FORD TRAINING

Technical Service Training

Sensors and Actuators

Actuators

E163452

TC4012084H
CG 8436/S en 01/2013
To the best of our knowledge, the illustrations, technical information, data and descriptions in this
issue were correct at the time of going to print. The right to change prices, specifications, equipment
and maintenance instructions at any time without notice is reserved as part of FORD policy of
continuous development and improvement for the benefit of our customers.

No part of this publication may be reproduced, stored in a data processing system or transmitted in
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publication, although every possible care has been taken to make it as complete and accurate as
possible.

Please remember that our training literature has been prepared for FORD TRAINING PURPOSES
only. Repairs and adjustments MUST always be carried out according to the instructions and
specifications in the workshop literature. Please make full use of the training offered by Ford Technical
Training Courses to gain extensive knowledge of both theory and practice.

Copyright ©2013

Ford-Werke GmbH
Service training programs D-F/GT1 (GB)
 Preface

It is impossible to imagine motor vehicles without electronic control modules with their
sensors and actuators. They have revolutionized the automotive world. These compact
electronic modules provide open and closed-loop control for all key vehicle functions: the
engine and transmission control systems, the safety systems as well as the variety of comfort
systems that are continuing to grow at an enormous rate. There is no end in sight to this
development.
Electronic open and closed-loop control open up a variety of options. They improve driving
safety and driving comfort. At the same time, the vehicles are becoming increasingly
economical and environmentally compatible.
Actuators convert electrical energy into mechanical work (movement) and are used in
electromechanical adjustment systems.
They can be used either purely as actuators, or as components in a closed or open-loop
control circuit.
Currently, the most frequently used actuators in motor vehicles are electric motors and
solenoids.
Based on the sensor signals they receive, the control modules calculate the variables for
the control and consequently the activation of actuators.
In some cases, actuators are combined with sensors or integrated as complete systems
which include a control module. As a result the testing or replacement of individual actuators
is often no longer possible.
Self-tests performed by control modules increasingly account for connected actuators and
the related wiring. In addition, diagnosis is performed with the help of FordEtis IDS.
This Student Information provides an overview of the actuators installed in the vehicles,
their purpose, design, and function as well as information on additional diagnoses. It does
not replace the existing symptom-based diagnoses in FordEtis IDS. The systems installed
in the vehicle must always be diagnosed first using the symptom-based diagnoses.
Completion of the eLearning program Sensors and Actuators (TC401 2 071C) is a
prerequisite for the study of this Student Information.
The training course on sensors and actuators includes the following information for
technicians:
– Sensors, TC401 2 083H
– Actuators, TC401 2 084H
– Communications network, TC401 2 085H

Service Training (G522585) 1

Preface

Note: The supplied data and values only serve as demonstration and to facilitate
understanding. Current values should always be taken from the workshop literature.

2 (G522585) Service Training

 Table of Contents

PAGE

Preface................................................................................................. 1

Lesson 1 – General Information

OSC mode.................................................................................................................. 6
General...................................................................................................................................... 6

Test questions............................................................................................................ 7

Lesson 2 – Actuators
Exhaust gas recirculation (EGR) valves................................................................. 8
Actuator motor-controlled EGR valve (DC motor)................................................................... 8
Actuator motor-controlled EGR valve (stepper motor)............................................................. 11
EGR valve (vacuum-controlled)................................................................................................ 13
Intake manifold runner control (IMRC) electric motor............................................................ 15
Swirl plate actuator................................................................................................................... 16
Throttle plate actuator motor..................................................................................................... 18
Fuel injector (petrol engines).................................................................................................... 20
Fuel injector (diesel engines).................................................................................................... 22
Electronic parking brake actuator............................................................................................. 24
Electronic throttle plate............................................................................................................. 26
Electronic steering lock unit...................................................................................................... 28
Electrical turbocharger guide vane adjustment actuator........................................................... 30
Electrically heated thermostat................................................................................................... 33
Window regulator motor........................................................................................................... 34
Roof opening panel motor......................................................................................................... 34
Parking brake actuator (TRW).................................................................................................. 36
Gas solenoid valve..................................................................................................................... 38
Gas shut-off valve...................................................................................................................... 40
Blower motor............................................................................................................................. 42
Glow plugs................................................................................................................................ 44
Heater control valve.................................................................................................................. 47
Air conditioning clutch............................................................................................................. 49
Instrument cluster...................................................................................................................... 51

Service Training 3
Table of Contents

Fuel metering valve................................................................................................................... 53

Fuel pressure regulator.............................................................................................................. 55
Engine cooling fan.................................................................................................................... 57
Clutch actuator.......................................................................................................................... 58
Gearshift actuator...................................................................................................................... 58
Idle air control (IAC) valve....................................................................................................... 60
Variable camshaft timing solenoid valves................................................................................. 63
Solenoid valves for vacuum control (engine management)...................................................... 64
Solenoid valve for the shock absorber control system (active suspension).............................. 67
Fuel pump driver module (FPDM)............................................................................................ 68
Electric power steering motor................................................................................................... 69
Relay......................................................................................................................................... 72
Shift solenoid valve................................................................................................................... 74
Pressure control valve............................................................................................................... 74
Actuator motor-controlled intake manifold flap....................................................................... 76
Actuator motor-controlled intake manifold flap/charge air cooler bypass flap........................ 78
Wiper motor.............................................................................................................................. 80
Anti-lock brake system/traction control actuator...................................................................... 82
Liftgate release actuator............................................................................................................ 84
Blend door actuator................................................................................................................... 85
Selector lever lock actuator....................................................................................................... 87
Ignition key removal inhibitor actuator..................................................................................... 87
Door lock actuator..................................................................................................................... 89
Vacuum pump............................................................................................................................ 91

Pyrotechnic actuators............................................................................................... 92
Air bag module.......................................................................................................................... 92
Safety belt pretensioners........................................................................................................... 94

Other actuators......................................................................................................... 96
Headlamp leveling motors......................................................................................................... 96
Mirror adjustment motors......................................................................................................... 96
Fuel filler door release actuator................................................................................................. 96

Test questions............................................................................................................ 98

4 Service Training
 Table of Contents

Answers to the test questions............................................................. 99

List of Abbreviations.......................................................................... 100

Service Training 5
OSC mode Lesson 1 – General Information

General After selecting the signal (signal displayed

with black border), further icons appear in
In addition to symptom-based diagnosis in the vertical menu bar:
FordEtis IDS (Integrated Diagnostic
System), the IDS Standard datalogger "Activate control position" icon
provides the option of simulating various – Actuation of the previously selected
output signals from vehicle modules in OSC output signal is enabled using this icon.
(output state control) mode and thus directly If an exclamation mark "!" appears upon
activating actuators. activation of this icon, the module output
signal cannot be overwritten and the
The principle advantage of testing an
actuator can therefore not be activated.
actuator using this function is that providing
the OSC mode is operating correctly, faults The plus icon (+)
between modules and actuators can be – switches on the output signal. In the case
virtually excluded. of analogue output signals, the control
variable is increased.
1
The minus icon (–)
2
– switches off the output signal. In the case
3 of analog output signals, the control
4 variable is decreased.
Delete icon
– Signal overwriting is reset and the
5 actuator deactivated using this icon.
When quitting OSC mode, all overwritten
output signals are automatically reset.
E44009
Notes on OSC mode
1 OSC mode icon When activating an actuator with the help
2 "Activate control position" icon of OSC mode, it must be ensured that the
3 Plus icon duration of activation corresponds to the
4 Minus icon relevant use.
5 Delete icon For instance, activation of the windshield
washer pump for more than 30 seconds may
The output signals which can be actuated lead to destruction of the pump.
by the user are marked with a hash symbol
(#) in the signal selection. For further information on OSC mode,
please refer to the current Student
Information IDS, TC101 1 023H.

6 (G522586) Service Training

Lesson 1 – General Information Test questions

Tick the correct answer or fill in the gaps.

1. All actuators can be selected in OSC.

a. True
b. False

2. Which of the following statements is true?

a. When quitting OSC mode, all output signals remain overwritten.
b. The plus icon (+) activates the output signal or, in the case of analog output signals,
increases the control variable.
c. The plus icon (+) activates the output signal or, in the case of analog output signals,
decreases the control variable.
d. Output signals are always activated for a limited time only.

Service Training (G522587) 7

Exhaust gas recirculation (EGR)
valves Lesson 2 – Actuators

Actuator motor-controlled EGR The position sensor integrated in the

valve (DC motor) actuator motor housing detects the current
position of the EGR valve. The more the
EGR valve is opened, the higher the
1
resistance of the sensor.

Operating range
Value
• Supply voltage Approx. 12 V

2 • (actuator motor)
E60555
• Reference voltage Approx. 5 V
Examples of actuator motor-controlled EGR
(exhaust gas recirculation) valves • (position sensor)
1 1.6L Duratorq TDCi (DV) diesel • Signal type / PWM signal
2 2.0L Duratorq TDCi (DW) diesel voltage
• (actuator motor)
Installation position
• Signal type / • DC voltage:
In the exhaust tract, near the exhaust
voltage • 0.5 – 4.5 V
manifold
• (position sensor)
Physical operating principle
Resistance (actuator Approx. 3 – 6 Ohms
DC motor (actuator) motor)
Sliding-contact (position sensor) Frequency –

Task / function Testing options

The actuator motor opens or closes the Diagnostic tool Compatibility
EGR valve according to the required IDS – DTC Yes
recirculated exhaust gas quantity. (diagnostic trouble
The actuator motor is actuated via PWM code)
(pulse width modulation) signals. Guided diagnosis +
(IDS), if available
The duty cycle determines the aperture
DMM ++
cross-section of the EGR valve.
Datalogger ++

8 (G522588) Service Training

 Exhaust gas recirculation (EGR)
Lesson 2 – Actuators valves

Diagnostic tool Compatibility Diagnostic tool Compatibility

OSC mode # + Powerprobe ––
Oscilloscope + ++ very suitable, + suitable
(breakout box and - unsuitable, - - very unsuitable
adapter cable
required)
Signal trace for correctly operating EGR valve after the engine is switched off

E122650

In some versions, the EGR valve can be Example test on 2.0L Duratorq TDCi
tested easily and reliably using the IDS (DW) diesel engine:
datalogger. – Call up PIDs EGRDC (actuator motor
duty cycle) and DPFEGR (position sensor
voltage characteristic).
– When switching off the engine, the
engine control system starts a
cleaning/adaptation cycle that opens and
closes the EGR valve six times.

Service Training (G522588) 9

Exhaust gas recirculation (EGR)
valves Lesson 2 – Actuators

– The position sensor in the operates in a

voltage range of approx.:
– 1 V (closed EGR valve) to approx.
– 4.2 V (fully open EGR valve).
– In this manner, EGR valve faults can be
located via the datalogger display.
OSC mode test method
– Select the relevant PID in the IDS
datalogger.
– Call up and activate OSC mode.
– Press the "+" key several times (the EGR
valve is progressively opened further in
steps); the engine should run increasingly
roughly (the engine may stall).
– If this is the case, the actuator motor is
operating correctly.

Special features
Following installation of a new actuator
motor-controlled EGR valve, a parameter
reset of the EGR valve must be performed
using IDS.

10 (G522588) Service Training

Lesson 2 – Actuators

Actuator motor-controlled EGR Operating range

valve (stepper motor)
Value
Supply voltage • 11 – 14 V
• see table
Signal type / voltage Pulse signals
Resistance see table
Frequency –
Coil supply voltage
E60927 Supply voltage
between Voltage (Volts)
Installation position PIN 2 (coil assembly 11 – 14
On the cylinder head A) and ground
PIN 5 (coil assembly 11 – 14
Operating principle B) and ground
Stepper motor Stepper motor coil resistance values
Resistance
Task / function Coil between (Ohms)
The stepper motor opens and closes the A1 PIN 1 and 2 5 – 13
EGR valve via an actuating spindle. A2 PIN 3 and 2 5 – 13
The stepper motor comprises two coil B1 PIN 4 and 5 5 – 13
assemblies (coil assembly A and B) and a B2 PIN 6 and 5 5 – 13
rotor. The coil assemblies are sub-divided
into coil sections A1/A2 and B1/B2. Testing options
The EGR valve is opened to a smaller or Diagnostic tool Compatibility
greater extent by the stepper motor in IDS – DTC Yes
accordance with the number of pulse Guided diagnosis +
signals. (IDS), if available
DMM ++
Datalogger +

Service Training (G522588) 11

 Lesson 2 – Actuators

Diagnostic tool Compatibility

OSC mode # ++
Oscilloscope ––
(breakout box and
adapter cable
required)
Powerprobe ––
++ very suitable, + suitable

- unsuitable, - - very unsuitable

OSC mode test method

– Select the relevant PID in the IDS
datalogger.
– Call up and activate OSC mode.
– Press the "+" key several times (the EGR
valve is progressively opened further in
steps); the engine should run increasingly
roughly (the engine may stall).
– If this is the case, the stepper motor is
operating correctly.

12 (G522588) Service Training

Lesson 2 – Actuators

EGR valve (vacuum-controlled) Operating range

The table applies to the position sensor
Value
Reference voltage Approx. 5 V
Signal type / voltage • DC voltage:
• 0.5 – 4.5 V
Resistance • Approx. 1 kOhm
• (valve closed)
• Approx. 5 kOhms
• (valve open)
Frequency –
E47849

Testing options
Installation position
Diagnostic tool Compatibility
In the feed line from the exhaust tract to the
intake tract. IDS – DTC Yes
Guided diagnosis +
Operating principle (IDS), if available
Vacuum-controlled valve (actuator) DMM ++
Datalogger +
Sliding-contact potentiometer (position
OSC mode # ––
sensor)
Oscilloscope –
Task / function (breakout box and
adapter cable
The vacuum-controlled EGR valve
required)
operates purely mechanically and is
Powerprobe ––
therefore not subject to any electrical
testing. ++ very suitable, + suitable

The position sensor measures the current - unsuitable, - - very unsuitable

position of the EGR valve.

In the 2.0L Duratorq TDCi (Puma)
The more the EGR valve is opened, the emission standard IV diesel engine, the
higher the resistance of the sensor. position of the EGR valve is indicated in
millimeters (mm) in the IDS datalogger.

Service Training (G522588) 13

 Lesson 2 – Actuators

Operation of the EGR valve and of the

position sensor can be tested as follows
using the vacuum pump:
– Disconnect the vacuum hose from the
EGR valve.
– Connect the vacuum pump to the vacuum
hose of the EGR valve.
– Turn ignition 'ON'.
– Operate the vacuum pump several times
until the EGR valve is fully open.
– The value indicated in the datalogger
should increase from 0 to 9 mm.
– During pressure equalization, the
indicated value should fall back to 0 mm.

14 (G522588) Service Training

Lesson 2 – Actuators

Intake manifold runner control Testing options

(IMRC) electric motor
Diagnostic tool Compatibility
IDS – DTC Yes
Guided diagnosis –
(IDS), if available
DMM +*
Datalogger ––
OSC mode # ––
Oscilloscope ––
E61002 (breakout box and
adapter cable
Installation position required)
Powerprobe ––
On the cylinder bank 2 cylinder head cover
(Duratec VE (VE6) engines) ++ very suitable, + suitable

- unsuitable, - - very unsuitable

At the centre of the bulkhead (Duratec RS
(Zetec)) * Only for testing the supply voltage

Operating principle
Special features
DC motor
Malfunctions are often caused by
Task / function overheating of the IMRC (intake manifold
runner control) electric motor.
The electric motor for intake manifold
runner control actuates the changeover flaps If the electric motor becomes blocked when
of the intake manifold runner control system the changeover flaps are closed, this results
(Duratec-VE (VE6)) or the variable intake in low engine power output in the full load
manifold (Duratec-RS (Zetec)). range.
The electric motor often operates correctly
Operating range again after switching the ignition off and
Value back on again. The electric motor may
become blocked again after a certain time.
Supply voltage Approx. 12 V
Signal type / voltage ON/OFF
Resistance –*
Frequency –
* Measuring the resistance is not possible as this is
an integrated circuit.

Service Training (G522588) 15

 Lesson 2 – Actuators

Swirl plate actuator Operating range

Value
1
2 • Supply voltage • 11 – 14 V
• (stepper motor) • (see table)

• Reference voltage 4.7 – 5.3 V

• (position sensor)
• Signal type / Pulse signals
E60929 voltage
1 Position sensor • (stepper motor)
2 Swirl plate adjustment stepper motor • Signal type / • DC voltage:
voltage • 0.5 – 4.5 V
Installation position
• (position sensor)
In intake manifold (1.8L Duratec SCi)
Resistance see table
Operating principle Frequency –
Stepper motor (actuator) Stepper motor coil supply voltage
Sliding-contact (position sensor) Supply voltage
between Voltage (Volts)
Task / function PIN 2 (coil A) and 11 – 14
ground
The stepper motor opens and closes the
swirl plates in the intake manifold via a PIN 5 (coil B) and 11 – 14
reduction gear. Actuation is via pulse ground
signals. Stepper motor coil resistance values
Depending on the number of pulse signals, Resistance
the swirl plates are opened to a smaller or Coil Between (Ohms)
greater extent by the stepper motor. A1 PIN 1 and 2 5 – 13
The position sensor detects the current A2 PIN 3 and 2 5 – 13
position of the swirl plates. The more the B1 PIN 4 and 5 5 – 13
swirl plates are opened, the higher the B2 PIN 6 and 5 5 – 13
resistance of the sensor.

16 (G522588) Service Training

Lesson 2 – Actuators

Testing options
Diagnostic tool Compatibility
IDS – DTC Yes
Guided diagnosis +
(IDS), if available
DMM ++
Datalogger +
OSC mode # ––
Oscilloscope ––
(breakout box and
adapter cable
required)
Powerprobe ––
++ very suitable, + suitable

- unsuitable, - - very unsuitable

Signal voltage of position sensor with

engine at operating temperature:
– Setpoint value at ignition ON (no load):
0.6 – 1.0 V
– Setpoint value 2000 rpm (no load): 1.3 –
1.7 V
– Setpoint value 4000 rpm (no load): 3.1 –
3.5 V

Service Training (G522588) 17

 Lesson 2 – Actuators

Throttle plate actuator motor A two-stage reduction gear and a threaded

spindle with a pushrod are integrated in the
throttle plate actuator motor.
The rotary motion of the actuator motor is
converted into a linear, i.e. "pushing"
motion of the pushrod via the threaded
1 spindle.
The pushing motion of the pushrod is
limited at each end by limit switches.
An idle switch, against which the threaded
spindle presses, is also integrated in the
1 actuator motor. As soon as the plunger and
the throttle flap stop come into contact, the
idle switch opens and interrupts the circuit
to the PCM (powertrain control module).
This activates the engine idle speed control.

2 4 Operating range
3
E61369 Value
1 Throttle plate actuator motor Supply voltage Approx. 12 V
Signal type / voltage • DC voltage:
2 Pushrod
3 Throttle plate stop • ON/OFF

4 Throttle plate Resistance (idle 0 – 0.5 Ohm *

switch)
Installation position Frequency –
On the throttle body fuel injection unit * See idle switch operational test

Physical operating principle

Testing options
DC motor (in vehicles with EEC IV/EEC
Diagnostic tool Compatibility
V engine management and throttle body fuel
injection) IDS – DTC Yes *
Guided diagnosis +*
Task / function (IDS), if available
The throttle plate actuator motor acts as an DMM ++
adjustable throttle plate stop. Datalogger +*

18 (G522588) Service Training

Lesson 2 – Actuators

Diagnostic tool Compatibility

OSC mode # +*
Oscilloscope –
(breakout box and
adapter cable
required)
Powerprobe ++
++ very suitable, + suitable

- unsuitable, - - very unsuitable

* If supported by IDS

Actuator motor operational test (1)

The pushrod of the actuator motor should
change position when the ignition is
switched on. Then bring the engine to
operating temperature. When the ignition is
switched off, the pushrod must retract and
extend again following a few seconds.

Actuator motor operational test (2)

Using the powerprobe, check whether the
actuating motor fully extends and retracts
the pushrod. The pushrod is extended and
retracted by means of reversed polarity.

Operational test of idle switch

When the throttle plate is closed, no
continuity should be measured (resistance
= infinite).
When the throttle plate is open, a resistance
of 0 – 0.5 Ohms should be measured.

Service Training (G522588) 19

 Lesson 2 – Actuators

Fuel injector (petrol engines) Task / function

Cross-section of a fuel injector
1

1 2 3 4 5

2
E60526
7
E60525
Examples of fuel injectors
1 Intake manifold fuel injector 1 Injector outlet bore
2 Direct injection fuel injector 2 Sealing ring to cylinder head
3 Fuel injector needle with solenoid
Installation position armature
In the cylinder head, at the fuel rail 4 Coil
5 Electrical connection
Operating principle
6 Sealing ring to fuel rail
Solenoid valve
7 Fuel feed with fine screen
The solenoid-controlled fuel injectors serve
for metering and atomizing the fuel.
The fuel injectors consist of a housing with
fuel passages, a coil and an injector needle
with a solenoid armature. The fuel feed in
the injector features a fine screen.
The fuel injector is either closed (not
actuated) or opened (actuated).

20 (G522588) Service Training

Lesson 2 – Actuators

Operating range
Value
Supply voltage • Approx. 12 V
(intake manifold
fuel injection)
• – (direct fuel
injection)
Signal type / voltage Injection signal
Resistance • Approx. 10 – 20
Ohms
• (intake manifold
fuel injection)
• Approx. 1.5 – 1.9
Ohms
• (direct fuel injec-
tion)
Frequency –

Testing options
Diagnostic tool Compatibility
IDS – DTC Yes
Guided diagnosis +
(IDS), if available
DMM ++
Datalogger –
OSC mode # ––
Oscilloscope +
(breakout box and
adapter cable
required)
Powerprobe –
++ very suitable, + suitable

- unsuitable, - - very unsuitable

Service Training (G522588) 21

 Lesson 2 – Actuators

Fuel injector (diesel engines) Operating range

Value
1
Supply voltage –
Signal type / voltage Injection signal
Resistance (at 20°C) • < 1 Ohm
(solenoid valve)
• 150 – 250 kOhm
(piezo)
2
E60951 Frequency –
Examples of fuel injectors
1 Fuel injector, 1.6L Duratorq TDCi Testing options
(DV) diesel Diagnostic tool Compatibility
2 Fuel injector, 1.4L Duratorq TDCi IDS – DTC Yes
(DV) diesel Guided diagnosis +
(IDS), if available
Installation position
DMM ++
In the cylinder head Datalogger –
OSC mode # –
Operating principle
Oscilloscope ++
Solenoid valve or piezo (breakout box and
adapter cable
Task / function required)
The fuel injectors serve for metering and Powerprobe ––
atomizing the fuel. ++ very suitable, + suitable
The fuel injector is either closed (not - unsuitable, - - very unsuitable
actuated) or opened (actuated).
In piezo fuel injectors, a capacitance test of
the piezo element can be performed in
addition to the resistance test.
– Setpoint value at 20°C: > 3.0 µF.

22 (G522588) Service Training

Lesson 2 – Actuators

Special features

015 38415
1724
2809

760680
11

6
5 13
0 8 0 440 FO
F DD
1
2

E51116

Position of identification number on Bosch

common rail system fuel injector
1 Fuel injector
2 Identification number
Within the hydraulic servo system of the
fuel injector, there are different orifices with
extremely small diameters with
factory-determined manufacturing
tolerances.
In some systems, these manufacturing
tolerances are given as part of an
identification number which is located on
the outside of the injector (see current
service literature).
In order to ensure optimum fuel metering,
the PCM must be informed of a change of
injector (or several injectors) using IDS.

Service Training (G522588) 23

 Lesson 2 – Actuators

Electronic parking brake actuator The hollow shaft is connected to a force

sensor via a link which can be released
1 2 3
mechanically (emergency release).
4 The parking brake cables are attached at the
force sensor and the splined shaft.
Evaluation electronics are integrated in the
housing. The actuator can only be renewed
5
as a complete unit.
5
8 7 6
E60540 Operating range
1 Electrical connection Value
2 DC motor Supply voltage Approx. 12 V
3 Control module Signal type / voltage –
4 Emergency release cable Resistance –
5 Handbrake cable Frequency –
6 Gear mechanism Testing options
7 Hollow shaft
Diagnostic tool Compatibility
8 Force sensor
IDS – DTC Yes
Installation position Guided diagnosis ++
(IDS), if available
Underneath the vehicle on the rear axle
DMM +
Operating principle Datalogger ++
OSC mode # ––
DC motor (integrated in the actuator)
Oscilloscope –
Task / function (breakout box and
adapter cable
The electronic parking brake actuator required)
operates the parking brake cables.
Powerprobe ––
The motor/gear mechanism is ++ very suitable, + suitable
floating-mounted in the parking brake
- unsuitable, - - very unsuitable
actuator.
A hollow shaft is driven via the gear The force acting upon the force sensor is
mechanism. A splined shaft engages in turn displayed in the datalogger along with a
in the hollow shaft. possible DTC.

24 (G522588) Service Training

Lesson 2 – Actuators

When the brake is applied and the system

is operating correctly, this force should be
approx. 1100 – 1300 Newtons (N). In this
condition, the rear wheels should be
blocked.

Special features
When renewing the rear brake pads, the
brake pedal must be pressed several times
before actuating the electronic parking
brake.
For further instructions on renewing the
parking brake actuator, please refer to the
workshop literature.

Service Training (G522588) 25

 Lesson 2 – Actuators

Electronic throttle plate Operating range

Value
• Supply voltage Approx. 12 V
• (actuator)
• Reference voltage Approx. 5 V
• (position sensors)
• Signal type / PWM signal
E61154 voltage
• (actuator)
Installation position
• Signal type / • DC voltage:
In the intake tract (intake manifold) voltage • 0.4 – 4.5 V
Operating principle • (position sensors)

DC motor (actuator) Resistance (actuator) Approx. 10 – 30

ohms
Sliding-contact (position sensors)
• Resistance see table
Task / function • (position sensors)
Both a DC motor and two position sensors Frequency –
are integrated in the electronic throttle plate.
Position sensors, 1.8L Duratec HE (MI4)
The DC motor adjusts the throttle plate.
Resistance
Actuation is via PWM signals. The longer
the activation time of the PWM signals, the Sensor 1 • Throttle plate closed:
wider the throttle plate is opened. (PIN 4 and • Approx. 2.1 kOhms
6):
The position sensors detect the current • Throttle plate open:
position of the throttle plate. For reliable • Approx. 4.3 kOhms
fault detection, position sensor 1 can operate
redundantly or output a different voltage Sensor 2 • Throttle plate closed:
signal than position sensor 2. (PIN 3 and • Approx. 4.8 kOhms
4):
• Throttle plate open:
• Approx. 2.4 kOhms

26 (G522588) Service Training

Lesson 2 – Actuators

Position sensors, 1.4L/1.6L Duratec 16V Testing options

Resistance
Diagnostic tool Compatibility
Sensor 1 • Throttle plate closed:
IDS – DTC Yes
(PIN 4 and • Approx. 0.9 kOhms
6): Guided diagnosis +
• Throttle plate open: (IDS), if available
• Approx. 4.3 kOhms DMM ++
Datalogger +
Sensor 2 • Throttle plate closed:
OSC mode # –
(PIN 3 and • Approx. 4.8 kOhms
4): Oscilloscope –
• Throttle plate open: (breakout box and
• Approx. 2.4 kOhms adapter cable
required)
Position sensors, 1.8L Duratec SCi (MI4) Powerprobe ––
Resistance ++ very suitable, + suitable
Sensor 1 • Throttle plate closed: - unsuitable, - - very unsuitable
(PIN 6 and • Approx. 520 – 820 Ohms
3):
Special features
Sensor 2 • Throttle plate closed:
(PIN 5 and • Approx. 1.1 – 1.5 KOhms The throttle plate end stops are detected and
3): stored in the PCM.

Voltage (in volts) * Following replacement of the electronic

throttle plate, a calibration procedure must
Sensor 1 • Accelerator pedal not
be started. The instructions in the current
(PIN 6 and actuated:
workshop literature must be observed here.
3): • Approx. 0.43 – 0.83
• Accelerator pedal actu-
ated:
• Approx. 4.0 – 4.5
Sensor 2 • Accelerator pedal not
(PIN 5 and actuated:
3): • Approx. 4.0 – 4.5
• Accelerator pedal actu-
ated:
• Approx. 0.43 – 0.83

* Test with ignition ON, engine OFF

Service Training (G522588) 27

 Lesson 2 – Actuators

Electronic steering lock unit Operating range

Value
Supply voltage Approx. 12 V
Signal type / voltage LIN (local intercon-
nect network) – data
bus
Resistance –
Frequency approx. 9.6 kbit/s
E127175
Testing options
Installation position Diagnostic tool Compatibility
Underneath the steering column IDS – DTC Yes
Guided diagnosis –
Operating principle (IDS), if available
DC motor DMM –
Datalogger ++
Task / function OSC mode # –
Locking and unlocking the steering Oscilloscope –
(breakout box and
adapter cable
required)
Powerprobe ––
++ very suitable, + suitable

- unsuitable, - - very unsuitable

28 (G522588) Service Training

Lesson 2 – Actuators

Course of signal during locking of the steering lock on 2012.75 B-MAX

E163475

During locking, the electronic steering lock

unit is supplied with positive and negative
voltage by the keyless vehicle system.

Service Training (G522588) 29

 Lesson 2 – Actuators

Course of signal during unlocking of the steering lock on 2012.75 B-MAX

E163476

During unlocking, the electronic steering

lock unit is supplied with only positive Installation position
voltage by the keyless vehicle system. Adjusting linkage of the variable geometry
turbocharger
Electrical turbocharger guide
vane adjustment actuator Operating principle
DC motor (integrated in the electrical
1 actuator)
Additionally integrated in the electrical
actuator:
– Contactless (inductive) position sensor
2
Task / function
E85271 Electrical adjustment of the of the variable
geometry turbocharger guide vanes.
1 Electrical turbocharger guide vane
adjustment actuator
2 Variable geometry turbocharger

30 (G522588) Service Training

Lesson 2 – Actuators

Operating range Diagnostic tool Compatibility

Value Datalogger ++
Supply voltage Approx. 12 V OSC mode # –
Signal type / voltage • CAN * Oscilloscope +*
(breakout box and
• PWM signal * adapter cable
Resistance – required)
Frequency – Powerprobe ––
* depending on version ++ very suitable, + suitable

- unsuitable, - - very unsuitable

Testing options * depending on vehicle and engine management
system
Diagnostic tool Compatibility
IDS – DTC Yes
Guided diagnosis –
(IDS), if available
DMM +*

Illustration shows correct operation (shown: Mondeo 2001) under sharp acceleration

E122651

Service Training (G522588) 31

 Lesson 2 – Actuators

1 MAP (manifold absolute pressure) 3 Signal for electrical turbocharger

2 Engine speed (rpm) guide vane adjustment (VGTDC)
actuator

In the case of a malfunction, the electrical

actuator is normally no longer activated.
Thus, no activation by the PCM takes place
(VGTDC = 0%).

Special features
Depending on the vehicle and engine
management system, the electrical
turbocharger guide vane adjustment actuator
is activated differently. The descriptions of
the individual systems as well as the circuit
diagrams can be found in the current
workshop literature.

32 (G522588) Service Training

Lesson 2 – Actuators

Electrically heated thermostat Testing options

Diagnostic tool Compatibility
IDS – DTC Yes
Guided diagnosis +
(IDS), if available
DMM ++
Datalogger +
OSC mode # ––
E61000 Oscilloscope –
(breakout box and
Installation position adapter cable
required)
On the cylinder block in the coolant circuit
Powerprobe ++ *
Operating principle ++ very suitable, + suitable

Coil (heating resistor) - unsuitable, - - very unsuitable

* With part removed

Task / function
The engine temperature is controlled in
accordance with the operating conditions
via the electrically heated thermostat.
Actuation can be performed continuously
or via PWM signals as required.

Operating range
Value
Supply voltage Approx. 12 V
Signal type / voltage • ON/OFF or
• PWM signals
Resistance 11 – 22 Ohm
Frequency –

Service Training (G522588) 33

 Lesson 2 – Actuators

Window regulator motor Operating range

Roof opening panel motor Value

Supply voltage Approx. 12 V
Signal type / voltage ON/OFF
A B
Resistance –
Frequency –

Testing options
Diagnostic tool Compatibility
IDS – DTC Yes *
E60463
Guided diagnosis –
Examples of window regulator motors (roof (IDS), if available
opening panel motors are similar) DMM +
A Without pinch protection Datalogger –
B With pinch protection OSC mode # –
Oscilloscope –
Installation position (breakout box and
In doors or at roof opening panel adapter cable
required)
Operating principle Powerprobe +
DC motor, with integral electronics, ++ very suitable, + suitable
depending on version - unsuitable, - - very unsuitable

Task / function * In module-controlled systems (e.g. GEM (generic

electronic module)) via the module self-test
Window regulator motors and roof opening
panel motors open and close the windows
and the roof opening panel via a mechanism.
Depending on the version, electronics are
integrated which monitor the speed of the
motor and are used for functions such as
pinch protection.

34 (G522588) Service Training

Lesson 2 – Actuators

Special features Window regulator motor with pinch

protection
Window regulator motor without pinch
protection

2 3 1

4 2

5
E60453
6
E60452
1 Hall sensors
2 Electronics
1 Housing with magnets
2 Connector In motors with pinch protection, Hall
sensors and evaluation electronics are
3 Ring gear for window regulator drive
installed in addition to the worm drive.
4 Carbon brushes These detect the speed of the motor via a
5 Thermocouple (overload protection) magnet attached to the armature (pinch
6 Armature coil with commutators and protection feature).
worm drive For this reason, the electronic control of the
In motors without pinch protection, only a window regulator motors must be calibrated
motor with a worm drive is installed, which following a power interruption. For notes
changes the rotary direction of the motor on calibrating window regulator motors and
through 90 degrees in order to achieve more roof opening panel motors, please refer to
compact installation dimensions. the relevant workshop literature.
Depending on the vehicle, a speed signal
may also be required for control of the roof
opening panel motor. This serves as a
correction factor, e.g. in the Mondeo 2001
for pinch protection, as the roof opening
panel closing forces increase with the
vehicle speed.

Service Training (G522588) 35

 Lesson 2 – Actuators

Parking brake actuator (TRW) brake piston. When the parking brake is
actuated, the thrust pad pushes the brake
piston out of the brake caliper.

Operating range
Value
Supply voltage Approx. 12 V
Signal type / voltage ON/OFF
Resistance –
E68787
Frequency –

Installation position Testing options

Installed on the brake caliper of the rear disc Diagnostic tool Compatibility
brake
IDS – DTC Yes
Operating principle Guided diagnosis –
(IDS), if available
DC motor
DMM +
Task / function Datalogger ++
OSC mode # –
Applying and releasing the parking brake.
Oscilloscope ++
The parking brake actuator consists of an (breakout box and
electric motor which uses a two-stage gear adapter cable
(toothed belt and planetary gear set) to rotate required)
a threaded spindle clockwise/anti-clockwise. Powerprobe +
A thrust pad is positioned on the threaded
++ very suitable, + suitable
spindle, which is moved radially into the
- unsuitable, - - very unsuitable

36 (G522588) Service Training

Lesson 2 – Actuators

Current consumption of the parking brake actuators when applying/releasing the parking
brake

1 2

1 2

E122652

A Left-hand parking brake actuator 1 Current consumption when applying

B Right-hand parking brake actuator the parking brake
2 Current consumption when releasing
the parking brake

The current consumption of the parking

brake actuators can be made visible using
the IDS datalogger.
Power consumption when
– Applying: approx. 15 amps
– Releasing: approx. 10 amps

Service Training (G522588) 37

 Lesson 2 – Actuators

Gas solenoid valve valves so that they open quickly. The current
is then reduced by the gas control module
so that the gas solenoid valves are held
1 2 open.

Operating range
Value
Supply voltage • Approx. 12 V
(peak)
• Approx. 6 V
(hold)
Signal type / voltage Injection signal
Resistance • Approx. 2.04
Ohms / 2.35 mH
at 20 °C (68 °F)
• (BRC gas
solenoid valve)

E123930
• Approx. 1.25
ohms / 3.5 mH at
1 Keihin gas solenoid valve 20 °C (68 °F)
2 BRC gas solenoid valve • (Keihin gas
solenoid valve)
Installation position
Frequency –
The gas solenoid valves are installed in the
gas manifold. Testing options

Operating principle Diagnostic tool Compatibility

IDS – DTC No
Solenoid valve
Guided diagnosis No
Task / function (IDS), if available
DMM ++
The gas solenoid valves are used to meter
Datalogger ––
the gas to the dry-injection nozzles.
The gas solenoid valves are actuated in two
stages. This method of control is called peak
and hold. Peak and hold means that a high
current will be applied to the gas solenoid

38 (G522588) Service Training

Lesson 2 – Actuators

Diagnostic tool Compatibility

OSC mode # No
Oscilloscope +
(breakout box and
adapter cable
required)
Powerprobe ––
++ very suitable, + suitable

- unsuitable, - - very unsuitable

Special features
The gas systems can only be checked using
special programming and diagnostic
software provided by the manufacturer of
the gas system (BRC). The signals from the
gas solenoid valves can be checked using
the Data Monitoring function. In the event
of failure of the gas solenoid valves, a DTC
is stored in the gas control module. This can
also be read out and deleted using the
programming and diagnostic software.
The gas solenoid valves can also be
statically and dynamically checked using
the Test Actuator function.

Service Training (G522588) 39

 Lesson 2 – Actuators

Gas shut-off valve Operating principle

Electromagnetic valve

Task / function
1 In their currentless state the gas shut-off
valves are closed. During gas operation, the
coils are actuated and the valve opened so
that the gas can reach the evaporator core
or gas pressure regulator.

Operating range
Value
2 Supply voltage Approx. 12 V
Signal type / voltage ON/OFF
Resistance Approx. 8 - 12
Ohms
Frequency –

E123931 Testing options

1 Front gas solenoid valve, LPG Diagnostic tool Compatibility
(liquefied petroleum gas) system IDS – DTC No
2 Front gas solenoid valve, CNG Guided diagnosis No
(compressed natural gas) system (IDS), if available
DMM ++
Installation position
Datalogger ––
The front gas shut-off valves are mounted OSC mode # No
on the bulkhead, the suspension strut dome, Oscilloscope +
or the side member depending on the (breakout box and
vehicle. adapter cable
On the LPG systems, the rear gas shut-off required)
valve is integrated in the gas valve unit on Powerprobe ––
the ring fuel tank. ++ very suitable, + suitable
On the CNG systems, there is one rear gas - unsuitable, - - very unsuitable
shut-off valve integrated in the gas valve
unit on each cylindrical fuel tank.

40 (G522588) Service Training

Lesson 2 – Actuators

Special features
The gas systems can only be checked using
special programming and diagnostic
software provided by the manufacturer of
the gas system (BRC). In the event of failure
of the gas shut-off valves, a DTC is stored
in the gas control module. This can be read
out and deleted using the programming and
diagnostic software.
The gas shut-off valves can be actuated
using the Test Actuator function.

Service Training (G522588) 41

 Lesson 2 – Actuators

Blower motor Blower setting Voltage (V)

4 Approx. 6.5
5 Approx. 8.3
6 Approx. 10.7
7 (MAX) > 12
Focus 1999 (02/2002-11/2004) with
manual A/C (air conditioning), measured
with engine running
E60544
Blower setting Voltage (V)
1 Approx. 2.8
Examples of blower motors
2 Approx. 5.2
Installation position 3 Approx. 8.1
4 > 12
In the climate control housing
Testing options
Operating principle
Diagnostic tool Compatibility
DC motor with/without brushes
IDS – DTC • Yes (with
Task / function brushes)
The blower motor forces the ambient or • No (brushless)
recirculated air through the climate control Guided diagnosis ––
housing. (IDS), if available
Operating range DMM +*
Datalogger ++ **
Value OSC mode # ++ **
Supply voltage Approx. 12 V Oscilloscope –
Signal type / voltage see table (breakout box and
Resistance < 10 Ohm adapter cable
Frequency – required)
Powerprobe ++ *
Mondeo 2001 (06/2003-) with EATC
(electronic automatic temperature ++ very suitable, + suitable
control), measured with engine running - unsuitable, - - very unsuitable
Blower setting Voltage (V) * Not with brushless blower motors
1 Approx. 3.5
** With module-controlled blower motors
2 Approx. 4.5
3 Approx. 5.2

42 (G522588) Service Training

Lesson 2 – Actuators

Special features Brushless blower motor

The rotational speed of blower motors is 1 2 3

generally achieved via series resistors or
separate controllers. These are usually
located in the immediate vicinity of the
blower so that they are cooled by the air
flow.

A B 5 4
E60457

1 Control electronics
2 Stator with coil
3 Rotor with permanent magnet
4 Centrifugal fan
5 Motor cooling fan
E60464

Brushless blower motors are equipped with

A Four-stage blower series resistor
electronics which control the rotational
(Focus 1999 (02/2002-11/2004) with
speed. In this case, no separate testing of
manual A/C)
the electronics is possible, the complete
B Blower motor control module blower must be replaced in the event of a
(Mondeo 2001 (06/2003-) with EATC) fault.
Correct operation of the series resistor or In the case of a blocked pollen filter, the
the blower motor control module is a series resistor may burn out due to the
prerequisite during testing of the blower. In long-term lack of cooling. The blower motor
the event of a defective series resistor or may also be damaged in the long term owing
blower motor control module, the blower to insufficient air flow.
often only runs at the highest setting.

Service Training (G522588) 43

 Lesson 2 – Actuators

Glow plugs Task / function

In modern diesel engines, glow plugs
perform two functions:
– Warming of the combustion chambers at
low outside temperatures (Preheating),
2
– Improvement of exhaust emissions and
idling quality as well as reduction of
2 engine noise following cold starting
3 4 (Postheating).
– Warming of the combustion chambers to
prevent cooling of the particle filter in
overrun phases (intermediate heating).
1 5
TIE42517
Operating range
1 Hot tube
Value
2 Electrical connection
Supply voltage Approx. 12 V
3 Heater filament Signal type / voltage • 40 – 60 A *
4 Control filament
• 15 – 20 A **
5 Annular orifice
• < 5 Ohm ***
Installation position Resistance
Screwed into the cylinder head Frequency –
* Parallel connection (current consumption of all
Operating principle glow plugs), engine cold (see "Glow plug system
PTC (positive temperature coefficient) function check")

** Individual connection, engine cold (see "Glow

plug system function check")

*** on-vehicle tested, supply line disconnected

Testing options
Diagnostic tool Compatibility
IDS – DTC +*
Guided diagnosis –
(IDS), if available
DMM ++

44 (G522588) Service Training

Lesson 2 – Actuators

Diagnostic tool Compatibility Example: "parallel-connected glow

Datalogger – plugs" in the 2.0L Duratorq TDCi
OSC mode # –– (Puma) diesel engine:
Oscilloscope – – Supply voltage = 12 volts / current
(breakout box and consumption per glow plug approx. 15
adapter cable amps
required) – Measurement of the total power
Powerprobe –– consumption results in the following
++ very suitable, + suitable evaluation:

- unsuitable, - - very unsuitable

– 60 amps = all glow plugs OK,
– 45 amps = one glow plug defective,
* depending on version
– 30 amps = two glow plugs defective,
Glow plug system function check – 15 amps = three glow plugs defective,

However, in some cases reading out the fault – 0 amps = all four glow plugs defective,
memory does not indicate a malfunction or but please note: Before replacing the
only gives a rough indication of the glow plugs, first check that the glow
problem. It is therefore often necessary to plugs are being supplied with voltage
check the complete glow system, including (check fuse/ glow plug relay).
each individual glow plug. Individually-connected glow plugs:
– On certain vehicle versions, the glow
Checking the glow system power
plugs are individually actuated by a glow
consumption
system control module. On these
Power consumption is most effectively versions, it can immediately be
measured using a clip-on ammeter. determined which glow plug is defective,
The glow element of one glow plug usually using the clip-on ammeter. Instructions
has a power consumption of 10 – 20 amps. on this can be found in the relevant
This results in a total power consumption, workshop literature.
for a four-cylinder diesel engine glow – For this purpose, connect the clip-on
system with glow plugs connected in ammeter, in succession, to the supply line
parallel, of approximately 40 – 60 amps. of the relevant glow plug. After the
ignition is switched ON, a current
consumption of between 15 and 20 A
(engine cold) must be measured.

Service Training (G522588) 45

 Lesson 2 – Actuators

– If no current consumption is measured, Values:

it must first be checked whether the – See section "On-vehicle resistance test"
voltage supply (approx. 12 V to each
glow plug) is present at the relevant glow
plug.
– If the voltage supply is present, it is
highly probable that the glow plug is
defective. However, before installing a
new glow plug, a resistance test must be
performed.

On-vehicle resistance test

Note: On-vehicle testing eliminates the risk
of damaging the glow plugs during removal.
Tools required:
– Multimeter function in IDS or
commercially-available multimeter.
During the on-vehicle resistance test, the
first multimeter probe must be connected to
the glow plug electrical connector and the
second probe must be connected directly to
the engine block.
Values:
– Infinite resistance: Glow-plug filament
damaged (glow plug defective).
– Resistance < 5 ohms: Glow-plug filament
not damaged (glow plug OK).

Off-vehicle glow plug resistance test

NOTE: Thoroughly clean rust and other
dirt (oil, combustion residues) from the glow
plug thread.
To test a glow plug off-vehicle, the first
probe must be attached to the electrical
connection and the second probe to the glow
plug thread.

46 (G522588) Service Training

Lesson 2 – Actuators

Heater control valve

1
1
4
5
2

4 3

3
E60455
2

E60454
1 Solenoid valve
2 Feed from the engine
1 Solenoid valve
3 Return to engine
2 Connections to the heater core
4 Feed from the heater core
3 Connections to the engine
5 Connections to the heater core
4 Connector
Operating range
Installation position
In the coolant circuit (engine compartment) Value
behind the climate control housing Supply voltage Approx. 12 V
– Ka 1997 (09/1996-), Signal type / voltage Clock pulse
Resistance Approx. 14 – 16
– Fiesta 1996 (08/1995-02/2002),
Ohms *
– Puma 1998 (06/1997-12/2001). Frequency Approx. 18/min **
Operating principle * Values are temperature-dependent, ** Temperature
control in center setting
Solenoid valve

Task / function Testing options

In water based heating systems, the heater Diagnostic tool Compatibility
control valve interrupts the coolant circuit IDS – DTC No
between the engine and the heater core. Guided diagnosis –
The valve contains a piston which closes (IDS), if available
off the openings between the feed from the DMM +
engine and the return to the heater core. Datalogger –
The solenoid valve is fully open when
de-energized.

Service Training (G522588) 47

 Lesson 2 – Actuators

Diagnostic tool Compatibility

OSC mode # –
Oscilloscope –
(breakout box and
adapter cable
required)
Powerprobe ++
++ very suitable, + suitable

- unsuitable, - - very unsuitable

During testing, the temperature control

should be brought to the center setting. The
valve must open and close regularly, approx.
18 times per minute, when the engine is
running.

Special features
In the Focus 2004.75 with 1. 6L Duratec
16V Ti- VCT engine (Sigma), a valve with
a similar function is used for shutting off
the coolant expansion tank during cold
starting. Shortly after the engine is started,
the shut-off valve is closed, reducing the
quantity of coolant flowing through the
engine.
Fuel consumption during cold starting is
improved and the coolant heats up more
quickly. When the coolant temperature has
reached 80°C the valve opens, allowing hot
coolant to circulate through the coolant
expansion tank.
In this application, the valve is referred to
as the coolant expansion tank shut-off
valve/cut-off valve.
The valve is located in the engine
compartment, behind the front-end frame,
next to the headlamp.

48 (G522588) Service Training

Lesson 2 – Actuators

Air conditioning clutch Operating range

Value
Supply voltage Approx. 12 V
Signal type / voltage ON/OFF
Resistance (field coil) Approx. 4 – 5.5
Ohms
Frequency –

Testing options
E60459

Diagnostic tool Compatibility

1 Field coil
IDS – DTC No
2 Multigroove belt pulley
Guided diagnosis ++
3 Securing ring (IDS), if available
4 Spacer washers for adjusting the clutch DMM +
air gap Datalogger –
5 Flexplate OSC mode # –
Oscilloscope –
Installation position
(breakout box and
At the air conditioning compressor (vehicles adapter cable
with A/C) required)
Powerprobe ++
Operating principle
++ very suitable, + suitable
Magnetic clutch
- unsuitable, - - very unsuitable

Task / function
When testing the air conditioning clutch by
During activation of the air conditioning activating the air conditioning, it must be
clutch, current flows through the field coil. ensured that all the necessary parameters
A magnetic field is generated. for switching on the compressor are met
The flexplate, which is fixed to the (e.g. pressure in the refrigerant circuit,
compressor drive shaft is pulled towards the ambient temperature).
pulley. During activation, the clutch must engage
The clutch is closed and the compressor is audibly and visibly following a short delay.
accelerated, depending on the engine speed.
When the current ceases to flow in the field
coil, the flexplate is released from the pulley
with the aid of return springs.

Service Training (G522588) 49

 Lesson 2 – Actuators

Special features
In order to ensure correct operation of the
air conditioning clutch, the correct clutch
air gap must be adjusted. Spacer washers
with a precisely measured thickness are
inserted between the pulley and flexplate
for this purpose.
NOTE: When dismantling the air
conditioning clutch, these spacer washers
often adhere to the pulley owing to residual
grease. This can lead to these spacer washers
being installed together with the new spacer
washers. The resulting air gap is too large.
Please refer to the relevant workshop
literature for instructions on dismantling and
assembling the air conditioning clutch.

50 (G522588) Service Training

Lesson 2 – Actuators

Instrument cluster Testing options

Diagnostic tool Compatibility
1 2
IDS – DTC Yes
Guided diagnosis ++
(IDS), if available
DMM +
Datalogger ++
OSC mode # ++
3
E61128 Oscilloscope –
(breakout box and
1 Analog displays adapter cable
2 LEDs required)
3 Digital display LCD (liquid crystal Powerprobe ––
display) ++ very suitable, + suitable

Installation position - unsuitable, - - very unsuitable

In the instrument panel Although virtually all the displays and

warning indicators can be tested
Operating principle
individually, apart from a few exceptions,
Combination of stepper motors, LEDs, and instrument clusters cannot be repaired but
LCD only completely replaced.

Task / function Special features

The electronic instrument cluster indicates A self-test can be performed on all
various conditions using analog/digital electronic instrument clusters.
displays and LEDs. For activation:
In the current vehicle range, only electronic – press and hold the odometer reset button,
instrument clusters are installed.
– switch on the ignition,
Operating range – release the reset button when "test"
appears in the display.
Value
Supply voltage Approx. 12 V Then select the individual self-test menu
items by pressing the reset button.
Signal type / voltage –
Resistance –
Frequency –

Service Training (G522588) 51

 Lesson 2 – Actuators

In more recent vehicles, the electronic

instrument cluster is a significant component
of the communications network and
performs numerous functions.
The electronic instrument cluster is renewed
using IDS. Depending on the system,
various configurations and some
user-defined parameter adjustments must
be made.
Please refer to the relevant workshop
literature for further instructions on the
functions, the relevant self-test, and renewal.

52 (G522588) Service Training

Lesson 2 – Actuators

Fuel metering valve Operating range

Value
A 1
1
Supply voltage Approx. 12 V
Signal type / voltage PWM signals
Resistance see table
Frequency –
Resistance values of the fuel metering
valve employed
B
E60950 Fuel metering valve Resistance (Ohms)
Examples of fuel metering valves Delphi common rail Approx. 5.3
A High-pressure pump in the 1.8L system (diesel)
Duratec-SCi (MI4) Bosch common rail Approx. 3.8
B High-pressure pump in the 1.6L system (diesel)
Duratorq TDCi (DV) diesel Siemens common rail Approx. 3.0
1 Fuel metering valve system (diesel)
Denso common rail Approx. 2.3
Installation position system (diesel)
Bosch petrol direct 9.2 – 11.2
In the diesel common rail high-pressure
fuel injection
pump or in the petrol direct fuel injection
system high-pressure pump
Testing options
Operating principle Diagnostic tool Compatibility
Solenoid valve IDS – DTC Yes
Guided diagnosis +
Task / function (IDS), if available
The fuel metering valve regulates the fuel DMM ++
quantity delivered to the high pressure Datalogger +
chambers of the high-pressure pump. OSC mode # –
Actuation is via PWM signals. Oscilloscope +
The aperture cross-section of the fuel (breakout box and
metering valve depends on the duty cycle adapter cable
of the PWM signal. required)
Powerprobe ––
++ very suitable, + suitable

- unsuitable, - - very unsuitable

Service Training (G522588) 53

 Lesson 2 – Actuators

Special features
A defective fuel metering valve can be
renewed separately in the Delphi common
rail system and the Denso common rail
system. In the other systems, the complete
high-pressure pump must be replaced in the
event of a defective fuel metering valve.

54 (G522588) Service Training

Lesson 2 – Actuators

Fuel pressure regulator Task / function

In Siemens common rail systems, the fuel
A pressure regulator regulates the fuel pressure
at the high-pressure outlet of the
high-pressure pump and consequently the
pressure in the fuel rail.
In the other systems, the pressure is
regulated directly at the fuel rail.
In addition, pressure fluctuations arising
during fuel supply and the injection process
are compensated by the fuel pressure
regulator.
B
All systems are activated via PWM signals.
The aperture cross-section of the fuel
pressure regulator depends on the duty cycle
of the PWM signal.

E98146
Operating range
Value
A Fuel pressure regulator at the fuel
Supply voltage Approx. 12 V
pump
Signal type / voltage PWM signals
B Fuel pressure regulator at the fuel rail
Resistance • 1.5 – 15 Ohm
Installation position • (at the common
rail high-pressure
Component of the common rail
pump)
high-pressure pump (in Siemens common
rail systems only) • 3.5 – 5 Ohm

Component of the fuel rail (in the Bosch • (at the fuel rail)
common rail system with piezo-controlled Frequency –
fuel injectors and Magneti Marelli common
rail system)

Operating principle
Solenoid valve

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 Lesson 2 – Actuators

Testing options
Diagnostic tool Compatibility
IDS – DTC Yes
Guided diagnosis +
(IDS), if available
DMM ++
Datalogger +
OSC mode # –
Oscilloscope +
(breakout box and
adapter cable
required)
Powerprobe ––
++ very suitable, + suitable

- unsuitable, - - very unsuitable

Special features
In the case of a defective fuel pressure
control valve (e.g. if the valve is
permanently de-energized) a fuel rail
pressure of only 50 bar is reached during
starting. This holding pressure is a result of
the closing force of the compression spring
when the valve is de-energized.
The required pressure in the fuel rail during
starting must be at least 150 bar. Below this
minimum pressure, fuel injector needle lift
is not possible. Consequently, the engine
cannot be started or stalls.

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Engine cooling fan Operating range

Value
Supply voltage Max. 12 V
Signal type / voltage ON/OFF or PWM
Resistance < 5 Ohm
Frequency Approx. 20 kHz
PWM

Testing options
E61170
Diagnostic tool Compatibility
Installation position IDS – DTC No
On the radiator (heat exchanger) Guided diagnosis ++
(IDS), if available
Operating principle DMM +
DC motor (with and without brushes) Datalogger ++
OSC mode # ++
Task / function Oscilloscope –
The cooling fan accelerates the air, which (breakout box and
is routed through the radiator cooling fins adapter cable
and the condenser. This ensures improved required)
cooling of the radiator and the condenser. Powerprobe ––
The cooling fan consists of one or two DC ++ very suitable, + suitable
motor(s) with propeller(s). - unsuitable, - - very unsuitable

Depending on the version, cooling fans can

be controlled via series resistors (stage I and Owing to the high power consumption of
II) or in several stages via a power output the motor, it is not suitable for testing using
stage. the powerprobe.

The serial resistor is usually located in the Special features

immediate vicinity of the radiator and is
cooled by the air stream of the cooling fan. In the case of repairs to the cooling fan
connector, correct polarity und consequently
The power output stage is installed directly the direction of rotation of the propeller
next to the cooling fan motor. It actuates the must be ensured. If the cooling fan runs in
cooling fan via a PWM signal. the incorrect direction, the coolant
The fan speed depends on the duty cycle of temperature could increase.
the PWM signal.

Service Training (G522588) 57

 Lesson 2 – Actuators

Clutch actuator Both the external gearshift mechanism and

the clutch slave cylinder are actuated via
Gearshift actuator hydraulic lines.
In the Fiesta the gearshift lever and selector
A lever of the external gearshift mechanism
are operated separately, each via an electric
C B
motor.
The clutch actuator consists of a DC motor,
a gear mechanism for operating the
integrated clutch master cylinder, an
integrated travel sensor, which measures the
E60581
actuation travel and a control module.
A Gearshift/clutch actuator, Transit
Operating range
B Gearshift actuator, Fiesta
C Clutch actuator, Fiesta (with integrated Value
clutch travel sensor) Supply voltage Approx. 12 V
Signal type / voltage • ON/OFF (gear-
Installation position shift actuator)
Near the transmission (vehicles with • PWM (clutch
automated manual transmission) actuator) **

Operating principle Resistance • Approx. 30 – 35

Ohms *
Electric motor with solenoid valves
• (Solenoid valves,
(Transit), electric motor (Fiesta)
Transit)
Task / function Frequency –
Gearshift actuators operate the gearshift * Values are temperature dependent
lever and selector lever, clutch actuators ** Cannot be measured in the Fiesta, circuit integrated
operate the clutch. in actuator
In the Transit, both actuators are integrated
into a single unit together with an Testing options
electrically-operated hydraulic pump and
solenoid valves. Diagnostic tool Compatibility
IDS – DTC Yes
The hydraulic pump generates the necessary
pressure, which is applied via the solenoid Guided diagnosis ++
valves controlled by the TCM (transmission (IDS), if available
control module). DMM +

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Lesson 2 – Actuators

Diagnostic tool Compatibility

Datalogger ++
OSC mode # • ++ Transit
• – Fiesta
Oscilloscope –
(breakout box and
adapter cable
required)
Powerprobe ––
++ very suitable, + suitable

- unsuitable, - - very unsuitable

Special features
NOTE: On the Transit with ASM it is
possible to shift gears directly in OSC mode.
The safety instructions must always be
observed for this purpose (e.g. applying the
handbrake).
After replacing clutch actuator components
or in the event of a concern, the clutch
contact point must be recalibrated. A
relevant test routine is available for both
systems in IDS.

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 Lesson 2 – Actuators

Idle air control (IAC) valve The IAC valve is located in a bypass line
around the throttle plate.

1 Operating principle
Solenoid valve or stepper motor

Task / function
The purpose of the IAC valve is to adjust
2 the required engine idle speed when the
E60928 throttle plate is closed.
Examples of IAC (idle air control) valves This is achieved by bypass around the
1 Solenoid valve-controlled IAC valve throttle plate which is opened to a greater
2 Stepper motor-controlled IAC valve or lesser extent according to requirements.
Solenoid valve-controlled IAC valve:
Installation position
In the inlet manifold.

1 2 3 4

6 5

E124003

Cross-section of a solenoid valve-controlled IAC valve

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Lesson 2 – Actuators

A PWM signal 4 Valve for air throughput

1 Plug connection 5 Air bypass line
2 Coil 6 Throttle plate
3 Valve needle with solenoid armature

Electrical actuation is via PWM signals. When de-energized, a spring closes the
These determine the magnetic force for the valve or, in newer design versions, opens
aperture cross-section of the valve. The it.
position of the IAC valve depends on the Stepper motor-controlled IAC valve:
duty cycle of the PWM signal.

A 1 2 3

E124468

A Aspirated air mass 3 Stepper motor

B Pulse signals 4 Engine
1 Bypass air 5 Fuel injectors
2 Valve spindle 6 Intake manifold

The stepper motor-controlled IAC valve is

actuated via targeted pulse signals.

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 Lesson 2 – Actuators

The valve spindle is moved upwards and

downwards via the rotary motion of the
stepper motor. The number of signal pulses
determines the aperture cross-section of the
IAC valve.

Operating range
Value
Supply voltage Approx. 12 V
Signal type / voltage • Solenoid valve:
PWM signals
• Stepper motor.
Pulse signals
Resistance –
Frequency –

Testing options
Diagnostic tool Compatibility
IDS – DTC Yes
Guided diagnosis +
(IDS), if available
DMM ++
Datalogger ++
OSC mode # ++
Oscilloscope +
(breakout box and
adapter cable
required)
Powerprobe ––
++ very suitable, + suitable

- unsuitable, - - very unsuitable

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Variable camshaft timing solenoid Testing options

valves
Diagnostic tool Compatibility
IDS – DTC Yes
Guided diagnosis +
(IDS), if available
DMM ++
Datalogger +
OSC mode # ––
Oscilloscope +
E124504 (breakout box and
adapter cable
Installation position required)
Powerprobe ––
On the front face of the cylinder head
++ very suitable, + suitable
Operating principle - unsuitable, - - very unsuitable
Solenoid valve

Task / function
The VCT solenoid valves adjust the intake
and exhaust VCT oil control units.
Actuation is via PWM signals.
The position of the solenoid valves changes
depending on the duty cycle.

Operating range
Value
Supply voltage Approx. 12 V
Signal type / voltage PWM signal
Resistance 7.5 ± 0.5 Ohm
Frequency –

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 Lesson 2 – Actuators

Solenoid valves for vacuum Task / function

control (engine management) Vacuum-controlled solenoid valves convert
electrical signals into a vacuum for control
1 2 purposes.
With the aid of this control vacuum,
mechanical actuators (for instance the EGR
valve or intake manifold flap) are adjusted
according to requirements.
3
Vacuum-controlled solenoid valves can be
E60524
activated in two ways:

Examples of solenoid valves for vacuum – Switched on (maximum vacuum) or

control switched off (no vacuum)
1 EGR solenoid valve – Actuation is via PWM signals
2 Evaporative emission canister purge During actuation via PWM signals, the
solenoid valve following applies:
3 Swirl plate solenoid valve – The greater the duty cycle, the greater the
vacuum applied.
Application
Operating range
EGR solenoid valve
Value
Swirl plate solenoid valve
Supply voltage Approx. 12 V
Boost pressure solenoid valve (diesel
Signal type / voltage PWM signals and/or
engines only)
ON/OFF
Intake manifold flap solenoid valve (diesel Resistance • < 150 Ohm
engines only)
• (see table)
Intake manifold runner control solenoid
valve Frequency –

Charge air cooler bypass flap solenoid valve

EVAP (evaporative emission) solenoid
valve

Operating principle
Solenoid valve

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Examples of resistance values for Diagnostic tool Compatibility

individual solenoid valves OSC mode # ++ **
Solenoid valve Resistance (Ohms) Oscilloscope –
Swirl plates (1.8L Approx. 32 (breakout box and
Duratec HE (MI4)) adapter cable
EGR (2.0L Duratorq- Approx. 14 required)
TDCi (Puma) diesel Powerprobe +
engine) ++ very suitable, + suitable
EGR (EEC IV/EEC Approx. 30 – 150
- unsuitable, - - very unsuitable
V systems with petrol
engines) * Not always with intake manifold flap control

Boost pressure Approx. 18 ** If supported by IDS

control (2.0L
Duratorq TDCi (DW) A number of solenoid valves for vacuum
diesel) control can be displayed via the IDS
Intake manifold flap Approx. 18 datalogger depending on the vehicle and
(2.0L Duratorq TDCi system.
(DW) diesel) Connect the vacuum hand pump to the
EVAP (EEC V) Approx. 30 – 120 solenoid valve.
EVAP (1.8L Duratec 15 – 25
During engine speed/load changes (or in the
SCi (MI4)
case of some intake manifold flaps when
EVAP(Magneti 23 – 29 switching off the engine) a corresponding
Marelli) change should simultaneously be registered
in the dial of the hand pump gauge.
Testing options
Operational test of EGR solenoid valve
Diagnostic tool Compatibility via OSC mode (if supported):
IDS – DTC Yes *
– Select the relevant PID in the IDS
Guided diagnosis + datalogger.
(IDS), if available
– Call up and activate OSC mode.
DMM +
– Progressively increase the PWM to the
Datalogger ++
maximum level by repeatedly pressing
the "+" key.
– If idling becomes significantly rougher
as the duty cycle increases and returns to
normal when the duty cycle is reduced
again, the EGR solenoid valve is
operating correctly.

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 Lesson 2 – Actuators

Operational test of EVAP solenoid valve

via OSC mode (if supported):
– Select the relevant PID in the IDS
datalogger.
– Call up and activate OSC mode.
– Set the PWM to the maximum activation
time by repeatedly pressing the "+" key.
The engine should run increasingly
roughly.
– If this is the case, the EVAP solenoid
valve is operating correctly.

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Solenoid valve for the shock Operating range

absorber control system (active
Value
suspension)
Supply voltage Approx. 12 V
Signal type / voltage PWM signal *
A B Resistance approx. 30 - 50
ohms
Frequency –
* The control current resulting from the PWM is
between 0.29 and 1.6 A.

Testing options
Diagnostic tool Compatibility
IDS – DTC Yes
Guided diagnosis –
(IDS), if available
DMM ++
C
Datalogger +
OSC mode # –
Oscilloscope +
E68869
(breakout box and
A Front shock absorber adapter cable
B Rear shock absorber required)
C Solenoid valve Powerprobe –
++ very suitable, + suitable
Installation position - unsuitable, - - very unsuitable
On the shock absorber

Operating principle
Solenoid valve

Task / function
The shock absorber control module adjusts
the shock absorber stiffness.

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 Lesson 2 – Actuators

Fuel pump driver module Task / function

(FPDM) The fuel pump delivers fuel from the fuel
tank to the injection system.
2
1 3 Operating range
Value
Supply voltage Approx. 12 V
Signal type / voltage ON/OFF
Resistance –
Frequency –
4
Testing options
Diagnostic tool Compatibility
IDS – DTC Yes
5
Guided diagnosis +
(IDS), if available
DMM +
Datalogger ++
E53598 OSC mode # ++
Example of an FPDM (fuel pump driver Oscilloscope –
module) (breakout box and
1 Fuel feed adapter cable
required)
2 Electrical connection
Powerprobe +
3 Fuel return
++ very suitable, + suitable
4 Integrated electric fuel pump
- unsuitable, - - very unsuitable
5 Fuel level sensor

Installation position
In the fuel tank

Operating principle
DC motor

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Electric power steering motor 1 EPAS (electronic power assist

steering) motor
1 2 Housing, steering assistance drive
2

E130020

Recirculating ball nut

2 3 4

6
E130062

1 Inner ring, ball bearing 4 Ball return

2 Outer ring, ball bearing 5 Steering rack with ball track
3 Balls 6 Output pinion, toothed belt drive

A toothed belt is used to transfer the Installation position

rotational movement of the motor via a
recirculating ball nut to the steering rack of The electric motor is bolted directly to the
the steering gear. The recirculating ball nut steering assistance drive housing.
produces a linear movement of the steering
rack from the rotational movement of the Operating principle
output pinion. Solenoid

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 Lesson 2 – Actuators

Task / function NOTE: The electric power steering motor

may not be separately replaced during
The electric power steering motor is of
service repairs. If the event of a fault, the
brushless type with a stator and three phases
whole steering column together with the
connected in star-delta.
electric power steering unit must be
The rotor is a permanent magnet. The rotor replaced.
position is detected by a total of three Hall
sensors and transmitted to the PSC (power Testing options
steering control) module.
Diagnostic tool Compatibility
The signals from the Hall sensors are used IDS – DTC Yes
for the following calculations: Guided diagnosis ––
• Calculating the actuation current for each (IDS), if available
stator winding DMM +
• Calculation of the steering center Datalogger +
position. OSC mode # ––
Oscilloscope –
Operating range
(breakout box and
Value adapter cable
Supply voltage Approx. 12 V required)
Signal type / voltage PWM signals Powerprobe ––
Resistance – ++ very suitable, + suitable
Frequency approx. 18 kHz - unsuitable, - - very unsuitable

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Course of signal: actuation of power steering motor on 2013.25 Kuga

E163474

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 Lesson 2 – Actuators

Relay Operating range

Value
Supply voltage Approx. 12 V
Signal type / voltage ON/OFF
Resistance 60 – 150 Ohms
(control circuit)
Frequency –
1 Diodes can also be integrated in the control
E60671 circuit "in series" or "in parallel".
Examples of relays NOTE: If a diode is connected with the
1 Circuit diagram control circuit "in series", the measured
values in the control circuit change.
Installation position
Testing options
Depending on the application, for example
in the CJB (central junction box) or in the Diagnostic tool Compatibility
GEM IDS – DTC Yes *
Guided diagnosis +*
Operating principle
(IDS), if available
Solenoid DMM ++
Datalogger +*
Task / function
OSC mode # ++ *
Relays switch high operating currents by Oscilloscope –
means of low control currents. Relays also (breakout box and
disconnect the operating circuit from the adapter cable
control circuit. required)
Normally closed and normally open relays Powerprobe ++
have four, and changeover relays five ++ very suitable, + suitable
connections.
- unsuitable, - - very unsuitable
On some relays, the circuit is shown on the
* Depending on use
housing.
Operating circuit relays can be tested by
applying control voltage. If the relay clicks,
the control circuit is probably OK.

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In order to test the operating circuit, the

unused connections should simultaneously
be tested for continuity.
In the changeover relay, 3 connections are
not used. Two of them are always in contact,
depending on the switch position.

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 Lesson 2 – Actuators

Shift solenoid valve Furthermore, depending on use, the solenoid

valves can either be replaced individually
Pressure control valve or only together with other solenoid valves.

Operating range
1
Value
2
Supply voltage Max. 12 V
Signal type / voltage ON/OFF or PWM
Resistance < 20 Ohm *
Frequency –
* Values are transmission fluid temperature dependent
E60451

Examples of solenoid valves

Testing options
1 Pressure control valve
2 Shift solenoid valves Diagnostic tool Compatibility
IDS – DTC Yes *
Installation position Guided diagnosis +
In the transmission housing (automatic (IDS), if available
transmissions) DMM +
Datalogger ++
Operating principle OSC mode # +
Solenoid valves Oscilloscope –
(breakout box and
Task / function adapter cable
Shift solenoid valves open and close required)
channels within the valve body. The Powerprobe ––
solenoid valves installed can be either closed ++ very suitable, + suitable
or opened when de-energized.
- unsuitable, - - very unsuitable
Depending on the application, some of the * Some consequential faults resulting from mechan-
solenoid valves installed can only switch ically defective solenoid valves are also indicated via
between ON and OFF, others are actuated DTCs.
via a PWM signal or are variably actuated
via voltage (proportioning valve) and can
During testing of the solenoid valve for the
consequently perform control (e.g. fluid
torque converter clutch (PID = TCC (torque
pressure) in a number of stages.
converter clutch)), it should be noted that it
must not be activated when the vehicle is
stationary, as the clutch may be damaged.

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Special features
Terms used:
– SSA or SSB (SS (shift solenoid))
– EPC (electronic pressure control)
solenoid valve
– T/CCS (timing/coast clutch solenoid)
– Overrun clutch solenoid valve
– Shift point solenoid valve
– Idle clutch solenoid valve

Service Training (G522588) 75

 Lesson 2 – Actuators

Actuator motor-controlled intake Task / function

manifold flap The intake manifold flap unit has the
following functions:

1
• preventing "serious engine judder" when
the engine is stopped,
• throttling the intake air during the DPF
(diesel particulate filter) regeneration
process,
The intake manifold flap is actuated by a
DC (direct current) motor. Actuation is
performed via PWM by the PCM. The
2
position of the intake manifold flap depends
on the duty cycle of the PWM signal.
In the case of the actuator motor-controlled
intake manifold flap with position sensor,
the current position of the intake manifold
flap is detected by a position sensor. The
output signal is an analogue voltage signal.
E124002
Operating range
1 Actuator motor-controlled intake Value
manifold flap (1.4L Duratorq-TDCi Supply voltage Approx. 12 V
(DV) diesel engine, emission standard
Signal type / voltage PWM signals
IV)
Resistance Approx. 8.3 Ohm
2 Actuator motor-controlled intake
Frequency –
manifold flap with position sensor
(potentiometer) Testing options
Installation position Diagnostic tool Compatibility
In the intake system IDS – DTC Yes
Guided diagnosis +
Operating principle (IDS), if available
DC motor DMM ++
Datalogger +

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Lesson 2 – Actuators

Diagnostic tool Compatibility

OSC mode # –
Oscilloscope +
(breakout box and
adapter cable
required)
Powerprobe ––
++ very suitable, + suitable

- unsuitable, - - very unsuitable

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 Lesson 2 – Actuators

Actuator motor-controlled intake The intake manifold flap is fully open when
manifold flap/charge air cooler de-energized.
bypass flap During the regeneration phase, the charge
air cooler bypass flap actuator motor
opens the charge air cooler bypass flap,
1
directing uncooled charge air to the
combustion chambers.
The charge air cooler bypass flap is fully
closed when de-energized.
Actuation of the actuator motors performed
2 via PWM signals in both cases. The duty
E61257
cycle determines the aperture cross-section
1 Charge air cooler bypass flap actuator of the respective flaps.
motor
The position sensor integrated in the
2 Intake manifold flap actuator motor respective actuator motor housings detects
the current position of the flaps.
Installation position
In the intake tract (1.6L Duratorq TDCi Operating range
(DV) diesel with diesel particulate filter Value
only)
• Supply voltage Approx. 12 V
Physical operating principle • (actuator motor)
DC motor (actuator) • Reference voltage Approx. 5 V
Sliding-contact (position sensor) • (position sensor)

Task / function • Signal type / PWM signal

voltage
The intake manifold flap actuator motor
• (actuator motor)
adjusts the intake manifold flap in the intake
tract, which has the following functions: • Signal type / • DC voltage:
– Restricting the intake air for exhaust gas voltage • 0.5 – 4.5 V
recirculation, • (position sensor)
– Closing the intake system when the
Resistance (actuator Approx. 3 – 6 Ohms
engine is switched off
motor)
– Closing the air route via the charge air Frequency –
cooler during the regeneration process of
the diesel particulate filter

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Testing options
Diagnostic tool Compatibility
IDS – DTC Yes
Guided diagnosis +
(IDS), if available
DMM ++
Datalogger +
OSC mode # ++ *
Oscilloscope +
(breakout box and
adapter cable
required)
Powerprobe ––
++ very suitable, + suitable

- unsuitable, - - very unsuitable

* If supported by IDS

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 Lesson 2 – Actuators

Wiper motor In the case of wiper motors with two speed

settings, motors with two commutator tracks
A B 1
are often used. The armature is supplied
1
with power via a commutator and two
2 opposing brushes in the first setting. This
2 achieves a low speed with high torque.
3 In the second setting, power supply is via
the third brush, increasing the speed.

3 The different intermittent settings are

E61126 achieved via timer modules (previously via
Examples of wiper motors relays or a CTM (central timer module),
A Rear window wiper motor now via the GEM).
B Windshield wiper motor Operating range
1 Motor
Value
2 Drive
Supply voltage Approx. 12 V
3 Mounting for wiper arm / wiper
Signal type / voltage ON/OFF
linkage
Resistance –
Installation position Frequency Depending on wiper
setting
Under the cowl panel / in the liftgate
Testing options
Operating principle
Diagnostic tool Compatibility
DC motor with integrated drive (worm gear)
and self-parking function IDS – DTC Yes *
Guided diagnosis ++
Task / function (IDS), if available
The wiper motor moves the wiper arms. DMM +
Depending on use, a wiper linkage is Datalogger –
integrated directly in the motor. This linkage
converts the rotary motion of the motor to
an alternating motion.
The self-parking function ensures that
regardless of when it is switched off, the
wiper only stops when it has reached its
limit position, i.e. outside the field of view
(also referred to as park position).

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Diagnostic tool Compatibility

OSC mode # ++ **
Oscilloscope –
(breakout box and
adapter cable
required)
Powerprobe ++
++ very suitable, + suitable

- unsuitable, - - very unsuitable

* In module-controlled systems (e.g. GEM) via the

module self-test

** Only one setting

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 Lesson 2 – Actuators

Anti-lock brake system/traction Depending on the system, either simple

control actuator changeover valves or proportional valves
(e.g. with EBD (electronic brake force
distribution)) are installed.
1 2

Operating range
Value
Supply voltage Approx. 12 V
Signal type / voltage ON/OFF
Resistance –
E60460
Frequency –
Example of an ABS (anti-lock brake
system)/traction control unit Testing options
1 Solenoid coil Diagnostic tool Compatibility
2 Coil core (armature) IDS – DTC Yes
Guided diagnosis ++
Installation position
(IDS), if available
In the engine compartment on the left in DMM ––
front of the bulkhead Datalogger +
OSC mode # ++
Operating principle
Oscilloscope ––
Combination of electric motor and solenoid (breakout box and
valves adapter cable
required)
Task / function
Powerprobe ––
The ABS/traction control actuator consists ++ very suitable, + suitable
of a valve block with integrated solenoid
- unsuitable, - - very unsuitable
valves, an electric motor, and a control
module.
For nearly all systems, complete testing of
The ABS/traction control actuator monitors the actuator is possible using guided
the input signals of all sensors and actuates diagnosis in IDS. Individual components
the electromagnetic brake pressure valves such as solenoid valves or electric motors
and the ABS pump. cannot be tested in the workshop.
Depending on the vehicle equipment, eight In some systems it is possible to replace the
(with ABS) or twelve (with BTCS (brake valve block together with the electric motor.
traction control system)) solenoid valves are
installed.

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Special features
In older systems, a separate traction control
actuator was installed.

E54029

1 Potentiometer
2 Two-part flexplate
3 Drive motor
This actuator is required for the return
movement of the mechanical throttle plate.
The two actuator cables (accelerator pedal
and throttle plate) and connected via a
two-part flexplate.
During control intervention, the movement
of the accelerator pedal cable is overridden
by the electric motor so that the throttle plate
is closed, contrary to driver input.
A potentiometer fitted to the traction control
actuator informs the PCM about the current
position of the traction control actuator.

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 Lesson 2 – Actuators

Liftgate release actuator Operating range

Value
3 Supply voltage Approx. 12 V
Signal type / voltage ON/OFF
1 Resistance < 5 Ohms (solenoid
valve)
Frequency –

2 Testing options
E60542

Example of a liftgate release actuator Diagnostic tool Compatibility

1 Connector IDS – DTC Yes *
Guided diagnosis –
2 DC motor
(IDS), if available
3 Solenoid coil
DMM +
Installation position Datalogger ++ *
OSC mode # ++ *
In the liftgate at the lock cylinder
Oscilloscope –
Operating principle (breakout box and
adapter cable
DC motor or solenoid coil required)
Task / function Powerprobe ++
++ very suitable, + suitable
The liftgate release actuator unlocks the
- unsuitable, - - very unsuitable
liftgate or luggage compartment lid.
Depending on the system, unlocking may * In module-controlled systems (e.g. GEM) via the
be performed by a DC motor or a solenoid module self-test
coil.
A voltage is applied briefly to the DC motor
or solenoid coil, actuating an unlocking
lever via an integrated mechanism (DC
motor) or directly (solenoid coil).
Return is performed by a return spring in
either case.
In contrast to vehicle doors, liftgates are not
double-locked.

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Blend door actuator Operating range

Value
1 2
Supply voltage Approx. 12 V
Signal type / voltage • Pulse signals
(stepper motor)
• ON/OFF (all
others)
3
Resistance < 100 Ohm *
E60462 Frequency –
Examples of blend door actuators * Can only be measured in the case of motors with 2
1 Actuator motor connections
2 DC motor
3 Stepper motor Testing options
Diagnostic tool Compatibility
Installation position
IDS – DTC • Yes (stepper
At the blower housing motors)

Operating principle • No (all others)

Mechanical, pneumatic, DC motor, stepper Guided diagnosis –

motor (IDS), if available
DMM • + (motors with
Task / function two connections)
Blend door actuators control the air flow in • – (all others)
the air distribution housing. Depending on
Datalogger ++ *
the blend door being operated, actuators
with different designations are used, e.g.
blend flap actuator, air distribution door
actuator or temperature blend door actuator
(see also "Special features").
Blend doors operated via stepper motors are
adjustable virtually infinitely within their
movement range.

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 Lesson 2 – Actuators

Diagnostic tool Compatibility Pneumatic actuator

OSC mode # ++ *
Oscilloscope • + (motors with
(breakout box and two connections)
adapter cable • – (all others)
required)
Powerprobe • + (motors with
two connections)
• – (all others) E60461

++ very suitable, + suitable 1 Vacuum connection

- unsuitable, - - very unsuitable 2 Diaphragm and return spring
* Only with module-controlled air conditioning 3 Blend door linkage
systems Pneumatically actuated blend doors can only
open or close. In two-setting systems, an
Special features intermediate position is possible.
Possible designations / uses: Pneumatic actuators are connected to the
vacuum reservoir via hoses.
– Air inlet blend door actuator
– Defroster vent/air vent distribution door When a vacuum is applied to the actuator
actuator connection, the diaphragm and the linkage
attached to it are fully retracted. The blend
– Footwell air vent flap actuator
door, which is attached to the extension of
– Cold air bypass blend door actuator the linkage is opened.
– Air distribution flap actuator If an actuator has two vacuum connections,
– Temperature blend door actuator it can move to three different positions.
When a vacuum is applied to only one
connection, the linkage moves to an
intermediate position. When a vacuum is
applied to both connections, the linkage is
extended to the limit position.
As long as the vacuum is maintained in the
actuator, the blend door remains in position.
Leaks in the actuator or in the vacuum
system lead to failure of the pneumatic
actuator.

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Lesson 2 – Actuators

Selector lever lock actuator Operating range

Ignition key removal inhibitor Value

actuator Supply voltage Approx. 12 V
Signal type / voltage ON/OFF
A B
Resistance < 16 Ohm
Frequency –

Testing options
Diagnostic tool Compatibility
IDS – DTC No
Guided diagnosis ––
E61127
(IDS), if available
A Ignition key removal inhibitor actuator DMM +
B Selector lever lock actuator Datalogger –
OSC mode # –
Installation position Oscilloscope –
At the ignition lock (keyless vehicles) or on (breakout box and
the selector lever (vehicles with automatic adapter cable
transaxle) required)
Powerprobe ++
Operating principle
++ very suitable, + suitable
Solenoid - unsuitable, - - very unsuitable

Task / function
The ignition key removal inhibitor actuator
blocks the ignition lock, preventing the
ignition key from being removed. It is not
activated, i.e. not blocked, when
de-energized.
The selector lever lock actuator prevents the
selector lever from being moved from the
P position. It is activated, i.e. not blocked,
when de-energized.

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 Lesson 2 – Actuators

Special features

TIE45383

1 Cover
In the event of a fault, the selector lever lock
can often be released manually. A cover at
the selector lever must be removed for this
purpose.
A suitable object should then be inserted in
the aperture, allowing the selector lever to
be moved from the P position.
For further information, please refer to the
relevant workshop literature or the Owner's
Handbook.

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Lesson 2 – Actuators

Door lock actuator The necessary DC motors are integrated in

the various door locks and cannot be
1 2 replaced separately.
At the driver-side front door, all the
3 functions with the exception of double
locking can be performed mechanically via
the lock cylinder.
4

Operating range
E60543 Value
Example of a door lock actuator Supply voltage Approx. 12 V
1 Release lever (exterior door handle) Signal type / voltage ON/OFF
2 Cable to release lever (interior of door) Resistance –
3 Lever to release lever (exterior door Frequency –
handle)
Testing options
4 Connector
Diagnostic tool Compatibility
Installation position IDS – DTC Yes *
In the vehicle door Guided diagnosis ++
(IDS), if available
Operating principle DMM +
DC motor(s) Datalogger ++
OSC mode # ++
Task / function Oscilloscope –
The door lock actuator has several functions, (breakout box and
depending on the vehicle equipment: adapter cable
– Unlocking the door required)
Powerprobe ++
– Single locking the door
++ very suitable, + suitable
– Double locking of the door
- unsuitable, - - very unsuitable
During single locking, the mechanical
connection of the release lever (exterior door * In module-controlled systems (e.g. GEM) via the

handle) to the lock is interrupted. module self-test

During double locking, the mechanical

connection of the release lever (interior of
door) to the lock is interrupted.

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 Lesson 2 – Actuators

Special features
In the central locking systems, various
options with regard to the unlocking
sequence are often available (e.g. unlocking
the driver door by pressing the remote
control once).
When testing a door lock actuator, currently
activated option should be taken into
account.

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Lesson 2 – Actuators

Vacuum pump Operating range

Value
Supply voltage Approx. 12 V
Signal type / voltage ON/OFF
Resistance –
Frequency –

Testing options
Diagnostic tool Compatibility
IDS – DTC No
Guided diagnosis ––
(IDS), if available
DMM ++
Datalogger ––
OSC mode # ++
Oscilloscope ––
(breakout box and
E123932 adapter cable
required)
Installation position Powerprobe ++
In the engine compartment ++ very suitable, + suitable

- unsuitable, - - very unsuitable

Operating principle
DC motor

Task / function
The vacuum pump ensures that sufficient
vacuum for brake boosting is always
provided under all of the combustion
engine's operating conditions.
The vacuum pump is actuated via a relay
by the brake vacuum switch.

Service Training (G522588) 91

Pyrotechnic actuators Lesson 2 – Actuators

Air bag module In terms of the igniter, systems using an air

bag inflator (driver air bag and passenger
Example of a driver air bag air bag in older systems) or with pre-filled
gas cartridges (all except driver air bag) are
1
used.
2
3 4
Operating range
Value
Supply voltage –
Signal type / voltage DC/AC voltage,
TIE41391 millivolts
1 Container Resistance Approx. 2 – 4 Ohms
*
2 Air bag inflator
Frequency –
3 Air bag
4 Padded cover cap WARNING: * No resistance
measurements must be performed in
Installation position the vicinity of air bag igniters.

Depending on use: Testing options

– in the steering wheel (driver air bag) WARNING: The safety instructions
– in the instrument panel (passenger air contained in the relevant workshop
bag) literature must always be observed
– in the front seat (side air bag) door-side when working on air bags.
– in the roof rail, between the A and C or Diagnostic tool Compatibility
D-pillar IDS – DTC Yes
Guided diagnosis –
Operating principle
(IDS), if available
Pyrotechnic DMM ––
Datalogger +*
Task / function
Air bags protect vehicle occupants from
injuries in the event of a crash/impact. All
air bag units consist of an igniter which
inflates an air bag.

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Lesson 2 – Actuators Pyrotechnic actuators

Diagnostic tool Compatibility

OSC mode # ––
Oscilloscope ––
(breakout box and
adapter cable
required)
Powerprobe ––
++ very suitable, + suitable

- unsuitable, - - very unsuitable

* In some systems, the resistance of air bags can be

displayed in the datalogger (air bag module).

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 Lesson 2 – Actuators

Safety belt pretensioners Operating range

Examples of safety belt pretensioners Value
Supply voltage –
A B
Signal type / voltage DC voltage, milli-
volts
Resistance 2 – 4 Ohm *
Frequency –
WARNING: * No resistance
measurements must be performed in
E60541 the vicinity of safety belt pretensioner
A Safety belt pretensioner integrated in igniters.
the safety belt retractor Testing options
B Safety belt pretensioner on seat or seat
track WARNING: The safety instructions
contained in the relevant workshop
Installation position literature must always be observed
when working on safety belt
On seat or seat track or in safety belt pretensioners.
retractor
Table does not apply to mechanical safety
Operating principle belt pretensioners
Diagnostic tool Compatibility
Mechanical (older systems), pyrotechnic
with mechanical (Galaxy) or electrical (all IDS – DTC Yes
others) triggering Guided diagnosis –
(IDS), if available
Task / function DMM ––
Safety belt pretensioners ensure that the Datalogger +*
safety belts are held closely to the occupants'
body in the event of an accident.
The belt pretensioner can be triggered only
once. A triggered safety belt pretensioner
does not affect the operation of the safety
belt itself or retraction.
Pyrotechnic safety belt pretensioners, like
air bags, operate using an igniter and a
mechanical drive or a pretensioned spring
(Galaxy only).

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Lesson 2 – Actuators

Diagnostic tool Compatibility

OSC mode # ––
Oscilloscope ––
(breakout box and
adapter cable
required)
Powerprobe ––
++ very suitable, + suitable

- unsuitable, - - very unsuitable

* In some systems, the resistance values for air bags

can be displayed in the datalogger (air bag module).

A triggered safety belt pretensioner can be

identified by means of the significantly
shorter belt anchorage (exception: safety
belt pretensioner integrated in safety belt
retractor)
In the case of pyrotechnic belt pretensioners
with electrical triggering, a DTC is always
stored in the SRS (supplemental restraint
system) module in the event of triggering.

Special features
A safety belt pretensioner can only ever
trigger once and must then always be
replaced.
In the case of safety belt pretensioners
integrated in the safety belt retractor, web
grabbers/belt stoppers and belt tension
limiters may also be installed.
In the case of replacement, the entire unit,
including the safety belt must be replaced.
Mechanical safety belt tensioners trigger a
pretensioned spring via a spring-mass
sensor.

Service Training (G522588) 95

Other actuators Lesson 2 – Actuators

Headlamp leveling motors Operating range

Mirror adjustment motors Value

Supply voltage Approx. 12 V
Fuel filler door release actuator Signal type / voltage • ON/OFF *
Installation position • Pulse signals
(adaptive forward
In the headlamps lighting)
In the exterior mirrors • PWM signals
At the fuel filler door (headlamp
leveling) **
Operating principle
Resistance –
DC motor (headlamp leveling system, Frequency –
mirror adjustment, fuel filler door), stepper * Mirror adjustment, fuel filler door
motor (adaptive front lighting)
** Cannot be measured, integrated in the motor
Task / function
Motors for mirror adjustment alter the Testing options
position of the mirror glass in the horizontal Diagnostic tool Compatibility
and vertical directions as well as the mirror
IDS – DTC • Yes *
housing (folding function).
• No (all others)
Headlamp leveling motors adjust the
headlamp reflector in the horizontal Guided diagnosis –
direction. (IDS), if available
In the case of adaptive forward lighting, DMM +
the headlamp reflector is adjusted in the Datalogger +
vertical direction.
The fuel filler door actuator locks and
unlocks the fuel filler door.

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Lesson 2 – Actuators Other actuators

Diagnostic tool Compatibility

OSC mode # ++ *
Oscilloscope –
(breakout box and
adapter cable
required)
Powerprobe –
++ very suitable, + suitable

- unsuitable, - - very unsuitable

* With Xenon light and adaptive front lighting, mirror

adjustment (Focus 2004.75, Focus C-MAX 2003.75,
S-MAX/Galaxy 2006.5, and Mondeo 2007.5)

Service Training (G522588) 97

Test questions Lesson 2 – Actuators

Tick the correct answer or fill in the gaps.

1. Airbag resistors must not be tested using a multimeter.

a. True
b. False

2. When testing blower motors and cooling fans, it should be noted that:
a. these are always designed as brushless motors.
b. a DTC is always stored in the event of a defective blower motor.
c. depending on the version, a serial resistor is defective although the blower motor
is operative.
d. these are only used in conjunction with air conditioning systems.

3. During testing using the powerprobe

a. nothing needs to be noted.
b. it should be noted that no positive voltage is applied to the module.
c. only ground should be connected in all cases.
d. it should be noted that only electric motors can be tested.

4. To check stepper motors

a. the powerprobe should always be used.
b. it is sufficient to perform a continuity test to the coils.
c. OSC mode is always available.
d. the OSC mode should be used where possible.

5. Fuel injectors can always be checked using the powerprobe as they are always
solenoid valves.
a. True
b. False

98 (G522589) Service Training

 Answers to the test questions

Lesson 1 – General Information

1. b
2. b

Lesson 2 – Actuators

1. a
2. c
3. b
4. d
5. b

Service Training 99
List of Abbreviations

A/C air conditioning LPG liquefied petroleum gas

ABS anti-lock brake system MAP manifold absolute pressure

BTCS brake traction control system OSC output state control

CJB central junction box PCM powertrain control module

CNG compressed natural gas PSC power steering control

CTM central timer module PTC positive temperature coefficient

DC direct current PWM pulse width modulation

DPF diesel particulate filter SRS supplemental restraint system

DTC diagnostic trouble code SS shift solenoid

EATC electronic automatic temperature T/CCS timing/coast clutch solenoid

control
TCC torque converter clutch
EBD electronic brake force distribution
TCM transmission control module
EGR exhaust gas recirculation

EPAS electronic power assist steering

EPC electronic pressure control

EVAP evaporative emission

FPDM fuel pump driver module

GEM generic electronic module

IAC idle air control

IDS Integrated Diagnostic System

IMRC intake manifold runner control

LCD liquid crystal display

LIN local interconnect network

100 Service Training