battery 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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E89021
123
56
798
12
4
13
Description
Item
Hazardous voltage/Electrical
shock/Electrocution
1
Fire Hazard/Highly flammable
2
Burn hazard/Hot surface
3
Automatic start-up
4
Toxic
5
Explosive material
6
Battery hazard
7Description
Item
Corrosive material
8
Lifting hazard
9
Hand crush/Force from above
10
Cutting of fingers or hand
11
Pressure hazard
12
Invisible laser radiation. Do not view
directly with optical instruments
(magnifiers). Class 1M laser product
13
G955392en2008.50 Kuga8/2011
100-00-
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General Information
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Health and Safety Precautions
Introduction
Many of the procedures associated with vehicle
maintenance and repair involve physical hazards
or other risks to health. This subsection lists,
alphabetically, some of these hazardous operations
and the materials and equipment associated with
them. Precautions necessary to avoid these
hazards are identified.
The list is not exhaustive and all operations and
procedures, and the handling of materials, should
be carried out with health and safety in mind.
Before using any product the Materials Safety Data
Sheet supplied by the manufacturer or supplier
should be consulted.
Acids and Alkalis
See alsoBattery Acids.
For example caustic soda, sulphuric acid.
Used in batteries and cleaning materials.
Irritant and corrosive to the skin, eyes, nose and
throat. Cause burns. Can destroy ordinary
protective clothing.
Avoid splashes to the skin, eyes and clothing. Wear
suitable protective impervious apron, gloves and
goggles. Do not breath mists.
Make sure access to eye wash bottles, shower and
soap are readily available for splashing accidents.
Display Eye Hazard sign.
Air Bags
See also Fire, Chemical Materials.
Highly flammable, explosive – observe No Smoking
policy.
Used as a safety restraint system mounted in the
steering wheel and passenger side of the
instrument panel.
The inflator contains a high-energetic propellant
which, when ignited, produces a VERY HOT GAS
(2500°C).
The gas generant used in air bags is Sodium Azide.
This material is hermetically sealed in the module
and is completely consumed during deployment.
No attempt should be made to open an air bag inflator as this will lead to the risk of exposure to
Sodium Azide. If a gas generator is ruptured, full
protective clothing should be worn when dealing
with the spillage.
After normal deployment, gloves and safety
goggles must be worn during the handling process.
Deployed air bags should be disposed of in a
plastic bag in accordance with local regulations at
an approved chemical waste site.
For additional information, refer to:
Supplemental
Restraint System (SRS) Health and Safety
Precautions (100-00 General Information,
Description and Operation).
Air Conditioning Refrigerant
See also Chlorofluorocarbon, Chemical Materials
Highly flammable, combustible – observe No
Smoking policy.
Skin contact may result in frostbite.
Instructions given by the manufacturer must be
followed. Avoid naked lights, wear suitable
protective gloves and goggles.
If refrigerant comes into contact with the skin or
eyes, immediately rinse the affected areas with
water. Eyes should also be rinsed with an
appropriate irrigation solution and should not be
rubbed. SEEK MEDICAL ASSISTANCE IF
NECESSARY.
For additional information, refer to: Air Conditioning
(A/C) System Health and Safety Precautions
(100-00 General Information, Description and
Operation).
Adhesives and Sealers
See also Fire, Chemical Materials.
Highly flammable, flammable, combustible –
observe No Smoking policy.
Generally should be stored in No Smoking areas.
Cleanliness and tidiness in use should be
observed, for example disposable paper covering
benches; should be dispensed from applicators
where possible; containers, including secondary
containers, should be labeled appropriately.
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The use of drum cleaning units, vacuum cleaning
or damp wiping is preferred.
Asbestos dust waste should be dampened, placed
in a sealed container and marked for safe disposal.
If any cutting or drilling is attempted on materials
containing asbestos the item should be dampened
and only hand tools or low speed power tools used.
Battery Acids
See also Acids and Alkalis.
For additional information, refer to:Battery and
Battery Charging Health and Safety Precautions
(100-00 General Information, Description and
Operation).
Brake and Clutch Linings and Pads
See Asbestos.
Brake Fluids (Polyalkylene Glycols)
See also Fire.
For additional information, refer to: Brake System
Health and Safety Precautions (100-00 General
Information, Description and Operation).
Brazing
See Welding.
Chemical Materials
See also Legal Aspects.
Chemical materials such as solvents, sealers,
adhesives, paints, resin foams, battery acids,
antifreeze, brake fluids, fuels, oils and grease
should always be used with caution and stored and
handled with care. They may be toxic, harmful,
corrosive, irritant or highly flammable and give rise
to hazardous fumes and dusts.
The effects of excessive exposure to chemicals
may be immediate or delayed; briefly experienced
or permanent; cumulative; superficial; life
threatening; or may reduce life expectancy.
Chemical Materials - Do's
– Do carefully read and observe hazard and precaution warnings given on material
containers (labels) and in any accompanying
leaflets, posters or other instructions. Material
health and safety data sheets can be obtained
from manufacturers.
– Do remove chemical materials from the skin and clothing as soon as practicable after soiling.
Change heavily soiled clothing and have it
cleaned.
– Do organize work practices and protective clothing to avoid soiling of the skin and eyes;
breathing vapors, aerosols, dusts or fumes;
inadequate container labeling; fire and explosion
hazards.
– Do wash before job breaks, before eating, smoking, drinking or using toilet facilities when
handling chemical materials.
– Do keep work areas clean, uncluttered and free of spills.
– Do store chemical materials according to national and local regulations.
– Do keep chemical materials out of the reach of children.
Chemical Materials - Do Nots
– Do not mix chemical materials except under themanufacturers instructions; some chemicals can
form other toxic or harmful chemicals, give off
toxic or harmful fumes or become explosive
when mixed together.
– Do not spray chemical materials, particularly those based on solvents, in confined spaces,
for example when people are inside a vehicle.
– Do not apply heat or flame to chemical materials except under the manufacturers instructions.
Some are highly flammable and some may
release toxic or harmful fumes.
– Do not leave containers open. Fumes given off can build up to toxic, harmful or explosive
concentrations. Some fumes are heavier than
air and will accumulate in confined areas such
as pits.
– Do not transfer chemical materials to unlabelled containers.
– Do not clean hands or clothing with chemicals. Chemicals, particularly solvents and fuels, will
dry the skin and may cause irritation leading to
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Standard Workshop Practices
Vehicle in Workshop
When working on a vehicle in the workshop always
make sure that:
– the parking brake is applied or the wheels aresecurely chocked to prevent the vehicle moving
forwards or backwards.
– the key is removed from key operated hood locks before any work is carried out around the
front of the vehicle.
– if the engine is to be run, there is adequate ventilation, or an extraction hose to remove
exhaust fumes.
– there is adequate room to raise the vehicle and remove the wheels, if necessary.
– fender covers are always fitted if any work is to be carried out in the engine compartment.
– the battery is disconnected if working on the engine, underneath the vehicle, or if the vehicle
is raised.
CAUTION: When electric arc welding on a
vehicle, always disconnect the generator
wiring to prevent the possibility of a surge
of current causing damage to the internal
components of the generator.
– if using welding equipment on the vehicle, a suitable fire extinguisher is readily available.
Towing the Vehicle
WARNING: When the vehicle is being
towed, the ignition switch must be in
position II (steering lock released and
warning lamps illuminated). Only then will
the steering, turn signal lamps, horn and
stop lamps be operational. Failure to follow
these instructions may result in personal
injury.
NOTE: The removable towing eye (if equipped),
has a left-hand thread and must be fully tightened
before towing can commence.
When towing is necessary, the vehicle towing eyes
should be used. The rope must be securely
fastened to the towing eyes and must also be
attached to the other vehicle such that the rope will
not foul the bodywork.
When a vehicle with automatic transmission is
towed, the gear selector must be in position N (Neutral). Never tow a vehicle with automatic
transmission at a speed greater than 30 mph (50
km/h) or for a distance greater than 30 miles (50
km). If it is necessary to tow the vehicle a greater
distance, the drive wheels must be lifted clear off
the ground.
Alternatively the vehicle can be transported on a
low loader or a trailer.
Connecting a Slave Battery Using
Jumper Cables
WARNING: If the slave battery has recently
been charged and is gassing, cover the
vent plugs or covers with a damp cloth to
reduce the risk of explosion should arcing
occur when connecting the jumper cables.
Failure to follow these instructions may
result in personal injury.
CAUTIONS:
A discharged battery condition may have
been caused by an electrical short circuit.
If this condition exists there will be an
apparently live circuit on the vehicle even
when all normal circuits are switched off.
This can cause arcing when the jumper
cables are connected.
While it is not recommended that the
vehicle is jump started, it is recognized
that this may occasionally be the only
practical way to mobilize a vehicle. In such
an instance, the discharged battery must
be recharged immediately after jump
starting to avoid permanent damage.
– Always make sure that the jumper cables are adequate for the task. Heavy duty cables must
be used.
– Always make sure that the slave battery is of the same voltage as the vehicle battery. The
batteries must be connected in parallel.
– Always make sure that switched electric circuits are switched off before connecting jumper
cables. This reduces the risk of arcing occurring
when the final connection is made.
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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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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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Body Repair Health and Safety and General Precautions
General
Appropriate repair methods and carrying out repair
and paint jobs correctly is particularly important to
the operating safety of vehicles and the safety of
people.
WARNING: There is danger of injury
through:
• High voltage when electrical welding. – Do not perform welding work in a dampenvironment or on a wet substrate. Use
suitable insulation underneath.
• Welding spatter and UV radiation. – Wear protective clothing, gloves and weldingmask or welding goggles.
• Fire, explosion and hot surfaces in the work area.
– Always have a suitable fire extinguisheravailable when using welding or heating
equipment.
– Remove flammable substances from the danger area. Remove the fuel tank and fuel
pipes and hoses.
– Welding and grinding near the battery presents the danger of explosion. Remove
the battery before you start working.
– During paint work there is an increased danger of fire or explosion. Prevent any
sparks being created. Fire, open light and
smoking are forbidden.
– Always ventilate the workplace well and use an extraction system.
– Wear protective footwear made from anti-static material.
– Only use tools made of wood, brass or copper to clean stands and extraction ducts.
Do not use tools made of steel.
– Only fill or decant paint materials in a specially marked area. • Inhalation and/or absorption through the skin of
harmful substances.
– Welding fumes grinding dusts and solventvapours can be extremely harmful to the
health.
– Sealants, underbody protection and paint residues must not be burnt down with an
unshielded flame, as this will produce harmful
substances.
– Always ventilate the workplace well and use an extraction system.
– Wear protective clothing.
• Pyrotechnic components. – Disconnect the battery negative clamp andcover the battery terminal.
– Remove any airbag components.
• Noise – Cutting, grinding and alignment work cancause a noise level over 85 dB (A).
– Always wear ear protection.
• High Forces. – The various body areas are subject to veryhigh forces during realignment work. Should
any component suddenly become detached
during this process, there is a very great
danger of injury.
– Pulling chains and pulling shackles must be secured with arrester cables.
As well as these general instructions on the
dangers in body and paint shops, you must
observe:
• All valid local national and international regulations governing Health and Safety at Work
• Safety instructions of material equipment and tool manufacturers
For additional information, refer to: (100-00 General
Information) Solvents, Sealants and Adhesives (Description
and Operation),
Air Conditioning (A/C) System Health and Safety Precautions (Description and Operation),
Supplemental Restraint System (SRS) Health and Safety Precautions (Description and
Operation).
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maintained, depending on the vehicle.
Work on airbag systems may only be
performed by persons who have a relevant
certificate of competence.
For additional information, refer to: (501-20
Supplemental Restraint System) Driver Air Bag Module (Removal and
Installation),
Passenger Air Bag Module (Removal and
Installation),
Side Air Bag Module (Removal and Installation),
Side Air Curtain Module (Removal and
Installation),
Restraints Control Module (RCM) (Removal and
Installation).
Pay attention to the following points:
• Disconnect the battery negative clamp and cover the battery terminal.
• Disconnect the electrical connector at the airbag control module.
• If welding is to be performed directly near a control module, it must be disconnected or
removed.
• Never connect the negative cable of the welder near an airbag or a control module.
• Connect the negative cable of the welder close to the location of the weld.
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