2011 FORD KUGA relay

TIE44583
5. Remove the glow plug relay.
6. Lower the vehicle.
7. Remove the cowl panel grille.REFER to: Cowl Panel Grille (501-02 Front End
Body Panels, Removal and Installation).
E50527
8. NOTE: The engine upper cover is held in place by 3 ball clips. The ball clips are not
vertical, but are angled backwards by
approximately 20 degrees.
Location of the engine upper cover ball clips.
E50472
2
1
3
4
9.CAUTION: Contact of the engine upper
cover with the cowl panel may cause damage
(scratches) on the engine upper cover. If the
ambient temperature is below 0°C, detach
the engine upper cover with extreme caution. Failure to follow this instruction may cause
the engine upper cover to be damaged.
NOTE: Only remove and install the engine upper
cover in the sequence shown.
Remove the engine upper cover.• Detach the engine upper cover ball clips in the sequence shown.
TIE39594
10.CAUTION: Do not disconnect the fuel
injection pump electrical connectors and
crank the engine.
Disconnect the fuel injector electrical
connectors.
11. Remove the exhaust gas recirculation (EGR) cooler.
12. Remove the EGR valve.
TIE39687
13. Remove the glow plug power supply.
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Put the engine cover into installation position
and clip it in place by pressing at the places
shown.• Make sure that the engine upper cover is fully engaged in the area of the fuel filter, if
necessary apply more pressure in the areas
shown.
25. Install the cowl panel grille.
REFER to: Cowl Panel Grille (501-02 Front End
Body Panels, Removal and Installation).
26. Raise and support the vehicle.
REFER to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
TIE44583
27. Install the glow plug relay.
VFE0035752
28. Install the radiator undershield.
VFE0035742
29. Install the engine undershield.
30. Lower the vehicle.
31. Reset the PCM fault memory.
Measure the oil pressure (21 113 0)
The oil pressure depends on various factors
(engine speed, oil temperature, oil viscosity,
amount of oil filter contamination etc.).
Measure the oil pressure (Engine - 2.5L
Duratec-ST (VI5))
1. Raise and support the vehicle.
REFER to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
E65955
2. Remove the engine undershield.
E68443
3. Disconnect the oil pressure switch electrical connector.
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Engine System - General Information
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Description
Item
Vehicles with manual transaxle.
A
If equipped with an automatic transaxle.
B
Ignition key
Comments:With transponder for PATS (passive
anti-theft system)
1
PAT S
2
Ignition lock
3
GEM (generic electronic module)
4
PCM (powertrain control module)
5
Battery
6Description
Item
Starter relay
7
Starter motor
8
Stoplight Switch
Comments:If equipped with an automatic transaxle.
9
TCM (transmission control module)
Comments:If equipped with an automatic transaxle.
10
Starting deactivation relay
Comments:If equipped with an automatic transaxle.
11
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Starting System— 2.5L Duratec (147kW/200PS) - VI5303-06-
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Description
Item
Start/stop button
1
CPP (clutch pedal position) switches
Comments:Switches when the clutch pedal is
operated
2
Keyless vehicle module
3
Electronic steering lock with mount -
passive key and PATS transmitter/receiver
unit
Comments:for emergency start function
4Description
Item
Radio frequency receiver
Comments:Signal is only executed in GEM
5
GEM
6
PCM
7
Starter relay
8
Starter motor
9
Battery
10
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Starting System— 2.5L Duratec (147kW/200PS) - VI5303-06-
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Description
Item
Start/stop button
1
Keyless vehicle module
2
Electronic steering lock with mount -
passive key and PATS transmitter/receiver
unit
Comments:for emergency start function
3
Radio frequency receiver
Comments:Signal is only executed in GEM
4Description
Item
GEM
5
Stoplight Switch
6
TCM7
Starting deactivation relay
8
PCM
9
Starter relay
10
Starter motor
11
Battery
12
System Operation
Smart Start
The PCM enables the starting process when a key
providing a valid code is read via the PATS. This
code is then verified in the GEM and compared
with the saved code. If this code is recognized as
correct, synchronization with other modules is
carried out. After successful synchronization, the
engine is cleared to start in the PCM. The PCM
connects earth to the starter relay, which then
connects power to the starter solenoid. As soon
as the engine reaches a certain speed, the PCM
disconnects the starter relay and so turns off the
starter. This protects the starter.
If the engine does not turn or turns only slowly, the
starting process is aborted by the PCM.
The starter is notactivated if:
• the engine is running (i.e. the engine speed is above a particular value),
• the PATS does not permit the engine to be started,
• the clutch pedal is not operated (vehicles with manual transmission),
• the gear selector level is not set to P or N (vehicles with automatic transmission),
• the brake pedal is not operated (vehicles with automatic transmission).
Emergency starting function
If the keyless vehicle system is unable to recognize
the passive key, the vehicle can be started via the
emergency starting function. In this case, there is a passive key mount on the
steering wheel. A PATS transmission/reception
unit is attached to this.
To start the engine, the passive key must be
inserted into the passive key mount. The Start/Stop
button can then be used to turn on the ignition and
start the engine as normal. To deactivate the
PATS, a transponder is fitted in the passive key,
which is read by the transmission/reception unit.
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Starting System
Refer toWiring Diagrams Section 303-06, for
schematic and connector information.
General Equipment
Ford diagnostic equipment
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of electrical damage.
Visual Inspection Chart
Electrical
• Fuse(s)
• Wiring harness
• Electrical connector(s)
• Relay
• Switch(es)
• Battery junction box (BJB)
• Engine junction box (EJB)
• Central junction box (CJB)
• Keyless vehicle module (KVM) (if equipped)
• Battery
• Starter motor
• Powertrain Control Module (PCM)
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible)
before proceeding to the next step.
4. If the cause is not visually evident, verify the symptom and refer to the diagnostictab within
the Ford diagnostic equipment .
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Engine Emission Control
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanicaldamage.
Visual Inspection Chart
Electrical
Mechanical
– Electricalconnector(s)
– Wiring harness
– Fuse(s)
– Relay
– Powertain control module (PCM)
– Hose(s)/hose joints
– Gasket(s)
– Positive crankcase
ventilation (PCV)
valve
– PCV crankcase vent oil separator
– Turbocharger 3. If an obvious cause for an observed or reported
concern is found, correct the cause (if possible)
before proceeding to the next step.
4. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart.
Symptom Chart
Action
Possible Sources
Symptom
• CLEAN or INSTALL new PCVcomponents as necessary.
TEST the system for normal
operation.
• Blocked PCV crankcase vent
oil separator.
• Blocked PCV hose.
• Excessive crankcase pressure
• Worn or damaged enginecomponents.
REFER to: Engine(303-00
Engine System - General
Information, Diagnosis and
Testing).
• Engine.
• CLEAN or INSTALL a newcrankcase vent oil separator.
TEST the system for normal
operation.
• Crankcase vent oil separator.
• Oil in the air intake system
• Worn or damagedturbocharger.
REFER to: Turbocharger (303-
04 Fuel Charging and
Controls - Turbocharger -
2.5L Duratec (147kW/200PS)
- VI5, Diagnosis and Testing).
• Turbocharger.
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Powertrain Control Module (PCM)
E65160
The PCM communicates with all engine sensors
and the other modules. Communication of the PCM
with the other modules and the system diagnostics
takes place via the CAN (controller area network)
data bus.
The following functions are regulated or controlled
by the PCM:
• Fuel supply to the engine including lambdacontrol
• Ignition setting including knock control
• Idle speed control
• Control of optimum valve timing via the camshaft adjustment for intake and exhaust camshafts
• The refrigerant compressor is controlled by the air conditioning clutch relay and the delivery of
the refrigerant compressor is controlled by a
PWM (pulse width modulation) signal.
• Control of EVAP purge valve
• Boost pressure control
• Control of the cooling fan
• Charging system (Smart Charge)
• Starting system (Smart Start)
If the PCM is isolated from the vehicle electrical
system or the battery is disconnected, the throttle
control unit mustbe initialized.
The PCM is fitted in the engine compartment in the
air filter housing. On right hand drive vehicles a
protective metal plate is also installed to prevent
the plug connector from being pulled off, or make
it harder to pull off, in case of theft. The protective
plate is secured with a shear bolt. The shear bolt
needs to be drilled out in order to remove the
protective plate.
Knock Sensor
E96986
Two KSs are fitted. They are on the cylinder block,
one close to the 2nd cylinder and one close to the
4th cylinder.
When fitting, adhere strictly to the specified
tightening torque, otherwise the KS will not work
properly.
If the signal from one or both KS is implausible or
absent, knock control is deactivated. The PCM
switches to an ignition map that is further away
from the knock limit. As a result, engine damage
caused by combustion knock is avoided. If a fault
occurs, a fault code is stored in the error memory
of the PCM.
Camshaft Position (CMP) Sensor
E89993
If one or both CMP sensors fail, a fault is saved in
the error memory of the PCM and the camshaft
adjustment and knock control are deactivated.
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Electronic Engine Controls— 2.5L Duratec (147kW/200PS) - VI5303-14-
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