ENGINE FORD KUGA 2011 1.G Workshop Manual

SECTION 100-00 General Information
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
DESCRIPTION AND OPERATION
100-00-3
About This Manual ........................................................................\
......................................
100-00-3
Introduction ........................................................................\
.................................................
100-00-4
How to use Repair Procedures ........................................................................\
...................
100-00-4
Global Authoring Standards (GAS) Repair Procedures ..................................................
100-00-18
How to use Diagnosis and Testing procedures ..................................................................
100-00-19
Symbols Glossary ........................................................................\
.......................................
100-00-41
Steering System Health and Safety Precautions ................................................................
100-00-42
Health and Safety Precautions ........................................................................\
...................
100-00-42
Introduction ........................................................................\
.................................................
100-00-42
Acids and Alkalis ........................................................................\
........................................
100-00-42
Air Bags ........................................................................\
......................................................
100-00-42
Air Conditioning Refrigerant ........................................................................\
.......................
100-00-42
Adhesives and Sealers ........................................................................\
...............................
100-00-43
Antifreeze ........................................................................\
...................................................
100-00-43
Asbestos ........................................................................\
.....................................................
100-00-44
Battery Acids ........................................................................\
..............................................
100-00-44
Brake and Clutch Linings and Pads ........................................................................\
...........
100-00-44
Brake Fluids (Polyalkylene Glycols) ........................................................................\
...........
100-00-44
Brazing ........................................................................\
.......................................................
100-00-44
Chemical Materials ........................................................................\
.....................................
100-00-45
Chlorofluorocarbons (CFC) ........................................................................\
........................
100-00-45
Clutch Fluids ........................................................................\
...............................................
100-00-45
Clutch Linings and Pads ........................................................................\
.............................
100-00-45
Corrosion Protection Materials ........................................................................\
...................
100-00-45
Cutting ........................................................................\
....................................................... .
100-00-45
Dewaxing ........................................................................\
....................................................
100-00-45
Dusts ........................................................................\
..........................................................
100-00-45
Electric Shock ........................................................................\
.............................................
100-00-45
Engine Oils ........................................................................\
.................................................
100-00-46
Exhaust Fumes ........................................................................\
...........................................
100-00-46
Fibre Insulation ........................................................................\
...........................................
100-00-46
Fire ........................................................................\
.............................................................
100-00-46
First Aid
........................................................................\
......................................................
100-00-46
Fluoroelastomer ........................................................................\
..........................................
100-00-46
Foams

- Polyurethane ........................................................................\
................................
100-00-47
Freon ........................................................................\
..........................................................
100-00-47
Fuels ........................................................................\
...........................................................
100-00-47
Gas Cylinders ........................................................................\
.............................................
100-00-47
Gases ........................................................................\
.........................................................
100-00-47
Gaskets (Fluoroelastomer) ........................................................................\
.........................
100-00-47
General Workshop Tools and Equipment ........................................................................\
...
100-00-48
High Pressure Air, Lubrication and Oil Test Equipment ......................................................
100-00-48
Halon ........................................................................\
..........................................................
100-00-48
Legal Aspects ........................................................................\
.............................................
100-00-1
General Information
100-00- 1
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PAGE 1 OF 2 FORD KUGA 2011.0MY WORKSHOP REPAIR 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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About This Manual
Introduction
This manual covers diagnosis and testing and
repair procedures.
It is structured into groups and sections, with
specific system sections grouped together under
their relevant group.
A group covers a specific portion of the vehicle.
The manual is divided into five groups, General
Information, Chassis, Powertrain, Electrical and
Body and Paint. The number of the group is the
first number of a section number.
Within Etis, the navigation tree will list the groups.
After selecting a group the navigation tree will then
list the sections within that group. Each section has
a contents list detailing Specifications, Description
and Operation, Diagnosis and Testing, General
Procedures, Disassembly and Assembly, Removal
and Installation.
References to LH (left-hand) and RH
(right-hand)
All LH and RH references to the vehicle are taken
from a position sitting in the driver seat looking
forward.
Vehicle LH and RH definition
E126780
12
Description
Item
LH
1
RH
2
All LH and RH references to the engine are taken
from a position at the flywheel looking towards the
crankshaft pulley.
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Description
Item
Self contained breathing apparatus
4
General prohibition used in combination
with another symbol
5
Do not use power tools
6
Visual check
7
Noise check
8
Dispose the specified component
9
Replaced by item 9 (Dispose the specified
component)
10
Set the engine speed to the specified
value
11Description
Item
Fully apply the parking brake lever
12
Fully release the parking brake lever
13
Do not dispose of batteries into the waste
bin
14
Visual check using a mirror
15
Area/component must be dry
16
Mandatory Protective equipment - Health and safety
symbols
The protective equipment symbols advise to use
a mandatory protective equipment to avoid or at
least reduce possible health and safety risks.
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Exhaust Fumes
These contain asphyxiating, harmful and toxic
chemicals and particles such as carbon oxides,
nitrogen oxides, aldehydes, lead and aromatic
hydrocarbons. Engines should be run only under
conditions of adequate exhaust extraction or
general ventilation and not in confined spaces.
Gasoline (petrol) engine
There may not be adequate warning of odor or of
irritation before toxic or harmful effects arise. These
may be immediate or delayed.
Diesel engine
Soot, discomfort and irritation usually give
adequate warning of hazardous fume
concentrations.
Fibre Insulation
See alsoDusts.
Used in noise and sound insulation.
The fibrous nature of surfaces and cut edges can
cause skin irritation. This is usually a physical and
not a chemical effect.
Precautions should be taken to avoid excessive
skin contact through careful organization of work
practices and the use of gloves.
Fire
See also Welding,Foams,Legal Aspects.
Many of the materials found on or associated with
the repair of vehicles are highly flammable. Some
give off toxic or harmful fumes if burnt.
Observe strict fire safety when storing and handling
flammable materials or solvents, particularly near
electrical equipment or welding processes.
Make sure, before using electrical or welding
equipment, that there is no fire hazard present.
Have a suitable fire extinguisher available when
using welding or heating equipment.
First Aid
Apart from meeting any legal requirements it is
desirable for someone in the workshop to be
trained in First Aid procedures.
Splashes in the eye should be flushed carefully
with clean water for at least ten minutes.
Soiled skin should be washed with soap and water.
In case of cold burns, from alternative fuels, place
affected area in cool to cold water.
Individuals affected by inhalation of gases and
fumes should be removed to fresh air immediately.
If effects persist, consult a doctor.
If liquids are swallowed inadvertently, consult a
doctor giving him the information on the container
or label. Do not induce vomiting unless this action
is indicated on the label.
Fluoroelastomer
See Viton.
Foams - Polyurethane
See also Fire.
Used in sound and noise insulation. Cured foams
used in seat and trim cushioning.
Follow manufacturers instructions.
Unreacted components are irritating and may be
harmful to the skin and eyes. Wear gloves and
goggles.
Individuals with chronic respiratory diseases,
asthma, bronchial medical problems, or histories
of allergic diseases should not work in or near
uncured materials.
The components, vapors or spray mists can cause
direct irritation, sensitivity reactions and may be
toxic or harmful.
Vapors and spray mists must not be inhaled. These
materials must be applied with adequate ventilation
and respiratory protection. Do not remove the
respirator immediately after spraying; wait until the
vapors/mists have cleared.
Burning of the uncured components and the cured
foams can generate toxic and harmful fumes.
Smoking, naked flames or the use of electrical
equipment during foaming operations and until
vapors/mists have cleared should not be allowed.
Any heat cutting of cured foams or partially cured
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Solvent-based Adhesives/Sealers - See
Solvents
Follow manufacturers instructions.
Water-based Adhesives/Sealers
Those based on polymer emulsions and rubber
latexes may contain small amounts of volatile toxic
and harmful chemicals. Skin and eye contact
should be avoided and adequate ventilation
provided during use.
Hot Melt Adhesives
In the solid state, they are safe. In the molten state
they may cause burns and health hazards may
arise from the inhalation of toxic fumes.
Use appropriate protective clothing and a
thermostatically controlled heater with a thermal
cut-out and adequate extraction.
Resin-based Adhesives/Sealers, for
example Epoxide and Formaldehyde
Resin-based
Mixing should be carried out in well ventilated
areas, as harmful or toxic volatile chemicals may
be released.
Skin contact with uncured resins and hardeners
can result in irritation, dermatitis, and absorption
of toxic or harmful chemicals through the skin.
Splashes can damage the eyes.
Provide adequate ventilation and avoid skin and
eye contact.
Anaerobic, Cyanoacrylate (super-glues)
and other Acrylic Adhesives
Many are irritant, sensitizing or harmful to the skin
and respiratory tract. Some are eye irritants.
Skin and eye contact should be avoided and the
manufacturers instructions followed.
Cyanoacrylate adhesives (super-glues) MUST NOT
contact the skin or eyes. If skin or eye tissue is
bonded, cover with a clean moist pad and SEEK
IMMEDIATE MEDICAL ATTENTION. Do not
attempt to pull tissue apart. Use in well ventilated
areas as vapors can cause irritation to the nose
and eyes.For two-pack systems see Resin-based and
Isocyanate Adhesives/Sealers.
Isocyanate (Polyurethane)
Adhesives/Sealers
See also
Resin-based Adhesives.
Individuals suffering from asthma or respiratory
allergies should not work with or near these
materials as sensitivity reactions can occur.
Over exposure is irritating to the eyes and
respiratory system. Excessive concentrations may
produce effects on the nervous system including
drowsiness. In extreme cases, loss of
consciousness may result. Long term exposure to
vapor concentrations may result in adverse health
effects.
Prolonged contact with the skin may have a
defatting effect which may lead to skin irritation
and in some cases, dermatitis.
Splashes entering the eye will cause discomfort
and possible damage.
Any spraying should preferably be carried out in
exhaust ventilated booths, removing vapors and
spray droplets from the breathing zone.
Wear appropriate gloves, eye and respiratory
protection.
Antifreeze
See also Fire, Solvents.
For example isopropanol, ethylene glycol,
methanol.
Highly flammable, flammable, combustible.
Used in vehicle coolant systems, brake air pressure
systems, screenwash solutions.
For additional information, refer to: Engine Cooling
System Health and Safety Precautions (100-00
General Information, Description and Operation).
Asbestos
See also Warning Symbols on Vehicles at the end
of this subsection.
Breathing asbestos dust may cause lung damage
or, in some cases, cancer.
Used in brake and clutch linings, transmission
brake bands and gaskets.
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dermatitis or be absorbed through the skin in
toxic or harmful quantities.
– Do not use emptied containers for other materials except when they have been cleaned
under supervised conditions.
– Do not sniff or smell chemical materials. Brief exposure to high concentrations of fumes can
be toxic or harmful.
Chlorofluorocarbons (CFC)
There is concern in the scientific community that
CFCs and Halons are depleting the upper ozone
layer which filters out harmful ultraviolet radiation.
Decreased filtration of ultraviolet radiation may
result in increases in skin cancer, cataracts and
immune system suppression in humans, as well
as decreased productivity of crops and aquatic
systems.
CFCs are used primarily as refrigerants in vehicle
air conditioning systems and as aerosol
propellants. Halons are used as fire extinguishants.
Clutch Fluids
See Brake fluids.
Clutch Linings and Pads
SeeAsbestos.
Corrosion Protection Materials
See also Solvents, Fire.
Highly flammable, flammable – observe No
Smoking policy.
These materials are varied and the manufacturers
instructions must be followed. They may contain
solvents, resins or petroleum products. Skin and
eye contact should be avoided. They should only
be sprayed in conditions of adequate ventilation
and not in confined spaces.
Cutting
See Welding.
Dewaxing
SeeSolvents andFuels (Kerosene).
Dusts
Powder, dusts or clouds may be irritant, harmful
or toxic. Avoid breathing dusts from powdery
chemical materials or those arising from dry
abrasion operations. Wear respiratory protection
if ventilation is inadequate.
Fine dusts of combustible material can present an
explosion hazard. Avoid explosive limits and
sources of ignition.
Electric Shock
Electric shock can result from the use of faulty
electrical equipment or from the misuse of
equipment in good condition.
Make sure that electrical equipment is maintained
in good condition and frequently tested. Faulty
equipment should be labeled and preferably
removed from the workstation.
Make sure that flexes, cables, plugs and sockets
are not frayed, kinked, cut, cracked or otherwise
damaged.
Make sure that electrical equipment and flexes do
not come into contact with water.
Make sure that electrical equipment is protected
by the correct rated fuse.
Never misuse electrical equipment and never use
equipment that is in any way faulty. The results
could be fatal.
Make sure that the cables of mobile electrical
equipment cannot get trapped and damaged, such
as in a vehicle hoist.
Make sure that the designated electrical workers
are trained in basic First Aid.
In cases of electrocution:
– switch off the power supply before approaching
the victim.
– if this is not possible push or drag the victim from the source of electricity using dry
non-conductive material.
– commence resuscitation if trained to do so.
– SUMMON MEDICAL ASSISTANCE.
Engine Oils
See Lubricants and Grease.
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Accidental eye contact should be dealt with as per
normal first aid practices, by flushing the eyes with
an eye wash or clean cool water for 10 minutes,
after which medical attention should be obtained.
Remove and launder clothing which becomes
contaminated with the fluids. Do not place rags
contaminated with fluid in clothing pockets.
Wash thoroughly after completing operations where
skin exposure may have occurred.
It is important that personnel do not smoke, eat or
drink whilst handling the fluids or affected
transmissions. These measures are designed to
limit the risk from accidental ingestion.
Label any decanted fluid properly/use an equivalent
label to that on original product containers.
Clean up any spills promptly using an inert
absorbent and wash down contaminated surfaces
with detergent and water.
Dispose of any waste fluids safely as hazardous
waste.
Safety Data Sheets
Safety Data Sheets, which detail specific material
handling instructions and precautions are available
from the respective national sales company, and
via internet www.msds.ford.com.
Used Engine Oil
Prolonged and repeated contact with mineral oil
will result in the removal of natural fats from the
skin, leading to dryness, irritation and dermatitis.
In addition, used engine oil contains potentially
harmful contaminants, which may cause skin
cancer. Adequate means of skin protection and
washing facilities must be provided.
Do not employ used engine oils as lubricants or
for any application where appreciable skin contact
is likely to occur.
Environmental Precautions
Burning used engine oil in small space heaters or
boilers can be recommended only for units of
approved design. If in doubt check with the
appropriate local authority and manufacturer of
approved appliances.
Dispose of used oil and used oil filters through
authorized waste disposal contractors or licensedwaste disposal sites, or to the waste oil reclamation
trade. If in doubt, contact the relevant local
authority for advice on disposal facilities.
It is illegal to pour used oil on to the ground, down
sewers or drains, or into watercourses.
Noise
Some operations may produce high noise levels,
which could, in time, damage hearing. In these
cases, suitable ear protection must be worn.
Noise Insulation Materials
See
Foams, Fibre Insulation.
O-Rings (Fluoroelastomer)
SeeViton.
Paints
See also Solvents, Chemical Materials.
Highly flammable, flammable - observe No
Smoking policy
One Pack
Can contain harmful or toxic pigments, driers and
other components as well as solvents. Spraying
should be carried out only with adequate
ventilation.
Two Pack
Can also contain harmful and toxic unreacted
resins and resin hardening agents. The
manufacturers instructions should be followed. See
also Resin-based Adhesives and Isocyanate
Adhesives and Sealers under Adhesives and
Sealers.
Spraying should preferably be carried out in
exhausted ventilated booths removing vapor and
spray mists from the breathing zone. Individuals
working in booths should wear appropriate
respiratory protection. Those doing small-scale
repair work in the open workshop should wear
air-fed respirators.
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Pressurized Equipment
See HighPressure Air, Lubrication and Oil Test
Equipment.
Solder
Solders are mixtures of metals such that the
melting point of the mixture is below that of the
constituent metals (normally lead and tin). Solder
application does not normally give rise to toxic lead
fumes, provided a gas/air flame is used.
Oxy-acetylene flames should not be used, as they
are much hotter and will cause lead fumes to be
produced.
Some fumes may be produced by the application
of any flame to surfaces coated with grease, and
inhalation of these should be avoided.
Removal of excess solder should be undertaken
with care, to make sure that fine lead dust is not
produced, which can give toxic effects if inhaled.
Respiratory protection may be necessary.
Solder spillage and filings should be collected and
removed promptly to prevent general air
contamination by lead.
High standards of personal hygiene are necessary
in order to avoid ingestion of lead or inhalation of
solder dust from clothing.
Solvents
See also Chemical Materials, Fuels (Kerosene),
Fire.
For example acetone, white spirit, toluene, xylene,
trichloroethane.
Used in cleaning and dewaxing materials, paints,
plastics, resins and thinners.
Some may be highly flammable or flammable.
Skin contact will degrease the skin and may result
in irritation and dermatitis following repeated or
prolonged contact. Some can be absorbed through
the skin in toxic or harmful quantities.
Splashes in the eye may cause severe irritation
and could lead to loss of vision.
Brief exposure of high concentrations of vapors or
mists will cause eye and throat irritation,
drowsiness, dizziness, headaches and, in the worst
circumstances, unconsciousness.
Repeated or prolonged exposure to excessive but
lower concentrations of vapors or mists, for which there might not be adequate warning indications,
can cause more serious toxic or harmful effects.
Aspiration into the lungs, for example through
vomiting, is the most serious consequence of
swallowing.
Avoid splashes to the skin, eyes and clothing. Wear
protective gloves, goggles and clothing if
necessary.
Make sure there is good ventilation when in use,
avoid breathing fumes, vapors and spray mists and
keep containers tightly sealed. Do not use in
confined spaces.
When spraying materials containing solvents, for
example paints, adhesive, coatings, use extraction
ventilation or personal respiratory protection in the
absence of adequate general ventilation.
Do not apply heat or flame except under specific
and detailed manufacturers instructions.
Sound Insulation
See
Fibre Insulation, Foams.
Suspended Loads
CAUTION: Never improvise lifting tackle.
There is always a danger when loads are lifted or
suspended. Never work under an unsupported,
suspended or raised load, for example a
suspended engine.
Always make sure that lifting equipment such as
jacks, hoists, axle stands and slings are adequate
and suitable for the job, in good condition and
regularly maintained.
Transmission Brake Bands
See Asbestos.
Underseal
SeeCorrosion Protection.
Viton
In common with many other manufacturers
vehicles, some components have O-rings, seals
or gaskets, which contain a material known as
`Viton'.
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SPECIAL PRECAUTIONS MUST BE TAKEN
BEFORE ANY WELDING OR CUTTING TAKES
PLACE ON VESSELS, WHICH HAVE
CONTAINED COMBUSTIBLE MATERIALS, FOR
EXAMPLE BOILING OR STEAMING OUT OF
FUEL TANKS.
Warning Symbols on Vehicles
Decals showing warning symbols will be found on
various vehicle components.
These decals must not be removed. The warnings
are for the attention of owners/operators and
persons carrying out service or repair operations
on the vehicle.
The most commonly found decals are reproduced
below together with an explanation of the warnings.
TIM0101001
1. Components or assemblies displaying thecaution triangle and open book symbol advise
consultation of the relevant section of the owner
literature before touching or attempting
adjustments of any kind.
TIM0101002
2. Components or assemblies displaying thewarning triangle with the `electrified' arrow and
open book symbol give warning of inherent high
voltages. Never touch these with the engine
running or the ignition switched on. See Electric
Shock in this subsection.
TIM0101003
3. Vehicles and replacement components whichcontain asbestos are identified by this symbol.
See Asbestos in this subsection.
TIM0101004
4. Components or assemblies displaying thissymbol give warning that the component
contains a corrosive substance. See Acids and
Alkalis in this subsection.
TIM0101005
5. Displaying the caution circle with a deletedlighted match symbol, caution against the use
of naked lights or flames within the immediate
vicinity due to the presence of highly flammable
or explosive liquids or vapors. See Fire in this
subsection.
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