can FORD KUGA 2011 1.G Workshop Manual

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thisissuewerecorrectatthetimeofgoingtoprint.Therighttochangeprices,specifications,
equipmentandmaintenanceinstructionsatanytimewithoutnoticeisreservedaspartofFORD
policyofcontinuousdevelopmentandimprovementforthebenefitofourcustomers.
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inanyform,electronic,mechanical,photocopy,recording,translationorbyanyothermeans
withoutpriorpermissionofFord Motor Company.Noliabilitycanbeacceptedforany
inaccuraciesinthispublication,althougheverypossiblecarehasbeentakentomakeitas
completeandaccurateaspossible.
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FOREWORD

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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Powertrain LH and RH definition
E126781
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Description
Item
front
1
right hand
2
rear
3
left hand
4
How to use Repair Procedures
This manual has been written in a format that is
designed to meet the needs of technicians
worldwide. It provides general descriptions for
accomplishing repair work with tested and effective
techniques.
Important Safety Instructions
Appropriate service methods and correct repair
procedures are essential for the safe and reliable
operation of all vehicles as well as the personal
safety of the individual carrying out the work.
Anyone who departs from the instructions provided
in this manual must first establish that personal safety or vehicle integrity is not compromised by
the choice of method, tools or components.
Warnings, Cautions and Notes in This
Manual
WARNING: Warnings are used to indicate
that failure to follow a procedure correctly
may result in personal injury.
CAUTION: Cautions are used to indicate
that failure to follow a procedure correctly
may result in damage to the vehicle or
equipment being used.
NOTE: Notes are used to provide additional
essential information required to carry out a
complete and satisfactory repair.
Generic warnings or cautions are in their relevant
description and operation procedure within section
100-00. If the generic warnings or cautions are
required for a procedure, there will be a referral to
the appropriate description and operation
procedure.
If a warning, caution or note only applies to one
step, it is placed at the beginning of the specific
step.
Global Authoring Standards (GAS) Repair
Procedures
NOTE: GAS style procedures can be identified by
steps that have no accompanying step text and
the magenta color of the electrical connectors and
fasteners such as nuts, bolts, clamps or clips.
A GAS removal and installation procedure uses a
sequence of color illustrations to indicate the order
to be followed when removing/disassembling or
installing/assembling a component.
Many of the GAS procedures will have the
installation information within the removal steps.
These procedures will have the following note at
the beginning of the procedure:
NOTE: Removal steps in this procedure may
contain installation details.
Reuse of fasteners and seals and gaskets
The following list details the general policy for the
reuse of fasteners and seals and gaskets.
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numerically in a graphic and the corresponding text
will be numbered accordingly.
Special Tools, Equipment, Materials and Torque
Figures
Special tools will be shown with the tool numbers
in the illustration. The special tool numbers, general
equipment, materials and torque figures used for
the procedure step will be shown in the text
column.
GAS Graphics
NOTE:Colors used in the graphic are as follows:
4
6
5
14
2
36
5
E141161
Description
Item
Blue - Target or primary component to be
removed/installed (or
disassembled/assembled).
1
Green - Components that need to be
removed prior to or installed after the
target/primary.
2
Description
Item
Brown - Components that need to be
removed prior to or installed after the
target/primary.
3
Yellow - Components to be set aside only,
that remains in the vehicle. Also
highlighted areas to inspect or adjust.
4
Magenta - Electrical connectors and
fasteners such as nuts, bolts, clamps, or
5
clips to be: detached, attached, loosened,
moved, removed or installed.
Pale Blue - Special tool(s), general
equipment, or common tools (used in an
uncommon way).
6
One illustration may have multiple steps assigned
to it.
Numbered pointers are used to indicate the number
of electrical connectors and fasteners such as nuts,
bolts, clamps and clips.
Items in the illustration can be transparent or use
cutouts to show hidden details.
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Instruction symbols are used to apply sealer,
lubricant, weight, tape or cleaning detergent to acomponent.
E84834
Location symbols are used to show the location of
a component or system within the vehicle.
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E84837
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1
1
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x12
Movement arrows are used to show three
dimensional or rotational movements. Thesemovements can include specific values inside the
symbol if required.
E84838
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TO BE UPDATED

Standard tool symbols recommend the use of
certain standard tools. These tools can includedimension values if required.
E84839
The following graphic illustrates a set of symbols
that are used to provide detailed information on
where to apply a material.
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E84840
Measurement symbols provide detailed information
on where to carry out a specific measurement.These symbols can include specific values if
required.
1
2
1
2
E84841
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Symbols Glossary
Symbols are used inside the graphics and in the
text area to enhance the information display.Movement Symbols
Movement symbols provide detailed information
to a required component movement. These
component movements can be rotational or 1-3
dimensional movements.
E88969
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8
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Description
Item
Apply the substance from the specified
tube
1
Apply the substance from the specified
cartridge
2
Apply the specified chemical with a brush
3
Apply the specified load to the specified
component
4
Apply a bead with a specific diameter from
the specified tube
5
Apply a bead with a specific diameter from
the specified cartridge
6
Apply the specified chemical with a roller
7
Apply hot glue to the specified component
8
Apply the specified amount of fluid from
the fluid can
9
Apply fluid from the fluid can
10
Clean the specified component with the
specified material
11Description
Item
Apply a broken bead from the specified
tube
12
Apply the specified chemical from a spray
can
13
Apply the specified lubricant to the
specified component
14
Apply spot welds to the specified
component
15
Apply a continuous weld to the specified
component
16
Handle the fluid using a syringe
17
Extract the specified amount of fluid using
a syringe
18
Measurement symbols
The measurement symbols are used to show
where to measure which type of measurement to
carry out a procedure step.
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