2011 FORD KUGA steering system

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.
G1001270en2008.50 Kuga8/2011
211-02-
8
Power Steering
211-02- 8
DESCRIPTION AND OPERATION
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1
2
3
45
6
7
8
9
10
E42460
Description
Item
Connector
1
Power steering module
2
Seal
3
Bearing
4
Shaft
5Description
Item
Cover
6
Rotor with magnets
7
Stator8
Distributor
9
Bearing
10
In the electrohydraulic power steering system, a
brushless 12 volt direct current motor drives the
hydraulic pump. Higher pumping rates are only
provided when they are required for steering
manoeuvres. This avoids unnecessary energy
consumption in the majority of phases in a drive
cycle.
Commutation in the motor is done electronically.
As a result, there are no brushes to wear away.
The entire system is designed for maintenance-free
operation.
In more than 85% of all driving situations, the
power steering pump operates at standby speed
and consumes less than 4A. However, pump speed
can quickly increase to full rotational speed if
emergency steering manoeuvres require it. The system has a continuously variable pump
rotational speed.
G1001270en2008.50 Kuga8/2011
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Power Steering
211-02- 12
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Power Steering Pressure Line and Return Line Assembly — 2.5LDuratec (147kW/200PS) - VI5(13 443 0)
General Equipment
Hose Clamp Remover/Installer
Removal
NOTE: Removal steps in this procedure may
contain installation details.
1. Refer to: Steering System Health and Safety
Precautions (100-00 General Information,
Description and Operation).
2. Refer to: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation).
3.
E98543
x7
4.
E99630
5.
E99631
6. WARNING: Be prepared to collect escaping fluid.
1. General Equipment: Hose ClampRemover/Installer
2. Torque: 30
Nm
E114706
1
2
7. Torque: 23Nm1.
2. Torque: 7
Nm
G1185534en2008.50 Kuga8/2011
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Power Steering
211-02- 13
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E114707
x4
2.To install, reverse the removal procedure.
3.
E141077
4.
E141078
5. NOTE: Make sure the fluid in the reservoir does
not fall below the MIN mark, as air could enter
the system.
Slowly turn the steering wheel from lock to lock
five times.
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Power Steering
211-02- 16
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Power Steering Pump — 2.5L Duratec (147kW/200PS) -VI5(13 434 0)
General Equipment
Hose Clamp(s)
Hose Clamp Remover/Installer
Removal
NOTE: Removal steps in this procedure may
contain installation details.
1. Refer to: Steering System Health and Safety
Precautions (100-00 General Information,
Description and Operation).
2. Refer to: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation).
3.
E98543
x7
4.
E99630
5.
E99631
6. 1. WARNING: Be prepared to collect
escaping fluid.
General Equipment: Hose Clamp(s)
2. General Equipment: Hose Clamp Remover/Installer
E114163
12
7.1. WARNING: Be prepared to collect
escaping fluid.
Torque: 30Nm
3. General Equipment: Hose Clamp
Remover/Installer
4. Torque: 10
Nm
G1176952en2008.50 Kuga8/2011
211-02- 18
Power Steering
211-02- 18
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

3.
E141078
4. NOTE:Make sure the fluid in the reservoir does
not fall below the MIN mark, as air could enter
the system.
Slowly turn the steering wheel from lock to lock
five times.
E131522
123
5.
E141079
12
6.
E141077
G1176952en2008.50 Kuga8/2011
211-02- 20
Power Steering
211-02- 20
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Power Steering Pump to Steering Gear Pressure Line — 2.5LDuratec (147kW/200PS) - VI5(13 440 0; 13 443 0)
General Equipment
Hose Clamp Remover/Installer
Removal
NOTE: Removal steps in this procedure may
contain installation details.
1. Refer to: Steering System Health and Safety
Precautions (100-00 General Information,
Description and Operation).
2. Refer to: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation).
3.
E98543
x7
4.
E99630
5.
E99631
6. WARNING: Be prepared to collect escaping fluid.
1. General Equipment: Hose ClampRemover/Installer
2. Torque: 30
Nm
E114706
1
2
7. Torque: 23Nm1.
2. Torque: 7
Nm
G1185535en2008.50 Kuga8/2011
211-02- 21
Power Steering
211-02- 21
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Installation
1.To install, reverse the removal procedure.
2.
E141077
3.
E141078
4. NOTE: Make sure the fluid in the reservoir does
not fall below the MIN mark, as air could enter
the system.
Slowly turn the steering wheel from lock to lock
five times.
E131522
123
5.
E141079
12
6.
E141077
G1185535en2008.50 Kuga8/2011
211-02- 24
Power Steering
211-02- 24
REMOVAL AND INSTALLATION
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BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL