fuse diagram FORD KUGA 2011 1.G User Guide

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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Generic Electronic Module (GEM)
General Equipment
Ford Diagnostic Equipment
Removal
CAUTIONS: Modules must not be swapped between
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.
When installing a new GEM on vehicles
with a diesel engine, make sure that a fuel
pump fuse (F111) with 5A is used.
When installing a new GEM on vehicles
with a petrol engine, make sure that a fuel
pump fuse (F111) with 15A is used.
NOTE: GEM is integrated into the central junction
box (CJB) and cannot be removed individually.
1. NOTE: This step is only necessary when
installing a new component.
Upload the GEM configuration information using
the Programmable Modules Installation Routine.
General Equipment: Ford Diagnostic Equipment
2. Refer to: Battery Disconnect and Connect
(414-01 Battery, Mounting and Cables,
General Procedures).
3. 4.
5.
Installation
1.
To install, reverse the removal procedure.
2. NOTE: This step is only necessary when
installing a new component.
Download the GEM configuration information
to the newly installed GEM using the
programmable modules installation routine.
3. NOTE: This step is only necessary when
installing a new component.
Program all keys using the Key Programming
Routine.
General Equipment: Ford Diagnostic Equipment G1065605en
2008.50 Kuga 8/2011 419-10-14
Multifunction Electronic Modules
419-10-14
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Anti-Lock Control
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)
• Electricalconnector(s)
• Wiring harness(s).
• Anti-lock brake system (ABS)
module
• Wheel speed
sensor(s)
• Wheel speed sensor ring(s)
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.
G1058976en2008.50 Kuga8/2011
206-09A- 5
Anti-Lock Control
206-09A- 5
DIAGNOSIS AND TESTING
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Refer to
Wiring Diagrams Section 206-09A, for

Starting System
Refer toWiring Diagrams Section 303-06, 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 electrical damage.
Visual Inspection Chart
Electrical
• Fuse(s)
• Wiring harness
• Electrical connector(s)
• Relay
• Switch(es)
• Battery junction box (BJB)
• Engine junction box (EJB)
• Central junction box (CJB)
• Keyless vehicle module (KVM) (if equipped)
• Battery
• Starter motor
• Powertrain Control Module (PCM)
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 diagnostictab within
the Ford diagnostic equipment .
G1183444en2008.50 Kuga8/2011
303-06-9
Starting System— 2.5L Duratec (147kW/200PS) - VI5303-06-
9
DIAGNOSIS AND TESTING
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Climate Control System
Refer to Wiring Diagrams Section 412-00, for
schematic and connector information.
Special Tool(s) / General EquipmentTerminal Probe Kit
418-S035
29011A
Digital Multimeter (compatible with K-type
thermocouple)
The Ford approved diagnostic tool
Refrigerant center
Thermometer - Fluke 80 PK-8 (FSE number 260
4102 001 07)
Inspection and Checking
NOTE:The electronic automatic temperature
control (EATC) module is integrated into the air
conditioning control assembly.
1. VERIFY customer concern.
2. Visually CHECK for any obvious mechanical or electrical damage.
NOTE: Ensure correct locking of the wiring harness
connector.
Visual Inspection
Electrical
Mechanical
• Fuses
• Wiring harness
• Connector
• Refrigerant lines
• Condenser core
• Coolant level
• Drive belt
• A/C compressor
3. RECTIFY any obvious causes for a concern found during the visual inspection before
performing any further tests. CHECK the
operation of the system.
4. If the concern is still present after the visual inspection, perform fault diagnosis on the
electronic engine management, the charging
system, the generic electronic module (GEM)
and the instrument cluster (vehicles with EATC:
read out the EATC fault memory as well) using the Ford approved diagnostic tool and RECTIFY
the fault(s) displayed in accordance with the
fault description. CHECK the operation of the
system.
5. For vehicles with no stored fault(s), PROCEED in accordance with the Symptom Chart
according to the fault symptom.
6. Following checking or elimination of the fault(s) and after completion of operations, the fault
memories of all vehicle modules must be READ
OUT and any stored faults must be DELETED.
Refrigerant Circuit - Quick Check
WARNING: The air conditioning system is
filled with refrigerant R134a. Observe
"Health and Safety Precautions". For
further information
REFER to: Air Conditioning (A/C) System
Recovery, Evacuation and Charging
(412-00 Climate Control System - General
Information, General Procedures).
Refrigerant circuit check
WARNING: Under certain circumstances,
refrigerant lines and A/C components may
be extremely hot or cold. Exercising care,
touch the refrigerant lines or A/C
components in order to check this. Failure
to follow these instructions may result in
personal injury.
When the A/C system is operating, the following
conditions should apply:
• The refrigerant line from the refrigerant compressor to the condenser must be hot.
• The refrigerant line from the A/C condenser to the fixed orifice tube must be warm, but not so
hot as the refrigerant line mentioned above.
• Determine the difference in temperature upstream and downstream of the A/C condenser
by measuring the temperatures at the refrigerant
lines. The temperature difference should be
more than 20° C, depending on the ambient
temperature. If the temperature difference is
less, check the condenser for contamination or
damage to the fins as well as operation of the
radiator fans.
G1055878en2008.50 Kuga8/2011
412-00- 3
Climate Control System - General Information
412-00- 3
DIAGNOSIS AND TESTING
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Air Conditioning (A/C) Clutch Air Gap Adjustment
1.Check the gap A (measure the difference
between the engaged and disengaged positions
of the air conditioning clutch) at 60° intervals
around the circumference of the pulley. Operate
the air conditioning clutch several times with the
aid of a 5 A fused cable. Refer to the relevant
wiring diagram for the correct electrical
connection.
Refer to: Specifications (412-00 Climate Control
System - General Information, Specifications).
E92144
A
2.
E68442
3. If necessary correct the gap A using spacer
washers.
E68470
4.Refer to: Specifications (412-00 Climate Control
System - General Information, Specifications).
E68442
5. Check the gap A as described in step 1. If
necessary, repeat steps 2-5.
G549835en2008.50 Kuga8/2011
412-00- 11
Climate Control System - General Information
412-00- 11
GENERAL PROCEDURES
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