed to produce a charge
effect even at medium engine speeds and lower
exhaust gas flows. This means that, when the engine speed is high and there is a large amount
of exhaust gas, either the boost pressure of the
TC will become too high or its speed will be too
high. The TC must therefore be regulated. The
best regulation is achieved by an electronically
controlled wastegate control valve. The wastegate
control valve controls the pressure on the
membrane in the boost pressure regulator.
The wastegate control valve is actuated by the
PCM with a PWM signal according to a map. The
boost pressure is applied to the wastegate control
valve via the pressure line from the compressor.
This pressure is passed to the boost pressure
regulator via the wastegate control valve. This
opens the bypass valve using a linkage. This
channels a portion of the exhaust gases around
the turbine. If the wastegate control valve is
actuated by the PCM, a bypass is opened in the
wastegate control valve. This causes the pressure
which can act on the membrane in the boost
pressure regulator to be reduced. This occurs until
the boost pressure has reached a set value. By
actuation with a PWM signal, it is also possible to
partially open or close the wastegate control valve.
This results in a constant boost pressure and
therefore high torque over a wide range of engine
speeds.
Because the PCM calculates the boost pressure
using the signal from the boost pressure sensor
and the IAT (intake air temperature) sensor, the
atmospheric pressure and the temperature are
automatically compensated for. Because of this
compensation, the engine power is not noticeably
affected by variations in atmospheric temperature
or pressure.
G1032426en2008.50 Kuga8/2011
303-04B-
6
Fuel Charging and Controls - Turbocharger
—
2.5L Duratec (147kW/200PS) - VI5
303-04B- 6
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E105848
1
2
3
Description
Item
Throttle body mechanism
Comments:Incorporates the TP (throttle position)
sensor
1
PCM (powertrain control module) cover
2
The MAPT (manifold absolute pressure
and temperature) sensor
3
G1079094en2008.50 Kuga8/2011
303-12-
3
Intake Air Distribution and Filtering
— 2.5L Duratec
(147kW/200PS) - VI5
303-12- 3
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SECTION 303-14 Electronic Engine Controls— 2.5L Duratec
(147kW/200PS) - VI5
VEHICLE APPLICATION: 2008.50 Kuga
PA G E
CONTENTS
DESCRIPTION AND OPERATION
303-14-3
Electronic Engine Controls (Component Location) .............................................................
303-14-7
Electronic Engine Controls (Overview) ........................................................................\
.......
303-14-7
General overview ........................................................................\
........................................
303-14-8
Powertrain Control Module (PCM) ........................................................................\
..............
303-14-8
Knock Sensor ........................................................................\
.............................................
303-14-8
Camshaft Position (CMP) Sensor ........................................................................\
...............
303-14-9
Crankshaft Position (CKP) sensor ........................................................................\
..............
303-14-9
Camshaft adjuster solenoid valve........................................................................\
...............
303-14-9
Manifold absolute pressure and temperature sensor .........................................................
303-14-9
Accelerator pedal position (APP) sensor ........................................................................\
....
303-14-10
Throttle control unit ........................................................................\
.....................................
303-14-10
Engine Coolant Temperature (ECT) sensor.......................................................................
303-14-10
Ignition coil-on-plug ........................................................................\
....................................
303-14-12
Electronic Engine Controls (System Operation and Component Description) ...................
303-14-12
System Diagram ........................................................................\
.........................................
303-14-16
System Operation ........................................................................\
.......................................
303-14-18
Speed and TDC recording ........................................................................\
......................
303-14-19
Calculation of the ignition angle ........................................................................\
..............
303-14-20
Engine fueling ........................................................................\
.........................................
303-14-22
Engine speed control ........................................................................\
..............................
303-14-22
Oil monitoring ........................................................................\
..........................................
303-14-23
Calculation of valve timing adjustment angle..................................................................
303-14-23
Boost pressure control ........................................................................\
............................
303-14-24
Starting process ........................................................................\
......................................
303-14-24
Alternator control (Smart Charge) ........................................................................\
...........
303-14-24
Component Description ........................................................................\
..............................
303-14-24

CKP sensor ........................................................................\
.............................................
303-14-25

Broadband HO2S ........................................................................\
...................................
303-14-26

VCT (variable camshaft timing) solenoids ......................................................................
303-14-27

MAF sensor ........................................................................\
.............................................
303-14-28

APP sensor ........................................................................\
.............................................
303-14-29

CPP sensor ........................................................................\
.............................................
303-14-29

BPP switches ........................................................................\
..........................................
303-14-30

Air conditioning (A/C) pressure sensor ........................................................................\
...
303-14-30

Throttle
control unit ........................................................................\
.................................
303-14-31

ECT sensor ........................................................................\
.............................................
303-14-31

Cooling fan module ........................................................................\
.................................
303-14-32

injectors........................................................................\
...................................................
303-14-32

Ignition coil-on-plug ........................................................................\
.................................
303-14-33

Fuel pressure/fuel temperature sensor ........................................................................\
...
303-14-33

Wastegate control valve ........................................................................\
..........................
303-14-34

Engine oil level, temperature and quality sensor ............................................................
303-14-1
Electronic Engine Controls— 2.5L Duratec (147kW/200PS) - VI5303-14-
1
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303-14-34
Exterior aor temperature sensor ........................................................................\
.............
DIAGNOSIS AND TESTING 303-14-35
Electronic Engine Controls ........................................................................\
.........................
303-14-35
Inspection and Verification ........................................................................\
..........................
REMOVAL AND INSTALLATION 303-14-36
(29 232 0)
Camshaft Position (CMP) Sensor ...................................................................
303-14-37
(29 219 0)
Catalyst Monitor Sensor ........................................................................\
.........
303-14-38
(29 230 0)
Crankshaft Position (CKP) Sensor .................................................................
303-14-40
(29 220 0)
Heated Oxygen Sensor (HO2S) .....................................................................
303-14-41
(29 222 0)
Knock Sensor (KS) ........................................................................\
.................
303-14-42
(29 226 0)
Mass Air Flow (MAF) Sensor ........................................................................\
..
303-14-43
(29 200 0)
Powertrain Control Module (PCM) .................................................................
303-14-45
(29 233 0)
Variable Valve Timing (VVT) Oil Control Solenoid ..........................................
303-14-46
(33 502 0)
Brake Pedal Position (BPP) Switch ................................................................
303-14-47
(33 503 0)
Clutch Pedal Position (CPP) Switch ...............................................................
303-14-2
Electronic Engine Controls— 2.5L Duratec (147kW/200PS) - VI5303-14-
2
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Electronic Engine Controls – Component Location
E96941
1
12
2
3
4
5
6
7
8
9
10
11
Description
Item
Throttle control unit
1
injectors
Comments:One injector for each cylinder
2
Fuel pressure/fuel temperature sensor
3Description
Item
VVT (variable valve timing) - exhaust
camshaft solenoid
Comments:One each for the inlet and outlet
camshaft
4
Ignition coil-on-plug
Comments:One injection coil for each cylinder
5
G1021906en2008.50 Kuga8/2011
303-14-
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Electronic Engine Controls— 2.5L Duratec (147kW/200PS) - VI5303-14-
3
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Description
Item
CMP (camshaft position) sensor
Comments:One each for the inlet and outlet
camshaft
6
EVAP (evaporative emission) valve
7
CKP (crankshaft position) sensor
8Description
Item
MAF (mass air flow) sensor
9
PCM (powertrain control module)
10
Fan control module
11
MAPT (manifold absolute pressure and
temperature) sensor
12
E96950
1
23
4
56
G1021906en2008.50 Kuga8/2011
303-14-
4
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4
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Description
Item
Catalyst monitor sensor
1
Fuel pressure/fuel temperature sensor
2
Throttle control unit
3
Ambient air temperature sensor
4Description
Item
MAPT sensor
5
KS (knock sensor)
Comments:Two, on 2nd and 4th cylinder
6
E96980
1
234
Description
Item
EVAP valve
1
Wastegate control valve
2Description
Item
Turbo boost pressure controller
3
HO2S (heated oxygen sensor)
4
G1021906en2008.50 Kuga8/2011
303-14- 5
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5
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Electronic Engine Controls – Overview
General overview
Engine Management System
• Bosch ME 9.0 engine management system
• Knock control with two knock sensors
• Electronic Throttle Control Unit.
• Electronic accelerator pedal
• Variable camshaft timing for intake and exhaustcamshafts • Fuel injection supply manifold with combined
fuel pressure and temperature sensor
• Sequential multi-port fuel injection
• Camshaft position (CMP) sensors for intake and exhaust camshafts.
• satisfies the European exhaust emissions standard IV
• EOBD (European On-board Diagnostic) for the monitoring of emissions-related components.
Engine power output and engine speed
2
E62614
1
Description
Item
Torque
1
Power output
2
The engine is controlled by the PCM.
The PCM uses various sensors to calculate the
optimum ignition timing, the optimum injection
quantity and injection time and the position of the
throttle. In addition, various corrections are carried
out, including adjustment of the ignition timing using
the KS and adjustment of the fuel quantity by the Lambda control. Boost pressure control and fuel
pressure control are also performed by the PCM.
For all work on the engine electronics, it is
essential to ensure that the connectorsare
seated and locked properly.
G1021907en2008.50 Kuga8/2011
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Crankshaft Position (CKP) sensor
E89994
The CKP sensor can be checked during starting
by measuring the resistance and/or voltage with
the oscilloscope.
The engine cannot work without the CKP signal.
A limp-home mode is therefore not possible. The
engine is switched off or the engine will not start
and a fault is stored in the error memory of the
PCM.
Camshaft adjuster solenoid valve
E96870
For work on the camshaft adjuster solenoids,
extreme cleanliness must be ensured as even
slight impurities can result in failure. The camshaft
adjustment solenoids for the intake and exhaust
camshafts differ only in terms of the position of the
fastening point by which they are fixed to the
cylinder head cover.
If a fault is detected in the camshaft adjustment
solenoids, the solenoids are no longer actuated.
Manifold absolute pressure and
temperature sensor
E96146
During installation of the MAPT sensor, correct
sealing must be ensured to ensure that no
infiltrated air can penetrate into the intake manifold
from outside.
If the MAP (manifold absolute pressure) sensor
fails, the PCM operates with a substitute value.
Accelerator pedal position (APP)
sensor
E74146
The APP (accelerator pedal position) sensor
comprises two separate sensors.
G1021907en2008.50 Kuga8/2011
303-14-9
Electronic Engine Controls— 2.5L Duratec (147kW/200PS) - VI5303-14-
9
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