FORD KUGA PCM FORD KUGA 2011 1.G Repair Manual

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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E74168
1
23456
Description
Item
Stop screw
1
Toothed segment
2
Throttle flap spindle
3
Throttle flap return spring
4
Joint shaft
5
Electric motor with pinion
6
CAUTION: The throttle control unit must
not be repaired or adjusted. The stop of
the throttle valve must on no account be
adjusted.
If there is a fault, the throttle is returned to its
original position by means of the throttle valve
return spring. In this position, the throttle valve is
still slightly open. As a result, a higher idle speed
is set, enabling the vehicle to be driven, though
within narrow limits.
ECT sensor
E94804
The ECT sensor is designed as an NTC resistor.
A voltage of 5V is applied to the ECT sensor by
the PCM. The PCM is able to determine the coolant
temperature from the temperature-dependent
voltage drop at the sensor.
Cooling fan module
E94806
The cooling fan module is directly supplied with
battery power via a 60A fuse in the BJB. The
radiator fan speed is controlled by the PWM via a
PCM signal.
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Description
Item
Coil-on-plug ignition coil
1
Spark plug connector
2
Low-voltage connection
3
Laminated soft-iron core
4Description
Item
Primary winding
5
Secondary winding
6
Spark plug
7
High-voltage connection via spring contact
8
In an ignition system with coil-on-plug ignition coils,
each cylinder is actuated individually and only once
per cycle (working stroke). The coil-on-plug ignition
coils are mounted directly on the spark plugs,
therefore no ignition cables are required between
the ignition coils and the spark plugs.
Each individual ignition coil is actuated on the
low-voltage side by the PCM. The power
end-stages are incorporated into the coil-on-plug
ignition coils. Only the actuating current for these
power end-stages is controlled by the PCM.
Fuel pressure/fuel temperature sensor
E73531
The fuel pressure/fuel temperature sensor is a
combination of two sensors, one for the fuel
absolute pressure and one for the fuel temperature.
The sensors register the fuel values in the fuel
injection supply manifold. The sensor is supplied
with a 5V voltage by the PCM.
The fuel pressure sensor is a piezoresistor and
works using an analog signal. The change in output
voltage mirrors the change in pressure in the fuel
rail. If the pressure is low, the output voltage is also
low.
The fuel temperature sensor is an NTC resistor.
When the fuel pressure/fuel temperature sensor is
disconnected, the resistance of the fuel
temperature sensor between connections 1 and 2
of the sensor can be measured.
Resistor
Temperature
5896 Ohm
0° C
3792 Ohm
10° C
2500 Ohm
20° C
1707 Ohm
30° C
1175 Ohm
40° C
The values of the fuel pressure/fuel temperature
sensor can be read out with IDS. The displayed
values are absolute values (fuel pressure +
atmospheric pressure).
Wastegate control valve
E73539
The boost control solenoid valve is a 2/3-way valve
that is actuated with a PWM signal. This allows the
valve opening to be steplessly adjusted.
Power (battery voltage) is supplied via the
Powertrain Control Module relay in the BJB. The
solenoid coil resistance is around 23 ohms at 20°
C.
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Engine oil level, temperature and quality
sensor
E95312
The sensor is a combined oil level and oil
temperature sensor.
The sensor consists of:
• Electrical connector
• Integral electronics
• PTC resistor
• Capacitive element consisting of two tubes witha space between them. The one tube represents
the positive side, the other the negative. The oil
between the tubes creates the capacitive
properties.
The sensor receives a 5V voltage from the PCM.
The sensor generates a PWM signal that is sent
to the PCM.
Exterior aor temperature sensor
The outside air temperature sensor is a NTC
resistor and is supplied with a 5V voltage by the
PCM.
The resistance of, and consequently the voltage
from, the outside air temperature sensor changes
as a function of temperature.
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Electronic Engine Controls
General EquipmentFord diagnostic equipment
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical or electrical damage.
Visual Inspection Chart
Electrical
– Fuse(s)
– Wiring harness
– Electrical connector(s)
– Relay(s)
– Sensor(s)
– Switch(es)
– Powertrain control module (PCM)
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible)
before proceeding to the next step
4. If the cause is not visually evident, verify the symptom and refer to the Ford diagnostic
equipment to diagnose the system.
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DIAGNOSIS AND TESTING
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Powertrain Control Module (PCM)(29 200 0)
General Equipment3.5 mm Drill Bit
Center Punch
Ford Diagnostic Equipment
Removal
NOTE: Removal steps in this procedure may
contain installation details.
1. NOTE: This step is only necessary when
installing a new component.
Download the PCM and throttle body
configuration information into the diagnostic tool,
using the Programmable Modules Installation
routine.
General Equipment: Ford Diagnostic Equipment
2. Refer to: Battery Disconnect and Connect
(414-01 Battery, Mounting and Cables,
General Procedures).
Vehicles without PCM security shield
3.
E63329
4.
E93509
5.
E65856
6. Torque: 7Nm
E66285
Vehicles with PCM security shield
7.Refer to: Air Cleaner (303-12 Intake Air
Distribution and Filtering - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
8. General Equipment: Center Punch
1.
2. General Equipment: 3.5 mm Drill Bit
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E923483
1
2
4
x2
9.
E65361
Installation
1.To install, reverse the removal.
Vehicles with PCM security shield
2.Tighten the shear bolt until the shear bolt head
is sheared off.
E92350
All vehicles
3. NOTE: This step is only necessary when
installing a new component.
Upload the PCM and throttle body configuration
information into the PCM, using the
Programmable Modules Installation routine.
General Equipment: Ford Diagnostic Equipment
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E112805
59
13
2
6
10
14
3
7
11
15
4
8
12
16
17
19202118
1
Description
Item
TCM1
GEM (generic electronic module)
2Description
Item
Instrument Cluster
3
PCM (powertrain control module)
4
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Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 13
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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
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E112322
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. This leads to lower fuel consumption together
with improved comfort through smoother gear
changes and lower noise levels.
The TCM receives information on the driver's
desired transmission range and type of driving
mode. In contrast to a transmission which is only
controlled hydraulically, the control module can
calculate the best times to shift gear and activate
torque converter lockup by using the signals from
the sensors in the transmission and the engine
management system.
The control module enables small changes in the
operating conditions to be made and adapts thevarious transmission functions to ensure that the
correct gear is always selected in relation to the
type of driving mode.
The TCM has adaptive capabilities. This ensures
smooth gear changes throughout the whole service
life of the transmission.
To exactly determine the activation points of the
gear shifts and torque converter lockup on the
basis of the type of driving mode chosen, the TCM
receives the following information:
• Transmission range chosen (TR sensor).
• Type of driving mode chosen
(normal/sport/select-shift).
• Transmission input shaft speed (TSS sensor).
• Transmission output shaft speed (OSS sensor).
• Transmission fluid temperature (TFT sensor).
• The engine speed and the torque as well as the throttle plate opening - from the PCM via the
CAN data bus.
• Actuation of the accelerator pedal - from the PCM via the CAN data bus.
• Coolant temperature - from the PCM via the CAN data bus.
• Vehicle speed - from the ABS via the CAN data bus.
• Actuation of the brake pedal - from the ABS via the CAN data bus.
Pin assignment for TCM connector 'A' (connection to vehicle)
11
E125669
Description
Item
Battery (+)
1
not assigned
2Description
Item
not assigned
3
not assigned
4
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Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 26
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