Engine FORD KUGA 2011 1.G Owner's Manual

Action
Possible Sources
Symptom
BLEED the power steering
system.
REFER to:Power Steering
System Vacuum Bleeding (211-
00 Steering System - General
Information, General Proced-
ures).
Power steering fluid aeration.
Power steering system whine
noise – a high pitched buzzing
sound like an electric motor or
drill. Whine occurs at the higher
engine rpm, 1500 - 5000 rpm,
frequency does not change if
system is loaded or not loaded. FLUSH the power steering
system.
REFER to:
Power Steering
System Flushing (211-00
Steering System - General
Information, General Proced-
ures).
Incorrect power steering fluid.
FLUSH the power steering
system.
REFER to:Power Steering
System Flushing (211-00
Steering System - General
Information, General Proced-
ures).
Overheated power steering fluid.
Certain amount of noise level
acceptable, not a safety critical
item.
Hydraulic operating condition of
the power steering pump.
Power Steering Hiss Noise
Test Condition
Listen for steering hiss noise with the vehicle
parked, transmission in neutral and all windows
closed in the following test conditions.
G37349en2008.50 Kuga8/2011
100-04-
8
Noise, Vibration and Harshness
100-04- 8
DIAGNOSIS AND TESTING
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Action
Possible Sources
Symptom
CHECK the installation and
potential damage of the floor
seal.
Floor seal.
NOTE:
Engine speed at idle
turning the steering wheel slowly
lock to lock.
Power steering system hiss noise
– a high frequency, continuous
rush or swish noise like escaping
air from a balloon. Hiss occurs
while turning between the
steering lock stops, all steering
angles. Noise does not change
with engine rpm and is worse at
high operating temperatures. Certain amount of noise level
acceptable, not a safety critical
item.
Power steering gear valve
design.
Certain amount of noise level
acceptable, not a safety critical
item.
Power steering system hydraulic
design.
Certain amount of noise level
acceptable, not a safety critical
item.
Power steering pump pressure
relief valve.
NOTE:
Engine speed at idle
holding the steering wheel
against a steering lock for three
seconds. Do not hold for more
than five seconds.
Power steering system hiss noise
– a continuous noise like
escaping air occurs while holding
the steering against a steering
lock stop.
Power Steering Lock Stop Impact Knock
Noise
Test Condition
Listen for steering knock noise with the engine
speed at idle in the following test conditions (noise
also apparent with engine off). 1. Turn the steering wheel to the left-hand and
right-hand steering locks and listen for the
impact noise.
Action
Possible Sources
Symptom
Certain amount of noise level
acceptable, not a safety critical
item.
Power steering gear mechanical
noise, metal to metal at end of
steering travel.
Power steering system knock
noise – a heavy loud sound like
a knock on a door that occurs in
parking condition when hitting the
lock stop.
Power Steering Mechanical Knock Noise
(PAS off)
Test Condition
Listen for steering knock noise with the engine off
in the following test conditions (no power assist). 1. Turn the steering wheel 90 degrees to the right,
hold and then quickly release.
2. Turn the steering wheel 90 degrees to the left, hold and then quickly release.
G37349en2008.50 Kuga8/2011
100-04- 9
Noise, Vibration and Harshness
100-04- 9
DIAGNOSIS AND TESTING
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Action
Possible Sources
Symptom
Certain amount of noise level
acceptable, not a safety critical
item.
Power steering system knock
noise – a damped, metallic knock
noise which only occurs at
steering condition with engine off
(very high efforts).
Power steering system knock
noise – a heavy loud repeating
sound like a knock on a door that
occurs in several driving and
steering conditions.
Certain amount of noise level
acceptable, not a safety critical
item.
Tolerances in the steering gear
components.
Power Steering Mechanical Knock Noise
(PAS on)
Test Condition
Listen for steering knock noise with the engine
speed at idle in the following test conditions (power
assist). 1. Turn the steering wheel to a steering lock and
return to center quickly.
2. Turn the steering wheel 90 degrees to the left and then 90 degrees to the right quickly.
Action
Possible Sources
Symptom
REFER to Steering System.
REFER to:Steering System (211-
00 Steering System - General
Information, Diagnosis and
Testing).
Worn tie-rod ball joints (inner and
outer ball joints).
Power steering system knock
noise – clear knock noise from
steering gear linkage area.
Power Steering Hammer Knock (Hydraulic)
Noise
Test Condition
Listen for steering knock noise with the engine
speed at idle in the following test conditions (for vehicles with hydraulic power assisted steering
only, not electro-hydraulic power steering).
1. Turn the steering wheel to a steering lock
position and return quickly.
Action
Possible Sources
Symptom
Certain amount of noise level
acceptable, not a safety critical
item.
Hydraulic noise created by pres-
sure impulses.
Power steering system knock
noise – loud, metallic sound if
hitting the suspension cross-
member with a hammer (sounds
like metallic noise but is created
by pressure impulse in gear and
return line).
Power Steering Hydraulic Knock/Clonk
Noise
Test Condition
Listen for steering knock/clonk noise in the
following test conditions with the windows closed. 1. Drive over cobbled roads at low speed 10-30
km/h (6-20 mph) with and without turning.
2. Drive over straight tar strips road rails or 25 mm tall harshness strips at low speed 10-30 km/h
(6-20 mph) both driving straight and with
moderate turning.
G37349en2008.50 Kuga8/2011
100-04- 10
Noise, Vibration and Harshness
100-04- 10
DIAGNOSIS AND TESTING
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Action
Possible Sources
Symptom
Certain amount of noise level
acceptable, not a safety critical
item.
Power steering return lines.
Power steering system knock/
clonk noise – sounds almost
identical to column knock that
occurs when driving and
cornering over cobbled stones or
rough roads. Noise may appear
to emanate from a location closer
to the floor than that for column
knock (Sounds like metallic noise
but is created by pressure
impulse in gear and return line –
similar to a sound like quickly
turning off a water tap). Certain amount of noise level
acceptable, not a safety critical
item.
High power assist gain of power
steering gear valve (steering gear
design - no quality issue).
Certain amount of noise level
acceptable, not a safety critical
item.
High power steering pump flow
rate (by design).
Power Steering Column Knock Noise
Test Condition
Listen for steering knock noise in the following test
conditions with windows closed. 1. Drive over cobbled stones at low speed 16-40
km/h (10-25 mph) with and without steering
input carefully listening for knock sounds.
2. Drive over straight tar strips, road rails or 25 mm tall harshness strips at low speed 16-40 km/h
(10-25 mph) both driving straight and with
moderate cornering.
Action
Possible Sources
Symptom
CHECK the steering column
retaining bolts and attachments
to the steering column and
secure if necessary.
Steering column or steering
column shaft.
Power steering system column
knock noise – a loose sounding
rattle or vibration coming from the
column. Noticeable by hearing
and touch. Check steering column and
intermediate shaft for free play or
loose components.
REFER to:
Steering System (211-
00 Steering System - General
Information, Diagnosis and
Testing).
Power Steering Toc-Toc Noise
Test Condition
Listen for steering toc-toc noise with the engine
speed at idle and the vehicle parked, automatic
transmission in "P" (PARK) or manual transmission
in neutral and the windows closed. 1. Turn the steering wheel from left to right abruptly
changing direction.
2. Drive the vehicle for low speed parking manoeuvres constantly changing steering
direction.
G37349en2008.50 Kuga8/2011
100-04- 11
Noise, Vibration and Harshness
100-04- 11
DIAGNOSIS AND TESTING
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Action
Possible Sources
Symptom
Certain amount of noise level
acceptable, not a safety critical
item.
Steering gear (design tolerance
in steering rack).
Power steering system toc-toc
noise – a metallic noise created
when changing direction of
steering wheel rotation during
parking manoeuvre or at stand-
still.
Power Steering Grinding Noise
Test Condition
Listen for steering grinding noise with the engine
speed at idle and the vehicle parked, automatic transmission in "P" (PARK) or manual transmission
in neutral and the windows closed.
1. Slowly turn the steering wheel from lock to lock.
2. Tilt and extend the steering column in various
positions and slowly turn the steering wheel
from lock to lock.
G37349en2008.50 Kuga8/2011
100-04- 12
Noise, Vibration and Harshness
100-04- 12
DIAGNOSIS AND TESTING
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Action
Possible Sources
Symptom
Certain amount of noise level
acceptable, not a safety critical
item.
Steering wheel to shroud interfer-
ence.
Power steering system grinding
noise – an abrasive noise (like
sand paper rubbing against
wood) occurs between moving
components such as steering
wheel and the steering column
shroud. Certain amount of noise level
acceptable, not a safety critical
item.
Steering column bearing.
CHECK if floor covering is
obstructing the steering gear
pinion.
Foreign material in contact with
the steering column shaft.
CHECK the installation of the
floor seal.
CHECK the clockspring and
secure if necessary.
REFER to:Clockspring (501-20
Supplemental Restraint
System, Removal and Installa-
tion).
Clockspring.
Power Steering Zip Noise
Action
Possible Sources
Symptom
Certain amount of noise level
acceptable, not a safety critical
item.
High viscosity of power steering
fluid at low temperature.
Power steering system zip noise
– occurs when hydraulic fluid
does not flow freely through the
power steering pump supply hose
from steering fluid reservoir to
power steering pump causing
cavitation at the pump. Zip is
primarily a cold weather start-up
phenomenon (below -10°C). BLEED the power steering
system.
REFER to:
Power Steering
System Vacuum Bleeding (211-
00 Steering System - General
Information, General Proced-
ures).
Aeration of the power steering
fluid.
Driveline Noise and Vibration
Action
Possible Sources
Symptom
GO toPinpoint Test A.
• Wheel end vibration.
• Engine/transmission.
Shake and vibration while driving
GO toPinpoint Test B.
• Air cleaner.
• Power assisted steering.
• Powertrain.
• Powertrain/drivetrain mounts.
• Exhaust system.
Tip-in moan
G37349en2008.50 Kuga8/2011
100-04-
13
Noise, Vibration and Harshness
100-04- 13
DIAGNOSIS AND TESTING
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
B4: CHECK THE POWERTRAIN/DRIVETRAIN MOUNTS
1 Carry out the powertrain/drivetrain mount neut-
ralizing procedure
• Are the powertrain/drivetrain mounts OK?
zYe s Vehicle condition corrected. ROAD TEST as
necessary.
zNoINSTALL new powertrain/drivetrain mounts
as necessary. ROAD TEST as necessary.
PINPOINT TEST C : IDLE BOOM/SHAKE/VIBRATION/SHUDDER
DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
C1: CHECK THE CABLE/HOSES
1 Check the engine compartment for any
component that may have a touch condition
between the engine and body or chassis. For
example: control cable, air conditioning (A/C)
hoses, acceleration cable.
• Are the components OK?
zYe s GO to C2 .
zNo
REPAIR or INSTALL new components as
necessary. ROAD TEST as necessary.
C2: CHECK THE ENGINE COOLING RADIATOR
1 Check the engine cooling radiator mountings
and bushings for security and condition. Check
the radiator installation for any component that
may have a touch condition.
• Is the installation and bushings OK?
zYe s GO to C3 .
zNo
REPAIR or INSTALL new components as
necessary. ROAD TEST as necessary.
G37349en2008.50 Kuga8/2011
100-04- 16
Noise, Vibration and Harshness
100-04- 16
DIAGNOSIS AND TESTING
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Blower Motor — RHD(34 374 0)
Special Tool(s)412-131
Remover/Installer, Blower
Engine
E42948
Removal
NOTE:Removal steps in this procedure may
contain installation details.
1. Refer to: Cowl Panel Grille (501-02 Front End
Body Panels, Removal and Installation).
2. Torque: 25
Nm
E101389
3.Refer to: Steering Column (211-04 Steering
Column, Removal and Installation).
4. Refer to: Floor Console Extension - Vehicles
With: Center Armrest (501-12 Instrument
Panel and Console, Removal and Installation).
5.
E102293
6. Torque: 25Nm
G1065500en2008.50 Kuga8/2011
412-01- 37
Climate Control
412-01- 37
REMOVAL AND INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Description
Item
Electric Booster HeaterRefer to Component Description: (page
?)
1
GEM (generic electronic module)
2
Outside temperature sensor
3
Climate control system control assembly
4 Description
Item
Generator and Alternator
5
PCM (powertrain control module)
6
Coolant temperature sensor (ECT (engine
coolant temperature) sensor)Refer to Component Description: ECT
(page ?)
7
instrument cluster
8 G1066982en
2008.50 Kuga 8/2011 412-02-7
Auxiliary Climate Control
412-02-7
DESCRIPTION AND OPERATIONTO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

System Operation
Electric Booster Heater
In diesel vehicles which give off little residual heat,
a booster heater is used to heat the passenger
compartment rapidly in the case of low ambient
temperatures.
If the interior temperature has been set to HI, or if
the heater controls have been switched to the
highest setting, the two-zone air conditioning
system sends an "electric booster heater ON"
request signal to the CAN (controller area network)
via the medium speed GEM bus. If a manual air
conditioning system is installed, the signal is
transmitted via a conventional cable connection.
The GEM switches on the electric booster heater
depending on the following parameters:
• Engine coolant temperature is below 60 °C.
• Ambient air temperature is below 10 °C.
• Sufficient generator capacity is available.
The electric booster heater electronics activate
three output stages as a function of a pulse width
modulated signal PWM (pulse width modulation)
generated by the GEM. The output stages switch
the three heating elements of the electric booster
heater ON or OFF individually, whereby the heating
periods of the individual elements can overlap. Due
to the variable switch-on duration, continuously
variable temperature control is possible. The overall
heating power of the three heating elements is
linearly proportional to the PWM signal. If the PWM
signal is below 10% or above 95%, the electric
booster heater is not activated.
The electric booster heater is switched off when
an engine coolant temperature of 70°C or an
ambient air temperature of 20°C is exceeded.
Fuel-fired heater - function diagram G1066982en
2008.50 Kuga 8/2011 412-02-12
Auxiliary Climate Control
412-02-12
DESCRIPTION AND OPERATIONTO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL12345671205304254481201056820108V58911121112E977670