2011 FORD KUGA can

ESP switch
E99006
Stability assist can be deactivated via the menu in
the instrument cluster. The stability assist functions
are deactivated when the Set switch is actuated.
The ABS control module makes the stability assist
functions available once more when the Set switch
is actuated again. The stability assist function is
automatically reactivated when the ignition is
switched on.
The electronic EBA is a constant function and will
remain active even if the ESP has been switched
off.
Combined yaw rate sensor and lateral
acceleration sensor / longitudinal
acceleration sensor
E96822
The heart of the combined yaw rate sensor and
lateral acceleration sensor/longitudinal acceleration
sensor is a small, double-sided tuning fork made
of a piezo crystal (A). The exciter side of this tuning
fork is set to a resonance of 11 kHz with the aid of
an alternating current. The measuring side of the
tuning fork features a resonance frequency of 11.33
kHz and therefore does not vibrate (B). Since,
under influence of an external accelerating force,
a vibrating mass reacts slower than a comparable
mass that is not vibrating, the tuning fork twists
within itself with rotational movement being
imparted on the sensor (C). This rotation results
in a change in the charge distribution in the Piezo
element, which is subsequently picked up and
converted into an electronic signal by electronics
integrated into the sensor. This electronic signal is
then sent to the ESP module. The ESP module
evaluates these data and takes into account the
other input data (vehicle speed, wheel speed)
before deciding whether the ESP function is
required.
G1001304en2008.50 Kuga8/2011
206-09B-13
Anti-Lock Control - Stability Assist
206-09B- 13
DESCRIPTION AND OPERATION
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generate a square wave output signal. The signal
acts in proportion to the rotational speed of the
sensor ring. The ABS sensor rings are built into
the seals in the front wheel bearings. The ABS
module evaluates the signals from all four sensors
to calculate a vehicle speed signal based on the
rotational speeds of all wheels. The road speed is
transmitted on the CAN bus. The powertrain controlmodule (PCM) uses this signal and the
programmed tire size to calculate the vehicle
speed. The calculated vehicle speed is forwarded
on the CAN bus and is requested by other control
units that need this input information.
Rear wheel sensor
E96824
The sensors are joined to the main wiring harness
using a separate connecting cable.
G1001304en2008.50 Kuga8/2011
206-09B-
15
Anti-Lock Control - Stability Assist
206-09B- 15
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Steering gear
E96209
1
2
3
4
5
1
2
63
Description
Item
Tie-rod end
1
Tie-rod
2
steering gear boot
3Description
Item
Steering angle sensor - vehicles built up
to 09/2009
4
Input shaft
5
Valve unit housing
6
The steering gear is mounted on the front axle
crossmember and is secured with two bolts. The
bolts are inserted in the steering gear from above
and screwed into the threaded lugs on the front
axle crossmember.
The following components can be renewed
separately or as a unit:
• Complete steering gear
• Steering gear rubber bushes
• Tie rods.
• Steering gear boot
• Tie-rod end
• Steering angle sensor - vehicles built up to 09/2009 During removal and installation or renewal of
components of the steering gear, pay attention to
the following: (excluding steering angle sensor)
• Before undertaking repair work on an accident
damaged steering gear, the scope of the repair
must be determined using the inspection
instructions "Steering gear inspection after an
accident". For additional information, refer to
"Diagnosis and Testing" in this section.
• When the steering gear is removed and installed, the front axle crossmember must be
aligned with the bodywork using the appropriate
special tools.
• After completing the work, the suspension geometry of the vehicle must be checked and
corrected as necessary.
G1001269en2008.50 Kuga8/2011
211-02- 4
Power Steering
211-02- 4
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Description
Item
Electro-hydraulic power steering pump
with integrated power steering moduleRefer to Component Description:
Electro-hydraulic power steering pump
(page5)
1
Ignition switch
2
Generic electronic module (GEM)
3
Data link connector (DLC)
4
Powertrain Control Module (PCM)
5
ABS module or ESP module
6Description
Item
Steering gear
7
Integrated steering angle sensor - vehicles
built up to 09/2009RefertoComponentDescription:(page
10)
8
High pressure pipe
9
Fluid Return Line
10
Battery junction box (BJB)
11
Battery
12
System Operation
Electronic principle of operation
The power steering module requires the following
information in order to ensure precise steering
behavior in all driving situations:
• Steering wheel position
• Rate of turn of the steering wheel
• Vehicle speed
• Information about the vehicle configuration
• Information about the ignition switch position
• Instantaneous engine operating status
The required information is made available to the
power steering module via direct connections and
via the CAN bus (refer to the flow chart).
The steering wheel position and the rate of turn of
the steering wheel are transmitted to the power
steering module as PWM signals from the steering
angle sensor. The steering angle sensor receives
its voltage and ground supply from the power
steering module and operates inductively with an
input voltage of 5 V.
The vehicle speed is made available to the power
steering module as a CAN bus signal from the ABS
module or ESP module. The engine operating status is made available to
the power steering module as a CAN bus signal
from the PCM.
The power steering module obtains the vehicle
configuration information via the CAN bus from the
GEM. This information is required by the power
steering module in order to define the internal
characteristics of the power steering.
The power steering module obtains information
about the current ignition switch position via the
voltage input (terminal 15) of the ignition switch.
Whilst constantly monitoring the relevant input
signals the power steering module accesses stored
maps. With the aid of this information the pump
speed is matched to the current driving situation.
An electronic diagnosis of the electro-hydraulic
power steering can be performed with the aid of a
diagnostic tester via the DLC of the vehicle. For
additional information please refer to "Diagnosis
and Testing" in this section.
G1001270en2008.50 Kuga8/2011
211-02-
8
Power Steering
211-02- 8
DESCRIPTION AND OPERATION
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E96430
The steering angle sensor is a inductive sensor.
The steering angle sensor monitors the steering
wheel position and the rate of turn of the steering
wheel. This information is sent to the power
steering module.
On vehicles built from 09/2009the power steering
module uses the information from the steering angle sensor at the steering column. The required
information is made available to the power steering
module via the CAN bus.
Brushless DC motor with integral power
steering module
G1001270en2008.50 Kuga8/2011
211-02-
11
Power Steering
211-02- 11
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1
2
3
45
6
7
8
9
10
E42460
Description
Item
Connector
1
Power steering module
2
Seal
3
Bearing
4
Shaft
5Description
Item
Cover
6
Rotor with magnets
7
Stator8
Distributor
9
Bearing
10
In the electrohydraulic power steering system, a
brushless 12 volt direct current motor drives the
hydraulic pump. Higher pumping rates are only
provided when they are required for steering
manoeuvres. This avoids unnecessary energy
consumption in the majority of phases in a drive
cycle.
Commutation in the motor is done electronically.
As a result, there are no brushes to wear away.
The entire system is designed for maintenance-free
operation.
In more than 85% of all driving situations, the
power steering pump operates at standby speed
and consumes less than 4A. However, pump speed
can quickly increase to full rotational speed if
emergency steering manoeuvres require it. The system has a continuously variable pump
rotational speed.
G1001270en2008.50 Kuga8/2011
211-02-
12
Power Steering
211-02- 12
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Action
Possible Sources
Symptom
• CHECK if the PCV system isoperating correctly and repair
as necessary. Engine - 2.5L
Duratec-ST (VI5) -
REFER to: Engine Emission
Control (303-08 Engine
Emission Control - 2.5L
Duratec (147kW/200PS) -
VI5, Diagnosis and Testing).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Faulty positive crankcase vent-
ilation (PCV) system.
- Hoses or ventilation orbreather valves are blocked.
This causes excessive
pressure in the crankcase
which causes more oil to
enter the combustion
chamber.
- PCV oil separator is faulty and engine oil can enter the
combustion chamber
through the intake manifold.
• INSTALL a new turbocharger.Engine - 2.5L Duratec-ST (VI5)
-
REFER to: Turbocharger (303-
04 Fuel Charging and
Controls - Turbocharger -
2.5L Duratec (147kW/200PS)
- VI5, Removal and Installa-
tion).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Turbocharger seals.
• CHECK the gaskets and matingsurfaces for damage.
Remove the cylinder head.
CHECK the mating faces, cylinder
head gasket and the evenness of
the cylinder head and engine block
mating faces.
INSTALL new valve seals. Engine
- 2.5L Duratec-ST (VI5) -
REFER to: Valve Stem Seals
(303-01 Engine - 2.5L Duratec
(147kW/200PS) - VI5, Removal
and Installation).
Engine - 2.0L Duratorq-TDCi (DW)
Diesel -
• Damaged gaskets or mating
surfaces.
- Cylinder head gasket isdamaged or mating face are
warped.
- Valve stem seals are worn and engine oil can enter the
combustion chamber
between the valve stem and
the valve stem guide.
• INSTALL new components asnecessary.
• Piston ring or cylinder liner
wear.
• CHECK the running surfacesand clearances of the individual
engine components. INSTALL
new components as necessary.
INSTALL a new cylinder block
if necessary.
• Check the pistons and piston rings.
• Damaged cylinder liners or
excessive clearance of engine
components.
- Pistons.
- Piston rings (clearance ingroove and end gap).
- Cylinder liners.
G1055128en2008.50 Kuga8/2011
303-00- 3
Engine System - General Information
303-00- 3
DIAGNOSIS AND TESTING
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Action
Possible Sources
Symptom
• CHECK the engine compon-ents for wear or damage. Make
sure that all components are
within specification. INSTALL
new components as necessary.
Engine - 2.5L Duratec-ST (VI5)
-
REFER to: Specifications (303-
01 Engine - 2.5L Duratec
(147kW/200PS) - VI5,
Specifications).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Engine components
- Pistons.
- Piston rings.
- Connecting rod big end,main bearing or thrust
bearing journals.
- Connecting rods bent or damaged.
• Noisy running or engine noise
Engine - Oil Leaks
NOTE:
Before installing new gaskets or oil seals,
make sure that the fault is clearly established.
If the oil leak cannot be identified clearly by a visual
inspection, carry out an ultraviolet (UV) test:
Ultraviolet (UV) Testing
1. Clean the engine and transmission with a suitable cleaning fluid.
2. Pour the UV-test fluid in accordance with the quantity specified by the manufacturer through
the oil filler neck into the engine and install the
oil filler cap.
WARNING: Vehicles with manual transaxle,
shift the transaxle into Neutral. Failure to
follow this instruction may result in
personal injury.
3. Start the engine and let it run for about five minutes.
4. Switch off the engine.
NOTE: If no leak can be found, road test the
vehicle under various loads and check the engine
for leaks again.
5. Check the engine for oil leaks using a suitable UV lamp.
6. Rectify any leaks found and check the engine for oil leaks.
Measure the compression pressure
NOTE: The powertrain control module (PCM)
receives an error message when the fuel pump
relay is removed or electrical components are disconnected. This error message must be deleted
from the fault memory using the Ford diagnostic
equipment after completing the compression test.
NOTE:
Valve clearance must be set correctly
before performing a compression test. Make sure
the engine is at the normal operating temperature.
NOTE: The varying design of compression
checking devices and fluctuating starter motor
speeds normally only allows for a comparison to
be made of the compression pressures in all
cylinders.
G1055128en2008.50 Kuga8/2011
303-00- 9
Engine System - General Information
303-00- 9
DIAGNOSIS AND TESTING
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