100 FORD KUGA 2011 1.G Workshop Manual

Rear Brake Flexible Hose
Removal
CAUTION:
Refer to:Brake System Health and Safety
Precautions (100-00 General Information,
Description and Operation).
NOTE: Removal steps in this procedure may
contain installation details. 1.
Refer to: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation).
2. WARNINGS:
Make sure that no load is placed on the
brake hose.
Be prepared to collect escaping fluid.
CAUTION: Make sure that all openings
are sealed.
1. Torque: 15
Nm
E99425
1
2
3
G1001210en2008.50 Kuga8/2011
206-04- 5
Rear Disc Brake
206-04- 5
REMOVAL AND INSTALLATION
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3.Torque: 28Nm
E99426
Installation
1.To install, reverse the removal procedure.
2. Refer to: Component Bleeding (206-00 Brake
System - General Information, General
Procedures).
G1001210en2008.50 Kuga8/2011
206-04- 6
Rear Disc Brake
206-04- 6
REMOVAL AND INSTALLATION
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Pinpoint Tests
PINPOINT TEST A : THE PARKING BRAKE WILL NOT APPLY
DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
A1: CHECK PARKING BRAKE CABLE ADJUSTMENT
1 Release the parking brake and measure the gap
between the lever and the caliper.
• Is the gap 1.2mm?
zYe s
E83778
1.2 mm
Vehicle OK
zNo REFER to: Parking Brake Cable Adjustment
(206-05 Parking Brake and Actuation,
General Procedures).
A2: CHECK FUNCTION OF PARKING BRAKE ON BRAKE CALIPER
1 Raise and support the vehicle on a lift with the
parking brake fully applied.
REFER to:
Lifting(100-02 Jacking and Lifting,
Description and Operation).
– With the aid of another technician, release the parking brake and check the operation of the
brake cables and levers.
• Are the left-hand (LH) and right-hand (RH) parking brake levers moving a similar distance?
zYe s
CHECK the other causes such as conventional
brake system components. REPAIR or
INSTALL new components as necessary.
zNoREFER to: Brake Caliper (206-04 Rear Disc
Brake, Removal and Installation).
TEST the system for normal operation.
G1063696en2008.50 Kuga8/2011
206-05- 5
Parking Brake and Actuation
206-05- 5
DIAGNOSIS AND TESTING
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Parking Brake Cable Adjustment
1.Fully apply the parking brake.
1.
2. Fully release the parking brake control.
2.
E92650
3. NOTE: This step is only necessary if the parking
brake cable was removed.
1. Torque: 2
Nm
E102065
21
G1001211en2008.50 Kuga8/2011
206-05- 9
Parking Brake and Actuation
206-05- 9
GENERAL PROCEDURES
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4.Loosen the parking brake cable adjustment
nut to the end of the parking brake cable
thread.
2.
E102067
2
P1
5.
Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
6. NOTE: This step requires the aid of another
technician.
1. Insert a 1.2 mm feeler gauge between the parking brake lever and the brake caliper
abutment, on both sides.
2. Tighten the parking brake cable adjustment nut until movement is observed on one of the
parking brake levers.
3. Remove the feeler gauges.
4. Rotate the rear wheels and tires and check for brake drag. If brake drag is felt, loosen
the parking brake cable adjustment nut to
the end of the parking brake cable thread,
clean the parking brake cables and repeat
the parking brake cable adjustment
procedure.
5. If brake drag is still felt after, repeat the adjustment using a 1.0 mm feeler gauge. If
brake drag is still felt, loosen the parking
brake adjustment nut and reduce the feeler
gauge measurement by 0.2 mm each time,
until no brake drag can be felt at the rear
wheels and tires.
E83778
1.2 mm
G1001211en2008.50 Kuga8/2011
206-05- 10
Parking Brake and Actuation
206-05- 10
GENERAL PROCEDURES
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Brake Master Cylinder — 2.5L Duratec (147kW/200PS) -VI5(12 343 0)
Removal
NOTE: Removal steps in this procedure may
contain installation details.
1. Refer to: Brake System Health and Safety
Precautions (100-00 General Information,
Description and Operation).
2. Connect one end of a suitable piece of clear
plastic pipe to the brake caliper bleed nipple
1.
and place the other end into a suitable
container.
2. Loosen the bleed nipple.
3. Depress the brake pedal until no more brake fluid comes through the bleed nipple.
4. Tighten the bleed nipple.
5. Repeat the draining procedure on the opposite side brake caliper.
E86914
Left-hand drive vehicles
3. CAUTION: Make sure that all openings are sealed.
1. Torque: 18Nm
2.NOTE: Make sure that new components are
installed.
Torque: 25
Nm
G1174985en2008.50 Kuga8/2011
206-06- 5
Hydraulic Brake Actuation
206-06- 5
REMOVAL AND INSTALLATION
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Brake Booster — 2.5L Duratec (147kW/200PS) - VI5, RHD4WD/RHD FWD(12 451 0)
Removal
NOTE: Removal steps in this procedure may
contain installation details.
1. Refer to: Brake System Health and Safety
Precautions (100-00 General Information,
Description and Operation).
2. Torque: 24
Nm
E69829
x4
1
2
3.Refer to: Air Conditioning (A/C) System
Recovery, Evacuation and Charging (412-00
Climate Control System - General Information,
General Procedures).
Refer to: Brake Master Cylinder - 2.5L Duratec
(147kW/200PS) - VI5 (206-06 Hydraulic Brake
Actuation, Removal and Installation).
Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
4.
E65299
5. Torque:
• Stage 1: 10
Nm
• Stage 2: 25Nm
E99866
x6
6.
G1185955en2008.50 Kuga8/2011
206-07- 2
Power Brake Actuation
206-07- 2
REMOVAL AND INSTALLATION
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Anti-Lock Control – Component Location
NOTE:
Refer to:Brake System (206-00 Brake System -
General Information, Description and Operation).
E96610
G1001298en2008.50 Kuga8/2011
206-09A- 2
Anti-Lock Control
206-09A- 2
DESCRIPTION AND OPERATION
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Anti-Lock Control – Overview
Anti-lock Brake System
Refer to:Anti-Lock Control - Stability Assist (206-09
Anti-Lock Control - Stability Assist, Description
and Operation).
G1001218en2008.50 Kuga8/2011
206-09A- 3
Anti-Lock Control
206-09A- 3
DESCRIPTION AND OPERATION
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Anti-Lock Control – System Operation and Component Description
System Operation
Refer to:Anti-Lock Control - Stability Assist (206-09
Anti-Lock Control - Stability Assist, Description
and Operation).
G1001220en2008.50 Kuga8/2011
206-09A- 4
Anti-Lock Control
206-09A- 4
DESCRIPTION AND OPERATION
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