ECT FORD KUGA 2011 1.G Workshop Manual

Position the spring in the correct position (on
both sides) for the vehicle body style. 2. NOTE:
This step is only necessary when
installing a new component.
Remove the CD changer transportation retaining
clips. 3.
To install, reverse the removal procedure.
4. NOTE: This step is only necessary when
installing a new component.
Configure the CD changer by selecting the
Programmable Module Installation Routine.
General Equipment: Ford Diagnostic Equipment G1065585en
2008.50 Kuga 8/2011 415-01-36
Information and Entertainment System
415-01-36
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL12E91627 E91630

Portable Support Electronics (PSE) Module(33 635 0)
Removal
1.
Refer to: Floor Console Extension - Vehicles
With: Center Armrest (501-12 Instrument
Panel and Console, Removal and Installation).
2. 3.
Installation
1.
To install, reverse the removal procedure. G1065590en
2008.50 Kuga 8/2011 415-01-37
Information and Entertainment System
415-01-37
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUALE102293 E101801

SECTION 417-01 Exterior Lighting
VEHICLE APPLICATION:
2008.50 Kuga
PAGE
CONTENTS
SPECIFICATIONS
417-01-3
Specifications ......................................................................................................................
417-01-3
Headlamp adjustment.....................................................................................................
DESCRIPTION AND OPERATION 417-01-4
Exterior Lighting (Component Location).............................................................................
417-01-5
Exterior Lighting (Overview)...............................................................................................
417-01-5
Front headlamps.................................................................................................................
417-01-5
Conventional Headlamps................................................................................................
417-01-5
Xenon headlamp.............................................................................................................
417-01-6
Headlamp levelling.........................................................................................................
417-01-7
Combined rain sensor/light sensor.....................................................................................
417-01-7
autolamps ...........................................................................................................................
417-01-7
Headlamp switch-off delay.................................................................................................
417-01-7
Turn signals........................................................................................................................
417-01-7
Door entry illumination........................................................................................................
417-01-8
Rear Lighting......................................................................................................................
417-01-9
Exterior Lighting (System Operation and Component Description)....................................
417-01-9
System Diagram.................................................................................................................
417-01-10
System Operation...............................................................................................................
417-01-10
Headlamp levelling.........................................................................................................
417-01-10
Xenon headlamp.............................................................................................................
417-01-10
Conventional Headlamps................................................................................................
417-01-11
Turn signals....................................................................................................................
417-01-11
Combined rain sensor/light sensor.................................................................................
417-01-11
Component Description......................................................................................................417-01-11Combined rain sensor/light sensor.................................................................................
DIAGNOSIS AND TESTING 417-01-12
Fog Lamps..........................................................................................................................
417-01-12
Description of operation......................................................................................................
417-01-13
Inspection and Checking....................................................................................................
417-01-15
Headlamps..........................................................................................................................
417-01-15
Description of operation......................................................................................................
417-01-16
Inspection and Checking....................................................................................................
417-01-17
Headlamp Leveling.............................................................................................................
417-01-17
Description of operation......................................................................................................
417-01-18
Inspection and Checking....................................................................................................
417-01-19
Parking, Rear and License Plate Lamps............................................................................
417-01-19
Description of operation......................................................................................................
417-01-20
Inspection and Checking....................................................................................................
417-01-21
Reversing Lamps................................................................................................................
417-01-21
Description of operation......................................................................................................
417-01-22
Inspection and Checking.................................................................................................... 417-01-1
Exterior Lighting
417-01-1
.
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PAGE 1 OF 2 FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

417-01-24
Stoplamps ...........................................................................................................................
417-01-24
Description of operation......................................................................................................
417-01-25
Inspection and Checking....................................................................................................
417-01-26
Turn Signal and Hazard Lamps..........................................................................................
417-01-26
Description of operation......................................................................................................
417-01-27
Inspection and Checking....................................................................................................
GENERAL PROCEDURES 417-01-29
Front Fog Lamp Adjustment...............................................................................................
417-01-30
Headlamp Adjustment........................................................................................................
REMOVAL AND INSTALLATION
417-01-32
Headlamp Switch................................................................................................................
417-01-34
Stoplamp Switch.................................................................................................................
417-01-35
Trailer Module.....................................................................................................................
417-01-36
Front Fog Lamp..................................................................................................................
417-01-37
Headlamp Assembly........................................................................................................... 417-01-2
Exterior Lighting
417-01-2
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PAGE 2 OF 2 FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

The turn signal lamps and side lights are the same as in conventional headlamps.
Bulb color
Current draw
Bulb
Lamp
Clear
35W
D1S
Low-beams
Clear
55W
H1
High beam headlamp
Clear
21W
H21W
Turn signal indicator
Clear
5W
W5W
Side lamp
Headlamp levelling
Vehicles with conventional headlamps are
equipped with a manual headlamp leveling system. An automatic headlamp leveling system is a legal
requirement for vehicles with gas discharge
headlamps.
The automatic headlamp levelling system is a
dynamic system which provides additional benefits
for the driver in terms of improved illumination of
the road due to improved control over the
headlamp beam.
In a static system, the vehicle is only considered
as a stationary object, whereas a dynamic system
also takes into account the dynamic changes to
the inclination of the vehicle whilst driving.
In order to prevent unnecessary changes in the
height of the headlamp beam, the system filters
out surface irregularities and any pitching of the
vehicle under braking and acceleration.
The system is designed to respond to changes in
the inclination of the vehicle caused by load
changes or long-term effects of aerodynamic forces
acting on the vehicle (e.g. due to continuous driving
at high speeds).
Accordingly, the system needs to be set up with
the aid of WDS (Worldwide Diagnostic System)
after any components are replaced or any other
repairs are carried out.
G1079626en
2008.50 Kuga 8/2011 417-01-6
Exterior Lighting
417-01-6
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUALE101614

Combined rain sensor/light sensor
CAUTIONS:
On vehicles with autolamps, retrofitting
with daytime running lamps is not
permissible, as otherwise, the engine
cannot be stopped when the lighting is
switched on.
On vehicles with autolamps, the daytime
running lamp fuse must not be fitted, as
otherwise, the engine cannot be stopped
when the lighting is switched on.
The combined rain sensor/light sensor is located
behind the interior rear view mirror.
autolamps The low beams, side lamps, license plate lamps
as well as the instrument cluster and instrument
panel illumination are switched on automatically if
all the following conditions are met:
• Ignition ON
• Light switch in the "AUTO" position
•
Detected ambient light conditions below a stored
threshold value
These are switched on and off by the GEM (generic
electronic module) in accordance with the input
signals from the combined rain/light sensor.
Headlamp switch-off delay
In vehicles with mid to high-end equipment, the
headlamp switch-off delay uses the dipped beam
headlamps and the door entry illumination (if
equipped) to illuminate the vehicle surroundings.
This function is activated by operating the main
beam headlamp lever with the ignition switched
off. After the last door has been closed, the function
remains active for a further 30 seconds and then
switches off automatically.
When a door or the tailgate is open, the switch-off
time is extended to 180 seconds. After the last door
has been closed, the switch-off time is reset to 30
seconds.
The headlamp switch-off delay can be deactivated
prematurely by operating the high beam lever again
or by switching on the ignition.
The switch-off time is adjusted to fixed values at
the factory and can
notbe re-programmed using
WDS.
Turn signals The turn signals and the warning lamp flash at a
specified frequency and, in the case of failure of a
turn signal, the frequency is doubled.
The turn signal lamps also have a one-touch lane
change function. If the multifunction lever is
pressed just slightly then the relevant turn signal
lamp is actuated 3 times.
Door entry illumination
G1079626en
2008.50 Kuga 8/2011 417-01-7
Exterior Lighting
417-01-7
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUALE101615 E101616 E101617

On some models, the door entry lamps are installed
in the external mirrors.
The door entry lamps should illuminate the ground
in the immediate vicinity of the front doors; they
are equipped with white bulbs, which are installed
in the underside of the mirror.
The door entry illumination is switched on when
one of the doors or the tailgate are opened, or if
an unlocking command is detected and the
following conditions are satisfied:
• Vehicle Ignition is off.
• Reverse gear is not engaged.
• The vehicle speed is below 7 km/h.
The door entry illumination is switched off if one of
the following conditions is satisfied:
• The ignition is selected on.
• Reverse gear is engaged.
• The vehicle speed exceeds 7 km/h.
• More than 25 seconds have elapsed since the
tailgate was closed or a central locking
command was determined.
• The time set for the battery protection function for the interior lighting has elapsed.
• More than 5 seconds have elapsed since the doors and the tailgate were closed.
• More than 5 seconds have elapsed since a central locking command was received and the
all doors and the tailgate were closed. Rear Lighting The rear lamps are each divided into three units.
The reversing lamps are located in the units in the
liftgate.
The outer units in the D-pillars contain the side
lamp as well as the turn signal and stoplamp.
The rear fog lamp is integrated in the lower area
of the bumper.
The high-mounted additional stop lamp is installed
in the middle of the roof spoiler.
Bulb color
Current draw
Bulb
Lamp
Orange
19W
PSY19W
Turn signal indicator
Clear
21W
P21W
Reversing Lamp
Clear
21/5W
W21/5W
Stoplamp/side lamp
Clear
21W
P21W
Rear fog lamp
–
1,4W
1 x LED board
Additional high-mounted
stoplamp G1079626en
2008.50 Kuga 8/2011 417-01-8
Exterior Lighting
417-01-8
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUALE101618

The manual headlamp levelling system operates
with an electric motor which is controlled via a
rotary control in the instrument cluster.
Turn signals
The GEM switches the direction indicators and the
direction indicator side repeaters on.
The GEM sends a signal to the instrument cluster
via the CAN (controller area network) bus to switch
on the relevant turn indicator and the acoustic
signal.
The signals from the hazard flasher switch and
from the multifunction switch are transmitted to the
GEM via a wiring connection.
Combined rain sensor/light sensor
The ambient light sensor determines the general
light intensity.
For this purpose, it detects the light over as wide
an angle as possible, without taking the direction
of incidence into account.
The front light sensor determines the light intensity
directly in front of the vehicle.
If both the ambient light sensor and the front light
sensor detect a sudden reduction in light intensity
at the same time, then an algorithm-based
calculation is used to determine the fact that the
vehicle has entered a tunnel, a multi-storey car
park or a long underpass.
In this case the request for switching on the
external lighting and the indicator in the instrument
cluster is transmitted to the GEM.
If the vehicle enters into the shade thrown by a
large truck, the two sensors will register different
light intensities.. In this case, the algorithm-based
calculation will not result in the lights being
switched on.
The GEM incorporates a stepped switch-off of the
dipped beam headlamps, side lamps, license plate
illumination and the instrument cluster and
instrument panel illumination. If the ambient light
changes from dark to bright, the GEM first switches
off the low beams. The side lamps, license plate
lamps as well as the instrument cluster and
instrument panel illumination are switched off
approx. 6 seconds after the low beams have been
switched off.
Component Description
Combined rain sensor/light sensor
Description
Item
Lens1
Front light sensor
2
Ambient light sensor
3 G1079627en
2008.50 Kuga 8/2011 417-01-11
Exterior Lighting
417-01-11
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL213E40968

Fog Lamps
Refer to Wiring Diagrams Section 417-01, for
schematic and connector information.
Special Tool(s)
Terminal Probe Kit
29-011ADescription of operation
A diagnosis of the generic electronic module (GEM)
can be performed with the Ford approved
diagnostic tool. Furthermore, an integrated service
mode enables testing of the input and output
signals without the need for further tools. To enable
activation of service mode:
• switch off the ignition,
• switch off all other electrical consumers,
• apply the handbrake,
• shift to neutral
• and close the doors.
Activating the service mode
Proceed as follows to activate the service mode:
•
OPERATE the switch of the heated rear window
and HOLD IT THERE
• Turn on the ignition.
• RELEASE the switch of the heated rear window
A signal sounds and the turn signal lamps come
on to indicate that service mode has been
successfully activated.
NOTE: If the alarm is activated (in vehicles fitted
with an anti-theft alarm system), service mode
cannot be activated.
Inputs
SWITCH the windshield wiper switch to the "Off"
position to test the input signals. The following is
a list of the switch signals to be tested, in no
particular order:
• Turn signals (right, left, hazard warning lights)
• Windshield wiper stage I
• Windshield wiper stage II
• Windshield washer system • Rear window wiper
• Rear window washer system
• Doors open/closed
• Remote control for central locking with double
locking
• Hood open/closed (in vehicles equipped with an anti-theft alarm system)
• Tailgate open/closed
• A/C request signal
• Heated windscreen (if fitted)
• Parking Brake
• Brake reservoir fluid level
• Speed control system
• Autolamps
• dipped beam
• main beam
• headlamp flasher
• Marker Lamps
• Reversing lamp
• Liftgate release
• Ignition switch, terminal 15 (turn key to 0 position, then turn key to II position.)
An acoustic signal sounds and the turn signal
lamps flash to indicate receipt of each input signal
by the generic electronic module.
Test the windshield wiper "intermittent mode" stage
input signal (only vehicles with adjustable
intermittent mode)
The windshield wiper switch must be switched to
"intermittent mode" in order to test the input signal.
The delay times of the input signals can then be
tested by operating the rotary switch. Each change
of the rotary switch position is indicated by an
acoustic signal and illumination of the turn signals.
Output signals
SWITCH the wiper switch to the "intermittent""
position to test the output signals. PRESSING the
heated rear window switch activates the output
signals in the following order:
a. Turn Indicator Left Hand
b. Turn Indicator Right Hand
c. main beam
d. dipped beam
e. Windshield wiper stage I
f. Windshield wiper stage II G1055006en
2008.50 Kuga 8/2011 417-01-12
Exterior Lighting
417-01-12
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL29011A

g.
Heated rear window
h. Heater blower motor
i. Headlamp washer system (vehicles with gas discharge headlamps)
j. Electric booster heater (if fitted)
k. Autolamps (if fitted)
l. Alarm horn (vehicles with alarm system)
m. Rear window wiper
n. Rear heated window relay
When the heated rear window switch is pressed
again, the test of the relevant signal is terminated.
When the heated rear window switch is pressed
once more, the test for the next signal in the list is
started.
Ending the service mode
The GEM automatically ends service mode 20
seconds after the last input or at a driving speed
of over 7 km/h. However, service mode can be
manually ended at any time by proceeding as
follows:
• OPERATE the switch of the heated rear window
and HOLD IT THERE
• SWITCH OFF the ignition
• RELEASE the switch of the heated rear window
3 signals sound and the turn signal lamps illuminate
to indicate that service mode has ended.
Reset service mode
If, after completion of service mode, some functions
do not operate or do not operate properly, check
the following functions:
• Instrument cluster illumination, side lamps and license plate lamp in autolamps mode
• Rear wiper
• Headlamp Washers
• Electric booster heater
• Active anti-theft sounder
• Heated windshield
If one or more of the listed functions is not OK, it's
possible that the cause of the fault is due to not
exiting service mode properly. To reactivate the
functions correctly, perform the following steps:
1. SWITCH OFF the ignition
2. SWITCH OFF the switch for the windscreen wash/wipe system
3. OPERATE the switch of the heated rear window
and HOLD IT THERE
4. Turn on the ignition. 5. RELEASE the heated rear window switch (an
acoustic signal will sound if activation has been
performed correctly)
6. SWITCH the windscreen wash/wipe switch to the "Intermittent wipe" position
7. OPERATE the heated rear window switch 6 times (the main beam headlamps switch on and
off automatically)
8. SWITCH OFF the switch for the windscreen wash/wipe system
9. OPERATE the switch of the heated rear window
and HOLD IT THERE
10. SWITCH OFF the ignition
11. RELEASE the heated rear window switch (three
acoustic signals will sound if activation has been
performed correctly)
After completion of the work, check all the
functions.
Inspection and Checking
NOTE: The generic electronic module (GEM) forms
part of the central junction box (CJB).
NOTE: If the instrument cluster is changed, it must
be re-configured. For this purpose, the
vehicle-specific data is read out of the module to
be replaced using the Ford approved diagnostic
tool and is transferred to the new module.
NOTE: Before reading out the vehicle-specific data,
remake all the separated electrical connections in
the vehicle, so that communication between the
module and the Ford approved diagnostic tool is
ensured.
1. Verify the customer concern.
2. Visually inspect for obvious signs of electrical damage.
Visual Inspection Electrical
• Fuse(s)
• Lamp(s)
• Bulb(s)
• Connector(s)
• Switch(s)
• Wiring harness
3. Resolve any obvious causes or concerns found during the visual inspection before carrying out
any further tests. G1055006en
2008.50 Kuga 8/2011 417-01-13
Exterior Lighting
417-01-13
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL