100 FORD KUGA 2011 1.G Workshop Manual

Rear Wheel Speed Sensor
Removal
NOTE:Removal steps in this procedure may
contain installation details.
4x2
1. Torque: 5Nm
E98809
4x4
2.Refer to: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation).
3. Torque: 5
Nm
E98810
All vehicles
4. NOTE: The O-ring seal is to be reused unless
damaged.
E98820
Installation
1. NOTE: Make sure that the sensor housing is
clean and free of foreign material.
NOTE: Make sure that the sensor ring is
correctly located.
To install, reverse the removal procedure.
G1001228en2008.50 Kuga8/2011
206-09B- 22
Anti-Lock Control - Stability Assist
206-09B- 22
REMOVAL AND INSTALLATION
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Steering System
Special Tool(s) / General EquipmentAlignment Pins, Subframe
205-316 (15-097A)
15097
Simulator, Driver and
Passenger Air Bags and Side
Air Curtains
501-073 (40-016)
501073
The Ford approved diagnostic tool
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanicalor electrical damage.
Visual Inspection Chart
Electrical
Mechanical
• Battery
• Battery cables
• Steering anglesensor electrical
connector
• Power steering pump control
module electrical
connectors
• Power steering pump control
module ground
cable
• Power steering pump control
module ground
cable retaining
screw
• Steering angle sensor warning
indicator
• Fuse(s)
• Tire pressure(s)
• Loose tie-rod end(s)
• Loose strut and
spring assemblies or
ball joints
• Loose pinch bolts on steering column
shaft flexible coup-
ling
• Wheels and tires
• Power steering line fluid leaks
• Steering gear bellows 3. If an obvious cause for an observed or reported
concern is found, correct the cause (if possible)
before proceeding to the next step.
4. If the cause is not visually evident, verify the symptom and refer to the diagnostic tab within
the Ford approved diagnostic tool.
Components Tests
Steering Linkage
1. Grasp the steering wheel firmly and move it upand down and to the left and right without
turning the steering wheel to check the steering
column bearing for wear, steering column shaft
for wear, steering wheel for looseness and
steering column for looseness. If the steering
column bearing or the steering column shaft is
worn install a new steering column. If the
steering wheel or the steering column is loose,
tighten the steering wheel or the steering column
retaining bolts.
2. With the road wheels in the straight ahead position, gently turn the steering wheel to the
left and the right to check for free play in the
steering linkage.
3. There should be no excessive free play at the steering wheel rim. If there is excessive free
play, CHECK the tie-rod inner and outer ball
joints, REFER to Tie-Rod Component Test in
this procedure. CHECK the steering column
universal joint, REFER to Steering Column
Universal Joint Component Test in this
procedure. If there is no free play in the tie-rod
and the steering column, install a new steering
gear.
Tie-Rod
CAUTION: Steering gear boots must be
handled carefully to avoid damage. Use
new steering boot clamps when installing
the steering gear boots.
NOTE: Noises such as knocks, which may appear
to originate from the steering linkage, may also be
generated by front suspension components.
REFER to: Noise, Vibration and Harshness (NVH)
(100-04 Noise, Vibration and Harshness,
Diagnosis and Testing).
G1059437en2008.50 Kuga8/2011
211-00- 2
Steering System - General Information
211-00- 2
DIAGNOSIS AND TESTING
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1. Raise and support the vehicle. REFER to:(100-02 Jacking and Lifting)
Jacking (Description and Operation),
Lifting (Description and Operation).
TIE0005728
2. Firmly grasp the road wheel and apply a rocking
motion checking for any free play in the wheel
bearing or suspension components.
3.
CAUTION: To prevent damage to the
steering linkage, turn the steering wheel to
move the steering linkage to the right-hand
steering lock stop.
Turn the steering wheel to position the steering
linkage against the right-hand steering lock stop.
TIE0005727
4. NOTE: To isolate the steering gear design clearance, check the right-hand steering
linkage with the steering held against the
right-hand steering lock stop.
With the aid of another technician holding the
steering linkage against the right-hand steering
lock stop, firmly grasp the road wheel and apply
a rocking motion checking for any free play in
the steering linkage.
TIE0005729
5. Detach the steering gear boot from the steering gear body and check for free play at the tie-rod
inner ball joint.
6. If there is free play at the tie-rod inner ball joint, install a new tie-rod.
REFER to: Tie Rod End (211-03 Steering
Linkage, Removal and Installation)
/ Tie Rod (211-03 Steering Linkage, Removal
and Installation).
7. Check the tie-rod end for free play. Install a new tie-rod end if necessary.
REFER to: Tie Rod End (211-03 Steering
Linkage, Removal and Installation)
/ Tie Rod (211-03 Steering Linkage, Removal
and Installation).
8.
CAUTION: To prevent damage to the
steering linkage, turn the steering wheel to
move the steering linkage to the left-hand
steering lock stop.
Turn the steering wheel to position the steering
linkage against the left-hand steering lock stop.
TIE0005727
9. NOTE: To isolate the steering gear design clearance, check the left-hand steering
linkage with the steering held against the
left-hand steering lock stop.
With the aid of another technician holding the
steering against the left-hand steering lock stop,
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Steering System - General Information
211-00- 3
DIAGNOSIS AND TESTING
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Steering Gear Checks After a Collision
General EquipmentFeeler gauge
Straight edge
Items to be observed when checking the steering
system
The following list of steering gear conditions and
the methods of testing should be taken into account
when carrying out checks to the steering system:
• If the steering gear has no faults after completing the following checks, do not install
a new steering gear.
• Surface corrosion and marks on the tie-rod are acceptable.
• When checking for turning effort torque peaks in the steering gear, turn the steering wheel from
steering lock stop to steering lock stop in
approximately 15 seconds.
• A steady increase of turning effort torque from steering center to steering lock stop is
acceptable.
• When checking for power steering fluid leaks, turn the steering wheel to the steering lock stop
in approximately 10 seconds.
• Noises from the power steering, for example the power steering pump relief valve, are
acceptable.
STEERING GEAR HOUSING
1. Raise and support the vehicle. REFER to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
2. Visually inspect the steering gear housing for cracks and damage. If the steering gear housing
is cracked or damaged, install a new steering
gear.
REFER to: Steering Gear (211-02 Power
Steering, Removal and Installation).
TIE-RODS
1. Using a straight edge and feeler gauge, check the tie-rods to see if they are straight. If the
distance between the tie-rod and straight edge is greater than 0.5 mm, install a new steering
gear.
REFER to:
Steering Gear (211-02 Power
Steering, Removal and Installation).
2. Check the tightening torque of the tie-rod end to wheel knuckle nut.
REFER to: Tie Rod End (211-03 Steering
Linkage, Removal and Installation).
3. Check the tightening torque of the tie-rod end locking nut.
REFER to: Tie Rod End (211-03 Steering
Linkage, Removal and Installation).
CHECK FOR TURNING EFFORT TORQUE
PEAKS IN THE STEERING GEAR
1. Lower and support the vehicle making sure that the road wheels are just clear of the floor.
2. With the ignition switch in position I, slowly turn the steering wheel from steering lock stop to
steering lock stop. If a turning effort torque peak
or judder is felt while turning the steering wheel,
detach the tie-rods from the wheel knuckles.
3. Slowly turn the steering wheel from steering lock stop to steering lock stop. If a turning effort
torque peak or judder is felt while turning the
steering wheel, install a new steering gear.
REFER to: Steering Gear (211-02 Power
Steering, Removal and Installation).
CHECK FOR POWER STEERING FLUID LEAKS
1. Lower the vehicle.
2. Run the engine at a fast idle and slowly turn the steering wheel to the left-hand steering lock
stop. Hold the steering wheel in this position for
5 seconds with a turning effort torque of 15 Nm
at the steering wheel rim.
3. Turn the steering wheel away from the left-hand steering lock stop for 30 seconds.
4. Run the engine at a fast idle and slowly turn the steering wheel to the right-hand steering lock
stop. Hold the steering wheel in this position for
5 seconds with a turning effort torque of 15 Nm
at the steering wheel rim.
5. Turn the steering wheel away from the right-hand steering lock stop.
6. Check for power steering fluid leaks at the steering gear housing and the power steering
line connections to the steering gear. If there is
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211-00- 6
Steering System - General Information
211-00- 6
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Power Steering System Flushing
MaterialsSpecification
Name
WSS-M2C204-A2 /
5U7J-M2C204-AA
Hydraulic Fluid DP-PS
1. WARNING: Be prepared to collect escaping fluids.
Using a blanking cap, cap the power steering
fluid reservoir.
E74090
2.Place the end of the steering gear return line
into a container.
3. Fill the power steering reservoir to the MAX
mark.
Material: Hydraulic Fluid DP-PS
(WSS-M2C204-A2 / 5U7J-M2C204-AA)
hydraulic fluid
4. Raise the vehicle until the road wheels are clear
of the floor. Support the vehicle.
Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
5. NOTE: This step requires the aid of another
technician.
1. Start the engine and slowly turn the steering from steering lock to steering lock until clean
power steering fluid comes out of the return
line.
2. With the aid of another technician, add the power steering fluid until the system is free
of contaminated power steering fluid.
Material: Hydraulic Fluid DP-PS(WSS-M2C204-A2 / 5U7J-M2C204-AA)
hydraulic fluid
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211-00- 8
Steering System - General Information
211-00- 8
GENERAL PROCEDURES
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Power Steering System Filling
Special Tool(s)211-189
Adapter, Power Steering
Bleeding
13016
416-D001
Hand Vacuum
Pump/Pressure Pump
23036A
Materials
Specification
Name
WSS-M2C204-A2 /
5U7J-M2C204-AA
Hydraulic Fluid DP-PS
1. Fill the power steering fluid reservoir to the MAX
mark.
Material: Hydraulic Fluid DP-PS
(WSS-M2C204-A2 / 5U7J-M2C204-AA)
hydraulic fluid
2. Raise the vehicle until the road wheels are clear
of the floor. Support the vehicle.
Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
3. Slowly turn the steering wheel from lock to lock
and add power steering fluid until the power
steering fluid in the power steering fluid reservoir
stops dropping.
4. Start the engine and slowly turn the steering
wheel from lock to lock and add power steering
fluid until the power steering fluid in the power
steering fluid reservoir stops dropping. 5.
Switch the engine OFF and using the special
tools, create a vacuum of 62cm-Hg - 75cm-Hg
for 30 seconds.
Special Tool(s): 211-189, 416-D001
E73916
211-189
416-D001
6. Observe the vacuum gauge reading.
1.
2. If the vacuum decreases by more than
5cm-Hg in 5 minutes, the system should be
checked for leaks.
7. Remove the special tools. Fill the power steering
fluid reservoir to the MAX mark as necessary.
Material: Hydraulic Fluid DP-PS
(WSS-M2C204-A2 / 5U7J-M2C204-AA)
hydraulic fluid
8. Lower the vehicle.
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Steering System - General Information
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Power Steering System Vacuum Bleeding
Special Tool(s)211-189
Adapter, Power Steering
Bleeding
13016
416-D001
Hand Vacuum
Pump/Pressure Pump
23036A
Materials
Specification
Name
WSA-M2C195-A / 9U7J-
M2C195-AA
Power Steering Fluid IW
Bleeding
9.
Refer to: Steering System Health and Safety
Precautions (100-00 General Information,
Description and Operation).
10.
E141054
11 . Material: Power Steering Fluid IW
(WSA-M2C195-A / 9U7J-M2C195-AA)
hydraulic fluid
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Power Steering – Component Location
E96448
1
Description
Item
Integrated steering angle sensor - vehicles
built up to 09/2009
1
G1001311en2008.50 Kuga8/2011
211-02-
2
Power Steering
211-02- 2
DESCRIPTION AND OPERATION
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Power Steering – Overview
Power Steering
E96186
1
2
3
4
5
6
Description
Item
Reservoir
1
Electro-hydraulic power steering pump
2
power steering return hose
3Description
Item
Power steering fluid pressure line
4
Heat shield
5
Steering gear
6
The EHPS system uses an electrically driven
hydraulic pump and a conventional rack and pinion
steering gear. This ensures precise steering operation and steering assistance with minimum
energy consumption.
G1001269en2008.50 Kuga8/2011
211-02-
3
Power Steering
211-02- 3
DESCRIPTION AND OPERATION
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Steering gear
E96209
1
2
3
4
5
1
2
63
Description
Item
Tie-rod end
1
Tie-rod
2
steering gear boot
3Description
Item
Steering angle sensor - vehicles built up
to 09/2009
4
Input shaft
5
Valve unit housing
6
The steering gear is mounted on the front axle
crossmember and is secured with two bolts. The
bolts are inserted in the steering gear from above
and screwed into the threaded lugs on the front
axle crossmember.
The following components can be renewed
separately or as a unit:
• Complete steering gear
• Steering gear rubber bushes
• Tie rods.
• Steering gear boot
• Tie-rod end
• Steering angle sensor - vehicles built up to 09/2009 During removal and installation or renewal of
components of the steering gear, pay attention to
the following: (excluding steering angle sensor)
• Before undertaking repair work on an accident
damaged steering gear, the scope of the repair
must be determined using the inspection
instructions "Steering gear inspection after an
accident". For additional information, refer to
"Diagnosis and Testing" in this section.
• When the steering gear is removed and installed, the front axle crossmember must be
aligned with the bodywork using the appropriate
special tools.
• After completing the work, the suspension geometry of the vehicle must be checked and
corrected as necessary.
G1001269en2008.50 Kuga8/2011
211-02- 4
Power Steering
211-02- 4
DESCRIPTION AND OPERATION
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