2011 FORD KUGA warning

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

Powertrain LH and RH definition
E126781
1
2
3
4
Description
Item
front
1
right hand
2
rear
3
left hand
4
How to use Repair Procedures
This manual has been written in a format that is
designed to meet the needs of technicians
worldwide. It provides general descriptions for
accomplishing repair work with tested and effective
techniques.
Important Safety Instructions
Appropriate service methods and correct repair
procedures are essential for the safe and reliable
operation of all vehicles as well as the personal
safety of the individual carrying out the work.
Anyone who departs from the instructions provided
in this manual must first establish that personal safety or vehicle integrity is not compromised by
the choice of method, tools or components.
Warnings, Cautions and Notes in This
Manual
WARNING: Warnings are used to indicate
that failure to follow a procedure correctly
may result in personal injury.
CAUTION: Cautions are used to indicate
that failure to follow a procedure correctly
may result in damage to the vehicle or
equipment being used.
NOTE: Notes are used to provide additional
essential information required to carry out a
complete and satisfactory repair.
Generic warnings or cautions are in their relevant
description and operation procedure within section
100-00. If the generic warnings or cautions are
required for a procedure, there will be a referral to
the appropriate description and operation
procedure.
If a warning, caution or note only applies to one
step, it is placed at the beginning of the specific
step.
Global Authoring Standards (GAS) Repair
Procedures
NOTE: GAS style procedures can be identified by
steps that have no accompanying step text and
the magenta color of the electrical connectors and
fasteners such as nuts, bolts, clamps or clips.
A GAS removal and installation procedure uses a
sequence of color illustrations to indicate the order
to be followed when removing/disassembling or
installing/assembling a component.
Many of the GAS procedures will have the
installation information within the removal steps.
These procedures will have the following note at
the beginning of the procedure:
NOTE: Removal steps in this procedure may
contain installation details.
Reuse of fasteners and seals and gaskets
The following list details the general policy for the
reuse of fasteners and seals and gaskets.
G836098en2008.50 Kuga8/2011
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100-00- 4
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2
1
3
E85027
Warning symbols are used to indicate potential
risks resulting from a certain component or area.
E85028
G836098en2008.50 Kuga8/2011
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E89020
12
34
56
7
Description
Item
General prohibition symbol
1
No naked flames
2
No smoking
3
No water
4
Do not touch
5Description
Item
Do not switch
6
No grinding
7
Warning symbols - Health and safety and component
damage
The warning symbols are used to advise on
hazardous conditions to avoid or at least reduce
possible component damage and health and safety
risks.
G955392en2008.50 Kuga8/2011
100-00- 38
General Information
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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.
G1185951en2008.50 Kuga8/2011
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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
G566527en2008.50 Kuga8/2011
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General Information
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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.
G566527en2008.50 Kuga8/2011
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General Information
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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.
G566527en2008.50 Kuga8/2011
100-00- 47
General Information
100-00- 47
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