Coolant temperature sensor FORD KUGA 2011 1.G Workshop Manual

Auxiliary Climate Control – Overview
Initial start-up of the fuel-fired booster
heater
The fuel-fired booster heater needs to be filled
before being taken into operation for the first time.
Activation of the fuel pump for the fuel-fired booster
heater is controlled by the Ford diagnostic unit.
Lockout
Flame sensor
If the flame goes out independently during
operation of the booster heater, a restart is carried
out. If the booster heater does not ignite within 90
seconds of fuel delivery or if the flame goes out
within 15 minutes of starting, a lockout will be
implemented by the flame sensor.
Lockout can be cancelled by switching the booster
heater off then on again, although this may only
be repeated at most 2 times.
Overheating sensor
In the event of overheating (water shortage, poorly
ventilated coolant circuit), the fuel supply to the
booster heater is interrupted and a lockout occurs.
After the cause of the overheating has been
eliminated, the booster heater can be started again
by switching it off and on, if the coolant temperature
is below 70°C. If the booster heater overheats ten
times in a row, the control unit will be locked.
Unlocking the control unit
Delete the fault memory of the fuel-fired booster
heater after eliminating the cause of the fault using
the Ford diagnostic unit.
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Description
Item
Electric Booster HeaterRefer to Component Description: (page
?)
1
GEM (generic electronic module)
2
Outside temperature sensor
3
Climate control system control assembly
4 Description
Item
Generator and Alternator
5
PCM (powertrain control module)
6
Coolant temperature sensor (ECT (engine
coolant temperature) sensor)Refer to Component Description: ECT
(page ?)
7
instrument cluster
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Description
Item
Electric Booster HeaterRefer to Component Description: (page
?)
1
GEM2
Outside temperature sensor
3
Climate control system control assembly
4 Description
Item
Generator and Alternator
5
PCM6
Coolant temperature sensor (ECT sensor)Refer to Component Description: ECT
(page ?)
7
instrument cluster
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reprogrammed. However, if the engine hasn't been
run since the last programmed start, the fuel-fired
booster heater will not start up the second time so
as to prevent the battery from being discharged.
The length of time required to pre-heat the vehicle
is calculated in the control unit of the fuel-fired
booster heater and is based on two temperature
values:
• Ambient air temperature: this message is taken
from the GEM via the CAN bus.
• Coolant temperature: this is determined via an internal sensor in the fuel-fired booster heater.
The maximum heating time is 30 minutes at an
outside air temperature of -10 °C or lower. The
heating time decreases proportionally with
increasing ambient temperature until the ambient
temperature is between +15 °C and +20 °C. Then
the minimum heating time is 10 minutes. The
parking heater is deactivated at temperatures
above +20 °C.
The sequence for a programmed start of the
booster heater is as follows:
• Two minutes before the start of the maximum heating time the driver information
system/instrument cluster sends an activation
message to the fuel-fired booster heater via the
CAN bus.
• The fuel-fired booster heater calculates the required heating time and, if necessary, sends
a delay request on the CAN bus.
• At the calculated time, the fuel-fired booster heater starts up. The conditions for start-up are:
engine not running and amount of fuel in the
fuel tank is above 14% of maximum.
• When the coolant temperature reaches +30 °C, the control unit of the fuel-fired booster heater
sends a request to switch on the passenger
compartment blower.
• Eight minutes after the programmed switch-off time, the booster heater stops heating mode
and starts a run-on operation to clean the
system's spark plugs.
• Ten minutes after the switch-off time, the post-cleaning operation is complete. The
additional ten minutes run-on time provides
some leeway in case the driver is late arriving.
After a programmed start-up of the booster heater
it is switched off again after the heating time has
elapsed (or if the fuel level in the fuel tank drops
below 8%). The booster heater stops within 2 minutes of the engine starting. This leaves enough
time to check whether the switch-on conditions for
boost heat mode have been met, thus preventing
the booster heater from having to switch off and
switch back on again. The heater can be switched
off manually at any time from the menu.
Whilst the fuel-fired booster heater is in additional
heating mode and/or parking heating mode, the
instrument cluster receives a fuel consumption
signal; this is used to re-calculate the vehicle's
remaining range and fuel consumption data.
Emergency shutoff
In the event of an accident in which the airbags
are deployed, the control unit of the fuel-fired
booster heater receives a message on the CAN
bus from the restraints control module (RCM).
When this message is received, the booster heater
system switches off immediately.
The booster heater control module deactivates the
system and does not respond to further messages
on the CAN bus. The booster heater control module
needs to be activated with WDS.
Component Description
Electric Booster Heater
The electric booster heater consists of three
individual heating elements, which are incorporated
into a single housing. It is controlled by the generic
electronic module (GEM), taking into account the
following factors:
Detailed illustration of fuel-fired heater
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Description
Item
Combustion chamber
16
'O' Ring
17 Description
Item
Combustion blower motor cover
18
Glow plug wiring harness
19
Flame sensor
If the flame goes out independently during
operation of the booster heater, a restart is carried
out. If the booster heater does not ignite within 90
seconds of fuel delivery or if the flame goes out
within 15 minutes of starting, a lockout will be
implemented by the flame sensor.
Lockout can be cancelled by switching the booster
heater off then on again, although this may only
be repeated at most 2 times.
Overheat Sensor
The overheating sensor enables the fuel-fired
booster heater module to determine the coolant
temperature, protecting the heater from
overheating. The overheating sensor is installed
next to the coolant temperature sensor under a
cover on the top of the fuel-fired heater.
In the event of overheating (lack of water, poorly
ventilated coolant circuit), the fuel supply to the
heater is interrupted and a lockout occurs. After
the cause of the overheating has been eliminated,
the heater can be restarted by switching it off and
on again, if the coolant temperature is below 70°C.
If the heater overheats ten times in a row, the
control unit is locked.
ECT
The fuel-fired booster heater module uses the
temperature sensor to determine the coolant
temperature, which it then uses to set the starting
and stopping time. The coolant temperature sensor
is installed next to the overheating sensor under a
cover on the top of the fuel-fired heater. Water pump The coolant pump is located on the holder for the
fuel-fired heater on the bulkhead in the rear of the
engine compartment. The coolant pump is driven
by a built-in electric motor and circulates the
coolant in the engine cooling system. The delivery
rate for the pump is 820l/h at a delivery pressure
of 0.1 bar.
Fuel pump
The fuel required for the fuel-fired heater is taken
from the fuel system by a fuel pump fitted in the
fuel tank and is delivered to the heater via a fuel
line.
The fuel pump is an electric piston pump which
meters the corresponding fuel volume for the
fuel-fired heater according to a cycle set by the
fuel-fired heater module.
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUALE97646 E97647

Description
Item
Instrument Cluster
1
PCM (powertrain control module)
2
EHPS (electro-hydraulic power steering)
control module
3
Audio unit
4
GEM (generic electronic module)
5
RCM (restraints control module)
6
PATS transceiver
7 Description
Item
Steering wheel lock module
8
Left-hand steering column switch
9
Fuel level sensor
10
Washer water level warning lamp switch
11
Accelerator pedal position sensor
12
CPP (clutch pedal position) sensor/BPP
(brake pedal position) sensor
13
Lighting control switch
14
System Operation
Instrument Cluster
The instrument cluster contains analog displays
as well as warning and control lamps for displaying
the system status; in addiiton, there is an LCD
indicator field for driver information.
The instrument cluster receives the following
signals from the PCM via the high speed CAN
(controller area network) Bus (HS-CAN):
• Vehicle speed – The PCM receives the necessary signalsfrom the ABS (anti-lock brake system) wheel
sensors from the ABS control unit on the
HS-CAN.
• Engine Coolant Temperature
• Engine oil pressure.
• Engine speed
The instrument cluster receives the following
signals from the GEM via the medium speed CAN
Bus (MS-CAN):
• Ambient temperature
• Brake fluid level
• Handbrake control
• Door latch control
• Liftgate latch control
• High beam control
• Headlamp flasher control
• Direction indicator control
The fuel level signal is sent by the two fuel level
sensors in the fuel pumps in the semitrailer tank,
which is wired to the instrument cluster. The
sensors are connected in series, and the total
resistance is determined from the two individual resistors. The instrument cluster converts the raw
fuel level signal into a damped fuel level value.
The odometer shows the total distance travelled
by the vehicle and is based on the same signal as
is processed for the daily mileage counter. The
value is recorded by the instrument cluster and
stored in a protected EEPROM (Electronically
Erasable Programmable Read Only Memory) area.
This area is a memory protected against
manipulation. If the instrument cluster detects an
error in this memory area, e.g. through damage,
the driver is notified with the "Odometer error"
message.
Message center
The message center is operated using the left-hand
switch on the steering column.
The SET/RESET button is activated to select a
submenu and change the settings. If signal tones
have been activated, a short acoustic signal will
sound each time a button is pressed.
By turning the rotary switch, the different menu
displays can be scrolled through or a setting
selected.
In this display, the navigation system can also
display direction and distance information.
In addition, safety and warning messages can be
displayed in this system, such as "Coolant
overheating", "Engine system error" or "Washer
fluid level too low". In addition to a safety message,
a general warning light (red/yellow) lights up.
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Instrument Cluster
Refer to
Wiring Diagrams Section 413-01, for
schematic and connector information. General Equipment
The Ford approved diagnostic tool
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical
or electrical damage.
Visual Inspection Chart Electrical
Mechanical
– Fuse(s)
– Wiring harness
– Electricalconnector(s)
– Instrument cluster
– Light emitting diode(s) (LED)(s)
– Engine oil filter
– Engine oil level
–
Engine coolant level
– Oil pressure switch
– Engine coolant level
– Coolant thermostat
– Engine coolant temperature (ECT)
sensor
– Fuel gauge
– Collapsed or damaged fuel tank
– Recirculation hose
– Fuel tank filler pipe/hose
– Indicated fuel level
– Fuel lines
– Fuel tank filler cap
– Fuel filter (external to the fuel tank)
– Fuel tank
– Door adjustment
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. NOTE: If none of the following warning indicators are operating correctly this may
indicate a concern with the central junction
box (CJB). If only one or two of the following
warning indicators are not operating
correctly this may indicate an instrument
cluster concern. Verify the following warning indicators are
working correctly:
• Charging.
• Turn signals.
• Headlamps.
5. If the cause is not visually evident, verify the symptom and refer to the diagnostic tab within
the Ford approved diagnostic tool.
Configuration of the Instrument Cluster
The instrument cluster is a programmable module,
which must be configured by selecting the
Programmable Module Installation Routine on the
Ford approved diagnostic tool.
NOTE: When the new instrument cluster has been
configured with the odometer value, its
configuration cannot be decreased or matched. A
new configuration will result in an increase in the
displayed odometer value by a minimum of two
units.
NOTE: The odometer value must be recorded from
the original instrument cluster before removal.
If the odometer value cannot be obtained from
the original instrument cluster (display failure)
the customer should supply the approximate
value.
The following features will need to be configured
when a new instrument cluster is installed:
• Anti-lock Brake System (ABS)
• All wheel drive
• Keyless vehicle entry
• Electronic power assisted steering
• Trip computer
• Voice control
• Parking aid
• Belt minder
• Safety belt not fastened
• Right hand drive
• Overspeed warning
• Reverse warning
• Turbocharger boost pressure
• Speed control
• Auxiliary heater
• Suspension control
• Washer fluid sensor G1054964en
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Engine Cooling
Special Tool(s) / General EquipmentPressure Tester, Cooling
System
303-396 (24-001 A)
IA24001A
Adaptor for 303-396
303-396-09
E55030
Ford approved diagnostic tool
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanicalor electrical damage.
Visual Inspection Chart
Electrical
Mechanical
– Fuse(s)
– Wiring harness
– Electricalconnector(s)
– Engine coolant temperature (ECT)
sensor
– Cooling fan motor
– Cooling fan module
– Powertrain control module (PCM)
– Coolant shut off valve
– Coolant degas shut off valve
– Coolant leaks
– Gaskets/seals
– Core plug(s)
– Hose(s)/hose joints
– Coolant expansion
tank cap and seal(s)
– Coolant expansion tank
– Radiator
– Coolant pump
– Thermostat
– Heater core
– Exhaust gas recircu- lation (EGR) cooler
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 diagnostic tab within
the Ford approved diagnostic tool.
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Engine Cooling
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Action
Possible Sources
Symptom
• Check the fuel system pres-sure.
• Low fuel system pressure.
• Poor starting
• CHECK the system for fuelleak(s). REPAIR the system as
necessary.
• Fuel system leak.
• INSPECT the fuel system.INSTALL new components as
necessary. TEST the system
for normal operation.
• Fuel system restriction.
• INSTALL a new fuel filter.
• Fuel filter blocked.
• INSTALL a new air cleanerelement.
• Air cleaner element blocked.
• INSTALL a new engine oil filterand engine oil.
• Incorrect engine oil.
• DRAIN and REFILL the powersteering system with the correct
fluid.
REFER to: Power Steering
System Filling (211-00
Steering System - General
Information, General Proced-
ures).
• Incorrect power steering fluid.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• CKP sensor.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• Engine coolant temperature
(ECT) sensor.
• INSPECT the fuel injectors.CLEAN the fuel injectors or
INSTALL a new set of injectors
as required only after the
checks have been carried out.
REFER to: Fuel Injectors (303-
04 Fuel Charging and
Controls - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
• Fuel injector(s).
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• Fuel rail fuel pressure sensor.
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Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 6
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SECTION 303-14 Electronic Engine Controls— 2.5L Duratec
(147kW/200PS) - VI5
VEHICLE APPLICATION: 2008.50 Kuga
PA G E
CONTENTS
DESCRIPTION AND OPERATION
303-14-3
Electronic Engine Controls (Component Location) .............................................................
303-14-7
Electronic Engine Controls (Overview) ........................................................................\
.......
303-14-7
General overview ........................................................................\
........................................
303-14-8
Powertrain Control Module (PCM) ........................................................................\
..............
303-14-8
Knock Sensor ........................................................................\
.............................................
303-14-8
Camshaft Position (CMP) Sensor ........................................................................\
...............
303-14-9
Crankshaft Position (CKP) sensor ........................................................................\
..............
303-14-9
Camshaft adjuster solenoid valve........................................................................\
...............
303-14-9
Manifold absolute pressure and temperature sensor .........................................................
303-14-9
Accelerator pedal position (APP) sensor ........................................................................\
....
303-14-10
Throttle control unit ........................................................................\
.....................................
303-14-10
Engine Coolant Temperature (ECT) sensor.......................................................................
303-14-10
Ignition coil-on-plug ........................................................................\
....................................
303-14-12
Electronic Engine Controls (System Operation and Component Description) ...................
303-14-12
System Diagram ........................................................................\
.........................................
303-14-16
System Operation ........................................................................\
.......................................
303-14-18
Speed and TDC recording ........................................................................\
......................
303-14-19
Calculation of the ignition angle ........................................................................\
..............
303-14-20
Engine fueling ........................................................................\
.........................................
303-14-22
Engine speed control ........................................................................\
..............................
303-14-22
Oil monitoring ........................................................................\
..........................................
303-14-23
Calculation of valve timing adjustment angle..................................................................
303-14-23
Boost pressure control ........................................................................\
............................
303-14-24
Starting process ........................................................................\
......................................
303-14-24
Alternator control (Smart Charge) ........................................................................\
...........
303-14-24
Component Description ........................................................................\
..............................
303-14-24

CKP sensor ........................................................................\
.............................................
303-14-25

Broadband HO2S ........................................................................\
...................................
303-14-26

VCT (variable camshaft timing) solenoids ......................................................................
303-14-27

MAF sensor ........................................................................\
.............................................
303-14-28

APP sensor ........................................................................\
.............................................
303-14-29

CPP sensor ........................................................................\
.............................................
303-14-29

BPP switches ........................................................................\
..........................................
303-14-30

Air conditioning (A/C) pressure sensor ........................................................................\
...
303-14-30

Throttle
control unit ........................................................................\
.................................
303-14-31

ECT sensor ........................................................................\
.............................................
303-14-31

Cooling fan module ........................................................................\
.................................
303-14-32

injectors........................................................................\
...................................................
303-14-32

Ignition coil-on-plug ........................................................................\
.................................
303-14-33

Fuel pressure/fuel temperature sensor ........................................................................\
...
303-14-33

Wastegate control valve ........................................................................\
..........................
303-14-34

Engine oil level, temperature and quality sensor ............................................................
303-14-1
Electronic Engine Controls— 2.5L Duratec (147kW/200PS) - VI5303-14-
1
.
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