2011 FORD KUGA AUX

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
G1066982en
2008.50 Kuga 8/2011 412-02-14
Auxiliary Climate Control
412-02-14
DESCRIPTION AND OPERATIONTO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUALE97621

Description
Item
Cooling sleeve cover
1
Combustion air blower cover
2
Fuel fired additional heater module
3
Combustion Air Blower
4
Cooling sleeve
5
Glow plug
6
Flame sensor
7
Overheat Sensor
8 Description
Item
ECT9
Compression spring
10
'O' Ring
11
Internal wiring harness - fuel fired
additional heater
12
Gasket
13
Gasket
14
Heat exchanger
15 G1066982en
2008.50 Kuga 8/2011 412-02-15
Auxiliary Climate Control
412-02-15
DESCRIPTION AND OPERATIONTO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUALE850351132126791011115144316171518198

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.
G1066982en
2008.50 Kuga 8/2011 412-02-16
Auxiliary Climate Control
412-02-16
DESCRIPTION AND OPERATIONTO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUALE97646 E97647

Auxiliary Coolant Flow Pump
General Equipment
Hose Clamp(s) General Equipment
Hose Clamp Remover/Installer
Removal
1. Refer to: Engine Cooling System Health and
Safety Precautions (100-00 General
Information, Description and Operation).
2. Refer to: Jacking(100-02 Jacking and Lifting,
Description and Operation).
3. General Equipment: Hose Clamp(s)
General Equipment: Hose Clamp
Remover/Installer Installation
1.
To install, reverse the removal procedure.
2. Check the coolant level.
Refer to: Cooling System Draining and Vacuum
Filling (303-03 Engine Cooling, General
Procedures). G1163562en
2008.50 Kuga 8/2011 412-02-17
Auxiliary Climate Control
412-02-17
REMOVAL AND INSTALLATIONTO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL11E112651

Electric Booster Heater
Removal
NOTE:
Removal steps in this procedure may
contain installation details.
1. Refer to: Floor Console (501-12 Instrument
Panel and Console, Removal and Installation).
2. Torque: 9 Nm 3.
Refer to: Climate Control Assembly - Vehicles
With: Manual Temperature Control (412-01
Climate Control, Removal and Installation).
Refer to: Climate Control Assembly - Vehicles
With: Automatic Temperature Control (412-01
Climate Control, Removal and Installation).
4. Torque: 10 Nm1.
2. Torque: 25
Nm
G1074270en
2008.50 Kuga 8/2011 412-02-18
Auxiliary Climate Control
412-02-18
REMOVAL AND INSTALLATIONTO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUALx4E101619

5.
Installation
1.
To install, reverse the removal procedure. G1074270en
2008.50 Kuga 8/2011 412-02-20
Auxiliary Climate Control
412-02-20
REMOVAL AND INSTALLATIONTO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUALE101466

Fuel Fired Booster Heater — 2.5L Duratec (147kW/200PS) - VI5
General Equipment
Hose Clamp(s) General Equipment
Hose Clamp Remover/Installer
Removal
NOTE: Removal steps in this procedure may
contain installation details. 1.
Refer to: Engine Cooling System Health and
Safety Precautions (100-00 General
Information, Description and Operation).
Refer to: Petrol and Petrol-Ethanol Fuel
Systems Health and Safety Precautions
(100-00 General Information, Description and
Operation).
2. Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
3. G1163563en
2008.50 Kuga 8/2011 412-02-21
Auxiliary Climate Control
412-02-21
REMOVAL AND INSTALLATIONTO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUALE112641

7.
Installation
1.
To install, reverse the removal procedure.
2. Check the coolant level.
Refer to: Cooling System Draining and Vacuum
Filling (303-03 Engine Cooling, General
Procedures). G1163563en
2008.50 Kuga 8/2011 412-02-24
Auxiliary Climate Control
412-02-24
REMOVAL AND INSTALLATIONTO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUALE112645