Electric FORD KUGA 2011 1.G Service Manual

Component Description
DC/AC converter
The converter operates with a series connection
of two power converter circuits. The primary power
converter here is a push-pull converter. It converts
the 12 V supply from the electrical system of the
vehicle to an intermediate direct current link of
approx. 320 V.
From this intermediate direct current link, the
downstream full H-bridge circuit generates a
pulse-width modulated output voltage with 230
V/50 Hz.
A controller modulates the pulse width of the
square-wave output voltage and maintains an
effective output voltage of 230 V under varying
load conditions and under different input voltages.
Here, the rising and falling edge of the positive and
negative square wave pulse are controlled
symmetrically to the ideal shape of a sine wave,
which - among other things - also makes a positive
contribution to electromagnetic compatibility.
DC/AC converters which supply a modified square
wave output voltage are referred to as 'Modified
Sine Wave Inverters".
With this type of system there is no need for a
residual current operated device for protection in
the event of accidental contact, as all of the 230 V
lines are double-insulated. Potential-free separation
of the entire 230 V voltage part from the vehicle is
provided (electrical isolation).
The output voltage of 230 V/50 Hz is not generated
until the switching voltage is present at terminal 1
of the converter via the AC mains outlet switch.
The converter operates with the ignition switched
on and a vehicle electrical supply of between 11
V and 16 V. Internal voltage monitoring in the converter deactivates the system if the input
voltage is outside this range.
AC mains outlet
Description
Item
230 V/50 Hz outlet
1
LED (light emitting diode)
2
Cover3 Description
Item
230 V/50 Hz outlet (for UK vehicles)
1
LED2
Cover3
In order to prevent accidents and the risk of
electrical shock, the outlet is protected with a child
safety device and the AC outlet switch.
In order to make the system safer for children, the
safety catches for the 230 V contacts can only be
pushed to one side by pressing a Euro plug evenly
into both of the connector openings.
The AC mains outlet switch only activates the
system when a consumer is connected to the
outlet. G1055639en
2008.50 Kuga 8/2011 414-05-5
Voltage Converter/Inverter
414-05-5
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUALE98879 E98864312 E98865312

Audio System
Refer to Wiring Diagrams Section 415-01, for
schematic and connector information.
Refer to Wiring Diagrams Section 415-03, for
schematic and connector information.
General Equipment
The Ford approved diagnostic tool
Inspection and Verification
NOTE: If the keycode is entered incorrectly 3 times,
the system will allow the next keycode in 30
minutes. After entering the keycode the 10th time
incorrectly the system will lock out. The component
can only be unlocked by the manufacturer.
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)
– Audio unit
– Audio control switch (if equipped)
– CD changer
– Central junction box (CJB)
– Audio unit
– Antenna
– Foreign objects
contacting speaker
– Trim poorly fitted/resonance
– Audio control switch (if equipped)
– Compact disc (CD) changer
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 Self-Diagnostic Mode.
Self-Diagnostic Mode - Low Series
Audio Unit
NOTE: The audio unit must be in radio mode
before entering the Self-Diagnostic Mode.
1. To enter the audio unit Self-Diagnostic Mode, switch the audio unit ON. Within four seconds
depress the preset buttons 3 and 6 together.
2. Release the preset buttons 3 and 6 and the audio unit will enter the Self-Diagnostic Mode. 3.
The Self-Diagnostic Mode will automatically stop
after one iterration or to interrupt it , switch the
audio unit OFF.
Self-Diagnostic Mode Circuit Tested
Message Displayed
Right hand front woofercircuit
1. 4CH RF low
Right hand fronttweeter circuit.
2. 4CH RF high
Left hand front woofercircuit.
3. 4CH LF low
Left hand front tweetercircuit.
3. 4CH LF High
Right hand rear woofercircuit
1. 4CH RR low
Right hand rear tweetercircuit
2. 4CH RR high
Left hand rear woofercircuit
3. 4CH LR low
Left hand rear tweetercircuit.
3. 4CH LR High
Antenna connection
Seek 87.5 - 108.0
4. If the cause is not evident after the Self-Diagnostic Mode, connect the Ford
approved diagnostic tool to the data link
connector (DLC).
Self-Diagnostic Mode - High Series
Audio Unit GEN 2
NOTE: The audio unit must be in radio mode
before entering the Self-Diagnostic Mode.
1. To enter the audio unit Self-Diagnostic Mode, switch the audio unit ON. Within four seconds
depress the preset button 3 and 6 together.
2. Release the preset button 3 and 6 and the audio
unit will enter the Self-Diagnostic Mode.
3. The Self-Diagnostic Mode will automatically stop
after one iterration or to interrupt it , switch the
audio unit OFF.
Self-Diagnostic Mode Circuit Tested
Message Displayed
Right hand front woofercircuit
RF speaker 600Hz G1055068en
2008.50 Kuga 8/2011 415-00-2
Information and Entertainment System -
General Information
415-00-2
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Cellular Phone
Refer to
Wiring Diagrams Section 415-00, for
schematic and connector information. General Equipment
Ford diagnostic equipment
Principles of Operation
NOTE: Voice control will only operate with the
audio unit and components required switched ON.
Voice Control
The portable support electronics (PSE) module
has a voice control system. The customer will be
able to push the VOICE button on the audio control
switch located on the steering column lower
shroud, this will activate the PSE module and allow
voice control. An audible tone will be heard through
the audio unit speakers after which, a voice
command can then be spoken into the microphone
located in the overhead console.
The incoming calls and voice confirmation can be
heard through the audio system speakers.
When a voice command is spoken into the
microphone it will be sent as a signal to the PSE
module. The signal is then sent from the PSE
module to the relevant components on the
medium-speed controller area network (CAN) bus
network. The component will then convert the
signal back into the original voice command.
The components that the PSE module interacts
with are as follows:
• audio unit
• navigation system display module
• cellular phone
For additional information on the cellular phone
system, REFER to the cellular phone Owner's
Guide.
Bluetooth
An input can be given through the cellular phone
with or without the cellular phone connected to the
handset holder. Providing that the cellular phone
is one of the recommended cellular phones for the
system, is supplied with the Bluetooth technology
and the cellular phone is programmed to the PSE
module.
When selected as active the Bluetooth technology
is a wireless system that interacts with the relevant component modules through the PSE module. The
general operation of the Bluetooth is similar to the
voice control.
Bluetooth technology cannot transfer the cellular
phone's PHONEBOOK or recent outgoing and
incoming call details to the audio unit or navigation
system display module. If the cellular phone is
placed into the handset holder the PHONEBOOK
data and recent outgoing and incoming call
information will be transferred to the audio unit or
navigation system display module.
For additional information, REFER to the cellular
phone Owner's Guide.
Inspection and Verification
NOTE: Make sure that the cellular phone is
featured on the list of recommended cellular
phones for the system.
Make sure that the PSE module and cellular
phone are configured to each other before
starting a system diagnosis. ENTER the
following PIN number on the cellular phone to
configure the cellular phone to the PSE module:
0000.
Make sure that the MUTE symbol is not
displayed on the audio unit when trying to
operate the cellular phone system. If the MUTE
symbol is displayed, this indicates that the PSE
module requires configuring to the vehicle and
the cellular phone requires programming to the
PSE module. GO to
Pinpoint Test C.
1. Verify the customer concern by operating the system using the customers cellular phone.
2. Visually inspect for obvious signs of electrical damage.
Visual Inspection Chart Electrical
• Fuse(s)
• Wiring harness
• Electrical connector(s)
• Cellular phone
• Microphone
• PSE module
• Audio unit
• Instrument cluster
• Navigation system display module G1189085en
2008.50 Kuga 8/2011 415-00-4
Information and Entertainment System -
General Information
415-00-4
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Action
Possible Sources
Symptom
• CHECK all communicationbetween the audio unit and
PSE module. REFER to the
Ford diagnostic equipment.
• Audio unit.
• PSE module.
• Reduced sound or no sound
through the speakers
• REFER to the Ford diagnosticequipment.
• Circuit(s).
• Audio unit.
• PSE module.
• CHECK all communicationbetween the instrument cluster,
audio unit, navigation system
display module and PSE
module. REFER to the Ford
diagnostic equipment.
• Audio unit.
• Navigation system display
module.
• PSE module.
• Instrument cluster.
• The cellular phone information
is not displayed
• CHECK all communicationbetween the instrument cluster,
audio unit, navigation system
display module and PSE
module. REFER to the Ford
diagnostic equipment.
• Circuit(s).
• Cellular Phone.
• Audio unit.
• Navigation system display
module.
• PSE module.
• Instrument cluster.
• The voice activated phone
functions are inoperative
• CHECK the make and modelof the cellular phone against
those on the list of recom-
mended cellular phones for the
system.
• Cellular phone is not featured
on the list of recommended
cellular phones for the system
Pinpoint Tests
NOTE: ENTER the following PIN number on the
cellular phone to configure the cellular phone to
the PSE module: 0000. NOTE:
Use a digital multimeter for all electrical
measurements.
PINPOINT TEST A : NO COMMUNICATION WITH THE PORTABLE SUPPORT ELECTRONICS (PSE)
MODULE DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
A1: CHECK FOR VOLTAGE AT THE PSE MODULE 1
Disconnect PSE Module C432. G1189085en
2008.50 Kuga 8/2011 415-00-7
Information and Entertainment System -
General Information
415-00-7
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Cellular Phone – Overview
Software update - control module for
mobile electronic auxiliary equipment
(variant 1)
There is a USB port near the central electrical
module. Software updates for the control module
for mobile electronic auxiliary equipment can be
carried out here.
Software update - control module for
mobile electronic auxiliary equipment
(variants 2 and 3)
Software updates for the mobile electronic auxiliary
equipment control module can be performed via
the USB port which is integrated into the center
console.
G1055657en
2008.50 Kuga 8/2011 415-01-12
Information and Entertainment System
415-01-12
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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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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL213E40968

Fog Lamps
Refer to Wiring Diagrams Section 417-01, for
schematic and connector information.
Special Tool(s)
Terminal Probe Kit
29-011ADescription of operation
A diagnosis of the generic electronic module (GEM)
can be performed with the Ford approved
diagnostic tool. 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
Proceed as follows to activate the service mode:
•
OPERATE the switch of the heated rear window
and HOLD IT THERE
• Turn 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.
NOTE: If the alarm is activated (in vehicles fitted
with an anti-theft alarm system), service mode
cannot be 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:
• Turn signals (right, left, hazard warning lights)
• 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 reservoir fluid level
• Speed control system
• Autolamps
• dipped beam
• main beam
• headlamp flasher
• Marker Lamps
• Reversing lamp
• Liftgate release
• Ignition switch, terminal 15 (turn key to 0 position, then turn key to II position.)
An acoustic signal sounds and the turn signal
lamps flash to indicate receipt of each input signal
by the generic electronic module.
Test the windshield wiper "intermittent mode" stage
input signal (only vehicles with adjustable
intermittent mode)
The windshield wiper switch must be switched to
"intermittent mode" in order to test the input signal.
The delay times of the input signals can then be
tested by operating the rotary switch. Each change
of the rotary switch position is indicated by an
acoustic signal and illumination of the turn signals.
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. Turn Indicator Left Hand
b. Turn Indicator Right Hand
c. main beam
d. dipped beam
e. Windshield wiper stage I
f. Windshield wiper stage II G1055006en
2008.50 Kuga 8/2011 417-01-12
Exterior Lighting
417-01-12
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL29011A

g.
Heated rear window
h. Heater blower motor
i. Headlamp washer system (vehicles with gas discharge headlamps)
j. Electric booster heater (if fitted)
k. Autolamps (if fitted)
l. Alarm horn (vehicles with alarm system)
m. Rear window wiper
n. Rear heated 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.
Ending the service mode
The GEM automatically ends service mode 20
seconds after the last input or at a driving speed
of over 7 km/h. However, service mode can be
manually ended at any time by proceeding as
follows:
• OPERATE the switch of the heated rear window
and HOLD IT THERE
• 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 lamps and license plate lamp in autolamps mode
• Rear wiper
• Headlamp Washers
• Electric booster heater
• Active anti-theft sounder
• 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. Turn 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) forms
part of the central junction box (CJB).
NOTE: If the instrument cluster is changed, it must
be re-configured. For this purpose, the
vehicle-specific data is read out of the module to
be replaced using the Ford approved diagnostic
tool and is transferred to the new module.
NOTE: Before reading out the vehicle-specific data,
remake all the separated electrical connections in
the vehicle, so that communication between the
module and the Ford approved diagnostic tool is
ensured.
1. Verify the customer concern.
2. Visually inspect for obvious signs of electrical damage.
Visual Inspection Electrical
• Fuse(s)
• Lamp(s)
• Bulb(s)
• Connector(s)
• Switch(s)
• Wiring harness
3. Resolve any obvious causes or concerns found during the visual inspection before carrying out
any further tests. G1055006en
2008.50 Kuga 8/2011 417-01-13
Exterior Lighting
417-01-13
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Headlamps
Refer to
Wiring Diagrams Section 417-1, for
schematic and connector information.
Description of operation
A diagnosis of the generic electronic module (GEM)
can be performed with the Ford approved
diagnostic tool. 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
Proceed as follows to activate the service mode:
• OPERATE the switch of the heated rear window
and HOLD IT THERE
• Turn 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.
NOTE: If the alarm is activated (in vehicles fitted
with an anti-theft alarm system), service mode
cannot be 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:
• Turn signals (right, left, hazard warning lights)
• 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 reservoir fluid level
• Speed control system
• Autolamps
• dipped beam
• main beam
• headlamp flasher
• Marker Lamps
• Reversing lamp
• Liftgate release
• Ignition switch, terminal 15 (turn key to 0
position, then turn key to II position.)
An acoustic signal sounds and the turn signal
lamps flash to indicate receipt of each input signal
by the generic electronic module.
Test the windshield wiper "intermittent mode" stage
input signal (only vehicles with adjustable
intermittent mode)
The windshield wiper switch must be switched to
"intermittent mode" in order to test the input signal.
The delay times of the input signals can then be
tested by operating the rotary switch. Each change
of the rotary switch position is indicated by an
acoustic signal and illumination of the turn signals.
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. Turn Indicator Left Hand
b. Turn Indicator Right Hand
c. main beam
d. dipped beam
e. Windshield wiper stage I
f. Windshield wiper stage II
g. Heated rear window
h. Heater blower motor
i. Headlamp washer system (vehicles with gas discharge headlamps)
j. Electric booster heater (if fitted)
k. Autolamps (if fitted)
l. Alarm horn (vehicles with alarm system) G1056684en
2008.50 Kuga 8/2011 417-01-15
Exterior Lighting
417-01-15
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m.
Rear window wiper
n. Rear heated 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.
Ending the service mode
The GEM automatically ends service mode 20
seconds after the last input or at a driving speed
of over 7 km/h. However, service mode can be
manually ended at any time by proceeding as
follows:
• OPERATE the switch of the heated rear window
and HOLD IT THERE
• 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 lamps and license plate lamp in autolamps mode
• Rear wiper
• Headlamp Washers
• Electric booster heater
• Active anti-theft sounder
• 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. Turn 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) forms
part of the central junction box (CJB).
NOTE: If the instrument cluster is changed, it must
be re-configured. For this purpose, the
vehicle-specific data is read out of the module to
be replaced using the Ford approved diagnostic
tool and is transferred to the new module.
NOTE: Before reading out the vehicle-specific data,
remake all the separated electrical connections in
the vehicle, so that communication between the
module and the Ford approved diagnostic tool is
ensured.
1. Verify the customer concern.
2. Visually inspect for obvious signs of electrical damage.
Visual Inspection Electrical
Mechanical
• Fuse(s)
• Bulb(s)
• Lamp(s)
• Connector(s).
• Switch(s)
• Wiring loom
• Headlamp
3. Resolve any obvious causes or concerns found during the visual inspection before carrying out
any further tests.
4. If the cause is not visually evident, verify the symptom and refer to the diagnostic tab within
the Ford approved diagnostic tool. G1056684en
2008.50 Kuga 8/2011 417-01-16
Exterior Lighting
417-01-16
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