2011 FORD KUGA pump

E100542
Description
Item
Barometric Pressure
A
Base pressure
BDescription
Item
Increased base pressure (preload)
C
Operating pressure
Drive
The pump plungers generate the operating
pressure that is controlled by the control valve as
a function of the difference in speed between the
input and output shafts. The control valve works
progressively from fully open to fully closed. The
fluid pressure can be approx. 67 bar when the
control valve is fully open. The maximum pressure is mechanically controlled by means of the
pressure relief valve.
Design of the 4th generation Haldex
clutch
General overview
G1076981en2008.50 Kuga8/2011
205-02-
14
Rear Drive Axle/Differential
205-02- 14
DESCRIPTION AND OPERATION
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1
2
3
4
E115887
Description
Item
Fluid filter
1
All-wheel drive control unit
2Description
Item
Electric feed pump
3
Pressure accumulator
4
The electric feed pump is an axial piston pump
which is more robustly designed than the gerotor
pump in the 3rd generation Haldex. The higher
feed pressure means that the ring piston pump at
the clutch plate assembly, the pressure relief
valves, preload valve and the high pressure valves
are no longer necessary.
The pressure accumulator on the 4th generation
Haldex is larger and is designed for the higher
pressure. The 4th generation Haldex has a larger fluid filter
which contains a non-return valve.
The all-wheel drive control unit no longer contains
a pressure sensor in the 4th generation Haldex.
Pressure control - 4th generation Haldex
clutch
G1076981en2008.50 Kuga8/2011
205-02-
15
Rear Drive Axle/Differential
205-02- 15
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6
7
8
9
10
11
1
2
3
4
5
6
7
8
9
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11
E114914
Description
Item
Haldex clutch fluid
1
Inlet filter
2
Electric feed pump
3
Filters4
Pressure accumulator
5Description
Item
Control valve
6
Dished washer
7
Ring piston
8
Clutch plate pack
9
Return pressure accumulator
10
Return control valve
11
Full torque is available at any time on the 4th
generation Haldex clutch because the pressure is
not dependent on the difference in the speeds of
rotation. This is used for instance to activate the
Haldex clutch for better traction when moving off.
On the 4th generation Haldex clutch, the preload
function which applied 80 Nm to the plates in the
3rd generation is no longer required.
On request from the control unit and at engine
speeds above 400 rpm, the electric feed pump runs
and maintains the storage pressure at about 30
bar.
A pressure reducing valve acts as a control valve,
allowing the all-wheel drive control unit to control
the pressure with much greater precision. The
all-wheel drive control unit monitors the position and function of the control valve. The control valve
distributes the pressure, depending on the
requirements, across its three outlet openings
(storage pressure, working pressure, return).
From the storage pressure (30 bar) and depending
on the requirements, the control valve regulates a
working pressure of 0 - 17 bar, which is applied to
the ring piston. At 17 bar working pressure, the
maximum torque of 1000 Nm is transferred to the
rear wheels. The all-wheel drive control unit
ensures the best possible performance under all
driving conditions, for all road conditions and
independent of the speed.
G1076981en2008.50 Kuga8/2011
205-02-
16
Rear Drive Axle/Differential
205-02- 16
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Action
Possible Sources
Symptom
• ADJUST the parking brakecable or switch
REFER to: Parking Brake
Cable Adjustment (206-05
Parking Brake and Actuation,
General Procedures).
• Incorrectly adjusted parking
brake or brake pedal switch
• Brake drag
• REFER to brake booster opera-tion check in this procedure.
• Brake booster.
• INSTALL a new wheel cylinderor brake caliper.
REFER to: Brake Caliper (206-
03 Front Disc Brake,
Removal and Installation).
• Seized wheel cylinder or brake
caliper.
• INSTALL a new brake caliper.REFER to: Brake Caliper (206-
03 Front Disc Brake,
Removal and Installation).
• Seized brake caliper slide pins.
• INSTALL new parking brakecables.
REFER to: Parking Brake
Cable Adjustment (206-05
Parking Brake and Actuation,
General Procedures).
• Seized parking brake cables.
• Check the parking brake leaverposition and make sure there
are no obstructions.
• Parking brake not fully
released.
• Check all brake hose(s) forcorrect fitment.
REFER to: Rear Brake Flexible
Hose (206-04 Rear Disc
Brake, Removal and Installa-
tion)
/ Front Brake Flexible Hose
(206-03 Front Disc Brake,
Removal and Installation).
• Brake hose incorrectly fitted.
• INSTALL new brake shoes orbrake pads.
REFER to: Brake Pads (206-03
Front Disc Brake, Removal
and Installation).
• Worn or contaminated brake
shoes or brake pads.
• Excessive brake pedal effort
• INSTALL a new brake vacuumpump.
• Malfunctioning vacuum pump
(diesel).
• CONNECT or INSTALL a newbrake booster vacuum pipe as
necessary.
• Disconnected or damaged
brake booster vacuum pipe.
• GO toPinpoint Test D.
• Brake booster.
G1058975en2008.50 Kuga8/2011
206-00- 9
Brake System - General Information
206-00- 9
DIAGNOSIS AND TESTING
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Action
Possible Sources
Symptom
• INSTALL new brake shoes orbrake pads.
REFER to: Brake Pads (206-03
Front Disc Brake, Removal
and Installation).
• Worn or damaged brake shoes
or brake pads.
• Brake noise
• GO toPinpoint Test E.
• Brake booster.
• GO toPinpoint Test F.
• Brake booster.
• Seized brake pedal pivot.
• Slow or incomplete brake pedal
return
Pinpoint Tests
PINPOINT TEST A : PEDAL GOES DOWN FAST
DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
A1: PRESSURIZE THE SYSTEM
1 Pump the foot brake rapidly five times.
• Does the brake pedal height build up and then hold?
zYe s
CHECK parking brake adjustment and
ADJUST as necessary.
REFER to: Parking Brake Cable Adjustment
(206-05 Parking Brake and Actuation,
General Procedures).
If the condition still exists. BLEED the brake
system. REFER to: (206-00 Brake System -
General Information)
Brake System Bleeding (General Procedures),
Brake System Pressure Bleeding (General
Procedures),
Component Bleeding (General Procedures).
TEST the system for normal operation.
zNo
GO to A2.
G1058975en2008.50 Kuga8/2011
206-00- 10
Brake System - General Information
206-00- 10
DIAGNOSIS AND TESTING
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E139456
8.Operate the brake pedal fully (pumping brake
fluid and air into the bleed jar) and allow the
brake pedal to return to the rest position. 9.
Continue operating the brake pedal until air-free
fluid is being pumped into the bleed jar.
10. Refer to: Specifications (206-00 Brake System
- General Information, Specifications).
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206-00- 24
Brake System - General Information
206-00- 24
GENERAL PROCEDURES
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E139456
8.Operate the brake pedal fully (pumping brake
fluid and air into the bleed jar) and allow the
brake pedal to return to the rest position. 9.
Continue operating the brake pedal until air-free
fluid is being pumped into the bleed jar.
10. Refer to: Specifications (206-00 Brake System
- General Information, Specifications).
G1057428en2008.50 Kuga8/2011
206-00- 29
Brake System - General Information
206-00- 29
GENERAL PROCEDURES
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SECTION 206-07 Power Brake Actuation
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
REMOVAL AND INSTALLATION
206-07-2
(12 451 0)
Brake Booster — 2.5L Duratec (147kW/200PS) - VI5, RHD 4WD/RHD FWD .
206-07-7
Brake Vacuum Hose — 2.5L Duratec (147kW/200PS) - VI5 ..............................................
206-07-9
(12 414 0)
Brake Vacuum Pump — 2.5L Duratec (147kW/200PS) - VI5 ........................
206-07-1
Power Brake Actuation
206-07- 1
.
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