2011 FORD KUGA ECT

16.TO MODEL INDEX
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL 17.
If equipped.
1.
E101425 18. 19.
WARNING: Be prepared to collect
escaping fluid. General Equipment: Air Body Saw
G1065510en
2008.50 Kuga 8/2011 412-01-50
Climate Control
412-01-50
REMOVAL AND INSTALLATIONE101621E101424

Evaporator Core Orifice
Special Tool(s)
412-027
Disconnect Tool, Spring Lock
Coupling (1/2" blue) 412-034
Remover/Installer, Evaporator
Core Orifice Special Tool(s)
412-034-01
Adapter for 412-034 412-035
Remover, Damaged
Evaporator Core Orifice
Materials
Specification
Name
WSH-M1C231-B /
6U7J-M1C231-AA
Compressor Oil - Air
Conditioning
Removal
NOTE: Removal steps in this procedure may
contain installation details. 1.
Refer to: Air Conditioning (A/C) System
Recovery, Evacuation and Charging (412-00
Climate Control System - General Information,
General Procedures).
2. Refer to: Cowl Panel Grille (501-02 Front End
Body Panels, Removal and Installation).
3. G1071472en
2008.50 Kuga 8/2011 412-01-65
Climate Control
412-01-65
REMOVAL AND INSTALLATIONTO MODEL INDEX
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL34001 34004 E129004 34005

SECTION 412-02 Auxiliary Climate Control
VEHICLE APPLICATION:
2008.50 Kuga
PAGE
CONTENTS
DESCRIPTION AND OPERATION
412-02-2
Auxiliary Climate Control (Component Location) ................................................................
412-02-4
Auxiliary Climate Control (Overview) ..................................................................................
412-02-4
Initial start-up of the fuel-fired booster heater .....................................................................
412-02-4
Lockout ...............................................................................................................................
412-02-4
Unlocking the control unit ...................................................................................................
412-02-5
Auxiliary Climate Control (System Operation and Component Description) ......................
412-02-5
System Diagram.................................................................................................................
412-02-12
System Operation ...............................................................................................................
412-02-12
Electric Booster Heater ...................................................................................................
412-02-12
Fuel-fired heater - function diagram................................................................................
412-02-13
Boost heat mode.............................................................................................................
412-02-13
Programmable fuel fired booster heater .........................................................................
412-02-13
Immediate start-up of the booster heater ........................................................................
412-02-13
Programmed start-up of the booster heater ....................................................................
412-02-14
Emergency shutoff ..........................................................................................................
412-02-14
Component Description ......................................................................................................412-02-14Electric Booster Heater...................................................................................................
412-02-14Detailed illustration of fuel-fired heater ...........................................................................
412-02-16Flame sensor..................................................................................................................
412-02-16Overheat Sensor.............................................................................................................
412-02-16ECT.................................................................................................................................
412-02-16Water pump....................................................................................................................
412-02-16Fuel pump.......................................................................................................................
REMOVAL AND INSTALLATION 412-02-17
Auxiliary Coolant Flow Pump ..............................................................................................
412-02-18
Electric Booster Heater .......................................................................................................
412-02-21
Fuel Fired Booster Heater — 2.5L Duratec (147kW/200PS) - VI5 .....................................
412-02-25
Fuel Fired Booster Heater Fuel Pump ................................................................................
DISASSEMBLY AND ASSEMBLY 412-02-26
Fuel Fired Booster Heater .................................................................................................. 412-02-1
Auxiliary Climate Control
412-02-1
.
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Programmable fuel fired booster heater
Description
Item
Fuel powered booster heater
1
Fresh air inlet
2
Coolant intake
3
Connector for the booster heater
4 Description
Item
Coolant exhaust
5
Fuel intake
6
Holder for the fuel-fired booster heater
7
Exhaust System
8
Coolant Pump
9 G1066978en
2008.50 Kuga 8/2011 412-02-3
Auxiliary Climate Control
412-02-3
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL269835471E97620

Description
Item
Electric Booster HeaterRefer to Component Description: (page
?)
1
GEM (generic electronic module)
2
Outside temperature sensor
3
Climate control system control assembly
4 Description
Item
Generator and Alternator
5
PCM (powertrain control module)
6
Coolant temperature sensor (ECT (engine
coolant temperature) sensor)Refer to Component Description: ECT
(page ?)
7
instrument cluster
8 G1066982en
2008.50 Kuga 8/2011 412-02-7
Auxiliary Climate Control
412-02-7
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Description
Item
Electric Booster HeaterRefer to Component Description: (page
?)
1
GEM2
Outside temperature sensor
3
Climate control system control assembly
4 Description
Item
Generator and Alternator
5
PCM6
Coolant temperature sensor (ECT sensor)Refer to Component Description: ECT
(page ?)
7
instrument cluster
8 G1066982en
2008.50 Kuga 8/2011 412-02-9
Auxiliary Climate Control
412-02-9
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System Operation
Electric Booster Heater
In diesel vehicles which give off little residual heat,
a booster heater is used to heat the passenger
compartment rapidly in the case of low ambient
temperatures.
If the interior temperature has been set to HI, or if
the heater controls have been switched to the
highest setting, the two-zone air conditioning
system sends an "electric booster heater ON"
request signal to the CAN (controller area network)
via the medium speed GEM bus. If a manual air
conditioning system is installed, the signal is
transmitted via a conventional cable connection.
The GEM switches on the electric booster heater
depending on the following parameters:
• Engine coolant temperature is below 60 °C.
• Ambient air temperature is below 10 °C.
• Sufficient generator capacity is available.
The electric booster heater electronics activate
three output stages as a function of a pulse width
modulated signal PWM (pulse width modulation)
generated by the GEM. The output stages switch
the three heating elements of the electric booster
heater ON or OFF individually, whereby the heating
periods of the individual elements can overlap. Due
to the variable switch-on duration, continuously
variable temperature control is possible. The overall
heating power of the three heating elements is
linearly proportional to the PWM signal. If the PWM
signal is below 10% or above 95%, the electric
booster heater is not activated.
The electric booster heater is switched off when
an engine coolant temperature of 70°C or an
ambient air temperature of 20°C is exceeded.
Fuel-fired heater - function diagram G1066982en
2008.50 Kuga 8/2011 412-02-12
Auxiliary Climate Control
412-02-12
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Description
Item
Glow plug
1
Combustion Air Blower
2
Fuel pump
3
Fuel-fired heater on
4
Fuel-fired heater - large regulating step
5
Fuel-fired heater - small regulating step
6 Description
Item
Fuel-fired heater off
7
Blower motor on
8
Flame detection
9
Blower motor off
10
Large regulating step
11
Small regulating step
12
Boost heat mode
When the engine is running, the booster heater
helps the engine to heat the passenger
compartment at low ambient temperatures.
When the coolant temperature reaches 30 °C, the
control unit transmits a switch-on signal for the
passenger compartment blower via the CAN bus.
When the coolant temperature drops, the blower
remains on until the temperature reaches 20 °C
whereupon it is deactivated.
The fuel tank must be filled to at least 14% for the
system to be switched on. If the fuel level drops
below 8% then the system is switched off.
In boost mode, the fuel fired booster heater is only
switched on if all of the following criteria are met:
• Engine speed above 500 rpm. The fuel fired booster heater is not allowed to start up while
the engine is being cranked; this prevents a
shut-down due to low voltage if the battery
charge is low.
• Ambient temperature below 5 °C.
• Fuel level above 14% of total capacity.
• Function is active on the trip computer menu.
One of the following conditions is sufficient to
switch off the booster heater in boost heat mode:
• Engine speed below 500 rpm.
• Ambient temperature above 11 °C.
• Function is active on the trip computer menu.
• Fuel level below 8% of total capacity.
Programmable fuel fired booster heater
The programmable fuel fired booster heater has
two operating modes:
• Instant start
• Programmed start
The heater status is displayed on the instrument
cluster display. The parking heater mode is controlled via a menu in the message centre. The
fuel fired booster heater can be activated and
deactivated via the message centre. (If set to 'Auto'
the system is activated, if set to 'Off' the system is
completely deactivated)
Immediate start-up of the booster
heater
This function enables the fuel-fired booster heater
to be switched on manually when the engine is not
running. This function is activated via the menu on
the driver information system.
The ignition key must be in the II" position before
this menu can be accessed. The timer function of
the booster heater remains active when the ignition
key is in position "0".
After an immediate start-up of the booster heater
it is switched off again after 30 minutes (or if the
fuel level in the fuel tank drops below 8%). The
booster heater stops within 2 minutes of the engine
starting. This leaves enough time to check whether
the switch-on conditions for boost heat mode have
been met, thus preventing the booster heater from
having to switch off and switch back on again. The
heater can be switched off manually at any time
from the menu.
Programmed start-up of the booster
heater
The driver can use a menu to adjust the time at
which the vehicle is to be pre-heated. The following
options are available:
• Time setting. One or two times can be
programmed for each day of the week. It is
possible to program days either individually or
together in groups (Mon-Sun/Mon-Sat/Mon-Fri).
• Time and data setting
With the first option, the fuel-fired booster heater
will start repeatedly without needing to be G1066982en
2008.50 Kuga 8/2011 412-02-13
Auxiliary Climate Control
412-02-13
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