Index FORD KUGA 2011 1.G Workshop Manual
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FOREWORD
Page 3 of 2057
11 . X J D
: R U N V K R S 0 D Q X D O
7 D E O H R I & R Q W H Q W V
* 5 2 8 3 * H Q H U D O , Q I R U P D W L R Q
6 H U Y L F H , Q I R U P D W L R Q * H Q H U D O , Q I R U P D W L R Q
- D F N L Q J D Q G / L I W L Q J
1 R L V H 9 L E U D W L R Q D Q G + D U V K Q H V V
* 5 2 8 3 & K D V V L V
6 X V S H Q V L R Q
6 X V S H Q V L R Q 6 \ V W H P * H Q H U D O , Q I R U P D W L R Q
) U R Q W 6 X V S H Q V L R Q
5 H D U 6 X V S H Q V L R Q
: K H H O V D Q G 7 L U H V
' U L Y H O L Q H ' U L Y H V K D I W
5 H D U ' U L Y H $ [ O H ' L I I H U H Q W L D O
) U R Q W ' U L Y H + D O I V K D I W V
5 H D U ' U L Y H + D O I V K D I W V
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) U R Q W ' L V F % U D N H
5 H D U ' L V F % U D N H
3 D U N L Q J % U D N H D Q G $ F W X D W L R Q
+ \ G U D X O L F % U D N H $ F W X D W L R Q
3 R Z H U % U D N H $ F W X D W L R Q
$ Q W L / R F N & R Q W U R O $
$ Q W L / R F N & R Q W U R O 6 W D E L O L W \ $ V V L V W %
6 W H H U L Q J 6 \ V W H P 6 W H H U L Q J 6 \ V W H P * H Q H U D O , Q I R U P D W L R Q
3 R Z H U 6 W H H U L Q J
6 W H H U L Q J / L Q N D J H
6 W H H U L Q J & R O X P Q
6 W H H U L Q J & R O X P Q 6 Z L W F K H V
* 5 2 8 3 3 R Z H U W U D L Q
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( Q J L Q H / ' X U D W H F N : 3 6 9 ,
( Q J L Q H & R R O L Q J
) X H O & K D U J L Q J D Q G & R Q W U R O V / ' X U D W H F N : 3 6
9 , $
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( Q J L Q H , J Q L W L R Q / ' X U D W H F N : 3 6 9 ,
( Q J L Q H ( P L V V L R Q & R Q W U R O / ' X U D W H F N : 3 6 9 ,
, Q W D N H $ L U ' L V W U L E X W L R Q D Q G ) L O W H U L Q J / ' X U D W H F N : 3 6
9 ,
( Y D S R U D W L Y H ( P L V V L R Q V
( O H F W U R Q L F ( Q J L Q H & R Q W U R O V / ' X U D W H F N : 3 6
9 ,
$ X W R P D W L F 7 U D Q V P L V V L R Q 7 U D Q V D [ O H $ X W R P D W L F 7 U D Q V P L V V L R Q 7 U D Q V D [ O H 9 H K L F O H V : L W K 6 S H H G $ X W R P D W L F
7 U D Q V D [ O H $ : $ : '
7 U D Q V P L V V L R Q 7 U D Q V D [ O H & R R O L Q J 9 H K L F O H V : L W K 6 S H H G $ X W R P D W L F
7 U D Q V D [ O H $ : $ : ' 6 S H H G
$ X W R P D W L F 7 U D Q V D [ O H
' & 7
$ X W R P D W L F 7 U D Q V P L V V L R Q 7 U D Q V D [ O H ( [ W H U Q D O & R Q W U R O V 9 H K L F O H V : L W K
6 S H H G $ X W R P D W L F 7 U D Q V D [ O H $ :
$ : ' 6 S H H G $ X W R P D W L F 7 U D Q V D [ O H
' & 7
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7 U D Q V I H U & D V H 9 H K L F O H V : L W K 6 S H H G $ X W R P D W L F 7 U D Q V D [ O H $ :
$ : ' 6 S H H G $ X W R P D W L F 7 U D Q V D [ O H
' & 7
( [ K D X V W 6 \ V W H P ( [ K D X V W 6 \ V W H P / ' X U D W H F N : 3 6 9 ,
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) X H O 7 D Q N D Q G / L Q H V
$ F F H O H U D W L R Q & R Q W U R O
6 S H H G & R Q W U R O
* 5 2 8 3 ( O H F W U L F D O
& O L P D W H & R Q W U R O 6 \ V W H P
& O L P D W H & R Q W U R O 6 \ V W H P * H Q H U D O , Q I R U P D W L R Q
& O L P D W H & R Q W U R O
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, Q V W U X P H Q W D W L R Q D Q G : D U Q L Q J 6 \ V W H P V , Q V W U X P H Q W & O X V W H U D Q G 3 D Q H O , O O X P L Q D W L R Q
, Q V W U X P H Q W & O X V W H U
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3 D U N L Q J $ L G
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, Q I R U P D W L R Q D Q G ( Q W H U W D L Q P H Q W 6 \ V W H P
/ L J K W L Q J ( [ W H U L R U / L J K W L Q J
, Q W H U L R U / L J K W L Q J
' D \ W L P H 5 X Q Q L Q J / D P S V ' 5 / ( O H F W U L F D O ' L V W U L E X W L R Q
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$ Q W L 7 K H I W 3 D V V L Y H %
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* 5 2 8 3 % R G \ D Q G 3 D L Q W
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, Q W H U L R U 7 U L P D Q G 2 U Q D P H Q W D W L R Q
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5 H D U 9 L H Z 0 L U U R U V
6 H D W L Q J
* O D V V ) U D P H V D Q G 0 H F K D Q L V P V
, Q V W U X P H Q W 3 D Q H O D Q G & R Q V R O H
+ D Q G O H V / R F N V / D W F K H V D Q G ( Q W U \ 6 \ V W H P V
: L S H U V D Q G : D V K H U V
% X P S H U V
6 D I H W \ % H O W 6 \ V W H P $
6 X S S O H P H Q W D O 5 H V W U D L Q W 6 \ V W H P %
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% R G \ 5 H S D L U V 9 H K L F O H 6 S H F L I L F , Q I R U P D W L R Q D Q G 7 R O H U D Q F H
& K H F N V
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5 R R I 6 K H H W 0 H W D O 5 H S D L U V
6 L G H 3 D Q H O 6 K H H W 0 H W D O 5 H S D L U V
5 H D U ( Q G 6 K H H W 0 H W D O 5 H S D L U V
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) U D P H D Q G 0 R X Q W L Q J 8 Q L % R G \ 6 X E I U D P H D Q G 0 R X Q W L Q J 6 \ V W H P
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
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* 5 2 8 3
* H Q H U D O , Q I R U P D W L R Q
6 ( & 7 , 2 1 7 , 7 / ( 3 $ * (
6 H U Y L F H , Q I R U P D W L R Q * H Q H U D O , Q I R U P D W L R Q
- D F N L Q J D Q G / L I W L Q J
1 R L V H 9 L E U D W L R Q D Q G + D U V K Q H V V
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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 7 of 2057
![FORD KUGA 2011 1.G Workshop Manual 100-00-48
Lubricants and Greases ........................................................................\
.............................
100-00-48
Transmission Fluids .................................](/img/11/5478/w960_5478-6.png "FORD KUGA 2011 1.G Workshop Manual 100-00-48
Lubricants and Greases ........................................................................\
.............................
100-00-48
Transmission Fluids .................................")
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
Page 8 of 2057
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.
G836098en2008.50 Kuga8/2011
100-00- 3
General Information
100-00- 3
DESCRIPTION AND OPERATION
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Powertrain LH and RH definition
E126781
1
2
3
4
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.
G836098en2008.50 Kuga8/2011
100-00- 4
General Information
100-00- 4
DESCRIPTION AND OPERATION
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Types of self-locking nuts and bolts
NOTE:There are more types of self-locking fasteners available than shown in following illustration.
E126782
123
4567
Description
Item
Completely coated self-locking bolt
1
Partially coated self-locking bolt
2
Self-locking bolt with a locking washer
3
Self-locking nut with a plastic locking insert
4
Self-locking nut with thread deformation
(3 identations)
5
Self-locking nut with thread deformation
(to oval shape)
6
Self-locking nut with integrated locking ring
7
• All types of seals and gaskets must be discarded and new seals and gaskets installed
unless otherwise stated within the procedure.
• Nuts and bolts with a chemical coating for locking and/or sealing and/or antiseize must be
discarded unless the procedure advises to
reapply the coating with a specified material. • Nuts and bolts with a mechanical locking such
as thread inserts, thread deformation or locking
washers must be discarded and new nuts and
bolts installed unless otherwise stated within
the procedure.
• Torque to yield bolts must be discarded and new torque to yield bolts installed unless
otherwise stated within the procedure,
recognizable by a tightening torque with more
than one stage together with a torque angle.
Reuse of exterior trim parts
All type of glued exterior trim parts or parts
fastened with adhesive tape must be discarded
and new parts installed unless otherwise stated
within the procedure.
Specification data
Specification procedures will only contain technical
data that is not already part of a repair procedure.
Sequence of tasks
If components must be removed or installed in a
specific sequence, the sequence will be identified
G836098en2008.50 Kuga8/2011
100-00- 5
General Information
100-00- 5
DESCRIPTION AND OPERATION
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Page 11 of 2057
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.
E132042
x2
1
2
3
G836098en2008.50 Kuga8/2011
100-00- 6
General Information
100-00- 6
DESCRIPTION AND OPERATION
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