tow FORD KUGA 2011 1.G Workshop 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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PAGE 2 OF 2 FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

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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Description
Item
Minor component movement
clockwise/counterclockwise
1
Major component movement
clockwise/counterclockwise
2
Component movement to the
left/right/up/down
3
Component movement towards/away
4
3 dimensional component movement
5Description
Item
2 dimensional component movement
6
3 dimensional component rotation
7
3 dimensional component cycling
8
Turn Symbols
Turn symbols are used to provide further
information on the direction or angle of component
turns.
E88970
12
34
6
7
5
8
G955392en2008.50 Kuga8/2011
100-00- 20
General Information
100-00- 20
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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.
G17373en2008.50 Kuga8/2011
100-00- 54
General Information
100-00- 54
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E59517
Description
Item
Activated charcoal filter
1
Coarse filter
2
Filter masks with wadding, sponge or colloid filters
and also paper masks are all unsuitable for working
with coating materials because they do not stop
solvent vapors.
Eye protection
Cutting grinding welding solvents and paint bear
fundamental risks for your eyes.
Damage ranging from irritation of the cornea to
incurable illnesses is possible.
Solvents and paint – even water based – could not
only be absorbed via your skin but also via your
eyes.
Therefore always wear the appropriate eye
protection for your work.
Protective goggles must be inert toward splashes
of solvent, and must have side protection. Best
protection during spray painting is offered by full
mask respirators or helmet respirators with built-in
visor.
Skin protection
Spray painters must wear suitable protective work
clothing (flame-proof and anti-static). Also, when
working with water based materials, comprehensive
skin protection must be worn, because these
materials are very easily absorbed through the
skin.
Change your protective clothing at proper intervals.
Clothes contaminated with coating materials can
easily catch fire.
Do not choose clothes or underwear with a large
content of easy melting synthetic fiber, because
this material considerably increases the danger
and degree of injuries (melted plastic on the skin!). For areas of the skin which are not covered by
protective clothing suitable skin protection cleaning
and care agents must be used.
Ear protection
Cutting grinding compressors and extractor fans
and ducts are the main sources of noise in body
and paint shops.
Always wear suitable ear protection like ear plugs
or ear defenders.
Protection of the vehicle
Protect affected areas from weld spatter and dust
during all welding and grinding work on the vehicle.
If metallic dust stays on the vehicle for some time,
there is the likelihood of film rust formation.
Grinding produces tiny spots of damage to the paint
surface, which may cause corrosion. Also use
suitable protective measures to protect the interior
when performing repair operations which relate to
the inside of the vehicle.
For this reason, make sure to:
• Use carbon fiber blankets to protect the vehicle
body and the interior.
• Use covering film to protect the vehicle body from grinding dust and metal dust.
• Use covering paper to protect the interior from grinding dust.
In addition, take into account:
• Remove fuel supply components as necessary.
• Protect working areas which are in danger of catching fire with a fireproof blanket.
• Keep heat away from all components of the air conditioning system.
• Remove all components in the space adjoining the repair area.
Electronic components
Increased use of comfort and safety electronics in
modern vehicles requires additional attention to be
paid during body work.
Over voltages produced during welding can cause
electronic systems to be damaged. In particular,
the safety instructions for performing welding work
on vehicles with airbag systems must be adhered
to.
WARNING: After disconnecting the power
supply and before performing further work,
a wait time of up to 15 minutes must be
G963390en2008.50 Kuga8/2011
100-00- 69
General Information
100-00- 69
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Parking Aid — Vehicles With: Rear Parking Aid
Refer to
Wiring Diagrams Section 413-13, for
schematic and connector information. General Equipment
Ford diagnostic equipment
Principles of Operation
NOTE: The rear parking aid system will be
de-activated when a Ford rear trailer tow module
is attached to the vehicle.
The ultrasonic parking aid system will default to
enabled when the ignition switch is turned to the
RUN position, the system is activated by selecting
reverse gear. The parking aid system will be
disabled if a fault is detected in one of the four rear
parking aid sensors, the parking aid speaker or the
parking aid module. An error tone approximately
3 seconds long will be emitted from the rear parking
aid speaker if a fault is detected. The rear parking
aid speaker will also sound for approximately 3
seconds if an error is detected at each ignition
cycle or if an error is detected when the system
has been activated.
Inspection and Verification
1. Verify the customer concern. 2. Visually inspect for obvious signs of electrical
damage.
Visual Inspection Chart Electrical
– Fuse(s)
– Wiring harness(s)
– Electrical connector(s)
– Battery junction box (BJB)
– Rear parking aid sensor(s)
– Rear parking aid speaker
– Parking aid module
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, connect the Ford diagnostic equipment to the data link
connector (DLC) and select the vehicle system
to be tested from the diagnostic menu.
5. Retrieve the Diagnostic Trouble Code (DTC)s and refer to the DTC Index.
6. If no DTCs are retrieved or there is no communication with the module, proceed to the
Symptom Chart to continue diagnostics.
Diagnostic Trouble Codes (DTC) Index
DTC Index Action
Possible Source
Description
DTC
Check the circuit 8-GN22
(WH/GN) for short to battery.
IF the circuit is OK, INSTALL
a new parking aid module.
REFER to:Parking Aid
Module (413-13 Parking
Aid, Removal and Installa-
tion).
TEST the system for normal
operation.
• Parking aid sensor signal
circuit.
• Parking aid module.
Rear outer left sensor signal
circuit short to battery
C1699
GO toPinpoint Test C.
• Parking aid sensor signal
circuit.
• Parking aid sensor.
• Parking aid module.
Rear outer left sensor signal
circuit open or short to
ground
C1700 G295937en
2008.50 Kuga 8/2011 413-13-29
Parking Aid
413-13-29
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Install the wheel bearing with the black colored
wheel speed sensor ring facing towards the
transmission side.
Special Tool(s): 204-740
General Equipment: Hydraulic Press
E99402
204-740/1
2.Special Tool(s): 204-740
General Equipment: Hydraulic Press
E99403
204-740/1
3. NOTE: Make sure that this component is
installed to the noted removal position.
E99320
4. Refer to: Wheel Knuckle (204-01 Front
Suspension, Removal and Installation).
G1000206en2008.50 Kuga8/2011
204-01- 12
Front Suspension
204-01- 12
REMOVAL AND INSTALLATION
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Rear Drive Axle and Differential – System Operation andComponent Description
System Operation
General Information
The powertrain with all-wheel drive consists of the
following main components:
• engine
• transaxle with front axle differential
• transfer box
• halfshafts and driveshafts
• Haldex clutch
• rear axle differential
The Haldex clutch guarantees continuous variable
torque transmission to the rear axle under all
driving conditions. The Haldex clutch reacts
immediately and equally quickly with slow or fast
wheel slip.
A difference in angle of rotation of 90° between the
input and output shafts is required to build up
maximum pressure at the multi-plate clutch or to
transmit maximum torque.
The advantage of vehicles with all-wheel drive is
that they distribute the drive between all four
wheels. They therefore have a higher tractive
power. They feature improved cornering behaviour,
as the grip at all four wheels can be better utilised.
Thus, the wheels contribute to a greater degree
towards cornering stability.
The engine torque is transmitted from the transfer
box to the rear axle via a driveshaft. The driveshaft
is flange-mounted to the input side of the Haldex
clutch.
Driving situations
Pulling away and accelerating
• When pulling away and accelerating, as muchall-wheel drive as necessary must be available
immediately in the short-term. During
acceleration, the electronic system detects slip
at the front axle. This slip is counter-controlled
and thus the propulsive force optimally
distributed to the two axes.
Cornering • A sporty driving style, in particular dynamic
cornering, demands stable cornering behaviour.
The all-wheel system distributes the propulsive
force to all four wheels and by so doing boosts
the high cornering forces so that the vehicle
makes optimum contact with the road surface.
Snow and black ice
• Snow and black ice require particularly high grip. Under these conditions, the Haldex clutch
always distributes the propulsive force to the
axle with the better traction. The all-wheel
system reacts intelligently and quickly to all
driving situations.
Trailer operation
• When driving with a trailer, the trailer weight (support load) is transmitted to the rear axle via
the towbar. This reduces the load on the front
wheels, which means they can slip. The
electronic system detects this difference and
distributes most of the propulsive force to the
rear axle.
Haldex clutch
E100642
G1076981en2008.50 Kuga8/2011
205-02- 6
Rear Drive Axle/Differential
205-02- 6
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Action
Possible Sources
Symptom
• CHECK ride height, VERIFYcorrect spring rate and CHECK
items under Halfshaft Joint
Pullout. REPAIR or INSTALL
new as necessary.
• Excessively high CV joint oper-
ating angles caused by incor-
rect ride height.
• Shudder Vibration During
Acceleration.
• INSPECT and INSTALL newas necessary.
• Excessively worn or damaged
inboard front wheel driveshaft
joint or outboard front wheel
driveshaft joint.
• INSPECT and REPAIR orINSTALL new as necessary.
• Inboard driveshaft bearing
retainer circlip missing or not
correctly seated in differential
side gear.
• Halfshaft Joint Pullout
• CHECK engine mounts fordamage or wear. REPAIR or
INSTALL new as necessary.
• Engine/transaxle assembly
mispositioned.
• CHECK underbody dimensions.REFER to REFER to
Section 501-00 [Body System
-General Information] .
• Frame rail or strut tower out of
position or damaged.
• CHECK for worn bushings orbent components (front stabil-
izer bar, front suspension lower
arm). REPAIR or INSTALL new
as necessary.
• Front suspension components
worn or damaged.
G17442en2008.50 Kuga8/2011
205-04- 4
Front Drive Halfshafts
205-04- 4
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Hydraulic principle of operation
E96442
3
4
5
7
8
6
1
2
Description
Item
Reservoir
1
Valve unit
2
Steering rack and pinion
3
Flow control/pressure relief - return
4
Flow control/pressure relief valve
5Description
Item
Outlet of the power steering pump
6
Electro-hydraulic power steering pumpRefertoComponentDescription:(page
5)
7
Low pressure suction line
8
When the engine is started, the electro-hydraulic
power steering pump sucks in power steering fluid
from the reservoir. The fluid flows through the pump
and is discharged under high pressure from the
outlet. The high-pressure line carries the power
steering fluid to the servo valve.
If no steering effort is applied, there is no resistance
to the circulation of power steering fluid and the
supply pressure from the pump is very low. Only
minimal pressure is applied by the servo valve to
the two sides of the piston in the working cylinder.
When the steering wheel is turned in either
direction, the return flow of fluid to the reservoir is restricted by the servo valve, causing the pressure
to increase on the supply side. The power steering
fluid is directed by the servo valve to the
corresponding side of the piston in the working
cylinder, providing the power assistance required
to reduce the steering effort. The power steering
fluid which is displaced towards the low-pressure
side of the cylinder flows through the servo valve
and the return line back to the reservoir.
Component Description
Electro-hydraulic power steering pump
G1001270en2008.50 Kuga8/2011
211-02-
9
Power Steering
211-02- 9
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