connectors FORD KUGA 2011 1.G Workshop Manual

Powertrain LH and RH definition
E126781
1
2
3
4
Description
Item
front
1
right hand
2
rear
3
left hand
4
How to use Repair Procedures
This manual has been written in a format that is
designed to meet the needs of technicians
worldwide. It provides general descriptions for
accomplishing repair work with tested and effective
techniques.
Important Safety Instructions
Appropriate service methods and correct repair
procedures are essential for the safe and reliable
operation of all vehicles as well as the personal
safety of the individual carrying out the work.
Anyone who departs from the instructions provided
in this manual must first establish that personal safety or vehicle integrity is not compromised by
the choice of method, tools or components.
Warnings, Cautions and Notes in This
Manual
WARNING: Warnings are used to indicate
that failure to follow a procedure correctly
may result in personal injury.
CAUTION: Cautions are used to indicate
that failure to follow a procedure correctly
may result in damage to the vehicle or
equipment being used.
NOTE: Notes are used to provide additional
essential information required to carry out a
complete and satisfactory repair.
Generic warnings or cautions are in their relevant
description and operation procedure within section
100-00. If the generic warnings or cautions are
required for a procedure, there will be a referral to
the appropriate description and operation
procedure.
If a warning, caution or note only applies to one
step, it is placed at the beginning of the specific
step.
Global Authoring Standards (GAS) Repair
Procedures
NOTE: GAS style procedures can be identified by
steps that have no accompanying step text and
the magenta color of the electrical connectors and
fasteners such as nuts, bolts, clamps or clips.
A GAS removal and installation procedure uses a
sequence of color illustrations to indicate the order
to be followed when removing/disassembling or
installing/assembling a component.
Many of the GAS procedures will have the
installation information within the removal steps.
These procedures will have the following note at
the beginning of the procedure:
NOTE: Removal steps in this procedure may
contain installation details.
Reuse of fasteners and seals and gaskets
The following list details the general policy for the
reuse of fasteners and seals and gaskets.
G836098en2008.50 Kuga8/2011
100-00- 4
General Information
100-00- 4
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numerically in a graphic and the corresponding text
will be numbered accordingly.
Special Tools, Equipment, Materials and Torque
Figures
Special tools will be shown with the tool numbers
in the illustration. The special tool numbers, general
equipment, materials and torque figures used for
the procedure step will be shown in the text
column.
GAS Graphics
NOTE:Colors used in the graphic are as follows:
4
6
5
14
2
36
5
E141161
Description
Item
Blue - Target or primary component to be
removed/installed (or
disassembled/assembled).
1
Green - Components that need to be
removed prior to or installed after the
target/primary.
2
Description
Item
Brown - Components that need to be
removed prior to or installed after the
target/primary.
3
Yellow - Components to be set aside only,
that remains in the vehicle. Also
highlighted areas to inspect or adjust.
4
Magenta - Electrical connectors and
fasteners such as nuts, bolts, clamps, or
5
clips to be: detached, attached, loosened,
moved, removed or installed.
Pale Blue - Special tool(s), general
equipment, or common tools (used in an
uncommon way).
6
One illustration may have multiple steps assigned
to it.
Numbered pointers are used to indicate the number
of electrical connectors and fasteners such as nuts,
bolts, clamps and clips.
Items in the illustration can be transparent or use
cutouts to show hidden details.
E132042
x2
1
2
3
G836098en2008.50 Kuga8/2011
100-00- 6
General Information
100-00- 6
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TIM0103001
WARNING: Make sure that the ends of the
jumper cables do not touch each other or
ground against the vehicle body at any
time while the cables are attached to the
battery. A fully charged battery, if shorted
through jumper cables, can discharge at
a rate well above 1000 amps causing
violent arcing and very rapid heating of the
jumper cables and terminals, and can even
cause the battery to explode. Failure to
follow these instructions may result in
personal injury.
Always connect the jumper cables in the following
sequence:
– Slave battery positive first and then vehicle battery positive.
– Slave battery negative next and then vehicle ground at least 12 inches (300 mm) from the
battery terminal, for example engine lifting eye.
Always reduce the engine speed to idle before
disconnecting the jumper cables.
Before removing the jumper cables from the vehicle
that had the discharged battery, switch on the
heater blower (high) or the heated rear window, to
reduce the voltage peak when the cables are
removed.
Always disconnect the jumper cables in the reverse
order to the connecting sequence and do not short
the ends of the cables.
Do not rely on the generator to restore a
discharged battery. For a generator to recharge a
battery, it would take in excess of eight hours
continuous driving with no additional loads placed
on the battery.
Component Cleaning
To prevent the ingress of dirt, accumulations of
loose dirt and greasy deposits should be removed before disconnecting or dismantling components
or assemblies.
Components should be thoroughly cleaned before
inspection prior to reassembly.
Cleaning Methods:
– Dry cleaning.
– Removal of loose dirt with soft or cable brushes.
– Scraping dirt off with a piece of metal or wood.
– Wiping off with a rag.
WARNING: Wear eye protection when
cleaning vehicle components with
compressed air, a steam cleaner or a
power washer. Failure to follow this
instruction may result in personal injury.
CAUTIONS:
Compressed air is sometimes 'wet' so use
with caution, especially on hydraulic
systems.
To prevent damage to the electrical
connectors in the engine compartment, do
not use a steam cleaner or a power washer
to clean the engine compartment.
– Blowing dirt off with compressed air.
– Removal of dry dust using vacuum equipment. This method must always be used to remove
friction lining material dust (asbestos particles).
– Steam cleaning.
WARNING: Most solvents require careful
handling and some are harmful. Refer to
Health and Safety Precautions and to the
manufacturers literature for the relevant
safety precautions. Failure to follow these
instructions may result in personal injury.
Various solvents are available which are suitable
for component cleaning. Some components, such
as brake hydraulic parts and electrical assemblies
should be cleaned only with recommended solvents
— refer to Solvents, Sealers and Adhesives or to
the section of the manual relevant to the
component.
Calibration of Essential Measuring
Equipment
WARNING: Equipment, which requires
regular calibration, must be calibrated in
accordance with the manufacturers
G17373en2008.50 Kuga8/2011
100-00- 55
General Information
100-00- 55
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Component Description
Rear parking aid speaker
The rear parking aid speaker, in addition to its
actual function, is also used for audible indication
of various types of error in the front and rear
parking aids. If the rear parking aid speaker
becomes defective, the front parking aid speaker
will then be used to indicate failure modes.
If an error is detected in the system, a signal tone
is emitted via the speaker for 3 seconds.
Parking aid sensors
CAUTIONS:
Always keep sensors free from dirt, ice and
snow. Do not use any sharp objects to
clean the sensors.
If a high-pressure cleaner is used to wash
the vehicle, the jet must only be aimed at
the sensors briefly at a distance of at least
20 cm.
The parking aid sensor consists of the following:
• Plastic housing
• Aluminum membrane with Piezo disc
• Decoupling ring
• Printed circuit board (PCB)
The parking aid sensor consists of a sensor and a
holder. The holder makes sure that each parking
aid sensor is correctly orientated in relation to its
location in the rear bumper.
The sensors have a 3-pin connector which is
connected to the wiring harness of the front
bumper. This in turn is connected to the main body
wiring harness. Three pins provide for power
supply, ground and signal lines to and from the
parking aid module. The disc resonates at a frequency of ca. 50kHz,
producing the ultrasonic output. The disc also
receives the reflected echo signal from any objects
within range.
Parking aid module
The parking aid module has three connectors which
provide for power, ground and MS CAN bus
connections, as well as the front and rear parking
aid sensors, the parking aid switch and parking aid
speaker.
The parking aid module carries out self-check
routines and when the parking aid is active, checks
the parking aid sensor wiring for short or open
circuits. If a concern is detected, a diagnostic
trouble code (DTC) is stored in a memory in the
parking aid module and the front and rear parking
aid sensors will be disabled until the DTC is cleared
and the ignition cycled. The driver recognizes a
problem through the flashing LED and a shrill
continuous tone, which is emitted for 3 seconds
when the parking aid is activated. If the parking aid
is working properly, short tones are emitted instead
of this continuous tone. DTCs can be read using
the Ford approved diagnostic tool through the data
link connector (DLC).
G1034399en
2008.50 Kuga 8/2011 413-13-15
Parking Aid
413-13-15
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUALE89773 E89772

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)
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 generic electronic module (GEM) is
changed, the new one must be reconfigured. 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. REFER to: (418-00 Module
Communications Network)
Communications Network (Description and
Operation),
Communications Network (Description and
Operation).
NOTE: Before reading out the vehicle-specific data,
remake all the electrical connections which were
separated 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:
NOTE: Ensure correct engagement of the wiring
harness connectors. G1055008en
2008.50 Kuga 8/2011 417-01-22
Exterior Lighting
417-01-22
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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
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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

Wiring Harness
General Equipment
Ford approved diagnostic tool
Inspection and Verification
1. Verify the customer concern. 2. Check the electrical connectors for security,
damage and incorrect connection. If the
electrical connectors are broken, damaged or
incorrectly connected, repair or replace the
components as required. TEST the system for
normal operation before proceeding to the next
step. 3. Disconnect the electrical connectors and check
for the following:
• Moisture in the connector due to misaligned, damaged or missing seals.
• Contamination from leaking fluids in the region of the connector. • Damaged or oxidised connector pins.
•
Disengaged connector pins (this can be checked
by carefully pressing on the individual pins).
4. If any of the conditions listed are present, repair or replace the components as required. TEST
the system for normal operation before
proceeding to the next step. G1021921en
2008.50 Kuga 8/2011 418-02-2
Wiring Harnesses
418-02-2
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUALE61215

1.
Wiring harness.
2. Component.
5. Check the wiring harness for the following:
• Incorrect routing or installed too tightly.
• Pinched or kinked sections.
• Chafed insulation.
• Security and orientation of retaining clips.
• Damage in areas where the wiring harness is subjected to noise, vibration and harshness
(NVH). For example, transmission or suspension
systems.
6. If any of the conditions listed are present, repair or replace the components as required. TEST
the system for normal operation. If the concern
persists, REFER to the digital multimeter
function of the Ford approved diagnostic tool to
check the integrity of the wiring harness and
electrical connectors. G1021921en
2008.50 Kuga 8/2011 418-02-3
Wiring Harnesses
418-02-3
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUALE6121621

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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