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Ford Kuga Owners Manual
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Introduction
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About This Manual
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Symbols Glossary
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Data Recording
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Replacement Parts Recommendation
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Mobile Communications Equipment
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At a Glance
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Front Exterior Overview
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Instrument Panel Overview
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Child Safety
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Installing Child Seats
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Child Seat Positioning
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Child Safety Locks
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Safety Belts
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Fastening the Safety Belts
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Safety Belt Height Adjustment
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Safety Belt Minder
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Supplementary Restraints System
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Principle of Operation
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Driver Airbag
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Passenger Airbag
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Side Airbags
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Driver Knee Airbag
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Side Curtain Airbags
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Keys and Remote Controls
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General Information on Radio Frequencies
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Remote Control
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Locks
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Locking and Unlocking
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Power Door Locks
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Power Liftgate
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Locking the Doors Individually with the Key
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Manual Liftgate
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Power Liftgate
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Liftgate Switch
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Closing the Liftgate
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Hands-Free Feature
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Keyless Entry
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Passive Key
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Unlocking Your Vehicle
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Unlocking Your Vehicle
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Disabled Keys
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Security
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Passive Anti-Theft System
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Anti-Theft Alarm
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Alarm System
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Triggering the Alarm
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Full and Reduced Guard
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Disarming the Alarm
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Steering Wheel
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Adjusting the Steering Wheel
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Audio Control
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Information Display Control
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Wipers and Washers
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Windshield Wipers
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Autowipers
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Windshield Washers
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Rear Window Wiper and Washers
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Lighting
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General Information
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Lighting Control
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Autolamps
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Headlamp Exit Delay
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Daytime Running Lamps
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Automatic High Beam Control
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Rear Fog Lamps
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Headlamp Leveling
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Interior Lamps
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Ambient Lighting
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Windows and Mirrors
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Power Windows
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Global Opening and Closing
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Exterior Mirrors
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Interior Mirror
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Sun Visors
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Moonroof
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Instrument Cluster
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Gauges
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Warning Lamps and Indicators
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Audible Warnings and Indicators
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Information Displays
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General Information
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Trip Computer
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Personalized Settings
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Information Messages
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Climate Control
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Principle of Operation
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Manual Climate Control
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Automatic Climate Control
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Hints on Controlling the Interior Climate
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Heated Windows and Mirrors
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Auxiliary Heater
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Seats
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Sitting in the Correct Position
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Head Restraints
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Manual Seats
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Power Seats
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Rear Seats
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Heated Seats
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Auxiliary Power Points
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Storage Compartments
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Starting and Stopping the Engine
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General Information
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Ignition Switch
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Keyless Starting
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Steering Wheel Lock
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Starting a Gasoline Engine
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Starting a Diesel Engine
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Diesel Particulate Filter
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Switching Off the Engine
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Unique Driving Characteristics
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Fuel and Refueling
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Safety Precautions
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Fuel Quality - Gasoline
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Fuel Quality - 2.0L Duratorq-TDCi (DW) Diesel
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Running Out of Fuel
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Catalytic Converter
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Refueling
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Fuel Consumption
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Transmission
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Automatic Transmission
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Hill Start Assist
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Four-Wheel Drive
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Principle of Operation
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Using Four-Wheel Drive
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Brakes
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General Information
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Hints on Driving With Anti-Lock Brakes
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Parking Brake
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Traction Control
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Principle of Operation
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Using Traction Control
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Stability Control
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Parking Aids
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Principle of Operation
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Parking Aid
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Active Park Assist
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Rear View Camera
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Cruise Control
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Using Cruise Control
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Using Adaptive Cruise Control
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Detection Beam Issues
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Automatic Braking
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Using the System
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Setting the Vehicle Gap
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Automatic Switch Off
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Forward Alert Function
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Driving Aids
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Speed Limiter
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Driver Alert
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Principle of Operation
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Using Driver Alert
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Lane Keeping System
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Lane Keeping Alert
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Lane Keeping Aid
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Blind Spot Information System
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Traffic Sign Recognition
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Principle of Operation
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Using the System
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Active City Stop
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Principle of Operation
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Switching the System Off and On
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Eco Mode
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Load Carrying
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General Information
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Rear Under Floor Storage
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Luggage Covers
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Roof Racks and Load Carriers
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Towing
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Towing a Trailer
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Trailer Sway Control
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Tow Ball
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Unlocking the Tow Ball Arm Mechanism
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Inserting the Tow Ball Arm
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Driving with a Trailer
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Removing the Tow Ball Arm
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Driving without a Trailer
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Towing Points
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Towing the Vehicle on Four Wheels
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Driving Hints
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Breaking-In
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Driving Through Water
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Floor Mats
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Roadside Emergencies
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Hazard Warning Flashers
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Fuel Shutoff
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Jump Starting the Vehicle
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Fuses
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Fuse Box Locations
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Fuse Specification Chart
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Changing a Fuse
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Maintenance
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General Information
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Opening and Closing the Hood
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Under Hood Overview - 1.6L EcoBoost
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Under Hood Overview - 2.0L EcoBoost
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Under Hood Overview - 2.0L Duratorq-TDCi (DW) Diesel
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Under Hood Overview - 1.5L EcoBoost
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Engine Oil Check
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Engine Coolant Check
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Washer Fluid Check
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Changing the 12V Battery
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Changing the Wiper Blades
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Removing a Headlamp
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Changing a Bulb
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Bulb Specification Chart
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Technical Specifications
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Vehicle Care
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Cleaning the Exterior
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Cleaning the Interior
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Repairing Minor Paint Damage
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Cleaning the Alloy Wheels
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Wheels and Tires
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General Information
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Temporary Mobility Kit
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General Information
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Using the Kit
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Inflating the Tire
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Checking the Tire Pressure
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Tire Care
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Using Snow Chains
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Tire Pressure Monitoring System
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Changing a Road Wheel
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Vehicles with a Spare Wheel
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Vehicle Jack
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Jacking and Lifting Points
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Assembling the Wheel Brace
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Removing the Wheel Trim
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Removing a Road Wheel
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Installing a Road Wheel
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Stowing the Flat Tire
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Technical Specifications
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Capacities and Specifications
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Vehicle Identification Plate
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Vehicle Identification Number
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Capacities and Specifications - 1.6L EcoBoost
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Capacities and Specifications - 2.5L
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Capacities and Specifications - 2.0L Duratorq-TDCi (DW) Diesel
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Technical Specifications
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Audio System
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General Information
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Audio Unit - Vehicles With: AM/FM/ CD
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Audio Unit - Vehicles With: Digital Audio Broadcast (DAB) Radio/SYNC
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Audio Unit - Vehicles With: Digital Audio Broadcast (DAB) Radio/Navigation System/SYNC
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Audio Unit - Vehicles With: Digital Audio Broadcast (DAB) Radio/SYNC/Sony AM/FM/CD
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Audio Unit - Vehicles With: Digital Audio Broadcast (DAB) Radio/Navigation System/SYNC/Sony AM/FM/CD
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Digital Radio
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Audio Input Jack
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USB Port
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SYNC
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General Information
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Using Voice Recognition
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Using SYNC With Your Phone
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SYNC Applications and Services
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Using SYNC With Your Media Player
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SYNC Troubleshooting
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Navigation
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Appendices
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Electromagnetic Compatibility
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End User License Agreement
Ford Kuga Service Manual
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General Information
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About This Manual
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Introduction
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How to use Repair Procedures
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Global Authoring Standards (GAS) Repair Procedures
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How to use Diagnosis and Testing procedures
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Symbols Glossary
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Steering System Health and Safety Precautions
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Health and Safety Precautions
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Introduction
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Acids and Alkalis
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Air Bags
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Air Conditioning Refrigerant
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Adhesives and Sealers
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Asbestos
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Battery Acids
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Chemical Materials
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Chlorofluorocarbons (CFC)
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Clutch Fluids
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Electric Shock
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Engine Oils
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Transmission Fluids
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Paints
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Solder
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Solvents
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Suspended Loads
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Viton
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Welding
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Warning Symbols on Vehicles
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Standard Workshop Practices
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Vehicle in Workshop
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Towing the Vehicle
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Connecting a Slave Battery Using Jumper Cables
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Solvents, Sealants and Adhesives
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Road/Roller Testing
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Pre-Test Checks
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Starting the Engine
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Road or Roller Testing
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Brake Testing
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Air Conditioning (A/C) System Health and Safety Precautions
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Battery and Battery Charging Health and Safety Precautions
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Brake System Health and Safety Precautions
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Engine Cooling System Health and Safety Precautions
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Window Glass Health and Safety Precautions
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Petrol and Petrol-Ethanol Fuel Systems Health and Safety Precautions
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Supplemental Restraint System (SRS) Health and Safety Precautions
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Body Repair Health and Safety and General Precautions
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General
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Personal protection
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Protection of the vehicle
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Jacking and Lifting
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Noise, Vibration and Harshness
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Noise, Vibration and Harshness (NVH)
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Road Test
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Road Test Quick Checks
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Noise Diagnostic Procedure
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Road Conditions
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Power Steering Conditions
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Power Steering Operation Noise Check
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Symptom Chart
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Pinpoint Tests
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Suspension System - General Information
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Suspension System
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Symptom Chart
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Climate Control
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Condenser
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Clutch and Clutch Field Coil
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Pollen Filter - RHD
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Blower Motor - RHD(34 374 0)
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Blower Motor Resistor - Vehicles With: Manual Temperature Control, RHD(34 382 0)
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Blower Motor Resistor - Vehicles With: Dual Automatic Temperature Control(34 382 0)
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Heater Core and Evaporator Core Housing
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Heater Core - RHD(34 364 0)
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Suction Accumulator
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Suction Accumulator to Air Conditioning (A/C) Compressor Line
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Suction Accumulator to Air Conditioning (A/C) Compressor Line - 2.5L Duratec (147kW/200PS) - VI5
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Low-Pressure Cutoff Switch
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High-Pressure Cutoff Switch
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Evaporator
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Evaporator Outlet Line
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Evaporator Core Orifice
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Condenser to Evaporator Line
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Climate Control Assembly - Vehicles With: Manual Temperature Control(34 300 0)
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Climate Control Assembly - Vehicles With: Automatic Temperature Control(34 300 0)
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Footwell Air Discharge Temperature Sensor(34 485 4)
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Center Register Air Discharge Temperature Sensor
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In-Vehicle Temperature Sensor
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Footwell Vent/Duct Blend Door Actuator - RHD(34 591 0)
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Air Inlet Blend Door Actuator(34 606 0)
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Driver Side Temperature Blend Door Actuator(34 608 0)
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Passenger Side Temperature Blend Door Actuator(34 608 0)
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Defrost Vent/Register Blend Door Actuator - RHD(34 591 0)
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Auxiliary Climate Control
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Auxiliary Climate Control (Component Location)
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Auxiliary Climate Control - Overview
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Auxiliary Climate Control (System Operation and Component Description)
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System Diagram
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System Operation
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Component Description
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Auxiliary Coolant Flow Pump
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Electric Booster Heater
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Fuel Fired Booster Heater - 2.5L Duratec (147kW/200PS) - VI5
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Fuel Fired Booster Heater Fuel Pump
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Fuel Fired Booster Heater
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Instrument Cluster and Panel Illumination
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Instrument Cluster and Dimmable Backlighting
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Inspection and Verification
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Instrument Cluster
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Instrument Cluster (Overview)
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Replacing the instrument cluster
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Self-diagnostic mode
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Instrument Cluster (System Operation and Component Description)
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System Diagram
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System Operation
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Component Description
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Instrument Cluster
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Inspection and Verification
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Configuration of the Instrument Cluster
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Horn
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Principles of Operation
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Inspection and Verification
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Warning Devices
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Inspection and Verification
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Safety Belt Minder Deactivating/Activating
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Preparation
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Deactivating/Activating
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Oil Change Indicator Reset
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Parking Aid
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Parking Aid (Component Location)
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Parking Aid (Overview)
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Parking aid sensors
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Parking Aid Camera
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Parking Aid (System Operation and Component Description)
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System Operation
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Component Description
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Parking Aid - Vehicles With: Front Parking Aid
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Principles of Operation
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Inspection and Verification
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Diagnostic Trouble Codes (DTC) Index
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Pinpoint Tests
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Parking Aid - Vehicles With: Rear Parking Aid
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Principles of Operation
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Inspection and Verification
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Diagnostic Trouble Codes (DTC) Index
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Pinpoint Tests
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Parking Aid Module
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Parking Aid Camera Module
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Parking Aid Camera
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Front Parking Aid Speaker
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Front Parking Aid Sensor
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Rear Parking Aid Sensor
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Charging System - General Information
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Inspection and Verification
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Component Tests
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Generator On-Vehicle Tests - No-Load Test
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Generator On-Vehicle Tests - Load Test
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Midtronics EXP-1050 battery tester
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Using the Midtronics EXP-1050 battery tester
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Midtronics EXP-1050 Battery Tester Test Code
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Battery, Mounting and Cables
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Battery Disconnect and Connect
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Battery
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Generator and Regulator
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Generator
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Generator - 2.5L Duratec (147kW/200PS) - VI5
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Voltage Converter/Inverter
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Direct Current/Alternating Current (DC/AC) Inverter (Overview)
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Direct Current/Alternating Current (DC/AC) Inverter (System Operation and Component Description)
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System Diagram
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System Operation
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Component Description
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Direct Current/Alternating Current (DC/AC) Inverter
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Information and Entertainment System - General Information
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Audio System
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Inspection and Verification
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Self-Diagnostic Mode - Low Series Audio Unit
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Self-Diagnostic Mode - High Series Audio Unit GEN 2
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Cellular Phone
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Principles of Operation
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Inspection and Verification
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Diagnostic Trouble Code (DTC) Index Chart
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Symptom Chart
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Pinpoint Tests
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Information and Entertainment System
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Audio System (Component Location)
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Audio System (Overview)
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Keycode entry - vehicle with standard audio system
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Vehicle Identification Number (VID) - entry - vehicle with standard audio system
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Keycode entry - vehicles with upgraded audio system
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Audio System (System Operation and Component Description)
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System Diagram
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System Operation
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Component Description
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Cellular Phone (Component Location)
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Cellular Phone (Overview)
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Cellular Phone (System Operation and Component Description)
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System Diagram
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System Operation
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Component Description
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Audio Unit
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Audio Unit Antenna - Vehicles With: Glass Roof Panel
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Audio Unit Antenna - Vehicles Without: Glass Roof Panel
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Audio Unit Antenna to Connector Cable - Vehicles With: Glass Roof Panel
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Audio Unit Antenna to Connector Cable - Vehicles Without: Glass Roof Panel
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Connector to Audio Unit Antenna Cable
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Compact Disc (CD) Changer
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Portable Support Electronics (PSE) Module
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Cellular Phone Microphone
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Exterior Lighting
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Exterior Lighting (Component Location)
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Exterior Lighting (Overview)
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Front headlamps
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Combined rain sensor/light sensor
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Autolamps
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Headlamp switch-off delay
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Turn signals
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Door entry illumination
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Rear Lighting
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Exterior Lighting (System Operation and Component Description)
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System Diagram
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System Operation
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Component Description
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Fog Lamps
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Description of operation
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Inspection and Checking
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Headlamps
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Description of operation
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Inspection and Checking
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Headlamp Leveling
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Description of operation
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Inspection and Checking
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Parking, Rear and License Plate Lamps
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Description of operation
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Inspection and Checking
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Reversing Lamps
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Description of operation
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Inspection and Checking
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Stoplamps
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Description of operation
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Inspection and Checking
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Turn Signal and Hazard Lamps
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Description of operation
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Inspection and Checking
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Front Fog Lamp Adjustment
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Headlamp Adjustment
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Headlamp Switch
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Stoplamp Switch
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Trailer Module
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Front Fog Lamp
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Headlamp Assembly
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Interior Lighting
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Daytime Running Lamps (DRL)
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Description of operation
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Inspection and Checking
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Module Communications Network
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Communications Network (Component Location)
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Communications Network (Overview)
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Communications Network (System Operation and Component Description)
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System Diagram
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System Operation
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Communications Network
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Module Configuration
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Module Configuration
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Programmable Module Installation
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Wiring Harnesses
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Passenger Compartment Wiring Harness
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Instrument Panel Wiring Harness
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Engine Compartment Wiring Harness
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Anti-Theft - Active
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Anti-Theft - Active (Component Location)
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Anti-Theft - Active (Overview)
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Anti-Theft - Active (System Operation and Component Description)
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System Diagram
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System Operation
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Component Description
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Anti-Theft - Active
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Anti-Theft Alarm Horn
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Anti-Theft Alarm Horn with Integral Battery
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Anti-Theft - Passive
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Anti-Theft - Passive (Component Location)
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Anti-Theft - Passive (Overview)
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Anti-Theft - Passive (System Operation and Component Description)
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System Diagram
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System Operation
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Component Description
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Anti-Theft - Passive
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Multifunction Electronic Modules
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Module Controlled Functions (Overview)
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Generic electronics module (GEM)
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Emergency function
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Service mode
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Module Controlled Functions (System Operation and Component Description)
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System Diagram
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System Operation
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Component Description
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Battery charging (Smart Charge)
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Ignition overload protection
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Headlamp switch-off delay
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Turn signals
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Interior lighting
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Heated windscreen
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Heated rear window and heated external mirrors
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Ambient air temperature
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Generic Electronic Module (GEM)
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Description of operation
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Inspection and Checking
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Generic Electronic Module (GEM)
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Lighting Control Module (LCM)
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Front End Body Panels
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Cowl Panel Grille
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Fender Splash Shield
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Body Closures
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Front Door Alignment
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Rear Door Alignment
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Liftgate Alignment
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Hood Alignment
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Liftgate
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Upper Liftgate
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Upper Liftgate
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Interior Trim and Ornamentation
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Loadspace Trim Panel LH
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Loadspace Trim Panel RH
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Headliner
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Glass Roof Panel Blind
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Front Door Trim Panel
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Rear Door Trim Panel
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Liftgate Upper Trim Panel
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Liftgate Lower Trim Panel
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Exterior Trim and Ornamentation
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Exterior Trim (Component Location)
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Rear Spoiler
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Roof Rail
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Front Fender Moulding
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Rear View Mirrors
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Seating
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Seats (Overview)
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Seat
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Seat warmer unit
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Seat occupancy sensor, passenger side
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Seats (System Operation and Component Description)
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System Diagram
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System Operation
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Component Description
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Seats
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Front Seat (40 100 0; 40 100 4; 40 101 0)
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Driver Seat Track
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Front Seat Control Switch (33 580 0; 33 583 0; 33 585 0)
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Front Seat Cushion Cover (40 105 0)
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Front Seat Cushion Heater Mat (33 401 0; 33 401 4)
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Front Seat Cushion (40 104 0)
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Front Seat Backrest Cover (40 108 0)
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Front Seat Backrest Heater Mat (33 402 0; 33 402 4)
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Lumbar Assembly
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Front Seat Track Motor( 33 784 0 ; 33 784 4)
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Front Seat Recliner Motor (33 785 0; 33 785 4)
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Front Seat Height Adjustment Motor (33 797 0; 33 797 4)
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Seat Occupant Sensor
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Rear Seat Cushion
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Rear Seat Backrest Latch
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Rear Seat Backrest
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Rear Seat Armrest
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Front Seat Backrest
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Rear Seat Cushion
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Rear Seat Backrest
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Glass, Frames and Mechanisms
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Glass, Frames and Mechanisms (Component Location)
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Glass, Frames and Mechanisms (Overview)
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Fixed Glass
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Electric window regulators
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Folding Rear Window
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Panoramic roof
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Glass, Frames and Mechanisms (System Operation and Component Description)
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System Diagram
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System Operation
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Glass, Frames and Mechanisms - Vehicles With: Front and Rear Power Windows
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Door Window Motor Initialization
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Front Door Window Glass
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Front Door Window Regulator
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Front Door Window Regulator Motor
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Glass Roof Panel
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Liftgate Window Glass
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Rear Door Window Glass
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Rear Door Window Regulator
L
Rear Door Window Regulator Motor
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Rear Quarter Window Glass
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Windshield Glass
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Instrument Panel and Console
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Instrument Panel
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Floor Console
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Overhead Console
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In-Vehicle Crossbeam
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Handles, Locks, Latches and Entry Systems
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Handles, Locks, Latches and Entry Systems (Component Location)
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Handles, Locks, Latches and Entry Systems (Overview)
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Vehicles with keyless start system
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Vehicles with Keyless Vehicle System
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Handles, Locks, Latches and Entry Systems (System Operation and Component Description)
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System Diagram
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System Operation
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Component Description
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Locks, Latches and Entry Systems
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Principles of Operation (Vehicles with Remote Keyless Entry (RKE)
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Inspection and Verification (Vehicles with Remote Keyless Entry (RKE)
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Front Door Latch
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Rear Door Latch
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Exterior Front Door Handle
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Exterior Rear Door Handle
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Front Door Lock Cylinder
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Keyless Vehicle Module (KVM)
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Keyless Vehicle Front Antenna
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Keyless Vehicle Center Antenna
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Keyless Vehicle Rear Antenna
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Keyless Vehicle Rear Bumper Antenna
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Radio Frequency (RF) Receiver
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Wipers and Washers
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Wipers and Washers (Component Location)
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Wipers and Washers (Overview)
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Windshield wipers
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Automatic wiper system
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Rear windshield wiper
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Combined rain sensor/light sensor
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Windshield washer control
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Headlamp Washers
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Wipers and Washers (System Operation and Component Description)
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System Diagram
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System Operation
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Component Description
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Wipers and Washers
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Description of operation
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Inspection and Checking
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Wiper Blade Angle Adjustment
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Windshield Wiper Motor
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Rear Window Wiper Motor
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Windshield Washer Pump
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Windshield Washer Reservoir
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Headlamp Washer Pump
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Headlamp Washer Jet
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Rain Sensor
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Bumpers
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Front Bumper Cover
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Rear Bumper Cover
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Front Bumper Cover
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Rear Bumper Cover
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Safety Belt System
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Principles of Operation
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Inspection and Verification
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Component Test
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Vehicle Motion Sensor Test
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Test Method 1 (braking)
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Test Method 2 (turning circle)
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Static Test
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Front Safety Belt Retractor
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Rear Safety Belt Retractor
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Rear Center Safety Belt Retractor
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Safety Belt Shoulder Height Adjuster
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Front Safety Belt Buckle
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Supplemental Restraint System
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Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS) (Overview)
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Overview
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Restraints control module (RCM)
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Pyrotechnic belt pretensioner
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Side air curtain module
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Crash sensor, left/right
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Passenger air bag module deactivation (PAD) switch
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Front impact sensor
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Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS) (System Operation and Component Description)
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System Diagram
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System Operation
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Component Description
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Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS) - Vehicles Built From: 06/2004
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Inspection and Verification
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Diagnosing Customer Concerns Without Hard DTCs
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Diagnosing Customer Concerns with Hard DTCs
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Deactivation
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Reactivation
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Glossary
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Principles of Operation
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Clockspring Adjustment
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Deployed Air Bag Disposal
L
Scrapped Vehicle Air Bag and Safety Belt Pretensioner Disposal - In-Vehicle Disposal
L
Unserviceable Air Bag Disposal
L
Front Impact Severity Sensor
L
Crash Sensor
L
Driver Air Bag Module
L
Passenger Air Bag Module
L
Restraints Control Module (RCM)
L
Side Air Bag Module
L
Side Air Curtain Module
L
Clockspring
L
Body Repairs - General Information
L
Description and Usage of Body Repair Literature
L
Symbols
L
Warnings and hazard notices
L
Symbols used
L
Color coding
L
Health and Safety Precautions
L
General
L
Personal protection
L
Protection of the vehicle
L
Electronic components
L
Liquefied gas vehicles
L
Refrigerated conversion vehicles
L
Environmental Regulations
L
Body Construction
L
General
L
Integral body-frame
L
Convertible
L
Non-monocoque bodywork
L
Special points
L
Deformation behavior
L
Crash element
L
Diagnosis and Damage Evaluation
L
Noticeable damage to the bodywork structure
L
No noticeable damage to the bodywork structure
L
Non-monocoque bodywork
L
Body Sheet Metal
L
High strength steels
L
Ultra-high-strength steels
L
Coated steel panels
L
Tools and Equipment for Body Repairs
L
Alignment systems
L
Measuring systems
L
Welding gear
L
Establish Repair Method
L
Planning
L
Chronological sequence of repair
L
Alignment Check
L
Straightening
L
General
L
Special features of non-monocoque bodywork
L
Complete Panel Replacement/Partial Replacement
L
Corrosion Prevention
L
Panel coatings and corrosion protection
L
Corrosion protection measures during repair work
L
Corrosion protection for the floor pan (example)
L
Corrosion Damage/Corrosion Repair
L
Sealer, Underbody Protection Material and Adhesives
L
Cutting Technique
L
Spot weld milling tool
L
Rod sander
L
Short stroke saw
L
Orbital saw
L
Panel Beating Technique and Smart Repairs
L
General
L
Dent removal using special panel beating levers
L
Dynamic puller with counter bearing
L
Hollow leveling (removing dent without a dolly)
L
Dent removal using hammer and dolly
L
Heat-induced material shrinking
L
Lead loading
L
Paintless Dent Removal
L
Plastic Repairs
L
General
L
Plastic identification
L
Safety instructions
L
Plastic welding
L
Plastic adhesive bonding
L
GRP repairs
L
Joining Techniques
L
Welding
L
Resistance spot welding
L
MIG brazes
L
Soft soldering
L
Rivets
L
Bonding
L
Bonding and welding
L
Bonding and riveting
L
Special Repair Techniques
L
Cabriolet vehicles
L
Liquefied gas vehicles
L
Refrigerated conversion vehicles
L
Impact of Insufficient Repair Quality
L
Water Leaks
L
General
L
Test method
L
Test with UV lamp
L
Chalk/powder test
L
Smoke test
L
Stethoscope test
L
Ultrasonic detection
L
Workflow for tracing water entry
L
Possible complaints and corrective actions
L
Wind Noise
L
General information
L
Rubber grommets I plugs
L
Heater housing/ventilation
L
Seal welds
L
Attached parts
L
Wind Noise
L
General information
L
Workshop diagnosis
L
Test method
L
Diagnosis
L
Possible concerns with corrective measures
L
Noise, Vibration and Harshness
L
Body Repairs - Vehicle Specific Information and Tolerance Checks
L
Body and Frame (Component Location)
L
Body and Frame (Overview)
L
Introduction
L
Body - floor pan
L
Plastic fenders
L
MIG brazed joints
L
Anti-corrosion protection
L
Tailored blanks
L
Underbody Tolerance Check
L
Frame Tolerance Check
L
Front End Sheet Metal Repairs
L
Fender Apron Panel Reinforcement
L
Front Side Member Section
L
Front Side Member and Fender Apron Panel LH
L
Front Fender
L
Fender Apron Panel Section
L
Roof Sheet Metal Repairs
L
Roof Panel
L
Roof Front Frame
L
Roof Rear Frame
L
Side Panel Sheet Metal Repairs
L
Rocker Panel
L
B-Pillar and Reinforcement
L
B-Pillar Outer Panel
L
Rocker Panel Inner Reinforcement
L
A-Pillar Outer Panel Section and Reinforcement
L
Rear End Sheet Metal Repairs
L
Quarter Panel LH
L
Water Drain Panel
L
Water Drain Panel Reinforcement
L
Rear Wheelhouse Outer
L
Back Panel and Reinforcement
L
Rear Floor Panel
L
Inner Quarter Panel and Wheelhouse
L
Rear Side Member Section
L
Paint - General Information
L
Description and Usage of Paint Literature
L
Symbols
L
General
L
Hazardous materials designations
L
Instructions on measures to be taken for personal protection
L
Icons
L
Health and Safety Precautions
L
General instructions for the paint shop and handling paint materials
L
Personal protection
L
Breathing protection
L
Skin protection
L
Eye protection
L
Ear protection
L
Environmental Regulations
L
Waste disposal in the repair paint shop
L
The new VOC (Volatile Organic Compounds) solvent regulation
L
Factory Paint Application
L
General fundamentals of paint technology
L
Painting process and corrosion protection
L
The structure of an original paint finish
L
Colored fillers applied in production
L
Paintwork Defects and Damage
L
Diagnosis and Damage Assessment
L
Paint damage guide
L
Paint damage caused by environmental factors
L
Mechanical damage
L
Damage due to corrosion
L
Damage caused by faults in treatment
L
Tools and Equipment for Paint Repairs
L
General work equipment
L
Filler and spray guns
L
Hand and machine sanding tools
L
Polishing and finishing tools
L
Infrared drying technology
L
Air dryers
L
Paint mixing system
L
Painting cabin
L
Refinishing Materials
L
Stopper materials
L
HS primer filler and HS tinted filler
L
Additional Materials
L
Adhesive sealants
L
Underbody protection
L
Paint additives
L
Additive materials
L
Paint Repairs
L
General information
L
Pre-treatment of the surface
L
Top coat application
L
Repair stages for repair painting
L
Polish
L
Aids
L
Painting Plastic Parts
L
General
L
Plastic groups
L
Painting new components
L
Unknown primer
L
Paint faults on plastic substrates
L
Spot Repairs
L
General
L
Repair process
L
Dirt inclusions
L
Corrosion Prevention
L
General
L
Operations after painting
L
Definition of the degree of rust
L
Color Identification and Chromatics
L
Basic color theory
L
Metallic and pearl pigments
L
Color codes and their determination on Ford vehicles
L
Matching tinted filler to the color code
L
Tips and Tricks
L
Comparing paint structures
L
Etching substrate
L
Masking the vehicle
L
Color shade problems
L
Temperature reduction spray
L
Paint plane
L
Shading
L
Sanding marks
L
Improving touch-up work
L
Uni-Body, Subframe and Mounting System
L
Front Subframe
L
Front Subframe Front Bushing
L
Front Subframe Rear Bushing
L
Rear Subframe
L
Rear Subframe Bushing
L
Suspension System - General Information
L
Front Toe Adjustment(14 117 3)
L
Rear Toe Adjustment(15 211 3)
L
Front Suspension
L
Front Suspension (Overview)
L
Overview
L
Spring and damper assembly
L
Subframe
L
Stabilizer bar
L
Front Wheel Bearing (14 411 0; 14 411 4; 14 412 0; 14 414 4; 14 416 4)
L
Lower Arm (14 706 0; 14 707 0; 14 709 0)
L
Front Stabilizer Bar (14 752 0)
L
Wheel Knuckle (14 343 0)
L
Front Strut and Spring Assembly (14 781 0; 14 782 0)
L
Front Strut and Spring Assembly (14 783 4)
L
Rear Suspension
L
Rear Suspension (Overview)
L
Overview
L
Upper control arm
L
Rear lower arm and spring lower pad
L
Front lower arm
L
Stabilizer bar
L
Wheel Bearing and Wheel Hub
L
Upper Arm (15 701 0)
L
Front Lower Arm (15 690 0)
L
Rear Lower Arm(15 705 0)
L
Rear Stabilizer Bar (15 752 0)
L
Rear Stabilizer Bar Link
L
Wheel Knuckle - LHD FWD/RHD FWD
L
Wheel Knuckle - LHD 4WD/RHD 4WD
L
Spring
L
Wheels and Tires
L
Wheels and Tires (Overview)
L
Tire/wheel rim combinations
L
Tire repair kit
L
Run-Flat Tires (Overview)
L
Tire Pressure Monitoring System (TPMS) (Overview).
L
Wheels and Tires
L
Inspection and Verification
L
Symptom Chart
L
Wheel and Tire
L
Driveshaft
L
Rear Drive Axle/Differential
L
Rear Drive Axle and Differential (Component Location)
L
Rear Drive Axle and Differential (System Operation and Component Description)
L
General Information
L
Driving situations
L
Haldex clutch
L
Design of the 3rd generation Haldex clutch
L
Design of the multi-plate clutch
L
All-wheel drive control unit
L
Electric feed pump
L
Pressure control - 3rd generation Haldex clutch
L
Base pressure
L
Increased base pressure (preload)
L
Pressure build-up
L
Design of the 4th generation Haldex clutch
L
Pressure control - 4th generation Haldex clutch
L
Differential Fluid Level Check
L
Active On-Demand Coupling Fluid Level Check
L
Differential Case
L
Active On-Demand Coupling Module
L
Differential Input Shaft Seal
L
Differential Support Insulator
L
Rear Halfshaft Seal
L
Drive Pinion Seal
L
Active On-Demand Coupling - Vehicles With: 5-Speed Automatic Transaxle - AW55 AWD/6-Speed Automatic Transaxle - 6DCT450
L
Front Drive Halfshafts
L
Front Drive Halfshafts
L
Front Halfshaft LH (14 320 0)
L
Front Halfshaft RH - LHD 4WD/RHD 4WD
L
Inner Constant Velocity (CV) Joint Boot (14 336 0)
L
Outer Constant Velocity (CV) Joint Boot
L
Halfshaft Bearing
L
Rear Drive Halfshafts
L
Brake System - General Information
L
Brake System
L
Inspection and Verification
L
Road Test
L
Pinpoint Tests
L
Component Tests
L
Brake System Check
L
Brake Booster Functional Test
L
Brake Disc Runout Check (12 221 0)
L
Component Bleeding
L
Brake System Bleeding
L
Brake System Draining and Filling (12 154 0; 12 154 4)
L
Brake System Pressure Bleeding
L
Front Disc Brake
L
Brake Pads
L
Brake Caliper(12 243 0)
L
Front Brake Flexible Hose
L
Rear Disc Brake
L
Brake Pads (12 238 0)
L
Brake Caliper (12 253 0)
L
Rear Brake Flexible Hose
L
Parking Brake and Actuation
L
Parking Brake (Overview)
L
Overview
L
Parking brake cable
L
Parking brake control
L
Parking Brake
L
Inspection and Verification
L
Pinpoint Tests
L
Parking Brake Cable Adjustment
L
Parking Brake Control(12 664 0)
L
Parking Brake Rear Cables
L
Hydraulic Brake Actuation
L
Brake Pedal and Bracket - RHD 4WD/RHD FWD
L
Brake Master Cylinder - 2.5L Duratec (147kW/200PS) - VI5
L
Power Brake Actuation
L
Brake Booster-2.5L Duratec (147kW/200PS) - VI5, RHD 4WD/RHD FWD. (12 451 0)
L
Brake Vacuum Hose - 2.5L Duratec (147kW/200PS) - VI5
L
Brake Vacuum Pump - 2.5L Duratec (147kW/200PS) - VI5
L
Anti-Lock Control
L
Anti-Lock Control (Component Location)
L
Anti-Lock Control
L
Anti-Lock Control - Stability Assist
L
Anti-Lock Control - Stability Assist (Overview)
L
Overview
L
ABS/ESP module or hydraulic control unit (HCU)
L
Combined yaw rate sensor and lateral acceleration sensor / longitudinal acceleration sensor
L
Rear wheel sensor
L
Opto-electronic steering wheel rotation sensor
L
Anti-Lock Control - Stability Assist (System Operation and Component Description)
L
System Diagram
L
System Operation
L
Component Description
L
Hydraulic Control Unit (HCU)
L
Stability Assist Module
L
Front Wheel Speed Sensor
L
Rear Wheel Speed Sensor
L
Yaw Rate Sensor
L
Steering System - General Information
L
Steering System
L
Inspection and Verification
L
Components Tests
L
Steering Gear Checks After a Collision
L
Power Steering System Flushing
L
Power Steering System Filling
L
Power Steering System Vacuum Bleeding
L
Power Steering
L
Power Steering (Overview)
L
Power Steering
L
Steering gear
L
Electro-hydraulic power steering pump
L
Pressure and return lines
L
Power Steering (System Operation and Component Description)
L
System Diagram
L
System Operation
L
Component Description
L
Power Steering Pressure Line and Return Line Assembly - 2.5L Duratec (147kW/200PS) - VI5(13 434 0)
L
Power Steering Pump - 2.5L Duratec (147kW/200PS) - VI5(13 434 0)
L
Power Steering Pump to Steering Gear Pressure Line - 2.5L Duratec (147kW/200PS) - VI5(13 440 0; 13 443 0)
L
Steering Gear(13 116 0)
L
Steering Gear to Power Steering Fluid Reservoir Return Line-2.5L Duratec (147kW/200PS) - VI5(13 439 0)
L
Steering Linkage
L
Tie Rod End
L
Tie Rod
L
Steering Gear Boot
L
Steering Column
L
Steering Column (Overview)
L
General overview
L
Steering wheel
L
Extension, steering shaft
L
Steering Column
L
Steering Wheel
L
Steering Column
L
Steering Column Shaft
L
Steering Column Switches
L
Steering Column Switches (Overview)
L
Switch unit, steering column
L
Clockspring
L
Steering Column Lock Module
L
Steering Column Multifunction Switch LH
L
Steering Column Multifunction Switch RH
L
Engine System - General Information
L
Engine - Oil Leaks
L
Ultraviolet (UV) Testing
L
Measure the compression pressure
L
Measure the compression pressure (Engine - 2.5L Duratec-ST (VI5)
L
Measure the compression pressure (Engine - 2.0L Duratorq-TDCi (DW) Diesel)
L
Measure the oil pressure (Engine - 2.5L Duratec-ST (VI5)
L
Measure the oil pressure (Engine - 2.0L Duratorq-TDCi (DW) Diesel)
L
Engine- 2.5L Duratec (147kW/200PS) - VI5
L
Engine (Component Location)
L
Engine (Overview)
L
General
L
Cylinder head
L
Cylinder block
L
Engine (System Operation and Component Description).
L
System Operation
L
Variable camshaft timing
L
Valve Clearance Adjustment
L
Intake Manifold (21 183 0) Removal
L
Crankshaft Front Seal (21 467 0)
L
Valve Stem Seals (21 238 0)
L
Timing Belt (21 304 0)
L
Camshafts (21 284 0)
L
Camshaft Seal (21 288 0)
L
Oil Pan (21 154 0)
L
Oil Pump (21 714 0)
L
Exhaust Manifold (21 187 0)
L
Cylinder Head (21 163 0)
L
Crankshaft Rear Seal (21 468 4)
L
Oil Cooler
L
Engine - Vehicles With: 5-Speed Automatic Transaxle (AW55)
L
Engine Accessories
L
Engine
L
Cylinder Head
L
Engine
L
Engine Accessories (21 139 4)
L
Engine - Vehicles With: 5-Speed Automatic Transaxle (AW55)
L
Engine Cooling
L
Engine Cooling - 2.5L Duratec (147kW/200PS) - VI5 (Component Location)
L
Engine Cooling - 2.5L Duratec (147kW/200PS) - VI5 (Overview)
L
Engine Cooling
L
Cooling System Draining and Vacuum Filling
L
Draining
L
Evacuating and Filling
L
Radiator Lower Mounting Repair
L
Coolant Pump - 2.5L Duratec (147kW/200PS) - VI5
L
Cooling Fan Motor and Shroud - 2.5L Duratec (147kW/200PS) - VI5
L
Radiator - 2.5L Duratec (147kW/200PS) - VI5
L
Thermostat - 2.5L Duratec (147kW/200PS) - VI5
L
Thermostat Housing - 2.5L Duratec (147kW/200PS) - VI5
L
Fuel Charging and Controls-2.5L Duratec (147kW/200PS) - VI5
L
Fuel Charging and Controls
L
Fuel Charging and Controls
L
Inspection and Verification
L
Symptom Chart
L
Fuel Injectors
L
Throttle Body (23 198 0)
L
Fuel Rail
L
Fuel Charging and Controls - Turbocharger- 2.5L Duratec (147kW/200PS) - VI5
L
Turbocharger (Component Location)
L
Turbocharger (Overview)
L
Turbocharger (System Operation and Component Description)
L
System Diagram
L
System Operation
L
Component Description
L
Turbocharger
L
Turbocharger
L
Accessory Drive - 2.5L Duratec (147kW/200PS) - VI5
L
Accessory Drive
L
Inspection and Verification
L
Accessory Drive Belt Concerns
L
Symptom Chart
L
Component Tests
L
Accessory Drive Belt Tensioner
L
Accessory Drive Belt
L
Air Conditioning (A/C) Compressor Belt
L
Air Conditioning (A/C) Compressor Belt Tensioner
L
Starting System- 2.5L Duratec (147kW/200PS) - VI5
L
Starting System (System Operation and Component Description)
L
System Diagram
L
System Operation
L
Starting System
L
Starter Motor
L
Start Inhibit Switch
L
Engine Ignition - 2.5L Duratec (147kW/200PS) - VI5
L
Engine Ignition
L
Inspection and Verification
L
Symptom Chart
L
Ignition Coil-On-Plug
L
Engine Emission Control - 2.5L Duratec (147kW/200PS) - VI5
L
Engine Emission Control
L
Engine Emission Control
L
Inspection and Verification
L
Symptom Chart
L
Intake Air Distribution and Filtering - 2.5L Duratec (147kW/200PS) - VI5
L
Intake Air Distribution and Filtering (Component Location)
L
Intake Air Distribution and Filtering
L
Inspection and Verification
L
Symptom Chart
L
Air Cleaner
L
Charge Air Cooler
L
Evaporative Emissions
L
Electronic Engine Controls
L
Electronic Engine Controls (Component Location)
L
Electronic Engine Controls (Overview)
L
General overview
L
Powertrain Control Module (PCM)
L
Knock Sensor
L
Crankshaft Position (CKP) sensor
L
Camshaft adjuster solenoid valve
L
Manifold absolute pressure and temperature sensor
L
Accelerator pedal position (APP) sensor
L
Throttle control unit
L
Engine Coolant Temperature (ECT) sensor
L
Electronic Engine Controls (System Operation and Component Description)
L
System Diagram
L
System Operation
L
Component Description
L
Electronic Engine Controls
L
Camshaft Position (CMP) Sensor
L
Catalyst Monitor Sensor
L
Crankshaft Position (CKP) Sensor
L
Heated Oxygen Sensor (HO2S)
L
Knock Sensor (KS)
L
Mass Air Flow (MAF) Sensor
L
Powertrain Control Module (PCM)
L
Variable Valve Timing (VVT) Oil Control Solenoid
L
Brake Pedal Position (BPP) Switch
L
Clutch Pedal Position (CPP) Switch
L
Automatic Transmission/Transaxle
L
Transmission Description (Overview)
L
Components of the AW55 automatic transaxle
L
Transaxle cooling
L
External shift mechanism
L
Components of the electronic control
L
Knowing and Understanding Customer Concerns
L
Testing Possible Causes of Transmission Control Faults
L
Visual inspection
L
Towing the vehicle
L
Push-starting the Vehicle
L
Selector Lever Emergency Release
L
Transmission Fluid Level Check
L
Changing the Transmission Fluid
L
Diagnosis with IDS
L
Programming the 'N' position of the TR sensor
L
Resetting the values learned by the TCM
L
Transmission Description (System Operation and Component Description)
L
System Operation
L
Gearshift control
L
Power flow through the transmission
L
Service instructions
L
Component Description
L
Transmission Fluid Level Check
L
Transmission Fluid Drain and Refill
L
Halfshaft Seal LH
L
Halfshaft Seal RH
L
Main Control Valve Body
L
Output Shaft Speed (OSS) Sensor
L
Torque Converter Seal
L
Transmission Fluid Pan
L
Transmission Range (TR) Sensor
L
Turbine Shaft Speed (TSS) Sensor
L
Transmission
L
Transmission/Transaxle Cooling
L
Transmission Cooling (Component Location)
L
Transmission Cooling (Overview).
L
Transmission Fluid Cooler-Vehicles With: 5-Speed Automatic Transaxle - AW55 AWD
L
Transmission Fluid Cooler Tubes-Vehicles With: 5-Speed Automatic Transaxle - AW55 AWD
L
Automatic Transmission/Transaxle External Controls
L
External Controls (Component Location)
L
External Controls (Overview)
L
Transmission range selector
L
Transmission range selector lever emergency release
L
Selector Lever Cable Adjustment-Vehicles With: 5-Speed Automatic Transaxle - AW55 AWD
L
Selector Lever Cable - Vehicles With: 5-Speed Automatic Transaxle - AW55 AWD
L
Selector Lever Assembly - Vehicles With: 5-Speed Automatic Transaxle - AW55 AWD
L
Transfer Case
L
Transfer Case (Component Location)
L
Transfer Case (System Operation and Component Description)
L
Transfer Case Fluid Level Check
L
Transfer Case Connecting Sleeve
L
Transfer Case Connecting Sleeve Seals - Vehicles With: 5-Speed Automatic Transaxle - AW55 AWD
L
Transfer Case Rear Seal
L
Transfer Case Seal LH
L
Transfer Case Seal RH
L
Transfer Case
L
Exhaust System-
L
Exhaust System (Component Location)
L
Exhaust Flexible Pipe
L
Catalytic Converter
L
Fuel System
L
Fuel System - Vehicles With: Fuel Additive Tank
L
Principles of Operation
L
Inspection and Verification
L
Spring Lock Couplings
L
Quick Release Coupling
L
Fuel System Pressure Check - 2.5L Duratec (162kW/220PS) - VI5
L
Fuel System Pressure Release
L
Fuel Tank Draining
L
Fuel Tank and Lines
L
Fuel Tank and Lines - 2.5L Duratec (147kW/200PS) - VI5 (Component Location)
L
Fuel Tank and Lines - 2.5L Duratec (147kW/200PS) - VI5 (Overview)
L
Fuel pump and sender unit
L
Fuel filler pipe and tank cap
L
Fuel Tank - 2.5L Duratec (147kW/200PS) - VI5
L
Fuel Level Sensor - 2.5L Duratec (147kW/200PS) - VI5
L
Fuel Tank Filler Pipe
L
Fuel Filler Nozzle Inhibitor
L
Fuel Pump and Sender Unit - 2.5L Duratec (147kW/200PS) - VI5
L
Acceleration Control
L
Acceleration Control
L
Accelerator Pedal
L
Speed Control
L
Speed Control (Overview).
L
Speed Control (System Operation and Component Description).
L
System Diagram
L
System Operation
L
Component Description
L
Speed Control
L
Climate Control System
L
Climate Control System
L
Inspection and Checking
L
Refrigerant Circuit - Quick Check
L
Sequence of A/C Request Signal
L
Air Conditioning (A/C) System Recovery, Evacuation and Charging
L
Spring Lock Coupling
L
Air Conditioning (A/C) Clutch Air Gap Adjustment
L
Refrigerant Oil Adding
L
Contaminated Refrigerant Handling
L
Electronic Leak Detection
L
Fluorescent Dye Leak Detection
L
Climate Control
L
Climate Control (Component Location)
L
Climate Control (Overview)
L
Pollen filter
L
Heat exchanger
L
Evaporator assembly
L
Blower motor
L
Fault Memory Interrogation without diagnostics unit - vehicles with automatic temperature control
L
Climate Control (System Operation and Component Description)
L
System Diagram
L
System Operation
L
Component Description
L
Air Conditioning (A/C) Compressor - 2.5L Duratec (147kW/200PS) - VI5(34 626 4)
L
Air Conditioning (A/C) Compressor to Condenser Discharge Line
L
Air Conditioning (A/C) Compressor to Condenser Discharge Line - 2.5L Duratec (147kW/200PS) - VI5
Total pages: 1403
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Ford Kuga Service Manual
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