gem module FORD KUGA 2011 1.G Workshop Manual

Description
Item
Electric Booster HeaterRefer to Component Description: (page
?)
1
GEM (generic electronic module)
2
Outside temperature sensor
3
Climate control system control assembly
4 Description
Item
Generator and Alternator
5
PCM (powertrain control module)
6
Coolant temperature sensor (ECT (engine
coolant temperature) sensor)Refer to Component Description: ECT
(page ?)
7
instrument cluster
8 G1066982en
2008.50 Kuga 8/2011 412-02-7
Auxiliary Climate Control
412-02-7
DESCRIPTION AND OPERATIONTO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

reprogrammed. However, if the engine hasn't been
run since the last programmed start, the fuel-fired
booster heater will not start up the second time so
as to prevent the battery from being discharged.
The length of time required to pre-heat the vehicle
is calculated in the control unit of the fuel-fired
booster heater and is based on two temperature
values:
• Ambient air temperature: this message is taken
from the GEM via the CAN bus.
• Coolant temperature: this is determined via an internal sensor in the fuel-fired booster heater.
The maximum heating time is 30 minutes at an
outside air temperature of -10 °C or lower. The
heating time decreases proportionally with
increasing ambient temperature until the ambient
temperature is between +15 °C and +20 °C. Then
the minimum heating time is 10 minutes. The
parking heater is deactivated at temperatures
above +20 °C.
The sequence for a programmed start of the
booster heater is as follows:
• Two minutes before the start of the maximum heating time the driver information
system/instrument cluster sends an activation
message to the fuel-fired booster heater via the
CAN bus.
• The fuel-fired booster heater calculates the required heating time and, if necessary, sends
a delay request on the CAN bus.
• At the calculated time, the fuel-fired booster heater starts up. The conditions for start-up are:
engine not running and amount of fuel in the
fuel tank is above 14% of maximum.
• When the coolant temperature reaches +30 °C, the control unit of the fuel-fired booster heater
sends a request to switch on the passenger
compartment blower.
• Eight minutes after the programmed switch-off time, the booster heater stops heating mode
and starts a run-on operation to clean the
system's spark plugs.
• Ten minutes after the switch-off time, the post-cleaning operation is complete. The
additional ten minutes run-on time provides
some leeway in case the driver is late arriving.
After a programmed start-up of the booster heater
it is switched off again after the heating time has
elapsed (or if the fuel level in the fuel tank drops
below 8%). The booster heater stops within 2 minutes of the engine starting. This leaves enough
time to check whether the switch-on conditions for
boost heat mode have been met, thus preventing
the booster heater from having to switch off and
switch back on again. The heater can be switched
off manually at any time from the menu.
Whilst the fuel-fired booster heater is in additional
heating mode and/or parking heating mode, the
instrument cluster receives a fuel consumption
signal; this is used to re-calculate the vehicle's
remaining range and fuel consumption data.
Emergency shutoff
In the event of an accident in which the airbags
are deployed, the control unit of the fuel-fired
booster heater receives a message on the CAN
bus from the restraints control module (RCM).
When this message is received, the booster heater
system switches off immediately.
The booster heater control module deactivates the
system and does not respond to further messages
on the CAN bus. The booster heater control module
needs to be activated with WDS.
Component Description
Electric Booster Heater
The electric booster heater consists of three
individual heating elements, which are incorporated
into a single housing. It is controlled by the generic
electronic module (GEM), taking into account the
following factors:
Detailed illustration of fuel-fired heater
G1066982en
2008.50 Kuga 8/2011 412-02-14
Auxiliary Climate Control
412-02-14
DESCRIPTION AND OPERATIONTO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUALE97621

Description
Item
Instrument Cluster
1
PCM (powertrain control module)
2
EHPS (electro-hydraulic power steering)
control module
3
Audio unit
4
GEM (generic electronic module)
5
RCM (restraints control module)
6
PATS transceiver
7 Description
Item
Steering wheel lock module
8
Left-hand steering column switch
9
Fuel level sensor
10
Washer water level warning lamp switch
11
Accelerator pedal position sensor
12
CPP (clutch pedal position) sensor/BPP
(brake pedal position) sensor
13
Lighting control switch
14
System Operation
Instrument Cluster
The instrument cluster contains analog displays
as well as warning and control lamps for displaying
the system status; in addiiton, there is an LCD
indicator field for driver information.
The instrument cluster receives the following
signals from the PCM via the high speed CAN
(controller area network) Bus (HS-CAN):
• Vehicle speed – The PCM receives the necessary signalsfrom the ABS (anti-lock brake system) wheel
sensors from the ABS control unit on the
HS-CAN.
• Engine Coolant Temperature
• Engine oil pressure.
• Engine speed
The instrument cluster receives the following
signals from the GEM via the medium speed CAN
Bus (MS-CAN):
• Ambient temperature
• Brake fluid level
• Handbrake control
• Door latch control
• Liftgate latch control
• High beam control
• Headlamp flasher control
• Direction indicator control
The fuel level signal is sent by the two fuel level
sensors in the fuel pumps in the semitrailer tank,
which is wired to the instrument cluster. The
sensors are connected in series, and the total
resistance is determined from the two individual resistors. The instrument cluster converts the raw
fuel level signal into a damped fuel level value.
The odometer shows the total distance travelled
by the vehicle and is based on the same signal as
is processed for the daily mileage counter. The
value is recorded by the instrument cluster and
stored in a protected EEPROM (Electronically
Erasable Programmable Read Only Memory) area.
This area is a memory protected against
manipulation. If the instrument cluster detects an
error in this memory area, e.g. through damage,
the driver is notified with the "Odometer error"
message.
Message center
The message center is operated using the left-hand
switch on the steering column.
The SET/RESET button is activated to select a
submenu and change the settings. If signal tones
have been activated, a short acoustic signal will
sound each time a button is pressed.
By turning the rotary switch, the different menu
displays can be scrolled through or a setting
selected.
In this display, the navigation system can also
display direction and distance information.
In addition, safety and warning messages can be
displayed in this system, such as "Coolant
overheating", "Engine system error" or "Washer
fluid level too low". In addition to a safety message,
a general warning light (red/yellow) lights up.
G1030770en
2008.50 Kuga 8/2011 413-01-4
Instrument Cluster
413-01-4
DESCRIPTION AND OPERATIONTO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Description
Item
Parking aid moduleRefertoComponentDescription:(page
15)
1
Rear parking aid speakerRefertoComponentDescription:(page
15)
2
Generic Electronic Module (GEM)
3
Reverse gear switch
4
Instrument cluster
5
ABS sensor assembly
6
ABS7 Description
Item
Trailer relay
8
Rear parking aid sensorRefer to Component Description: Parking
aidsensors(page15)
9
Rear parking aid sensorRefer to Component Description: Parking
aidsensors(page15)
10
Rear parking aid sensorRefer to Component Description: Parking
aidsensors(page15)
11
Rear parking aid sensorRefer to Component Description: Parking
aidsensors(page15)
12 G1034399en
2008.50 Kuga 8/2011 413-13-8
Parking Aid
413-13-8
DESCRIPTION AND OPERATIONTO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Description
Item
Rear parking aid sensorRefer to Component Description: Parking
aid sensors (page ?)
7
Rear parking aid sensorRefer to Component Description: Parking
aid sensors (page ?)
8 Description
Item
Rear parking aid sensorRefer to Component Description: Parking
aid sensors (page ?)
9
steering angle sensor
10
Navigation device
11
System Operation
Parking Aid WARNING: It is the driver's responsibility
to stay alert during reversing procedures.
The system may fail to detect small
children or animals.
CAUTION: The driver is responsible for
detecting obstacles and judging the
distance between these and the vehicle.
The system may fail to detect some
hanging objects, barriers, narrow obstacles
or painted surfaces, which could damage
the vehicle. Always pay attention when
parking.
The parking aid provides an audible warning to the
driver if there are any obstacles in front of or behind
the vehicle during reverse parking maneuvers.
At low speeds, the parking aid module uses the
parking aid sensors to monitor the area around the
vehicle. If an object is detected within a monitored
area, the parking aid module emits a warning tone
using the respective parking aid speaker.
The rear parking aid is switched on with the
ignition. However, it is only enabled when reverse
gear is selected.
The front and rear parking aid is always switched
off when the ignition is switched on. It is switched
on when reverse gear is selected or if the parking
aid switch in the center console is actuated up to
a speed of 16 km/h.
The parking aid is switched off when the vehicle is
travelling forwards at more than 16 km/h or if the
parking aid switch in the center console is actuated
again.
When the parking aid module activates the system,
the parking aid switch LED is illuminated. If the
vehicle is only fitted with the rear parking aid, there
is no switch.
The parking aid sensors emit a series of ultrasonic
impulses and switch to receiver mode to receive the echo reflected by an obstacle within the
detection range. The received echo signals are
amplified and converted from an analog signal to
a digital signal by the sensor. The digital signal is
passed to the parking aid module and compared
with pre-programmed data stored in an EEPROM
within the module. The module calculates the
distance to the obstacle by measuring the time
taken between the emitted and received impulses.
If no objects are detected there are no further
warning tones. If an object is detected, repeated
audible tones are emitted from either parking aid
speaker(s) as appropriate. The time delay between
the tones decreases as the distance between the
object and the vehicle decreases, until at
approximately 250 mm (10 inches), the audible
tone becomes continuous.
If the distance between the obstacle and the
vehicle does not decrease, the warning tone
remains constant if the object has been detected
by an internal parking aid sensor. If the obstacle
was detected by an external sensor and the
distance remains unchanged, the warning tone
stops after 3 seconds.
The parking aid module continues to monitor the
distance and will resume the warning tones if a
decrease in distance is detected.
If a trailer is connected to the vehicle, a signal is
sent to the GEM (generic electronic module) via
the trailer relay. This signal is sent to the parking
aid module via the MS CAN bus. When the parking
aid module detects that a trailer is connected to
the vehicle, the rear parking aid sensors are
disabled to prevent constant warnings due to the
close proximity of the trailer.
G1034399en
2008.50 Kuga 8/2011 413-13-12
Parking Aid
413-13-12
DESCRIPTION AND OPERATIONTO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Generator
General information
The powertrain control module (PCM) controls the
alternator charging voltage. The connection
between the PCM and the generator is made via
the control module subnetwork (LIN) bus.
If the load on the alternator is high, the PCM can
increase the idle speed.
The alternator is temporarily deactivated during
engine starting so that the engine drag moment is
minimized and it is reactivated again after the
starting procedure.
The PCM controls the charge control lamp in the
instrument cluster via the controller area network
(CAN) bus.
Smart Charge system
In addition to the familiar functions, the Smart
Charge system also performs the following
functions:
•
Automatic deactivation of non-critical high power
electrical consumers when the battery voltage
is low in order to reduce the level of current
drawn.
• Automatic activation of non-critical high power electrical consumers when the battery voltage
is excessively high in order to protect
components which are sensitive to increased
voltages.
The battery charging current is optimized through
continuous calculation of the battery temperature
and monitoring of the alternator output voltage.
By receiving the forwarded alternator load signal,
the PCM is given early warning whenever an
electric consumer is switched on or off. This means
that the PCM receives information about imminent
changes in the torque drawn by the alternator. By
evaluating this information the PCM can provide a
higher level of idling stability.
The two remaining functions of the Smart Charge
System are controlled by the GEM.
Electrical consumers are switched off due to low
voltage when the GEM determines (on the basis
of the message received from the PCM on the CAN
bus via the instrument cluster) that the battery
voltage has dropped below the threshold.
When the threshold for low battery voltage is
reached the GEM automatically deactivates the following consumers - in this order and with a gap
of 5 seconds between each:
• Electric booster heater (vehicles with diesel
engines)
• Heated exterior mirrors
• Heated rear window
• Heated windscreen
If the battery voltage rises back above the lower
threshold then the GEM re-enables all of the
electrical consumers which were previously
disabled. They then have switched off status and
must be switched back on by the driver.
Electrical consumers are switched on due to
excessively high voltage if the GEM determines
that the battery voltage is above the threshold for
overvoltage and the charge control lamp has been
switched on.
When the threshold is reached the GEM
automatically activates the following consumers -
in this order and with a gap of 5 seconds between
each:
• Heated rear window
• Heated exterior mirrors
• Electric booster heater (vehicles with diesel engines)
• Blower motor
If the battery voltage drops back below the
threshold then the GEM automatically deactivates
any consumers that were switched on. However,
if they were switched on by the driver before the
automatic activation, they will then be switched on
again in turn with a 5-second time interval. G964174en
2008.50 Kuga 8/2011 414-02-2
Generator and Regulator
414-02-2
DESCRIPTION AND OPERATIONTO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Description
Item
In-car entertainment
1
Genetic electronic module (GEM).
2
instrument cluster
3
ABS4
ABS sensor assembly
5
Rear LH mid/bass range speaker
6
Rear RH mid/bass range speaker
7 Description
Item
AUX port
8
Radio remote control.
9
FM/AM antenna
10
Front LH mid/bass speaker
11
Front RH mid/bass speaker
12
Front LH tweeter
13
Front RH tweeter
14 G1055647en
2008.50 Kuga 8/2011 415-01-6
Information and Entertainment System
415-01-6
DESCRIPTION AND OPERATIONTO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Description
Item
In-car entertainment
1
Genetic electronic module (GEM).
2
instrument cluster
3
ABS4
ABS sensor assembly
5
Rear LH mid/bass range speaker
6
Rear RH mid/bass range speaker
7
Rear LH tweeter
8 Description
Item
Rear RH tweeter
9
AUX port
10
Radio remote control.
11
FM/AM antenna
12
Front LH mid/bass speaker
13
Front RH mid/bass speaker
14
Front LH tweeter
15
Front RH tweeter
16
System Operation
In-car entertainment
The audio system is connected to the MS CAN
network and uses an internal amplifier which
directly drives the system speakers. It can only be
operated via the head unit and the radio remote
control. The head unit is connected to the vehicle
on the medium speed CAN bus. This allows the
unit to be interrogated for diagnostic purposes.
The automatic volume control (AVC) adjusts the
audio volume depending on the driving speed. The
audio device receives the necessary signals for
the ABS (anti-lock brake system) wheel sensors
from the instrument cluster on the MS-CAN. As
vehicle speed increases the audio level is adjusted
to compensate for extra road and vehicle noise.
Eight AVC settings are possible.
To choose the setting for automatic volume control,
press the MENU button until the AVC display
appears.
The required adjustment level is determined by the
Infotainment control unit based on the driving
speed signal. The vehicle speed signal is received
over the CAN. The signal is an average of the four
wheel speed sensor signals. Should an invalid
speed signal be received the AVC will not alter the
output volume.
AVC is controlled by the audio amplifier. Component Description
Vehicles with standard audio system
The standard audio system can only be used via
the head unit, the radio remote control and the
mobile electronic accessories module.
G1055647en
2008.50 Kuga 8/2011 415-01-8
Information and Entertainment System
415-01-8
DESCRIPTION AND OPERATIONTO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUALE99206

Combined rain sensor/light sensor
CAUTIONS:
On vehicles with autolamps, retrofitting
with daytime running lamps is not
permissible, as otherwise, the engine
cannot be stopped when the lighting is
switched on.
On vehicles with autolamps, the daytime
running lamp fuse must not be fitted, as
otherwise, the engine cannot be stopped
when the lighting is switched on.
The combined rain sensor/light sensor is located
behind the interior rear view mirror.
autolamps The low beams, side lamps, license plate lamps
as well as the instrument cluster and instrument
panel illumination are switched on automatically if
all the following conditions are met:
• Ignition ON
• Light switch in the "AUTO" position
•
Detected ambient light conditions below a stored
threshold value
These are switched on and off by the GEM (generic
electronic module) in accordance with the input
signals from the combined rain/light sensor.
Headlamp switch-off delay
In vehicles with mid to high-end equipment, the
headlamp switch-off delay uses the dipped beam
headlamps and the door entry illumination (if
equipped) to illuminate the vehicle surroundings.
This function is activated by operating the main
beam headlamp lever with the ignition switched
off. After the last door has been closed, the function
remains active for a further 30 seconds and then
switches off automatically.
When a door or the tailgate is open, the switch-off
time is extended to 180 seconds. After the last door
has been closed, the switch-off time is reset to 30
seconds.
The headlamp switch-off delay can be deactivated
prematurely by operating the high beam lever again
or by switching on the ignition.
The switch-off time is adjusted to fixed values at
the factory and can
notbe re-programmed using
WDS.
Turn signals The turn signals and the warning lamp flash at a
specified frequency and, in the case of failure of a
turn signal, the frequency is doubled.
The turn signal lamps also have a one-touch lane
change function. If the multifunction lever is
pressed just slightly then the relevant turn signal
lamp is actuated 3 times.
Door entry illumination
G1079626en
2008.50 Kuga 8/2011 417-01-7
Exterior Lighting
417-01-7
DESCRIPTION AND OPERATIONTO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUALE101615 E101616 E101617

Description
Item
Headlamp units with turn signal lamp, side
lamp, dipped beam headlamp, main beam
headlamp, positioning motor for headlamp
leveling system
8
External mirror with side turn signal lamps
and door entry lamp
9
Door locking units for the front doors
10
Fog lamp
11
Rear fog lights
12
Gas discharge headlamp control module
13 Description
Item
GEM14
Vehicle level sensors
15
Lighting switch
16
Multifunction lever
17
Hazard flasher switch
18
Combined rain sensor/light sensor
19
Reverse gear switch
20
Keyless Vehicle Module
21
System Operation
Headlamp levelling
Xenon headlamp
The following components are part of the automatic
headlamp leveling system:
• Vehicle level sensors on the front and rear axles
• Control module
• Actuator motors for headlamp leveling Accordingly, the system needs to be set up with
the aid of WDS after any components are replaced
or any other repairs are carried out.
The front and rear sensors are Hall sensors which
send a digital signal to the control unit.
Conventional HeadlampsDescription
Item
Light switch with manual headlamp
leveling system
1
Headlamp units with positioning motors
for headlamp leveling system
2 G1079627en
2008.50 Kuga 8/2011 417-01-10
Exterior Lighting
417-01-10
DESCRIPTION AND OPERATIONTO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUALE10260312