2011 FORD KUGA oil pressure

Turbocharger – Overview
Turbocharger(s)
CAUTION: Do not switch off the engine
while it is running at high speed. If the
engine is switched off while it is running
at high speed, the turbocharger will
continue to run after the engine oil
pressure has already dropped to zero. This
will cause premature wear in the
turbocharger bearings.
A TC consists of an exhaust turbine located in the
exhaust gas flow, this turbine is connected to a
compressor by a shaft. The turbine is made to
rotate by the exhaust gas flow from the engine and
thus drives the compressor. The compressor
increases the pressure in the engine intake tract
so that a greater mass of air enters the cylinder
during the intake stroke.
The turbine housing of the TC is integrated into the
exhaust manifold. This construction offers
thermodynamic advantages compared with the
usual construction, the maximum exhaust
temperature is up to 1050°C.
The maximum boost pressure is 0.65 bar.
The exhaust manifold is secured to the exhaust
side of the cylinder head with 12 self-locking nuts.
The exhaust manifold gasket is a multi-layer steel
gasket and cannot be reused. In order to
compensate for the thermal expansion of the
exhaust manifold, the flange of the TC is provided
with two grooves.
The TC and the exhaust manifold are joined by a
hose clip. The hose clip must not be loosened or
removed. The TC and the exhaust manifold are
not available as separate replacement parts,
exchange is only possible as a complete unit.
The turbocharger heat shield is secured to the
exhaust manifold by four bolts. Two of the bolts
have spring washers underneath their heads.
During removal, make a note of the installation
location of the spring washers to refer to during
installation.
The recirculated air valve is built into the TC
housing and cannot be changed.
The Ford diagnostic unit can test the operation of
the wastegate control valve using actuator
diagnosis.
The boost pressure regulator is set in the factory.
Adjustments to the boost pressure regulator must never be attempted. A red colored seal is applied
to the adjustment nut of the operating rod, in order
to monitor the factory setting of the boost pressure.
The bearings of the TC are lubricated with engine
oil. The engine oil passes from the cylinder block
through the oil supply pipe to the TC. The oil is
returned to the oil pan through the oil return pipe,
The TC is cooled by the engine coolant circuit.
When installing hoses and lines, make certain that
their ends are free of oil residues and dirt.
G1032425en2008.50 Kuga8/2011
303-04B-
4
Fuel Charging and Controls - Turbocharger
—
2.5L Duratec (147kW/200PS) - VI5
303-04B- 4
DESCRIPTION AND OPERATION
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Turbocharger
Special Tool(s) / General EquipmentHand Vacuum/Pressure
Pump
416 - D001 (23 - 036A)
23036A
Fuel Pressure Gauge
310-053 (23-046)
23046
Ford diagnostic equipment
Inspection and Verification
NOTE:It is normal for a small amount of
combustion gas to pass into the crankcase. This
gas is scavenged into the air intake system through
the positive crankcase ventilation (PCV) system,
which incorporates an crankcase vent oil separator.
Some engine oil, in the form of a vapor is carried
into the air intake system with the blow-by gases
(this engine oil also contributes to valve seat
durability). This means that oil will collect inside
the air intake components and the turbocharger.
This is not an indication that the turbocharger oil
seal has failed. The turbocharger oil seal will not
fail unless the bearings fail first, which will cause
the turbocharger to become noisy or seize. Do not
install a new turbocharger due to oil inside the
turbocharger or the air intake components. If a leak
is detected in the oil supply or return tubes or connections, locate and rectify the source. Do not
install a new turbocharger due to an oil leak.
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical
or electrical damage.
Visual Inspection Chart
Electrical
Mechanical
• Wiring harness
• Boost controlsolenoid valve
• Powertrain control module (PCM)
• Oil leak(s)
• Air cleaner element
• Air cleaner outlet
pipe
• Air cleaner intake pipe
• Turbocharger oil supply or oil return
tube
• Turbocharger intake pipe
• Turbocharger vacuum diaphragm
unit
• Turbocharger housing
• Charge air cooler
• Charge air cooler intake pipe and
hose(s)
• Charge air cooler outlet pipe and
hose(s)
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.
NOTE: The vacuum diaphragm unit is a fixed part of the turbocharger and cannot be adjusted or renewed.
G1183442en2008.50 Kuga8/2011
303-04B- 9
Fuel Charging and Controls - Turbocharger
—
2.5L Duratec (147kW/200PS) - VI5
303-04B- 9
DIAGNOSIS AND TESTING
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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.
G1183446en2008.50 Kuga8/2011
303-08-
4
Engine Emission Control— 2.5L Duratec (147kW/200PS) - VI5303-08-
4
DIAGNOSIS AND TESTING
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Intake Air Distribution and Filtering
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanicalor electrical damage.
Visual Inspection Chart
Electrical
Mechanical
– Mass air flow (MAF)sensor
– Manifold absolute pressure (MAP)
sensor
– Electrical connector(s)
– Air cleaner element
– Air cleaner intake
pipe
– Air cleaner outlet pipe
– Charge air cooler
– Charge air cooler intake pipe
– Charge air cooler outlet pipe 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
• CHECK the pipe(s) for securityand leaks to atmosphere.
INSTALL new intake air
components as necessary.
TEST the system for normal
operation.
• Detached air cleaner pipe(s).
• Detached turbocharger pipe(s).
• Detached charge air cooler
pipe(s).
• Excessive intake air noise
• REFER to:Engine Emission
Control (303-08 Engine
Emission Control - 2.5L
Duratec (147kW/200PS) -
VI5, Diagnosis and Testing).
• Blocked or damaged PCV
pipe(s)/hose(s).
• Blocked or damaged crankcase vent oil separator.
• Oil in the air intake system
• REFER to:Turbocharger(303-
04 Fuel Charging and
Controls - Turbocharger -
2.5L Duratec (147kW/200PS)
- VI5, Diagnosis and Testing).
• Turbocharger.
• CHECK the air intake pipesplash shield for correct install-
ation and alignment.
REPAIR/INSTALL the air intake
pipe splash shield as neces-
sary. TEST the system for
normal operation.
• Air intake pipe splash shield.
• Water in the air cleaner
G1183447en2008.50 Kuga8/2011
303-12- 4
Intake Air Distribution and Filtering
— 2.5L Duratec
(147kW/200PS) - VI5
303-12- 4
DIAGNOSIS AND TESTING
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SECTION 303-14 Electronic Engine Controls— 2.5L Duratec
(147kW/200PS) - VI5
VEHICLE APPLICATION: 2008.50 Kuga
PA G E
CONTENTS
DESCRIPTION AND OPERATION
303-14-3
Electronic Engine Controls (Component Location) .............................................................
303-14-7
Electronic Engine Controls (Overview) ........................................................................\
.......
303-14-7
General overview ........................................................................\
........................................
303-14-8
Powertrain Control Module (PCM) ........................................................................\
..............
303-14-8
Knock Sensor ........................................................................\
.............................................
303-14-8
Camshaft Position (CMP) Sensor ........................................................................\
...............
303-14-9
Crankshaft Position (CKP) sensor ........................................................................\
..............
303-14-9
Camshaft adjuster solenoid valve........................................................................\
...............
303-14-9
Manifold absolute pressure and temperature sensor .........................................................
303-14-9
Accelerator pedal position (APP) sensor ........................................................................\
....
303-14-10
Throttle control unit ........................................................................\
.....................................
303-14-10
Engine Coolant Temperature (ECT) sensor.......................................................................
303-14-10
Ignition coil-on-plug ........................................................................\
....................................
303-14-12
Electronic Engine Controls (System Operation and Component Description) ...................
303-14-12
System Diagram ........................................................................\
.........................................
303-14-16
System Operation ........................................................................\
.......................................
303-14-18
Speed and TDC recording ........................................................................\
......................
303-14-19
Calculation of the ignition angle ........................................................................\
..............
303-14-20
Engine fueling ........................................................................\
.........................................
303-14-22
Engine speed control ........................................................................\
..............................
303-14-22
Oil monitoring ........................................................................\
..........................................
303-14-23
Calculation of valve timing adjustment angle..................................................................
303-14-23
Boost pressure control ........................................................................\
............................
303-14-24
Starting process ........................................................................\
......................................
303-14-24
Alternator control (Smart Charge) ........................................................................\
...........
303-14-24
Component Description ........................................................................\
..............................
303-14-24

CKP sensor ........................................................................\
.............................................
303-14-25

Broadband HO2S ........................................................................\
...................................
303-14-26

VCT (variable camshaft timing) solenoids ......................................................................
303-14-27

MAF sensor ........................................................................\
.............................................
303-14-28

APP sensor ........................................................................\
.............................................
303-14-29

CPP sensor ........................................................................\
.............................................
303-14-29

BPP switches ........................................................................\
..........................................
303-14-30

Air conditioning (A/C) pressure sensor ........................................................................\
...
303-14-30

Throttle
control unit ........................................................................\
.................................
303-14-31

ECT sensor ........................................................................\
.............................................
303-14-31

Cooling fan module ........................................................................\
.................................
303-14-32

injectors........................................................................\
...................................................
303-14-32

Ignition coil-on-plug ........................................................................\
.................................
303-14-33

Fuel pressure/fuel temperature sensor ........................................................................\
...
303-14-33

Wastegate control valve ........................................................................\
..........................
303-14-34

Engine oil level, temperature and quality sensor ............................................................
303-14-1
Electronic Engine Controls— 2.5L Duratec (147kW/200PS) - VI5303-14-
1
.
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Electronic Engine Controls – Component Location
E96941
1
12
2
3
4
5
6
7
8
9
10
11
Description
Item
Throttle control unit
1
injectors
Comments:One injector for each cylinder
2
Fuel pressure/fuel temperature sensor
3Description
Item
VVT (variable valve timing) - exhaust
camshaft solenoid
Comments:One each for the inlet and outlet
camshaft
4
Ignition coil-on-plug
Comments:One injection coil for each cylinder
5
G1021906en2008.50 Kuga8/2011
303-14-
3
Electronic Engine Controls— 2.5L Duratec (147kW/200PS) - VI5303-14-
3
DESCRIPTION AND OPERATION
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Description
Item
Medium speed CAN data bus (MS-CAN)
1
DLC (data link connector)
2
GEM (generic electronic module)
Comments:Serves as a gateway between the two
CAN databus systems.
3
High speed CAN data bus (HS-CAN)
4
CPP (clutch pedal position) sensorRefertoComponentDescription:(page
29)
5
BPP switchesRefertoComponentDescription:(page
29)
6
MAF sensorRefertoComponentDescription:(page
27)
7
TP sensorRefer to Component Description: Throttle
controlunit(page33)
Comments: It is incorporated into the throttle control
unit
8
ECT sensorRefertoComponentDescription:(page
31)
9
CKP sensorRefertoComponentDescription:(page
24)
10
CMP sensor - intake camshaftRefertoComponentDescription:(page
8)
11
CMP sensor - exhaust camshaftRefertoComponentDescription:(page
8)
12Description
Item
Broadband HO2SRefertoComponentDescription:(page
25)
13
Catalyst monitor sensor
14
Air conditioning (A/C) pressure sensorRefertoComponentDescription:(page
30)
15
KSRefertoComponentDescription:(page
8)
16
APP sensorRefertoComponentDescription:(page
28)
17
MAPT sensorRefertoComponentDescription:(page
9)
18
Fuel pressure/fuel temperature sensorRefertoComponentDescription:(page
33)
19
Exterior aor temperature sensorRefertoComponentDescription:(page
34)
20
Engine oil level, temperature and quality
sensorRefertoComponentDescription:(page
34)
21
Ignition switch
22
Battery
23
PCMRefertoComponentDescription:(page
8)
24
G1021908en2008.50 Kuga8/2011
303-14-
14
Electronic Engine Controls— 2.5L Duratec (147kW/200PS) - VI5303-14-
14
DESCRIPTION AND OPERATION
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• Starting process
• Engine running– Fuel supply to the engine including lambdacontrol
– Ignition setting including knock control
– Idle speed control
– Boost pressure control
– Valve timing via the camshaft adjuster for the intake and exhaust camshafts (including
internal exhaust gas recirculation)
• Refrigerant compressor (activation, deactivation and delivery)
• EVAP purge valve
• Charging system
Fuel is supplied to the engine via a sequential
multi-point injection system. Ignition is performed
by a distributor-less ignition system with one
ignition coil unit for each cylinder.
The PCM optimizes engine power and emissions
at all times by processing the sensor signals and
information received via the CAN databus and
using these for open or closed loop control of the
different variables.
The PCM contains part of the PATS (passive
anti-theft system).
The PCM is supplied with battery voltage via a fuse
in the BJB (battery junction box). This power supply
is needed to ensure that saved data is not lost
when the engine is switched off.
For other power supply requirements, the PCM
switches on a relay in the BJB which is responsible
for supplying power to the PCM and to some
sensors and actuators. Each of these are protected
by fuses in the BJB.
To guarantee optimum engine running at all times,
the PCM has several adaptive (self-learning)
functions. These adapt the output signals to
changing circumstances, such as wear or system
faults.
In some cases a faulty signal is replaced with a
substitute value or limited. A substitute value can
be calculated from other signals or it can be
predefined by the PCM. The substitute value allows
the vehicle to keep on running without the emission
values changing unduly. Depending on the signal
failure, the PCM operates in emergency mode. In
this mode, the engine power and/or the engine
speed is reduced to prevent further damage.
Depending on the faulty signal, a fault code is
stored in the error memory of the PCM. These can be read out using IDS (Integrated Diagnostic
System) via the DLC.
The PCM processes and evaluates the signals
from the sensors. The following sensors send
signals to the PCM:
• CMP sensors
• CKP sensor
• MAF sensor
•KS
• ECT sensor
• TP sensor
• APP sensor
• Broadband HO2S
• Catalyst monitor sensor
• MAPT sensor
• Air conditioning (A/C) pressure sensor
• Alternator
• Fuel temperature and fuel pressure sensor
• Engine oil level, temperature and quality sensor
• Outside air temperature sensor
The following components receive signals from the
PCM:
• Powertrain Control Module relay
• A/C clutch relay
• injectors
• Direct ignition coils
• Cooling fan module
• Throttle control unit
• Camshaft adjuster solenoid valve
• Starter Relay
• EVAP purge valve
• Alternator
• Heating element - broadband HO2S
• Catalyst monitor sensor heating element
• FPDM
• Wastegate control valve
• Air conditioning compressor
The PCM receives the following signals via the
CAN databus:
• APP
•CPP
• BPP
• Vehicle speed.
• Refrigerant compressor request
• PAT S
G1021908en2008.50 Kuga8/2011
303-14-
17
Electronic Engine Controls— 2.5L Duratec (147kW/200PS) - VI5303-14-
17
DESCRIPTION AND OPERATION
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