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).
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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