body FORD KUGA 2011 1.G Owner's Guide

1. Raise and support the vehicle. REFER to:(100-02 Jacking and Lifting)
Jacking (Description and Operation),
Lifting (Description and Operation).
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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.
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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.
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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.
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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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211-00- 3
Steering System - General Information
211-00- 3
DIAGNOSIS AND TESTING
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firmly grasp the road wheel and apply a rocking
motion checking for any free play in the steering
linkage.
E56375
10. Detach the steering gear boot from the steeringgear body and check for free play at the tie-rod
inner ball joint.
11. If there is free play at the tie-rod inner ball joint, install a new tie-rod.
REFER to: Tie Rod(211-03 Steering Linkage,
Removal and Installation).
12. 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).
Turning Effort Test
NOTE: Before carrying out this test, make sure
that the suspension components are serviceable.
NOTE: Before carrying out this test, make sure
that the steering column is serviceable.
NOTE: Before carrying out this test, make sure
that the toe adjustment and tire pressures are
correct.
1. Park the vehicle on a dry, even surface and apply the parking brake.
2. Remove the driver air bag module.
REFER to: Driver Air Bag Module (501-20
Supplemental Restraint System, Removal and
Installation).
3. Connect the air bag simulators to the sub-harnesses in place of the driver air bag
module at the top of the steering column.
4. Start the engine and turn the steering wheel from lock to lock several times until the power
steering fluid has reached normal operating
temperature. 5. Using a suitable torque wrench and socket,
check the steering wheel turning effort.
6. If the steering wheel turning effort is greater than the specification, install a new steering gear.
Steering Column Universal Joint
1.WARNING: Install a new steering column
to steering gear pinion retaining bolt. Failure
to follow this instruction may result in
personal injury.
Detach the steering column from the steering
gear pinion.• Discard the steering column to steering gear pinion retaining bolt.
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1
2
2
2. Check for smooth movement of the steeringcolumn universal joint.
1. Hold the steering column universal joint yoke.
2. Articulate the free yoke in a figure of eight movement.
• If the movement is not smooth or resistance is felt, install a new steering column.
REFER to: Steering Column (211-04 Steering
Column, Removal and Installation).
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3. Hold both of the steering column universal joint yokes and twist them clockwise and
counterclockwise.
G1059437en2008.50 Kuga8/2011
211-00- 4
Steering System - General Information
211-00- 4
DIAGNOSIS AND TESTING
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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.
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211-02- 4
Power Steering
211-02- 4
DESCRIPTION AND OPERATION
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E96312
1
2
3
Description
Item
Reservoir
1
Hydraulic pump
2
Brushless DC motor with integral power
steering moduleRefertoComponentDescription:(page
11)
3
NOTE: The power steering pump must be filled
and vented as specified.
The electro-hydraulic power steering pump
comprises a brushless DC motor, the hydraulic
pump and the power steering fluid reservoir.
The hydraulic pump is a gear pump; a resonance
chamber incorporated into the pump body reduces
noise emissions.
The operating pressure is also regulated by means
of a pressure limiting valve which is integrated in
the pump housing. The pressure limiting valve
stabilizes the throughput to the steering gear to a
particular level independently of engine speed.
The pressure relief valve will operate if the
discharge from the pump is restricted, for example, steering held on full lock. If the output from the
pump is blocked, all output is recirculated through
the pump. As no fresh fluid from the reservoir is
drawn into the pump in the process, the
temperature of the power steering fluid in the pump
quickly increases. Consequently, periods of holding
the steering wheel at full lock should be kept to a
minimum to prevent overheating of the pump and
the power steering fluid within it.
The pressure limiting valve limits the pressure on
the outlet side to 120 bar.
Integrated steering angle sensor - vehicles
built up to 09/2009
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211-02-
10
Power Steering
211-02- 10
DESCRIPTION AND OPERATION
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5. Remove the glow plug relay.
6. Lower the vehicle.
7. Remove the cowl panel grille.REFER to: Cowl Panel Grille (501-02 Front End
Body Panels, Removal and Installation).
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8. NOTE: The engine upper cover is held in place by 3 ball clips. The ball clips are not
vertical, but are angled backwards by
approximately 20 degrees.
Location of the engine upper cover ball clips.
E50472
2
1
3
4
9.CAUTION: Contact of the engine upper
cover with the cowl panel may cause damage
(scratches) on the engine upper cover. If the
ambient temperature is below 0°C, detach
the engine upper cover with extreme caution. Failure to follow this instruction may cause
the engine upper cover to be damaged.
NOTE: Only remove and install the engine upper
cover in the sequence shown.
Remove the engine upper cover.• Detach the engine upper cover ball clips in the sequence shown.
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10.CAUTION: Do not disconnect the fuel
injection pump electrical connectors and
crank the engine.
Disconnect the fuel injector electrical
connectors.
11. Remove the exhaust gas recirculation (EGR) cooler.
12. Remove the EGR valve.
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13. Remove the glow plug power supply.
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Engine System - General Information
303-00- 12
DIAGNOSIS AND TESTING
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Put the engine cover into installation position
and clip it in place by pressing at the places
shown.• Make sure that the engine upper cover is fully engaged in the area of the fuel filter, if
necessary apply more pressure in the areas
shown.
25. Install the cowl panel grille.
REFER to: Cowl Panel Grille (501-02 Front End
Body Panels, Removal and Installation).
26. Raise and support the vehicle.
REFER to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
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27. Install the glow plug relay.
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28. Install the radiator undershield.
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29. Install the engine undershield.
30. Lower the vehicle.
31. Reset the PCM fault memory.
Measure the oil pressure (21 113 0)
The oil pressure depends on various factors
(engine speed, oil temperature, oil viscosity,
amount of oil filter contamination etc.).
Measure the oil pressure (Engine - 2.5L
Duratec-ST (VI5))
1. Raise and support the vehicle.
REFER to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
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2. Remove the engine undershield.
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3. Disconnect the oil pressure switch electrical connector.
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Engine System - General Information
303-00- 14
DIAGNOSIS AND TESTING
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Engine — Vehicles With: 5-Speed Automatic Transaxle(AW55)(21 132 0; 21 132 6; 21 132 7)
Removal
Special Tool(s) / General Equipment
303-122
Lifting Bracket, Engine
21068A
Cable Ties
Hose Clamp Remover/Installer
Hydraulic Jib Crane
Mounting Table Set
Special Tool(s) / General EquipmentRetaining Strap
Trolley Jack
Wooden Block
1. Refer to: Fuel System Pressure Release
(310-00 Fuel System - General Information,
General Procedures).
2. Refer to: Cowl Panel Grille (501-02 Front End
Body Panels, Removal and Installation).
3. Refer to: Battery(414-01 Battery, Mounting and
Cables, Removal and Installation).
4.
E114689
5. On both sides.
Loosen: 3
turn(s)
E99147
x3
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Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
59
REMOVAL
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67.Install the following items:
1. Refer to: Battery(414-01 Battery, Mounting
and Cables, Removal and Installation).
2. Refer to: Cowl Panel Grille (501-02 Front
End Body Panels, Removal and
Installation).
68.
E79327
69. Refer to: Cooling System Draining and Vacuum
Filling (303-03 Engine Cooling, General
Procedures).
70. Refer to: Power Steering System Filling (211-00
Steering System - General Information,
General Procedures).
71. Refer to: Door Window Motor Initialization
(501-11 Glass, Frames and Mechanisms,
General Procedures).
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Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
138
INSTALLATION
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SECTION 303-04A Fuel Charging and Controls— 2.5L Duratec
(147kW/200PS) - VI5
VEHICLE APPLICATION: 2008.50 Kuga
PA G E
CONTENTS
DESCRIPTION AND OPERATION
303-04A-2
Fuel Charging and Controls ........................................................................\
........................
DIAGNOSIS AND TESTING 303-04A-4
Fuel Charging and Controls ........................................................................\
........................
303-04A-4
Inspection and Verification ........................................................................\
..........................
303-04A-4
Symptom Chart ........................................................................\
...........................................
REMOVAL AND INSTALLATION 303-04A-22
Fuel Injectors ........................................................................\
..............................................
303-04A-23
(23 198 0)
Throttle Body ........................................................................\
..........................
303-04A-24
Fuel Rail ........................................................................\
......................................................
303-04A- 1
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 1
.
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Description
Item
Fuel Injectors
1
Valve
2
Fuel rail
3
Throttle body
4
Fuel tank to fuel rail fuel supply line
5
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303-04A- 3
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 3
DESCRIPTION AND OPERATION
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