2011 FORD KUGA gem module

Daytime Running Lamps (DRL)
Refer to Wiring Diagrams Section 417-04, 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 G1055032en
2008.50 Kuga 8/2011 417-04-2
Daytime Running Lamps (DRL)
417-04-2
DIAGNOSIS AND TESTINGTO MODEL INDEX
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL29011A

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: Before reading out the vehicle-specific data,
remake all the separated electrical connections in
the vehicle, so that communication between the
module and the Ford approved diagnostic tool is
ensured.
1. Verify the customer concern.
2. Visually check the following electrical causes for the concern:
Visual Inspection Electrical
Mechanical
• Fuse(s)
• Connector(s).
• Switche(s)
• Wiring loom
• Headlamp
3. Resolve any obvious causes or concerns found during the visual inspection before carrying out
any further tests.
4. If the cause is not visually evident, verify the symptom and refer to the diagnostic tab within
the Ford approved diagnostic tool. G1055032en
2008.50 Kuga 8/2011 417-04-3
Daytime Running Lamps (DRL)
417-04-3
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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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must use the same language. This language is
called a protocol.
At present, Ford uses three different data bus
systems. Depending upon model and equipment
level, all three data bus systems are used. Each
of these data bus systems has its own protocol.
Data bus systems
ISO 9141 bus
The International Organisation for Standardisation
ISO 9141 bus. This consists of a single wire and
is used exclusively for communication between the
modules and the Ford diagnostic unit. The fault
memories of the various modules are read out via
the ISO 9141 bus.
Local Interconnect Network (LIN) bus
The LIN bus is a standard specifically designed for
cost-effective communication between intelligent
sensors and actuators in vehicles. The LIN control
unit subnet is used in every situation where the
bandwidth and versatility of CAN is not needed.
The LIN specification comprises the LIN protocol,
a standard format for describing a complete LIN
and the interface between an LIN and the
application. An LIN comprises a LIN master and
one or more LIN slaves. The LIN utilizes the
master/slave principle for the purpose of bus
access control. This has the significant advantage
that few resources (CPU performance, ROM, RAM)
are required for bus management in the slave
module. The master is implemented in a control
module or a gateway which has the necessary
resources. All communication is initiated by the
master. Consequently, a message always consists
of a header, which is generated by the master, and
a response from the slave. The data transfer rate
is in the region of up to 20 Kbit/s. The LIN master
knows the time sequence of all data which are to
be transmitted. These data are transmitted by the
corresponding LIN slaves (e.g. ultrasonic sensors)
if they are requested to do so by the LIN master.
LIN is a single-wire bus, i.e. the data are
transmitted in the cable via one wire. Usually the
same cable is also used to provide the supply
voltage. The ground connection of the supply
voltage also acts as the ground connection of the
data transmission. An LIN does not use a
terminating resistor.
Controller Area Network (CAN) bus
This consists of two twisted wires and operates
serially (data is transmitted sequentially). It is used
for communication between the modules
themselves and between the modules and the Ford
diagnostic unit. The modules are connected to the
data bus in parallel. New modules can be
incorporated easily, without modifying the other
wiring or modules. The transmitted data is received
by every module connected to the control unit
network (CAN). As each data packet has an
identifier (label), in which the priority of the
message is determined as well as the content
identification, each module can detect whether or
not the data is relevant for its own information
processing. This enables several modules to be
addressed with a particular data packet and
supplied with data simultaneously. For this
purpose, it is ensured that important data (for
example from the ABS) is transmitted first. The
other modules are only able to submit their data to
the data bus after the high-priority messages have
been received.
The advantages of the CAN bus are:
• Minimization of wiring requirements
•
High degree of error protection (fault / fail-proof)
• Robustness
• Good extendibility
• Prioritization of messages
• Inexpensive
• Automatic repetition of faulty messages
• Independent system monitoring and the ability to disconnect faulty modules from the data bus
automatically
Due to the increased number of modules and the
resulting continued increase in data transfer, two
different CAN bus systems are used. Essentially,
they only differ in terms of their data transmission
rates and application areas.
To be able to distinguish between the individual
CAN bus systems, the CAN bus system with the
high transfer speed is called the high speed CAN
bus (HS-CAN). The data are transmitted at a baud
rate of 500 kB/s.
The CAN bus system with the medium transfer
speed is called the medium speed CAN bus
(MS-CAN) and is mainly used for communication
in the comfort electronics or the multimedia system.
The data are transmitted at a baud rate of 125 kB/s.
An interface (gateway) is used to exchange data
between the HS-CAN and the MS-CAN. This
provides the connection between the three CAN
databus systems and is installed in the GEM and
in the electronic instrument cluster. The number of
modules which are connected to the three databus G1030779en
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Module Communications Network
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systems depends on the equipment level of the
vehicle.
In order to guarantee a high degree of error
protection, two 120 Ohm terminating resistors are
installed in the CAN. These are integrated in the
first module connected to the CAN and in the last
module connected to the CAN respectively and
are used for suppression as well as the elimination
of voltage peaks. In order to ensure correct
functioning of the data bus system, the modules
must always be connected with an integral
terminating resistor. In order to enable
communication between the modules on the
HS-CAN and the modules on the MS-CAN, one
module is connected to both data bus systems.
The connection of both data bus systems is
designated as a gateway. In this gateway, the
received data is converted to the transmission rate
required for the relevant data bus and is
transmitted. This ensures an optimal distribution
of information between both data bus systems.
Component Description
ABS
The GEM is integrated in the CJB (central junction
box) and cannot be replaced as a separate unit.
G1030779en
2008.50 Kuga 8/2011 418-00-8
Module Communications Network
418-00-8
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Programmable Module Installation
Activation
5.
Install the most up-to-date software version in
IDS.
6. If, before replacing a module, it was not possible
to read out the vehicle-specific data using the
integrated diagnostic system (IDS) (the module
to be replaced does not respond) then, during
programming of the new module, the
vehicle-specific data must be entered manually
via a selection list in IDS or via a code which
can be obtained from the Technical Hotline.
7. In order to program, select the "Install
programmable module" submenu in the "Module
programming" menu tool box and then follow
the instructions.
8. The following modules must be programmed
after replacement:
•
• Anti-lock braking system module (ABS)
• Audio system module (ACM)
• CD player (CDP)
• Driver's door control unit (D-DCU)
• Passenger's door control unit (P-DCU)
• Rear left door control unit (RL-DCU)
• Rear right door control unit (RR-DCU)
• Electrical power steering (EPS)
• Generic Display Module (GDM) (vehicles
with DVD navigation system with
touchscreen)
• Generic electronic module (GEM)
• Headlamp control module (HCM) (vehicles with gas discharge headlamps)
• Instrument cluster (IC)
• Navigation system (NAV) (vehicles with navigation system)
• Parking aid module(PAM)
• Powertrain control module (PCM)
• Restraint control module (RCM)
• Rear entertainment system module (RETM) (vehicles with rear seat entertainment
system)
9. In order to configure the PCM, select the
"Programmable parameters" submenu in the
"Module programming" menu tool box and then
follow the instructions.
10. For vehicles with anti-lock braking system and
electronic stability program, these must also be configured using IDS following replacement of
the lateral acceleration sensor, yaw rate sensor
or pressure sensor. Configuration is performed
in the "Programmable parameters" menu tool
box.
G1158258en
2008.50 Kuga 8/2011 418-01-3
Module Configuration
418-01-3
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Description
Item
High speed CAN (controller area network)
bus (HS-CAN)
1
DLC (data link connector)
2
Medium speed CAN bus (MS-CAN)
3
Instrument cluster (gateway)
4
GEM5
Hood contact switch
6
Folding rear window contact switch
7
Liftgate contact switch
8
Door ajar switch in all four doors
9
Switch for deactivation of interior scanning
sensors (right-hand drive vehicles)
10
Interior scanning sensorsRefer to Component Description: (page
?)
11 Description
Item
Driver's door set/reset switch
12
Driver's door door module
13
Keyless vehicle module (KVM)
14
RF receiver
15
Radio remote control
16
Anti-theft alarm system signal horn
(left-hand drive vehicles)
17
Anti-theft alarm system horn with
integrated battery (right-hand drive
vehicles)Refer to Component Description:
Anti-theft alarm horn with integral battery
(page ?)
18
Hazard warning lights
19
System Operation
Anti-theft warning system
Three anti-theft alarm systems are available,
depending on the market and model version:
• The system with perimeter monitoring detects whenever the doors, the hood, the folding rear
window and the liftgate are opened.
• The system with perimeter and interior monitoring in addition detects unauthorised
access, for example, through a broken window.
• A Thatcham category I anti-theft alarm system (mainly for the British market) is fitted with a
horn that has its own battery power supply; it
also uses slightly different detection strategies.
The anti-theft alarm system outputs an acoustic
and visual signal if unauthorised persons attempt
to gain access to the vehicle.
As a visual warning, the system switches on the
hazard warning lights, whilst the acoustic warning
is done with the anti-theft alarm system horn or the
horn with its own battery power supply.
When the ignition is switched off, the anti-theft
alarm system is activated 20 seconds after any
latch is activated, i.e. the hood, all doors, the
folding rear window and the liftgate are alarmed,
provided that they are fully closed. If the hood, one of the doors, the folding rear
window or the liftgate is not completely closed, it
can be opened without the alarm being triggered
since the system was not activated.
The anti-theft alarm system can be switched off by
unlocking the vehicle either via the remote controls
or the door lock.
NOTE:
To switch off the alarm on a Thatcham
category I anti-theft alarm system, the ignition must
be switched on within 12 seconds of the door being
unlocked with the key.
If the folding rear window or the liftgate is opened
via the remote control, the anti-theft alarm system
blocks the trigger for the alarm system or the
interior monitoring (if fitted) for 20 seconds after
closing.
NOTE: If a window is not fully closed, there is a
risk that a false alarm will be triggered. G1065780en
2008.50 Kuga 8/2011 419-01A-6
Anti-Theft - Active
419-01A-6
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Anti-Theft - Active
Refer to
Wiring Diagrams Section 419-01A, for
schematic and connector information. General Equipment
The Ford approved diagnostic tool
Inspection and Verification
1. Verify the customer concern, perform a full alarm function test
2. Visually inspect for obvious signs of mechanical
or electrical damage.
Visual Inspection Chart Electrical
Mechanical
– Fuse(s)
– Wiring harness
– Electricalconnector(s)
– Relay(s)
– Generic electronic module (GEM)
– Anti-theft alarm horn
– Anti-theft alarm horn
with integral battery
(if equipped)
– Misaligned door(s),
hood or tailgate
– Door ajar switche(s)
– Latch(es)
– Cable(s)
– Lock cylinder(s)
– Set/reset switch(s)
– Linkage(s)
– Remote key
– Passive key
– Interior scanning system
– Interior scanning system disable
button (if equipped)
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible)
before proceeding to the next step.
4. If the cause is not visually evident, verify the symptom and refer to the Ford approved
diagnostic tool to diagnose the system. G167420en
2008.50 Kuga 8/2011 419-01A-8
Anti-Theft - Active
419-01A-8
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