calibration FORD KUGA 2011 1.G Workshop Manual

100-00-48
Lubricants and Greases ........................................................................\
.............................
100-00-48
Transmission Fluids ........................................................................\
....................................
100-00-49
Noise ........................................................................\
..........................................................
100-00-49
Noise Insulation Materials ........................................................................\
..........................
100-00-49
O-Rings (Fluoroelastomer) ........................................................................\
.........................
100-00-49
Paints ........................................................................\
..........................................................
100-00-50
Pressurized Equipment ........................................................................\
..............................
100-00-50
Solder ........................................................................\
.........................................................
100-00-50
Solvents ........................................................................\
......................................................
100-00-50
Sound Insulation ........................................................................\
.........................................
100-00-50
Suspended Loads ........................................................................\
.......................................
100-00-50
Transmission Brake Bands ........................................................................\
.........................
100-00-50
Underseal ........................................................................\
...................................................
100-00-50
Viton ........................................................................\
............................................................
100-00-51
Welding ........................................................................\
.......................................................
100-00-52
Warning Symbols on Vehicles ........................................................................\
....................
100-00-53
White Spirit ........................................................................\
.................................................
100-00-54
Standard Workshop Practices ........................................................................\
....................
100-00-54
Vehicle in Workshop ........................................................................\
...................................
100-00-54
Towing the Vehicle ........................................................................\
......................................
100-00-54
Connecting a Slave Battery Using Jumper Cables ............................................................
100-00-55
Component Cleaning ........................................................................\
..................................
100-00-55
Calibration of Essential Measuring Equipment ...................................................................
100-00-57
Solvents, Sealants and Adhesives ........................................................................\
.............
100-00-57
Introduction ........................................................................\
.................................................
100-00-58
Road/Roller Testing ........................................................................\
....................................
100-00-58
Pre-Test Checks ........................................................................\
.........................................
100-00-58
Starting the Engine ........................................................................\
.....................................
100-00-58
Road or Roller Testing ........................................................................\
................................
100-00-59
Brake Testing ........................................................................\
..............................................
100-00-60
Air Conditioning (A/C) System Health and Safety Precautions ..........................................
100-00-61
Battery and Battery Charging Health and Safety Precautions ............................................
100-00-62
Brake System Health and Safety Precautions
....................................................................
100-00-63
Engine

Cooling System Health and Safety Precautions .....................................................
100-00-64
Petrol and Petrol-Ethanol Fuel Systems Health and Safety Precautions ...........................
100-00-65
Supplemental Restraint System (SRS) Health and Safety Precautions .............................
100-00-66
Window Glass Health and Safety Precautions ...................................................................
100-00-67
Body Repair Health and Safety and General Precautions .................................................
100-00-67
General ........................................................................\
.......................................................
100-00-68
Personal protection ........................................................................\
.....................................
100-00-69
Protection of the vehicle ........................................................................\
.............................
100-00-2
General Information
100-00- 2
.
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PAGE 2 OF 2 FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

TIM0103001
WARNING: Make sure that the ends of the
jumper cables do not touch each other or
ground against the vehicle body at any
time while the cables are attached to the
battery. A fully charged battery, if shorted
through jumper cables, can discharge at
a rate well above 1000 amps causing
violent arcing and very rapid heating of the
jumper cables and terminals, and can even
cause the battery to explode. Failure to
follow these instructions may result in
personal injury.
Always connect the jumper cables in the following
sequence:
– Slave battery positive first and then vehicle battery positive.
– Slave battery negative next and then vehicle ground at least 12 inches (300 mm) from the
battery terminal, for example engine lifting eye.
Always reduce the engine speed to idle before
disconnecting the jumper cables.
Before removing the jumper cables from the vehicle
that had the discharged battery, switch on the
heater blower (high) or the heated rear window, to
reduce the voltage peak when the cables are
removed.
Always disconnect the jumper cables in the reverse
order to the connecting sequence and do not short
the ends of the cables.
Do not rely on the generator to restore a
discharged battery. For a generator to recharge a
battery, it would take in excess of eight hours
continuous driving with no additional loads placed
on the battery.
Component Cleaning
To prevent the ingress of dirt, accumulations of
loose dirt and greasy deposits should be removed before disconnecting or dismantling components
or assemblies.
Components should be thoroughly cleaned before
inspection prior to reassembly.
Cleaning Methods:
– Dry cleaning.
– Removal of loose dirt with soft or cable brushes.
– Scraping dirt off with a piece of metal or wood.
– Wiping off with a rag.
WARNING: Wear eye protection when
cleaning vehicle components with
compressed air, a steam cleaner or a
power washer. Failure to follow this
instruction may result in personal injury.
CAUTIONS:
Compressed air is sometimes 'wet' so use
with caution, especially on hydraulic
systems.
To prevent damage to the electrical
connectors in the engine compartment, do
not use a steam cleaner or a power washer
to clean the engine compartment.
– Blowing dirt off with compressed air.
– Removal of dry dust using vacuum equipment. This method must always be used to remove
friction lining material dust (asbestos particles).
– Steam cleaning.
WARNING: Most solvents require careful
handling and some are harmful. Refer to
Health and Safety Precautions and to the
manufacturers literature for the relevant
safety precautions. Failure to follow these
instructions may result in personal injury.
Various solvents are available which are suitable
for component cleaning. Some components, such
as brake hydraulic parts and electrical assemblies
should be cleaned only with recommended solvents
— refer to Solvents, Sealers and Adhesives or to
the section of the manual relevant to the
component.
Calibration of Essential Measuring
Equipment
WARNING: Equipment, which requires
regular calibration, must be calibrated in
accordance with the manufacturers
G17373en2008.50 Kuga8/2011
100-00- 55
General Information
100-00- 55
DESCRIPTION AND OPERATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Action
Possible Sources
Symptom
• CHECK the system for fuelleak(s). REPAIR or INSTALL
new parts as necessary.
• Fuel system leak(s).
• INSTALL a new fuel filter.
• Fuel filter blocked.
• INSTALL a new oil filter andengine oil.
• Incorrect engine oil.
• REFER to the Ford diagnosticequipment.
• Generator.
•
• Slipping clutch.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• ECT sensor.
• INSPECT the fuel injectors.CLEAN the fuel injectors or
INSTALL a new set of injectors
as required only after the
checks have been carried out.
REFER to: Fuel Injectors (303-
04 Fuel Charging and
Controls - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
• Fuel injectors.
• Using the Ford diagnosticequipment, CHECK for the
availability of a calibration
update.
• PCM calibration.
• CHECK the valve timing.REFER to: Timing Belt (303-01
Engine - 2.5L Duratec
(147kW/200PS) - VI5,
Removal and Installation).
• Incorrect valve timing.
• CHECK the engine compres-sion.
REFER to: Engine(303-00
Engine System - General
Information, Diagnosis and
Testing).
• Low cylinder compression.
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• CMP sensor.
• Engine cuts out during hard
acceleration
• Carry out a full enginediagnosis using the guided
diagnostic menu in the Ford
diagnostic equipment.
• CKP sensor.
G1183441en2008.50 Kuga8/2011
303-04A-
20
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 20
DIAGNOSIS AND TESTING
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Engine Ignition
General EquipmentFord diagnostic equipment
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of electrical damage. Visual Inspection Chart
Electrical
• Circuit(s)
• Wiring harness
• Electrical connector(s)
• Spark plug(s)
• Ignition coil-on-plug(s)
• Powertrain control module (PCM)
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 Symptom Chart.
Symptom Chart
Action
Possible Sources
Symptom
• CARRY OUT a KV test usingthe Ford diagnostic equipment.
• Spark plug(s).
• Engine misfire
• REFER to the Ford diagnosticequipment.
• Circuit(s).
• Ignition coil-on-plug(s).
•PCM.
• PCM calibration.
• CARRY OUT a KV test usingthe Ford diagnostic equipment.
• Spark plug(s).
• Engine stumbling
• REFER to the Ford diagnosticequipment.
• Circuit(s).
• Ignition coil-on-plug(s).
•PCM.
• PCM calibration.
• CARRY OUT a KV test usingthe Ford diagnostic equipment.
• Spark plug(s).
• Engine lacks power
• REFER to the Ford diagnosticequipment.
• Circuit(s).
• Ignition coil-on-plug(s).
G323557en2008.50 Kuga8/2011
303-07-
3
Engine Ignition— 2.5L Duratec (147kW/200PS) - VI5303-07-
3
DIAGNOSIS AND TESTING
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Air Conditioning (A/C) System Recovery, Evacuation and Charging
General EquipmentAir Conditioning Service Unit
Automatic Calibration Halogen Leak Detector
Electronic Leak Detector
Refrigerant Identification Equipment
UV Leak Detector
1. Refer to: Air Conditioning (A/C) System Health
and Safety Precautions (100-00 General
Information, Description and Operation).
2.
E100846
x4
3. CAUTION: The refrigerant analyzer must be used before recovery, otherwise the
refrigerant center may become
contaminated. Contaminated refrigerant
must be disposed of as hazardous
waste. Always follow the manufacturer's
instructions when using the refrigerant
center and the refrigerant analyzer.
Unscrew and remove the protective caps from
the A/C charging connections.
General Equipment: Air Conditioning Service Unit
General Equipment: Refrigerant Identification Equipment 4.
Low-pressure connection
1.
2. High-pressure connection
2
E51608
1
5. Connect the service unit lines to the filling
connection of the air conditioning system.
VFE0031288
6.Drain the air conditioning system via the
low-pressure port in accordance with the service
unit manufacturer instructions.
7. CAUTION: Make sure that the specified amount of refrigerant oil is added.
NOTE:This step is only required when installing
a new component.
Fill up with refrigerant oil.
Refer to: Specifications (412-00 Climate Control
System - General Information, Specifications).
Refer to: Refrigerant Oil Adding (412-00 Climate
Control System - General Information, General
Procedures).
8. Evacuate the air conditioning system in
accordance with the service unit manufacturer
instructions.
9. NOTE: The system is leak-tight if the pressure
increase does not exceed 20 mbar.
G1022208en2008.50 Kuga8/2011
412-00- 7
Climate Control System - General Information
412-00- 7
GENERAL PROCEDURES
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Perform the leak test, by closing the hand valves
on the gauge set, switching off the service unit
vacuum pump and observing the low pressure
gauge.
10. N O T E : This step is only necessary if the
pressure increase exceeds 20 mbar.
Locate and rectify any leaks in the A/C
refrigerant circuit using a leak tester.
General Equipment: UV Leak Detector
General Equipment: Electronic Leak Detector
General Equipment: Automatic Calibration Halogen Leak Detector
11 . Add refrigerant oil to the air conditioning system.
Refer to: Specifications (412-00 Climate Control
System - General Information, Specifications).
Refer to: Refrigerant Oil Adding (412-00 Climate
Control System - General Information, General
Procedures).
12. Fill the air conditioning system with liquid
through the high-pressure connection.
Refer to: Specifications (412-00 Climate Control
System - General Information, Specifications).
13. Open the shut-off valve on the high-pressure
side.
1.
2. Switch the service unit to "Fill" mode and fill
the system with the specified quantity of
liquid refrigerant (R134a).
14. Fill the air conditioning system with gas through
the low-pressure connection.
Refer to: Specifications (412-00 Climate Control
System - General Information, Specifications).
15. Open the shut-off valve on the low-pressure
side.
1.
2. Switch the service unit to "Fill" mode and fill
the system with the specified quantity of
gaseous refrigerant.
3. Add the remaining amount of refrigerant with the air conditioning switched on. To do so
run the engine at about 1200-1500 rev/min.
Set the air conditioning system to full cooling
power and fresh air mode. Set the blower
motor to the highest setting. Fill with the
remainder of the specified fill capacity.
16. Disconnect the service unit. 17.
Close the shut-off valve.
1.
2. Switch off the service unit.
3. Disconnect the service unit lines from the
filling connections of the air conditioning
system.
4. Screw the protective caps onto the charging connections.
18. Install all components in reverse order.
G1022208en2008.50 Kuga8/2011
412-00- 8
Climate Control System - General Information
412-00- 8
GENERAL PROCEDURES
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Electronic Leak Detection
1.Refer to: Air Conditioning (A/C) System Health
and Safety Precautions (100-00 General
Information, Description and Operation).
2. WARNINGS:
Before starting leak detection, make
sure that the area where it is to be done
is well ventilated. If the surrounding air
is contaminated with refrigerant gas, the
leak detector will indicate this gas all
the time. Odors from other chemicals
such as antifreeze, diesel fuel, disc
brake cleaner, or other cleaning
solvents can cause the same problem.
Prevent air movement while performing
leak detection.
The refrigerant identification equipment
must be used before attaching the
manifold gauge set. Otherwise the
manifold gauge set may become
contaminated. Contaminated refrigerant
must be disposed of as special waste.
Follow the manufacturer's instructions
when working with the service unit.
NOTE: At 24°C with the engine switched off,
both manifold gauges should show 4.1 to 5.5
bar.
Attach the manifold gauge set to the service
gauge port valves.
3. For the leak test, close the manual valves on
the gauge set.
4. If little or no pressure is indicated, charge the
system with approx. 300g of refrigerant. Refer
to: Air Conditioning System - Evacuate and
Refill.
5. Use the R-134a Automatic Calibration Halogen
Leak Detector to leak test the refrigerant system.
Follow the instructions included with leak
detector for handling and operation techniques.
6. If any leak is found, extract the refrigerant under
suction. Refer to: Air Conditioning System -
Evacuate and Refill.
G549836en2008.50 Kuga8/2011
412-00- 14
Climate Control System - General Information
412-00- 14
GENERAL PROCEDURES
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Fluorescent Dye Leak Detection
General EquipmentUV Leak Detector
1. Refer to: Air Conditioning (A/C) System Health
and Safety Precautions (100-00 General
Information, Description and Operation).
2. NOTE: Some vehicles may have signs of
refrigerant oil at the spring lock couplers. The
cause of this may be a procedure used in
production before installation of the fittings in
order to assist their assembly. When a spring
lock coupler is suspected of leaking, always
wipe the fitting clean and verify the leak with
R-134a Automatic Calibration Halogen Leak
Detector.
NOTE: The exact location of leaks can be
pinpointed by the bright yellow - green glow of
the tracer dye. Since more than one leak can
exist, always inspect each component.
• Locate the leaks. Check all components, fittings and lines of the A/C system for leaks.
General Equipment: UV Leak Detector
3. After the leak is found and rectified, remove any
traces of dye with a general purpose solvent.
4. Check the repair by operating the system for
some minutes and inspecting with the UV lamp
again.
G1065493en2008.50 Kuga8/2011
412-00- 15
Climate Control System - General Information
412-00- 15
GENERAL PROCEDURES
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