Ford Kuga

 Service Manual

Body Repairs - General Information

Specifications

• Description and Usage of Body Repair Literature
• Symbols
1. Warnings and hazard notices
2. Symbols used
3. Color coding
• Health and Safety Precautions
1. General
2. Personal protection
3. Protection of the vehicle
4. Electronic components
5. Liquefied gas vehicles
6. Refrigerated conversion vehicles
• Environmental Regulations
• Body Construction
1. General
2. Integral body-frame
3. Convertible
4. Non-monocoque bodywork
5. Special points
6. Deformation behavior
7. Crash element
• Diagnosis and Damage Evaluation
1. Noticeable damage to the bodywork structure
2. No noticeable damage to the bodywork structure
3. Non-monocoque bodywork
• Body Sheet Metal
1. High strength steels
2. Ultra-high-strength steels
3. Coated steel panels
• Tools and Equipment for Body Repairs
1. Alignment systems
2. Measuring systems
3. Welding gear
• Establish Repair Method
1. Planning
2. Chronological sequence of repair
• Alignment Check
• Straightening
1. General
2. Special features of non-monocoque bodywork
• Complete Panel Replacement/Partial Replacement
• Corrosion Prevention
1. Panel coatings and corrosion protection
2. Corrosion protection measures during repair work
3. Corrosion protection for the floor pan (example)
• Corrosion Damage/Corrosion Repair
• Sealer, Underbody Protection Material and Adhesives
• Cutting Technique
1. Spot weld milling tool
2. Rod sander
3. Short stroke saw
4. Orbital saw
• Panel Beating Technique and Smart Repairs
1. General
2. Dent removal using special panel beating levers
3. Dynamic puller with counter bearing
4. Hollow leveling (removing dent without a dolly)
5. Dent removal using hammer and dolly
6. Heat-induced material shrinking
7. Lead loading
• Paintless Dent Removal
• Plastic Repairs
1. General
2. Plastic identification
3. Safety instructions
4. Plastic welding
5. Plastic adhesive bonding
6. GRP repairs
• Joining Techniques
1. Welding
2. Resistance spot welding
3. MIG brazes
4. Soft soldering
5. Rivets
6. Bonding
7. Bonding and welding
8. Bonding and riveting
• Special Repair Techniques
1. Cabriolet vehicles
2. Liquefied gas vehicles
3. Refrigerated conversion vehicles
• Impact of Insufficient Repair Quality
• Water Leaks
1. General
2. Test method
3. Test with UV lamp
4. Chalk/powder test
5. Smoke test
6. Stethoscope test
7. Ultrasonic detection
8. Workflow for tracing water entry
9. Possible complaints and corrective actions
• Wind Noise
1. General information
2. Rubber grommets I plugs
3. Heater housing/ventilation
4. Seal welds
5. Attached parts
• Wind Noise
1. General information
2. Workshop diagnosis
3. Test method
4. Diagnosis
5. Possible concerns with corrective measures
• Noise, Vibration and Harshness

General Information

Jacking and Lifting

Noise, Vibration and Harshness

Suspension System - General Information

Climate Control

Auxiliary Climate Control

Instrument Cluster and Panel Illumination

Instrument Cluster

Horn

Warning Devices

Parking Aid

Charging System - General Information

Battery, Mounting and Cables

Generator and Regulator

Voltage Converter/Inverter

Information and Entertainment System - General Information

Information and Entertainment System

Exterior Lighting

Interior Lighting

Daytime Running Lamps (DRL)

Module Communications Network

Module Configuration

Wiring Harnesses

Anti-Theft - Active

Anti-Theft - Passive

Multifunction Electronic Modules

Front End Body Panels

Body Closures

Interior Trim and Ornamentation

Exterior Trim and Ornamentation

Rear View Mirrors

Seating

Glass, Frames and Mechanisms

Instrument Panel and Console

Handles, Locks, Latches and Entry Systems

Wipers and Washers

Bumpers

Safety Belt System

Supplemental Restraint System

Body Repairs - General Information

Body Repairs - Vehicle Specific Information and Tolerance Checks

Front End Sheet Metal Repairs

Roof Sheet Metal Repairs

Side Panel Sheet Metal Repairs

Rear End Sheet Metal Repairs

Paint - General Information

Uni-Body, Subframe and Mounting System

Suspension System - General Information

Front Suspension

Rear Suspension

Wheels and Tires

Driveshaft

Rear Drive Axle/Differential

Front Drive Halfshafts

Rear Drive Halfshafts

Brake System - General Information

Front Disc Brake

Rear Disc Brake

Parking Brake and Actuation

Hydraulic Brake Actuation

Power Brake Actuation

Anti-Lock Control

Anti-Lock Control - Stability Assist

Steering System - General Information

Power Steering

Steering Linkage

Steering Column

Steering Column Switches

Engine System - General Information

Engine- 2.5L Duratec (147kW/200PS) - VI5

Engine Cooling

Fuel Charging and Controls-2.5L Duratec (147kW/200PS) - VI5

Fuel Charging and Controls - Turbocharger- 2.5L Duratec (147kW/200PS) - VI5

Accessory Drive - 2.5L Duratec (147kW/200PS) - VI5

Starting System- 2.5L Duratec (147kW/200PS) - VI5

Engine Ignition - 2.5L Duratec (147kW/200PS) - VI5

Engine Emission Control - 2.5L Duratec (147kW/200PS) - VI5

Intake Air Distribution and Filtering - 2.5L Duratec (147kW/200PS) - VI5

Evaporative Emissions

Electronic Engine Controls

Automatic Transmission/Transaxle

Transmission/Transaxle Cooling

Automatic Transmission/Transaxle External Controls

Transfer Case

Exhaust System-

Fuel System

Fuel Tank and Lines

Acceleration Control

Speed Control

Climate Control System

Climate Control