FORD KUGA 2011 1.G Owners Manual
Manufacturer: FORD, Model Year: 2011, Model line: KUGA, Model: FORD KUGA 2011 1.GPages: 2057
Page 91 of 2057
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
Page 92 of 2057
Action
Possible Sources
Symptom
GO toPinpoint Test C.
• Cable(s)/hose(s).
• Powertrain/drivetrain mounts.
• Exhaust system.
• Belt/pulleys.
Idle boom/shake/vibration/
shudder
Suspension Noise and Vibration
Action
Possible Sources
Symptom
GO toPinpoint Test D.
• Suspension.
• Wheel bearings.
Wheel end vibration analysis
GO toPinpoint Test E.
• Trim panels.
• Air conditioning (A/C) system.
• Accessories.
Non-axle noise
Pinpoint Tests
NOTE:
These Pinpoint Tests are designed to take
the technician through a step-by-step diagnosis
procedure to determine the cause of a condition.
It may not always be necessary to follow the chart
to its conclusion. Carry out only the pinpoint test steps necessary to correct the condition. Then
check the operation of the system to make sure
the condition has been corrected.
After verifying that the condition has been
corrected, make sure all components removed
have been installed.
PINPOINT TEST A : SHAKE AND VIBRATION WHILE DRIVING
DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
A1: NEUTRAL COAST
1 Carry out the neutral coast test.
• Does the vibration disappear during the neutral coast test?
zYe s
GO to A2.
zNoGO to Pinpoint Test D.
A2: CHECK THE POWERTRAIN/DRIVETRAIN MOUNTS
1 Carry out the powertrain/drivetrain mount neut-
ralizing procedure
• Are the mounts OK?
zYe s Vehicle condition corrected. ROAD TEST as
necessary.
zNoINSTALL new powertrain/drivetrain mounts
as necessary. ROAD TEST as necessary.
G37349en2008.50 Kuga8/2011
100-04- 14
Noise, Vibration and Harshness
100-04- 14
DIAGNOSIS AND TESTING
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
Page 93 of 2057
PINPOINT TEST B : TIP-IN MOAN
DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
B1: CHECK THE AIR CLEANER
1 Check the condition of the air cleaner mounts,
inlet tube, outlet tube, resonators and all other
components associated with the air induction
system for correct installation and tightness of
all connections.
• Are the components OK?
zYe s GO to B2.
zNoREPAIR or INSTALL new components as
necessary. ROAD TEST as necessary.
B2: CHECK THE EXHAUST SYSTEM
1 Carry out the exhaust system neutralizing
procedure.
• Is the exhaust system OK?
zYe s GO to B3.
zNoREPAIR as necessary. ROAD TEST as
necessary.
B3: CHECK THE POWER STEERING
1 Remove the accessory drive belt and test for
tip-in moan. REFER to:
Accessory Drive Belt (303-05 Accessory Drive
- 2.5L Duratec (147kW/200PS) - VI5, Removal
and Installation),
• Is the tip-in moan OK?
zYe s REPAIR the power steering as necessary.
REFER to: Steering System (211-00 Steering
System - General Information, Diagnosis
and Testing).
zNo
GO to B4.
G37349en2008.50 Kuga8/2011
100-04- 15
Noise, Vibration and Harshness
100-04- 15
DIAGNOSIS AND TESTING
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
Page 94 of 2057
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
Page 95 of 2057
DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
C3: CHECK THE EXHAUST SYSTEM
1 Carry out the exhaust system neutralizing
procedure.
• Is the exhaust system OK?
zYe s GO to C4 .
zNo
REPAIR as necessary. ROAD TEST as
necessary.
C4: 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 D : WHEEL END VIBRATION ANALYSIS
DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
D1: INSPECT THE WHEELS AND TIRES
1 Inspect the wheels and tires.
REFER to:
Wheels and Tires (204-04 Wheels
and Tires, Diagnosis and Testing).
• Are the wheels and tires OK?
zYe s GO to D2 .
zNo
INSTALL new wheels or tires as necessary.
REFER to: Wheel and Tire (204-04 Wheels
and Tires, Removal and Installation).
ROAD TEST as necessary.
G37349en2008.50 Kuga8/2011
100-04- 17
Noise, Vibration and Harshness
100-04- 17
DIAGNOSIS AND TESTING
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
Page 96 of 2057
DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
D2: INSPECT THE WHEEL BEARINGS
1 Inspect the wheel bearings.
• Are the wheel bearings OK?
zYe s GO to D3 .
zNo
INSTALL new wheel bearings as necessary.
REFER to: Front Wheel Bearing (204-01 Front
Suspension, Removal and Installation).
ROAD TEST as necessary.
D3: INSPECT THE WHEEL AND TIRE RUNOUT
1 Inspect the wheel and tire runout.
• Is the wheel and tire runout OK?
zYe s Balance the wheels and tires. Refer to the
wheel balance equipment manufacturer's
instructions. ROAD TEST as necessary.
zNoINSTALL new wheels or tires as necessary.
REFER to: Wheel and Tire (204-04 Wheels
and Tires, Removal and Installation).
ROAD TEST as necessary.
PINPOINT TEST E : NON-AXLE NOISE
DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
E1: INSPECT THE VEHICLE TRIM
1 Check the radiator grille and trim panels to see
if they are the source of the noise.
• Are the vehicle trim components causing the noise?
zYe s
INSTALL new trim components or REPAIR as
necessary. ROAD TEST as necessary.
zNoGO to E2.
E2: CHECK THE AIR CONDITIONING (A/C) SYSTEM FOR NOISE
1 Ignition switch in position III.
2Ignition switch in position II.
G37349en2008.50 Kuga8/2011
100-04-
18
Noise, Vibration and Harshness
100-04- 18
DIAGNOSIS AND TESTING
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
Page 97 of 2057
DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
3 Check the A/C system components for noise by
turning the A/C system on and off.
• Is the A/C system causing the noise?
zYe s INSPECT the A/C system.
REFER to: Climate Control System (412-00
Climate Control System - General Informa-
tion, Diagnosis and Testing).
ROAD TEST as necessary.
zNo
GO to E3.
E3: CHECK NON-FACTORY FITTED ACCESSORIES
1 Check any non-factory installed accessories for
being the source of the noise. For example:
touch condition body-to-frame, antennas,
deflectors and fog lights.
• Are the accessories the cause of the noise?
zYe s ADJUST, REPAIR, or INSTALL new
accessories or fasteners as required. ROAD
TEST as necessary.
zNoVERIFY the customer concern.
G37349en2008.50 Kuga8/2011
100-04- 19
Noise, Vibration and Harshness
100-04- 19
DIAGNOSIS AND TESTING
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
Page 98 of 2057
* 5 2 8 3
& K D V V L V
6 ( & 7 , 2 1 7 , 7 / ( 3 $ * (
6 X V S H Q V L R Q 6 X V S H Q V L R Q 6 \ V W H P * H Q H U D O , Q I R U P D W L R Q
) U R Q W 6 X V S H Q V L R Q
5 H D U 6 X V S H Q V L R Q
: K H H O V D Q G 7 L U H V
' U L Y H O L Q H ' U L Y H V K D I W
5 H D U ' U L Y H $ [ O H ' L I I H U H Q W L D O
) U R Q W ' U L Y H + D O I V K D I W V
5 H D U ' U L Y H + D O I V K D I W V
% U D N H 6 \ V W H P % U D N H 6 \ V W H P * H Q H U D O , Q I R U P D W L R Q
) U R Q W ' L V F % U D N H
5 H D U ' L V F % U D N H
3 D U N L Q J % U D N H D Q G $ F W X D W L R Q
+ \ G U D X O L F % U D N H $ F W X D W L R Q
3 R Z H U % U D N H $ F W X D W L R Q
$ Q W L / R F N & R Q W U R O $
$ Q W L / R F N & R Q W U R O 6 W D E L O L W \ $ V V L V W %
6 W H H U L Q J 6 \ V W H P 6 W H H U L Q J 6 \ V W H P * H Q H U D O , Q I R U P D W L R Q
3 R Z H U 6 W H H U L Q J
6 W H H U L Q J / L Q N D J H
6 W H H U L Q J & R O X P Q
6 W H H U L Q J & R O X P Q 6 Z L W F K H V
. X J D
TO MODEL INDEX
BACK TO MAIN INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
Page 99 of 2057
SECTION 204-00 Suspension System - General
Information
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
DIAGNOSIS AND TESTING
204-00-2
Suspension System ........................................................................\
....................................
204-00-2
Inspection and Verification ........................................................................\
..........................
204-00-2
Symptom Chart ........................................................................\
...........................................
204-00-5
Pinpoint Tests ........................................................................\
.............................................
204-00-12
Component Tests ........................................................................\
........................................
GENERAL PROCEDURES 204-00-15
(14 117 3)
Front Toe Adjustment ........................................................................\
.............
204-00-16
(15 211 3)
Rear Toe Adjustment ........................................................................\
..............
204-00-1
Suspension System - General Information
204-00- 1
.
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
Page 100 of 2057
Suspension System
Special Tool(s)Alignment Pins, Subframe
205-316 (15-097A)
15097A
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanicaldamage.
Visual Inspection Chart
Mechanical
Tire pressure(s) Wheel and tires
Mechanical
Wheel knuckles Tie-rod ends
Front suspension lower arm ball joints Front suspension lower arm bushings Front strut and spring assemblies
Front and rear stabilizer bar and connecting links Rear springs
Rear shock absorbers
Rear suspension lower arms
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 Symptom Chart.
Symptom Chart
Symptom Chart
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 / left or right is high or
low).
• Drift left or right
• CHECK the steering system.REFER to: Steering System
(211-00 Steering System -
General Information,
Diagnosis and Testing).
• Steering gear or linkage worn
or damaged.
• CHECK the brake system.REFER to: Brake System (206-
00 Brake System - General
Information, Diagnosis and
Testing).
• Brake system.
• Using the special tool, CHECKthe front subframe alignment..
• Incorrect front crossmember
alignment.
• CHECK the wheel bearings.
• Worn front wheel bearings.
• GO toPinpoint Test A.
• Wheel and tires.
G1080717en2008.50 Kuga8/2011
204-00- 2
Suspension System - General Information
204-00- 2
DIAGNOSIS AND TESTING
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL