battery FORD KUGA 2011 1.G Repair Manual

Turbocharger(23 612 0)
General EquipmentCable Ties
Hose Clamp Remover/Installer
Materials
Specification
Name
SA-M1C9107-A / YS5J-
M1C9107-AA
Grease KS-PS
Removal
NOTE:
Removal steps in this procedure may
contain installation details.
1. Refer to: Battery Disconnect and Connect
(414-01 Battery, Mounting and Cables,
General Procedures).
2. Refer to: Cooling System Draining and Vacuum
Filling (303-03 Engine Cooling, General
Procedures).
3. Refer to: Cowl Panel Grille (501-02 Front End
Body Panels, Removal and Installation).
4.
E65070
5. CAUTION: Make sure that the inside of the pipe ends are clean and free of oil
residue.
1. Torque: 10Nm
2. Torque: 4Nm
3. Torque: 10Nm
2
1
3
E68504
6.
E67948
2
1
7.Torque: 26Nm1.
2. Torque: 26
Nm
3. Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
Torque: 38
Nm
E112143
3
2
1
G1079058en2008.50 Kuga8/2011
303-04B- 11
Fuel Charging and Controls - Turbocharger
—
2.5L Duratec (147kW/200PS) - VI5
303-04B- 11
REMOVAL AND INSTALLATION
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Description
Item
Vehicles with manual transaxle.
A
If equipped with an automatic transaxle.
B
Ignition key
Comments:With transponder for PATS (passive
anti-theft system)
1
PAT S
2
Ignition lock
3
GEM (generic electronic module)
4
PCM (powertrain control module)
5
Battery
6Description
Item
Starter relay
7
Starter motor
8
Stoplight Switch
Comments:If equipped with an automatic transaxle.
9
TCM (transmission control module)
Comments:If equipped with an automatic transaxle.
10
Starting deactivation relay
Comments:If equipped with an automatic transaxle.
11
G1032961en2008.50 Kuga8/2011
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Starting System— 2.5L Duratec (147kW/200PS) - VI5303-06-
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Description
Item
Start/stop button
1
CPP (clutch pedal position) switches
Comments:Switches when the clutch pedal is
operated
2
Keyless vehicle module
3
Electronic steering lock with mount -
passive key and PATS transmitter/receiver
unit
Comments:for emergency start function
4Description
Item
Radio frequency receiver
Comments:Signal is only executed in GEM
5
GEM
6
PCM
7
Starter relay
8
Starter motor
9
Battery
10
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Starting System— 2.5L Duratec (147kW/200PS) - VI5303-06-
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Description
Item
Start/stop button
1
Keyless vehicle module
2
Electronic steering lock with mount -
passive key and PATS transmitter/receiver
unit
Comments:for emergency start function
3
Radio frequency receiver
Comments:Signal is only executed in GEM
4Description
Item
GEM
5
Stoplight Switch
6
TCM7
Starting deactivation relay
8
PCM
9
Starter relay
10
Starter motor
11
Battery
12
System Operation
Smart Start
The PCM enables the starting process when a key
providing a valid code is read via the PATS. This
code is then verified in the GEM and compared
with the saved code. If this code is recognized as
correct, synchronization with other modules is
carried out. After successful synchronization, the
engine is cleared to start in the PCM. The PCM
connects earth to the starter relay, which then
connects power to the starter solenoid. As soon
as the engine reaches a certain speed, the PCM
disconnects the starter relay and so turns off the
starter. This protects the starter.
If the engine does not turn or turns only slowly, the
starting process is aborted by the PCM.
The starter is notactivated if:
• the engine is running (i.e. the engine speed is above a particular value),
• the PATS does not permit the engine to be started,
• the clutch pedal is not operated (vehicles with manual transmission),
• the gear selector level is not set to P or N (vehicles with automatic transmission),
• the brake pedal is not operated (vehicles with automatic transmission).
Emergency starting function
If the keyless vehicle system is unable to recognize
the passive key, the vehicle can be started via the
emergency starting function. In this case, there is a passive key mount on the
steering wheel. A PATS transmission/reception
unit is attached to this.
To start the engine, the passive key must be
inserted into the passive key mount. The Start/Stop
button can then be used to turn on the ignition and
start the engine as normal. To deactivate the
PATS, a transponder is fitted in the passive key,
which is read by the transmission/reception unit.
G1032961en2008.50 Kuga8/2011
303-06-
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Starting System— 2.5L Duratec (147kW/200PS) - VI5303-06-
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Starting System
Refer toWiring Diagrams Section 303-06, for
schematic and connector information.
General Equipment
Ford diagnostic equipment
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of electrical damage.
Visual Inspection Chart
Electrical
• Fuse(s)
• Wiring harness
• Electrical connector(s)
• Relay
• Switch(es)
• Battery junction box (BJB)
• Engine junction box (EJB)
• Central junction box (CJB)
• Keyless vehicle module (KVM) (if equipped)
• Battery
• Starter motor
• 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 diagnostictab within
the Ford diagnostic equipment .
G1183444en2008.50 Kuga8/2011
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Starting System— 2.5L Duratec (147kW/200PS) - VI5303-06-
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DIAGNOSIS AND TESTING
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Starter Motor(26 204 0)
Removal
NOTE:Removal steps in this procedure may
contain installation details.
1. Refer to: Battery Disconnect and Connect
(414-01 Battery, Mounting and Cables,
General Procedures).
2. Refer to: Air Cleaner (303-12 Intake Air
Distribution and Filtering - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
3.
E63784
4. Torque: 10Nm
E63785
5.Torque: 12Nm
E64737
6.Torque: 50Nm
E64738
x2
Installation
1.To install, reverse the removal procedure.
2. Refer to: Door Window Motor Initialization
(501-11 Glass, Frames and Mechanisms,
General Procedures).
G962446en2008.50 Kuga8/2011
303-06- 10
Starting System— 2.5L Duratec (147kW/200PS) - VI5303-06-
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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.
G1021907en2008.50 Kuga8/2011
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If one of the two APP sensors fails, then only a
proportion of the engine's power will be available
when accelerating. Top speed can nevertheless
be achieved.
If both of the APP sensors fail, the engine is
regulated to a defined speed following a plausibility
check after the BPP (brake pedal position) switch
and brake light switch have been actuated once.
The vehicle can then only be accelerated to a
defined speed.
In either case, a fault is saved in the error memory
of the PCM.
Throttle control unit
E74167
1
2
Description
Item
TP (throttle position) sensor
1
Electric motor
2
CAUTION: The throttle control unit must
not be repaired or adjusted. The stop of
the throttle valve must on no account be
adjusted.
After disconnecting the battery or replacing the
throttle control unit or the PCM, initialization is
necessary. • engine off
• Accelerator pedal not pressed
• Battery voltage 11 ... 14 V
• Ignition key in ON position
• Wait approximately 30 seconds until initialization
is complete.
Engine Coolant Temperature (ECT)
sensor
E94804
The ECT (engine coolant temperature) sensor is
designed as an NTC (negative temperature
coefficient) resistor.
If the signal from the ECT sensor fails, the cooling
fan is on all the time and the A/C (air conditioning)
is turned off. When the ignition is switched on, the
value from the IAT (intake air temperature) sensor
is read. When the engine is running, the
temperature is calculated using a temperature map
stored in the PCM according to how long the
engine has been running. This substitute value is
then used as the basis for calculating the injected
fuel quantity and the ignition timing.
Ignition coil-on-plug
E73540
G1021907en2008.50 Kuga8/2011
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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
G1021908en2008.50 Kuga8/2011
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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
G1021908en2008.50 Kuga8/2011
303-14-
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