Ford - Kuga - Parts Catalogue - 2013 - 2013 (3)

TF Ford Kuga 2013 BODY REPAIR SUMMARY INTRODUCTION ABS braking and Dynamic Stability Control (DSC) is fitted as standard across the range. Side curtain airbags are standard across the range. The innovative design of the Ford Kuga offers a high vehicle ride height as well as an elevated seat position. The purpose of this document is to provide vehicle body specialists with an overview of the Supplemental Restraint System (SRS) and important information about the body construction of the vehicle. Key vehicle body dimension information is also included. The body construction incorporates crumple zones which are designed to buckle at strategically placed weak points to transfer crash loads and maintain the cabin space of the passenger cell. Please note that this body repair summary is intended as an overview of the SRS and the body construction of the vehicle and as such is not comprehensive. For comprehensive information, the Workshop Manual, which is available from an Authorised Ford Dealer, should be consulted. Further engineered safety features include collapsible steering columns, breakaway pedals and specially designed door trims for side impact absorption. TF Ford Kuga Disclaimer The TF generation Ford Kuga is a 5-door crossover vehicle that seats 5 people and is available in three specification levels, Ambiente, Trend and Titanium. It is available with a fuel efficient 1.6L EcoBoost turbo charged petrol engine or a 2.0L turbo charged diesel. FWD is available on the Ambiente only with a 6 speed manual transmission. Automatic transmissions are standard on Ambiente, Trend and Titanium AWD variants. The information contained in this publication was correct at the time of going to print. The Ford Kuga has a comprehensive array of safety equipment. Copyright – Ford Motor Company of Australia Limited. Reproduction in whole or part prohibited without written approval. Copyright © 2013 Page 1 In the interests of development, Ford Motor Company of Australia Limited (“Ford”) reserves its rights to change specifications, designs or equipment at any time without notice and without incurring any obligations. This publication, or part thereof, may not be reproduced nor translated without the approval of Ford. To the maximum extent permitted by law Ford is not liable for any errors or omissions in this document. TF Ford Kuga 2013 HEALTH AND SAFETY Appropriate repair methods and carrying out repairs correctly are particularly important for the operating safety of vehicles and for the safety of people. All relevant regulations governing Health and Safety at Work must be complied with during any repairs. The various body areas are subject to very high forces during realignment work. Should any component suddenly become detached during this process, there is a very great danger of injury. For this reason, pulling chains and pulling shackles must be secured with arrester cables. Note: Please refer to the TF Ford Kuga Workshop Manual (available to purchase from your Authorised Ford Dealer) for detailed instructions and precautions regarding the repair of the vehicle’s Supplementry Restraint System. Some special instructions must be followed when working on airbag systems: Note: After disconnecting the power supply and before performing further work, a wait time of 15 minutes must be maintained. Work on airbag systems may only be performed by persons who have a relevant certificate of competency. • Always stand to the side of the airbag when removing or installing an airbag. • Always store an airbag or an airbag/steering wheel with the airbag side pointing upwards and in a safe place. • Only install the airbag again when the vehicle is fully repaired and the complete electrical system has been tested. • Take into account the location of side airbags. Pay attention to the following points: • Disconnect the battery negative clamp and cover the battery terminal. • Disconnect the electrical connector at the airbag control module. • If welding is to be performed directly near a control module, it must be removed beforehand. • Never connect the negative cable of the welder near an airbag or a control module. • Connect the negative cable of the welder close to the location of the weld. Page 2 TF Ford Kuga 2013 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Component location 6 2 3 4 5 7 9 10 1 13 12 11 14 E152551 Item Page 3 Description 1 Front impact sensor 2 Knee air bag 3 Instrument cluster with airbag telltale and belt warning display 4 Driver Air bag 5 Acceleration sensor 6 Safety belt retractor 7 Safety belt retractor 8 Safety belt switch 9 Side air curtain 10 Side air bag 11 Seat occupant sensor (passenger side only) 12 RCM (restraints control module) 13 Pressure sensor 14 Front passenger airbag TF Ford Kuga 2013 8 General Overview The RCM conducts a self-diagnosis as soon as the ignition is switched on. All components of the safety restraint system are checked, except the front safety belt buckle switches and the seat occupancy sensor on the passenger side. If a fault is present, the airbag telltale is activated. Pressure sensors which are designed to react fast, are used in the front doors of this vehicle. Because of the higher ride height of the vehicle, the force appears above the rocker panel and its kinetic energy is firstly directed into the doors. Only then do the side impact sensors detect a movement. If there is a side impact, the door outer skin is pressed in and an excess pressure is produced in the door. If the pressure change exceeds a certain value, then the sensor transmits a corresponding signal to the air bag control module. The sensor requires a suitable location against any situations when misapplication would occur. The front door could accidentally be opened against a bollard, or a ball could be kicked against a door. In order that no undesirable triggering can occur, a threshold value has been defined which lies above these cases of incorrect use; in addition, the triggering signal must be confirmed by the accelerometer in the side impact sensor or at the RCM (restraints control module). Use of the pressure sensors has achieved a saving in time of 2 milliseconds. Pressure sensor and accelerometer Page 4 TF Ford Kuga 2013 Airbag Reconnect Checklist SRS COMPONENT REPLACEMENT IN THE EVENT OF DEPLOYMENT The checklist below should be completed following diagnosis or repair of any airbag system concern: CAUTION Safety with SRS components is paramount. Note: Please refer to the TF Ford Kuga Workshop Manual (available from your Authorised Ford Dealer) for detailed instructions and precautions regarding the repair of the vehicle’s Supplementry Restraint System. When any deployable device (driver airbag, passenger airbag, side airbag, safety belt pretensioner, etc.) or combination of devices are deployed and/or the Restraint Control Module (RCM) has stored Diagnostic Trouble Codes (DTC’s) in memory, the repair of the vehicle’s Supplemental Restraint System (SRS) is to include the removal of all deployed devices and the installation of new deployable devices. • All restraint system diagnostic tools removed? • All in-seat harness connectors connected? • All airbag modules connected? • Safety belt pretensioner connectors connected? • RCM connected? • All sensors (front and side impact sensors) connected? • Battery connected? For further assistance on DTC’s contact your Authorised Ford Dealer. When any damage to the impact sensor mounting points or mounting hardware has occurred, repair or install new mounting points and mounting hardware as needed. During the repair process, inspect the entire vehicle for damage, including the following components: • Steering column and clock spring. • Instrument panel knee bolsters and mounting points. • Instrument panel braces and brackets. • Instrument panel and mounting points. • Seats and seat mounting points. • Safety belts, safety belt buckles and safety belt retractors, SRS wiring, wiring harnesses, and connectors. After a collision where the front airbag(s) and seat belt tensioners have deployed, replace the following components: • RCM unit. • Deployed airbag module(s). • Seat belt pretensioners. • Seat belt outer lap tensioners. • Front impact severity sensor After a collision where the side airbag(s) have deployed, replace the following components: • RCM unit. • Deployed side airbag module(s). • B-pillar side impact sensor(s). • Seat trim(s). Page 5 TF Ford Kuga 2013 BODY CONSTRUCTION Item Steel Type Color The body consists of the following: 1 Mild Steel Yellow 2 Bake Hardened Steel (BH) Light Blue 3 Solid Solution Strength Pink 4 High Strength Low Alloy (HSLA) Dark Blue Steel hood 5 Green Steel luggage compartment lid Dual Phase (DP) 500, 600 Class Steel 6 Dual Phase (DP) 700, 800, 900, 1000 Class Steel Fuchsia 7 Laminate Steel Teal 8 Ultra High Strength Steel (UHSS) Martensitic, Boron Red 9 Transformation Induced Plasticity Steel (TRIP) Gold 10 Aluminum Purple High-Strength Low Alloy (HSLA), ultra high-strength steel (UHSS) and mild steels Roof outer panel constructed of mild steel Body side outer panels constructed of mild steel Dual-phase steel (DP) in select body structure components Bolted, removable front fenders, hinged doors and hood Dent resistant steel fenders Ultra high-strength steel (UHSS) front and rear bumper beam Underbody components constructed of mild, dual-phase and high-strength steels Mastic pads used on floor pan for sound deadening For recommended metal repair guidelines and recommendations, refer to the following illustrations and: For additional information, refer to the TF Ford Kuga Workshop Manual. Steel Type Legend Page 6 TF Ford Kuga 2013 Front Structure Components Floor and Body Side Components NOTE: LH (left-hand) side shown, RH (right-hand) side similar. NOTE: LH side shown, RH side similar. Item Description Steel Type 1 A-pillar High-Strength Low Alloy (HSLA) steel 2 A-pillar inner reinforcement High-Strength Low Alloy (HSLA) steel 3 4 Front floor pan Mild steel Floor pan reinforcement Mild steel 5 Front floor crossmember (forward) Dual Phase Steel (DP) 600 steel 6 Front floor crossmember (rear) Dual Phase Steel (DP) 600 steel Item Description Steel Type 1 Bumper bracket High-Strength Low Alloy (HSLA) steel 2 Frame rail and apron assembly High-Strength Low Alloy (HSLA) steel 3 Dash panel Mild steel 4 Plenum Mild steel 5 Fender support High-Strength Low Alloy (HSLA) steel 6 Fender apron reinforcement Mild steel 7 Fender Bake Hardened Steel (BH) 7 8 Rear floor pan Mild steel 8 Fender apron bracket High-Strength Low Alloy (HSLA) steel Windshield pillar inner High-Strength Low Alloy (HSLA) steel 9 Windshield pillar outer Boron steel 10 Rear frame rail Dual Phase Steel (DP) 500 steel Page 7 TF Ford Kuga 2013 Floor and Body Side Components Rear Components NOTE: LH side shown, RH side similar. NOTE: LH side shown, RH side similar. Item Description Steel Type 11 Rear bumper bracket Dual Phase Steel (DP) 500 steel 12 B-pillar inner High-Strength Low Alloy (HSLA) steel 13 B-pillar outer Boron steel 14 Roof reinforcement Dual Phase Steel (DP) 780 steel 15 Liftgate hinge reinforcement Mild steel 16 Upper body support to wheel house High-Strength Low Alloy (HSLA) steel 17 Inner body side panel Mild steel 18 Outer wheel house Mild steel 19 Outer body uniside Mild steel 20 Lower body support to wheel house Dual Phase Steel (DP) 600 steel 21 Lower body panel reinforcement Mild steel 22 Rocker panel reinforcement High-Strength Low Alloy (HSLA) steel 23 Floor inner side member Dual Phase Steel (DP) 600 steel 24 Floor side member Mild steel filler Page 8 Item Description 1 Rear corner lower panel Mild steel 2 Rear corner upper panel Mild steel 3 Roof rear header panel Mild steel 4 Drain trough panel Mild steel 5 Rear opening reinforcement Mild steel 6 Rear lower panel reinforcement Mild steel 7 Rear lower back panel Mild steel 8 Rear bumper anchor plate High-Strength Low Alloy (HSLA) steel TF Ford Kuga 2013 Steel Type Roof Panel(s) Front Door NOTE: LH side shown, RH side similar. Item Description Steel Type 1 Roof panel without roof opening panel Mild steel 2 Roof panel with roof opening panel Mild steel 3 Roof panel reinforcement Dual Phase Steel (DP) 780 steel 4 Windshield header assembly High-Strength Low Alloy (HSLA) 350 steel 5 Roof bow (less moonroof ) Mild steel 6 Roof bow Mild steel 7 Rear header assembly Mild steel Page 9 Item Description Steel Type 1 Front door shell assembly Mild steel 2 Front door anti-flutter beam Mild steel 3 Front door intrusion beam Boron steel 4 Front door outer panel reinforcement Mild steel 5 Front door outer panel Bake Hardened Steel (BH) 250 steel TF Ford Kuga 2013 Rear Door NOTE: LH side shown, RH side similar. Item Description Steel Type 1 Rear door shell assembly Mild steel 2 Rear door anti-flutter beam Mild steel 3 Rear door intrusion beam Boron steel 4 Rear door outer panel reinforcement Mild steel 5 Rear door outer panel Bake Hardened Steel (BH) 250 steel Page 10 TF Ford Kuga 2013 Under Body Measurements NOTE: All measurements are on center unless otherwise indicated. Page 11 TF Ford Kuga 2013 Under Hood Dimensions NOTE: All measurements are on center unless otherwise indicated. Page 12 TF Ford Kuga 2013 Front Door Opening Dimensions NOTE: All measurements are on center unless otherwise indicated. Page 13 TF Ford Kuga 2013 Rear Door Opening Dimensions NOTE: All measurements are on center unless otherwise indicated. Page 14 TF Ford Kuga 2013 Liftgate Opening Dimensions NOTE: All measurements are on center unless otherwise indicated. Page 15 TF Ford Kuga 2013 Datum Height Dimensions NOTE: All other measurements are on center. Page 16 TF Ford Kuga 2013