ELECTRICAL FORD KUGA 2011 1.G User Guide

Body Repair Health and Safety and General Precautions
General
Appropriate repair methods and carrying out repair
and paint jobs correctly is particularly important to
the operating safety of vehicles and the safety of
people.
WARNING: There is danger of injury
through:
• High voltage when electrical welding. – Do not perform welding work in a dampenvironment or on a wet substrate. Use
suitable insulation underneath.
• Welding spatter and UV radiation. – Wear protective clothing, gloves and weldingmask or welding goggles.
• Fire, explosion and hot surfaces in the work area.
– Always have a suitable fire extinguisheravailable when using welding or heating
equipment.
– Remove flammable substances from the danger area. Remove the fuel tank and fuel
pipes and hoses.
– Welding and grinding near the battery presents the danger of explosion. Remove
the battery before you start working.
– During paint work there is an increased danger of fire or explosion. Prevent any
sparks being created. Fire, open light and
smoking are forbidden.
– Always ventilate the workplace well and use an extraction system.
– Wear protective footwear made from anti-static material.
– Only use tools made of wood, brass or copper to clean stands and extraction ducts.
Do not use tools made of steel.
– Only fill or decant paint materials in a specially marked area. • Inhalation and/or absorption through the skin of
harmful substances.
– Welding fumes grinding dusts and solventvapours can be extremely harmful to the
health.
– Sealants, underbody protection and paint residues must not be burnt down with an
unshielded flame, as this will produce harmful
substances.
– Always ventilate the workplace well and use an extraction system.
– Wear protective clothing.
• Pyrotechnic components. – Disconnect the battery negative clamp andcover the battery terminal.
– Remove any airbag components.
• Noise – Cutting, grinding and alignment work cancause a noise level over 85 dB (A).
– Always wear ear protection.
• High Forces. – The various body areas are subject to veryhigh forces during realignment work. Should
any component suddenly become detached
during this process, there is a very great
danger of injury.
– Pulling chains and pulling shackles must be secured with arrester cables.
As well as these general instructions on the
dangers in body and paint shops, you must
observe:
• All valid local national and international regulations governing Health and Safety at Work
• Safety instructions of material equipment and tool manufacturers
For additional information, refer to: (100-00 General
Information) Solvents, Sealants and Adhesives (Description
and Operation),
Air Conditioning (A/C) System Health and Safety Precautions (Description and Operation),
Supplemental Restraint System (SRS) Health and Safety Precautions (Description and
Operation).
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General Information
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DESCRIPTION AND OPERATION
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maintained, depending on the vehicle.
Work on airbag systems may only be
performed by persons who have a relevant
certificate of competence.
For additional information, refer to: (501-20
Supplemental Restraint System) Driver Air Bag Module (Removal and
Installation),
Passenger Air Bag Module (Removal and
Installation),
Side Air Bag Module (Removal and Installation),
Side Air Curtain Module (Removal and
Installation),
Restraints Control Module (RCM) (Removal and
Installation).
Pay attention to the following points:
• Disconnect the battery negative clamp and cover the battery terminal.
• Disconnect the electrical connector at the airbag control module.
• If welding is to be performed directly near a control module, it must be disconnected or
removed.
• Never connect the negative cable of the welder near an airbag or a control module.
• Connect the negative cable of the welder close to the location of the weld.
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General Information
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DESCRIPTION AND OPERATION
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Noise, Vibration and Harshness (NVH)
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanicalor electrical damage.
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 concern is not visually evident, verify the symptom and REFER to the Symptom Chart.
How to Use this Diagnostic Procedure
Section
• Noise, vibration and harshness (NVH) concernshave become more important as vehicles have
become more sensitive to these vibrations. This
section is designed to aid in identifying these
concerns.
• The section provides diagnostic procedures based on symptom. If the condition occurs at
high speed, for instance, the most likely place
to start is under Shake and Vibration While
Driving.
• The road test procedure will tell how to sort the conditions into categories and how to tell a
vibration from a shake.
• A series of Road Test Quick Checks are provided to make sure that a cause is either
pinpointed or eliminated.
• Name the condition, proceed to the appropriate section and locate the correct diagnosis. When
the condition is identified, the job is partly done.
• Follow the diagnostic procedure as outlined.
• Quick Checks are described within the step, while more involved tests and adjustments are
outlined in General Procedures.
• Always follow each step exactly and make notes to recall important findings later.
Customer Interview
The road test and customer interview (if available)
provide information that will help identify the
concern and will provide direction to the correct
starting point for diagnosis.
Identify the Condition
NVH usually occur in four areas:
• tires
• engine accessories
• suspension
• driveline
It is important, therefore, that an NVH concern be
isolated into its specific area(s) as soon as
possible. The easiest and quickest way to do this
is to carry out the Road Test as outlined. To assist
in the diagnosis and testing procedure(s), use a
suitable approved NVH diagnosis tester.
Noise Diagnostic Procedure
Non-Axle Noise
The five most common sources of non-axle noise
are exhaust, tires, roof racks, trim panels and
transmission.
Therefore, make sure that none of the following
conditions are the cause of the noise before
proceeding with a driveline teardown and
diagnosis.
• In certain conditions, the pitch of the exhaustmay sound very much like gear noise. At other
times, it can be mistaken for a wheel bearing
rumble.
• Tires, especially snow tires, can have a high pitched tread whine or roar, similar to gear
noise. Radial tires may have this characteristic.
Also, any non-standard tire with an unusual
tread construction may emit a roar or whine
noise.
• Trim panels can also cause whistling or whining noise.
• Clunk may be a metallic noise heard when the automatic transaxle is engaged in "R"
(REVERSE) or "D" (DRIVE) or it may occur
when the throttle is applied or released. It is
caused by backlash somewhere in the driveline.
• Bearing rumble sounds like marbles being tumbled. This condition is usually caused by a
damaged wheel bearing.
G37349en2008.50 Kuga8/2011
100-04- 2
Noise, Vibration and Harshness
100-04- 2
DIAGNOSIS AND TESTING
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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
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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
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Instrument Cluster
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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
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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
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Parking Aid — Vehicles With: Front Parking Aid
Refer to Wiring Diagrams Section 413-13, for
schematic and connector information.
General Equipment
Ford diagnostic equipment
Principles of Operation
The ultrasonic parking aid system activates when
the ignition switch is turned to the RUN and when
the parking brake is OFF. If a front parking aid
switch is fitted the system will be de-activated and
a light emitting diode (LED) will indicate the state
of the system. A lit LED will indicate that the system
is currently deactivated. The parking aid system
will be disabled if a fault is detected in one of the
four front parking aid sensors, the parking aid
speaker or the parking aid module. An error tone
approximately 3 seconds long will be emitted from
the rear parking aid speaker if a fault is detected.
If the rear parking aid speaker is inoperative the
error tone will sound from the front parking aid
speaker.
Inspection and Verification
1. Verify the customer concern. 2. Visually inspect for obvious signs of electrical
damage.
Visual Inspection Chart Electrical
– Fuse(s)
– Wiring harness(s)
– Electrical connector(s)
– Battery junction box (BJB)
– Front parking aid sensor(s)
– Front parking aid speaker
– Parking aid module
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, connect the Ford diagnostic equipment to the data link
connector (DLC) and select the vehicle system
to be tested from the diagnostic menu.
5. Retrieve the Diagnostic Trouble Code (DTC)s and refer to the DTC Index.
6. If no DTCs are retrieved or there is no communication with the module, proceed to the
Symptom Chart to continue diagnostics.
Diagnostic Trouble Codes (DTC) Index
DTC Index Action
Possible Source
Description
DTC
Check the circuit 8-GN9
(WH/GN) for short to battery.
IF the circuit is OK, INSTALL
a new parking aid module.
REFER to:Parking Aid
Module (413-13 Parking
Aid, Removal and Installa-
tion).
TEST the system for normal
operation.
• Parking aid sensor signal
circuit.
• Parking aid module.
Front outer left sensor signal
circuit short to battery
C1711
GO toPinpoint Test C.
• Parking aid sensor signal
circuit.
• Parking aid sensor.
• Parking aid module.
Front outer left sensor signal
circuit open or short to
ground
C1712 G325369en
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Parking Aid
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Parking Aid — Vehicles With: Rear Parking Aid
Refer to
Wiring Diagrams Section 413-13, for
schematic and connector information. General Equipment
Ford diagnostic equipment
Principles of Operation
NOTE: The rear parking aid system will be
de-activated when a Ford rear trailer tow module
is attached to the vehicle.
The ultrasonic parking aid system will default to
enabled when the ignition switch is turned to the
RUN position, the system is activated by selecting
reverse gear. The parking aid system will be
disabled if a fault is detected in one of the four rear
parking aid sensors, the parking aid speaker or the
parking aid module. An error tone approximately
3 seconds long will be emitted from the rear parking
aid speaker if a fault is detected. The rear parking
aid speaker will also sound for approximately 3
seconds if an error is detected at each ignition
cycle or if an error is detected when the system
has been activated.
Inspection and Verification
1. Verify the customer concern. 2. Visually inspect for obvious signs of electrical
damage.
Visual Inspection Chart Electrical
– Fuse(s)
– Wiring harness(s)
– Electrical connector(s)
– Battery junction box (BJB)
– Rear parking aid sensor(s)
– Rear parking aid speaker
– Parking aid module
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, connect the Ford diagnostic equipment to the data link
connector (DLC) and select the vehicle system
to be tested from the diagnostic menu.
5. Retrieve the Diagnostic Trouble Code (DTC)s and refer to the DTC Index.
6. If no DTCs are retrieved or there is no communication with the module, proceed to the
Symptom Chart to continue diagnostics.
Diagnostic Trouble Codes (DTC) Index
DTC Index Action
Possible Source
Description
DTC
Check the circuit 8-GN22
(WH/GN) for short to battery.
IF the circuit is OK, INSTALL
a new parking aid module.
REFER to:Parking Aid
Module (413-13 Parking
Aid, Removal and Installa-
tion).
TEST the system for normal
operation.
• Parking aid sensor signal
circuit.
• Parking aid module.
Rear outer left sensor signal
circuit short to battery
C1699
GO toPinpoint Test C.
• Parking aid sensor signal
circuit.
• Parking aid sensor.
• Parking aid module.
Rear outer left sensor signal
circuit open or short to
ground
C1700 G295937en
2008.50 Kuga 8/2011 413-13-29
Parking Aid
413-13-29
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Charging System
Refer to Wiring Diagrams Section 414-02, for
schematic and connector information.
General Equipment
Midtronics EXP-1050 battery tester
Midtronics GR590-2
Ford diagnostic equipment
Inspection and Verification
WARNINGS: Batteries contain sulphuric acid. Avoid
contact with skin, eyes, or clothing. Also,
shield your eyes when working near
batteries to protect against possible
splashing of the acid solution. In case of
acid contact with skin or eyes, flush
immediately with water for a minimum of
15 minutes and get prompt medical
attention. If acid is swallowed, call a
physician immediately. Failure to follow
these instructions may result in personal
injury.
Batteries normally produce explosive
gases which can cause personal injury.
Therefore, do not allow flames, sparks or
lighted substances to come near the
battery. When charging or working near a
battery, always shield your face and
protect your eyes. Always provide
ventilation. Failure to follow these
instructions may result in personal injury.
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(es)
– Generator
– Electricalconnector(s)
– Battery junction box (BJB)
– Battery
– Battery cables
– Battery monitoring sensor (BMS)
– Charging system warning indicator
–
Accessory drive belt
– Generator
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. Check the operation of the charging system warning indicator lamp, located in the instrument
cluster. Normal operation is as follows:
Normal Charging System Voltages Charging System
Warning Indicator Operation
Engine to
battery ground
Battery
Gener-
ator B+ Circuit
I Circuit
Ignition Switch
Position
OFF
0V
10-12V
10-12V
0V
Position 0
Illuminated
0V
10-12V
10-12V
0V
Position II
OFF
0V
13-15V
13-15V
13-15V
Position II with
the engine
running
5. If the cause is not visually evident, verify the symptom and refer to the Component Tests. Component Tests
Generator On-Vehicle Tests - No-Load Test
1. Turn off all electrical loads and the ignition
switch. G1055063en
2008.50 Kuga 8/2011 414-00-2
Charging System - General Information
414-00-2
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