belt FORD KUGA 2011 1.G Workshop Manual

Supplemental Restraint System (SRS) Health and SafetyPrecautions
WARNINGS:
Only qualified technicians are allowed to
work on pyrotechnic components.
INHALED: Exposure to pyrotechnic residue
may cause low blood pressure, severe
headache, irritation of mucous membranes,
fainting, shortness of breath or rapid pulse.
Move a victim to fresh air. Seek immediate
medical attention.
EYE CONTACT: Exposure to unburned
pyrotechnic residue may cause irritation,
burning and etching of the eyes. Flush
immediately with plenty of cold running
water for at least 15 minutes. Seek
immediate medical attention.
EYE CONTACT: Exposure to burned
pyrotechnic residue may cause irritation,
burning and etching of the eyes. Flush
immediately with diluted boric acid
solution. Seek immediate medical
attention.
SKIN CONTACT: Unburned pyrotechnic
residue may be rapidly absorbed through
the skin in toxic quantities. Wash
immediately with plenty of soap and water.
Seek medical attention.
SKIN CONTACT: Burned pyrotechnic
residue may be rapidly absorbed through
the skin in toxic quantities. Wash with
plenty of water. Do not use soap. Seek
medical attention.
SWALLOWED: Unburned pyrotechnic
residue is extremely toxic. If conscious
drink plenty of water then induce vomiting.
Seek immediate medical attention. If
unconscious, or in convulsions do not
attempt to induce vomiting or give
anything by mouth. Seek immediate
medical attention.
SWALLOWED: Burned pyrotechnic residue
is extremely toxic. Drink plenty of water
and seek immediate medical attention.
The deployment key must only be
accessible to authorized personnel.
Make sure that the deployment key remains
removed from the deployment equipment
except during deployment.
If permenantly disabling or enabling the
passenger air bag a new seat belt for
vehicles without or with a passenger air
bag must be installed.
Undeployed pyrotechnic components must
not be deployed in the vehicle.
Pyrotechnic components must be deployed
following local regulations.
Check thoroughly that no loose objects
can be spread during the deployment of
pyrotechnic components.
Pyrotechnic components must be
transported following local regulations.
Never carry out any electrical measurement
on disconnected, undeployed pyrotechnic
components.
Pyrotechnic components must not be
disassembled.
Pyrotechnic components are not
interchangeable between vehicles.
Always carry a live air bag module away
from the body with the air bag or trim cover
pointing upwards.
Live air bag modules must be placed in a
suitable cage when removed from the
vehicle. The air bag or trim cover must be
facing upwards.
Do not install a rearward facing child safety
seat to the passenger seat with an
activated passenger air bag.
CAUTIONS:
Pyrotechnic components must not be
subjected to temperatures higher than
110°C.
Never install aftermarket accessories to
the vehicle on or adjacent to the
supplemental restraint system module.
G548998en2008.50 Kuga8/2011
100-00- 65
General Information
100-00- 65
DESCRIPTION AND OPERATION
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sometimes noticed in the steering wheel/column,
seats, front floor panel, front door trim panel or
front end sheet metal. It is a low frequency
vibration (around 9-15 cycles per second). It
may or may not be increased by applying the
brakes lightly. REFER to Idle
Boom/Shake/Vibration in the Driveline Noise
and Vibration Symptom Chart.
3. High Speed: A vibration is felt in the front floor panel or seats with no visible shake, but with
an accompanying sound or rumble, buzz, hum,
drone or booming noise. Coast with the clutch
pedal depressed (manual transmission) or shift
control selector lever in "N" (NEUTRAL)
(automatic transmission) and engine idling. If
vibration is still evident, it may be related to
wheels, tires, front brake discs, wheel hubs or
front wheel bearings. REFER to Shake and
Vibration While Driving in the Driveline Noise
and Vibration Symptom Chart.
4. Engine rpm Sensitive: A vibration is felt whenever the engine reaches a particular rpm.
It will disappear in neutral coasts. The vibration
can be duplicated by operating the engine at
the problem rpm while the vehicle is stationary.
It can be caused by any component, from the
accessory drive belt to the clutch or torque
converter which turns at engine speed when the
vehicle is stopped. REFER to Shake and
Vibration While Driving in the Driveline Noise
and Vibration Symptom Chart.
5. Noise and Vibration While Turning: Clicking, popping or grinding noises may be due to the
following:
• worn, damaged or incorrectly installed front wheel bearing.
• damaged powertrain/drivetrain mounts.
Road Conditions
An experienced technician will always establish a
route that will be used for all NVH diagnosis road
tests. The road selected should be reasonably
smooth, level and free of undulations (unless a
particular condition needs to be identified). A
smooth asphalt road that allows driving over a
range of speeds is best. Gravel or bumpy roads
are unsuitable because of the additional road noise
produced. Once the route is established and consistently used, the road noise variable is
eliminated from the test results.
NOTE:
Some concerns may be apparent only on
smooth asphalt roads.
If a customer complains of a noise or vibration on
a particular road and only on a particular road, the
source of the concern may be the road surface. If
possible, try to test the vehicle on the same type
of road.
Vehicle Preparation
Carry out a thorough visual inspection of the
vehicle before carrying out the road test. Note
anything which is unusual. Do not repair or adjust
any condition until the road test is carried out,
unless the vehicle is inoperative or the condition
could pose a hazard to the technician. After
verifying that the condition has been corrected,
make sure all components removed have been
installed.
Power Steering Conditions
Check for the noise in the following conditions to
verify the customer concern.
• Check for the noise in several temperature conditions.
• Is the noise from when the vehicle was new?
• Can the noise be repeated constantly or is it random?
• Check the condition of the vehicle age, mileage and service record.
• Interview the customer to find the operating condition in which the noise will occur. Test the
vehicle based on the detail(s) from the customer
interview.
• Follow the power steering operation noise condition tables below, to find which condition
the noise will occur.
Power Steering Operation Noise Check
Step 1: Check for NVH concerns from non-steering
components, which may sound like noises coming
from the steering system.
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100-04- 4
Noise, Vibration and Harshness
100-04- 4
DIAGNOSIS AND TESTING
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Action
Possible Sources
Symptom
GO toPinpoint Test C.
• Cable(s)/hose(s).
• Powertrain/drivetrain mounts.
• Exhaust system.
• Belt/pulleys.
Idle boom/shake/vibration/
shudder
Suspension Noise and Vibration
Action
Possible Sources
Symptom
GO toPinpoint Test D.
• Suspension.
• Wheel bearings.
Wheel end vibration analysis
GO toPinpoint Test E.
• Trim panels.
• Air conditioning (A/C) system.
• Accessories.
Non-axle noise
Pinpoint Tests
NOTE:
These Pinpoint Tests are designed to take
the technician through a step-by-step diagnosis
procedure to determine the cause of a condition.
It may not always be necessary to follow the chart
to its conclusion. Carry out only the pinpoint test steps necessary to correct the condition. Then
check the operation of the system to make sure
the condition has been corrected.
After verifying that the condition has been
corrected, make sure all components removed
have been installed.
PINPOINT TEST A : SHAKE AND VIBRATION WHILE DRIVING
DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
A1: NEUTRAL COAST
1 Carry out the neutral coast test.
• Does the vibration disappear during the neutral coast test?
zYe s
GO to A2.
zNoGO to Pinpoint Test D.
A2: CHECK THE POWERTRAIN/DRIVETRAIN MOUNTS
1 Carry out the powertrain/drivetrain mount neut-
ralizing procedure
• Are the mounts OK?
zYe s Vehicle condition corrected. ROAD TEST as
necessary.
zNoINSTALL new powertrain/drivetrain mounts
as necessary. ROAD TEST as necessary.
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Noise, Vibration and Harshness
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DIAGNOSIS AND TESTING
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PINPOINT TEST B : TIP-IN MOAN
DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
B1: CHECK THE AIR CLEANER
1 Check the condition of the air cleaner mounts,
inlet tube, outlet tube, resonators and all other
components associated with the air induction
system for correct installation and tightness of
all connections.
• Are the components OK?
zYe s GO to B2.
zNoREPAIR or INSTALL new components as
necessary. ROAD TEST as necessary.
B2: CHECK THE EXHAUST SYSTEM
1 Carry out the exhaust system neutralizing
procedure.
• Is the exhaust system OK?
zYe s GO to B3.
zNoREPAIR as necessary. ROAD TEST as
necessary.
B3: CHECK THE POWER STEERING
1 Remove the accessory drive belt and test for
tip-in moan. REFER to:
Accessory Drive Belt (303-05 Accessory Drive
- 2.5L Duratec (147kW/200PS) - VI5, Removal
and Installation),
• Is the tip-in moan OK?
zYe s REPAIR the power steering as necessary.
REFER to: Steering System (211-00 Steering
System - General Information, Diagnosis
and Testing).
zNo
GO to B4.
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Noise, Vibration and Harshness
100-04- 15
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Instrument Cluster
Refer to
Wiring Diagrams Section 413-01, 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)
– Instrument cluster
– Light emitting diode(s) (LED)(s)
– Engine oil filter
– Engine oil level
–
Engine coolant level
– Oil pressure switch
– Engine coolant level
– Coolant thermostat
– Engine coolant temperature (ECT)
sensor
– Fuel gauge
– Collapsed or damaged fuel tank
– Recirculation hose
– Fuel tank filler pipe/hose
– Indicated fuel level
– Fuel lines
– Fuel tank filler cap
– Fuel filter (external to the fuel tank)
– Fuel tank
– Door adjustment
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. NOTE: If none of the following warning indicators are operating correctly this may
indicate a concern with the central junction
box (CJB). If only one or two of the following
warning indicators are not operating
correctly this may indicate an instrument
cluster concern. Verify the following warning indicators are
working correctly:
• Charging.
• Turn signals.
• Headlamps.
5. If the cause is not visually evident, verify the symptom and refer to the diagnostic tab within
the Ford approved diagnostic tool.
Configuration of the Instrument Cluster
The instrument cluster is a programmable module,
which must be configured by selecting the
Programmable Module Installation Routine on the
Ford approved diagnostic tool.
NOTE: When the new instrument cluster has been
configured with the odometer value, its
configuration cannot be decreased or matched. A
new configuration will result in an increase in the
displayed odometer value by a minimum of two
units.
NOTE: The odometer value must be recorded from
the original instrument cluster before removal.
If the odometer value cannot be obtained from
the original instrument cluster (display failure)
the customer should supply the approximate
value.
The following features will need to be configured
when a new instrument cluster is installed:
• Anti-lock Brake System (ABS)
• All wheel drive
• Keyless vehicle entry
• Electronic power assisted steering
• Trip computer
• Voice control
• Parking aid
• Belt minder
• Safety belt not fastened
• Right hand drive
• Overspeed warning
• Reverse warning
• Turbocharger boost pressure
• Speed control
• Auxiliary heater
• Suspension control
• Washer fluid sensor G1054964en
2008.50 Kuga 8/2011 413-01-7
Instrument Cluster
413-01-7
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SECTION 413-09 Warning Devices
VEHICLE APPLICATION:
2008.50 Kuga
PAGE
CONTENTS
DIAGNOSIS AND TESTING
413-09-2
Warning Devices.................................................................................................................
413-09-2
Inspection and Verification..................................................................................................
GENERAL PROCEDURES 413-09-3
Safety Belt Minder Deactivating/Activating.........................................................................
413-09-3
Preparation .........................................................................................................................
413-09-3
Deactivating/Activating .......................................................................................................
413-09-4
Oil Change Indicator Reset................................................................................................ 413-09-1
Warning Devices
413-09-1
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Warning Devices
Refer to
Wiring Diagrams Section 501-20B, 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 mechanical
or electrical damage.
Visual Inspection Chart Electrical
Mechanical
– Wiring harness
– Electricalconnector(s)
– Safety belt buckle switch
– Restraints control module
– Safety belt buckle
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 diagnostic
equipment to diagnose the system. G1055053en
2008.50 Kuga 8/2011 413-09-2
Warning Devices
413-09-2
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Safety Belt Minder Deactivating/Activating
Preparation
1. Apply the parking brake.
2. Place the transmission selector lever in P
(Park) - vehicles with automatic transmission
or the neutral position - vehicles with manual
transmission.
3. Turn the ignition switch to the 0 position.
4. Close all the vehicle doors from the inside of the vehicle.
Deactivating/Activating
NOTE: Deactivation of the belt minder may also
be carried out using IDS. Follow the instructions
on the screen.
1. Unbuckle the drivers safety belt.
2. Turn the ignition switch to position II. (Do not start the engine).
3. Wait at least 15 seconds.
4. NOTE: This step must be completed within 60 seconds or the procedure must be
repeated.
Buckle then unbuckle the safety belt nine
times, ending with the safety belt unbuckled.
Release the red unbuckle switch completely
every cycle.
5. The safety belt warning indicator flashes three times to confirm the belt minder status
change.
6. Turn the ignition switch to position 0. The deactivation/activation procedure is now
complete. G167271en
2008.50 Kuga 8/2011 413-09-3
Warning Devices
413-09-3
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Charging System
Refer to Wiring Diagrams Section 414-02, for
schematic and connector information.
General Equipment
Midtronics EXP-1050 battery tester
Midtronics GR590-2
Ford diagnostic equipment
Inspection and Verification
WARNINGS: Batteries contain sulphuric acid. Avoid
contact with skin, eyes, or clothing. Also,
shield your eyes when working near
batteries to protect against possible
splashing of the acid solution. In case of
acid contact with skin or eyes, flush
immediately with water for a minimum of
15 minutes and get prompt medical
attention. If acid is swallowed, call a
physician immediately. Failure to follow
these instructions may result in personal
injury.
Batteries normally produce explosive
gases which can cause personal injury.
Therefore, do not allow flames, sparks or
lighted substances to come near the
battery. When charging or working near a
battery, always shield your face and
protect your eyes. Always provide
ventilation. Failure to follow these
instructions may result in personal injury.
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(es)
– Generator
– Electricalconnector(s)
– Battery junction box (BJB)
– Battery
– Battery cables
– Battery monitoring sensor (BMS)
– Charging system warning indicator
–
Accessory drive belt
– Generator
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. Check the operation of the charging system warning indicator lamp, located in the instrument
cluster. Normal operation is as follows:
Normal Charging System Voltages Charging System
Warning Indicator Operation
Engine to
battery ground
Battery
Gener-
ator B+ Circuit
I Circuit
Ignition Switch
Position
OFF
0V
10-12V
10-12V
0V
Position 0
Illuminated
0V
10-12V
10-12V
0V
Position II
OFF
0V
13-15V
13-15V
13-15V
Position II with
the engine
running
5. If the cause is not visually evident, verify the symptom and refer to the Component Tests. Component Tests
Generator On-Vehicle Tests - No-Load Test
1. Turn off all electrical loads and the ignition
switch. G1055063en
2008.50 Kuga 8/2011 414-00-2
Charging System - General Information
414-00-2
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Steering Column – Overview
General overview
E98628
1
2
3
4
5
6
7
8
9
Description
Item
Driver airbag
Refer to: Air Bag and Safety Belt
Pretensioner Supplemental Restraint
System (SRS) (501-20 Supplemental
Restraint System, Description and
Operation).
1
Steering wheel
2
Switch unit, steering column
Refer to: Steering Column Switches
(211-05 Steering Column Switches,
Description and Operation).
3Description
Item
Steering column lower shroud
4
Steering column upper shroud
5
Steering Column
6
Steering lock
7
Extension, steering shaft
8
Steering gear to bulkhead seal
9
G1030751en2008.50 Kuga8/2011
211-04- 2
Steering Column
211-04- 2
DESCRIPTION AND OPERATION
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