instrument panel FORD KUGA 2011 1.G Workshop Manual

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.
G566527en2008.50 Kuga8/2011
100-00- 42
General Information
100-00- 42
DESCRIPTION AND OPERATION
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Power assisted steering operating conditionDriving
Parking
Cornering condition
Driving straight ahead
Steering at a steering
lock stop
Steering central/slightly
off center
REFER to NVH
concerns from other
components column D
REFER to NVH
concerns from other
components column C
REFER to NVH
concerns from other
components column B
REFER to NVH
concerns from other
components column A
NVH concerns from other components
NVH concerns from other condition (column A to D) DCBA
Driving Condition
Noise
XOXX
Drive off, stop driving and slow cornering
over uneven roads
Pedal box knocking
XOOX
Drive off, driving and cornering
Stabilizer bar link
knocking
X
X
Drive off, driving, acceleration and
deceleration
Engine support insu-
lator knocking
OOXX
Engine on, activate switch for air condi-
tioning
Air conditioning
knocking
XO
X
Drive off, driving, cornering, acceleration
and deceleration
Suspension knocking
(Subframe, Springs)
X
OX
Drive off, driving, cornering, acceleration
and deceleration
Constant velocity (CV)
joint knocking
X
O
Deceleration, acceleration and single
impact
Washer bottle
XO
O
All driving conditions
Loose suspension
bolts
XXXX
All driving conditions. Engine rpm
dependant
Instrument panel
rattle/squeak
• X = Noise will most likely occur in this operating condition.
• O = Noise can possibly occur in this operating condition.
• Blank = Noise is unlikely to occur in this operating condition.
Step 2: Check for steering system NVH concerns
according to operation condition described at the
customer interview.
Power assisted steering operating condition
Vehicle stationary with engine off
Driving
Parking
Steering at a
steering lock stop
Steering central/
slightly off centre
Steering at a
steering lock
stop
Steering
central/slightly
off center
Steering at a
steering lock
stop
Steering
central/
slightly off
center
G37349en2008.50 Kuga8/2011
100-04-
5
Noise, Vibration and Harshness
100-04- 5
DIAGNOSIS AND TESTING
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Blower Motor — RHD(34 374 0)
Special Tool(s)412-131
Remover/Installer, Blower
Engine
E42948
Removal
NOTE:Removal steps in this procedure may
contain installation details.
1. Refer to: Cowl Panel Grille (501-02 Front End
Body Panels, Removal and Installation).
2. Torque: 25
Nm
E101389
3.Refer to: Steering Column (211-04 Steering
Column, Removal and Installation).
4. Refer to: Floor Console Extension - Vehicles
With: Center Armrest (501-12 Instrument
Panel and Console, Removal and Installation).
5.
E102293
6. Torque: 25Nm
G1065500en2008.50 Kuga8/2011
412-01- 37
Climate Control
412-01- 37
REMOVAL AND INSTALLATION
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Blower Motor Resistor — Vehicles With: Manual TemperatureControl, RHD(34 382 0)
Removal
1.Refer to: Floor Console Extension - Vehicles
With: Center Armrest (501-12 Instrument
Panel and Console, Removal and Installation).
2.
E102293
3.
E101666
x2
Installation
1. To install, reverse the removal procedure.
G1065567en2008.50 Kuga8/2011
412-01- 40
Climate Control
412-01- 40
REMOVAL AND INSTALLATION
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Blower Motor Resistor — Vehicles With: Dual AutomaticTemperature Control(34 382 0)
Removal
1.Refer to: In-Vehicle Crossbeam (501-12
Instrument Panel and Console, Removal and
Installation).
2.
E82113
x2
Installation
1. To install, reverse the removal procedure.
G1072295en2008.50 Kuga8/2011
412-01- 41
Climate Control
412-01- 41
REMOVAL AND INSTALLATION
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Footwell Vent/Duct Blend Door Actuator — RHD(34 591 0)
Removal
1.
Refer to: Floor Console Extension - Vehicles
With: Center Armrest (501-12 Instrument
Panel and Console, Removal and Installation).
2. 3.
Installation
1.
To install, reverse the removal procedure. G1065565en
2008.50 Kuga 8/2011 412-01-78
Climate Control
412-01-78
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUALE102293 E101545x2x3

Air Inlet Blend Door Actuator(34 606 0)
Removal
1.
Refer to: Floor Console Extension - Vehicles
With: Center Armrest (501-12 Instrument
Panel and Console, Removal and Installation).
2. 3.
Installation
1.
To install, reverse the removal procedure. G1065557en
2008.50 Kuga 8/2011 412-01-79
Climate Control
412-01-79
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUALE102293 E100655x3

Electric Booster Heater
Removal
NOTE:
Removal steps in this procedure may
contain installation details.
1. Refer to: Floor Console (501-12 Instrument
Panel and Console, Removal and Installation).
2. Torque: 9 Nm 3.
Refer to: Climate Control Assembly - Vehicles
With: Manual Temperature Control (412-01
Climate Control, Removal and Installation).
Refer to: Climate Control Assembly - Vehicles
With: Automatic Temperature Control (412-01
Climate Control, Removal and Installation).
4. Torque: 10 Nm1.
2. Torque: 25
Nm
G1074270en
2008.50 Kuga 8/2011 412-02-18
Auxiliary Climate Control
412-02-18
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SECTION 413-00 Instrument Cluster and Panel
Illumination
VEHICLE APPLICATION:
2008.50 Kuga
PAGE
CONTENTS
DIAGNOSIS AND TESTING
413-00-2
Instrument Cluster and Panel Illumination..........................................................................
413-00-2
Principles of Operation.......................................................................................................
413-00-2
Instrument Cluster and Dimmable Backlighting ................................................................
413-00-2
Inspection and Verification.................................................................................................. 413-00-1
Instrument Cluster and Panel Illumination
413-00-1
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Instrument Cluster and Panel Illumination
Refer to
Wiring Diagrams Section 413-00, for
schematic and connector information.
Principles of Operation
NOTE: A new instrument cluster must be
configured.
The instrument cluster and panel illumination
consists of dimmable and non-dimmable
illumination. The dimmable panel illumination is
controlled by the panel illumination switch (part of
the headlamp switch), which allows the brightness
level of the backlights to be adjusted dependent
on the customer preference. When the headlamp
switch is in the parking lamps ON or headlamps
ON position, the intensity of the backlighting can
be adjusted using the panel dimmer switch. The
non dimmable illumination allows for full intensity
dependant on the ignition switch position.
Instrument Cluster and Dimmable
Backlighting A.
Tachometer
B. Engine coolant temperature gauge
C. Fuel gauge
D. Speedometer
E. Information display
The dimmable illumination utilizes light emitting
diodes (LEDs) and bulb(s). The following dimmable
components are backlight using LEDs only:
• ashtray
• cigar lighter
• transmission control lever
• heater control panel
• audio unit • navigation system display module
• instrument cluster
• climate control module
• hazard switch
• traction control system disable switch
• right-hand and left-hand heated front seat
switch(es)
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical
or electrical damage.
Visual Inspection Chart Electrical
Mechanical
– Fuse(s)
– Loose or corrodedconnector(s)
– Instrument cluster
– Wiring Harness
– Circuit
– LED(s)
– Bulb(s)
– Engine/engine
compartment or
underbody compon-
ents
– Fluid levels
– Accessory installa- tion
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible)
before proceeding to the next step.
4. If the cause is not visually evident, verify the symptom and refer to the diagnostic tab within
the Ford approved diagnostic tool. G1054961en
2008.50 Kuga 8/2011 413-00-2
Instrument Cluster and Panel Illumination
413-00-2
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