air FORD KUGA 2011 1.G Workshop Manual

7RUTXH 1P
E67804
7RUTXH 1P
E69320
7RUTXH 1P
E67812
[
2Q ERRWK VLGHV
5HIHU WR 6SULQJ 5HDU 6XVSHQVLRQ
5HPRYDO DQG ,QVWDOODWLRQ
  2Q ERRWK VLGHV
5HIHU WR 5HDU 6WDELOL]HU %DU /LQN  5HDU
6XVSHQVLRQ 5HPRYDO DQG ,QVWDOODWLRQ
[
 5HIHU WR 'LIIHUHQWLDO &DVH  5HDU 'ULYH
$[OH'LIIHUHQWLDO 5HPRYDO DQG ,QVWDOODWLRQ
[
 2Q ERRWK VLGHV
5HIHU WR :KHHO DQG 7LUH  :KHHOV DQG
7LUHV 5HPRYDO DQG ,QVWDOODWLRQ
$OO YHKLFOHV
 5HIHU WR 5HDU 7RH $GMXVWPHQW 
6XVSHQVLRQ 6\VWHP  *HQHUDO ,QIRUPDWLRQ
*HQHUDO 3URFHGXUHV
*HQ .XJD

8QL%RG\ 6XEIUDPH DQG 0RXQWLQJ 6\VWHP

5(029$/ $1' ,167$//$7,21
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

5HDU 6XEIUDPH %XVKLQJ
6SHFLDO 7RROV
5HPRYHU,QVWDOOHU 6XEIUDPH
%XVKLQJ *XLGH
(

,QVWDOOHU 'LIIHUHQWLDO %HDULQJ
&RQH
15034

,QVWDOOHU 'LIIHUHQWLDO %HDULQJ
&RQH
15035
6SHFLDO 7RROV
$GDSWHU IRU 
15064

,QVWDOOHU 3LYRW %XVKLQJ
15084
5HPRYDO
127(5HPRYDO VWHSV LQ WKLV SURFHGXUH PD\
FRQWDLQ LQVWDOODWLRQ GHWDLOV 
5HIHU WR 'LIIHUHQWLDO &DVH  5HDU 'ULYH
$[OH'LIIHUHQWLDO 5HPRYDO DQG ,QVWDOODWLRQ
 6SHFLDO 7RROV   
*HQ .XJD

8QL%RG\ 6XEIUDPH DQG 0RXQWLQJ 6\VWHP

5(029$/ $1' ,167$//$7,21
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

(




,QVWDOODWLRQ
6SHFLDO 7RROV   
*HQ .XJD

8QL%RG\ 6XEIUDPH DQG 0RXQWLQJ 6\VWHP

5(029$/ $1' ,167$//$7,21
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

(



7R LQVWDOO UHYHUVH WKH UHPRYDO SURFHGXUH
*HQ .XJD

8QL%RG\ 6XEIUDPH DQG 0RXQWLQJ 6\VWHP

5(029$/ $1' ,167$//$7,21
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Action
Possible Sources
Symptom
• Vehicles without load levellingshock absorbers, CHECK for
abnormal loading, spring sag
or non-standard springs.
• Vehicles with load levelling shock absorbers, GO to
Pinpoint Test C.
• Vehicle attitude incorrect (front
or rear is high or low).
• Steering wheel off center
• CHECK the steering system.REFER to: Steering System
(211-00 Steering System -
General Information,
Diagnosis and Testing).
• Steering gear or linkage worn
or damaged.
• CARRY OUT the Ball JointInspection Component Test in
this procedure.
• Suspension lower arm ball joint.
• ADJUST the wheel alignment.REFER to: Front Toe Adjust-
ment (204-00 Suspension
System - General Informa-
tion, General Procedures)
/ Rear Toe Adjustment (204-00
Suspension System - General
Information, General Proced-
ures).
• Incorrect wheel alignment.
• CARRY OUT the Strut orShock Absorber Testing
component test in this
procedure.
• CHECK and INSTALL new suspension components as
necessary.
REFER to: Front Strut and
Spring Assembly (204-01
Front Suspension, Disas-
sembly and Assembly).
• Front strut and spring assem-
blies.
• Rough ride
• CHECK and INSTALL newsuspension components as
necessary. REFER to:
Front Strut and Spring Assembly (204-01 Front
Suspension, Disassembly
and Assembly),
Rear Stabilizer Bar (204-02
Rear Suspension, Removal
and Installation).
• Front or rear stabilizer bar
connecting links or bushings.
G1080717en2008.50 Kuga8/2011
204-00- 3
Suspension System - General Information
204-00- 3
DIAGNOSIS AND TESTING
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Action
Possible Sources
Symptom
• INSTALL a new lower arm.REFER to: Lower Arm (204-01
Front Suspension, Removal
and Installation).
• Front suspension lower arm
bushings.
• CHECK and INSTALL newcomponents as necessary.
REFER to: Rear Stabilizer Bar
Bushing (204-02 Rear
Suspension, Removal and
Installation).
• Rear suspension arm bushings.
• CARRY OUT the Strut orShock Absorber Testing
component test in this
procedure.
• CHECK and INSTALL new suspension components as
necessary.
• Rear shock absorbers.
• GO toPinpoint Test B.
• Front strut and spring assembly
or rear shock absorber and
spring upper mounting bolts or
nuts loose or broken.
• Excessive noise
• GO toPinpoint Test B.
• Shock absorbers leaking.
• GO toPinpoint Test B.
• Shock absorbers performance
incorrect.
• GO toPinpoint Test B.
• Stabilizer bar components.
• GO toPinpoint Test B.
• Strut and spring assembly and
springs.
• GO toPinpoint Test B.
• Springs moving on springs
upper or lower seats.
• GO toPinpoint Test B.
• Suspension bushings.
• GO toPinpoint Test B.
• Lower arm ball joint.
• GO toPinpoint Test B.
• Worn front wheel bearings
• GO toPinpoint Test B.
• Wheels and tires.
• CHECK and INSTALL newsuspension components as
necessary.
• Front or rear suspension
damage.
• Incorrect tire wear
• ADJUST the wheel alignment.REFER to: Front Toe Adjust-
ment (204-00 Suspension
System - General Informa-
tion, General Procedures)
/ Rear Toe Adjustment (204-00
Suspension System - General
Information, General Proced-
ures).
• Incorrect wheel alignment.
G1080717en2008.50 Kuga8/2011
204-00-
4
Suspension System - General Information
204-00- 4
DIAGNOSIS AND TESTING
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Action
Possible Sources
Symptom
• CHECK the front wheel bear-ings.
• Damaged or worn front wheel
bearings.
• Vibration
• CHECK the tires. BALANCE orINSTALL new tires as neces-
sary.
• Wheels and tires.
• CHECK the steering system.REFER to: Steering System
(211-00 Steering System -
General Information,
Diagnosis and Testing).
• Steering gear or linkage worn
or damaged.
• CARRY OUT the Strut orShock Absorber Testing
component test in this
procedure.
• CHECK and INSTALL new suspension components as
necessary.
REFER to: Front Strut and
Spring Assembly (204-01
Front Suspension, Removal
and Installation).
• Front strut and spring assem-
blies.
• CHECK and INSTALL newsuspension components as
necessary.
REFER to: Lower Arm (204-01
Front Suspension, Removal
and Installation).
• Damaged front suspension
lower arm(s).
• GO toPinpoint Test C.
• Load-levelling shock absorbers.
• Vehicle lean
Pinpoint Tests
PINPOINT TEST A : DRIFT LEFT OR RIGHT
DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
WARNING: To avoid personal injury due to the loss of vehicle control, the inspection should
be carried out by two people to maintain safe driving conditions. Adequate grip should
G1080717en2008.50 Kuga8/2011
204-00- 5
Suspension System - General Information
204-00- 5
DIAGNOSIS AND TESTING
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
always be maintained on the steering wheel. Failure to follow these instructions may result
in personal injury.
NOTE: The following conditions must be met when evaluating the vehicle.
NOTE: The tire swapping procedures are for bi-directional rotating tires only.
A1: SWAP THE FRONT WHEEL AND TIRE ASSEMBLIES
1 Raise and support the vehicle. REFER to: (100-
02 Jacking and Lifting)
Jacking (Description and Operation),
Lifting (Description and Operation).
– Swap the front left-hand wheel and tire assembly with the front right-hand wheel and
tire assembly.
– Road test the vehicle.
• Does the vehicle drift?
zYe s GO to A2.
zNoThe concern has been corrected.
A2: SWAP THE REAR WHEEL AND TIRE ASSEMBLIES
1 Raise and support the vehicle. REFER to: (100-
02 Jacking and Lifting)
Jacking (Description and Operation),
Lifting (Description and Operation).
– Swap the rear left-hand wheel and tire assembly with the rear right-hand wheel and
tire assembly.
– Road test the vehicle.
• Does the vehicle drift?
zYe s GO to A3.
zNoThe concern has been corrected.
G1080717en2008.50 Kuga8/2011
204-00- 6
Suspension System - General Information
204-00- 6
DIAGNOSIS AND TESTING
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
A3: SWAP THE LEFT-HAND WHEEL AND TIRE ASSEMBLIES
1 Raise and support the vehicle. REFER to: (100-
02 Jacking and Lifting)
Jacking (Description and Operation),
Lifting (Description and Operation).
– Swap the front left-hand wheel and tire assembly with the rear left-hand wheel and
tire assembly.
– Road test the vehicle.
• Does the vehicle drift?
zYe s GO to A4.
zNoThe concern has been corrected.
A4: SWAP THE RIGHT-HAND WHEEL AND TIRE ASSEMBLIES
1 Raise and support the vehicle. REFER to: (100-
02 Jacking and Lifting)
Jacking (Description and Operation),
Lifting (Description and Operation).
– Swap the front right-hand wheel and tire assembly with the rear right-hand wheel and
tire assembly.
– Road test the vehicle.
• Does the vehicle drift?
zYe s GO to A5.
zNoThe concern has been corrected.
A5: SWAP THE FRONT LEFT-HAND WHEEL AND TIRE ASSEMBLY
1 Raise and support the vehicle. REFER to: (100-
02 Jacking and Lifting)
Jacking (Description and Operation),
Lifting (Description and Operation).
– Swap the front left-hand wheel and tire assembly with the rear right-hand wheel and
tire assembly.
– Road test the vehicle.
• Does the vehicle drift?
zYe s GO to A6.
zNoThe concern has been corrected.
G1080717en2008.50 Kuga8/2011
204-00- 7
Suspension System - General Information
204-00- 7
DIAGNOSIS AND TESTING
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
A6: SWAP THE FRONT RIGHT-HAND WHEEL AND TIRE ASSEMBLY
1 Raise and support the vehicle. REFER to: (100-
02 Jacking and Lifting)
Jacking (Description and Operation),
Lifting (Description and Operation).
– Swap the front right-hand wheel and tire assembly with the rear left-hand wheel and
tire assembly.
– Road test the vehicle.
• Does the vehicle drift?
zYe s GO to A7.
zNoThe concern has been corrected.
A7: INSTALL NEW TIRES
NOTE: Install new tires only once.
1Install new tires to the four road wheels. TEST
the system for normal operation.
• Does the vehicle drift?
zYe s Verify possible sources, refer to the Symptom
Chart.
zNoThe concern has been corrected.
PINPOINT TEST B : EXCESSIVE NOISE
DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
B1: INSPECT ALL STRUT AND SPRING ASSEMBLY AND SHOCK ABSORBER MOUNTING BOLTS
AND NUTS
1 Inspect the strut and spring assembly and shock
absorber mounting bolts and nuts.
• Are the mounting bolts or nuts loose or broken?
zYe s TIGHTEN or INSTALL new suspension
mounting bolts.
REFER to: Specifications (204-01 Front
Suspension, Specifications).
zNo
GO to B2.
G1080717en2008.50 Kuga8/2011
204-00- 8
Suspension System - General Information
204-00- 8
DIAGNOSIS AND TESTING
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL