air conditioning FORD KUGA 2011 1.G Repair Manual

• Torque reduction request (stability assistmodule)
• Cruise control request
The PCM sends the following signals via the CAN
databus:
• Fuel pump relay on/off
• Engine speed
• Warning lights on/off (MIL (malfunction indicator lamp), battery warning lamp)
• PAT S
•ECT
• Air conditioning pressure transducer
• Outside air temperature
With the aid of the input and output signals listed
above, the PCM controls / regulates engine
starting, fuel injection and fuel pressure, ignition,
boost pressure, camshaft adjustment, tank purging,
the radiator fan and the refrigerant compressor.
Speed and TDC recording
The CKP uses the PCM sensor to record engine
speed and detect 1st cylinder TDC (top dead
center). An additional sensor wheel for the CKP sensor is
located on the flywheel. This has 60-2 teeth. The
gaps between the teeth are required for detection
of TDC. The CKP sensor works according to the
induction principle and generates a sinusoidal
signal voltage whose level and frequency are
speed-dependent.
From the frequency of the signal the PCM
calculates the engine speed. Each time the engine
rotates, the double gap in the sensor wheel alters
the sinusoidal oscillation that is generated; this
helps the PCM to detect the TDC position of
cylinder 1.
The signal from the CKP sensor is used to
determine
• the crankshaft position,
• the engine speed,
• the ignition timing,
• the injection timing and
• the adjustment angle of the VVT units.
2
3
4
1
9
7
8
6
5
2
3
4
1
9
7
8
6
5
E96631
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Electronic Engine Controls— 2.5L Duratec (147kW/200PS) - VI5303-14-
18
DESCRIPTION AND OPERATION
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Air conditioning (A/C) pressure sensor
E74157
The A/C pressure sensor is installed on the
high-pressure side of the A/C. The input voltage is
5V, the output voltage is between 0.5V and 4.5V
depending on the cryogenic fluid pressure. When
the cryogenic fluid pressure is low, the output
voltage is also low.
Voltage (Volts)
Pressure (bar)
3.9 - 4.0
Approx. 30
3.3 - 3.4
Approx. 25
2.7 - 2.8
Approx. 20
2.1 - 2.2
Approx. 15
1.6 - 1.7
Approx. 10
1.0 - 1.1
Approx. 5
0.5 - 0.7
Approx. 1
Throttle control unit
E74167
1
2
Description
Item
TP sensor
1
Electric motor
2
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Electronic Engine Controls— 2.5L Duratec (147kW/200PS) - VI5303-14-
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DESCRIPTION AND OPERATION
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Description
Item
ABS (anti-lock brake system)
5
Speed control
6
Select-shift switch module
7
PCM
8
Selector lever lock
9
PWM solenoid valve – shift pressure (SLS)
10
PWM solenoid valve for main line pressure
(SLT)
11
PWM- solenoid valve – TCC (SLU)
12Description
Item
Shift solenoid S1 (open when dormant)
13
Shift solenoid S2 (closed when dormant)
14
Shift solenoid S3 (closed when dormant)
15
Shift solenoid S4 (open when dormant)
16
Shift solenoid S5 (closed when dormant)
17
The TSS sensor
18
The OSS sensor
19
The TFT sensor
20
TR sensor in TCM
21
Knowing and Understanding Customer
Concerns
Knowing and understanding customer concerns is
necessary in order to perform diagnosis.
First of all, ask the customer under which operating
conditions the problem occurs. If possible, try to
reproduce the concern by road testing the vehicle
with the customer.
You should be familiar with the following operating
conditions:
• Engine operating state
– Cold, warm-up phase, or at operatingtemperature
• Ambient temperature – Below 0 °C (32 °F), 0 to 20 °C (32 to 68 °F),or above 20 °C (68 °F)
• Road conditions – Good, poor, or off-road
• Vehicle load status – Unloaded, loaded, or fully loaded
• Transaxle status in manual mode – Upshift, downshift, overrun or acceleration
Testing Possible Causes of Transmission
Control Faults
Before performing a symptom-based diagnosis,
first carry out checks to eliminate various other
potential causes of the fault.
These situations include:
• Battery state of charge
• Defective fuses • Loose or corroded cables or electrical
connectors
• Ground connections to the transmission
• Retrofitted add-on units which are not approved by Ford, such as air conditioning, car telephone,
cruise control
• Unapproved tire sizes
• Incorrect tire size programmed with IDS (Integrated Diagnostic System)
• Engine tuning
IDS Diagnosis
NOTE: Customer concerns relating to the transaxle
can also be caused by engine-related faults.
The transmission control system of the AW55 is
closely linked to the engine management system.
Faults in the engine management system may
affect the transmission control system.
Before repairing the transaxle, it should be ensured
that the fault is not caused by the engine
management system or other non-transaxle
components.
The diagnosis can be performed on the AW55 with
the aid of von IDS.
visual inspection
A thorough visual inspection of the transaxle is
necessary for successful diagnosis.
A visual inspection is made of the following
components:
• Connectors and plug connections
• Ease of operation of the selector lever
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Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 14
DESCRIPTION AND OPERATION
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SECTION 412-00 Climate Control System - General
Information
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
SPECIFICATIONS
412-00-2
Specifications ........................................................................\
..............................................
DIAGNOSIS AND TESTING 412-00-3
Climate Control System ........................................................................\
..............................
412-00-3
Inspection and Checking ........................................................................\
............................
412-00-3
Refrigerant Circuit - Quick Check ........................................................................\
...............
412-00-4
Sequence of A/C Request Signal ........................................................................\
...............
GENERAL PROCEDURES 412-00-6
Air Conditioning (A/C) System Flushing ........................................................................\
.....
412-00-7
Air Conditioning (A/C) System Recovery, Evacuation and Charging .................................
412-00-9
Spring Lock Coupling ........................................................................\
..................................
412-00-11
Air Conditioning (A/C) Clutch Air Gap Adjustment .............................................................
412-00-12
Refrigerant Oil Adding ........................................................................\
................................
412-00-13
Contaminated Refrigerant Handling ........................................................................\
...........
412-00-14
Electronic Leak Detection ........................................................................\
...........................
412-00-15
Fluorescent Dye Leak Detection ........................................................................\
................
412-00-16
Vacuum Leak Detection ........................................................................\
..............................
412-00-1
Climate Control System - General Information
412-00- 1
.
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Lubricants, Fluids, Sealers and Adhesives
Specifications
WSH-M17 B19-A
Refrigerant R134a
Specificat
ions
WSH-M1C 231-B
Refrigerant oil
Refrigerant Capacities (When Charging)
grams
600 ± 15
Air Conditioning
Refrigerant Oil Capacities (When Charging)
millilitres 200
Air Conditioning
Addition of Refrigerant Oil (When new components are installed)
CAUTIONS:
The refrigerant oil top-up quantity must not exceed the refrigerant oil fill quantity.
If other A/C components are being renewed in addition to the A/C compressor, there is no
need to top up with additional refrigerant oil, apart from filling the compressor.
Because the fill quantities differ, the refrigerant oil must be drained from the new A/C
compressor.
millilitres add 200.
After renewal of all lines and components.
add 150.
Air conditioning (A/C) compressor - if the quantity of refrigerant oil drained
from the faulty compressor is less than 150 ml
add 200.
Air conditioning compressor (if the amount of refrigerant oil drained from the
faulty compressor is more than 150 ml)
add 30.
A/C condenser
add 30.
A/C evaporator
add 90.
A/C dehydrator
Add the same quantity
as the quantity that was collected.
Always, if refrigerant was drained.
Clutch air gap
mm
0,35 - 0,75
Compressor clutch air gap
Torque Specifications
lb-in
lb-ft
Nm
Item
-
10
13
Compressor drive plate retaining bolt
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Climate Control System - General Information
412-00- 2
SPECIFICATIONS
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Climate Control System
Refer to Wiring Diagrams Section 412-00, for
schematic and connector information.
Special Tool(s) / General EquipmentTerminal Probe Kit
418-S035
29011A
Digital Multimeter (compatible with K-type
thermocouple)
The Ford approved diagnostic tool
Refrigerant center
Thermometer - Fluke 80 PK-8 (FSE number 260
4102 001 07)
Inspection and Checking
NOTE:The electronic automatic temperature
control (EATC) module is integrated into the air
conditioning control assembly.
1. VERIFY customer concern.
2. Visually CHECK for any obvious mechanical or electrical damage.
NOTE: Ensure correct locking of the wiring harness
connector.
Visual Inspection
Electrical
Mechanical
• Fuses
• Wiring harness
• Connector
• Refrigerant lines
• Condenser core
• Coolant level
• Drive belt
• A/C compressor
3. RECTIFY any obvious causes for a concern found during the visual inspection before
performing any further tests. CHECK the
operation of the system.
4. If the concern is still present after the visual inspection, perform fault diagnosis on the
electronic engine management, the charging
system, the generic electronic module (GEM)
and the instrument cluster (vehicles with EATC:
read out the EATC fault memory as well) using the Ford approved diagnostic tool and RECTIFY
the fault(s) displayed in accordance with the
fault description. CHECK the operation of the
system.
5. For vehicles with no stored fault(s), PROCEED in accordance with the Symptom Chart
according to the fault symptom.
6. Following checking or elimination of the fault(s) and after completion of operations, the fault
memories of all vehicle modules must be READ
OUT and any stored faults must be DELETED.
Refrigerant Circuit - Quick Check
WARNING: The air conditioning system is
filled with refrigerant R134a. Observe
"Health and Safety Precautions". For
further information
REFER to: Air Conditioning (A/C) System
Recovery, Evacuation and Charging
(412-00 Climate Control System - General
Information, General Procedures).
Refrigerant circuit check
WARNING: Under certain circumstances,
refrigerant lines and A/C components may
be extremely hot or cold. Exercising care,
touch the refrigerant lines or A/C
components in order to check this. Failure
to follow these instructions may result in
personal injury.
When the A/C system is operating, the following
conditions should apply:
• The refrigerant line from the refrigerant compressor to the condenser must be hot.
• The refrigerant line from the A/C condenser to the fixed orifice tube must be warm, but not so
hot as the refrigerant line mentioned above.
• Determine the difference in temperature upstream and downstream of the A/C condenser
by measuring the temperatures at the refrigerant
lines. The temperature difference should be
more than 20° C, depending on the ambient
temperature. If the temperature difference is
less, check the condenser for contamination or
damage to the fins as well as operation of the
radiator fans.
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DIAGNOSIS AND TESTING
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• The refrigerant line between the fixed orificetube and the evaporator must be cold from the
point where the fixed orifice tube is installed.
Depending on the weather, the refrigerant line
may also have ice on its surface.
• The refrigerant line between the evaporator and the A/C compressor including the dehydrator
must be cold.
Evaporator outlet line temperature test
To test the power of the A/C system, the
temperature at the evaporator outlet line must be
measured. To do this, the following preconditions
must be met:
• Open all windows.
• Set the air distribution to the defrost/dashboardposition and open all the ventilation nozzles.
• DO NOT switch on recirculated air.
• Select lowest blower switch setting.
• Select lowest temperature setting.
NOTE: The temperature measurement cannot be
done with a thermometer which makes no contact.
The surface reflection from the metal line may
cause incorrect readings.
Connect the temperature sensor (Fluke 80 PK-8)
to the outlet line of the evaporator. Locate the
temperature sensor as close as possible to the
evaporator. Connect the temperature sensor to the
multimeter.
Start the engine and allow it to run at idle speed
for several minutes.
Switch on the A/C.
After three minutes, measure the surface
temperature of the evaporator outlet line.
If the temperature measured is 4° C or lower, the
A/C system is OK. If the temperature is higher, the
A/C system may be under-filled. For further
information, refer to
REFER to: Air Conditioning (A/C) System
Recovery, Evacuation and Charging (412-00
Climate Control System - General Information,
General Procedures).
Frequent faults and their causes
If the cooling power of the A/C system is not
adequate, make certain that the temperature
control flap(s) is/are operating correctly. • No or poor cooling performance:
– Blockage or narrowing of a refrigerant line orin the dehydrator. The location of the
blockage or narrowing can easily be located
by temperature comparisons at the
refrigerant lines and the dehydrator. The
blockage or restriction is located at the point
where the temperature difference is
identified. Note: A temperature difference
in the area of the fixed orifice tube is
normal. If the location of the blockage or
narrowing is found, check the corresponding
component and renew as applicable.
• Sudden drop in cooling performance (after the air conditioning has been switched off for
approx. 5 minutes, the cooling performance
returns to normal):
– The cause is an iced-up fixed orifice tubebecause of moisture in the refrigerant circuit.
In order to ensure that moisture is completely
removed from the refrigerant circuit, the
dehydrator should be renewed and the
evacuation time should be extended to 2-3
hours. For further information
REFER to: Air Conditioning (A/C) System
Recovery, Evacuation and Charging
(412-00 Climate Control System - General
Information, General Procedures).
Sequence of A/C Request Signal
NOTE: The electronic automatic temperature
control (EATC) module is integrated into the air
conditioning control assembly.
NOTE: The generic electronic module (GEM) is
an integral part of the central junction box (CJB).
After actuating the A/C ON/OFF switch integrated
into the A/C control assembly, an A/C request
signal is sent from the A/C control assembly
(vehicles with EATC: EATC module) to the GEM.
From there, the signal is sent to the instrument
cluster via the MS-CAN bus. A gateway is installed
in the instrument cluster, which establishes the
connection between the MS-CAN bus and the
HS-CAN bus.
After the signal has been converted in the gateway,
it is relayed to the powertrain control module (PCM)
via the HS-CAN bus. Once all the required
parameters have been met, the PCM switches on
the refrigerant compressor and thus the A/C system
via the A/C clutch relay.
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Climate Control System - General Information
412-00- 4
DIAGNOSIS AND TESTING
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Air Conditioning (A/C) System Flushing
9. Information not available at this time.
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Climate Control System - General Information
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GENERAL PROCEDURES
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Air Conditioning (A/C) System Recovery, Evacuation and Charging
General EquipmentAir Conditioning Service Unit
Automatic Calibration Halogen Leak Detector
Electronic Leak Detector
Refrigerant Identification Equipment
UV Leak Detector
1. Refer to: Air Conditioning (A/C) System Health
and Safety Precautions (100-00 General
Information, Description and Operation).
2.
E100846
x4
3. CAUTION: The refrigerant analyzer must be used before recovery, otherwise the
refrigerant center may become
contaminated. Contaminated refrigerant
must be disposed of as hazardous
waste. Always follow the manufacturer's
instructions when using the refrigerant
center and the refrigerant analyzer.
Unscrew and remove the protective caps from
the A/C charging connections.
General Equipment: Air Conditioning Service Unit
General Equipment: Refrigerant Identification Equipment 4.
Low-pressure connection
1.
2. High-pressure connection
2
E51608
1
5. Connect the service unit lines to the filling
connection of the air conditioning system.
VFE0031288
6.Drain the air conditioning system via the
low-pressure port in accordance with the service
unit manufacturer instructions.
7. CAUTION: Make sure that the specified amount of refrigerant oil is added.
NOTE:This step is only required when installing
a new component.
Fill up with refrigerant oil.
Refer to: Specifications (412-00 Climate Control
System - General Information, Specifications).
Refer to: Refrigerant Oil Adding (412-00 Climate
Control System - General Information, General
Procedures).
8. Evacuate the air conditioning system in
accordance with the service unit manufacturer
instructions.
9. NOTE: The system is leak-tight if the pressure
increase does not exceed 20 mbar.
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Climate Control System - General Information
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Perform the leak test, by closing the hand valves
on the gauge set, switching off the service unit
vacuum pump and observing the low pressure
gauge.
10. N O T E : This step is only necessary if the
pressure increase exceeds 20 mbar.
Locate and rectify any leaks in the A/C
refrigerant circuit using a leak tester.
General Equipment: UV Leak Detector
General Equipment: Electronic Leak Detector
General Equipment: Automatic Calibration Halogen Leak Detector
11 . Add refrigerant oil to the air conditioning system.
Refer to: Specifications (412-00 Climate Control
System - General Information, Specifications).
Refer to: Refrigerant Oil Adding (412-00 Climate
Control System - General Information, General
Procedures).
12. Fill the air conditioning system with liquid
through the high-pressure connection.
Refer to: Specifications (412-00 Climate Control
System - General Information, Specifications).
13. Open the shut-off valve on the high-pressure
side.
1.
2. Switch the service unit to "Fill" mode and fill
the system with the specified quantity of
liquid refrigerant (R134a).
14. Fill the air conditioning system with gas through
the low-pressure connection.
Refer to: Specifications (412-00 Climate Control
System - General Information, Specifications).
15. Open the shut-off valve on the low-pressure
side.
1.
2. Switch the service unit to "Fill" mode and fill
the system with the specified quantity of
gaseous refrigerant.
3. Add the remaining amount of refrigerant with the air conditioning switched on. To do so
run the engine at about 1200-1500 rev/min.
Set the air conditioning system to full cooling
power and fresh air mode. Set the blower
motor to the highest setting. Fill with the
remainder of the specified fill capacity.
16. Disconnect the service unit. 17.
Close the shut-off valve.
1.
2. Switch off the service unit.
3. Disconnect the service unit lines from the
filling connections of the air conditioning
system.
4. Screw the protective caps onto the charging connections.
18. Install all components in reverse order.
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Climate Control System - General Information
412-00- 8
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