FORD KUGA 2011 1.G Workshop Manual

narrow the cause to a specific component or condition.
Symptom Chart
Action
Possible Sources
Symptom
• INSTALL new brake shoes orbrake pads.
REFER to: Brake Pads (206-03
Front Disc Brake, Removal
and Installation).
• Worn or damaged brake shoes
or brake pads and linings.
• Brakes pull or drift
• INSTALL a new front brakedisc.
REFER to: Brake Caliper (206-
03 Front Disc Brake,
Removal and Installation).
• Abnormal wear or distortion of
front brake disc.
• ADJUST the parking brakecable.
REFER to: Parking Brake
Cable Adjustment (206-05
Parking Brake and Actuation,
General Procedures).
• Incorrect rear brake adjust-
ment.
• ADJUST the wheel alignment.REFER to: (204-00 Suspension
System - General Information)
Front Toe Adjustment (General
Procedures),
Rear Toe Adjustment (General
Procedures).
• Incorrect wheel alignment
adjustment.
• ADJUST or INSTALL a newwheel bearing.
REFER to: Front Wheel
Bearing (204-01 Front
Suspension, Removal and
Installation).
• Incorrect wheel bearing preload
adjustment.
• INSTALL new brake shoes orbrake pads.
REFER to: Brake Pads (206-03
Front Disc Brake, Removal
and Installation).
• Grease or fluid on the brake
shoes or brake pads; glazed
linings.
• INSTALL a new wheel cylinderor brake caliper.
REFER to: Brake Caliper (206-
04 Rear Disc Brake, Removal
and Installation).
• Stuck or seized wheel cylinders
or brake calipers.
• FILL the reservoir. CHECK thebrake and clutch system for
leaks including brake fluid in
the brake booster.
• Low brake fluid level.
• The red brake warning indicator
is always on
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Action
Possible Sources
Symptom
• INSTALL a new brake mastercylinder.
REFER to: Brake Master
Cylinder - 2.5L Duratec
(147kW/200PS) - VI5 (206-06
Hydraulic Brake Actuation,
Removal and Installation).
• Leaking brake master cylinder
primary piston cup.
• FREE UP and ADJUST theparking brake cable.
REFER to: Parking Brake
Cable Adjustment (206-05
Parking Brake and Actuation,
General Procedures).
INSTALL new components as
necessary.
• Parking brake control not fully
released.
• REFER to:Anti-Lock Control
(206-09 Anti-Lock Control,
Diagnosis and Testing).
• Malfunctioning anti-lock braking
system (ABS).
• REFER to:Instrument Cluster
(413-01 Instrument Cluster,
Diagnosis and Testing).
• Shorted indicator circuit.
• INSTALL new brake shoes orbrake pads.
REFER to: Brake Pads (206-03
Front Disc Brake, Removal
and Installation).
• Grease or fluid on the brake
shoes or brake pads; glazed
linings.
• Vibration when the brakes are
applied
• INSTALL new brake shoes orbrake pads.
REFER to: Brake Pads (206-03
Front Disc Brake, Removal
and Installation).
• Worn or damaged brake shoes
or brake pads.
• TIGHTEN the caliper mountingbolt(s).
• Loose caliper mounting bolt(s).
•
• Excessive brake disc thickness
variation or brake disc runout.
• CHECK the tires. BALANCE orINSTALL new tires as neces-
sary.
REFER to: Wheels and Tires
(204-04 Wheels and Tires,
Diagnosis and Testing).
• Wheels and tires.
• TIGHTEN or INSTALL newwheel hub bolts as necessary.
• Loose or missing wheel hub
bolts.
• CARRY OUT a brake discrunout check.
• Worn or damaged brake drums
or brake discs.
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Action
Possible Sources
Symptom
• FILL the reservoir. CHECK thebrake and clutch system for
leaks including brake fluid in
the brake booster.
• Low brake fluid level.
• Pedal goes down fast
• REPAIR the leak. CHECK theentire hydraulic system. FILL
and BLEED the brake system.
REFER to: (206-00 Brake
System - General Information)
Brake System Bleeding (General Procedures),
Brake System Pressure Bleeding (General Proced-
ures),
Component Bleeding (General
Procedures).
• Leak in the hydraulic system.
• CHECK for leaks. BLEED thebrake system. REFER to: (206-
00 Brake System - General
Information)
Brake System Bleeding (General Procedures),
Brake System Pressure Bleeding (General Proced-
ures),
Component Bleeding (General
Procedures).
• Air in the system.
• CARRY OUT a brake discrunout check.
• Brake disc “brake knock back”
(Brake pads push the brake
caliper piston back into the
brake caliper. Caused by
excessive brake disc lateral
runout or loose wheel bear-
ings.)
• INSTALL new brake shoes orbrake pads.
REFER to: Brake Pads (206-03
Front Disc Brake, Removal
and Installation).
• Worn brake shoes or brake
pads.
• GO toPinpoint Test A.
• Worn brake master cylinder
piston cups or scored cylinder
bore.
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Action
Possible Sources
Symptom
• BLEED the brake system.REFER to: Brake System
Pressure Bleeding (206-00
Brake System - General
Information, General Proced-
ures).
REFER to: (206-00 Brake
System - General Information)
Brake System Bleeding (General Procedures),
Component Bleeding (General
Procedures).
• Air in the system.
• Pedal eases down slowly
• GO toPinpoint Test B.
• Malfunctioning brake master
cylinder.
• Low engine vacuum (stationary).
• INSTALL new brake shoes orbrake pads.
REFER to: Brake Pads (206-03
Front Disc Brake, Removal
and Installation).
• Worn brake shoes or brake
pads.
• Pedal is low or feels spongy
• CHECK for leaks. BLEED thebrake system. REFER to: (206-
00 Brake System - General
Information)
Brake System Bleeding (General Procedures),
Brake System Pressure Bleeding (General Proced-
ures),
Component Bleeding (General
Procedures).
• Air in the system.
• INSTALL new brake shoes orbrake pads.
REFER to: Brake Pads (206-03
Front Disc Brake, Removal
and Installation).
• Glazed or worn brake shoes or
brake pads.
• Brake lockup during light brake
pedal force
• GO toPinpoint Test C.
• Brake booster.
• Low engine vacuum.
• INSTALL new brake shoes orbrake pads.
REFER to: Brake Pads (206-03
Front Disc Brake, Removal
and Installation).
• Worn brake shoes or brake
pads.
• Excessive or erratic pedal
travel
• CARRY OUT a brake discrunout check.
• Wheel bearings
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Action
Possible Sources
Symptom
• ADJUST the parking brakecable or switch
REFER to: Parking Brake
Cable Adjustment (206-05
Parking Brake and Actuation,
General Procedures).
• Incorrectly adjusted parking
brake or brake pedal switch
• Brake drag
• REFER to brake booster opera-tion check in this procedure.
• Brake booster.
• INSTALL a new wheel cylinderor brake caliper.
REFER to: Brake Caliper (206-
03 Front Disc Brake,
Removal and Installation).
• Seized wheel cylinder or brake
caliper.
• INSTALL a new brake caliper.REFER to: Brake Caliper (206-
03 Front Disc Brake,
Removal and Installation).
• Seized brake caliper slide pins.
• INSTALL new parking brakecables.
REFER to: Parking Brake
Cable Adjustment (206-05
Parking Brake and Actuation,
General Procedures).
• Seized parking brake cables.
• Check the parking brake leaverposition and make sure there
are no obstructions.
• Parking brake not fully
released.
• Check all brake hose(s) forcorrect fitment.
REFER to: Rear Brake Flexible
Hose (206-04 Rear Disc
Brake, Removal and Installa-
tion)
/ Front Brake Flexible Hose
(206-03 Front Disc Brake,
Removal and Installation).
• Brake hose incorrectly fitted.
• INSTALL new brake shoes orbrake pads.
REFER to: Brake Pads (206-03
Front Disc Brake, Removal
and Installation).
• Worn or contaminated brake
shoes or brake pads.
• Excessive brake pedal effort
• INSTALL a new brake vacuumpump.
• Malfunctioning vacuum pump
(diesel).
• CONNECT or INSTALL a newbrake booster vacuum pipe as
necessary.
• Disconnected or damaged
brake booster vacuum pipe.
• GO toPinpoint Test D.
• Brake booster.
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Action
Possible Sources
Symptom
• INSTALL new brake shoes orbrake pads.
REFER to: Brake Pads (206-03
Front Disc Brake, Removal
and Installation).
• Worn or damaged brake shoes
or brake pads.
• Brake noise
• GO toPinpoint Test E.
• Brake booster.
• GO toPinpoint Test F.
• Brake booster.
• Seized brake pedal pivot.
• Slow or incomplete brake pedal
return
Pinpoint Tests
PINPOINT TEST A : PEDAL GOES DOWN FAST
DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
A1: PRESSURIZE THE SYSTEM
1 Pump the foot brake rapidly five times.
• Does the brake pedal height build up and then hold?
zYe s
CHECK parking brake adjustment and
ADJUST as necessary.
REFER to: Parking Brake Cable Adjustment
(206-05 Parking Brake and Actuation,
General Procedures).
If the condition still exists. BLEED the brake
system. REFER to: (206-00 Brake System -
General Information)
Brake System Bleeding (General Procedures),
Brake System Pressure Bleeding (General
Procedures),
Component Bleeding (General Procedures).
TEST the system for normal operation.
zNo
GO to A2.
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DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
A2: CHECK FOR BRAKE SYSTEM LEAKS
1 Check for external brake and clutch system
leaks. Refer to Brake Master Cylinder
Component Test in this procedure.
• Are any leaks present?
zYe s REPAIR as necessary. ADD fluid and BLEED
the brake system. REFER to: (206-00 Brake
System - General Information)
Brake System Bleeding (General Procedures),
Brake System Pressure Bleeding (General
Procedures),
Component Bleeding (General Procedures).
TEST the system for normal operation.
zNo
GO to A3.
A3: PERFORM A BRAKE MASTER CYLINDER BYPASS CONDITION TEST
1 Carry out a brake master cylinder bypass
Condition Test. Refer to the Brake Master
Cylinder Component Test in this procedure.
• Was a concern found?
zYe s INSTALL a new brake master cylinder.
REFER to: Brake Master Cylinder - 2.5L
Duratec (147kW/200PS) - VI5 (206-06
Hydraulic Brake Actuation, Removal and
Installation).
TEST the system for normal operation.
zNo
VERIFY the customer concern.
PINPOINT TEST B : PEDAL EASES DOWN SLOWLY
DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
B1: CHECK THE BRAKE PEDAL OPERATION
1 Depress the brake pedal.
• Does the pedal ease down slowly?
zYe s GO to B2.
zNoRefer to the Brake Master Cylinder
Component Test in this procedure.
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DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
B2: CHECK FOR BRAKE SYSTEM LEAKS
1 Check for external brake system leaks.
• Are any leaks present?
zYe s REPAIR as necessary. ADD fluid and BLEED
the brake system. REFER to: (206-00 Brake
System - General Information)
Brake System Bleeding (General Procedures),
Brake System Pressure Bleeding (General
Procedures),
Component Bleeding (General Procedures).
TEST the system for normal operation.
zNo
GO to B3.
B3: PERFORM A BRAKE MASTER CYLINDER BYPASS CONDITION TEST
1 Carry out a brake master cylinder bypass
Condition Test. Refer to the Brake Master
Cylinder Component Test in this procedure.
• Was a concern found?
zYe s INSTALL a new brake master cylinder.
REFER to: Brake Master Cylinder - 2.5L
Duratec (147kW/200PS) - VI5 (206-06
Hydraulic Brake Actuation, Removal and
Installation).
TEST the system for normal operation.
zNo
GO to B4.
B4: CHECK THE BRAKE BOOSTER CHECK VALVE
1 Disconnect the brake booster check valve
vacuum hose at the manifold.
2Blow into the hose attached to the brake booster
check valve.
• Does air pass through the valve?
zYe s INSTALL a new brake booster check valve.
zNoGO to B5.
B5: CHECK THE BRAKE BOOSTER CHECK VALVE VACUUM
1 Run the engine at idle.
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DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
2 Using a suitable vacuum gauge, check the
vacuum pressure.
• Is the vacuum pressure above 40.5 kPa (0.4 bar) with the brake booster non-operational?
zYe s
VERIFY the customer concern.
zNoINSTALL a new brake booster check valve
vacuum hose. TEST the system for normal
operation.
PINPOINT TEST C : BRAKE LOCK UP DURING LIGHT BRAKE PEDAL FORCE
DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
C1: CHECK THE BRAKE BOOSTER
1 Check the brake booster push rod alignment
and pedal travel.
• Is the push rod and pedal travel OK?
zYe s TEST the brake pedal application. GO to
Pinpoint Test D.
zNo
INSTALL a new brake booster. TEST the
system for normal operation.
PINPOINT TEST D : EXCESSIVE BRAKE PEDAL EFFORT
DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
D1: CHECK BRAKE APPLICATION
1 With the engine off, apply and release the brake
pedal five times to deplete all vacuum from the
brake booster. Apply the brake pedal, hold with
light pressure. Start the engine.
• Does the brake pedal hold?
zYe s GO to D2 .
zNo
GO to D3 .
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DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
D2: CHECK THE BRAKE BOOSTER FOR LEAKS
1 Run the engine at approximately 1000 rpm,
release the accelerator pedal and turn the
engine off. Wait 90 seconds and apply the
brakes. Two or more brake applications should
be power assisted.
• Does the brake booster work?
zYe s VERIFY the customer concern.
zNoGO to D4 .
D3: CHECK THE BRAKE PEDAL LINKAGE
1 Disconnect the actuator rod from the pedal pin
and fully depress the brake pedal.
• Did the pedal move freely?
zYe s VERIFY the customer concern.
zNoINSTALL new brake pedal bushings. TEST
the system for normal operation.
D4: CHECK THE BRAKE BOOSTER CHECK VALVE
1 Disconnect the brake booster check valve
vacuum hose at the manifold.
2Blow into the hose attached to the brake booster
check valve.
• Does air pass through the valve?
zYe s INSTALL a new brake booster check valve.
TEST the system for normal operation.
zNoGO to D5 .
D5: CHECK THE BRAKE BOOSTER CHECK VALVE VACUUM
1 Run the engine at idle.
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