2011 FORD KUGA bus

Steering gear
E96209
1
2
3
4
5
1
2
63
Description
Item
Tie-rod end
1
Tie-rod
2
steering gear boot
3Description
Item
Steering angle sensor - vehicles built up
to 09/2009
4
Input shaft
5
Valve unit housing
6
The steering gear is mounted on the front axle
crossmember and is secured with two bolts. The
bolts are inserted in the steering gear from above
and screwed into the threaded lugs on the front
axle crossmember.
The following components can be renewed
separately or as a unit:
• Complete steering gear
• Steering gear rubber bushes
• Tie rods.
• Steering gear boot
• Tie-rod end
• Steering angle sensor - vehicles built up to 09/2009 During removal and installation or renewal of
components of the steering gear, pay attention to
the following: (excluding steering angle sensor)
• Before undertaking repair work on an accident
damaged steering gear, the scope of the repair
must be determined using the inspection
instructions "Steering gear inspection after an
accident". For additional information, refer to
"Diagnosis and Testing" in this section.
• When the steering gear is removed and installed, the front axle crossmember must be
aligned with the bodywork using the appropriate
special tools.
• After completing the work, the suspension geometry of the vehicle must be checked and
corrected as necessary.
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211-02- 4
Power Steering
211-02- 4
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Electro-hydraulic power steering pump
E96414
1
2
3
4
5
3
Description
Item
Electro-hydraulic power steering pump
1
Cap, reservoir
2Description
Item
Rubber bushes, electro-hydraulic power
steering pump
3
Bracket #1
4
Bracket #2
5
The electro-hydraulic power steering pump is
mounted at the front right-hand side in the wheel
housing. The following components may be renewed:
• Electro-hydraulic power steering pump
• Cap, reservoir
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Power Steering
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• Rubber bushes, electro-hydraulic power steeringpump
• Bracket #1
• Bracket #2
During removal and installation or renewal of
components of the electro-hydraulic power steering
pump, pay attention to the following:
• Before starting work to renew the electro-hydraulic power steering pump, the
program code of the electro-hydraulic power steering must be read out using the diagnostic
unit and noted.
• After the work to renew the electro-hydraulic power steering pump is completed, the
electro-hydraulic power steering must be
reconfigured using the diagnostic unit. For
further information, see: Module Configuration
(418-01 Module Configuration, General
Procedures).
• The electro-hydraulic power steering pump must be filled and vented as specified.
Pressure and return lines
E96417
1
2
3
4
Description
Item
power steering return hose
1
Power steering fluid pressure line
2Description
Item
Bracket #1
3
Bracket #2
4
G1001269en2008.50 Kuga8/2011
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Power Steering
211-02- 6
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Description
Item
Electro-hydraulic power steering pump
with integrated power steering moduleRefer to Component Description:
Electro-hydraulic power steering pump
(page5)
1
Ignition switch
2
Generic electronic module (GEM)
3
Data link connector (DLC)
4
Powertrain Control Module (PCM)
5
ABS module or ESP module
6Description
Item
Steering gear
7
Integrated steering angle sensor - vehicles
built up to 09/2009RefertoComponentDescription:(page
10)
8
High pressure pipe
9
Fluid Return Line
10
Battery junction box (BJB)
11
Battery
12
System Operation
Electronic principle of operation
The power steering module requires the following
information in order to ensure precise steering
behavior in all driving situations:
• Steering wheel position
• Rate of turn of the steering wheel
• Vehicle speed
• Information about the vehicle configuration
• Information about the ignition switch position
• Instantaneous engine operating status
The required information is made available to the
power steering module via direct connections and
via the CAN bus (refer to the flow chart).
The steering wheel position and the rate of turn of
the steering wheel are transmitted to the power
steering module as PWM signals from the steering
angle sensor. The steering angle sensor receives
its voltage and ground supply from the power
steering module and operates inductively with an
input voltage of 5 V.
The vehicle speed is made available to the power
steering module as a CAN bus signal from the ABS
module or ESP module. The engine operating status is made available to
the power steering module as a CAN bus signal
from the PCM.
The power steering module obtains the vehicle
configuration information via the CAN bus from the
GEM. This information is required by the power
steering module in order to define the internal
characteristics of the power steering.
The power steering module obtains information
about the current ignition switch position via the
voltage input (terminal 15) of the ignition switch.
Whilst constantly monitoring the relevant input
signals the power steering module accesses stored
maps. With the aid of this information the pump
speed is matched to the current driving situation.
An electronic diagnosis of the electro-hydraulic
power steering can be performed with the aid of a
diagnostic tester via the DLC of the vehicle. For
additional information please refer to "Diagnosis
and Testing" in this section.
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211-02-
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Power Steering
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E96430
The steering angle sensor is a inductive sensor.
The steering angle sensor monitors the steering
wheel position and the rate of turn of the steering
wheel. This information is sent to the power
steering module.
On vehicles built from 09/2009the power steering
module uses the information from the steering angle sensor at the steering column. The required
information is made available to the power steering
module via the CAN bus.
Brushless DC motor with integral power
steering module
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11
Power Steering
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Action
Possible Sources
Symptom
• CHECK if the PCV system isoperating correctly and repair
as necessary. Engine - 2.5L
Duratec-ST (VI5) -
REFER to: Engine Emission
Control (303-08 Engine
Emission Control - 2.5L
Duratec (147kW/200PS) -
VI5, Diagnosis and Testing).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Faulty positive crankcase vent-
ilation (PCV) system.
- Hoses or ventilation orbreather valves are blocked.
This causes excessive
pressure in the crankcase
which causes more oil to
enter the combustion
chamber.
- PCV oil separator is faulty and engine oil can enter the
combustion chamber
through the intake manifold.
• INSTALL a new turbocharger.Engine - 2.5L Duratec-ST (VI5)
-
REFER to: Turbocharger (303-
04 Fuel Charging and
Controls - Turbocharger -
2.5L Duratec (147kW/200PS)
- VI5, Removal and Installa-
tion).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Turbocharger seals.
• CHECK the gaskets and matingsurfaces for damage.
Remove the cylinder head.
CHECK the mating faces, cylinder
head gasket and the evenness of
the cylinder head and engine block
mating faces.
INSTALL new valve seals. Engine
- 2.5L Duratec-ST (VI5) -
REFER to: Valve Stem Seals
(303-01 Engine - 2.5L Duratec
(147kW/200PS) - VI5, Removal
and Installation).
Engine - 2.0L Duratorq-TDCi (DW)
Diesel -
• Damaged gaskets or mating
surfaces.
- Cylinder head gasket isdamaged or mating face are
warped.
- Valve stem seals are worn and engine oil can enter the
combustion chamber
between the valve stem and
the valve stem guide.
• INSTALL new components asnecessary.
• Piston ring or cylinder liner
wear.
• CHECK the running surfacesand clearances of the individual
engine components. INSTALL
new components as necessary.
INSTALL a new cylinder block
if necessary.
• Check the pistons and piston rings.
• Damaged cylinder liners or
excessive clearance of engine
components.
- Pistons.
- Piston rings (clearance ingroove and end gap).
- Cylinder liners.
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Engine System - General Information
303-00- 3
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Action
Possible Sources
Symptom
• Check the cooling systemcomponents. Engine - 2.5L
Duratec-ST (VI5) -
REFER to: Engine Cooling
(303-03 Engine Cooling,
Diagnosis and Testing).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
REFER to: Engine Cooling
(303-03 Engine Cooling,
Diagnosis and Testing).
• Cooling system components.
• Coolant consumption
• INSTALL a new oil cooler.
• Oil cooler.
• CHECK the cylinder headgasket for damage. CHECK the
cylinder head for distortion.
• Damaged gaskets or warped
mating faces.
• DETERMINE the damagedengine component(s) and
install new component(s) as
necessary.
• Cracks or fractures in engine
components surrounded by
coolant, such as cylinder liners
and cylinder head combustion
chamber.
• CHECK the battery and cables.REFER to: Charging System
(414-00 Charging System -
General Information,
Diagnosis and Testing).
• Battery or cables.
• Engine will not crank
• CHECK the starting system.Engine - 2.5L Duratec-ST (VI5)
-
REFER to: Starting System
(303-06 Starting System -
2.5L Duratec (147kW/200PS)
- VI5, Diagnosis and Testing).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Starter motor or cables.
• CHECK the fuel level.
• Fuel tank is empty.
• Engine cranks but will not start
• Drain the water from the fuelsystem.
• Water in fuel (diesel engine
only).
• INSTALL a new fuel filter.Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Fuel filter blocked.
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Engine System - General Information
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Engine – System Operation and Component Description
System Operation
The variable camshaft timing occurs
electro-hydraulically and individually for both
camshafts.
The camshaft adjusters work according to the vane
cell principle and have an adjustment range of 52°
crank angle on the intake side and 47° crank angle
on the exhaust side. On starting the engine and
during idling, both camshafts are mechanically
locked in their starting positions. The exhaust
camshaft is in the early position and the intake
camshaft is in the late position. The camshaftadjuster on the exhaust side has a torsion spring
which compensates the camshaft drive torque.
This ensures that the assembly can return to the
starting position under all operating conditions and
when the engine is turned off.
Internal exhaust gas recirculation can be realized
through continuous adjustment of the timings. This
results in better fuel consumption and more
favorable combustion temperatures which produce
less pollutants. This means that pollutant level IV
can be adhered to with a 3-way catalytic converter.
The variable timings also make it possible to
optimize performance with wide open throttle.
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Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
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