2011 FORD KUGA Oil

SECTION 100-00 General Information
VEHICLE APPLICATION:2008.50 Kuga
PA G E
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 ........................................................................\
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100-00-44
Brake Fluids (Polyalkylene Glycols) ........................................................................\
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100-00-44
Brazing ........................................................................\
.......................................................
100-00-44
Chemical Materials ........................................................................\
.....................................
100-00-45
Chlorofluorocarbons (CFC) ........................................................................\
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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
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100-00-46
Fluoroelastomer ........................................................................\
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100-00-46
Foams

- Polyurethane ........................................................................\
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100-00-47
Freon ........................................................................\
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100-00-47
Fuels ........................................................................\
...........................................................
100-00-47
Gas Cylinders ........................................................................\
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100-00-47
Gases ........................................................................\
.........................................................
100-00-47
Gaskets (Fluoroelastomer) ........................................................................\
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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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PAGE 1 OF 2 FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Steering System Health and Safety Precautions
WARNINGS:
When handling the power steering fluid,
always wear protective goggles and gloves
made of nitril.
EYE CONTACT: Power steering fluid
contains long chain alkyl amine
thiophosphate. Avoid contact with the
eyes. Wash hands thoroughly after
handling. If power steering fluid comes into
contact with the eyes, flush the eyes with
plenty of cold running water for 15
minutes. Seek medical attention for any
persistent eye irritation or abnormality.
SKIN CONTACT: If power steering fluid
comes into contact with the skin, remove
contaminated clothing. Wash affected
areas of skin with soap and water. Seek
medical attention for any persistent skin
irritation or abnormality.
INHALED: If oil mist is inhaled, move a
victim to fresh air. Keep a victim warm and
at rest. Seek immediate medical attention
in cases of throat irritation or coughing.
SWALLOWED: Power steering fluid
contains long chain alkyl amine
thiophosphate. If swallowed, drink plenty
of water. Seek immediate medical attention.
CAUTION: If the power steering fluid is
spilled on the paintwork, the affected area
must be immediately washed down with
cold water.
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Exhaust Fumes
These contain asphyxiating, harmful and toxic
chemicals and particles such as carbon oxides,
nitrogen oxides, aldehydes, lead and aromatic
hydrocarbons. Engines should be run only under
conditions of adequate exhaust extraction or
general ventilation and not in confined spaces.
Gasoline (petrol) engine
There may not be adequate warning of odor or of
irritation before toxic or harmful effects arise. These
may be immediate or delayed.
Diesel engine
Soot, discomfort and irritation usually give
adequate warning of hazardous fume
concentrations.
Fibre Insulation
See alsoDusts.
Used in noise and sound insulation.
The fibrous nature of surfaces and cut edges can
cause skin irritation. This is usually a physical and
not a chemical effect.
Precautions should be taken to avoid excessive
skin contact through careful organization of work
practices and the use of gloves.
Fire
See also Welding,Foams,Legal Aspects.
Many of the materials found on or associated with
the repair of vehicles are highly flammable. Some
give off toxic or harmful fumes if burnt.
Observe strict fire safety when storing and handling
flammable materials or solvents, particularly near
electrical equipment or welding processes.
Make sure, before using electrical or welding
equipment, that there is no fire hazard present.
Have a suitable fire extinguisher available when
using welding or heating equipment.
First Aid
Apart from meeting any legal requirements it is
desirable for someone in the workshop to be
trained in First Aid procedures.
Splashes in the eye should be flushed carefully
with clean water for at least ten minutes.
Soiled skin should be washed with soap and water.
In case of cold burns, from alternative fuels, place
affected area in cool to cold water.
Individuals affected by inhalation of gases and
fumes should be removed to fresh air immediately.
If effects persist, consult a doctor.
If liquids are swallowed inadvertently, consult a
doctor giving him the information on the container
or label. Do not induce vomiting unless this action
is indicated on the label.
Fluoroelastomer
See Viton.
Foams - Polyurethane
See also Fire.
Used in sound and noise insulation. Cured foams
used in seat and trim cushioning.
Follow manufacturers instructions.
Unreacted components are irritating and may be
harmful to the skin and eyes. Wear gloves and
goggles.
Individuals with chronic respiratory diseases,
asthma, bronchial medical problems, or histories
of allergic diseases should not work in or near
uncured materials.
The components, vapors or spray mists can cause
direct irritation, sensitivity reactions and may be
toxic or harmful.
Vapors and spray mists must not be inhaled. These
materials must be applied with adequate ventilation
and respiratory protection. Do not remove the
respirator immediately after spraying; wait until the
vapors/mists have cleared.
Burning of the uncured components and the cured
foams can generate toxic and harmful fumes.
Smoking, naked flames or the use of electrical
equipment during foaming operations and until
vapors/mists have cleared should not be allowed.
Any heat cutting of cured foams or partially cured
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foams should be conducted with extraction
ventilation. See also the vehicle Body Repair
Manual.
Freon
SeeAir Conditioning Refrigerant.
Fuels
See also, Fire, Legal Aspects, Chemicalsand
Solvents.
Avoid skin contact with fuel where possible. Should
contact occur, wash the affected skin with soap
and water.
Gasoline (Petrol)
Highly flammable - observe No Smoking policy.
For additional information, refer to: Petrol and
Petrol-Ethanol Fuel Systems Health and Safety
Precautions (100-00 General Information,
Description and Operation).
Gas-oil (Diesel Fuel)
Kerosene (Paraffin)
Used also as heating fuel, solvent and cleaning
agent.
Flammable - observe No Smoking policy.
Irritation of the mouth and throat may result from
swallowing. The main hazard from swallowing
arises if liquid aspiration into the lungs occurs.
Liquid contact dries the skin and can cause
irritation or dermatitis. Splashes in the eye may be
slightly irritating.
In normal circumstances the low volatility does not
give rise to harmful vapors. Exposure to mists and
vapors from kerosene at elevated temperature
should be avoided (mists may arise in dewaxing).
Avoid skin and eye contact and make sure there
is adequate ventilation.
Gas Cylinders
See also Fire. Gases such as oxygen, acetylene, argon and
propane are normally stored in cylinders at
pressures of up to 138 bar (2000 psi) and great
care should be taken in handling these cylinders
to avoid mechanical damage to them or to the valve
gear attached. The contents of each cylinder
should be clearly identified by appropriate
markings.
Cylinders should be stored in well-ventilated
enclosures, and protected from ice and snow, or
direct sunlight. Fuel gases, for example acetylene
and propane, should not be stored in close
proximity to oxygen cylinders.
Care should be exercised to prevent leaks from
gas cylinders and lines, and to avoid sources of
ignition.
Only trained personnel should undertake work
involving gas cylinders.
Gases
See
Gas Cylinders.
Gaskets (Fluoroelastomer)
SeeViton.
General Workshop Tools and
Equipment
It is essential that all tools and equipment are
maintained in good condition and that the correct
safety equipment is used where required.
Never use tools or equipment for any purpose other
than that for which they were designed. Never
overload equipment such as hoists, jacks, axle and
chassis stands or lifting slings. Damage caused by
overloading is not always immediately apparent
and may result in a fatal failure the next time that
the equipment is used.
Do not use damaged or defective tools or
equipment, particularly high-speed equipment such
as grinding wheels. A damaged grinding wheel can
disintegrate without warning and cause serious
injury.
Wear suitable eye protection when using grinding,
chiseling or sand blasting equipment.
Wear a suitable breathing mask when using
abrasive blasting equipment, working with
asbestos-based materials or using spraying
equipment.
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The use of drum cleaning units, vacuum cleaning
or damp wiping is preferred.
Asbestos dust waste should be dampened, placed
in a sealed container and marked for safe disposal.
If any cutting or drilling is attempted on materials
containing asbestos the item should be dampened
and only hand tools or low speed power tools used.
Battery Acids
See also Acids and Alkalis.
For additional information, refer to:Battery and
Battery Charging Health and Safety Precautions
(100-00 General Information, Description and
Operation).
Brake and Clutch Linings and Pads
See Asbestos.
Brake Fluids (Polyalkylene Glycols)
See also Fire.
For additional information, refer to: Brake System
Health and Safety Precautions (100-00 General
Information, Description and Operation).
Brazing
See Welding.
Chemical Materials
See also Legal Aspects.
Chemical materials such as solvents, sealers,
adhesives, paints, resin foams, battery acids,
antifreeze, brake fluids, fuels, oils and grease
should always be used with caution and stored and
handled with care. They may be toxic, harmful,
corrosive, irritant or highly flammable and give rise
to hazardous fumes and dusts.
The effects of excessive exposure to chemicals
may be immediate or delayed; briefly experienced
or permanent; cumulative; superficial; life
threatening; or may reduce life expectancy.
Chemical Materials - Do's
– Do carefully read and observe hazard and precaution warnings given on material
containers (labels) and in any accompanying
leaflets, posters or other instructions. Material
health and safety data sheets can be obtained
from manufacturers.
– Do remove chemical materials from the skin and clothing as soon as practicable after soiling.
Change heavily soiled clothing and have it
cleaned.
– Do organize work practices and protective clothing to avoid soiling of the skin and eyes;
breathing vapors, aerosols, dusts or fumes;
inadequate container labeling; fire and explosion
hazards.
– Do wash before job breaks, before eating, smoking, drinking or using toilet facilities when
handling chemical materials.
– Do keep work areas clean, uncluttered and free of spills.
– Do store chemical materials according to national and local regulations.
– Do keep chemical materials out of the reach of children.
Chemical Materials - Do Nots
– Do not mix chemical materials except under themanufacturers instructions; some chemicals can
form other toxic or harmful chemicals, give off
toxic or harmful fumes or become explosive
when mixed together.
– Do not spray chemical materials, particularly those based on solvents, in confined spaces,
for example when people are inside a vehicle.
– Do not apply heat or flame to chemical materials except under the manufacturers instructions.
Some are highly flammable and some may
release toxic or harmful fumes.
– Do not leave containers open. Fumes given off can build up to toxic, harmful or explosive
concentrations. Some fumes are heavier than
air and will accumulate in confined areas such
as pits.
– Do not transfer chemical materials to unlabelled containers.
– Do not clean hands or clothing with chemicals. Chemicals, particularly solvents and fuels, will
dry the skin and may cause irritation leading to
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dermatitis or be absorbed through the skin in
toxic or harmful quantities.
– Do not use emptied containers for other materials except when they have been cleaned
under supervised conditions.
– Do not sniff or smell chemical materials. Brief exposure to high concentrations of fumes can
be toxic or harmful.
Chlorofluorocarbons (CFC)
There is concern in the scientific community that
CFCs and Halons are depleting the upper ozone
layer which filters out harmful ultraviolet radiation.
Decreased filtration of ultraviolet radiation may
result in increases in skin cancer, cataracts and
immune system suppression in humans, as well
as decreased productivity of crops and aquatic
systems.
CFCs are used primarily as refrigerants in vehicle
air conditioning systems and as aerosol
propellants. Halons are used as fire extinguishants.
Clutch Fluids
See Brake fluids.
Clutch Linings and Pads
SeeAsbestos.
Corrosion Protection Materials
See also Solvents, Fire.
Highly flammable, flammable – observe No
Smoking policy.
These materials are varied and the manufacturers
instructions must be followed. They may contain
solvents, resins or petroleum products. Skin and
eye contact should be avoided. They should only
be sprayed in conditions of adequate ventilation
and not in confined spaces.
Cutting
See Welding.
Dewaxing
SeeSolvents andFuels (Kerosene).
Dusts
Powder, dusts or clouds may be irritant, harmful
or toxic. Avoid breathing dusts from powdery
chemical materials or those arising from dry
abrasion operations. Wear respiratory protection
if ventilation is inadequate.
Fine dusts of combustible material can present an
explosion hazard. Avoid explosive limits and
sources of ignition.
Electric Shock
Electric shock can result from the use of faulty
electrical equipment or from the misuse of
equipment in good condition.
Make sure that electrical equipment is maintained
in good condition and frequently tested. Faulty
equipment should be labeled and preferably
removed from the workstation.
Make sure that flexes, cables, plugs and sockets
are not frayed, kinked, cut, cracked or otherwise
damaged.
Make sure that electrical equipment and flexes do
not come into contact with water.
Make sure that electrical equipment is protected
by the correct rated fuse.
Never misuse electrical equipment and never use
equipment that is in any way faulty. The results
could be fatal.
Make sure that the cables of mobile electrical
equipment cannot get trapped and damaged, such
as in a vehicle hoist.
Make sure that the designated electrical workers
are trained in basic First Aid.
In cases of electrocution:
– switch off the power supply before approaching
the victim.
– if this is not possible push or drag the victim from the source of electricity using dry
non-conductive material.
– commence resuscitation if trained to do so.
– SUMMON MEDICAL ASSISTANCE.
Engine Oils
See Lubricants and Grease.
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Make sure there is adequate ventilation to control
dusts, mists and fumes.
High Pressure Air, Lubrication and Oil
Test Equipment
See alsoLubricants and Greases.
Always keep high-pressure equipment in good
condition, and regularly maintained, particularly at
joints and unions.
Never direct a high-pressure nozzle, for example
diesel injector, at the skin as the fluid may
penetrate to the underlying tissue, and cause
serious injury.
Halon
See CFCs.
Legal Aspects
There are many laws and regulations relating to
health and safety in the use and disposal of
materials and equipment in a workshop.
For a safe working environment and to avoid
environmental pollution, workshops should be
familiar, in detail, with the many health and safety
laws and regulations within their country, published
by both national and local authorities.
Lubricants and Greases
Avoid all prolonged and repeated contact with
mineral oils. All lubricants and greases may be
irritating to the eyes and skin.
Transmission Fluids
Safety instructions
Certain Transmission and Power Steering fluids
supplied to Ford may contain additives which have
the potential to cause skin disease (dermatitis) to
exposed persons. The dermatitis may be irritant
or allergic in nature. Risks are higher where
prolonged or repeated skin contact with a fluid may
occur. These fluids are used for vehicle initial fill
and service purposes. This sub-section is to: • Inform Service personnel who may come into
contact with these vehicle fluids (hazard
communication).
• Summarise appropriate workplace control measures and personal protective equipment
requirements.
• Draw attention to the existence of Material Safety Datasheets (MSDS's) for the fluids
(available from Ford Customer Service Division).
These MSDS's contain detailed information on
hazards and appropriate controls.
Control measures
Workplace risk assessments made under national
chemical control regulations should identify
operations involving the fluids as potentially
hazardous and specify workplace control and
worker awareness measures. In such
circumstances, the relevant Material Safety
Datasheet (see the details specified below) which
specifies hazards and control measures in detail
should be made available for guidance.
Avoid unprotected skin contact with the fluids, and
in particular, avoid prolonged or repeated skin
contact. Work practices should be organised so as
to minimise the potential for skin contact. This may
include the use of drip trays, absorbents, correct
fluid handling equipment (funnels etc), and
workplace housekeeping measures such as the
cleaning of contaminated surfaces.
Personnel engaged in operations where skin
contact could occur (such as fluid draining or filling)
should wear impervious gloves made from nitrile
rubber, certified to a chemical protection standard,
e.g. Europe Standard EN374. This glove type is
widely available from reputable suppliers of gloves
for chemical protection [including the manufacturers
Ansell-Admont (Solvex Range), North Safety
products (North Nitrile Latex Gloves range), and
Marigold Industrial (Blue Nitrile range)]. If gloves
become torn or contaminated on the inside they
should be replaced. Eye protection with safety
glasses is appropriate. Use of an impervious apron
and arm protectors may be necessary if more
extensive exposure is possible. Use of skin barrier
creams suitable for work with mineral oil products
may offer some supplementary protection, but such
barrier creams should not be used in place of
protective clothing.
If accidental skin contact occurs with the fluids,
wash the area thoroughly with soap or skin
cleanser and water.
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Accidental eye contact should be dealt with as per
normal first aid practices, by flushing the eyes with
an eye wash or clean cool water for 10 minutes,
after which medical attention should be obtained.
Remove and launder clothing which becomes
contaminated with the fluids. Do not place rags
contaminated with fluid in clothing pockets.
Wash thoroughly after completing operations where
skin exposure may have occurred.
It is important that personnel do not smoke, eat or
drink whilst handling the fluids or affected
transmissions. These measures are designed to
limit the risk from accidental ingestion.
Label any decanted fluid properly/use an equivalent
label to that on original product containers.
Clean up any spills promptly using an inert
absorbent and wash down contaminated surfaces
with detergent and water.
Dispose of any waste fluids safely as hazardous
waste.
Safety Data Sheets
Safety Data Sheets, which detail specific material
handling instructions and precautions are available
from the respective national sales company, and
via internet www.msds.ford.com.
Used Engine Oil
Prolonged and repeated contact with mineral oil
will result in the removal of natural fats from the
skin, leading to dryness, irritation and dermatitis.
In addition, used engine oil contains potentially
harmful contaminants, which may cause skin
cancer. Adequate means of skin protection and
washing facilities must be provided.
Do not employ used engine oils as lubricants or
for any application where appreciable skin contact
is likely to occur.
Environmental Precautions
Burning used engine oil in small space heaters or
boilers can be recommended only for units of
approved design. If in doubt check with the
appropriate local authority and manufacturer of
approved appliances.
Dispose of used oil and used oil filters through
authorized waste disposal contractors or licensedwaste disposal sites, or to the waste oil reclamation
trade. If in doubt, contact the relevant local
authority for advice on disposal facilities.
It is illegal to pour used oil on to the ground, down
sewers or drains, or into watercourses.
Noise
Some operations may produce high noise levels,
which could, in time, damage hearing. In these
cases, suitable ear protection must be worn.
Noise Insulation Materials
See
Foams, Fibre Insulation.
O-Rings (Fluoroelastomer)
SeeViton.
Paints
See also Solvents, Chemical Materials.
Highly flammable, flammable - observe No
Smoking policy
One Pack
Can contain harmful or toxic pigments, driers and
other components as well as solvents. Spraying
should be carried out only with adequate
ventilation.
Two Pack
Can also contain harmful and toxic unreacted
resins and resin hardening agents. The
manufacturers instructions should be followed. See
also Resin-based Adhesives and Isocyanate
Adhesives and Sealers under Adhesives and
Sealers.
Spraying should preferably be carried out in
exhausted ventilated booths removing vapor and
spray mists from the breathing zone. Individuals
working in booths should wear appropriate
respiratory protection. Those doing small-scale
repair work in the open workshop should wear
air-fed respirators.
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