2011 FORD KUGA front

Anti-Lock Control - Stability Assist – Overview
Overview
E96701
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2
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45
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9
Description
Item
ABS/ESP module or hydraulic control unit
(HCU)
1
Front wheel sensor, left-hand side
2
Steering Wheel Rotation Sensor
3
Rear wheel sensor, left-hand side
4Description
Item
Rear wheel sensor, right-hand side
5
Combined yaw rate sensor and lateral
acceleration sensor / longitudinal
acceleration sensor
6
Wiring harness
7
G1001303en2008.50 Kuga8/2011
206-09B- 3
Anti-Lock Control - Stability Assist
206-09B- 3
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Description
Item
Front wheel sensor, right-hand side
8Description
Item
9 ESP switch
Testing the brakes on a roller dynamometer
- 4X4 vehicles only
On 4X4 vehicles a brake test on a roller
dynamometer must only be performed under the
following conditions.
• The brake test must not exceed a duration of 1 minute.
• Ignition key in position 0.
• The roller speed must not exceed 5 km/h.
ABS/ESP module or hydraulic control
unit (HCU)
E96821
1
23
The ABS/ESP module or the hydraulic control unit
(HCU) is mounted on the left-hand side of the
bulkhead. Diagnosis is performed with the aid of
a diagnostic tester.
The following components can be replaced
separately or as a unit:
• Hydraulic Control Unit (HCU)
• ABS/ESP module
• Mounting Bracket
The following must be taken into account when
removing/installing or renewing the ABS/ESP
module or the hydraulic control unit (HCU):
• Only hydraulic control units (HCU) which are pre-filled with brake fluid are available for
service operations.
• After replacing the HCU it is not necessary to bleed the system via the diagnostic tester.
• After replacing the brake fluid it is also only necessary to perform standard bleeding.
• The blanking caps/plugs must not be removed until the brake tubes are ready to be connected. • If accidentally dropped or knocked install a new
hydraulic control unit (HCU) and module
assembly.
• When the ABS/ESP module is removed/installed or replaced, it is necessary to reconfigure the
ABS/ESP module with the aid of the diagnostic
tester once all of the installation work has been
performed.
Refer to: Module Configuration (418-01 Module
Configuration, General Procedures).
Combined yaw rate sensor and lateral
acceleration sensor / longitudinal
acceleration sensor
E96822
The sensor is attached to the floor crossmember
at the front right. For vehicles with 4x4 drive, a
longitudinal acceleration sensor is also integrated
in the same housing.
The following must be taken into account when
removing/installing or replacing the combined yaw
rate sensor and lateral/longitudinal acceleration
sensor:
• Ensure the correct installation position of the yaw rate sensor and lateral/longitudinal
acceleration sensor.
G1001303en2008.50 Kuga8/2011
206-09B- 4
Anti-Lock Control - Stability Assist
206-09B- 4
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Front wheel sensor
E96823
The ABS sensor rings are built into the seals in the
front wheel bearings. The wheel sensors are joined
to the main wiring harness using a separate
connecting cable.
Rear wheel sensor
E96824
4X4:The ABS sensor rings are pressed onto the
rear drive shafts. The wheel sensors are joined to
the main wiring harness using a separate
connecting cable.
4X2: The ABS sensor rings are built into the hubs
of the rear wheel bearings. When installing a
replacement bearing, ensure that the new part is
aligned correctly. The wheel sensors are joined to
the main wiring harness using a separate
connecting cable.
Opto-electronic steering wheel rotation
sensor
E80158
G1001303en2008.50 Kuga8/2011
206-09B- 5
Anti-Lock Control - Stability Assist
206-09B- 5
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Description
Item
D.C. motor
9
Solenoid-operated pilot valve (2 off)
10
Solenoid-operated priming valve (2 off)
11
One way check valve
12
Low-pressure accumulator (2 off)
13
Solenoid-operated inlet valve (RH rear
brake)
14
Solenoid-operated inlet valve (LH front
brake)
15
Solenoid-operated outlet valve (LH front
brake)
16
Solenoid-operated outlet valve (RH rear
brake)
17Description
Item
Pressure sensor (5 off)
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LH front brake (secondary circuit)
19
RH rear brake (secondary circuit)
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LH rear brake (primary circuit)
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RH front brake (primary circuit)
22
Solenoid-operated outlet valve (RH front
brake)
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Solenoid-operated outlet valve (LH rear
brake)
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Solenoid-operated inlet valve (LH rear
brake)
25
Solenoid-operated inlet valve (RH front
brake)
26
System Operation
The HCU features 3 operating modes:
Normal braking:
Initially, no current is supplied to
any of the solenoid-operated valves. Operating the
brake pedal produces a corresponding increase
or decrease of pressure in the brakes, through the
open pilot valves and inlet valves. If the ABS
module determines that EBD is necessary, it
energizes the inlet valves for both the rear brakes,
to isolate the brakes from any further increase in
hydraulic pressure.
ABS braking: If the ABS module determines that
ABS braking is necessary, it actuates the inlet and
outlet valves of the relevant brake and starts the
hydraulic return pump. The inlet valve closes to
isolate the brake from pressurized fluid; the outlet
valve opens to release pressure from the brake
into the accumulator and the return pump circuit.
The brake releases slightly and the wheel starts to turn again. The ABS control unit then operates the
inlet and outlet valves to regulate the hydraulic
pressure acting on the brake in order to maximize
braking effect without the wheel locking up. Control
of the valves for each wheel takes place
individually.
Active braking:
With active braking, pressure is
generated for other braking functions than the
normal and ABS braking systems, e.g. for the ESP
and TCS systems. For active braking, the ABS
module energizes the pilot valves and priming
valves, starts the return pump and energizes all of
the inlet valves. Brake fluid, drawn from the
reservoir through the master cylinder and priming
valve, is pressurized by the return pump and
supplied to the inlet valves. The ABS control unit
then actuates the inlet and outlet valves in order
to regulate the pressure for the individual brakes.
Some noise may be generated during active
braking.
G1001304en2008.50 Kuga8/2011
206-09B- 8
Anti-Lock Control - Stability Assist
206-09B- 8
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Description
Item
Battery
1
Battery junction box (BJB) in the engine
compartment
2
Generic electronic module (GEM)
3
Powertrain Control Module (PCM)
4
Instrument cluster
5
Data link connector (DLC)
6
Steering Wheel Rotation Sensor
7
ABS/ESP module or hydraulic control unit
(HCU)
8Description
Item
Combined yaw rate sensor and lateral
acceleration sensor / longitudinal
acceleration sensor
9
Front wheel sensor
10
Rear wheel sensor
11
Rear wheel sensor
12
Front wheel sensor
13
ESP switch
14
Rear brakes
15
Front brake
16
The ABS monitors the different wheel speeds of
the vehicle with the aid of wheel speed sensors.
Using the data from all of the wheel speed sensors,
the ABS module calculates the so-called reference
speed, which is a measure of the actual road
speed. The ABS module compares the individual
circumferential wheel speeds with this reference
speed when the driver initiates braking. If one or
more of the circumferential wheel speeds deviates
too far from the reference speed, this means that
slip at the affected wheels is so great that steering
stability of the vehicle is no longer ensured. The
ABS module actuates electro-mechanical valves
which influence the brake pressure at the relevant
wheels.
Like the traction control system (TCS), the ESP
system uses a large proportion of the ABS
components. In addition, there are sensors which
pick up the steering angle, the acceleration forces
acting on the vehicle and the yaw rate or yaw
moment. The sensors transmit these signals to the
combined ABS/ESP module. Using the wheel
speed and steering angle data, the ABS/ESP
module calculates the direction of travel planned
by the driver and determines the corresponding
speed-dependent lateral acceleration and yaw
moment. These values are compared with those
actual measured. If the actual lateral acceleration
and the yaw moment deviate excessively from the
target values (unstable driving characteristics), the
ABS/ESP module actuates individual brakes
selectively via the HCU (hydraulic control unit). In
addition, the engine speed is reduced by
intervention in the engine management system.
How the system works for understeer: In the
event of understeer, brake intervention occurs at
the wheels on the inside of the curve. The rear
wheel is braked heavily, so that a high amount of slip is caused. In this way, the cornering force of
the rear axle is heavily reduced and the centrifugal
force that now becomes effective turns the rear of
the vehicle back into the curve. The front wheel is
not braked as hard. The braking force that is
transmitted via the front wheel to the road surface
generates a torque with the aid of the lever arm
(vertical tire force to the vehicle's centre of gravity),
which supports the yaw moment of the vehicle.
Both measures together result in the vehicle
reverting back to the curved path intended by the
driver.
How the system works for oversteer:
In the
event of oversteer the wheels on the outside of the
curve are braked. This time, the front wheel is
subjected to a high level of slip so that the
cornering force at the front axle is reduced. The
rear wheel is not braked as heavily and, together
with the effective lever arm, results in a reduction
in the vehicle yaw moment. Both measures
together result in the vehicle being stabilized and
reverting back to the curved path intended by the
driver.
If ESP control occurs, possible ABS interventions
will be overridden as the ESP works at higher slip
rates than the ABS.
Emergency brake assist (EBA): The emergency
brake assist helps drivers in emergency braking
situations by automatically applying the brakes with
the maximum possible braking force.
If the brake pedal is pressed very suddenly, the
ABS module increases the hydraulic pressure to
all of the brakes until the threshold for ABS
intervention is reached. This applies the maximum
braking effort for the available traction. The ABS
control unit monitors inputs from the brake pedal
switch and from the pressure sensor within the
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Anti-Lock Control - Stability Assist
206-09B- 10
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HCU to check for sudden actuation of the brakes.
With the brake pedal pressed, the ABS module
triggers emergency braking if the rate of increase
of hydraulic pressure exceeds the predetermined
limit.
If the brake pedal is pressed so hard that the ABS
becomes active on the front wheels then the ABS
control unit increases the pressure to the rear
wheel brakes up to the ABS intervention threshold.
EBA operation continues until the driver releases
the brake pedal sufficiently for the hydraulic
pressure in the HCU to drop below a threshold
value stored in the ABS module.
Trailer stability control:If the vehicle is ordered
with a trailer coupling then the Trailer Stability
Control function is integrated in the ESP. The ESP
detects snaking when driving with a trailer and
reduces the speed of the vehicle and trailer through
adapted braking and, if necessary, by also reducing
the engine output until the snaking movement of
the trailer is corrected.
Roll-over protection: The ESP dynamically
determines the tipping tendency of the vehicle and
works in conjunction with the EBA system to
prevent the vehicle from tipping over during
dynamic maneuvers like lane changing or while
negotiating bends.
Emergency brake light: The emergency brake
light automatically switches on the hazard flasher
system to warn drivers of other vehicles that
emergency braking is being initiated. Based on a
defined delay value, the ABS/ESP module sends
a signal to the generic electronic module (GEM)
via the CAN data bus. The GEM activates the
hazard flasher system, that then flashes 7 times.
Prerequisites for activation of the emergency brake
light are:
• The speed is higher than 50 km/h.
• The brake pedal is being actuated.
• The deceleration is greater than 9 m/s².
To prevent activation on snow or ice, for example,
the following prerequisites must be met:
• The speed is higher than 50 km/h.
• The brake pedal is being actuated.
• ABS regulation takes place.
• The deceleration is greater than 6 m/s².
Tire pressure monitoring system: The tire
pressure monitoring system used in the Kuga is
able to detect loss of air in a tire at an early stage
and warn the driver. Because it can only compare
the behaviour of the tyres with each other, it is not possible to draw conclusions about the absolute
tyre pressure. It is also not possible to monitor the
spare tyre pressure. In order for the system to
operate correctly, the tyre pressures must be
regularly checked and corrected and the system
subsequently initialised (see below).
The tire pressure monitoring system used here,
depending on the equipment level, is built into the
anti-lock braking system (ABS) as an extra function
and therefore does not have its own sensors.
The ABS module measures the loss of pressure
in the tyres by calculation using the wheel speed
sensors of the ABS system. If a tyre loses
pressure, its diameter decreases and the speed of
the wheel therefore increases. If the ABS module
detects such a loss in pressure, it sends a signal
to the instrument cluster via the CAN bus and a
warning message is displayed in the message
centre. The warning threshold depends among
other things on the dimension of the tyres being
used, the vehicle operating conditions and the
status at the last initialisation. Since neither the
absolute tyre pressure nor the position of the tyre
is known, the pressure of all the tyres must be
checked and the system re-initialised after a tyre
pressure warning. If necessary, the cause of the
loss of pressure must be investigated.
Regular tyre pressure checks are still necessary.
The system must be initialised after a tyre is
changed, winter or summer tyres fitted, the
pressures corrected or adjusted to suit the vehicle
load. This can be done by the driver using the
driver information system. For further information,
see: Owner’s Manual.
Component Description
Opto-electronic steering wheel rotation
sensor
E80158
G1001304en2008.50 Kuga8/2011
206-09B-
11
Anti-Lock Control - Stability Assist
206-09B- 11
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E53340
1
2
3
Description
Item
Tuning fork exciter
1
Suspension
2
Measuring side
3
Due to the special way in which it works. the
combined yaw rate sensor and lateral acceleration
sensor/longitudinal acceleration sensor must be
installed the right way up in the designated location
specified by the manufacturer. Any slight deviation
in the installation position and/or installation
location could lead to impaired functionality and
thereby possible failure of the stability assist.
Front wheel sensor
E96823
Active sensors are used to determine the rotational
speeds of the wheels at the hub. After the ignition
is switched on, the ABS module supplies the
sensors with power. The sensors work in
accordance with the Hall effect principle and
G1001304en2008.50 Kuga8/2011
206-09B- 14
Anti-Lock Control - Stability Assist
206-09B- 14
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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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