2011 FORD KUGA connecting rod

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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PAGE 2 OF 2 FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

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
G963390en2008.50 Kuga8/2011
100-00- 69
General Information
100-00- 69
DESCRIPTION AND OPERATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Suspension System
Special Tool(s)Alignment Pins, Subframe
205-316 (15-097A)
15097A
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanicaldamage.
Visual Inspection Chart
Mechanical
Tire pressure(s) Wheel and tires
Mechanical
Wheel knuckles Tie-rod ends
Front suspension lower arm ball joints Front suspension lower arm bushings Front strut and spring assemblies
Front and rear stabilizer bar and connecting links Rear springs
Rear shock absorbers
Rear suspension lower arms
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 cause is not visually evident, verify the symptom and refer to the Symptom Chart.
Symptom Chart
Symptom Chart
Action
Possible Sources
Symptom
• Vehicles without load levellingshock absorbers, CHECK for
abnormal loading, spring sag
or non-standard springs.
• Vehicles with load levelling shock absorbers, GO to
Pinpoint Test C.
• Vehicle attitude incorrect (front
or rear / left or right is high or
low).
• Drift left or right
• CHECK the steering system.REFER to: Steering System
(211-00 Steering System -
General Information,
Diagnosis and Testing).
• Steering gear or linkage worn
or damaged.
• CHECK the brake system.REFER to: Brake System (206-
00 Brake System - General
Information, Diagnosis and
Testing).
• Brake system.
• Using the special tool, CHECKthe front subframe alignment..
• Incorrect front crossmember
alignment.
• CHECK the wheel bearings.
• Worn front wheel bearings.
• GO toPinpoint Test A.
• Wheel and tires.
G1080717en2008.50 Kuga8/2011
204-00- 2
Suspension System - General Information
204-00- 2
DIAGNOSIS AND TESTING
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Battery Disconnect and Connect
Disconnect
WARNINGS:
Batteries normally produce explosive
gases which may cause personal injury,
therefore do not allow flames, sparks or
lighted substances to come near the
battery. When charging or working near
the battery always shield your face and
protect your eyes. Always provide
adequate ventilation. Failure to follow
these instructions may result in personal
injury.
The supplemental restraint system (SRS)
is active for a certain length of time after
the power supply has been disconnected.
Wait for a minimum of 3 minutes before
disconnecting or removing any SRS
components.
Audio unit key code saving devices must
not be used when working on
supplemental restraint or fuel systems.
When using these devices the vehicle
electrical system is still live but with a
reduced current flow. Failure to follow this
instruction may result in personal injury.
CAUTION: Make sure the engine is not
running before disconnecting the battery
ground cable to avoid damage to the
vehicle electrical system.
NOTE: Disconnecting the battery will erase fault
codes, drive values and customer data stored in
the modules.
NOTE: This procedure should be used to
disconnect the battery while carrying out repairs
that refer to the battery being disconnected.
1. Refer to: Battery and Battery Charging Health
and Safety Precautions (100-00 General
Information, Description and Operation).
2. Obtain and record the audio unit keycode and
preset radio frequencies. 3.
G1062389en
2008.50 Kuga 8/2011 414-01-2
Battery, Mounting and Cables
414-01-2
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUALE103137

Action
Possible Sources
Symptom
• CHECK the engine compon-ents for wear or damage. Make
sure that all components are
within specification. INSTALL
new components as necessary.
Engine - 2.5L Duratec-ST (VI5)
-
REFER to: Specifications (303-
01 Engine - 2.5L Duratec
(147kW/200PS) - VI5,
Specifications).
Engine - 2.0L Duratorq-TDCi
(DW) Diesel -
• Engine components
- Pistons.
- Piston rings.
- Connecting rod big end,main bearing or thrust
bearing journals.
- Connecting rods bent or damaged.
• Noisy running or engine noise
Engine - Oil Leaks
NOTE:
Before installing new gaskets or oil seals,
make sure that the fault is clearly established.
If the oil leak cannot be identified clearly by a visual
inspection, carry out an ultraviolet (UV) test:
Ultraviolet (UV) Testing
1. Clean the engine and transmission with a suitable cleaning fluid.
2. Pour the UV-test fluid in accordance with the quantity specified by the manufacturer through
the oil filler neck into the engine and install the
oil filler cap.
WARNING: Vehicles with manual transaxle,
shift the transaxle into Neutral. Failure to
follow this instruction may result in
personal injury.
3. Start the engine and let it run for about five minutes.
4. Switch off the engine.
NOTE: If no leak can be found, road test the
vehicle under various loads and check the engine
for leaks again.
5. Check the engine for oil leaks using a suitable UV lamp.
6. Rectify any leaks found and check the engine for oil leaks.
Measure the compression pressure
NOTE: The powertrain control module (PCM)
receives an error message when the fuel pump
relay is removed or electrical components are disconnected. This error message must be deleted
from the fault memory using the Ford diagnostic
equipment after completing the compression test.
NOTE:
Valve clearance must be set correctly
before performing a compression test. Make sure
the engine is at the normal operating temperature.
NOTE: The varying design of compression
checking devices and fluctuating starter motor
speeds normally only allows for a comparison to
be made of the compression pressures in all
cylinders.
G1055128en2008.50 Kuga8/2011
303-00- 9
Engine System - General Information
303-00- 9
DIAGNOSIS AND TESTING
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