2011 FORD KUGA pump

Description
Item
Glow plug
1
Combustion Air Blower
2
Fuel pump
3
Fuel-fired heater on
4
Fuel-fired heater - large regulating step
5
Fuel-fired heater - small regulating step
6 Description
Item
Fuel-fired heater off
7
Blower motor on
8
Flame detection
9
Blower motor off
10
Large regulating step
11
Small regulating step
12
Boost heat mode
When the engine is running, the booster heater
helps the engine to heat the passenger
compartment at low ambient temperatures.
When the coolant temperature reaches 30 °C, the
control unit transmits a switch-on signal for the
passenger compartment blower via the CAN bus.
When the coolant temperature drops, the blower
remains on until the temperature reaches 20 °C
whereupon it is deactivated.
The fuel tank must be filled to at least 14% for the
system to be switched on. If the fuel level drops
below 8% then the system is switched off.
In boost mode, the fuel fired booster heater is only
switched on if all of the following criteria are met:
• Engine speed above 500 rpm. The fuel fired booster heater is not allowed to start up while
the engine is being cranked; this prevents a
shut-down due to low voltage if the battery
charge is low.
• Ambient temperature below 5 °C.
• Fuel level above 14% of total capacity.
• Function is active on the trip computer menu.
One of the following conditions is sufficient to
switch off the booster heater in boost heat mode:
• Engine speed below 500 rpm.
• Ambient temperature above 11 °C.
• Function is active on the trip computer menu.
• Fuel level below 8% of total capacity.
Programmable fuel fired booster heater
The programmable fuel fired booster heater has
two operating modes:
• Instant start
• Programmed start
The heater status is displayed on the instrument
cluster display. The parking heater mode is controlled via a menu in the message centre. The
fuel fired booster heater can be activated and
deactivated via the message centre. (If set to 'Auto'
the system is activated, if set to 'Off' the system is
completely deactivated)
Immediate start-up of the booster
heater
This function enables the fuel-fired booster heater
to be switched on manually when the engine is not
running. This function is activated via the menu on
the driver information system.
The ignition key must be in the II" position before
this menu can be accessed. The timer function of
the booster heater remains active when the ignition
key is in position "0".
After an immediate start-up of the booster heater
it is switched off again after 30 minutes (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.
Programmed start-up of the booster
heater
The driver can use a menu to adjust the time at
which the vehicle is to be pre-heated. The following
options are available:
• Time setting. One or two times can be
programmed for each day of the week. It is
possible to program days either individually or
together in groups (Mon-Sun/Mon-Sat/Mon-Fri).
• Time and data setting
With the first option, the fuel-fired booster heater
will start repeatedly without needing to be G1066982en
2008.50 Kuga 8/2011 412-02-13
Auxiliary Climate Control
412-02-13
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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.
G1066982en
2008.50 Kuga 8/2011 412-02-16
Auxiliary Climate Control
412-02-16
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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
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL11E112651

Fuel Fired Booster Heater Fuel Pump
Removal
1.
Refer to: Petrol and Petrol-Ethanol Fuel
Systems Health and Safety Precautions
(100-00 General Information, Description and
Operation).
2. Refer to: Fuel Tank - 2.5L Duratec
(147kW/200PS) - VI5 (310-01 Fuel Tank and
Lines, Removal and Installation).
3. Refer to: Quick Release Coupling (310-00 Fuel
System - General Information, General
Procedures). Installation
1.
To install, reverse the removal procedure. G1163564en
2008.50 Kuga 8/2011 412-02-25
Auxiliary Climate Control
412-02-25
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUALE112750

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.
G1030770en
2008.50 Kuga 8/2011 413-01-4
Instrument Cluster
413-01-4
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Description
Item
HS CAN
1
DLC2
MS CAN
3
Instrument cluster (gateway)
4
Front windshield wiper motors
5
GEM6
Rear window wiper motors
7
Indicator/heated windshield
8
Indicator/heated rear window
9 Description
Item
Mini-liftgate latch motor
10
Liftgate latch motor
11
Electric booster Heater
12
Front wiper windscreen washer pump
13
Rear wiper windscreen washer pump
14
Headlamp
15
Courtesy Lighting
16
Alarm horn
17
System Operation
GEM.
The following functions are controlled or performed
by the GEM at a battery voltage of between 9 and
16 volts:
• Current distribution
• Battery charging (Smart Charge)
• Ignition overload protection
• Headlamp switch-off delay
• Turn signals
• Interior lighting
• Heated windscreen
• Heated rear window and heated external mirrors
• Ambient air temperature
• Brake fluid level
• Automatic headlamps
• Combined rain sensor/light sensor
• Windshield wash/wipe system
• Speed control – reads the speed control switches andtransmits signals on the CAN data bus
• central door locking – transmits signals on the CAN data bus
• Anti-theft
• Electric booster Heater
• Climate control
• Parking brake –(monitors the switch and transmits the signal
on the CAN data bus
• Communication via the medium-speed CAN data bus Component Description
Battery charging (Smart Charge)
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.
The alternator load is signaled to the PCM
(powertrain control module) in order to provide it
with an early indication when an electric component
is to be switched on or off, thereby also providing
information about imminent changes to the amount
of torque demanded by the alternator. By
evaluating this information the PCM is capable of
increasing the stability of the engine under idling.
The two remaining functions of the Smart Charge
system are controlled by the GEM. G1030788en
2008.50 Kuga 8/2011 419-10-6
Multifunction Electronic Modules
419-10-6
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Generic Electronic Module (GEM)
General Equipment
Ford Diagnostic Equipment
Removal
CAUTIONS: Modules must not be swapped between
vehicles.
Compare the number of relays and fuses
in the defective GEM and the new GEM.
Transfer from the defective GEM any relays
and fuses which are not in the new GEM.
In doing so, pay attention that fuses with
the correct Ampere rating are used, by
referring to the wiring diagrams.
When installing a new GEM on vehicles
with a diesel engine, make sure that a fuel
pump fuse (F111) with 5A is used.
When installing a new GEM on vehicles
with a petrol engine, make sure that a fuel
pump fuse (F111) with 15A is used.
NOTE: GEM is integrated into the central junction
box (CJB) and cannot be removed individually.
1. NOTE: This step is only necessary when
installing a new component.
Upload the GEM configuration information using
the Programmable Modules Installation Routine.
General Equipment: Ford Diagnostic Equipment
2. Refer to: Battery Disconnect and Connect
(414-01 Battery, Mounting and Cables,
General Procedures).
3. 4.
5.
Installation
1.
To install, reverse the removal procedure.
2. NOTE: This step is only necessary when
installing a new component.
Download the GEM configuration information
to the newly installed GEM using the
programmable modules installation routine.
3. NOTE: This step is only necessary when
installing a new component.
Program all keys using the Key Programming
Routine.
General Equipment: Ford Diagnostic Equipment G1065605en
2008.50 Kuga 8/2011 419-10-14
Multifunction Electronic Modules
419-10-14
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUALE51159 122E102019 E102020

SECTION 205-02 Rear Drive Axle/Differential
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
DESCRIPTION AND OPERATION
205-02-2
Rear Drive Axle and Differential (Component Location) .....................................................
205-02-6
Rear Drive Axle and Differential (System Operation and Component Description) ...........
205-02-6
System Operation ........................................................................\
.......................................
205-02-6
General Information ........................................................................\
................................
205-02-6
Driving situations ........................................................................\
....................................
205-02-6
Haldex clutch ........................................................................\
..........................................
205-02-7
General overview ........................................................................\
....................................
205-02-7
Operation ........................................................................\
................................................
205-02-7
Design of the 3rd generation Haldex clutch ....................................................................
205-02-9
Design of the multi-plate clutch ........................................................................\
...............
205-02-10
All-wheel drive control unit ........................................................................\
......................
205-02-10
Electric feed pump ........................................................................\
..................................
205-02-10
Pressure control - 3rd generation Haldex clutch .............................................................
205-02-11
Base pressure ........................................................................\
.........................................
205-02-12
Increased base pressure (preload) ........................................................................\
.........
205-02-13
Pressure build-up ........................................................................\
....................................
205-02-14
Design of the 4th generation Haldex clutch ...................................................................
205-02-14
General overview ........................................................................\
....................................
205-02-15
Pressure control - 4th generation Haldex clutch .............................................................
GENERAL PROCEDURES 205-02-17
Differential Fluid Level Check ........................................................................\
.....................
205-02-19
Active On-Demand Coupling Fluid Level Check ................................................................
REMOVAL AND INSTALLATION 205-02-21
Differential Case ........................................................................\
.........................................
205-02-25
Active On-Demand Coupling Module ........................................................................\
.........
205-02-32
Differential Input Shaft Seal ........................................................................\
........................
205-02-38
Differential Support Insulator ........................................................................\
......................
205-02-39
Rear Halfshaft Seal ........................................................................\
.....................................
205-02-41
Drive Pinion Seal ........................................................................\
........................................
DISASSEMBLY AND ASSEMBLY
205-02-42
Active On-Demand Coupling — Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450 ...............................................................
205-02-1
Rear Drive Axle/Differential
205-02- 1
.
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