2011 FORD KUGA fluid

wheel torque air conditioning sunroof check transmission fluid ESP inoperative brake fluid

Page 56 of 2057

FORD KUGA 2011 1.G Workshop Manual Viton is a fluoroelastomer, that is a synthetic rubber
type material, which contains Fluorine. It is
commonly used for O-rings, gaskets and seals of
all types. Although Viton is the most well known
fl

Viton is a fluoroelastomer, that is a synthetic rubber
type material, which contains Fluorine. It is
commonly used for O-rings, gaskets and seals of
all types. Although Viton is the most well known
fluoroelastomer, there are others, including Fluorel
and Tecmoflon.
When used under design conditions
fluoroelastomers are perfectly safe. If, however,
they are exposed to temperatures in excess of
400°C, the material will not burn, but will
decompose, and one of the products formed is
hydrofluoric acid.
This acid is extremely corrosive and may be
absorbed directly, through contact, into the general
body system.
O-rings, seals or gaskets which have been exposed
to very high temperatures will appear charred or
as a black sticky substance.
DO NOT; under any circumstances touch them or
the attached components.
Enquiries should be made to determine whether
Viton or any other fluoroelastomer has been used
in the affected O-ring, seal or gasket. If they are of
natural rubber or nitrile there is no hazard. If in
doubt, be cautious, as the material may be Viton
or any fluoroelastomer.
If Viton or any other fluoroelastomers have been
used, the affected area should be decontaminated
before the commencement of work.
Disposable heavy duty plastic gloves should be
worn at all times, and the affected area washed
down using wire wool and a limewater (calcium
hydroxide) solution to neutralize the acid before
disposing of the decomposed Viton residue and
final cleaning of the area. After use, the plastic
gloves should be discarded carefully and safely.
Welding
See alsoFire, Electric Shock, Gas Cylinders.
Welding processes include Resistance Welding
(Spot Welding), Arc Welding and Gas Welding.
Resistance Welding
This process may cause particles of molten metal
to be emitted at a high velocity, and the eyes and
skin must be protected.
Arc Welding
This process emits a high level of ultra-violet
radiation, which may cause arc-eye, and skin burns
to the operator and to other persons nearby.
Gas-shielded welding processes are particularly
hazardous in this respect. Personal protection must
be worn, and screens used to shield other people.
CONTACT LENS WEARERS ARE ADVISED TO
REVERT TO ORDINARY SPECTACLES WHEN
ARC WELDING as the arc spectrum is believed to
emit microwaves which dry out the fluid between
the lens and the eye. This may result in blindness
when the lens is removed from the eye.
Metal spatter will also occur, and appropriate eye
and skin protection is necessary.
The heat of the welding arc will produce fumes and
gases from the metals being welded, the rods and
from any applied coatings or contamination on the
surfaces being worked on. These gases and fumes
may be toxic and inhalation of these should be
avoided. The use of extraction ventilation to remove
the fumes from the working area may be necessary
particularly in cases where the general ventilation
is poor, or where considerable welding work is
anticipated. In extreme cases or confined spaces
where adequate ventilation cannot be provided,
air-fed respirators may be necessary.
Gas Welding (and Cutting)
Oxy-acetylene torches may be used for welding
and cutting, and special care must be taken to
prevent leakage of these gases, with consequent
risk of fire and explosion.
The process will produce metal spatter and eye
and skin protection is necessary.
The flame is bright, and eye protection should be
used, but the ultra-violet emission is much less
than that from arc welding, and lighter filters may
be used.
The process itself produces few toxic fumes, but
such fumes and gases may be produced from
coatings on the work, particularly during cutting
away of damaged body parts, and inhalation of the
fumes should be avoided.
In brazing, toxic fumes may be produced from the
metals in the brazing rod, and a severe hazard
may arise if brazing rods containing cadmium are
used. In this event particular care must be taken
to avoid inhalation of fumes and expert advice may
be required.
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Page 63 of 2057

FORD KUGA 2011 1.G Workshop Manual Road/Roller Testing
Road or roller testing may be carried out for various
reasons and a procedure detailing pre-test checks,
engine starting and stopping, pre-driving checks,
on-test checks and final

Road/Roller Testing
Road or roller testing may be carried out for various
reasons and a procedure detailing pre-test checks,
engine starting and stopping, pre-driving checks,
on-test checks and final checks to be completed
on completion of the test is given below.
Unless complete vehicle performance is being
checked, the full road test procedure need not be
carried out. Instead, those items particularly
relevant to the system(s) being checked can be
extracted.
Pre-Test Checks
WARNING: If the brake system hydraulic
fluid level is low, pedal travel is excessive
or a hydraulic leak is found, do not attempt
to road test the vehicle until the reason for
the low fluid level, excessive pedal travel
or hydraulic leak is found and rectified.
It is suggested that pre-test checks and functional
tests of those systems and circuits which affect the
safe and legal operations of the vehicle, such as
brakes, lights and steering, should always be
carried out before the road or roller test.
With the ignition switched off, check:
– the engine oil level.
– the engine coolant level.
– the tires, for correct pressure, compatible types and tread patterns, and wear within limits.
– that there is sufficient fuel in the tank to complete the test.
– all around the engine, transmission and under the vehicle for oil, coolant, hydraulic and fuel
leaks. Make a note of any apparent leaks and
wipe off the surrounding areas to make it easier
to identify the extent of the leak on completion
of the test.
Starting the Engine
NOTE: On initial drive away from cold and within
the first 1.5 km (1 mile), do not depress the
accelerator pedal beyond half travel until the
vehicle has attained a minimum speed of 25 km/h
(15 miles/h). Never operate at high engine speed
or with the accelerator pedal at full travel whilst the
engine is cold.
With the ignition switched off, check: – that the parking brake is applied.
– that the gear lever is in the neutral position.
– that all instrument gauges (except fuel gauge)
read zero.
With the ignition switched on, check:
– that the ignition controlled warning lamps are illuminated.
– that the engine temperature gauge registers a reading compatible with the engine temperature.
– that the fuel gauge registers a reading appropriate to the fuel level in the tank.
– the operation of the parking brake warning lamp and fluid level warning indicator.
Road or Roller Testing
CAUTION: If road testing, check the brake
operation while still traveling at low speed
before continuing with the test. If the
brakes pull to one side, or appear to be
otherwise faulty, do not continue with the
road test until the fault has been found and
rectified.
During the road or roller test, check:
– that the clutch pedal operation is not stiff or heavy.
– that the initial gear engagement is smooth and there is no evidence of clutch drag.
– that the parking brake control operates smoothly and releases quickly and completely.
– that the clutch takes up the drive smoothly, without slip or judder.
– that gear changing is smooth with no abnormal noises or vibrations from the transmission.
– the engine power output is satisfactory, full power is achieved, acceleration is smooth and
pedal operation is not stiff or heavy, and engine
speed returns to idle correctly.
– there is no excessive or abnormally colored smoke from the engine under normal driving,
heavy load or overrun conditions.
– that steering operation, including power steering (if equipped), is smooth, accurate, not
excessively heavy or with excessive free play
or vibration.
– that the steering does not pull to one side and self centers smoothly after cornering.
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Page 67 of 2057

FORD KUGA 2011 1.G Workshop Manual Brake System Health and Safety Precautions
WARNINGS:
EYE CONTACT: Brake fluid contains
polyglycol ethers and polyglycols. Avoid
contact with the eyes. Wash hands
thoroughly after handling. If brake fl

Page 68 of 2057

FORD KUGA 2011 1.G Workshop Manual Engine Cooling System Health and Safety Precautions
WARNINGS:
Extreme care must be exercised when
handling hot fluids. Always wash off spilled
fluids from affected areas of skin
immediately.
Vapors ma

Page 70 of 2057

FORD KUGA 2011 1.G Workshop Manual 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 se

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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Page 80 of 2057

FORD KUGA 2011 1.G Workshop Manual 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.
• Ch

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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Page 85 of 2057

FORD KUGA 2011 1.G Workshop Manual Before conducting a vehicle test to identify a NVH
concern carry out the following checks.
1. Check the tire pressures and adjust tospecification, as necessary.
2. Make sure the steering system fluid

Before conducting a vehicle test to identify a NVH
concern carry out the following checks.
1. Check the tire pressures and adjust tospecification, as necessary.
2. Make sure the steering system fluid is correct, the system is free of leaks and is operating
correctly.
3. Make sure the vehicle steering system temperature is the same as described at the
customer interview.
4. All evaluations must take place in a relatively quiet location.
5. The heating - air conditioning (A/C) fan and radio must be turned off during evaluations and
the windows closed.Symptom Chart
Power Steering Moan Noise
Test Condition
Listen for steering moan noise with the vehicle
parked, transmission in neutral and all windows
closed in the following test conditions.
1. Engine speed at idle with no steering action.
2. Engine speed at idle with slow 90 degrees persecond turning of the steering wheel.
3. Engine speed at 1250 +/- 50 rpm with no steering action.
4. Engine speed at 1250 +/- 50 rpm with slow 90 degrees per second turning of the steering
wheel.
Action
Possible Sources
Symptom
• CHECK the routing of thepower steering lines.
• CHECK the power steering line clamps are secure.
• CHECK the power steering lines for clearance from the
vehicle body, front axle cross-
member and steering gear.
Power steering lines.
Power steering system moan
noise – A continuous low pitched
humming noise occurs when the
steering wheel is turned and the
steering system is loaded. Noise
frequency changes with engine
rpm changes. Particularly
annoying at lower engine speed. FLUSH the power steering
system.
REFER to:
Power Steering
System Flushing (211-00
Steering System - General
Information, General Proced-
ures).
Incorrect power steering fluid.
Pressure pulses from the power
steering pump. Certain amount
of noise level acceptable, not a
safety critical item.
Power steering pump.
Power Steering Whine Noise
Test Condition
Listen for steering whine noise with the vehicle
parked, transmission in neutral and all windows
closed in the following test conditions. 1. Engine speed at 1800 +/- 50 rpm with no
steering action.
2. Engine speed at 1800 +/- 50 rpm with slow 90 degrees turning of the steering wheel.
3. Engine speed at 3000 +/- 50 rpm with no steering action.
4. Engine speed at 3000 +/- 50 rpm with slow 90 degrees turning of the steering wheel.
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Page 86 of 2057

FORD KUGA 2011 1.G Workshop Manual Action
Possible Sources
Symptom
BLEED the power steering
system.
REFER to:Power Steering
System Vacuum Bleeding (211-
00 Steering System - General
Information, General Proced-
ures).
Power steering fl

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