2011 FORD KUGA pressure

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 ........................................................................\
...........
100-00-44
Brake Fluids (Polyalkylene Glycols) ........................................................................\
...........
100-00-44
Brazing ........................................................................\
.......................................................
100-00-44
Chemical Materials ........................................................................\
.....................................
100-00-45
Chlorofluorocarbons (CFC) ........................................................................\
........................
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 ........................................................................\
..........................................
100-00-46
Foams

- Polyurethane ........................................................................\
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100-00-47
Freon ........................................................................\
..........................................................
100-00-47
Fuels ........................................................................\
...........................................................
100-00-47
Gas Cylinders ........................................................................\
.............................................
100-00-47
Gases ........................................................................\
.........................................................
100-00-47
Gaskets (Fluoroelastomer) ........................................................................\
.........................
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

Description
Item
Measure the current using a digital
multimeter
1
Measure the voltage using a digital
multimeter
2
Measure the resistance using a digital
multimeter
3
Measure the length/distance
4
Check that the specified pressure is
available using a suitable pressure gauge
5
Measure the pressure at the specified port
using a suitable pressure gauge
6
Measure the time using a suitable
stopwatch
7
Wait for the specified period of time
8
The specified task requires the specified
minimum temperature
9Description
Item
The specified task requires the specified
maximum temperature not to be exceeded
10
The specified task requires the specified
temperature range
11
The specified task requires the specified
temperature
12
Measure and check for the specified value
using a dial indicator gauge
13
Measure and check for the specified MAX
value using a dial indicator gauge
14
Measure and check for the specified MIN
value using a dial indicator gauge
15
General equipment symbols
The general equipment symbols are used to show
where to use which type of general equipment to
carry out a procedure step.
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E89021
123
56
798
12
4
13
Description
Item
Hazardous voltage/Electrical
shock/Electrocution
1
Fire Hazard/Highly flammable
2
Burn hazard/Hot surface
3
Automatic start-up
4
Toxic
5
Explosive material
6
Battery hazard
7Description
Item
Corrosive material
8
Lifting hazard
9
Hand crush/Force from above
10
Cutting of fingers or hand
11
Pressure hazard
12
Invisible laser radiation. Do not view
directly with optical instruments
(magnifiers). Class 1M laser product
13
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Solvent-based Adhesives/Sealers - See
Solvents
Follow manufacturers instructions.
Water-based Adhesives/Sealers
Those based on polymer emulsions and rubber
latexes may contain small amounts of volatile toxic
and harmful chemicals. Skin and eye contact
should be avoided and adequate ventilation
provided during use.
Hot Melt Adhesives
In the solid state, they are safe. In the molten state
they may cause burns and health hazards may
arise from the inhalation of toxic fumes.
Use appropriate protective clothing and a
thermostatically controlled heater with a thermal
cut-out and adequate extraction.
Resin-based Adhesives/Sealers, for
example Epoxide and Formaldehyde
Resin-based
Mixing should be carried out in well ventilated
areas, as harmful or toxic volatile chemicals may
be released.
Skin contact with uncured resins and hardeners
can result in irritation, dermatitis, and absorption
of toxic or harmful chemicals through the skin.
Splashes can damage the eyes.
Provide adequate ventilation and avoid skin and
eye contact.
Anaerobic, Cyanoacrylate (super-glues)
and other Acrylic Adhesives
Many are irritant, sensitizing or harmful to the skin
and respiratory tract. Some are eye irritants.
Skin and eye contact should be avoided and the
manufacturers instructions followed.
Cyanoacrylate adhesives (super-glues) MUST NOT
contact the skin or eyes. If skin or eye tissue is
bonded, cover with a clean moist pad and SEEK
IMMEDIATE MEDICAL ATTENTION. Do not
attempt to pull tissue apart. Use in well ventilated
areas as vapors can cause irritation to the nose
and eyes.For two-pack systems see Resin-based and
Isocyanate Adhesives/Sealers.
Isocyanate (Polyurethane)
Adhesives/Sealers
See also
Resin-based Adhesives.
Individuals suffering from asthma or respiratory
allergies should not work with or near these
materials as sensitivity reactions can occur.
Over exposure is irritating to the eyes and
respiratory system. Excessive concentrations may
produce effects on the nervous system including
drowsiness. In extreme cases, loss of
consciousness may result. Long term exposure to
vapor concentrations may result in adverse health
effects.
Prolonged contact with the skin may have a
defatting effect which may lead to skin irritation
and in some cases, dermatitis.
Splashes entering the eye will cause discomfort
and possible damage.
Any spraying should preferably be carried out in
exhaust ventilated booths, removing vapors and
spray droplets from the breathing zone.
Wear appropriate gloves, eye and respiratory
protection.
Antifreeze
See also Fire, Solvents.
For example isopropanol, ethylene glycol,
methanol.
Highly flammable, flammable, combustible.
Used in vehicle coolant systems, brake air pressure
systems, screenwash solutions.
For additional information, refer to: Engine Cooling
System Health and Safety Precautions (100-00
General Information, Description and Operation).
Asbestos
See also Warning Symbols on Vehicles at the end
of this subsection.
Breathing asbestos dust may cause lung damage
or, in some cases, cancer.
Used in brake and clutch linings, transmission
brake bands and gaskets.
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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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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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Pressurized Equipment
See HighPressure Air, Lubrication and Oil Test
Equipment.
Solder
Solders are mixtures of metals such that the
melting point of the mixture is below that of the
constituent metals (normally lead and tin). Solder
application does not normally give rise to toxic lead
fumes, provided a gas/air flame is used.
Oxy-acetylene flames should not be used, as they
are much hotter and will cause lead fumes to be
produced.
Some fumes may be produced by the application
of any flame to surfaces coated with grease, and
inhalation of these should be avoided.
Removal of excess solder should be undertaken
with care, to make sure that fine lead dust is not
produced, which can give toxic effects if inhaled.
Respiratory protection may be necessary.
Solder spillage and filings should be collected and
removed promptly to prevent general air
contamination by lead.
High standards of personal hygiene are necessary
in order to avoid ingestion of lead or inhalation of
solder dust from clothing.
Solvents
See also Chemical Materials, Fuels (Kerosene),
Fire.
For example acetone, white spirit, toluene, xylene,
trichloroethane.
Used in cleaning and dewaxing materials, paints,
plastics, resins and thinners.
Some may be highly flammable or flammable.
Skin contact will degrease the skin and may result
in irritation and dermatitis following repeated or
prolonged contact. Some can be absorbed through
the skin in toxic or harmful quantities.
Splashes in the eye may cause severe irritation
and could lead to loss of vision.
Brief exposure of high concentrations of vapors or
mists will cause eye and throat irritation,
drowsiness, dizziness, headaches and, in the worst
circumstances, unconsciousness.
Repeated or prolonged exposure to excessive but
lower concentrations of vapors or mists, for which there might not be adequate warning indications,
can cause more serious toxic or harmful effects.
Aspiration into the lungs, for example through
vomiting, is the most serious consequence of
swallowing.
Avoid splashes to the skin, eyes and clothing. Wear
protective gloves, goggles and clothing if
necessary.
Make sure there is good ventilation when in use,
avoid breathing fumes, vapors and spray mists and
keep containers tightly sealed. Do not use in
confined spaces.
When spraying materials containing solvents, for
example paints, adhesive, coatings, use extraction
ventilation or personal respiratory protection in the
absence of adequate general ventilation.
Do not apply heat or flame except under specific
and detailed manufacturers instructions.
Sound Insulation
See
Fibre Insulation, Foams.
Suspended Loads
CAUTION: Never improvise lifting tackle.
There is always a danger when loads are lifted or
suspended. Never work under an unsupported,
suspended or raised load, for example a
suspended engine.
Always make sure that lifting equipment such as
jacks, hoists, axle stands and slings are adequate
and suitable for the job, in good condition and
regularly maintained.
Transmission Brake Bands
See Asbestos.
Underseal
SeeCorrosion Protection.
Viton
In common with many other manufacturers
vehicles, some components have O-rings, seals
or gaskets, which contain a material known as
`Viton'.
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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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