ABS FORD KUGA 2011 1.G Owner's Manual

Description
Item
Medium speed CAN (controller area
network) bus (MS-CAN)
A
High speed CAN bus (HS-CAN)
B
LIN (local interconnect network) bus
C
Terminating resistors
Drive
DLC (data link connector)
E
GEMRefer to Component Description: ABS
(page ?)
1
Fuel fired booster heater /programmable
fuel fired booster heater
2
The EATC control module
3
Reversing camera module (RVC)
4
Parking aid module (PAM)
5
DDM6
Front driver's side switch unit
7
Driver's side RDM
8
PDM (Passenger Door Module)
9
Passenger side RDM
10
Audio unit/navigation unit
11
CD changer
12 Description
Item
Navigation system module - vehicles
equipped with DVD navigation system with
touch screen (not communicating with the
diagnostic unit)
13
Navigation system display - vehicles
equipped with DVD navigation system with
touch screen (not communicating with the
diagnostic unit)
14
Control module for electronic auxiliary
equipment (BVC)
15
RCM16
Keyless vehicle module (KVM)
17
Instrument Cluster
18
PCM19
Fuel additive system module.
20
ABS module or electronic stability program
module
21
Yaw rate sensor/lateral acceleration
sensor
22
Headlamp Leveling Module
23
All-wheel drive control unit
24
Electrohydraulic power steering module
25
System Operation
General
In a communications network (data bus system),
various modules of different systems are connected
to one another via one or several lines.
The data bus system is used exclusively for
transmitting data between the connected modules,
as well as between the connected modules and
the Ford diagnostic unit.
In a data bus system, complete data blocks are
transmitted instead of single on/off pulses. In
addition to the actual information, these data blocks
also contain data regarding the address of the
module to be addressed, the size of the data block
and information for monitoring the content of each
individual data block.
Data bus systems offer various advantages: • Simplified data transmission between the
modules due to a standardized protocol
• Fewer sensors and connectors
• Improved diagnostic options
• Lower costs
The DLC is connected to the various data bus
systems and to the power supply via the standard
16-pin GEM. The signal for the module
programming is also transferred via the DLC.
In a data bus system, if there is a break in one or
both lines or there is a short to ground or to voltage,
then communication between the modules and
with the Ford diagnostic unit is disturbed or is no
longer possible at all.
In order to be able to establish communication with
one another, the modules of the individual systems G1030779en
2008.50 Kuga 8/2011 418-00-6
Module Communications Network
418-00-6
DESCRIPTION AND OPERATIONTO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

must use the same language. This language is
called a protocol.
At present, Ford uses three different data bus
systems. Depending upon model and equipment
level, all three data bus systems are used. Each
of these data bus systems has its own protocol.
Data bus systems
ISO 9141 bus
The International Organisation for Standardisation
ISO 9141 bus. This consists of a single wire and
is used exclusively for communication between the
modules and the Ford diagnostic unit. The fault
memories of the various modules are read out via
the ISO 9141 bus.
Local Interconnect Network (LIN) bus
The LIN bus is a standard specifically designed for
cost-effective communication between intelligent
sensors and actuators in vehicles. The LIN control
unit subnet is used in every situation where the
bandwidth and versatility of CAN is not needed.
The LIN specification comprises the LIN protocol,
a standard format for describing a complete LIN
and the interface between an LIN and the
application. An LIN comprises a LIN master and
one or more LIN slaves. The LIN utilizes the
master/slave principle for the purpose of bus
access control. This has the significant advantage
that few resources (CPU performance, ROM, RAM)
are required for bus management in the slave
module. The master is implemented in a control
module or a gateway which has the necessary
resources. All communication is initiated by the
master. Consequently, a message always consists
of a header, which is generated by the master, and
a response from the slave. The data transfer rate
is in the region of up to 20 Kbit/s. The LIN master
knows the time sequence of all data which are to
be transmitted. These data are transmitted by the
corresponding LIN slaves (e.g. ultrasonic sensors)
if they are requested to do so by the LIN master.
LIN is a single-wire bus, i.e. the data are
transmitted in the cable via one wire. Usually the
same cable is also used to provide the supply
voltage. The ground connection of the supply
voltage also acts as the ground connection of the
data transmission. An LIN does not use a
terminating resistor.
Controller Area Network (CAN) bus
This consists of two twisted wires and operates
serially (data is transmitted sequentially). It is used
for communication between the modules
themselves and between the modules and the Ford
diagnostic unit. The modules are connected to the
data bus in parallel. New modules can be
incorporated easily, without modifying the other
wiring or modules. The transmitted data is received
by every module connected to the control unit
network (CAN). As each data packet has an
identifier (label), in which the priority of the
message is determined as well as the content
identification, each module can detect whether or
not the data is relevant for its own information
processing. This enables several modules to be
addressed with a particular data packet and
supplied with data simultaneously. For this
purpose, it is ensured that important data (for
example from the ABS) is transmitted first. The
other modules are only able to submit their data to
the data bus after the high-priority messages have
been received.
The advantages of the CAN bus are:
• Minimization of wiring requirements
•
High degree of error protection (fault / fail-proof)
• Robustness
• Good extendibility
• Prioritization of messages
• Inexpensive
• Automatic repetition of faulty messages
• Independent system monitoring and the ability to disconnect faulty modules from the data bus
automatically
Due to the increased number of modules and the
resulting continued increase in data transfer, two
different CAN bus systems are used. Essentially,
they only differ in terms of their data transmission
rates and application areas.
To be able to distinguish between the individual
CAN bus systems, the CAN bus system with the
high transfer speed is called the high speed CAN
bus (HS-CAN). The data are transmitted at a baud
rate of 500 kB/s.
The CAN bus system with the medium transfer
speed is called the medium speed CAN bus
(MS-CAN) and is mainly used for communication
in the comfort electronics or the multimedia system.
The data are transmitted at a baud rate of 125 kB/s.
An interface (gateway) is used to exchange data
between the HS-CAN and the MS-CAN. This
provides the connection between the three CAN
databus systems and is installed in the GEM and
in the electronic instrument cluster. The number of
modules which are connected to the three databus G1030779en
2008.50 Kuga 8/2011 418-00-7
Module Communications Network
418-00-7
DESCRIPTION AND OPERATIONTO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

systems depends on the equipment level of the
vehicle.
In order to guarantee a high degree of error
protection, two 120 Ohm terminating resistors are
installed in the CAN. These are integrated in the
first module connected to the CAN and in the last
module connected to the CAN respectively and
are used for suppression as well as the elimination
of voltage peaks. In order to ensure correct
functioning of the data bus system, the modules
must always be connected with an integral
terminating resistor. In order to enable
communication between the modules on the
HS-CAN and the modules on the MS-CAN, one
module is connected to both data bus systems.
The connection of both data bus systems is
designated as a gateway. In this gateway, the
received data is converted to the transmission rate
required for the relevant data bus and is
transmitted. This ensures an optimal distribution
of information between both data bus systems.
Component Description
ABS
The GEM is integrated in the CJB (central junction
box) and cannot be replaced as a separate unit.
G1030779en
2008.50 Kuga 8/2011 418-00-8
Module Communications Network
418-00-8
DESCRIPTION AND OPERATIONTO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Programmable Module Installation
Activation
5.
Install the most up-to-date software version in
IDS.
6. If, before replacing a module, it was not possible
to read out the vehicle-specific data using the
integrated diagnostic system (IDS) (the module
to be replaced does not respond) then, during
programming of the new module, the
vehicle-specific data must be entered manually
via a selection list in IDS or via a code which
can be obtained from the Technical Hotline.
7. In order to program, select the "Install
programmable module" submenu in the "Module
programming" menu tool box and then follow
the instructions.
8. The following modules must be programmed
after replacement:
•
• Anti-lock braking system module (ABS)
• Audio system module (ACM)
• CD player (CDP)
• Driver's door control unit (D-DCU)
• Passenger's door control unit (P-DCU)
• Rear left door control unit (RL-DCU)
• Rear right door control unit (RR-DCU)
• Electrical power steering (EPS)
• Generic Display Module (GDM) (vehicles
with DVD navigation system with
touchscreen)
• Generic electronic module (GEM)
• Headlamp control module (HCM) (vehicles with gas discharge headlamps)
• Instrument cluster (IC)
• Navigation system (NAV) (vehicles with navigation system)
• Parking aid module(PAM)
• Powertrain control module (PCM)
• Restraint control module (RCM)
• Rear entertainment system module (RETM) (vehicles with rear seat entertainment
system)
9. In order to configure the PCM, select the
"Programmable parameters" submenu in the
"Module programming" menu tool box and then
follow the instructions.
10. For vehicles with anti-lock braking system and
electronic stability program, these must also be configured using IDS following replacement of
the lateral acceleration sensor, yaw rate sensor
or pressure sensor. Configuration is performed
in the "Programmable parameters" menu tool
box.
G1158258en
2008.50 Kuga 8/2011 418-01-3
Module Configuration
418-01-3
GENERAL PROCEDURESTO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Action
Possible Sources
Symptom
• Vehicles without load levellingshock absorbers, CHECK for
abnormal loading, spring sag
or non-standard springs.
• Vehicles with load levelling shock absorbers, GO to
Pinpoint Test C.
• Vehicle attitude incorrect (front
or rear is high or low).
• Steering wheel off center
• CHECK the steering system.REFER to: Steering System
(211-00 Steering System -
General Information,
Diagnosis and Testing).
• Steering gear or linkage worn
or damaged.
• CARRY OUT the Ball JointInspection Component Test in
this procedure.
• Suspension lower arm ball joint.
• ADJUST the wheel alignment.REFER to: Front Toe Adjust-
ment (204-00 Suspension
System - General Informa-
tion, General Procedures)
/ Rear Toe Adjustment (204-00
Suspension System - General
Information, General Proced-
ures).
• Incorrect wheel alignment.
• CARRY OUT the Strut orShock Absorber Testing
component test in this
procedure.
• CHECK and INSTALL new suspension components as
necessary.
REFER to: Front Strut and
Spring Assembly (204-01
Front Suspension, Disas-
sembly and Assembly).
• Front strut and spring assem-
blies.
• Rough ride
• CHECK and INSTALL newsuspension components as
necessary. REFER to:
Front Strut and Spring Assembly (204-01 Front
Suspension, Disassembly
and Assembly),
Rear Stabilizer Bar (204-02
Rear Suspension, Removal
and Installation).
• Front or rear stabilizer bar
connecting links or bushings.
G1080717en2008.50 Kuga8/2011
204-00- 3
Suspension System - General Information
204-00- 3
DIAGNOSIS AND TESTING
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Action
Possible Sources
Symptom
• INSTALL a new lower arm.REFER to: Lower Arm (204-01
Front Suspension, Removal
and Installation).
• Front suspension lower arm
bushings.
• CHECK and INSTALL newcomponents as necessary.
REFER to: Rear Stabilizer Bar
Bushing (204-02 Rear
Suspension, Removal and
Installation).
• Rear suspension arm bushings.
• CARRY OUT the Strut orShock Absorber Testing
component test in this
procedure.
• CHECK and INSTALL new suspension components as
necessary.
• Rear shock absorbers.
• GO toPinpoint Test B.
• Front strut and spring assembly
or rear shock absorber and
spring upper mounting bolts or
nuts loose or broken.
• Excessive noise
• GO toPinpoint Test B.
• Shock absorbers leaking.
• GO toPinpoint Test B.
• Shock absorbers performance
incorrect.
• GO toPinpoint Test B.
• Stabilizer bar components.
• GO toPinpoint Test B.
• Strut and spring assembly and
springs.
• GO toPinpoint Test B.
• Springs moving on springs
upper or lower seats.
• GO toPinpoint Test B.
• Suspension bushings.
• GO toPinpoint Test B.
• Lower arm ball joint.
• GO toPinpoint Test B.
• Worn front wheel bearings
• GO toPinpoint Test B.
• Wheels and tires.
• CHECK and INSTALL newsuspension components as
necessary.
• Front or rear suspension
damage.
• Incorrect tire wear
• ADJUST the wheel alignment.REFER to: Front Toe Adjust-
ment (204-00 Suspension
System - General Informa-
tion, General Procedures)
/ Rear Toe Adjustment (204-00
Suspension System - General
Information, General Proced-
ures).
• Incorrect wheel alignment.
G1080717en2008.50 Kuga8/2011
204-00-
4
Suspension System - General Information
204-00- 4
DIAGNOSIS AND TESTING
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Action
Possible Sources
Symptom
• CHECK the front wheel bear-ings.
• Damaged or worn front wheel
bearings.
• Vibration
• CHECK the tires. BALANCE orINSTALL new tires as neces-
sary.
• Wheels and tires.
• CHECK the steering system.REFER to: Steering System
(211-00 Steering System -
General Information,
Diagnosis and Testing).
• Steering gear or linkage worn
or damaged.
• CARRY OUT the Strut orShock Absorber Testing
component test in this
procedure.
• CHECK and INSTALL new suspension components as
necessary.
REFER to: Front Strut and
Spring Assembly (204-01
Front Suspension, Removal
and Installation).
• Front strut and spring assem-
blies.
• CHECK and INSTALL newsuspension components as
necessary.
REFER to: Lower Arm (204-01
Front Suspension, Removal
and Installation).
• Damaged front suspension
lower arm(s).
• GO toPinpoint Test C.
• Load-levelling shock absorbers.
• Vehicle lean
Pinpoint Tests
PINPOINT TEST A : DRIFT LEFT OR RIGHT
DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
WARNING: To avoid personal injury due to the loss of vehicle control, the inspection should
be carried out by two people to maintain safe driving conditions. Adequate grip should
G1080717en2008.50 Kuga8/2011
204-00- 5
Suspension System - General Information
204-00- 5
DIAGNOSIS AND TESTING
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
A6: SWAP THE FRONT RIGHT-HAND WHEEL AND TIRE ASSEMBLY
1 Raise and support the vehicle. REFER to: (100-
02 Jacking and Lifting)
Jacking (Description and Operation),
Lifting (Description and Operation).
– Swap the front right-hand wheel and tire assembly with the rear left-hand wheel and
tire assembly.
– Road test the vehicle.
• Does the vehicle drift?
zYe s GO to A7.
zNoThe concern has been corrected.
A7: INSTALL NEW TIRES
NOTE: Install new tires only once.
1Install new tires to the four road wheels. TEST
the system for normal operation.
• Does the vehicle drift?
zYe s Verify possible sources, refer to the Symptom
Chart.
zNoThe concern has been corrected.
PINPOINT TEST B : EXCESSIVE NOISE
DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
B1: INSPECT ALL STRUT AND SPRING ASSEMBLY AND SHOCK ABSORBER MOUNTING BOLTS
AND NUTS
1 Inspect the strut and spring assembly and shock
absorber mounting bolts and nuts.
• Are the mounting bolts or nuts loose or broken?
zYe s TIGHTEN or INSTALL new suspension
mounting bolts.
REFER to: Specifications (204-01 Front
Suspension, Specifications).
zNo
GO to B2.
G1080717en2008.50 Kuga8/2011
204-00- 8
Suspension System - General Information
204-00- 8
DIAGNOSIS AND TESTING
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
B2: INSPECT THE STRUT AND SPRING ASSEMBLIES AND SHOCK ABSORBERS FOR LEAKS
NOTE:Make sure that the oil is not from another
source.
1 Inspect the strut and spring assemblies and
shock absorbers for signs of oil weepage or
leaks. Refer to weepage and leakage conditions
in the Strut or Shock Absorber Testing
component test in this procedure.
• Are the struts or shock absorbers leaking?
zYe s INSTALL new struts or shock absorbers as
necessary.
REFER to: Front Strut and Spring Assembly
(204-01 Front Suspension, Removal and
Installation).
zNo
GO to B3.
B3: INSPECT THE SPRINGS AND STABILIZER BAR(S)
1 Inspect the springs and stabilizer bar(s) for
damage.
• Are the springs or stabilizer bar(s) damaged?
zYe s INSTALL new springs or stabilzer bar(s).
REFER to:
Front Strut andSpring Assembly (204-01 Front
Suspension, Removal and Installation),
Front Stabilizer Bar (204-01 Front Suspension,
Removal and Installation),
Rear Stabilizer Bar Link (204-02 Rear Suspen-
sion, Removal and Installation).
zNo
GO to B4.
G1080717en2008.50 Kuga8/2011
204-00- 9
Suspension System - General Information
204-00- 9
DIAGNOSIS AND TESTING
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
B7: INSPECT THE WHEEL AND TIRES
1 Inspect the tires for uneven wear.
• Is there uneven wear?
zYe s REFER to the symptom chart.
zNoGO to B8.
B8: INSPECT THE STRUT AND SPRING ASSEMBLY AND REAR SUSPENSION SPRING INTERFACE
1 Loosen the strut and spring assemblies and
shock absorbers top and bottom mounting bolts
and nuts. Tighten the mounting bolts and nuts.
REFER to:
Specifications (204-01 Front Suspension,
Specifications),
Specifications (204-02 Rear Suspension,
Specifications).
• Is the concern still evident?
zYe s GO to B9.
zNoVehicle condition corrected.
B9: INSPECT THE STRUT AND SPRING ASSEMBLIES AND SHOCK ABSORBER COMPONENTS
1 Check that the spring is correctly located on the
spring seat and has not moved.
2Disassemble the strut and spring and assembly
and inspect the individual components.
REFER to:
Front Strut and Spring Assembly
(204-01 Front Suspension, Removal and
Installation).
3 Inspect the shock absorber top mount for wear
or damage.
G1080717en2008.50 Kuga8/2011
204-00-
11
Suspension System - General Information
204-00- 11
DIAGNOSIS AND TESTING
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL