2011 Ford Kuga Service & Repair Manual

2008-2012 FORD KUGA SERVICE AND REPAIR MANUAL

FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL BACK TO FRONT PAGE VIEW MAIN INDEX To the best of our knowledge, the illustrations, technical information, data and descriptions in this issue were correct at the time of going to print. The right to change prices, specifications, equipment and maintenance instructions at any time without notice is reserved as part of FORD policy of continuous development and improvement for the benefit of our customers. No part of this publication may be reproduced, stored in a data processing system or transmitted in any form, electronic, mechanical, photocopy, recording, translation or by any other means without prior permission of Ford Motor Company. No liability can be accepted for any inaccuracies in this publication, although every possible care has been taken to make it as complete and accurate as possible. Copyright © FOREWORD

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SECTION 100-00 General Information VEHICLE APPLICATION: 2008.50 Kuga PAGE 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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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 1 2 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. G836098en 2008.50 Kuga 8/2011 100-00-3 General Information 100-00-3 DESCRIPTION AND OPERATION TO MODEL INDEX BACK TO CHAPTER INDEX FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

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. G836098en 2008.50 Kuga 8/2011 100-00-4 General Information 100-00-4 DESCRIPTION AND OPERATION TO MODEL INDEX BACK TO CHAPTER INDEX FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Types of self-locking nuts and bolts NOTE: There are more types of self-locking fasteners available than shown in following illustration. E126782 1 2 3 4 5 6 7 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 G836098en 2008.50 Kuga 8/2011 100-00-5 General Information 100-00-5 DESCRIPTION AND OPERATION TO MODEL INDEX BACK TO CHAPTER INDEX FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

2011 Ford Kuga Service & Repair Manual

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