2011 FORD KUGA brake system

Description
Item
Reversing camera module (RVC)
10
Keyless vehicle module (KVM)
11
All-wheel drive control unit
12
RDM - Driver's side
13
RCM (restraints control module)
14
DDM (driver door module)
15
Instrument Cluster
16 Description
Item
High intensity discharge headlamp module
(optional)
17
ABS (anti-lock brake system) module or
electronic stability program module
18
PCM (powertrain control module)
19
The EATC (electronic automatic
temperature control) control module
20
Electrohydraulic power steering module
21 G1072290en
2008.50 Kuga 8/2011 418-00-3
Module Communications Network
418-00-3
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SECTION 419-10 Multifunction Electronic Modules
VEHICLE APPLICATION:
2008.50 Kuga
PAGE
CONTENTS
DESCRIPTION AND OPERATION
419-10-2
Module Controlled Functions (Overview)...........................................................................
419-10-2
Generic electronics module (GEM)....................................................................................
419-10-2
Emergency function............................................................................................................
419-10-2
Service mode......................................................................................................................
419-10-4
Module Controlled Functions (System Operation and Component Description)................
419-10-4
System Diagram.................................................................................................................
419-10-6
System Operation...............................................................................................................
419-10-6
GEM. ...............................................................................................................................
419-10-6
Component Description......................................................................................................
419-10-6
Battery charging (Smart Charge)....................................................................................
419-10-7
Ignition overload protection.............................................................................................
419-10-7
Headlamp switch-off delay..............................................................................................
419-10-8
Turn signals....................................................................................................................
419-10-8
Interior lighting................................................................................................................
419-10-8
Heated windscreen.........................................................................................................
419-10-9
Heated rear window and heated external mirrors...........................................................
419-10-9
Ambient air temperature.................................................................................................
419-10-9
Brake fluid level...............................................................................................................
419-10-9
Automatic headlamps.....................................................................................................
419-10-9
Combined rain sensor/light sensor.................................................................................419-10-10Windshield wash/wipe system........................................................................................
419-10-10Anti-theft ..........................................................................................................................
419-10-10Electric booster Heater...................................................................................................
419-10-10Climate control................................................................................................................
DIAGNOSIS AND TESTING 419-10-11
Generic Electronic Module (GEM)......................................................................................
419-10-11
Description of operation......................................................................................................
419-10-12
Inspection and Checking....................................................................................................
REMOVAL AND INSTALLATION 419-10-14
Generic Electronic Module (GEM)......................................................................................
419-10-15
Lighting Control Module (LCM)........................................................................................... 419-10-1
Multifunction Electronic Modules
419-10-1
.
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Module Controlled Functions – Overview
Generic electronics module (GEM)
CAUTIONS:
Never swap the GEM (generic electronic
module) between two vehicles.
Compare the number of relays and fuses
in the defective GEM and the new GEM.
Transfer from the defective GEM any relays
and fuses which are not in the new GEM.
In doing so, pay attention that fuses with
the correct Ampere rating are used, by
referring to the wiring diagrams.
NOTE: The GEM is integrated in the CJB (central
junction box) and cannot be replaced as a separate
unit.
For repair work during a service, vehicle-specific
configuration is necessary if a new GEM is
installed.
Emergency function
The GEM is equipped with restricted emergency
running functions on vehicles with mid or high-end
equipment levels.
The microcontroller sends a control signal to a
monitoring function within the GEM at regular
intervals. If the battery voltage falls below a value
of approx. 7.5 volts, this check signal is not present
and the GEM switches to emergency function after
a predetermined time.
In this case, the low beam is permanently switched
on, regardless of the light switch position. The
windshield wiper can only be operated in stage 1;
the wiper switch must however be in the stage I or
II position. The wiper park position is not
recognized. Intermittent wiping is not available.
When the control signal recurs, the GEM switches
back to normal operation.
Service mode
Description of operation
Diagnosis of the GEM can be carried out using the
Ford diagnostic unit. 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
NOTE:
If the alarm is activated (in vehicles fitted
with an anti-theft alarm system), service mode
cannot be activated.
Proceed as follows to activate the service mode:
• OPERATE the switch of the heated rear window
and HOLD IT THERE
• SWITCH 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.
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:
• 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 fluid level
• Cruise control system
• Autolamps
• Dipped beam
• Main beam
• Headlamp flasher
• Side lights
• Turn signals (right, left, hazard warning lights) G1030787en
2008.50 Kuga 8/2011 419-10-2
Multifunction Electronic Modules
419-10-2
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Description
Item
HS CAN
1
DLC2
MS CAN
3
Instrument cluster (gateway)
4
Front windshield wiper motors
5
GEM6
Rear window wiper motors
7
Indicator/heated windshield
8
Indicator/heated rear window
9 Description
Item
Mini-liftgate latch motor
10
Liftgate latch motor
11
Electric booster Heater
12
Front wiper windscreen washer pump
13
Rear wiper windscreen washer pump
14
Headlamp
15
Courtesy Lighting
16
Alarm horn
17
System Operation
GEM.
The following functions are controlled or performed
by the GEM at a battery voltage of between 9 and
16 volts:
• Current distribution
• Battery charging (Smart Charge)
• Ignition overload protection
• Headlamp switch-off delay
• Turn signals
• Interior lighting
• Heated windscreen
• Heated rear window and heated external mirrors
• Ambient air temperature
• Brake fluid level
• Automatic headlamps
• Combined rain sensor/light sensor
• Windshield wash/wipe system
• Speed control – reads the speed control switches andtransmits signals on the CAN data bus
• central door locking – transmits signals on the CAN data bus
• Anti-theft
• Electric booster Heater
• Climate control
• Parking brake –(monitors the switch and transmits the signal
on the CAN data bus
• Communication via the medium-speed CAN data bus Component Description
Battery charging (Smart Charge)
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.
The alternator load is signaled to the PCM
(powertrain control module) in order to provide it
with an early indication when an electric component
is to be switched on or off, thereby also providing
information about imminent changes to the amount
of torque demanded by the alternator. By
evaluating this information the PCM is capable of
increasing the stability of the engine under idling.
The two remaining functions of the Smart Charge
system are controlled by the GEM. G1030788en
2008.50 Kuga 8/2011 419-10-6
Multifunction Electronic Modules
419-10-6
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• 4 minutes have elapsed since the button for the
heated windshield was pressed.
• The ignition switch is turned to the "I" or "0" position.
• The "Defrost" function is deactivated or the switch for the heated windscreen is pressed
again while the heated windscreen is still
switched on.
• The charging system warning indicator is switched on.
• The battery voltage falls below the threshold value for low battery voltage for more than 20
seconds (power management strategy). Manual
requests for switching on the heated windshield
by pressing the switch are ignored at this time.
• More than 4 minutes have passed since starting
the engine.
Heated rear window and heated external
mirrors
The GEM transmits a request signal via the CAN
bus to the door modules to switch on the heated
exterior mirrors.
The heated rear window and the heated exterior
mirrors are switched on by the GEM under the
following conditions:
• The switch for the heated rear window is pressed and the ignition switch is in the "II"
position.
• The "defrost" function of the air conditioning is activated and the ignition switch is in the position
"II".
• The battery voltage has exceeded 16 V for more
than 20 seconds (power management strategy).
Manual requests to switch off the heated rear
window by pressing the button are ignored at
this time.
• The engine was started at an outside air temperature below 4°C and an engine
temperature below 65°. Manual requests for
switching off the heated rear window by pressing
the switch are accepted.
NOTE: If the battery voltage returns to the normal
range then the disabling of the heated rear window
is cancelled - the heated rear window is then in a
switched-off state.
The GEM transmits a request signal via the CAN
bus to the door modules to switch off the heated
exterior mirrors. The heated rear window and the heated exterior
mirrors are switched off by the GEM under the
following conditions
• 14 minutes have elapsed since the button for
the heated rear window was pressed.
• The ignition switch is turned to the position "0", "I" or "III".
• The switch for the heated rear window is pressed or the "defrost" function of the air
conditioning is deactivated while the heated rear
window is switched on.
• The battery voltage has dropped below 10.3 V for more than 20 seconds (power management
strategy). Manual requests for switching on the
heated rear window by pressing the switch are
ignored at this time.
• More than 14 minutes have passed since starting the engine.
Ambient air temperature
The ambient air temperature sensor is connected
via a cable to the GEM. It measures the outside
air temperature to an accuracy of around ±0.5 °C.
The GEM broadcasts the ambient air temperature
on the medium speed CAN bus, where it can be
evaluated by various systems.
Brake fluid level
The brake fluid level switch is connected via a
cable to the GEM.
The GEM transmits a message on the medium
speed CAN bus. The instrument cluster then
transfers this message to the high speed CAN bus
where it is made available for various other
functions.
Automatic headlamps
Refer to: Exterior Lighting (417-01 Exterior Lighting,
Description and Operation).
Combined rain sensor/light sensor
Refer to: Exterior Lighting (417-01 Exterior Lighting,
Description and Operation). G1030788en
2008.50 Kuga 8/2011 419-10-9
Multifunction Electronic Modules
419-10-9
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Generic Electronic Module (GEM)
Refer to Wiring Diagrams Section 419-10, for
schematic and connector information.
Special Tool(s) / General Equipment
Terminal Probe Kit
418-S035Digital multimeter
Ford approved diagnostic tool
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
• Close the doors.
Activate service mode
Proceed as follows to activate service mode:
• PRESS and HOLD the switch of the heated rear
window
• SWITCH ON the ignition.
• RELEASE the switch of the heated rear window
A signal sounds and the turn signal lamps
illuminate to indicate that service mode has been
successfully activated.
NOTE: If the alarm is armed (in vehicles fitted with
an anti-theft alarm system), service mode cannot
be activated.
Input signals
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
• Door key cylinder set/reset switch
• Remote control for central locking with double
locking
• Hood up/down (in vehicles fitted with anti-theft alarm system)
• Tailgate open/closed
• Mini liftgate open/closed
• Manual A/C request signal
• Manual AUX heater request signal
• Heated windshield (if fitted)
• Parking brake
• Brake fluid level
• Cruise control system
• Autolamps
• Dipped beam
• Main beam
• Headlamp flasher
• Side lights
• Reversing lamp
• Tailgate release
• Mini liftgate release
• Interior scanning system
• 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. G1055084en
2008.50 Kuga 8/2011 419-10-11
Multifunction Electronic Modules
419-10-11
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL29011A

Engine Speed Sensitive
This means that the vibration occurs at varying
vehicle speeds when a different transmission gear
is selected. It can sometimes be isolated by
increasing or decreasing engine speed with the
transmission in NEUTRAL or by stall testing with
the transmission in gear. If the condition is engine
speed sensitive, the cause is probably not related
to the tires.
If the road test indicates that there is tire whine,
but no shake or vibration, the noise originates with
the contact between the tire and the road surface.A thumping noise usually means that the tire is flat
or has soft spots making a noise as they slap the
roadway. Tire whine can be distinguished from axle
noise. Tire whine remains the same over a range
of speeds.
A complete road test procedure is described in
Section 100-04.
REFER to:
Noise, Vibration and Harshness (NVH)
(100-04 Noise, Vibration and Harshness,
Diagnosis and Testing).
Symptom Chart
Action
Possible Sources
Symptom
• ADJUST the tire pressure andreset the DDS. For additional
information REFER to the
owners guide.
• Loss of tire pressure.
• DDS warning lamp illuminated
• REFER to the DDS resetprocedure. For additional
information REFER to the
owners guide.
• The DDS reset procedure was
not carried out after adjustment
of the tire pressure.
• DDS warning lamp illuminated
with the correct tire pressure
• ADJUST the tire pressure andreset the DDS. For additional
information REFER to the
owners guide.
• The DDS reset procedure was
carried out under incorrect tire
conditions.
• DDS warning lamp not illumin-
ated when one or more tire(s)
have the incorrect tire pressure
• REFER to the DDS resetprocedure. For additional
information REFER to the
owners guide.
• The DDS reset procedure was
not completed.
• DDS reset command was not
confirmed
• REFER to the Ford approveddiagnostic tool.
• Anti-lock brake system (ABS)
module.
• DDS failure warning display
• ADJUST the tire pressure(s).
• Tire(s) under-inflated.
• Tire(s) show excess wear on
edge of tread
• CORRECT as necessary.
• Vehicle overloaded.
• ADJUST the wheel alignment.REFER to: Suspension System
(204-00 Suspension System
- General Information,
Diagnosis and Testing).
• Incorrect wheel alignment.
• ADJUST the tire pressure(s).
• Tire(s) over-inflated.
• Tire(s) show excess wear in
center of tread
• ADJUST the tire pressure(s).
• Incorrect tire pressure(s).
• Other excessive tire wear
concerns
G1061329en2008.50 Kuga8/2011
204-04- 7
Wheels and Tires
204-04- 7
DIAGNOSIS AND TESTING
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Front Drive Halfshafts
Inspection and Verification
NOTE:New front wheel drive halfshafts should not
be installed unless disassembly and inspection
reveals unusual wear.
1. Inspect front wheel driveshaft joint boots for evidence of cracks, tears or splits.
NOTE: While inspecting the front wheel driveshaft
CV joint boots, watch for indentations (dimples) in
the boot convolutions. If an indentation is observed,
it must be removed.
2. Inspect the underbody for any indication of grease splatter in the vicinity of the front wheel
driveshaft CV joint boots outboard and inboard
locations, which is an indication of front wheel
driveshaft CV joint boot and/or front wheel
driveshaft CV joint boot clamp damage. 3. Inspect for inboard CV joint stub shaft pilot
bearing housing seal leakage at the front wheel
driveshaft CV joint.
4. Make sure front axle wheel hub retainer is the correct prevailing torque type.
5. The silicone front wheel driveshaft CV joint boot will sweat during operation, causing a light film
of grease to show on the outside of the front
wheel driveshaft CV joint boot. This condition
is normal.
NOTE: Halfshafts are not balanced and do not
contribute to rotational vibration.
6. If the concerns remain after the inspection, determine the symptoms and go to the Symptom
Chart. For additional Noise, Vibration and
Harshness (NVH). REFER to Section 100-04
[Noise, Vibration and Harshness] .
Symptom Chart
Action
Possible Sources
Symptom
• INSPECT, CLEAN andLUBRICATE as necessary.
• Inadequate or contaminated
lube in outboard/inboard front
wheel driveshaft CV joint.
• Clicking, Popping or Grinding
Noises While Turning
• INSPECT and REPAIR asnecessary.
• Another component contacting
driveshaft assembly.
• INSPECT and REPAIR asnecessary. REFER to
Section 204-00 [Suspension
System - General Information]
/ 206-00 [Brake System -
General Information] /211-00
[Steering System - General
Information] .
• Wheel bearings, brakes,
suspension or steering
components.
• REPAIR or INSTALL new asnecessary. REFER to
Section 204-04 [Wheels and
Tires] .
• Out of balance front wheels or
tires.
• Vibration at Highway Speeds
• REPAIR or INSTALL new asnecessary. REFER to
Section 204-04 [Wheels and
Tires] .
• Out-of-round tires.
• REPAIR or INSTALL new asnecessary.
REFER to Halfshaft Disas-
semblv and Assembly in this
section.
• Incorrectly seated outboard
front wheel driveshaft CV joint
in front wheel hub.
G17442en2008.50 Kuga8/2011
205-04- 3
Front Drive Halfshafts
205-04- 3
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