fluid FORD KUGA 2011 1.G Owner's Guide

SECTION 419-10 Multifunction Electronic Modules
VEHICLE APPLICATION:
2008.50 Kuga
PAGE
CONTENTS
DESCRIPTION AND OPERATION
419-10-2
Module Controlled Functions (Overview)...........................................................................
419-10-2
Generic electronics module (GEM)....................................................................................
419-10-2
Emergency function............................................................................................................
419-10-2
Service mode......................................................................................................................
419-10-4
Module Controlled Functions (System Operation and Component Description)................
419-10-4
System Diagram.................................................................................................................
419-10-6
System Operation...............................................................................................................
419-10-6
GEM. ...............................................................................................................................
419-10-6
Component Description......................................................................................................
419-10-6
Battery charging (Smart Charge)....................................................................................
419-10-7
Ignition overload protection.............................................................................................
419-10-7
Headlamp switch-off delay..............................................................................................
419-10-8
Turn signals....................................................................................................................
419-10-8
Interior lighting................................................................................................................
419-10-8
Heated windscreen.........................................................................................................
419-10-9
Heated rear window and heated external mirrors...........................................................
419-10-9
Ambient air temperature.................................................................................................
419-10-9
Brake fluid level...............................................................................................................
419-10-9
Automatic headlamps.....................................................................................................
419-10-9
Combined rain sensor/light sensor.................................................................................419-10-10Windshield wash/wipe system........................................................................................
419-10-10Anti-theft ..........................................................................................................................
419-10-10Electric booster Heater...................................................................................................
419-10-10Climate control................................................................................................................
DIAGNOSIS AND TESTING 419-10-11
Generic Electronic Module (GEM)......................................................................................
419-10-11
Description of operation......................................................................................................
419-10-12
Inspection and Checking....................................................................................................
REMOVAL AND INSTALLATION 419-10-14
Generic Electronic Module (GEM)......................................................................................
419-10-15
Lighting Control Module (LCM)........................................................................................... 419-10-1
Multifunction Electronic Modules
419-10-1
.
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Module Controlled Functions – Overview
Generic electronics module (GEM)
CAUTIONS:
Never swap the GEM (generic electronic
module) between two vehicles.
Compare the number of relays and fuses
in the defective GEM and the new GEM.
Transfer from the defective GEM any relays
and fuses which are not in the new GEM.
In doing so, pay attention that fuses with
the correct Ampere rating are used, by
referring to the wiring diagrams.
NOTE: The GEM is integrated in the CJB (central
junction box) and cannot be replaced as a separate
unit.
For repair work during a service, vehicle-specific
configuration is necessary if a new GEM is
installed.
Emergency function
The GEM is equipped with restricted emergency
running functions on vehicles with mid or high-end
equipment levels.
The microcontroller sends a control signal to a
monitoring function within the GEM at regular
intervals. If the battery voltage falls below a value
of approx. 7.5 volts, this check signal is not present
and the GEM switches to emergency function after
a predetermined time.
In this case, the low beam is permanently switched
on, regardless of the light switch position. The
windshield wiper can only be operated in stage 1;
the wiper switch must however be in the stage I or
II position. The wiper park position is not
recognized. Intermittent wiping is not available.
When the control signal recurs, the GEM switches
back to normal operation.
Service mode
Description of operation
Diagnosis of the GEM can be carried out using the
Ford diagnostic unit. Furthermore, an integrated
service mode enables testing of the input and
output signals without the need for further tools.
To enable activation of service mode: • switch off the ignition,
• switch off all other electrical consumers,
• apply the handbrake,
• Shift to neutral
• and close the doors.
Activating the service mode
NOTE:
If the alarm is activated (in vehicles fitted
with an anti-theft alarm system), service mode
cannot be activated.
Proceed as follows to activate the service mode:
• OPERATE the switch of the heated rear window
and HOLD IT THERE
• SWITCH ON the ignition.
• RELEASE the switch of the heated rear window
A signal sounds and the turn signal lamps come
on to indicate that service mode has been
successfully activated.
Inputs
SWITCH the windshield wiper switch to the "OFF"
position to test the input signals. The following is
a list of the switch signals to be tested, in no
particular order:
• Windshield wiper stage I
• Windshield wiper stage II
• Windshield washer system
• Rear window wiper
• Rear window washer system
• Doors open/closed
• Remote control for central locking with double locking
• Hood open/closed (in vehicles equipped with an anti-theft alarm system)
• Tailgate open/closed
• A/C request signal
• Heated windscreen (if fitted)
• Parking brake
• Brake fluid level
• Cruise control system
• Autolamps
• Dipped beam
• Main beam
• Headlamp flasher
• Side lights
• Turn signals (right, left, hazard warning lights) G1030787en
2008.50 Kuga 8/2011 419-10-2
Multifunction Electronic Modules
419-10-2
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Description
Item
HS CAN
1
DLC2
MS CAN
3
Instrument cluster (gateway)
4
Front windshield wiper motors
5
GEM6
Rear window wiper motors
7
Indicator/heated windshield
8
Indicator/heated rear window
9 Description
Item
Mini-liftgate latch motor
10
Liftgate latch motor
11
Electric booster Heater
12
Front wiper windscreen washer pump
13
Rear wiper windscreen washer pump
14
Headlamp
15
Courtesy Lighting
16
Alarm horn
17
System Operation
GEM.
The following functions are controlled or performed
by the GEM at a battery voltage of between 9 and
16 volts:
• Current distribution
• Battery charging (Smart Charge)
• Ignition overload protection
• Headlamp switch-off delay
• Turn signals
• Interior lighting
• Heated windscreen
• Heated rear window and heated external mirrors
• Ambient air temperature
• Brake fluid level
• Automatic headlamps
• Combined rain sensor/light sensor
• Windshield wash/wipe system
• Speed control – reads the speed control switches andtransmits signals on the CAN data bus
• central door locking – transmits signals on the CAN data bus
• Anti-theft
• Electric booster Heater
• Climate control
• Parking brake –(monitors the switch and transmits the signal
on the CAN data bus
• Communication via the medium-speed CAN data bus Component Description
Battery charging (Smart Charge)
In addition to the familiar functions, the Smart
Charge system also performs the following
functions:
•
Automatic deactivation of non-critical high power
electrical consumers when the battery voltage
is low in order to reduce the level of current
drawn.
• Automatic activation of non-critical high power electrical consumers when the battery voltage
is excessively high in order to protect
components which are sensitive to increased
voltages.
The battery charging current is optimized through
continuous calculation of the battery temperature
and monitoring of the alternator output voltage.
The alternator load is signaled to the PCM
(powertrain control module) in order to provide it
with an early indication when an electric component
is to be switched on or off, thereby also providing
information about imminent changes to the amount
of torque demanded by the alternator. By
evaluating this information the PCM is capable of
increasing the stability of the engine under idling.
The two remaining functions of the Smart Charge
system are controlled by the GEM. G1030788en
2008.50 Kuga 8/2011 419-10-6
Multifunction Electronic Modules
419-10-6
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
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Generic Electronic Module (GEM)
Refer to Wiring Diagrams Section 419-10, for
schematic and connector information.
Special Tool(s) / General Equipment
Terminal Probe Kit
418-S035Digital multimeter
Ford approved diagnostic tool
Description of operation
A diagnosis of the generic electronic module (GEM)
can be performed with the Ford approved
diagnostic tool. Furthermore, an integrated service
mode enables testing of the input and output
signals without the need for further tools. To enable
activation of service mode:
• Switch off the ignition
• Switch off all other electrical consumers
• Apply the handbrake
• Shift to neutral
• Close the doors.
Activate service mode
Proceed as follows to activate service mode:
• PRESS and HOLD the switch of the heated rear
window
• SWITCH ON the ignition.
• RELEASE the switch of the heated rear window
A signal sounds and the turn signal lamps
illuminate to indicate that service mode has been
successfully activated.
NOTE: If the alarm is armed (in vehicles fitted with
an anti-theft alarm system), service mode cannot
be activated.
Input signals
SWITCH the windshield wiper switch to the "Off"
position to test the input signals. The following is
a list of the switch signals to be tested, in no
particular order: • Turn signals (right, left, hazard warning lights)
• Windshield wiper stage I
• Windshield wiper stage II
• Windshield washer system
• Rear window wiper
• Rear window washer system
• Doors open/closed
• Door key cylinder set/reset switch
• Remote control for central locking with double
locking
• Hood up/down (in vehicles fitted with anti-theft alarm system)
• Tailgate open/closed
• Mini liftgate open/closed
• Manual A/C request signal
• Manual AUX heater request signal
• Heated windshield (if fitted)
• Parking brake
• Brake fluid level
• Cruise control system
• Autolamps
• Dipped beam
• Main beam
• Headlamp flasher
• Side lights
• Reversing lamp
• Tailgate release
• Mini liftgate release
• Interior scanning system
• Ignition switch, terminal 15 (turn key to 0 position, then turn key to II position.)
An acoustic signal sounds and the turn signal
lamps flash to indicate receipt of each input signal
by the generic electronic module.
Test the windshield wiper "intermittent mode" stage
input signal (only vehicles with adjustable
intermittent mode)
The windshield wiper switch must be switched to
"intermittent mode" in order to test the input signal.
The delay times of the input signals can then be
tested by operating the rotary switch. Each change
of the rotary switch position is indicated by an
acoustic signal and illumination of the turn signals. G1055084en
2008.50 Kuga 8/2011 419-10-11
Multifunction Electronic Modules
419-10-11
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL29011A

SECTION 205-02 Rear Drive Axle/Differential
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
DESCRIPTION AND OPERATION
205-02-2
Rear Drive Axle and Differential (Component Location) .....................................................
205-02-6
Rear Drive Axle and Differential (System Operation and Component Description) ...........
205-02-6
System Operation ........................................................................\
.......................................
205-02-6
General Information ........................................................................\
................................
205-02-6
Driving situations ........................................................................\
....................................
205-02-6
Haldex clutch ........................................................................\
..........................................
205-02-7
General overview ........................................................................\
....................................
205-02-7
Operation ........................................................................\
................................................
205-02-7
Design of the 3rd generation Haldex clutch ....................................................................
205-02-9
Design of the multi-plate clutch ........................................................................\
...............
205-02-10
All-wheel drive control unit ........................................................................\
......................
205-02-10
Electric feed pump ........................................................................\
..................................
205-02-10
Pressure control - 3rd generation Haldex clutch .............................................................
205-02-11
Base pressure ........................................................................\
.........................................
205-02-12
Increased base pressure (preload) ........................................................................\
.........
205-02-13
Pressure build-up ........................................................................\
....................................
205-02-14
Design of the 4th generation Haldex clutch ...................................................................
205-02-14
General overview ........................................................................\
....................................
205-02-15
Pressure control - 4th generation Haldex clutch .............................................................
GENERAL PROCEDURES 205-02-17
Differential Fluid Level Check ........................................................................\
.....................
205-02-19
Active On-Demand Coupling Fluid Level Check ................................................................
REMOVAL AND INSTALLATION 205-02-21
Differential Case ........................................................................\
.........................................
205-02-25
Active On-Demand Coupling Module ........................................................................\
.........
205-02-32
Differential Input Shaft Seal ........................................................................\
........................
205-02-38
Differential Support Insulator ........................................................................\
......................
205-02-39
Rear Halfshaft Seal ........................................................................\
.....................................
205-02-41
Drive Pinion Seal ........................................................................\
........................................
DISASSEMBLY AND ASSEMBLY
205-02-42
Active On-Demand Coupling — Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450 ...............................................................
205-02-1
Rear Drive Axle/Differential
205-02- 1
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General overview
Haldex clutches of the 3rd and 4th generations are
used in the Ford Kuga.
The development of the third generation Haldex
clutch represents a big step forward in modern
all-wheel technology. The Haldex clutch is
electro-hydraulically controlled. Additional
information is taken into consideration during
control tasks via the all-wheel drive control unit.
Slip alone is no longer decisive for the distribution
of the propulsive forces; the vehicle's driving
dynamics are also taken into consideration. The
control unit accesses the driving-related data via
the data bus. With this data, the control unit has
all the essential information about speed, cornering,
coasting or traction operation, and can optimally
react to every driving situation.
Compared with the previous generation, the 4th
generation Haldex clutches operate with higher
pressure and achieve shorter response times when
distributing the drive forces.
Advantages of the Haldex clutch:
• Permanent all-wheel drive withelectronically-controlled multi-plate clutch
• Fast response
• No straining when parking and manoeuvring
• Compatible with different tyres (e.g. emergency spare wheel)
• Fully combinable with driving dynamic control systems
The driveshaft is connected to the input shaft of
the Haldex clutch. Within the Haldex clutch, the
input shaft is separated from the output shaft to
the rear axle differential by means of a multi-plate
clutch. Torque is only transmitted to the rear axle
differential when the plate assembly of the Haldex
clutch is closed.
The multi-plate clutch is electro-hydraulically
controlled via the all-wheel drive control unit. For
ecological driving, the torque to the rear axle is reduced to a minimum up to a throttle position of
approx. 50%. A prerequisite for this is that there is
no difference in speed in the Haldex clutch between
the input and output shafts.
Operation
E100645
16
3
25
4
Description
Item
Output shaft
1
Working piston
2
Plates
3
Ring piston pump
4
Control Valve
5
Input shaft
6
Within the Haldex clutch is a plate assembly and
a so-called ring piston pump with a pump plunger
and a working piston.
Fluid supply is started if there is a speed difference
between the input and output shafts.
This fluid pressure is transmitted to the working
piston and in this way the plate assembly is
compressed.
Design of the 3rd generation Haldex
clutch
G1076981en2008.50 Kuga8/2011
205-02- 7
Rear Drive Axle/Differential
205-02- 7
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E100664
1
3
4
11
11
10
9
8
76
5
2
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
7
4
3
2
8
1
6
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
DESCRIPTION AND OPERATION
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All-wheel drive control unit
E100663
14
3
2
5
Description
Item
Electronic Control Unit
1
Control valve
2
Pressure/temperature sensor
3
Electrical connection CAN (controller area
network) databus
4
Electric feed pump connection
5
The all-wheel drive control unit is bolted directly to
the housing of the Haldex clutch.
It forms one unit made up of the control valve, a
pressure/temperature sensor, and a control
module. It receives signals from the PCM and from
the ABS control module via the CAN data bus. The
control module in the control unit uses these
signals to determine the fluid pressure that is
needed to actuate the clutch plates depending on
the requirement. This determines how much torque
should be transmitted to the rear wheels. All-wheel
drive is deactivated if a fault occurs in the all-wheel
drive control unit.
A preload of approx. 80 Nm is always present at
the Haldex clutch. The temperature sensor of the Haldex clutch is
installed near the control valve in the control unit
and is surrounded by the hydraulic fluid. The
temperature is transmitted to the control module
and is used for adaptation to the changing viscosity
of the hydraulic fluid. If the hydraulic fluid is cold,
the control valve has to be opened slightly more
than requested. This allowance has to be reduced
as the temperature increases. The normal working
temperature of the hydraulic fluid is between +40
°C and +60 °C. If the temperature rises above 100
°C, the clutch is depressurised; if the temperature
falls below 95 °C, the clutch is pressurised again.
All-wheel drive is deactivated and a diagnostic
trouble code set if a fault occurs in the temperature
sensor.
With Haldex Generations I and II, the control valve
was actuated via a stepper motor. With Haldex
Generation III, the stepper motor has been omitted.
The control valve is now actuated via a solenoid
valve. The solenoid valve is actuated by the control
module in the all-wheel drive control unit by means
of pulse width modulation. The pulse width
modulation determines the position of the
adjustment spindle and thus the opening cross
section of the return hole. This is how the pressure
at the working piston of the plates is determined.
If the return hole is fully closed, maximum pressure
is applied to the plates. If the return hole is fully
open, the plates are unpressurized.
Electric feed pump
The electric feed pump is installed in the clutch
unit. It works according to the gerotor principle.
The main purpose of the feed pump is to fill the
pressure accumulator and the space behind the
pump plunger with hydraulic fluid, thereby ensuring
a fast response time of the Haldex clutch. The feed
pump used in the third generation is designed to
achieve an even higher pressure than the base
pressure of 4 bar. It is supplied with current by the
control module in the all-wheel drive control unit
when the engine is running above approx. 400 rpm.
Pressure control - 3rd generation
Haldex clutch
G1076981en2008.50 Kuga8/2011
205-02-
10
Rear Drive Axle/Differential
205-02- 10
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