clutch FORD KUGA 2011 1.G Owner's Guide

Powertrain Control Module (PCM)
E65160
The PCM communicates with all engine sensors
and the other modules. Communication of the PCM
with the other modules and the system diagnostics
takes place via the CAN (controller area network)
data bus.
The following functions are regulated or controlled
by the PCM:
• Fuel supply to the engine including lambdacontrol
• Ignition setting including knock control
• Idle speed control
• Control of optimum valve timing via the camshaft adjustment for intake and exhaust camshafts
• The refrigerant compressor is controlled by the air conditioning clutch relay and the delivery of
the refrigerant compressor is controlled by a
PWM (pulse width modulation) signal.
• Control of EVAP purge valve
• Boost pressure control
• Control of the cooling fan
• Charging system (Smart Charge)
• Starting system (Smart Start)
If the PCM is isolated from the vehicle electrical
system or the battery is disconnected, the throttle
control unit mustbe initialized.
The PCM is fitted in the engine compartment in the
air filter housing. On right hand drive vehicles a
protective metal plate is also installed to prevent
the plug connector from being pulled off, or make
it harder to pull off, in case of theft. The protective
plate is secured with a shear bolt. The shear bolt
needs to be drilled out in order to remove the
protective plate.
Knock Sensor
E96986
Two KSs are fitted. They are on the cylinder block,
one close to the 2nd cylinder and one close to the
4th cylinder.
When fitting, adhere strictly to the specified
tightening torque, otherwise the KS will not work
properly.
If the signal from one or both KS is implausible or
absent, knock control is deactivated. The PCM
switches to an ignition map that is further away
from the knock limit. As a result, engine damage
caused by combustion knock is avoided. If a fault
occurs, a fault code is stored in the error memory
of the PCM.
Camshaft Position (CMP) Sensor
E89993
If one or both CMP sensors fail, a fault is saved in
the error memory of the PCM and the camshaft
adjustment and knock control are deactivated.
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Description
Item
Medium speed CAN data bus (MS-CAN)
1
DLC (data link connector)
2
GEM (generic electronic module)
Comments:Serves as a gateway between the two
CAN databus systems.
3
High speed CAN data bus (HS-CAN)
4
CPP (clutch pedal position) sensorRefertoComponentDescription:(page
29)
5
BPP switchesRefertoComponentDescription:(page
29)
6
MAF sensorRefertoComponentDescription:(page
27)
7
TP sensorRefer to Component Description: Throttle
controlunit(page33)
Comments: It is incorporated into the throttle control
unit
8
ECT sensorRefertoComponentDescription:(page
31)
9
CKP sensorRefertoComponentDescription:(page
24)
10
CMP sensor - intake camshaftRefertoComponentDescription:(page
8)
11
CMP sensor - exhaust camshaftRefertoComponentDescription:(page
8)
12Description
Item
Broadband HO2SRefertoComponentDescription:(page
25)
13
Catalyst monitor sensor
14
Air conditioning (A/C) pressure sensorRefertoComponentDescription:(page
30)
15
KSRefertoComponentDescription:(page
8)
16
APP sensorRefertoComponentDescription:(page
28)
17
MAPT sensorRefertoComponentDescription:(page
9)
18
Fuel pressure/fuel temperature sensorRefertoComponentDescription:(page
33)
19
Exterior aor temperature sensorRefertoComponentDescription:(page
34)
20
Engine oil level, temperature and quality
sensorRefertoComponentDescription:(page
34)
21
Ignition switch
22
Battery
23
PCMRefertoComponentDescription:(page
8)
24
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Description
Item
Medium speed CAN data bus (MS-CAN)
1
DLC
2
GEM
Comments:Serves as a gateway between the two
CAN databus systems.
3
High speed CAN data bus (HS-CAN)
4
PCMRefertoComponentDescription:(page
8)
5
LIN (local interconnect network) databus
6
Alternator
7
Heating element - broadband HO2S
8
Catalyst monitor sensor heating element
9
Powertrain Control Module relay
10
Starter Relay
11
FPDM
Comments:Refer to: Fuel Tank and Lines - 2.5L
Duratec (147kW/200PS) - VI5 (310-01
Fuel Tank and Lines, Description and
Operation).
12
Fuel pump
13
injectorsRefertoComponentDescription:(page
?)
Comments: 5x
14Description
Item
Air conditioning clutch relay
Comments:Refer to: Climate Control (412-01
Climate Control, Description and
Operation).
15
EVAP valve
Comments:
16
VCT oil control solenoid, exhaust camshaftRefer to Component Description:
solenoids(page26)
17
VCT oil control solenoid, intake camshaftRefer to Component Description:
solenoids(page26)
18
Cooling fan module
Comments:Refer to: Engine Cooling - 2.5L Duratec
(147kW/200PS) - VI5 (303-03 Engine
Cooling, Description and Operation).
19
Wastegate control valve
Comments:Refer to: Turbocharger (303-04 Fuel
Charging and Controls - Turbocharger
- 2.5L Duratec (147kW/200PS) - VI5,
Description and Operation).
20
Ignition coil-on-plugRefertoComponentDescription:(page
10)
Comments: 5x
21
Throttle control unitRefertoComponentDescription:(page
30)
Comments: Actuator motor unit
22
System Operation
The engine is controlled by the PCM. For this
purpose, the PCM uses information from the
sensors, sender units and switches. In addition,
the PCM receives information from other control
modules via the CAN data bus. All the information
is processed in the PCM and is used to control or
regulate the different actuators.
These are:
• the throttle control unit,
• the fuel injectors, • the camshaft adjustment,
• the boost control solenoid valve
• and the ignition coils.
Some values are sent via the CAN databus to other
systems.
The following functions are regulated or controlled
by the PCM:
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• Starting process
• Engine running– Fuel supply to the engine including lambdacontrol
– Ignition setting including knock control
– Idle speed control
– Boost pressure control
– Valve timing via the camshaft adjuster for the intake and exhaust camshafts (including
internal exhaust gas recirculation)
• Refrigerant compressor (activation, deactivation and delivery)
• EVAP purge valve
• Charging system
Fuel is supplied to the engine via a sequential
multi-point injection system. Ignition is performed
by a distributor-less ignition system with one
ignition coil unit for each cylinder.
The PCM optimizes engine power and emissions
at all times by processing the sensor signals and
information received via the CAN databus and
using these for open or closed loop control of the
different variables.
The PCM contains part of the PATS (passive
anti-theft system).
The PCM is supplied with battery voltage via a fuse
in the BJB (battery junction box). This power supply
is needed to ensure that saved data is not lost
when the engine is switched off.
For other power supply requirements, the PCM
switches on a relay in the BJB which is responsible
for supplying power to the PCM and to some
sensors and actuators. Each of these are protected
by fuses in the BJB.
To guarantee optimum engine running at all times,
the PCM has several adaptive (self-learning)
functions. These adapt the output signals to
changing circumstances, such as wear or system
faults.
In some cases a faulty signal is replaced with a
substitute value or limited. A substitute value can
be calculated from other signals or it can be
predefined by the PCM. The substitute value allows
the vehicle to keep on running without the emission
values changing unduly. Depending on the signal
failure, the PCM operates in emergency mode. In
this mode, the engine power and/or the engine
speed is reduced to prevent further damage.
Depending on the faulty signal, a fault code is
stored in the error memory of the PCM. These can be read out using IDS (Integrated Diagnostic
System) via the DLC.
The PCM processes and evaluates the signals
from the sensors. The following sensors send
signals to the PCM:
• CMP sensors
• CKP sensor
• MAF sensor
•KS
• ECT sensor
• TP sensor
• APP sensor
• Broadband HO2S
• Catalyst monitor sensor
• MAPT sensor
• Air conditioning (A/C) pressure sensor
• Alternator
• Fuel temperature and fuel pressure sensor
• Engine oil level, temperature and quality sensor
• Outside air temperature sensor
The following components receive signals from the
PCM:
• Powertrain Control Module relay
• A/C clutch relay
• injectors
• Direct ignition coils
• Cooling fan module
• Throttle control unit
• Camshaft adjuster solenoid valve
• Starter Relay
• EVAP purge valve
• Alternator
• Heating element - broadband HO2S
• Catalyst monitor sensor heating element
• FPDM
• Wastegate control valve
• Air conditioning compressor
The PCM receives the following signals via the
CAN databus:
• APP
•CPP
• BPP
• Vehicle speed.
• Refrigerant compressor request
• PAT S
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Description
Item
Amperes
A
Volts
V
Valve rotor
1
Electronics
2
Primary coil
3
Secondary coil
4Description
Item
Analog alternating current
5
Generated PWM signal.
6
PCM
Comments:PWM signal is converted in the GEM
and forwarded via the CAN data bus.
7
The APP sensor is a double contactless inductive
sensor. The APP sensor is integrated with the
accelerator pedal in the accelerator pedal module.
The inductive sensor essentially works in a similar
way to a transformer. The incoming DC voltage
first has to be converted into AC voltage.
Depressing the accelerator pedal moves a rotor.
This induces the AC voltage from the primary coil
into the secondary coil. The strength of the
induction depends on the position of the rotor:
• no accelerator-pedal actuation: low induction, i.e. low amplitude of the AC voltage,
• full accelerator-pedal actuation: high induction, i.e., high amplitude of the AC voltage.
To allow the PCM to process the AC voltage signal
output by the secondary coil, the signal must first
be converted into a PWM signal in the sensor
electronics.
In the APP sensor the signals are split as follows:
– APP 1 = PWM signal to the GEM and from there via the CAN data bus to the PCM.
– APP 2 = the analogue DC (direct current) signal is sent directly to the PCM.
Both signals are monitored by the PCM for
plausibility.
CPP sensor
E70695
The sensor works on the Hall-effect principle and
records the position of the piston in the master
cylinder without contact. The permanent magnet
required for recording the position is located in the
piston of the clutch master cylinder.
The signal from the CPP sensor is recorded by the
GEM and transmitted to the CAN via the PCM bus.
BPP switches
E94800
The BPP switch is designed as normally-closed
contact. In its rest state the switch is closed and
sends an earth signal to the GEM.
The brake light switch is designed as
normally-open contact and is open in its rest state.
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Clutch Pedal Position (CPP) Switch(33 503 0)
Removal
1. CAUTION: Make sure that the clutchpedal remains in the rest position.
2
451
E101866
Installation
1.CAUTION: Make sure that the clutch
pedal remains in the rest position.
To install, reverse the removal procedure.
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SECTION 307-01 Automatic Transmission/Transaxle
— Vehicles With: 5-Speed Automatic Transaxle - AW55 AWD
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
SPECIFICATIONS
307-01-4
Specifications ........................................................................\
..............................................
DESCRIPTION AND OPERATION 307-01-5
Transmission Description (Component Location) ...............................................................
307-01-6
Transmission Description (Overview) ........................................................................\
.........
307-01-6
Components of the AW55 automatic transaxle ..................................................................
307-01-6
General overview ........................................................................\
....................................
307-01-8
Transaxle cooling ........................................................................\
....................................
307-01-8
External shift mechanism ........................................................................\
........................
307-01-9
Components of the electronic control ........................................................................\
.....
307-01-11
Overview of the brakes, clutches and one-way clutches ................................................
307-01-12
Input and output signals at the TCM ........................................................................\
.......
307-01-14
Knowing and Understanding Customer Concerns ..........................................................
307-01-14
Testing Possible Causes of Transmission Control Faults ...............................................
307-01-14
IDS Diagnosis ........................................................................\
.........................................
307-01-14
visual inspection ........................................................................\
.....................................
307-01-15
Towing the vehicle ........................................................................\
..................................
307-01-15
Push-starting the Vehicle ........................................................................\
........................
307-01-15
Jump-starting the Vehicle ........................................................................\
.......................
307-01-15
Selector Lever Emergency Release ........................................................................\
.......
307-01-16
Adjusting the Selector Lever Cable ........................................................................\
........
307-01-17
Transmission Fluid Level Check ........................................................................\
.............
307-01-17
Changing the Transmission Fluid ........................................................................\
...........
307-01-18
Diagnosis with IDS ........................................................................\
..................................
307-01-19
Resetting the counter for fluid change intervals. .............................................................
307-01-19
Programming the 'N' position of the TR sensor..............................................................
307-01-19
Resetting the values learned by the TCM .......................................................................
307-01-21
Transmission Description (System Operation and Component Description) .....................
307-01-21
System Operation ........................................................................\
.......................................
307-01-22
Functionality overview ........................................................................\
............................
307-01-24
Electronic Control System ........................................................................\
......................
307-01-24
Hydraulic Control System ........................................................................\
.......................
307-01-24
Type plate ........................................................................\
...............................................
307-01-25
Serial number of the transmission ........................................................................\
..........
307-01-25
Markings on the TCM ........................................................................\
.............................
307-01-25
Serial

number of the TCM ........................................................................\
.......................
307-01-25
Transmission Control ........................................................................\
..............................
307-01-27
Pin assignment for TCM connector 'C' (connection to transaxle) ...................................
307-01-28
Operation ........................................................................\
................................................
307-01-29
Gearshift control ........................................................................\
......................................
307-01-29
Adaptation ........................................................................\
...............................................
307-01-29
Shifting from 'P' to another transmission range ..............................................................
307-01-1
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 1
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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

E125525
Design:
• The gear ratios are achieved by means of acombined planetary gear set on the input side
and a Simpson set on the output side.
– The combined planetary gear set consists oftwo different, simple planetary gear sets. It
has a similar structure to a Ravigneaux set,
but with just one sun gear that engages with
the front planetary gears.
• Three multi-plate clutches
• Four multi-plate brakes • One band brake
• Two one-way clutches
The TCM adapts the gear changing to ensure that
the correct gear is selected for the style of driving,
the engine load, driver requirements, vehicle speed
etc.
The TCM features a self-learning strategy.
This leads to lower fuel consumption together with
improved comfort through smoother gear changes
and lower noise levels.
Gear ratios of the individual gears
Transmission Ratio
Gear
4.576
First
2.980
Second
1.948
Third
1.318
Fourth
1.000
5th
5.024
Reverse
1.018
Intermediate shaft
2.652
Differential
G1163604en2008.50 Kuga8/2011
307-01- 7
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 7
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E112323
1
2
7
6
4
5
3
10
9
11
12
Description
Item
The TSS sensor
1
The OSS sensor
2
PWM (pulse width modulation)- solenoid
valve – TCC (torque converter clutch)
(SLU)
3
PWM solenoid valve – shift pressure (SLS)
4
Shift solenoid S1
5
Shift solenoid S4
6Description
Item
Shift solenoid S3
7
Shift solenoid S5
8
Shift solenoid S2
9
The TFT (transmission fluid temperature)
sensor
10
PWM solenoid valve for main line pressure
(SLT)
11
TCM with integrated TR sensor
12
Depending on the input signals, the TCM mounted
on the transaxle actuates the solenoid valves
S1-S5 in the valve body. The solenoid valves are
either in the "open" or "closed" state.
The (SLT and SLS) control valves regulate the
hydraulic pressure according to the pulse/pause
ratio of the electrical PWM signal. The controlled
hydraulic pressure enables smooth shifting or the
generation of a defined slip through actuation of
the relevant clutches and brakes. The shift timing is calculated by the TCM using the
accelerator pedal position and vehicle speed.
Under normal conditions, gear shifting and torque
converter lockup occur at low engine speeds to
reduce fuel consumption.
If the accelerator pedal is pressed down quickly,
the TCM switches automatically into kickdown
mode.
G1163604en2008.50 Kuga8/2011
307-01-
10
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 10
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