case FORD KUGA 2011 1.G User Guide

Direct Current/Alternating Current (DC/AC) Inverter – System
Operation and Component Description
System Diagram Description
Item
DC/AC converterRefer to Component Description: (page
?)
1
AC mains outletRefer to Component Description: (page
?)
2 Description
Item
AC mains outlet switch
3
Battery
4
Ignition relay
5
Keylesss vehicle module
6
System Operation
DC/AC converter
In the rear part of the center console there is an
optional 230 V socket instead of the outlet of the
standard 12 V electrical system.
In this case a DC/AC converter supplies a
continuous power of 150 W at 230 V/50 Hz. It can
also absorb temporary power peaks of up to 300
W when consumers are switched on. For example, an output of 150 W is sufficient to
run laptops, games consoles and mobile phone
chargers.
G1055639en
2008.50 Kuga 8/2011 414-05-4
Voltage Converter/Inverter
414-05-4
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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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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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Module Configuration
Activation
1.
Install the most up-to-date software version in
the integrated diagnostic system (IDS).
2. In IDS, select the "Module reprogramming"
submenu in the "Module programming" menu
tool box and then follow the instructions.
3. Transfer a new software version (if available)
to the powertrain control module (PCM) using
IDS, if a module-reprogramming of the PCM
may be required in the case of engine running
concerns.
4. Following installation of a wheel/tire
combination, for which the tire-tread
circumference does not correspond to that of
standard tires, the tire size must be changed in
the PCM using IDS. Therefore select the
"Programmable parameters" submenu and enter
the corresponding tire size under the "tire size"
menu item. G1158256en
2008.50 Kuga 8/2011 418-01-2
Module Configuration
418-01-2
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Module Controlled Functions – Overview
Generic electronics module (GEM)
CAUTIONS:
Never swap the GEM (generic electronic
module) between two vehicles.
Compare the number of relays and fuses
in the defective GEM and the new GEM.
Transfer from the defective GEM any relays
and fuses which are not in the new GEM.
In doing so, pay attention that fuses with
the correct Ampere rating are used, by
referring to the wiring diagrams.
NOTE: The GEM is integrated in the CJB (central
junction box) and cannot be replaced as a separate
unit.
For repair work during a service, vehicle-specific
configuration is necessary if a new GEM is
installed.
Emergency function
The GEM is equipped with restricted emergency
running functions on vehicles with mid or high-end
equipment levels.
The microcontroller sends a control signal to a
monitoring function within the GEM at regular
intervals. If the battery voltage falls below a value
of approx. 7.5 volts, this check signal is not present
and the GEM switches to emergency function after
a predetermined time.
In this case, the low beam is permanently switched
on, regardless of the light switch position. The
windshield wiper can only be operated in stage 1;
the wiper switch must however be in the stage I or
II position. The wiper park position is not
recognized. Intermittent wiping is not available.
When the control signal recurs, the GEM switches
back to normal operation.
Service mode
Description of operation
Diagnosis of the GEM can be carried out using the
Ford diagnostic unit. 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
NOTE:
If the alarm is activated (in vehicles fitted
with an anti-theft alarm system), service mode
cannot be activated.
Proceed as follows to activate the service mode:
• OPERATE the switch of the heated rear window
and HOLD IT THERE
• SWITCH 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.
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:
• 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 fluid level
• Cruise control system
• Autolamps
• Dipped beam
• Main beam
• Headlamp flasher
• Side lights
• Turn signals (right, left, hazard warning lights) G1030787en
2008.50 Kuga 8/2011 419-10-2
Multifunction Electronic Modules
419-10-2
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Turn signals
Description
Item
External mirror housing
1
Turn signals
2
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 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.
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 by the GEM.
Interior lighting
Depending on the vehicle specification, the interior
lighting includes:
• Left and right-hand footwell lamps
• Overhead lights at front and rear
Depending on the vehicle specification, the
switchable interior lighting includes:
• Map lights
• Mirror lights in sun visors
• Glove compartment lamp
• Luggage compartment lamp
The front and rear overhead lights are switched on
by the GEM. The interior lighting is switched on if one of the
following conditions is satisfied:
One of the vehicle's doors is opened.
The ignition key is in the "0" or "I" position and the
vehicle is unlocked.
The ignition key is turned from the "II" to the "I" or
"0" position.
The interior lighting is switched off when all of the
doors are closed and one of the following
conditions is satisfied:
• 25 seconds have elapsed since the last door
was closed.
• The ignition key is turned from the "0" or "I" to the "II" position.
• The ignition key is in the "0" or "I" position while the vehicle is locked.
The dimmer function is not used if the interior
lighting is switched off via the battery protection
function.
Heated windscreen
The heated windshield is switched on by the GEM
under the following conditions:
• The heated windshield switch is operated, the ignition switch is in position "II" and the charge
warning lamp is switched off.
• The "Defrost" function of the two-zone air conditioning has been activated, the ignition
switch is in the position "II" and the charge
warning lamp is off.
• The battery voltage has exceeded 16 V for more
than 20 seconds (power management strategy).
Manual requests for switching off the heated
windshield by pressing the switch are ignored
at this time.
• The engine was started at an outside air temperature below 4°C and an engine
temperature below 65°. Manual requests for
switching off the heated windshield by pressing
the switch are accepted.
NOTE: If the battery voltage returns to the normal
range, the disabling of the heated windshield is
switched off. It is then switched off.
The heated windshield is switched off by the GEM
under the following conditions: G1030788en
2008.50 Kuga 8/2011 419-10-8
Multifunction Electronic Modules
419-10-8
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SECTION 205-02 Rear Drive Axle/Differential
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
DESCRIPTION AND OPERATION
205-02-2
Rear Drive Axle and Differential (Component Location) .....................................................
205-02-6
Rear Drive Axle and Differential (System Operation and Component Description) ...........
205-02-6
System Operation ........................................................................\
.......................................
205-02-6
General Information ........................................................................\
................................
205-02-6
Driving situations ........................................................................\
....................................
205-02-6
Haldex clutch ........................................................................\
..........................................
205-02-7
General overview ........................................................................\
....................................
205-02-7
Operation ........................................................................\
................................................
205-02-7
Design of the 3rd generation Haldex clutch ....................................................................
205-02-9
Design of the multi-plate clutch ........................................................................\
...............
205-02-10
All-wheel drive control unit ........................................................................\
......................
205-02-10
Electric feed pump ........................................................................\
..................................
205-02-10
Pressure control - 3rd generation Haldex clutch .............................................................
205-02-11
Base pressure ........................................................................\
.........................................
205-02-12
Increased base pressure (preload) ........................................................................\
.........
205-02-13
Pressure build-up ........................................................................\
....................................
205-02-14
Design of the 4th generation Haldex clutch ...................................................................
205-02-14
General overview ........................................................................\
....................................
205-02-15
Pressure control - 4th generation Haldex clutch .............................................................
GENERAL PROCEDURES 205-02-17
Differential Fluid Level Check ........................................................................\
.....................
205-02-19
Active On-Demand Coupling Fluid Level Check ................................................................
REMOVAL AND INSTALLATION 205-02-21
Differential Case ........................................................................\
.........................................
205-02-25
Active On-Demand Coupling Module ........................................................................\
.........
205-02-32
Differential Input Shaft Seal ........................................................................\
........................
205-02-38
Differential Support Insulator ........................................................................\
......................
205-02-39
Rear Halfshaft Seal ........................................................................\
.....................................
205-02-41
Drive Pinion Seal ........................................................................\
........................................
DISASSEMBLY AND ASSEMBLY
205-02-42
Active On-Demand Coupling — Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450 ...............................................................
205-02-1
Rear Drive Axle/Differential
205-02- 1
.
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Differential Case
General EquipmentCable Ties
Removal
All vehicles
1. Refer to: Rear Halfshaft (205-05 Rear Drive
Halfshafts, Removal and Installation).
Vehicles with 2.0L diesel engine
2.
1
2x6x3
1
2x6x3
E101687
3.
E101709
Vehicles with 2.5L engine
4. Refer to: Driveshaft (205-01 Driveshaft,
Removal and Installation).
5.
E114256
6.
x2x2
E114255
G1061458en2008.50 Kuga8/2011
205-02- 21
Rear Drive Axle/Differential
205-02- 21
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Differential Support Insulator
Special Tool(s)204-598
Hydraulic Cylinder 10t
E75373
204-598-03
Adapter for 204-598
E103784
Special Tool(s)308-762
Remover/Installer, Bush RDU
E102678
Materials
Specification
Name
WSS-M2C200-D2 /
7U7J-M2C200-BA
Transmission Oil 75W
FE
Removal
1.
Refer to: Differential Case (205-02 Rear Drive
Axle/Differential, Removal and Installation).
2. Special Tool(s): 204-598, 204-598-03, 308-762
308-762
204-598
204-598-03
308-762
204-598
204-598-03
E102574
Installation
1.Special Tool(s): 204-598, 204-598-03, 308-762
Material: Transmission Oil 75W FE
(WSS-M2C200-D2 / 7U7J-M2C200-BA)
transmission fluid
308-762
204-598
204-598-03
308-762
204-598
204-598-03
E102575
2. Refer to: Differential Case (205-02 Rear Drive
Axle/Differential, Removal and Installation).
G1076973en2008.50 Kuga8/2011
205-02- 38
Rear Drive Axle/Differential
205-02- 38
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Brake System
General EquipmentPressure/vacuum gauge set
The Ford approved diagnostic tool
The brake system operates by transferring effort
applied to the brake pedal by the driver to the
brakes at each wheel.
The braking effort is distributed to each wheel,
using a hydraulic system. The system is assisted
using a vacuum brake booster that reduces pedal
effort and increases hydraulic pressure.
The parking brake operates on the rear wheels
and is applied using a hand operated control.
Inspection and Verification
NOTE: Before carrying out any diagnosis, make
sure that the brake system warning indicator is
functional.
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical or electrical damage.
Visual Inspection Chart
Electrical
Mechanical
• Electricalconnector(s)
• Wiring harness(s)
• Switch(es)
• Tire pressure(s)
• Wheels and tires
• Fluid leak(s)
3. If an obvious cause for an observed or reported concern is found, correct the case (if possible)
before proceeding to the next step.
4. If the cause if not visually evident, verify the symptom and refer to the Symptom Chart.
Road Test
Carry out a road test to compare actual vehicle
braking performance with the performance
standards expected by the driver. The ability of the
test driver to make valid comparisons and detect
performance deficiencies will depend on
experience.
The driver should have a thorough knowledge of
the brake system operation and accepted general performance guidelines to make good comparisons
and detect performance concerns.
An experienced technician will always establish a
route that will be used for all brake diagnosis road
tests. The road selected will be reasonably smooth
and level. Gravel or bumpy roads are not suitable
because the surface does not allow the tires to grip
the road equally. Crowned roads should be avoided
because of the large amount of weight shifted to
the low set of wheels on this type of road. Once
the route is established and consistently used, the
road surface variable can be eliminated from the
test results.
Before a road test, get a complete description of
the customer concerns or suspected condition.
From the description, the technician will be able to
match possible causes with symptoms. Certain
components will be identified as possible sources
while others will be eliminated by the evidence.
More importantly, the customer description can
reveal unsafe conditions which should be checked
or corrected before a road test. The description will
also help form the basic approach to the road test
by narrowing the concern to specific components,
vehicle speed or conditions.
Begin the road test with a general brake
performance check. Using the description of the
concern, test the brakes at different vehicle speeds
using both light and heavy pedal pressure.
Determine if the concern is in the front or rear
braking system. First use the foot brake and then
the parking brake. If the condition (i.e. pull,
vibration, pulsation) occurs only on operation of
the parking brake, the concern is in the rear brake
system. If the condition occurs when the foot brake
is depressed, the concern is in the front brake
system.
Avoid locking the brakes and sliding the tires. This
condition will not indicate brake efficiency. A heavily
braked but turning wheel will stop the vehicle in a
shorter distance than locked wheels.
If the concern becomes evident during this check,
make sure it fits the description given before the
road test. If the concern is not evident, attempt to
duplicate the condition using the information from
the description.
If a concern exists, use the Brake System Symptom
Chart in order to isolate it to a specific sub-system
and condition description. From this description, a
list of possible sources can be used to further
G1058975en2008.50 Kuga8/2011
206-00-
4
Brake System - General Information
206-00- 4
DIAGNOSIS AND TESTING
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