FORD KUGA 2011 1.G Repair Manual

Solvents, Sealants and Adhesives
Introduction
WARNING: Always handle all solvents,
sealers and adhesives with extreme care.
Some contain chemicals or give off fumes
which can be dangerous to health. Always
follow the manufacturers instructions. If in
doubt about any substance, particularly a
solvent, DO NOT use it.
CAUTION: If in doubt about the suitability
of any proprietary solvent or sealer for a
particular application, contact the
manufacturer of the product for
information regarding storage, handling
and application.
The Health and Safety Precautions subsection
refers to some commonly used chemicals and
materials, hazards associated with their use, and
safety measures to be taken.
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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
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Road/Roller Testing
Road or roller testing may be carried out for various
reasons and a procedure detailing pre-test checks,
engine starting and stopping, pre-driving checks,
on-test checks and final checks to be completed
on completion of the test is given below.
Unless complete vehicle performance is being
checked, the full road test procedure need not be
carried out. Instead, those items particularly
relevant to the system(s) being checked can be
extracted.
Pre-Test Checks
WARNING: If the brake system hydraulic
fluid level is low, pedal travel is excessive
or a hydraulic leak is found, do not attempt
to road test the vehicle until the reason for
the low fluid level, excessive pedal travel
or hydraulic leak is found and rectified.
It is suggested that pre-test checks and functional
tests of those systems and circuits which affect the
safe and legal operations of the vehicle, such as
brakes, lights and steering, should always be
carried out before the road or roller test.
With the ignition switched off, check:
– the engine oil level.
– the engine coolant level.
– the tires, for correct pressure, compatible types and tread patterns, and wear within limits.
– that there is sufficient fuel in the tank to complete the test.
– all around the engine, transmission and under the vehicle for oil, coolant, hydraulic and fuel
leaks. Make a note of any apparent leaks and
wipe off the surrounding areas to make it easier
to identify the extent of the leak on completion
of the test.
Starting the Engine
NOTE: On initial drive away from cold and within
the first 1.5 km (1 mile), do not depress the
accelerator pedal beyond half travel until the
vehicle has attained a minimum speed of 25 km/h
(15 miles/h). Never operate at high engine speed
or with the accelerator pedal at full travel whilst the
engine is cold.
With the ignition switched off, check: – that the parking brake is applied.
– that the gear lever is in the neutral position.
– that all instrument gauges (except fuel gauge)
read zero.
With the ignition switched on, check:
– that the ignition controlled warning lamps are illuminated.
– that the engine temperature gauge registers a reading compatible with the engine temperature.
– that the fuel gauge registers a reading appropriate to the fuel level in the tank.
– the operation of the parking brake warning lamp and fluid level warning indicator.
Road or Roller Testing
CAUTION: If road testing, check the brake
operation while still traveling at low speed
before continuing with the test. If the
brakes pull to one side, or appear to be
otherwise faulty, do not continue with the
road test until the fault has been found and
rectified.
During the road or roller test, check:
– that the clutch pedal operation is not stiff or heavy.
– that the initial gear engagement is smooth and there is no evidence of clutch drag.
– that the parking brake control operates smoothly and releases quickly and completely.
– that the clutch takes up the drive smoothly, without slip or judder.
– that gear changing is smooth with no abnormal noises or vibrations from the transmission.
– the engine power output is satisfactory, full power is achieved, acceleration is smooth and
pedal operation is not stiff or heavy, and engine
speed returns to idle correctly.
– there is no excessive or abnormally colored smoke from the engine under normal driving,
heavy load or overrun conditions.
– that steering operation, including power steering (if equipped), is smooth, accurate, not
excessively heavy or with excessive free play
or vibration.
– that the steering does not pull to one side and self centers smoothly after cornering.
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– that the speedometer, coolant temperaturegauge and tachometer (if equipped) register the
correct readings and operate correctly.
– that the switches and controls operate smoothly and positively, warning and indicator lamps
operate correctly and the direction indicator
control self cancels when the steering is
returned to the straight ahead position.
– that the heating and ventilation systems operate correctly and effectively.
– the brake operation and efficiency.
Brake Testing
WARNING: When brake testing, avoid
breathing the fumes from hot brakes, this
may contain asbestos dust which is
hazardous to health. Failure to follow this
instruction may result in personal injury.
For additional information, refer to: Health
and Safety Precautions (100-00 General
Information, Description and Operation).
CAUTIONS:
Avoid brake testing on busy roads where
it may cause inconvenience or danger to
other road users.
Brake testing which includes heavy brake
applications should not be carried out with
new brake pads/discs or linings/drums
until the components have bedded-in. New
brake friction components will not reach
full efficiency until the bedding-in process
is complete.
Test the brakes at several speeds within the normal
operating range using both light and heavy pedal
pressure. Note any tendency to snatch, pull or
drag, and any undue delay in application or
release.
Allow the vehicle to coast and note any tendency
to pull to one side, or evidence that the brakes are
binding.
After stopping the vehicle (not immediately after a
period of heavy braking), carefully check the brake
temperature. A brake disc or brake drum that feels
hot or is appreciably hotter than the others,
indicates that the brake is binding.
After completion of the test, check for: – oil, coolant, hydraulic, air and fuel leaks.
– abnormal temperature of any moving
components or assemblies, for example wheel
hubs, transmission and axle, which might
indicate over tightness or lack of lubrication.
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Air Conditioning (A/C) System Health and Safety Precautions
WARNINGS:
Only qualified technicians are allowed to
work on air conditioning (A/C) systems.
Air conditioning (A/C) system components
can become particularly hot or cold.
Make sure that the air conditioning (A/C)
system is at ambient temperature before
carrying out any repair.
When handling refrigerants, always wear
protective goggles and gloves made of
fluoroelastomer. Leather or fabric gloves
are not suitable.
SKIN CONTACT: If liquid refrigerant comes
into contact with the skin, it produces
severe frostbite. Immediately flush affected
areas with plenty of cold running water for
15 minutes. Seek medical attention.
EYE CONTACT: If refrigerant comes into
contact with the eyes, immediately flush
the eyes with plenty of running water for
15 minutes. Seek medical attention.
INHALED: Toxic gases generated when
refrigerant is heated are hazardous to
health. The gases have an irritating smell
and can cause lung damage. The
symptoms can continue for a long time
after having been in contact with the gases.
The gases can cause lung damage even if
the amount of gas in the air is too small to
smell.
Refrigerant is flammable and explosive.
Make sure that refrigerant bottles are not
exposed to temperatures greater than 45°C.
Make sure that the local regulations
regarding work on air conditioning (A/C)
systems are adhered to.
Make sure that refrigerant bottles are
closed properly.
Gaseous refrigerant has a higher density
than air. There is a danger of suffocation
when working close to the ground or in
workshop pits.
Provide adequate ventilation when
handling refrigerant.
Never release refrigerant into the
atmosphere.
Only use special tools, equipment and
lubricants that are approved for the type
of refrigerant being used.
Always follow the manufacturer’s
instructions for the correct servicing unit
operating procedure.
CAUTIONS:
Do not mix refrigerant oils for different
types of refrigerant.
Never mix different types of refrigerant or
equipment intended for them.
Only use refrigerant in gas form when
filling the system through the low-pressure
connection.
Only use refrigerant in liquid form when
filling the system through the
high-pressure connection.
Refrigerant attacks certain plastics. Only
use seals suitable for refrigerant.
If the air conditioning (A/C) compressor is
damaged, the fixed orifice tube can
become blocked with metal particles.
Any sort of blockage in the refrigerant
circuit will damage the air conditioning
(A/C) compressor irreparably.
If the air conditioning (A/C) system has
been opened for a period greater than 2
hours, a new receiver drier must be
installed and the evacuating time to be
increased by a minimum of 2 hours.
NOTE: New air conditioning (A/C) compressors
are delivered prefilled.
NOTE: Refrigerant oil in new air conditioning (A/C)
compressors can contain Teflon, visible as white
particles, which will not harm the system.
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Battery and Battery Charging Health and Safety Precautions
WARNINGS:
Batteries contain sulphuric acid, avoid
contact with skin, eyes or clothing. Wear
safety goggles when working near the
battery to protect against possible
splashing of the acid solution.
EYE CONTACT: If acid comes into contact
with the eyes, flush immediately with
plenty of running water for a minimum of
15 minutes. Seek immediate medical
attention.
SKIN CONTACT: If acid comes into contact
with the skin, flush immediately with plenty
of running water for a minimum of 15
minutes. Seek immediate medical attention.
SWALLOWED: If acid is swallowed, rinse
the mouth with plenty of water and then
drink plenty of water or milk. Do not induce
vomiting. Seek immediate medical
attention.
Batteries normally produce explosive
gases. Do not allow naked flames, sparks
or lighted substances to come near the
battery.
When charging the battery shield your face
and wear safety goggles. Provide adequate
ventilation.
CAUTION: Boost charging with excessive
current or voltage above 16 volts will
damage the battery.
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Brake System Health and Safety Precautions
WARNINGS:
EYE CONTACT: Brake fluid contains
polyglycol ethers and polyglycols. Avoid
contact with the eyes. Wash hands
thoroughly after handling. If brake fluid
comes into contact with the eyes, flush the
eyes with plenty of cold running water for
15 minutes. Seek medical attention for any
persistent eye irritation or abnormality.
SWALLOWED: Brake fluid contains
polyglycol ethers and polyglycols. If
swallowed, drink plenty of water. Seek
immediate medical attention.
INHALED: Dust from friction materials can
be harmful if inhaled.
Only use new specified brake fluid from
airtight containers.
CAUTION: If brake fluid is spilled on the
paintwork, the affected area must be
immediately washed down with cold water.
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Engine Cooling System Health and Safety Precautions
WARNINGS:
Extreme care must be exercised when
handling hot fluids. Always wash off spilled
fluids from affected areas of skin
immediately.
Vapors may be given off from antifreeze
when heated. Avoid breathing these
vapors.
SKIN CONTACT: Antifreeze may be
absorbed through the skin in toxic or
harmful quantities.
SWALLOWED: If antifreeze is swallowed,
drink plenty of water, induce vomiting.
Seek immediate medical attention.
Antifreeze must not be used in any cooling
or industrial water system that is
connected or linked to general water
supplies.
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Window Glass Health and Safety Precautions
WARNINGS:
Cured polyurethane (PU) adhesive can
degrade if subjected to high temperatures.
Isocyanide compounds can be released
when grinding or welding in close
proximity to cured PU adhesive.
SKIN CONTACT: Prolonged exposure to
polyurethane (PU) adhesive may cause
skin irritation. If PU adhesive comes into
contact with the skin, remove any
contaminated clothing. Immediately wash
the skin with soap and water. Seek medical
attention for any persistent skin irritation
or abnormality.
EYE CONTACT: Polyurethane (PU)
adhesive may cause severe irritation or
damage. If PU adhesive comes into contact
with the eyes, immediately flush eyes with
plenty of running water for at least 15
minutes. Seek immediate medical attention.
SWALLOWED: If polyurethane (PU)
adhesive is swallowed, flush the mouth
thoroughly. Do not induce vomiting.
Provide rest, warmth and fresh air. Seek
immediate medical attention.
INHALED: Persons having a respiratory
allergy may have an allergic reaction when
handling polyurethane (PU) adhesive.
INHALED: Polyurethane (PU) adhesive can
cause asthma like symptoms. Isocyanate
vapor from primer or PU adhesive can
cause allergies in the respiratory tract.
INHALED: If polyurethane (PU) adhesive
fumes are inhaled, move victim to fresh
air. Provide oxygen if necessary. If
breathing stops, provide artificial
respiration. Keep a victim warm and at rest.
Seek immediate medical attention.
CAUTIONS:
Make sure that the direct glazing for
bonded glass cutting blades are changed
where the cutting depth changes to avoid
damage to the body and trim panels.
During the curing period of the PU
adhesive, the door windows must be left
open to avoid a build up of pressure when
the doors are opened and closed.
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Petrol and Petrol-Ethanol Fuel Systems Health and SafetyPrecautions
WARNINGS:
Fuel may not give adequate warning before
toxic or harmful effects arise.
Exposure to fuel can be harmful and can
cause severe health damage or death.
Extreme care must be exercised when
handling hot fluids. Always wash off spilled
fluids from affected areas of skin
immediately.
Highly flammable mixtures are always
present and may ignite when working on
fuel systems. Do not allow naked flames,
sparks or lighted substances to come near
fuel related components.
Fuel must not be used as a cleaning agent.
Keep fuel containers tightly closed, out of
direct sunlight and in a cool area. Keep
away from heat sources, ignition sources
and oxidizing agents.
SKIN CONTACT: Excessive or prolonged
skin contact with diesel fuel may cause
serious skin disorders including skin
cancer.
SKIN CONTACT: Fuel is mildly irritating to
the skin and may cause dermatitis due to
defatting effect. Remove contaminated
clothing. Wash affected areas of skin with
soap and water. Seek medical attention for
any persistent skin irritation or
abnormality. Wash contaminated clothing
before reuse.
EYE CONTACT: Fuel is mildly irritating to
the eyes. Flush with plenty of running
water, blinking as often as possible. Do not
force the eyelid open. Seek medical
attention for any persistent eye irritation
or abnormality.
SWALLOWED: Fuel is moderately toxic
and tends to foam on vomiting. If drawn
into the lungs, inflammation may develop.
Do not induce vomiting. If spontaneous
vomiting occurs place the victim in a
forward position to reduce the risk of fuel
being drawn into the lungs. Give nothing
by mouth. If breathing but unconscious,
place in the recovery position. If breathing has stopped, apply artificial respiration.
Seek immediate medical attention.
INHALED: Fuel is toxic to the respiratory
and other body systems. Exposure may
result in various symptoms including
drowsiness, unconsciousness or severe
health damage. Move a victim to fresh air.
Keep a victim warm and at rest. If
unconscious, place in the recovery
position. If not breathing, apply artificial
respiration. Give cardiac massage if
necessary. Seek immediate medical
attention.
CAUTIONS:
Fuel injection equipment is manufactured
to very precise tolerances and fine
clearances. It is essential that absolute
cleanliness is observed when working with
these components.
Make sure that the workshop area in which
the vehicle is being worked on is as clean
and as dust free as possible.
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