all FORD KUGA 2011 1.G Owners Manual

Instrument Cluster and Panel Illumination
Refer to
Wiring Diagrams Section 413-00, for
schematic and connector information.
Principles of Operation
NOTE: A new instrument cluster must be
configured.
The instrument cluster and panel illumination
consists of dimmable and non-dimmable
illumination. The dimmable panel illumination is
controlled by the panel illumination switch (part of
the headlamp switch), which allows the brightness
level of the backlights to be adjusted dependent
on the customer preference. When the headlamp
switch is in the parking lamps ON or headlamps
ON position, the intensity of the backlighting can
be adjusted using the panel dimmer switch. The
non dimmable illumination allows for full intensity
dependant on the ignition switch position.
Instrument Cluster and Dimmable
Backlighting A.
Tachometer
B. Engine coolant temperature gauge
C. Fuel gauge
D. Speedometer
E. Information display
The dimmable illumination utilizes light emitting
diodes (LEDs) and bulb(s). The following dimmable
components are backlight using LEDs only:
• ashtray
• cigar lighter
• transmission control lever
• heater control panel
• audio unit • navigation system display module
• instrument cluster
• climate control module
• hazard switch
• traction control system disable switch
• right-hand and left-hand heated front seat
switch(es)
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical
or electrical damage.
Visual Inspection Chart Electrical
Mechanical
– Fuse(s)
– Loose or corrodedconnector(s)
– Instrument cluster
– Wiring Harness
– Circuit
– LED(s)
– Bulb(s)
– Engine/engine
compartment or
underbody compon-
ents
– Fluid levels
– Accessory installa- tion
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible)
before proceeding to the next step.
4. If the cause is not visually evident, verify the symptom and refer to the diagnostic tab within
the Ford approved diagnostic tool. G1054961en
2008.50 Kuga 8/2011 413-00-2
Instrument Cluster and Panel Illumination
413-00-2
DIAGNOSIS AND TESTINGTO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUALE98738ABCED

SECTION 413-01 Instrument Cluster
VEHICLE APPLICATION:
2008.50 Kuga
PAGE
CONTENTS
DESCRIPTION AND OPERATION
413-01-2
Instrument Cluster (Overview)............................................................................................
413-01-2
Replacing the instrument cluster........................................................................................
413-01-2
Self-diagnostic mode..........................................................................................................
413-01-3
Instrument Cluster (System Operation and Component Description)................................
413-01-3
System Diagram.................................................................................................................
413-01-4
System Operation...............................................................................................................
413-01-4
Instrument Cluster..........................................................................................................
413-01-4
Message center..............................................................................................................
413-01-5
Component Description......................................................................................................
413-01-5
Vehicles with low series instrument cluster.....................................................................
413-01-6
Vehicles with high series instrument cluster...................................................................
DIAGNOSIS AND TESTING 413-01-7
Instrument Cluster..............................................................................................................
413-01-7
Inspection and Verification..................................................................................................
413-01-7
Configuration of the Instrument Cluster..............................................................................
REMOVAL AND INSTALLATION 413-01-9
Instrument Cluster.............................................................................................................. 413-01-1
Instrument Cluster
413-01-1
.TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Instrument Cluster – Overview
Replacing the instrument cluster
When installing a new instrument cluster, the Ford
diagnostics device must be connected before
dismantling the instrument cluster, in order to load
the configuration data of the defective instrument
cluster using the "Installation of programmable
modules" routine. In addition, the value on the
odometer of the defective instrument cluster must
be noted, as this is required for configuration of the
new instrument cluster. If the odometer value
cannot be obtained from the instrument cluster
(display failure), the customer should supply the
approximate value.
When installing a new instrument cluster, the Ford
diagnostics device must be connected after
installation in order to download the configuration
data of the defective instrument cluster into the
new instrument cluster using the "Installation of
programmable modules" routine, and to configure
the newly installed instrument cluster to the PATS
system.
Self-diagnostic mode
1.
To enter the instrument cluster self-diagnostic
mode, simultaneously press and hold the set
button and turn the ignition switch from position
0 to position II.
2. Entry to self-diagnostic mode is confirmed when
'TEST' is displayed in the odometer's liquid
crystal display (LCD). The instrument cluster
set button must be released within 3 seconds
of TEST being displayed in the tripmeter LCD
(liquid crystal display) display. Otherwise the
system will exit self-diagnostic mode.
3. To navigate through or skip any of the
instrument cluster self-diagnostic mode tests,
press the SET button. If the SET button is pressed for more than 3 seconds between tests,
the instrument cluster will exit self-diagnostic
mode.
4. Self-diagnostic mode is deactivated when the
ignition switch is turned to the OFF position or
low battery voltage is detected.
5. If input data to the instrument cluster is missing
or invalid, the tripmeter LCD will display '----'.
6. If the self-diagnostic mode cannot be activated,
test the instrument cluster using the Ford
diagnostic device. G1030769en
2008.50 Kuga 8/2011 413-01-2
Instrument Cluster
413-01-2
DESCRIPTION AND OPERATIONTO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUALE99006

Description
Item
Instrument Cluster
1
PCM (powertrain control module)
2
EHPS (electro-hydraulic power steering)
control module
3
Audio unit
4
GEM (generic electronic module)
5
RCM (restraints control module)
6
PATS transceiver
7 Description
Item
Steering wheel lock module
8
Left-hand steering column switch
9
Fuel level sensor
10
Washer water level warning lamp switch
11
Accelerator pedal position sensor
12
CPP (clutch pedal position) sensor/BPP
(brake pedal position) sensor
13
Lighting control switch
14
System Operation
Instrument Cluster
The instrument cluster contains analog displays
as well as warning and control lamps for displaying
the system status; in addiiton, there is an LCD
indicator field for driver information.
The instrument cluster receives the following
signals from the PCM via the high speed CAN
(controller area network) Bus (HS-CAN):
• Vehicle speed – The PCM receives the necessary signalsfrom the ABS (anti-lock brake system) wheel
sensors from the ABS control unit on the
HS-CAN.
• Engine Coolant Temperature
• Engine oil pressure.
• Engine speed
The instrument cluster receives the following
signals from the GEM via the medium speed CAN
Bus (MS-CAN):
• Ambient temperature
• Brake fluid level
• Handbrake control
• Door latch control
• Liftgate latch control
• High beam control
• Headlamp flasher control
• Direction indicator control
The fuel level signal is sent by the two fuel level
sensors in the fuel pumps in the semitrailer tank,
which is wired to the instrument cluster. The
sensors are connected in series, and the total
resistance is determined from the two individual resistors. The instrument cluster converts the raw
fuel level signal into a damped fuel level value.
The odometer shows the total distance travelled
by the vehicle and is based on the same signal as
is processed for the daily mileage counter. The
value is recorded by the instrument cluster and
stored in a protected EEPROM (Electronically
Erasable Programmable Read Only Memory) area.
This area is a memory protected against
manipulation. If the instrument cluster detects an
error in this memory area, e.g. through damage,
the driver is notified with the "Odometer error"
message.
Message center
The message center is operated using the left-hand
switch on the steering column.
The SET/RESET button is activated to select a
submenu and change the settings. If signal tones
have been activated, a short acoustic signal will
sound each time a button is pressed.
By turning the rotary switch, the different menu
displays can be scrolled through or a setting
selected.
In this display, the navigation system can also
display direction and distance information.
In addition, safety and warning messages can be
displayed in this system, such as "Coolant
overheating", "Engine system error" or "Washer
fluid level too low". In addition to a safety message,
a general warning light (red/yellow) lights up.
G1030770en
2008.50 Kuga 8/2011 413-01-4
Instrument Cluster
413-01-4
DESCRIPTION AND OPERATIONTO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Instrument Cluster
Refer to
Wiring Diagrams Section 413-01, for
schematic and connector information. General Equipment
The Ford approved diagnostic tool
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical
or electrical damage.
Visual Inspection Chart Electrical
Mechanical
– Fuse(s)
– Wiring harness
– Electricalconnector(s)
– Instrument cluster
– Light emitting diode(s) (LED)(s)
– Engine oil filter
– Engine oil level
–
Engine coolant level
– Oil pressure switch
– Engine coolant level
– Coolant thermostat
– Engine coolant temperature (ECT)
sensor
– Fuel gauge
– Collapsed or damaged fuel tank
– Recirculation hose
– Fuel tank filler pipe/hose
– Indicated fuel level
– Fuel lines
– Fuel tank filler cap
– Fuel filter (external to the fuel tank)
– Fuel tank
– Door adjustment
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible)
before proceeding to the next step.
4. NOTE: If none of the following warning indicators are operating correctly this may
indicate a concern with the central junction
box (CJB). If only one or two of the following
warning indicators are not operating
correctly this may indicate an instrument
cluster concern. Verify the following warning indicators are
working correctly:
• Charging.
• Turn signals.
• Headlamps.
5. If the cause is not visually evident, verify the symptom and refer to the diagnostic tab within
the Ford approved diagnostic tool.
Configuration of the Instrument Cluster
The instrument cluster is a programmable module,
which must be configured by selecting the
Programmable Module Installation Routine on the
Ford approved diagnostic tool.
NOTE: When the new instrument cluster has been
configured with the odometer value, its
configuration cannot be decreased or matched. A
new configuration will result in an increase in the
displayed odometer value by a minimum of two
units.
NOTE: The odometer value must be recorded from
the original instrument cluster before removal.
If the odometer value cannot be obtained from
the original instrument cluster (display failure)
the customer should supply the approximate
value.
The following features will need to be configured
when a new instrument cluster is installed:
• Anti-lock Brake System (ABS)
• All wheel drive
• Keyless vehicle entry
• Electronic power assisted steering
• Trip computer
• Voice control
• Parking aid
• Belt minder
• Safety belt not fastened
• Right hand drive
• Overspeed warning
• Reverse warning
• Turbocharger boost pressure
• Speed control
• Auxiliary heater
• Suspension control
• Washer fluid sensor G1054964en
2008.50 Kuga 8/2011 413-01-7
Instrument Cluster
413-01-7
DIAGNOSIS AND TESTINGTO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

• Navigation
• Fuel cap release
• Engine type
• Display language
In addition the new instrument cluster will require
the original odometer value to be entered.
After the installation and configuration of a new
instrument cluster. The passive anti-theft system
(PATS) will require programming by selecting the
Security Access routine on the Ford approved
diagnostic tool.
G1054964en
2008.50 Kuga 8/2011 413-01-8
Instrument Cluster
413-01-8
DIAGNOSIS AND TESTINGTO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Instrument Cluster
General Equipment
Ford Diagnostic Equipment General Equipment
Round-Ended Steel Rule
Removal
1. NOTE: This step is only necessary when
installing a new component.
Upload the instrument cluster configuration
information using the Programmable Modules
Installation Routine.
General Equipment: Ford Diagnostic Equipment
2. NOTE: This step is only necessary when
installing a new component.
Record the odometer value from the original
instrument cluster. If the odometer value cannot
be obtained from the instrument cluster (display
failure), the customer should supply the
approximate odometer value.
3. 4.
5.
General Equipment: Round-Ended Steel Rule G1065570en
2008.50 Kuga 8/2011 413-01-9
Instrument Cluster
413-01-9
REMOVAL AND INSTALLATIONTO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL12E101806 E100832

Horn
Principles of Operation
The horn system consists of a relay, a steering
wheel switch and either one or two horns. The
horn(s) receives voltage from the switched side of
the relay, and the relay switch is controlled on its
ground side by the steering wheel switch.
The horn relay, is located in the Battery junction
box (BJB) and is supplied with a permanent voltage
from the battery.
The steering wheel horn switch shares the steering
wheel clockspring circuit with the air-bag circuit.
Each of these systems work completely
independent of each other.
Inspection and Verification
1. Verify the customer concern.
2.
Visually inspect for obvious signs of mechanical
or electrical damage.
Visual Inspection Chart Electrical
• Fuse(s)
• Wiring harness
• Electrical connector(s)
• Horn switch
• Horn
• Clockspring
• Horn relay
• BJB
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible)
before proceeding to the next step.
4. If the cause is not visually evident, verify the symptom and refer to the diagnostic tab within
the Ford approved diagnostic tool. G1055042en
2008.50 Kuga 8/2011 413-06-2
Horn
413-06-2
DIAGNOSIS AND TESTINGTO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Warning Devices
Refer to
Wiring Diagrams Section 501-20B, for
schematic and connector information. General Equipment
Ford diagnostic equipment
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical
or electrical damage.
Visual Inspection Chart Electrical
Mechanical
– Wiring harness
– Electricalconnector(s)
– Safety belt buckle switch
– Restraints control module
– Safety belt buckle
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible)
before proceeding to the next step.
4. If the cause is not visually evident, verify the symptom and refer to the Ford diagnostic
equipment to diagnose the system. G1055053en
2008.50 Kuga 8/2011 413-09-2
Warning Devices
413-09-2
DIAGNOSIS AND TESTINGTO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Safety Belt Minder Deactivating/Activating
Preparation
1. Apply the parking brake.
2. Place the transmission selector lever in P
(Park) - vehicles with automatic transmission
or the neutral position - vehicles with manual
transmission.
3. Turn the ignition switch to the 0 position.
4. Close all the vehicle doors from the inside of the vehicle.
Deactivating/Activating
NOTE: Deactivation of the belt minder may also
be carried out using IDS. Follow the instructions
on the screen.
1. Unbuckle the drivers safety belt.
2. Turn the ignition switch to position II. (Do not start the engine).
3. Wait at least 15 seconds.
4. NOTE: This step must be completed within 60 seconds or the procedure must be
repeated.
Buckle then unbuckle the safety belt nine
times, ending with the safety belt unbuckled.
Release the red unbuckle switch completely
every cycle.
5. The safety belt warning indicator flashes three times to confirm the belt minder status
change.
6. Turn the ignition switch to position 0. The deactivation/activation procedure is now
complete. G167271en
2008.50 Kuga 8/2011 413-09-3
Warning Devices
413-09-3
GENERAL PROCEDURESTO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL