generator and regulator FORD KUGA 2011 1.G Workshop Manual

SECTION 414-02 Generator and Regulator
VEHICLE APPLICATION:
2008.50 Kuga
PAGE
CONTENTS
DESCRIPTION AND OPERATION
414-02-2
Generator ............................................................................................................................
414-02-2
Smart Charge system.........................................................................................................
REMOVAL AND INSTALLATION 414-02-3
(31 414 0)
Generator — 2.5L Duratec (147kW/200PS) - VI5.......................................... 414-02-1
Generator and Regulator
414-02-1
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Generator
General information
The powertrain control module (PCM) controls the
alternator charging voltage. The connection
between the PCM and the generator is made via
the control module subnetwork (LIN) bus.
If the load on the alternator is high, the PCM can
increase the idle speed.
The alternator is temporarily deactivated during
engine starting so that the engine drag moment is
minimized and it is reactivated again after the
starting procedure.
The PCM controls the charge control lamp in the
instrument cluster via the controller area network
(CAN) bus.
Smart Charge system
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.
By receiving the forwarded alternator load signal,
the PCM is given early warning whenever an
electric consumer is switched on or off. This means
that the PCM receives information about imminent
changes in the torque drawn by the alternator. By
evaluating this information the PCM can provide a
higher level of idling stability.
The two remaining functions of the Smart Charge
System are controlled by the GEM.
Electrical consumers are switched off due to low
voltage when the GEM determines (on the basis
of the message received from the PCM on the CAN
bus via the instrument cluster) that the battery
voltage has dropped below the threshold.
When the threshold for low battery voltage is
reached the GEM automatically deactivates the following consumers - in this order and with a gap
of 5 seconds between each:
• Electric booster heater (vehicles with diesel
engines)
• Heated exterior mirrors
• Heated rear window
• Heated windscreen
If the battery voltage rises back above the lower
threshold then the GEM re-enables all of the
electrical consumers which were previously
disabled. They then have switched off status and
must be switched back on by the driver.
Electrical consumers are switched on due to
excessively high voltage if the GEM determines
that the battery voltage is above the threshold for
overvoltage and the charge control lamp has been
switched on.
When the threshold is reached the GEM
automatically activates the following consumers -
in this order and with a gap of 5 seconds between
each:
• Heated rear window
• Heated exterior mirrors
• Electric booster heater (vehicles with diesel engines)
• Blower motor
If the battery voltage drops back below the
threshold then the GEM automatically deactivates
any consumers that were switched on. However,
if they were switched on by the driver before the
automatic activation, they will then be switched on
again in turn with a 5-second time interval. G964174en
2008.50 Kuga 8/2011 414-02-2
Generator and Regulator
414-02-2
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7. NOTE:
Install all the bolts finger tight before
final tightening.
1. Torque: 15 Nm
2. Torque: 25 Nm
Installation
1.
To install, reverse the removal procedure.
2. Refer to: Door Window Motor Initialization
(501-11 Glass, Frames and Mechanisms,
General Procedures). G1202465en
2008.50 Kuga 8/2011 414-02-4
Generator and Regulator
414-02-4
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Starting process
The PCM enables the starting process when a key
providing a valid code is read via the PATS.
Refer to:Starting System (303-06 Starting System
- 2.5L Duratec (147kW/200PS) - VI5, Description
and Operation).
Alternator control (Smart Charge)
The vehicle is fitted with a Smart Charging charge
system.
In this system, the charge voltage is regulated by
the PCM.
Refer to: Generator (414-02 Generator and
Regulator, Description and Operation).
Component Description
PCM
E73522
A voltage transformer integrated into the PCM
provides various components of the PCM and
sensors on the engine with a 5 volt supply.
Functions which work at battery voltage, such as
the injectors, are controlled via internal power end
stages or, like the ignition coils, via external power
end stages in the ignition coils themselves.
CMP
E89993
The intake and exhaust camshafts each have a
sensor installed on them.
The CMP sensor is realized as a Hall effect sensor
and is provided by the PCM with a 5 volt supply.
The Hall effect sensor emits a signal when the
pulse segments incorporated into the sensor wheel
rotate past the tip of the sensor. If an increase
occurs in the area of the sensor, the PCM receives
a 'high' signal with a maximum voltage of 4.5V. If
a gap occurs in the area of the sensor, a 'low'
signal is sent to the PCM. Here the voltage is
approx. 0.5V.
CKP sensor
E89994
The CKP sensor utilizes the induction principle. A
sinusoidal voltage is sent to the PCM. When
performing a voltage test, ensure that the CKP
sensor is connected to the engine wiring harness
This is necessary, otherwise the sensor will not be
subjected to any load and incorrect measurements
will result.
G1021908en2008.50 Kuga8/2011
303-14- 24
Electronic Engine Controls— 2.5L Duratec (147kW/200PS) - VI5303-14-
24
DESCRIPTION AND OPERATION
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