2011 FORD KUGA ESP

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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Window Glass Health and Safety Precautions
WARNINGS:
Cured polyurethane (PU) adhesive can
degrade if subjected to high temperatures.
Isocyanide compounds can be released
when grinding or welding in close
proximity to cured PU adhesive.
SKIN CONTACT: Prolonged exposure to
polyurethane (PU) adhesive may cause
skin irritation. If PU adhesive comes into
contact with the skin, remove any
contaminated clothing. Immediately wash
the skin with soap and water. Seek medical
attention for any persistent skin irritation
or abnormality.
EYE CONTACT: Polyurethane (PU)
adhesive may cause severe irritation or
damage. If PU adhesive comes into contact
with the eyes, immediately flush eyes with
plenty of running water for at least 15
minutes. Seek immediate medical attention.
SWALLOWED: If polyurethane (PU)
adhesive is swallowed, flush the mouth
thoroughly. Do not induce vomiting.
Provide rest, warmth and fresh air. Seek
immediate medical attention.
INHALED: Persons having a respiratory
allergy may have an allergic reaction when
handling polyurethane (PU) adhesive.
INHALED: Polyurethane (PU) adhesive can
cause asthma like symptoms. Isocyanate
vapor from primer or PU adhesive can
cause allergies in the respiratory tract.
INHALED: If polyurethane (PU) adhesive
fumes are inhaled, move victim to fresh
air. Provide oxygen if necessary. If
breathing stops, provide artificial
respiration. Keep a victim warm and at rest.
Seek immediate medical attention.
CAUTIONS:
Make sure that the direct glazing for
bonded glass cutting blades are changed
where the cutting depth changes to avoid
damage to the body and trim panels.
During the curing period of the PU
adhesive, the door windows must be left
open to avoid a build up of pressure when
the doors are opened and closed.
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Petrol and Petrol-Ethanol Fuel Systems Health and SafetyPrecautions
WARNINGS:
Fuel may not give adequate warning before
toxic or harmful effects arise.
Exposure to fuel can be harmful and can
cause severe health damage or death.
Extreme care must be exercised when
handling hot fluids. Always wash off spilled
fluids from affected areas of skin
immediately.
Highly flammable mixtures are always
present and may ignite when working on
fuel systems. Do not allow naked flames,
sparks or lighted substances to come near
fuel related components.
Fuel must not be used as a cleaning agent.
Keep fuel containers tightly closed, out of
direct sunlight and in a cool area. Keep
away from heat sources, ignition sources
and oxidizing agents.
SKIN CONTACT: Excessive or prolonged
skin contact with diesel fuel may cause
serious skin disorders including skin
cancer.
SKIN CONTACT: Fuel is mildly irritating to
the skin and may cause dermatitis due to
defatting effect. Remove contaminated
clothing. Wash affected areas of skin with
soap and water. Seek medical attention for
any persistent skin irritation or
abnormality. Wash contaminated clothing
before reuse.
EYE CONTACT: Fuel is mildly irritating to
the eyes. Flush with plenty of running
water, blinking as often as possible. Do not
force the eyelid open. Seek medical
attention for any persistent eye irritation
or abnormality.
SWALLOWED: Fuel is moderately toxic
and tends to foam on vomiting. If drawn
into the lungs, inflammation may develop.
Do not induce vomiting. If spontaneous
vomiting occurs place the victim in a
forward position to reduce the risk of fuel
being drawn into the lungs. Give nothing
by mouth. If breathing but unconscious,
place in the recovery position. If breathing has stopped, apply artificial respiration.
Seek immediate medical attention.
INHALED: Fuel is toxic to the respiratory
and other body systems. Exposure may
result in various symptoms including
drowsiness, unconsciousness or severe
health damage. Move a victim to fresh air.
Keep a victim warm and at rest. If
unconscious, place in the recovery
position. If not breathing, apply artificial
respiration. Give cardiac massage if
necessary. Seek immediate medical
attention.
CAUTIONS:
Fuel injection equipment is manufactured
to very precise tolerances and fine
clearances. It is essential that absolute
cleanliness is observed when working with
these components.
Make sure that the workshop area in which
the vehicle is being worked on is as clean
and as dust free as possible.
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Personal protection
Besides the body and limbs, several organs vital
to life are in very particular danger. Because
damage is mostly irreparable, special attention and
comprehensive protection is necessary.
Protective equipment
Always use the appropriate protective equipment:
• Protective helmet or welding mask
• Breathing protection
• Protective clothes gloves and safety boots
• Ear defenders
• Extraction systems
Always carry out an operational check on your
protective equipment every time before you start
working!
Breathing protection
WARNING: Vapor or spray mist containing
isocyanates as a paint base or hardener
can cause toxic respiratory disease
(conditions similar to asthma) leading to
permanent damage, even when inhaled in
the lowest concentrations
The instructions for use provided by the
manufacturer must be observed when working with
breathing protection equipment.
During painting work and in the preparations for
painting, gases, vapors, mists or dusts can appear
in dangerous concentrations.
Breathing protection devices which are
independent of the local atmosphere are most
suitable.
In these types of isolation systems, a compressed
air hose carries natural air from the compressor
line into the protective mask. During supply, the
air undergoes pressure reduction, water removal,
fine filtration and usually warming to natural breath
temperature.
E59518
Description
Item
Protective hood with fresh air supply
1
Protective clothing
2
Protective gloves
3
Protective footwear
4
Only for short periods of work or minimal
concentrations of hazardous substances breathing
protection devices with a combination filter is
suitable as breathing protection equipment.
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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
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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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reprogrammed. However, if the engine hasn't been
run since the last programmed start, the fuel-fired
booster heater will not start up the second time so
as to prevent the battery from being discharged.
The length of time required to pre-heat the vehicle
is calculated in the control unit of the fuel-fired
booster heater and is based on two temperature
values:
• Ambient air temperature: this message is taken
from the GEM via the CAN bus.
• Coolant temperature: this is determined via an internal sensor in the fuel-fired booster heater.
The maximum heating time is 30 minutes at an
outside air temperature of -10 °C or lower. The
heating time decreases proportionally with
increasing ambient temperature until the ambient
temperature is between +15 °C and +20 °C. Then
the minimum heating time is 10 minutes. The
parking heater is deactivated at temperatures
above +20 °C.
The sequence for a programmed start of the
booster heater is as follows:
• Two minutes before the start of the maximum heating time the driver information
system/instrument cluster sends an activation
message to the fuel-fired booster heater via the
CAN bus.
• The fuel-fired booster heater calculates the required heating time and, if necessary, sends
a delay request on the CAN bus.
• At the calculated time, the fuel-fired booster heater starts up. The conditions for start-up are:
engine not running and amount of fuel in the
fuel tank is above 14% of maximum.
• When the coolant temperature reaches +30 °C, the control unit of the fuel-fired booster heater
sends a request to switch on the passenger
compartment blower.
• Eight minutes after the programmed switch-off time, the booster heater stops heating mode
and starts a run-on operation to clean the
system's spark plugs.
• Ten minutes after the switch-off time, the post-cleaning operation is complete. The
additional ten minutes run-on time provides
some leeway in case the driver is late arriving.
After a programmed start-up of the booster heater
it is switched off again after the heating time has
elapsed (or if the fuel level in the fuel tank drops
below 8%). The booster heater stops within 2 minutes of the engine starting. This leaves enough
time to check whether the switch-on conditions for
boost heat mode have been met, thus preventing
the booster heater from having to switch off and
switch back on again. The heater can be switched
off manually at any time from the menu.
Whilst the fuel-fired booster heater is in additional
heating mode and/or parking heating mode, the
instrument cluster receives a fuel consumption
signal; this is used to re-calculate the vehicle's
remaining range and fuel consumption data.
Emergency shutoff
In the event of an accident in which the airbags
are deployed, the control unit of the fuel-fired
booster heater receives a message on the CAN
bus from the restraints control module (RCM).
When this message is received, the booster heater
system switches off immediately.
The booster heater control module deactivates the
system and does not respond to further messages
on the CAN bus. The booster heater control module
needs to be activated with WDS.
Component Description
Electric Booster Heater
The electric booster heater consists of three
individual heating elements, which are incorporated
into a single housing. It is controlled by the generic
electronic module (GEM), taking into account the
following factors:
Detailed illustration of fuel-fired heater
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Description
Item
Combustion chamber
16
'O' Ring
17 Description
Item
Combustion blower motor cover
18
Glow plug wiring harness
19
Flame sensor
If the flame goes out independently during
operation of the booster heater, a restart is carried
out. If the booster heater does not ignite within 90
seconds of fuel delivery or if the flame goes out
within 15 minutes of starting, a lockout will be
implemented by the flame sensor.
Lockout can be cancelled by switching the booster
heater off then on again, although this may only
be repeated at most 2 times.
Overheat Sensor
The overheating sensor enables the fuel-fired
booster heater module to determine the coolant
temperature, protecting the heater from
overheating. The overheating sensor is installed
next to the coolant temperature sensor under a
cover on the top of the fuel-fired heater.
In the event of overheating (lack of water, poorly
ventilated coolant circuit), the fuel supply to the
heater is interrupted and a lockout occurs. After
the cause of the overheating has been eliminated,
the heater can be restarted by switching it off and
on again, if the coolant temperature is below 70°C.
If the heater overheats ten times in a row, the
control unit is locked.
ECT
The fuel-fired booster heater module uses the
temperature sensor to determine the coolant
temperature, which it then uses to set the starting
and stopping time. The coolant temperature sensor
is installed next to the overheating sensor under a
cover on the top of the fuel-fired heater. Water pump The coolant pump is located on the holder for the
fuel-fired heater on the bulkhead in the rear of the
engine compartment. The coolant pump is driven
by a built-in electric motor and circulates the
coolant in the engine cooling system. The delivery
rate for the pump is 820l/h at a delivery pressure
of 0.1 bar.
Fuel pump
The fuel required for the fuel-fired heater is taken
from the fuel system by a fuel pump fitted in the
fuel tank and is delivered to the heater via a fuel
line.
The fuel pump is an electric piston pump which
meters the corresponding fuel volume for the
fuel-fired heater according to a cycle set by the
fuel-fired heater module.
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