park lamp FORD KUGA 2011 1.G Workshop Manual

Standard Workshop Practices
Vehicle in Workshop
When working on a vehicle in the workshop always
make sure that:
– the parking brake is applied or the wheels aresecurely chocked to prevent the vehicle moving
forwards or backwards.
– the key is removed from key operated hood locks before any work is carried out around the
front of the vehicle.
– if the engine is to be run, there is adequate ventilation, or an extraction hose to remove
exhaust fumes.
– there is adequate room to raise the vehicle and remove the wheels, if necessary.
– fender covers are always fitted if any work is to be carried out in the engine compartment.
– the battery is disconnected if working on the engine, underneath the vehicle, or if the vehicle
is raised.
CAUTION: When electric arc welding on a
vehicle, always disconnect the generator
wiring to prevent the possibility of a surge
of current causing damage to the internal
components of the generator.
– if using welding equipment on the vehicle, a suitable fire extinguisher is readily available.
Towing the Vehicle
WARNING: When the vehicle is being
towed, the ignition switch must be in
position II (steering lock released and
warning lamps illuminated). Only then will
the steering, turn signal lamps, horn and
stop lamps be operational. Failure to follow
these instructions may result in personal
injury.
NOTE: The removable towing eye (if equipped),
has a left-hand thread and must be fully tightened
before towing can commence.
When towing is necessary, the vehicle towing eyes
should be used. The rope must be securely
fastened to the towing eyes and must also be
attached to the other vehicle such that the rope will
not foul the bodywork.
When a vehicle with automatic transmission is
towed, the gear selector must be in position N (Neutral). Never tow a vehicle with automatic
transmission at a speed greater than 30 mph (50
km/h) or for a distance greater than 30 miles (50
km). If it is necessary to tow the vehicle a greater
distance, the drive wheels must be lifted clear off
the ground.
Alternatively the vehicle can be transported on a
low loader or a trailer.
Connecting a Slave Battery Using
Jumper Cables
WARNING: If the slave battery has recently
been charged and is gassing, cover the
vent plugs or covers with a damp cloth to
reduce the risk of explosion should arcing
occur when connecting the jumper cables.
Failure to follow these instructions may
result in personal injury.
CAUTIONS:
A discharged battery condition may have
been caused by an electrical short circuit.
If this condition exists there will be an
apparently live circuit on the vehicle even
when all normal circuits are switched off.
This can cause arcing when the jumper
cables are connected.
While it is not recommended that the
vehicle is jump started, it is recognized
that this may occasionally be the only
practical way to mobilize a vehicle. In such
an instance, the discharged battery must
be recharged immediately after jump
starting to avoid permanent damage.
– Always make sure that the jumper cables are adequate for the task. Heavy duty cables must
be used.
– Always make sure that the slave battery is of the same voltage as the vehicle battery. The
batteries must be connected in parallel.
– Always make sure that switched electric circuits are switched off before connecting jumper
cables. This reduces the risk of arcing occurring
when the final connection is made.
G17373en2008.50 Kuga8/2011
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General Information
100-00- 54
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Road/Roller Testing
Road or roller testing may be carried out for various
reasons and a procedure detailing pre-test checks,
engine starting and stopping, pre-driving checks,
on-test checks and final checks to be completed
on completion of the test is given below.
Unless complete vehicle performance is being
checked, the full road test procedure need not be
carried out. Instead, those items particularly
relevant to the system(s) being checked can be
extracted.
Pre-Test Checks
WARNING: If the brake system hydraulic
fluid level is low, pedal travel is excessive
or a hydraulic leak is found, do not attempt
to road test the vehicle until the reason for
the low fluid level, excessive pedal travel
or hydraulic leak is found and rectified.
It is suggested that pre-test checks and functional
tests of those systems and circuits which affect the
safe and legal operations of the vehicle, such as
brakes, lights and steering, should always be
carried out before the road or roller test.
With the ignition switched off, check:
– the engine oil level.
– the engine coolant level.
– the tires, for correct pressure, compatible types and tread patterns, and wear within limits.
– that there is sufficient fuel in the tank to complete the test.
– all around the engine, transmission and under the vehicle for oil, coolant, hydraulic and fuel
leaks. Make a note of any apparent leaks and
wipe off the surrounding areas to make it easier
to identify the extent of the leak on completion
of the test.
Starting the Engine
NOTE: On initial drive away from cold and within
the first 1.5 km (1 mile), do not depress the
accelerator pedal beyond half travel until the
vehicle has attained a minimum speed of 25 km/h
(15 miles/h). Never operate at high engine speed
or with the accelerator pedal at full travel whilst the
engine is cold.
With the ignition switched off, check: – that the parking brake is applied.
– that the gear lever is in the neutral position.
– that all instrument gauges (except fuel gauge)
read zero.
With the ignition switched on, check:
– that the ignition controlled warning lamps are illuminated.
– that the engine temperature gauge registers a reading compatible with the engine temperature.
– that the fuel gauge registers a reading appropriate to the fuel level in the tank.
– the operation of the parking brake warning lamp and fluid level warning indicator.
Road or Roller Testing
CAUTION: If road testing, check the brake
operation while still traveling at low speed
before continuing with the test. If the
brakes pull to one side, or appear to be
otherwise faulty, do not continue with the
road test until the fault has been found and
rectified.
During the road or roller test, check:
– that the clutch pedal operation is not stiff or heavy.
– that the initial gear engagement is smooth and there is no evidence of clutch drag.
– that the parking brake control operates smoothly and releases quickly and completely.
– that the clutch takes up the drive smoothly, without slip or judder.
– that gear changing is smooth with no abnormal noises or vibrations from the transmission.
– the engine power output is satisfactory, full power is achieved, acceleration is smooth and
pedal operation is not stiff or heavy, and engine
speed returns to idle correctly.
– there is no excessive or abnormally colored smoke from the engine under normal driving,
heavy load or overrun conditions.
– that steering operation, including power steering (if equipped), is smooth, accurate, not
excessively heavy or with excessive free play
or vibration.
– that the steering does not pull to one side and self centers smoothly after cornering.
G17375en2008.50 Kuga8/2011
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General Information
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Body Repair Health and Safety and General Precautions
General
Appropriate repair methods and carrying out repair
and paint jobs correctly is particularly important to
the operating safety of vehicles and the safety of
people.
WARNING: There is danger of injury
through:
• High voltage when electrical welding. – Do not perform welding work in a dampenvironment or on a wet substrate. Use
suitable insulation underneath.
• Welding spatter and UV radiation. – Wear protective clothing, gloves and weldingmask or welding goggles.
• Fire, explosion and hot surfaces in the work area.
– Always have a suitable fire extinguisheravailable when using welding or heating
equipment.
– Remove flammable substances from the danger area. Remove the fuel tank and fuel
pipes and hoses.
– Welding and grinding near the battery presents the danger of explosion. Remove
the battery before you start working.
– During paint work there is an increased danger of fire or explosion. Prevent any
sparks being created. Fire, open light and
smoking are forbidden.
– Always ventilate the workplace well and use an extraction system.
– Wear protective footwear made from anti-static material.
– Only use tools made of wood, brass or copper to clean stands and extraction ducts.
Do not use tools made of steel.
– Only fill or decant paint materials in a specially marked area. • Inhalation and/or absorption through the skin of
harmful substances.
– Welding fumes grinding dusts and solventvapours can be extremely harmful to the
health.
– Sealants, underbody protection and paint residues must not be burnt down with an
unshielded flame, as this will produce harmful
substances.
– Always ventilate the workplace well and use an extraction system.
– Wear protective clothing.
• Pyrotechnic components. – Disconnect the battery negative clamp andcover the battery terminal.
– Remove any airbag components.
• Noise – Cutting, grinding and alignment work cancause a noise level over 85 dB (A).
– Always wear ear protection.
• High Forces. – The various body areas are subject to veryhigh forces during realignment work. Should
any component suddenly become detached
during this process, there is a very great
danger of injury.
– Pulling chains and pulling shackles must be secured with arrester cables.
As well as these general instructions on the
dangers in body and paint shops, you must
observe:
• All valid local national and international regulations governing Health and Safety at Work
• Safety instructions of material equipment and tool manufacturers
For additional information, refer to: (100-00 General
Information) Solvents, Sealants and Adhesives (Description
and Operation),
Air Conditioning (A/C) System Health and Safety Precautions (Description and Operation),
Supplemental Restraint System (SRS) Health and Safety Precautions (Description and
Operation).
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General Information
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Before conducting a vehicle test to identify a NVH
concern carry out the following checks.
1. Check the tire pressures and adjust tospecification, as necessary.
2. Make sure the steering system fluid is correct, the system is free of leaks and is operating
correctly.
3. Make sure the vehicle steering system temperature is the same as described at the
customer interview.
4. All evaluations must take place in a relatively quiet location.
5. The heating - air conditioning (A/C) fan and radio must be turned off during evaluations and
the windows closed.Symptom Chart
Power Steering Moan Noise
Test Condition
Listen for steering moan noise with the vehicle
parked, transmission in neutral and all windows
closed in the following test conditions.
1. Engine speed at idle with no steering action.
2. Engine speed at idle with slow 90 degrees persecond turning of the steering wheel.
3. Engine speed at 1250 +/- 50 rpm with no steering action.
4. Engine speed at 1250 +/- 50 rpm with slow 90 degrees per second turning of the steering
wheel.
Action
Possible Sources
Symptom
• CHECK the routing of thepower steering lines.
• CHECK the power steering line clamps are secure.
• CHECK the power steering lines for clearance from the
vehicle body, front axle cross-
member and steering gear.
Power steering lines.
Power steering system moan
noise – A continuous low pitched
humming noise occurs when the
steering wheel is turned and the
steering system is loaded. Noise
frequency changes with engine
rpm changes. Particularly
annoying at lower engine speed. FLUSH the power steering
system.
REFER to:
Power Steering
System Flushing (211-00
Steering System - General
Information, General Proced-
ures).
Incorrect power steering fluid.
Pressure pulses from the power
steering pump. Certain amount
of noise level acceptable, not a
safety critical item.
Power steering pump.
Power Steering Whine Noise
Test Condition
Listen for steering whine noise with the vehicle
parked, transmission in neutral and all windows
closed in the following test conditions. 1. Engine speed at 1800 +/- 50 rpm with no
steering action.
2. Engine speed at 1800 +/- 50 rpm with slow 90 degrees turning of the steering wheel.
3. Engine speed at 3000 +/- 50 rpm with no steering action.
4. Engine speed at 3000 +/- 50 rpm with slow 90 degrees turning of the steering wheel.
G37349en2008.50 Kuga8/2011
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Noise, Vibration and Harshness
100-04- 7
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Instrument Cluster and Panel Illumination
Refer to
Wiring Diagrams Section 413-00, for
schematic and connector information.
Principles of Operation
NOTE: A new instrument cluster must be
configured.
The instrument cluster and panel illumination
consists of dimmable and non-dimmable
illumination. The dimmable panel illumination is
controlled by the panel illumination switch (part of
the headlamp switch), which allows the brightness
level of the backlights to be adjusted dependent
on the customer preference. When the headlamp
switch is in the parking lamps ON or headlamps
ON position, the intensity of the backlighting can
be adjusted using the panel dimmer switch. The
non dimmable illumination allows for full intensity
dependant on the ignition switch position.
Instrument Cluster and Dimmable
Backlighting A.
Tachometer
B. Engine coolant temperature gauge
C. Fuel gauge
D. Speedometer
E. Information display
The dimmable illumination utilizes light emitting
diodes (LEDs) and bulb(s). The following dimmable
components are backlight using LEDs only:
• ashtray
• cigar lighter
• transmission control lever
• heater control panel
• audio unit • navigation system display module
• instrument cluster
• climate control module
• hazard switch
• traction control system disable switch
• right-hand and left-hand heated front seat
switch(es)
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)
– Loose or corrodedconnector(s)
– Instrument cluster
– Wiring Harness
– Circuit
– LED(s)
– Bulb(s)
– Engine/engine
compartment or
underbody compon-
ents
– Fluid levels
– Accessory installa- tion
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. G1054961en
2008.50 Kuga 8/2011 413-00-2
Instrument Cluster and Panel Illumination
413-00-2
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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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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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SECTION 417-01 Exterior Lighting
VEHICLE APPLICATION:
2008.50 Kuga
PAGE
CONTENTS
SPECIFICATIONS
417-01-3
Specifications ......................................................................................................................
417-01-3
Headlamp adjustment.....................................................................................................
DESCRIPTION AND OPERATION 417-01-4
Exterior Lighting (Component Location).............................................................................
417-01-5
Exterior Lighting (Overview)...............................................................................................
417-01-5
Front headlamps.................................................................................................................
417-01-5
Conventional Headlamps................................................................................................
417-01-5
Xenon headlamp.............................................................................................................
417-01-6
Headlamp levelling.........................................................................................................
417-01-7
Combined rain sensor/light sensor.....................................................................................
417-01-7
autolamps ...........................................................................................................................
417-01-7
Headlamp switch-off delay.................................................................................................
417-01-7
Turn signals........................................................................................................................
417-01-7
Door entry illumination........................................................................................................
417-01-8
Rear Lighting......................................................................................................................
417-01-9
Exterior Lighting (System Operation and Component Description)....................................
417-01-9
System Diagram.................................................................................................................
417-01-10
System Operation...............................................................................................................
417-01-10
Headlamp levelling.........................................................................................................
417-01-10
Xenon headlamp.............................................................................................................
417-01-10
Conventional Headlamps................................................................................................
417-01-11
Turn signals....................................................................................................................
417-01-11
Combined rain sensor/light sensor.................................................................................
417-01-11
Component Description......................................................................................................417-01-11Combined rain sensor/light sensor.................................................................................
DIAGNOSIS AND TESTING 417-01-12
Fog Lamps..........................................................................................................................
417-01-12
Description of operation......................................................................................................
417-01-13
Inspection and Checking....................................................................................................
417-01-15
Headlamps..........................................................................................................................
417-01-15
Description of operation......................................................................................................
417-01-16
Inspection and Checking....................................................................................................
417-01-17
Headlamp Leveling.............................................................................................................
417-01-17
Description of operation......................................................................................................
417-01-18
Inspection and Checking....................................................................................................
417-01-19
Parking, Rear and License Plate Lamps............................................................................
417-01-19
Description of operation......................................................................................................
417-01-20
Inspection and Checking....................................................................................................
417-01-21
Reversing Lamps................................................................................................................
417-01-21
Description of operation......................................................................................................
417-01-22
Inspection and Checking.................................................................................................... 417-01-1
Exterior Lighting
417-01-1
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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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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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