Clutch pedal FORD KUGA 2011 1.G Workshop Manual

Road/Roller Testing
Road or roller testing may be carried out for various
reasons and a procedure detailing pre-test checks,
engine starting and stopping, pre-driving checks,
on-test checks and final checks to be completed
on completion of the test is given below.
Unless complete vehicle performance is being
checked, the full road test procedure need not be
carried out. Instead, those items particularly
relevant to the system(s) being checked can be
extracted.
Pre-Test Checks
WARNING: If the brake system hydraulic
fluid level is low, pedal travel is excessive
or a hydraulic leak is found, do not attempt
to road test the vehicle until the reason for
the low fluid level, excessive pedal travel
or hydraulic leak is found and rectified.
It is suggested that pre-test checks and functional
tests of those systems and circuits which affect the
safe and legal operations of the vehicle, such as
brakes, lights and steering, should always be
carried out before the road or roller test.
With the ignition switched off, check:
– the engine oil level.
– the engine coolant level.
– the tires, for correct pressure, compatible types and tread patterns, and wear within limits.
– that there is sufficient fuel in the tank to complete the test.
– all around the engine, transmission and under the vehicle for oil, coolant, hydraulic and fuel
leaks. Make a note of any apparent leaks and
wipe off the surrounding areas to make it easier
to identify the extent of the leak on completion
of the test.
Starting the Engine
NOTE: On initial drive away from cold and within
the first 1.5 km (1 mile), do not depress the
accelerator pedal beyond half travel until the
vehicle has attained a minimum speed of 25 km/h
(15 miles/h). Never operate at high engine speed
or with the accelerator pedal at full travel whilst the
engine is cold.
With the ignition switched off, check: – that the parking brake is applied.
– that the gear lever is in the neutral position.
– that all instrument gauges (except fuel gauge)
read zero.
With the ignition switched on, check:
– that the ignition controlled warning lamps are illuminated.
– that the engine temperature gauge registers a reading compatible with the engine temperature.
– that the fuel gauge registers a reading appropriate to the fuel level in the tank.
– the operation of the parking brake warning lamp and fluid level warning indicator.
Road or Roller Testing
CAUTION: If road testing, check the brake
operation while still traveling at low speed
before continuing with the test. If the
brakes pull to one side, or appear to be
otherwise faulty, do not continue with the
road test until the fault has been found and
rectified.
During the road or roller test, check:
– that the clutch pedal operation is not stiff or heavy.
– that the initial gear engagement is smooth and there is no evidence of clutch drag.
– that the parking brake control operates smoothly and releases quickly and completely.
– that the clutch takes up the drive smoothly, without slip or judder.
– that gear changing is smooth with no abnormal noises or vibrations from the transmission.
– the engine power output is satisfactory, full power is achieved, acceleration is smooth and
pedal operation is not stiff or heavy, and engine
speed returns to idle correctly.
– there is no excessive or abnormally colored smoke from the engine under normal driving,
heavy load or overrun conditions.
– that steering operation, including power steering (if equipped), is smooth, accurate, not
excessively heavy or with excessive free play
or vibration.
– that the steering does not pull to one side and self centers smoothly after cornering.
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General Information
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DESCRIPTION AND OPERATION
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sometimes noticed in the steering wheel/column,
seats, front floor panel, front door trim panel or
front end sheet metal. It is a low frequency
vibration (around 9-15 cycles per second). It
may or may not be increased by applying the
brakes lightly. REFER to Idle
Boom/Shake/Vibration in the Driveline Noise
and Vibration Symptom Chart.
3. High Speed: A vibration is felt in the front floor panel or seats with no visible shake, but with
an accompanying sound or rumble, buzz, hum,
drone or booming noise. Coast with the clutch
pedal depressed (manual transmission) or shift
control selector lever in "N" (NEUTRAL)
(automatic transmission) and engine idling. If
vibration is still evident, it may be related to
wheels, tires, front brake discs, wheel hubs or
front wheel bearings. REFER to Shake and
Vibration While Driving in the Driveline Noise
and Vibration Symptom Chart.
4. Engine rpm Sensitive: A vibration is felt whenever the engine reaches a particular rpm.
It will disappear in neutral coasts. The vibration
can be duplicated by operating the engine at
the problem rpm while the vehicle is stationary.
It can be caused by any component, from the
accessory drive belt to the clutch or torque
converter which turns at engine speed when the
vehicle is stopped. REFER to Shake and
Vibration While Driving in the Driveline Noise
and Vibration Symptom Chart.
5. Noise and Vibration While Turning: Clicking, popping or grinding noises may be due to the
following:
• worn, damaged or incorrectly installed front wheel bearing.
• damaged powertrain/drivetrain mounts.
Road Conditions
An experienced technician will always establish a
route that will be used for all NVH diagnosis road
tests. The road selected should be reasonably
smooth, level and free of undulations (unless a
particular condition needs to be identified). A
smooth asphalt road that allows driving over a
range of speeds is best. Gravel or bumpy roads
are unsuitable because of the additional road noise
produced. Once the route is established and consistently used, the road noise variable is
eliminated from the test results.
NOTE:
Some concerns may be apparent only on
smooth asphalt roads.
If a customer complains of a noise or vibration on
a particular road and only on a particular road, the
source of the concern may be the road surface. If
possible, try to test the vehicle on the same type
of road.
Vehicle Preparation
Carry out a thorough visual inspection of the
vehicle before carrying out the road test. Note
anything which is unusual. Do not repair or adjust
any condition until the road test is carried out,
unless the vehicle is inoperative or the condition
could pose a hazard to the technician. After
verifying that the condition has been corrected,
make sure all components removed have been
installed.
Power Steering Conditions
Check for the noise in the following conditions to
verify the customer concern.
• Check for the noise in several temperature conditions.
• Is the noise from when the vehicle was new?
• Can the noise be repeated constantly or is it random?
• Check the condition of the vehicle age, mileage and service record.
• Interview the customer to find the operating condition in which the noise will occur. Test the
vehicle based on the detail(s) from the customer
interview.
• Follow the power steering operation noise condition tables below, to find which condition
the noise will occur.
Power Steering Operation Noise Check
Step 1: Check for NVH concerns from non-steering
components, which may sound like noises coming
from the steering system.
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Noise, Vibration and Harshness
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DIAGNOSIS AND TESTING
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Description
Item
Instrument Cluster
1
PCM (powertrain control module)
2
EHPS (electro-hydraulic power steering)
control module
3
Audio unit
4
GEM (generic electronic module)
5
RCM (restraints control module)
6
PATS transceiver
7 Description
Item
Steering wheel lock module
8
Left-hand steering column switch
9
Fuel level sensor
10
Washer water level warning lamp switch
11
Accelerator pedal position sensor
12
CPP (clutch pedal position) sensor/BPP
(brake pedal position) sensor
13
Lighting control switch
14
System Operation
Instrument Cluster
The instrument cluster contains analog displays
as well as warning and control lamps for displaying
the system status; in addiiton, there is an LCD
indicator field for driver information.
The instrument cluster receives the following
signals from the PCM via the high speed CAN
(controller area network) Bus (HS-CAN):
• Vehicle speed – The PCM receives the necessary signalsfrom the ABS (anti-lock brake system) wheel
sensors from the ABS control unit on the
HS-CAN.
• Engine Coolant Temperature
• Engine oil pressure.
• Engine speed
The instrument cluster receives the following
signals from the GEM via the medium speed CAN
Bus (MS-CAN):
• Ambient temperature
• Brake fluid level
• Handbrake control
• Door latch control
• Liftgate latch control
• High beam control
• Headlamp flasher control
• Direction indicator control
The fuel level signal is sent by the two fuel level
sensors in the fuel pumps in the semitrailer tank,
which is wired to the instrument cluster. The
sensors are connected in series, and the total
resistance is determined from the two individual resistors. The instrument cluster converts the raw
fuel level signal into a damped fuel level value.
The odometer shows the total distance travelled
by the vehicle and is based on the same signal as
is processed for the daily mileage counter. The
value is recorded by the instrument cluster and
stored in a protected EEPROM (Electronically
Erasable Programmable Read Only Memory) area.
This area is a memory protected against
manipulation. If the instrument cluster detects an
error in this memory area, e.g. through damage,
the driver is notified with the "Odometer error"
message.
Message center
The message center is operated using the left-hand
switch on the steering column.
The SET/RESET button is activated to select a
submenu and change the settings. If signal tones
have been activated, a short acoustic signal will
sound each time a button is pressed.
By turning the rotary switch, the different menu
displays can be scrolled through or a setting
selected.
In this display, the navigation system can also
display direction and distance information.
In addition, safety and warning messages can be
displayed in this system, such as "Coolant
overheating", "Engine system error" or "Washer
fluid level too low". In addition to a safety message,
a general warning light (red/yellow) lights up.
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Instrument Cluster
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Action
Possible Sources
Symptom
• FILL the reservoir. CHECK thebrake and clutch system for
leaks including brake fluid in
the brake booster.
• Low brake fluid level.
• Pedal goes down fast
• REPAIR the leak. CHECK theentire hydraulic system. FILL
and BLEED the brake system.
REFER to: (206-00 Brake
System - General Information)
Brake System Bleeding (General Procedures),
Brake System Pressure Bleeding (General Proced-
ures),
Component Bleeding (General
Procedures).
• Leak in the hydraulic system.
• CHECK for leaks. BLEED thebrake system. REFER to: (206-
00 Brake System - General
Information)
Brake System Bleeding (General Procedures),
Brake System Pressure Bleeding (General Proced-
ures),
Component Bleeding (General
Procedures).
• Air in the system.
• CARRY OUT a brake discrunout check.
• Brake disc “brake knock back”
(Brake pads push the brake
caliper piston back into the
brake caliper. Caused by
excessive brake disc lateral
runout or loose wheel bear-
ings.)
• INSTALL new brake shoes orbrake pads.
REFER to: Brake Pads (206-03
Front Disc Brake, Removal
and Installation).
• Worn brake shoes or brake
pads.
• GO toPinpoint Test A.
• Worn brake master cylinder
piston cups or scored cylinder
bore.
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Brake System - General Information
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DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
A2: CHECK FOR BRAKE SYSTEM LEAKS
1 Check for external brake and clutch system
leaks. Refer to Brake Master Cylinder
Component Test in this procedure.
• Are any leaks present?
zYe s REPAIR as necessary. ADD fluid and BLEED
the brake system. REFER to: (206-00 Brake
System - General Information)
Brake System Bleeding (General Procedures),
Brake System Pressure Bleeding (General
Procedures),
Component Bleeding (General Procedures).
TEST the system for normal operation.
zNo
GO to A3.
A3: PERFORM A BRAKE MASTER CYLINDER BYPASS CONDITION TEST
1 Carry out a brake master cylinder bypass
Condition Test. Refer to the Brake Master
Cylinder Component Test in this procedure.
• Was a concern found?
zYe s INSTALL a new brake master cylinder.
REFER to: Brake Master Cylinder - 2.5L
Duratec (147kW/200PS) - VI5 (206-06
Hydraulic Brake Actuation, Removal and
Installation).
TEST the system for normal operation.
zNo
VERIFY the customer concern.
PINPOINT TEST B : PEDAL EASES DOWN SLOWLY
DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
B1: CHECK THE BRAKE PEDAL OPERATION
1 Depress the brake pedal.
• Does the pedal ease down slowly?
zYe s GO to B2.
zNoRefer to the Brake Master Cylinder
Component Test in this procedure.
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Brake System - General Information
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DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
F2: CHECK FOR BRAKE PEDAL BINDING
1 Check the brake pedal for free operation.
• Did the brake pedal operate freely?
zYe s INSTALL a new brake booster. TEST the
system for normal operation.
zNoINSTALL new brake pedal bushings. TEST
the system for normal operation.
Component Tests
Hydraulic Leak Check
NOTE: There is a common clutch and brake fluid
reservoir, therefore it is possible that a clutch leak
can lead to reduction in the reservoir level.
It is possible that all evidence of fluid leakage may
have washed off if the vehicle has been operated
in rain or snow, as brake fluid is water-soluble.
Refill the system, bleed then apply the brakes
several times. Examine the system to verify that
the reservoir fluid level is actually dropping. Locate
and repair the external leak. If the fluid level drops
and no external leak can be found, check for a
brake master cylinder bore end seal leak.
Brake System Check
Brake Pedal Reserve Check
Where a low brake pedal or the feel of a
bottomed-out condition exists, check for brake
pedal reserve.
1. Operate the engine at idle with the transaxle in the NEUTRAL position.
2. Apply the brake pedal lightly three or four times.
3. Allow 15 seconds for the vacuum to replenish the brake booster.
NOTE: This increased resistance may feel like
something has bottomed out.
4. Apply the brake pedal until it stops moving downward or an increased resistance to the
pedal travel occurs. 5. Hold the brake pedal in the applied position and
raise the engine speed to approximately 2000
rpm.
NOTE: The additional movement of the brake pedal
is the result of the increased engine manifold
vacuum which exerts more force on the brake
booster during engine rundown. This means that
additional stroke is available in the brake master
cylinder and the brake system is not bottoming out.
6. Release the accelerator pedal and observe that the brake pedal moves downward as the engine
returns to idle speed.
Brake Booster Functional Test
Inspect all hoses and connections. All unused
vacuum connectors should be capped. Hoses and
their connections should be correctly secured and
in good condition with no holes and no collapsed
areas. Inspect the check valve on the brake booster
for damage.
Brake Booster Operation Check
1. Check the hydraulic brake system for leaks orlow fluid.
2. With the transaxle in the NEUTRAL position, stop the engine and apply the parking brake.
Apply the brake pedal several times to exhaust
all the vacuum in the system.
3. With the engine turned off and the vacuum in the system exhausted, apply the brake pedal
and hold it down. Start the engine. If the vacuum
system is operating, the brake pedal will tend
to move downward under constant foot
pressure. If no motion is felt, the vacuum
booster system is not functioning.
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Brake System - General Information
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Description
Item
Start/stop button
1
CPP (clutch pedal position) switches
Comments:Switches when the clutch pedal is
operated
2
Keyless vehicle module
3
Electronic steering lock with mount -
passive key and PATS transmitter/receiver
unit
Comments:for emergency start function
4Description
Item
Radio frequency receiver
Comments:Signal is only executed in GEM
5
GEM
6
PCM
7
Starter relay
8
Starter motor
9
Battery
10
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Starting System— 2.5L Duratec (147kW/200PS) - VI5303-06-
6
DESCRIPTION AND OPERATION
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Description
Item
Start/stop button
1
Keyless vehicle module
2
Electronic steering lock with mount -
passive key and PATS transmitter/receiver
unit
Comments:for emergency start function
3
Radio frequency receiver
Comments:Signal is only executed in GEM
4Description
Item
GEM
5
Stoplight Switch
6
TCM7
Starting deactivation relay
8
PCM
9
Starter relay
10
Starter motor
11
Battery
12
System Operation
Smart Start
The PCM enables the starting process when a key
providing a valid code is read via the PATS. This
code is then verified in the GEM and compared
with the saved code. If this code is recognized as
correct, synchronization with other modules is
carried out. After successful synchronization, the
engine is cleared to start in the PCM. The PCM
connects earth to the starter relay, which then
connects power to the starter solenoid. As soon
as the engine reaches a certain speed, the PCM
disconnects the starter relay and so turns off the
starter. This protects the starter.
If the engine does not turn or turns only slowly, the
starting process is aborted by the PCM.
The starter is notactivated if:
• the engine is running (i.e. the engine speed is above a particular value),
• the PATS does not permit the engine to be started,
• the clutch pedal is not operated (vehicles with manual transmission),
• the gear selector level is not set to P or N (vehicles with automatic transmission),
• the brake pedal is not operated (vehicles with automatic transmission).
Emergency starting function
If the keyless vehicle system is unable to recognize
the passive key, the vehicle can be started via the
emergency starting function. In this case, there is a passive key mount on the
steering wheel. A PATS transmission/reception
unit is attached to this.
To start the engine, the passive key must be
inserted into the passive key mount. The Start/Stop
button can then be used to turn on the ignition and
start the engine as normal. To deactivate the
PATS, a transponder is fitted in the passive key,
which is read by the transmission/reception unit.
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Starting System— 2.5L Duratec (147kW/200PS) - VI5303-06-
8
DESCRIPTION AND OPERATION
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Start Inhibit Switch
Removal
1. CAUTION: Make sure that the clutchpedal remains in the rest position.
1
2
3E101868
Installation
1.CAUTION: Make sure that the clutch
pedal remains in the rest position.
To install, reverse the removal procedure.
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Starting System— 2.5L Duratec (147kW/200PS) - VI5303-06-
11
REMOVAL AND INSTALLATION
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303-14-34
Exterior aor temperature sensor ........................................................................\
.............
DIAGNOSIS AND TESTING 303-14-35
Electronic Engine Controls ........................................................................\
.........................
303-14-35
Inspection and Verification ........................................................................\
..........................
REMOVAL AND INSTALLATION 303-14-36
(29 232 0)
Camshaft Position (CMP) Sensor ...................................................................
303-14-37
(29 219 0)
Catalyst Monitor Sensor ........................................................................\
.........
303-14-38
(29 230 0)
Crankshaft Position (CKP) Sensor .................................................................
303-14-40
(29 220 0)
Heated Oxygen Sensor (HO2S) .....................................................................
303-14-41
(29 222 0)
Knock Sensor (KS) ........................................................................\
.................
303-14-42
(29 226 0)
Mass Air Flow (MAF) Sensor ........................................................................\
..
303-14-43
(29 200 0)
Powertrain Control Module (PCM) .................................................................
303-14-45
(29 233 0)
Variable Valve Timing (VVT) Oil Control Solenoid ..........................................
303-14-46
(33 502 0)
Brake Pedal Position (BPP) Switch ................................................................
303-14-47
(33 503 0)
Clutch Pedal Position (CPP) Switch ...............................................................
303-14-2
Electronic Engine Controls— 2.5L Duratec (147kW/200PS) - VI5303-14-
2
.
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