2011 FORD KUGA ESP

Programmable Module Installation
Activation
5.
Install the most up-to-date software version in
IDS.
6. If, before replacing a module, it was not possible
to read out the vehicle-specific data using the
integrated diagnostic system (IDS) (the module
to be replaced does not respond) then, during
programming of the new module, the
vehicle-specific data must be entered manually
via a selection list in IDS or via a code which
can be obtained from the Technical Hotline.
7. In order to program, select the "Install
programmable module" submenu in the "Module
programming" menu tool box and then follow
the instructions.
8. The following modules must be programmed
after replacement:
•
• Anti-lock braking system module (ABS)
• Audio system module (ACM)
• CD player (CDP)
• Driver's door control unit (D-DCU)
• Passenger's door control unit (P-DCU)
• Rear left door control unit (RL-DCU)
• Rear right door control unit (RR-DCU)
• Electrical power steering (EPS)
• Generic Display Module (GDM) (vehicles
with DVD navigation system with
touchscreen)
• Generic electronic module (GEM)
• Headlamp control module (HCM) (vehicles with gas discharge headlamps)
• Instrument cluster (IC)
• Navigation system (NAV) (vehicles with navigation system)
• Parking aid module(PAM)
• Powertrain control module (PCM)
• Restraint control module (RCM)
• Rear entertainment system module (RETM) (vehicles with rear seat entertainment
system)
9. In order to configure the PCM, select the
"Programmable parameters" submenu in the
"Module programming" menu tool box and then
follow the instructions.
10. For vehicles with anti-lock braking system and
electronic stability program, these must also be configured using IDS following replacement of
the lateral acceleration sensor, yaw rate sensor
or pressure sensor. Configuration is performed
in the "Programmable parameters" menu tool
box.
G1158258en
2008.50 Kuga 8/2011 418-01-3
Module Configuration
418-01-3
GENERAL PROCEDURESTO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Component Description
Interior scanning sensors
The interior monitoring is an additional security
system that triggers the alarm if unauthorised
access to the vehicle is detected in the area of the
windows.
The transceivers work ultrasonically. The
transmitter transmits at a specific frequency into
the monitoring area. The receiver receives the
corresponding echo signal. Here, the signals are
converted into digital values and compared with
the values from the signals received previously. If
there are significant differences between the two,
a trigger signal is sent to the GEM.
As the period during which no movement is
detected increases, so the sensitivity of the sensors
increases.
Anti-theft alarm horn with integral battery
A special horn is installed for vehicles that have to
comply with the Thatcham category I (CAT 1)
insurance standard. This horn has its own voltage
supply from an integrated battery. This ensures that the alarm horn will still be
powered even if the vehicle battery has been
disconnected.
G1065780en
2008.50 Kuga 8/2011 419-01A-7
Anti-Theft - Active
419-01A-7
DESCRIPTION AND OPERATIONTO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUALE100495 E100563

Description
Item
Passive key (radio remote control with
integrated emergency key)Refer to Component Description: (page
?)
4
RF receiverRefer to Component Description: (page
?)
5
PCM6 Description
Item
Transceiver of passive anti-theft system
(emergency start function)Refer to Component Description: (page
?)
7
Instrument clusterRefer to Component Description: (page
?)
8
System Operation
Passive Anti-theft System
The passive anti-theft system PATS (passive
anti-theft system) is based on an electronic engine
immobiliser.
The driver does not need to intervene in any way
to protect the vehicle, since PATS is automatically
activated when the ignition is switched off.
Component Description
Keyless vehicle module (KVM) The PATS functionality is saved in the KVM. After
pressing the start/stop button, the KVM activates
the interior antennas, which then transmit a signal.
If there is a valid passive key in the vehicle interior,
it sends an encrypted signal to the radio frequency
receiver. The radio receiver forwards this signal to
the KVM via a fixed wire. The KVM then forwards
a corresponding identification query via the HS
CAN (controller area network) to the PCM.
If a valid code was received to this query, then the
engine can be started. Interior antennas
The four interior antennas transmit an LF signal
which is identified by the passive key.
Passive key (radio remote control with
integrated emergency key)
G1065785en
2008.50 Kuga 8/2011 419-01B-5
Anti-Theft - Passive
419-01B-5
DESCRIPTION AND OPERATIONTO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUALE100587 E100793 E87065132

General overview
Haldex clutches of the 3rd and 4th generations are
used in the Ford Kuga.
The development of the third generation Haldex
clutch represents a big step forward in modern
all-wheel technology. The Haldex clutch is
electro-hydraulically controlled. Additional
information is taken into consideration during
control tasks via the all-wheel drive control unit.
Slip alone is no longer decisive for the distribution
of the propulsive forces; the vehicle's driving
dynamics are also taken into consideration. The
control unit accesses the driving-related data via
the data bus. With this data, the control unit has
all the essential information about speed, cornering,
coasting or traction operation, and can optimally
react to every driving situation.
Compared with the previous generation, the 4th
generation Haldex clutches operate with higher
pressure and achieve shorter response times when
distributing the drive forces.
Advantages of the Haldex clutch:
• Permanent all-wheel drive withelectronically-controlled multi-plate clutch
• Fast response
• No straining when parking and manoeuvring
• Compatible with different tyres (e.g. emergency spare wheel)
• Fully combinable with driving dynamic control systems
The driveshaft is connected to the input shaft of
the Haldex clutch. Within the Haldex clutch, the
input shaft is separated from the output shaft to
the rear axle differential by means of a multi-plate
clutch. Torque is only transmitted to the rear axle
differential when the plate assembly of the Haldex
clutch is closed.
The multi-plate clutch is electro-hydraulically
controlled via the all-wheel drive control unit. For
ecological driving, the torque to the rear axle is reduced to a minimum up to a throttle position of
approx. 50%. A prerequisite for this is that there is
no difference in speed in the Haldex clutch between
the input and output shafts.
Operation
E100645
16
3
25
4
Description
Item
Output shaft
1
Working piston
2
Plates
3
Ring piston pump
4
Control Valve
5
Input shaft
6
Within the Haldex clutch is a plate assembly and
a so-called ring piston pump with a pump plunger
and a working piston.
Fluid supply is started if there is a speed difference
between the input and output shafts.
This fluid pressure is transmitted to the working
piston and in this way the plate assembly is
compressed.
Design of the 3rd generation Haldex
clutch
G1076981en2008.50 Kuga8/2011
205-02- 7
Rear Drive Axle/Differential
205-02- 7
DESCRIPTION AND OPERATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

All-wheel drive control unit
E100663
14
3
2
5
Description
Item
Electronic Control Unit
1
Control valve
2
Pressure/temperature sensor
3
Electrical connection CAN (controller area
network) databus
4
Electric feed pump connection
5
The all-wheel drive control unit is bolted directly to
the housing of the Haldex clutch.
It forms one unit made up of the control valve, a
pressure/temperature sensor, and a control
module. It receives signals from the PCM and from
the ABS control module via the CAN data bus. The
control module in the control unit uses these
signals to determine the fluid pressure that is
needed to actuate the clutch plates depending on
the requirement. This determines how much torque
should be transmitted to the rear wheels. All-wheel
drive is deactivated if a fault occurs in the all-wheel
drive control unit.
A preload of approx. 80 Nm is always present at
the Haldex clutch. The temperature sensor of the Haldex clutch is
installed near the control valve in the control unit
and is surrounded by the hydraulic fluid. The
temperature is transmitted to the control module
and is used for adaptation to the changing viscosity
of the hydraulic fluid. If the hydraulic fluid is cold,
the control valve has to be opened slightly more
than requested. This allowance has to be reduced
as the temperature increases. The normal working
temperature of the hydraulic fluid is between +40
°C and +60 °C. If the temperature rises above 100
°C, the clutch is depressurised; if the temperature
falls below 95 °C, the clutch is pressurised again.
All-wheel drive is deactivated and a diagnostic
trouble code set if a fault occurs in the temperature
sensor.
With Haldex Generations I and II, the control valve
was actuated via a stepper motor. With Haldex
Generation III, the stepper motor has been omitted.
The control valve is now actuated via a solenoid
valve. The solenoid valve is actuated by the control
module in the all-wheel drive control unit by means
of pulse width modulation. The pulse width
modulation determines the position of the
adjustment spindle and thus the opening cross
section of the return hole. This is how the pressure
at the working piston of the plates is determined.
If the return hole is fully closed, maximum pressure
is applied to the plates. If the return hole is fully
open, the plates are unpressurized.
Electric feed pump
The electric feed pump is installed in the clutch
unit. It works according to the gerotor principle.
The main purpose of the feed pump is to fill the
pressure accumulator and the space behind the
pump plunger with hydraulic fluid, thereby ensuring
a fast response time of the Haldex clutch. The feed
pump used in the third generation is designed to
achieve an even higher pressure than the base
pressure of 4 bar. It is supplied with current by the
control module in the all-wheel drive control unit
when the engine is running above approx. 400 rpm.
Pressure control - 3rd generation
Haldex clutch
G1076981en2008.50 Kuga8/2011
205-02-
10
Rear Drive Axle/Differential
205-02- 10
DESCRIPTION AND OPERATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

E100540
Description
Item
Barometric Pressure
A
Base pressure
BDescription
Item
Increased base pressure (preload)
C
Operating pressure
Drive
The hydraulic fluid is drawn from the sump of the
hydraulic system and directed through a filter. The
feed pump pressurises the system and pumps
hydraulic fluid into the pump plungers. This base
pressure of 4 bar presses the rollers for the pump
plungers against the cam disc. At the same time,
hydraulic fluid flows into the working piston. This
eliminates the play in the clutch plates. The Haldex
clutch can respond quickly and distribute the torque
within fractions of a second. The spring force in
the pressure accumulator determines the base pressure of 4 bar and compensates pressure
fluctuations. A compensating spring works in the
opposite direction and prevents the plate discs
becoming blocked by the force of the working
piston. This restricts the transferable torque to
approx. 7 Nm. This value can, however, deviate
slightly due to temperature and/or the difference
in speed between the input and output shafts.
Increased base pressure (preload)
G1076981en2008.50 Kuga8/2011
205-02-
12
Rear Drive Axle/Differential
205-02- 12
DESCRIPTION AND OPERATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

SECTION 206-09B Anti-Lock Control - Stability Assist
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
DESCRIPTION AND OPERATION
206-09B-2
Anti-Lock Control - Stability Assist (Component Location) .................................................
206-09B-3
Anti-Lock Control - Stability Assist (Overview) ...................................................................
206-09B-3
Overview ........................................................................\
.....................................................
206-09B-4
Testing the brakes on a roller dynamometer - 4X4 vehicles only ...................................
206-09B-4
ABS/ESP module or hydraulic control unit (HCU) ..............................................................
206-09B-4
Combined yaw rate sensor and lateral acceleration sensor / longitudinal acceleration
sensor ........................................................................\
.......................................................
206-09B-5
Front wheel sensor ........................................................................\
.....................................
206-09B-5
Rear wheel sensor ........................................................................\
......................................
206-09B-5
Opto-electronic steering wheel rotation sensor ..................................................................
206-09B-6
ESP switch ........................................................................\
.................................................
206-09B-7
Anti-Lock Control - Stability Assist (System Operation and Component Description) ........
206-09B-7
System Diagram ........................................................................\
.........................................
206-09B-8
System Operation ........................................................................\
.......................................
206-09B-9
PRINCIPLES OF OPERATION ........................................................................\
...............
206-09B-11
Component Description ........................................................................\
..............................
206-09B-?
Opto-electronic steering wheel rotation sensor ..............................................................
206-09B-?
ABS/ESP module or hydraulic control unit (HCU) ..........................................................
206-09B-?
ESP switch ........................................................................\
..............................................
206-09B-?
Combined yaw rate sensor and lateral acceleration sensor / longitudinal acceleration
sensor........................................................................\
................................................... 206-09B-?
Front wheel sensor ........................................................................\
.................................
206-09B-?
Rear wheel sensor ........................................................................\
..................................
REMOVAL AND INSTALLATION 206-09B-16
Hydraulic Control Unit (HCU) ........................................................................\
.....................
206-09B-19
Stability Assist Module ........................................................................\
................................
206-09B-21
Front Wheel Speed Sensor ........................................................................\
........................
206-09B-22
Rear Wheel Speed Sensor ........................................................................\
.........................
206-09B-23
Yaw Rate Sensor ........................................................................\
........................................
206-09B-1
Anti-Lock Control - Stability Assist
206-09B- 1
.
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Anti-Lock Control - Stability Assist – Overview
Overview
E96701
1
2
3
45
6
7
8
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
DESCRIPTION AND OPERATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL