TF Ford Kuga

2013

BODY REPAIR SUMMARY

INTRODUCTION ABS braking and Dynamic Stability Control (DSC) is fitted as
The purpose of this document is to provide standard across the range. Side curtain airbags are standard
vehicle body specialists with an overview of the across the range. The innovative design of the Ford Kuga
Supplemental Restraint System (SRS) and important offers a high vehicle ride height as well as an elevated seat
information about the body construction of the position.
vehicle. Key vehicle body dimension information is The body construction incorporates crumple zones which
also included. are designed to buckle at strategically placed weak points
Please note that this body repair summary is to transfer crash loads and maintain the cabin space of the
intended as an overview of the SRS and the body passenger cell.
construction of the vehicle and as such is not Further engineered safety features include collapsible
comprehensive. For comprehensive information, steering columns, breakaway pedals and specially designed
the Workshop Manual, which is available from an door trims for side impact absorption.
Authorised Ford Dealer, should be consulted.
TF Ford Kuga Disclaimer

The TF generation Ford Kuga is a 5-door crossover vehicle The information contained in this publication was correct at the time of
that seats 5 people and is available in three specification going to print.
levels, Ambiente, Trend and Titanium. It is available with a fuel In the interests of development, Ford Motor Company of Australia Limited
efficient 1.6L EcoBoost turbo charged petrol engine or a 2.0L (“Ford”) reserves its rights to change specifications, designs or equipment
at any time without notice and without incurring any obligations. This
turbo charged diesel. FWD is available on the Ambiente only publication, or part thereof, may not be reproduced nor translated without
with a 6 speed manual transmission. Automatic transmissions the approval of Ford. To the maximum extent permitted by law Ford is not
are standard on Ambiente, Trend and Titanium AWD variants. liable for any errors or omissions in this document.

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 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

5
4
3
2

8
9
10
11
1 12
13

14

E152551

Item 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

Page 3 TF Ford Kuga 2013

General Overview 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
The RCM conducts a self-diagnosis as soon as the ignition is and its kinetic energy is firstly directed into the doors. Only
switched on. All components of the safety restraint system then do the side impact sensors detect a movement.
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. 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

SRS COMPONENT REPLACEMENT IN THE EVENT OF Airbag Reconnect Checklist
DEPLOYMENT The checklist below should be completed following
diagnosis or repair of any airbag system concern:
CAUTION
• All restraint system diagnostic tools removed?
Safety with SRS components is paramount.
• All in-seat harness connectors connected?
Note: Please refer to the TF Ford Kuga Workshop Manual
(available from your Authorised Ford Dealer) for detailed • All airbag modules connected?
instructions and precautions regarding the repair of the
• Safety belt pretensioner connectors connected?
vehicle’s Supplementry Restraint System.
• RCM connected?
When any deployable device (driver airbag, passenger airbag,
side airbag, safety belt pretensioner, etc.) or combination of • All sensors (front and side impact sensors) connected?
devices are deployed and/or the Restraint Control Module • Battery connected?
(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.
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
High-Strength Low Alloy (HSLA), ultra high-strength steel
(UHSS) and mild steels 3 Solid Solution Strength Pink
4 High Strength Low Alloy Dark Blue
Roof outer panel constructed of mild steel (HSLA)
Steel hood 5 Dual Phase (DP) 500, 600 Green
Class Steel
Steel luggage compartment lid 6 Dual Phase (DP) 700, 800, Fuchsia
Body side outer panels constructed of mild steel 900, 1000 Class Steel
7 Laminate Steel Teal
Dual-phase steel (DP) in select body structure components
8 Ultra High Strength Steel Red
Bolted, removable front fenders, hinged doors and hood (UHSS) Martensitic, Boron
9 Transformation Induced Gold
Dent resistant steel fenders
Plasticity Steel (TRIP)
Ultra high-strength steel (UHSS) front and rear bumper beam 10 Aluminum Purple

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 High-Strength Low Alloy
Item Description Steel Type reinforcement (HSLA) steel
1 Bumper bracket High-Strength Low 3 Front floor pan Mild steel
Alloy (HSLA) steel
4 Floor pan Mild steel
2 Frame rail and apron High-Strength Low reinforcement
assembly Alloy (HSLA) steel
5 Front floor Dual Phase Steel (DP) 600
3 Dash panel Mild steel crossmember steel
4 Plenum Mild steel (forward)
5 Fender support High-Strength Low 6 Front floor Dual Phase Steel (DP) 600
Alloy (HSLA) steel crossmember steel
6 Fender apron reinforcement Mild steel (rear)

7 Fender Bake Hardened Steel 7 Rear floor pan Mild steel

(BH) 8 Windshield pillar High-Strength Low Alloy
8 Fender apron bracket High-Strength Low inner (HSLA) steel
Alloy (HSLA) steel 9 Windshield pillar Boron steel
outer
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 Dual Phase Steel (DP) 500
bracket steel
12 B-pillar inner High-Strength Low Alloy
(HSLA) steel
13 B-pillar outer Boron steel

14 Roof Dual Phase Steel (DP) 780

reinforcement steel
15 Liftgate hinge Mild steel
reinforcement
16 Upper body High-Strength Low Alloy
support to wheel (HSLA) steel
house
17 Inner body side Mild steel
panel
18 Outer wheel house Mild steel
19 Outer body uni- Mild steel
side
20 Lower body Dual Phase Steel (DP) 600
support to wheel steel
house
21 Lower body panel Mild steel Item Description Steel Type
reinforcement
1 Rear corner lower panel Mild steel
22 Rocker panel High-Strength Low Alloy
2 Rear corner upper Mild steel
reinforcement (HSLA) steel
panel
23 Floor inner side Dual Phase Steel (DP) 600
3 Roof rear header panel Mild steel
member steel
4 Drain trough panel Mild steel
24 Floor side member Mild steel
filler 5 Rear opening Mild steel
reinforcement
6 Rear lower panel Mild steel
reinforcement
7 Rear lower back panel Mild steel
8 Rear bumper anchor High-Strength Low Alloy
plate (HSLA) steel

Page 8 TF Ford Kuga 2013

Roof Panel(s) Front Door
NOTE: LH side shown, RH side similar.

Item Description Steel Type

1 Front door shell Mild steel
assembly
2 Front door anti-flutter Mild steel
beam
3 Front door intrusion Boron steel
beam
4 Front door outer panel Mild steel
Item Description Steel Type reinforcement
1 Roof panel without roof Mild steel 5 Front door outer panel Bake Hardened Steel
opening panel (BH) 250 steel
2 Roof panel with roof Mild steel
opening panel
3 Roof panel reinforcement Dual Phase Steel (DP)
780 steel
4 Windshield header High-Strength Low
assembly Alloy (HSLA) 350 steel
5 Roof bow (less moonroof ) Mild steel
6 Roof bow Mild steel
7 Rear header assembly Mild steel

Page 9 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 Mild steel
reinforcement
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