fuse FORD KUGA 2011 1.G Owner's Manual

Communications Network
Special Tool(s) / General Equipment
Terminal Probe Kit
418-S035Digital multimeter
The Ford approved diagnostic tool
Inspection and Checking
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical
or electrical damage.
NOTE: Ensure correct locking of wiring harness
connectors.
Visual Inspection Chart Electrical
- Fuse(s)
- Wiring harness - Connector
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. G1055035en
2008.50 Kuga 8/2011 418-00-9
Module Communications Network
418-00-9
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL29011A

Anti-Theft - Active
Refer to
Wiring Diagrams Section 419-01A, for
schematic and connector information. General Equipment
The Ford approved diagnostic tool
Inspection and Verification
1. Verify the customer concern, perform a full alarm function test
2. Visually inspect for obvious signs of mechanical
or electrical damage.
Visual Inspection Chart Electrical
Mechanical
– Fuse(s)
– Wiring harness
– Electricalconnector(s)
– Relay(s)
– Generic electronic module (GEM)
– Anti-theft alarm horn
– Anti-theft alarm horn
with integral battery
(if equipped)
– Misaligned door(s),
hood or tailgate
– Door ajar switche(s)
– Latch(es)
– Cable(s)
– Lock cylinder(s)
– Set/reset switch(s)
– Linkage(s)
– Remote key
– Passive key
– Interior scanning system
– Interior scanning system disable
button (if equipped)
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 approved
diagnostic tool to diagnose the system. G167420en
2008.50 Kuga 8/2011 419-01A-8
Anti-Theft - Active
419-01A-8
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Anti-Theft - Passive
Refer to Wiring Diagrams Section 419-01B, 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)
– Relay(s)
– PCM
– PATS transceiver
– Ignition switch
– Instrument cluster
– Keyless vehicle module
– PATS ignition key
–
Ignition lock cylinder
– Passive anti-theft system (PATS)
tranceiver
– PATS ignition key
– Use of a non- encoded PATS igni-
tion key
– More than one PATS key in close
proximity of the
PATS transceiver
– Powertrain control module (PCM)
– Keyless vehicle module
– Instrument cluster
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 approved
diagnostic tool to diagnose the system. G1055072en
2008.50 Kuga 8/2011 419-01B-7
Anti-Theft - Passive
419-01B-7
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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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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.
Left-hand turn signal
b. Right-hand turn signal
c. Main beam
d. Dipped beam
e. Windshield wiper stage I
f. Windshield wiper stage II
g. Heated rear windshield
h. Heater blower motor
i. Headlamp washer system (vehicles with HID headlamps)
j. Electric booster heater (if fitted)
k. Autolamps (position lamps only if fitted)
l. Alarm horn (vehicles with alarm system)
m. Rear window wiper
n. Heated front 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.
End service mode
The GEM automatically ends service mode 20
seconds after the last input or at a driving speed
of over 7km/h. However, service mode can be
manually ended at any time by proceeding as
follows:
• PRESS and HOLD the switch of the heated rear
window
• 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 marker lamps (side lights) and licence plate lamp in
automatic headlamps mode
• Rear wiper
• Headlamp washer assembly
• Electric booster heater • Alarm horn
• 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. SWITCH 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) is
integrated into the central junction box (CJB).
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
Fuses
Wiring harness Connectors G1055084en
2008.50 Kuga 8/2011 419-10-12
Multifunction Electronic Modules
419-10-12
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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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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUALE51159 122E102019 E102020

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

Steering System
Special Tool(s) / General EquipmentAlignment Pins, Subframe
205-316 (15-097A)
15097
Simulator, Driver and
Passenger Air Bags and Side
Air Curtains
501-073 (40-016)
501073
The Ford approved diagnostic tool
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanicalor electrical damage.
Visual Inspection Chart
Electrical
Mechanical
• Battery
• Battery cables
• Steering anglesensor electrical
connector
• Power steering pump control
module electrical
connectors
• Power steering pump control
module ground
cable
• Power steering pump control
module ground
cable retaining
screw
• Steering angle sensor warning
indicator
• Fuse(s)
• Tire pressure(s)
• Loose tie-rod end(s)
• Loose strut and
spring assemblies or
ball joints
• Loose pinch bolts on steering column
shaft flexible coup-
ling
• Wheels and tires
• Power steering line fluid leaks
• Steering gear bellows 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.
Components Tests
Steering Linkage
1. Grasp the steering wheel firmly and move it upand down and to the left and right without
turning the steering wheel to check the steering
column bearing for wear, steering column shaft
for wear, steering wheel for looseness and
steering column for looseness. If the steering
column bearing or the steering column shaft is
worn install a new steering column. If the
steering wheel or the steering column is loose,
tighten the steering wheel or the steering column
retaining bolts.
2. With the road wheels in the straight ahead position, gently turn the steering wheel to the
left and the right to check for free play in the
steering linkage.
3. There should be no excessive free play at the steering wheel rim. If there is excessive free
play, CHECK the tie-rod inner and outer ball
joints, REFER to Tie-Rod Component Test in
this procedure. CHECK the steering column
universal joint, REFER to Steering Column
Universal Joint Component Test in this
procedure. If there is no free play in the tie-rod
and the steering column, install a new steering
gear.
Tie-Rod
CAUTION: Steering gear boots must be
handled carefully to avoid damage. Use
new steering boot clamps when installing
the steering gear boots.
NOTE: Noises such as knocks, which may appear
to originate from the steering linkage, may also be
generated by front suspension components.
REFER to: Noise, Vibration and Harshness (NVH)
(100-04 Noise, Vibration and Harshness,
Diagnosis and Testing).
G1059437en2008.50 Kuga8/2011
211-00- 2
Steering System - General Information
211-00- 2
DIAGNOSIS AND TESTING
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Engine
Special Tool(s) / General EquipmentSocket, Spark Plug
303-499
ES21202
Compression Test Adapter
303-1056
E42936
Ford diagnostic equipment
Materials
Specification
Name
WSK-M2G349-A7
Adhesive - Loctite 243 1. Verify the customer concern by operating the
system
2. Visually inspect for obvious signs of mechanical or 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 cause is not visually evident, verify the symptom and refer to the Symptom Chart.
Visual Inspection Chart
Electrical
Mechanical
– Fuse(s)
– Loose or corrodedconnector(s)
– Control module
– Damaged or worn switch(es)
– Coolant leaks
– Oil leaks
– Fuel system leaks
– Visibly damaged or
worn parts
– Loose or missing nuts or bolts
Action
Possible Sources
Symptom
• CHECK for evidence of oilleaks on components. Use an
ultraviolet (UV) leak tester if an
oil leak is not evident. INSTALL
new gaskets or components as
required.
• Oil leaks on components that
are either coated in oil them-
selves or on components local
to them.
• Loss of oil
• CHECK the coolant expansiontank for a film of oil on the
coolant surface. INSTALL a
new oil cooler or oil cooler
gasket.
• Internal or external leak at the
oil cooler.
• INSTALL a new crankshaftseal.
• Leak at the crankshaft seal.
• CHECK for cracks in oil-carrying components of the
basic engine by means of a UV
leak test. INSTALL new
components or seals as
necessary.
• Leaks from oil carrying
components or basic engine.
• DETERMINE the last type ofengine oil used and compare
with the specification. Change
the engine oil to the specifica-
tion.
• Use of the wrong type of engine
oil.
• Oil consumption
G1055128en2008.50 Kuga8/2011
303-00-
2
Engine System - General Information
303-00- 2
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Engine Cooling
Special Tool(s) / General EquipmentPressure Tester, Cooling
System
303-396 (24-001 A)
IA24001A
Adaptor for 303-396
303-396-09
E55030
Ford approved diagnostic tool
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanicalor electrical damage.
Visual Inspection Chart
Electrical
Mechanical
– Fuse(s)
– Wiring harness
– Electricalconnector(s)
– Engine coolant temperature (ECT)
sensor
– Cooling fan motor
– Cooling fan module
– Powertrain control module (PCM)
– Coolant shut off valve
– Coolant degas shut off valve
– Coolant leaks
– Gaskets/seals
– Core plug(s)
– Hose(s)/hose joints
– Coolant expansion
tank cap and seal(s)
– Coolant expansion tank
– Radiator
– Coolant pump
– Thermostat
– Heater core
– Exhaust gas recircu- lation (EGR) cooler
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.
G1058974en2008.50 Kuga8/2011
303-03- 4
Engine Cooling
303-03- 4
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