2011 FORD KUGA ELECTRICAL

Electrical consumers are switched off when the
battery voltage is low if the GEM determines (as a
result of the message received from the PCM on
the CAN bus via the instrument cluster) that the
battery voltage has dropped below the threshold
value.
When the threshold for low battery voltage is
reached the GEM switches off the following
consumers in this order at intervals of 5 seconds:
• Heated windscreen
• Heated rear window
• Electric booster Heater
• A/C system
If the battery voltage increases back above the
lower threshold then all of the consumers which
were previously switched off are reactivated by the
GEM.
Once the electric consumers have been reactivated
their status is "switched off", i.e. the consumers
are switched off and await an input signal provided
from the relevant switch via the GEM; this means
that the driver needs to switch these components
back on again.
Electrical consumers are switched on when the
battery voltage is excessively high if the GEM
determines that the battery voltage has increased
above the threshold for overvoltage and the
charging system warning indicator has come on.
When the threshold is reached the GEM switches
on the following consumers in this order at intervals
of 5 seconds:
• Heated windscreen
• Heated rear window
When these components are deactivated again
their status is "switched off". This means that the
consumers are waiting for an input signal provided
from the relevant switch via the GEM.
Ignition overload protection
The ignition overload protection intermittently
disconnects certain circuits in order to restrict the
current being drawn from the battery while the
starter motor is operating.
The position of the ignition switch is broadcast by
the instrument cluster on the medium speed CAN
bus.
The ignition overload protection relay which is
integrated in the battery junction box is activated
by the GEM if the message "ignition switch in
position III" is received from the instrument cluster.
All of the electric consumers controlled by the
ignition overload protection relay are then switched
off.
The following consumers (among others) are
controlled by the ignition overload protection relay:
• Fog lamps
• Windscreen/rear window wash/wipe systems
• Backup lamps
• Heated washer nozzles
• Heating blower motor
• Seat heating
Headlamp switch-off delay
The headlamp switch-off delay utilizes the low
beam together with the peripheral lights (if
equipped) to illuminate the area surrounding the
vehicle. The function is activated by operating the
high beam lever when the ignition switch is in the
"0" position.
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 set values at the
factory and cannot be re-programmed using the
Ford diagnostic unit.
G1030788en
2008.50 Kuga 8/2011 419-10-7
Multifunction Electronic Modules
419-10-7
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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

Output signals
SWITCH the wiper switch to the "intermittent""
position to test the output signals. PRESSING the
heated rear window switch activates the output
signals in the following order:
a.
Left-hand turn signal
b. Right-hand turn signal
c. Main beam
d. Dipped beam
e. Windshield wiper stage I
f. Windshield wiper stage II
g. Heated rear windshield
h. Heater blower motor
i. Headlamp washer system (vehicles with HID headlamps)
j. Electric booster heater (if fitted)
k. Autolamps (position lamps only if fitted)
l. Alarm horn (vehicles with alarm system)
m. Rear window wiper
n. Heated front window relay
When the heated rear window switch is pressed
again, the test of the relevant signal is terminated.
When the heated rear window switch is pressed
once more, the test for the next signal in the list is
started.
End service mode
The GEM automatically ends service mode 20
seconds after the last input or at a driving speed
of over 7km/h. However, service mode can be
manually ended at any time by proceeding as
follows:
• PRESS and HOLD the switch of the heated rear
window
• SWITCH OFF the ignition.
• RELEASE the switch of the heated rear window
3 signals sound and the turn signal lamps illuminate
to indicate that service mode has ended.
Reset service mode
If, after completion of service mode, some functions
do not operate or do not operate properly, check
the following functions:
• Instrument cluster illumination, side marker lamps (side lights) and licence plate lamp in
automatic headlamps mode
• Rear wiper
• Headlamp washer assembly
• Electric booster heater • Alarm horn
• Heated windshield
If one or more of the listed functions is not OK, it's
possible that the cause of the fault is due to not
exiting service mode properly. To reactivate the
functions correctly, perform the following steps:
1. Switch off the ignition.
2. SWITCH OFF the switch for the windscreen
wash/wipe system
3. OPERATE the switch of the heated rear window
and HOLD IT THERE
4. SWITCH ON the ignition.
5. RELEASE the heated rear window switch (an acoustic signal will sound if activation has been
performed correctly)
6. SWITCH the windscreen wash/wipe switch to the "Intermittent wipe" position
7. OPERATE the heated rear window switch 6 times (the main beam headlamps switch on and
off automatically)
8. SWITCH OFF the switch for the windscreen wash/wipe system
9. OPERATE the switch of the heated rear window
and HOLD IT THERE
10. Switch off the ignition.
11. RELEASE the heated rear window switch (three
acoustic signals will sound if activation has been
performed correctly)
After completion of the work, check all the
functions.
Inspection and Checking
NOTE: The generic electronic module (GEM) is
integrated into the central junction box (CJB).
1. VERIFY customer concern.
2. Visually CHECK for any obvious mechanical or electrical damage.
NOTE: Ensure correct locking of the wiring harness
connector.
Visual Inspection Electrical
Fuses
Wiring harness Connectors G1055084en
2008.50 Kuga 8/2011 419-10-12
Multifunction Electronic Modules
419-10-12
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All-wheel drive control unit
E100663
14
3
2
5
Description
Item
Electronic Control Unit
1
Control valve
2
Pressure/temperature sensor
3
Electrical connection CAN (controller area
network) databus
4
Electric feed pump connection
5
The all-wheel drive control unit is bolted directly to
the housing of the Haldex clutch.
It forms one unit made up of the control valve, a
pressure/temperature sensor, and a control
module. It receives signals from the PCM and from
the ABS control module via the CAN data bus. The
control module in the control unit uses these
signals to determine the fluid pressure that is
needed to actuate the clutch plates depending on
the requirement. This determines how much torque
should be transmitted to the rear wheels. All-wheel
drive is deactivated if a fault occurs in the all-wheel
drive control unit.
A preload of approx. 80 Nm is always present at
the Haldex clutch. The temperature sensor of the Haldex clutch is
installed near the control valve in the control unit
and is surrounded by the hydraulic fluid. The
temperature is transmitted to the control module
and is used for adaptation to the changing viscosity
of the hydraulic fluid. If the hydraulic fluid is cold,
the control valve has to be opened slightly more
than requested. This allowance has to be reduced
as the temperature increases. The normal working
temperature of the hydraulic fluid is between +40
°C and +60 °C. If the temperature rises above 100
°C, the clutch is depressurised; if the temperature
falls below 95 °C, the clutch is pressurised again.
All-wheel drive is deactivated and a diagnostic
trouble code set if a fault occurs in the temperature
sensor.
With Haldex Generations I and II, the control valve
was actuated via a stepper motor. With Haldex
Generation III, the stepper motor has been omitted.
The control valve is now actuated via a solenoid
valve. The solenoid valve is actuated by the control
module in the all-wheel drive control unit by means
of pulse width modulation. The pulse width
modulation determines the position of the
adjustment spindle and thus the opening cross
section of the return hole. This is how the pressure
at the working piston of the plates is determined.
If the return hole is fully closed, maximum pressure
is applied to the plates. If the return hole is fully
open, the plates are unpressurized.
Electric feed pump
The electric feed pump is installed in the clutch
unit. It works according to the gerotor principle.
The main purpose of the feed pump is to fill the
pressure accumulator and the space behind the
pump plunger with hydraulic fluid, thereby ensuring
a fast response time of the Haldex clutch. The feed
pump used in the third generation is designed to
achieve an even higher pressure than the base
pressure of 4 bar. It is supplied with current by the
control module in the all-wheel drive control unit
when the engine is running above approx. 400 rpm.
Pressure control - 3rd generation
Haldex clutch
G1076981en2008.50 Kuga8/2011
205-02-
10
Rear Drive Axle/Differential
205-02- 10
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Brake System
General EquipmentPressure/vacuum gauge set
The Ford approved diagnostic tool
The brake system operates by transferring effort
applied to the brake pedal by the driver to the
brakes at each wheel.
The braking effort is distributed to each wheel,
using a hydraulic system. The system is assisted
using a vacuum brake booster that reduces pedal
effort and increases hydraulic pressure.
The parking brake operates on the rear wheels
and is applied using a hand operated control.
Inspection and Verification
NOTE: Before carrying out any diagnosis, make
sure that the brake system warning indicator is
functional.
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical or electrical damage.
Visual Inspection Chart
Electrical
Mechanical
• Electricalconnector(s)
• Wiring harness(s)
• Switch(es)
• Tire pressure(s)
• Wheels and tires
• Fluid leak(s)
3. If an obvious cause for an observed or reported concern is found, correct the case (if possible)
before proceeding to the next step.
4. If the cause if not visually evident, verify the symptom and refer to the Symptom Chart.
Road Test
Carry out a road test to compare actual vehicle
braking performance with the performance
standards expected by the driver. The ability of the
test driver to make valid comparisons and detect
performance deficiencies will depend on
experience.
The driver should have a thorough knowledge of
the brake system operation and accepted general performance guidelines to make good comparisons
and detect performance concerns.
An experienced technician will always establish a
route that will be used for all brake diagnosis road
tests. The road selected will be reasonably smooth
and level. Gravel or bumpy roads are not suitable
because the surface does not allow the tires to grip
the road equally. Crowned roads should be avoided
because of the large amount of weight shifted to
the low set of wheels on this type of road. Once
the route is established and consistently used, the
road surface variable can be eliminated from the
test results.
Before a road test, get a complete description of
the customer concerns or suspected condition.
From the description, the technician will be able to
match possible causes with symptoms. Certain
components will be identified as possible sources
while others will be eliminated by the evidence.
More importantly, the customer description can
reveal unsafe conditions which should be checked
or corrected before a road test. The description will
also help form the basic approach to the road test
by narrowing the concern to specific components,
vehicle speed or conditions.
Begin the road test with a general brake
performance check. Using the description of the
concern, test the brakes at different vehicle speeds
using both light and heavy pedal pressure.
Determine if the concern is in the front or rear
braking system. First use the foot brake and then
the parking brake. If the condition (i.e. pull,
vibration, pulsation) occurs only on operation of
the parking brake, the concern is in the rear brake
system. If the condition occurs when the foot brake
is depressed, the concern is in the front brake
system.
Avoid locking the brakes and sliding the tires. This
condition will not indicate brake efficiency. A heavily
braked but turning wheel will stop the vehicle in a
shorter distance than locked wheels.
If the concern becomes evident during this check,
make sure it fits the description given before the
road test. If the concern is not evident, attempt to
duplicate the condition using the information from
the description.
If a concern exists, use the Brake System Symptom
Chart in order to isolate it to a specific sub-system
and condition description. From this description, a
list of possible sources can be used to further
G1058975en2008.50 Kuga8/2011
206-00-
4
Brake System - General Information
206-00- 4
DIAGNOSIS AND TESTING
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Parking Brake
Inspection and Verification
1. Verify the customer concern by operating theparking brake system.
2. Visually inspect for obvious signs of mechanical or electrical damage.
Visual Inspection Chart
Electrical
Mechanical
– Parking brakewarning circuit.
REFER to: Instru-
ment Cluster (413-
01 Instrument
Cluster, Diagnosis
and Testing).
– Parking brake
control
REFER to: Parking
Brake Control
(206-05 Parking
Brake and Actu-
ation, Removal
and Installation).
– Cable and conduit
REFER to: Parking
Brake Rear
Cables (206-05
Parking Brake and
Actuation,
Removal and
Installation). 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 concern is not visually evident, verify the symptom and refer to the Symptom Chart.
Symptom Chart
Symptom Chart
Action
Possible Sources
Symptom
• GO toPinpoint Test A.
• Parking brake control.
• Cable and conduit.
• The parking brake will not apply
• GO toPinpoint Test A.
• Parking brake control.
• The parking brake will not hold
the vehicle
• GO toPinpoint Test B.
• Parking brake control.
• Cable and conduit.
• The parking brake will not
release
G1063696en2008.50 Kuga8/2011
206-05- 4
Parking Brake and Actuation
206-05- 4
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Anti-Lock Control
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)
• Electricalconnector(s)
• Wiring harness(s).
• Anti-lock brake system (ABS)
module
• Wheel speed
sensor(s)
• Wheel speed sensor ring(s)
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.
G1058976en2008.50 Kuga8/2011
206-09A- 5
Anti-Lock Control
206-09A- 5
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Refer to
Wiring Diagrams Section 206-09A, for

The opto-electronic steering wheel rotation sensors
use light barriers for contactless scanning of a
segment disk which is connected fixedly to the
steering shaft.
E54014
1
23
4
Description
Item
Segment disk
1
Photoelectric barrier
2
Electronics
3
Electrical connection
4
Use is made of opto-electronic types of sensors
with relative and absolute steering angle sensing.
For relative steering angle sensing, changes in the
steering angle are measured exclusively by the
sensor and transmitted to the ABS/ESP module.
With the aid of other vehicle status signals (e.g.
wheel speed sensors) the module calculates the
straight ahead position of the steering. For absolute
steering angle sensing, the sensor transmits a
specific signal to the module for each steering
angle position (in relation to one turn of the steering
wheel). The straight ahead position of the steering
is therefore defined in the sensor. On an absolute
steering angle sensor, several photoelectric barrier
modules are distributed around the segment disk
at varying distances. The gaps between segments
of the segment disk are also unequal. For each specific steering angle there is therefore a specific
switch status of all photoelectric barriers.
ABS/ESP module or hydraulic control unit
(HCU)
E97648
1
2
3
Description
Item
ABS Pump Motor
1
Valve block (with low-pressure
accumulators)
2
ABS module
3
The HCU comprises the ABS module, the valve
block (with low-pressure accumulators) and the
ABS pump.
The valve block combines all of the brake pressure
control valves in one unit. Depending on the
system, either simple changeover valves or
proportioning valves (e.g. on EBD (electronic brake
force distribution) systems) are installed. The
low-pressure accumulators store the brake fluid
that is returned from the wheel brakes during the
pressure reduction phase until it is drawn back into
the system by the ABS pump.
The ABS pump is designed as a dual piston pump.
This means that two separate pump elements
assure an increase in brake pressure during control
interventions. A direct current motor drives the
pump pistons via an eccentric shaft.
The ABS/ESP module monitors the input signals
of all sensors and actuates the electro-magnetic
brake pressure valves and the ABS pump as
required. For reasons of safety, the module is of
the redundant type, whereby processing of the
signals is carried out via two separate processors
that also monitor each other.
G1001304en2008.50 Kuga8/2011
206-09B- 12
Anti-Lock Control - Stability Assist
206-09B- 12
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