2011 FORD KUGA index

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
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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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SECTION 100-02 Jacking and Lifting
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
DESCRIPTION AND OPERATION
100-02-2
Jacking ........................................................................\
....................................................... .
100-02-3
Lifting ........................................................................\
..........................................................
100-02- 1
Jacking and Lifting
100-02- 1
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Jacking
E100534
G1001882en2008.50 Kuga8/2011
100-02-2
Jacking and Lifting
100-02- 2
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Lifting
E96852
G1001883en2008.50 Kuga8/2011
100-02-3
Jacking and Lifting
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SECTION 100-04 Noise, Vibration and Harshness
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
DIAGNOSIS AND TESTING
100-04-2
Noise, Vibration and Harshness (NVH) ........................................................................\
......
100-04-2
Inspection and Verification ........................................................................\
..........................
100-04-2
Noise Diagnostic Procedure ........................................................................\
.......................
100-04-3
Road Test ........................................................................\
...................................................
100-04-3
Road Test Quick Checks........................................................................\
............................
100-04-4
Road Conditions ........................................................................\
.........................................
100-04-4
Vehicle Preparation ........................................................................\
....................................
100-04-4
Power Steering Conditions ........................................................................\
.........................
100-04-4
Power Steering Operation Noise Check ........................................................................\
.....
100-04-7
Symptom Chart ........................................................................\
...........................................
100-04-14
Pinpoint Tests ........................................................................\
.............................................
100-04-1
Noise, Vibration and Harshness
100-04- 1
.
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Noise Conditions
• Gear noise is typically a howling or whining dueto gear damage or incorrect bearing preload. It
can occur at various speeds and driving
conditions, or it can be continuous.
• Chuckle is a particular rattling noise that sounds like a stick against the spokes of a spinning
bicycle wheel. It occurs while decelerating from
64 km/h (40 mph) and can usually be heard all
the way to a stop. The frequency varies with
vehicle speed.
• Knock is very similar to chuckle, though it may be louder and occurs on acceleration or
deceleration. The teardown will disclose what
has to be corrected.
Clicking, popping or grinding noises may be caused
by the following:
• worn, damaged or incorrectly installed wheel bearing, suspension or brake component.
Check and rule out tires, exhaust and trim items
before disassembling the transmission to diagnose
and correct gear noise.
The noises described under Road Test usually
have specific causes that can be diagnosed by
observation as the unit is disassembled. The initial
clues are the type of noise heard on the road test
and driving conditions.
Vibration Conditions
Vibration at highway speeds may be caused by
the following:
• out-of-balance front or rear wheels.
• out-of-round tires.
Shudder or vibration during acceleration may be
caused by the following:
• damaged powertrain/drivetrain mounts.
• excessively high constant velocity (CV) joint operating angles caused by incorrect ride height.
Check ride height, verify correct spring rate and
check items under inoperative conditions.
Road Test
A gear-driven unit will produce a certain amount
of noise. Some noise is acceptable and may be
audible at certain speeds or under various driving
conditions, as on a newly paved asphalt road. The slight noise is in no way detrimental and must be
considered normal.
The road test and customer interview (if available)
provide information needed to identify the condition
and give direction to the correct starting point for
diagnosis.
1. Make notes throughout the diagnosis routine.
Make sure to write down even the smallest bit
of information, because it may turn out to be the
most important.
2. Do not touch anything until a road test and a thorough visual inspection of the vehicle have
been carried out. Leave the tire pressures and
vehicle load just where they were when the
condition was first observed. Adjusting tire
pressures, vehicle load or making other
adjustments may reduce the condition(s)
intensity to a point where it cannot be identified
clearly. It may also inject something new into
the system, preventing correct diagnosis.
3. Make a visual inspection as part of the preliminary diagnosis routine, writing down
anything that does not look right. Note tire
pressures, but do not adjust them yet. Note
leaking fluids, loose nuts and bolts, or bright
spots where components may be rubbing
against each other. Check the load space for
unusual loads.
4. Road test the vehicle and define the condition by reproducing it several times during the road
test.
5. Carry out the Road Test Quick Checks as soon as the condition is reproduced. This will identify
the correct diagnostic procedure. Carry out the
Road Test Quick Checks more than once to
verify they are providing a valid result.
Remember, the Road Test Quick Checks may
not tell where the concern is, but they will tell
where it is not.
Road Test Quick Checks
1. 24-80 km/h (15-50 mph): with light acceleration,a moaning noise is heard and possibly a
vibration felt in the front floor panel. It is usually
worse at a particular engine speed and at a
particular throttle setting during acceleration at
that speed. It may also produce a moaning
sound, depending on what component is
causing it. REFER to Tip-in Moan in the
Driveline Noise and Vibration Symptom Chart.
2. Acceleration/Deceleration: With slow acceleration and deceleration, a shake is
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Noise, Vibration and Harshness (NVH)
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanicalor electrical damage.
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 concern is not visually evident, verify the symptom and REFER to the Symptom Chart.
How to Use this Diagnostic Procedure
Section
• Noise, vibration and harshness (NVH) concernshave become more important as vehicles have
become more sensitive to these vibrations. This
section is designed to aid in identifying these
concerns.
• The section provides diagnostic procedures based on symptom. If the condition occurs at
high speed, for instance, the most likely place
to start is under Shake and Vibration While
Driving.
• The road test procedure will tell how to sort the conditions into categories and how to tell a
vibration from a shake.
• A series of Road Test Quick Checks are provided to make sure that a cause is either
pinpointed or eliminated.
• Name the condition, proceed to the appropriate section and locate the correct diagnosis. When
the condition is identified, the job is partly done.
• Follow the diagnostic procedure as outlined.
• Quick Checks are described within the step, while more involved tests and adjustments are
outlined in General Procedures.
• Always follow each step exactly and make notes to recall important findings later.
Customer Interview
The road test and customer interview (if available)
provide information that will help identify the
concern and will provide direction to the correct
starting point for diagnosis.
Identify the Condition
NVH usually occur in four areas:
• tires
• engine accessories
• suspension
• driveline
It is important, therefore, that an NVH concern be
isolated into its specific area(s) as soon as
possible. The easiest and quickest way to do this
is to carry out the Road Test as outlined. To assist
in the diagnosis and testing procedure(s), use a
suitable approved NVH diagnosis tester.
Noise Diagnostic Procedure
Non-Axle Noise
The five most common sources of non-axle noise
are exhaust, tires, roof racks, trim panels and
transmission.
Therefore, make sure that none of the following
conditions are the cause of the noise before
proceeding with a driveline teardown and
diagnosis.
• In certain conditions, the pitch of the exhaustmay sound very much like gear noise. At other
times, it can be mistaken for a wheel bearing
rumble.
• Tires, especially snow tires, can have a high pitched tread whine or roar, similar to gear
noise. Radial tires may have this characteristic.
Also, any non-standard tire with an unusual
tread construction may emit a roar or whine
noise.
• Trim panels can also cause whistling or whining noise.
• Clunk may be a metallic noise heard when the automatic transaxle is engaged in "R"
(REVERSE) or "D" (DRIVE) or it may occur
when the throttle is applied or released. It is
caused by backlash somewhere in the driveline.
• Bearing rumble sounds like marbles being tumbled. This condition is usually caused by a
damaged wheel bearing.
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