general procedures FORD KUGA 2011 1.G Owners Manual

SECTION 206-05 Parking Brake and Actuation
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
DESCRIPTION AND OPERATION
206-05-2
Parking Brake (Overview) ........................................................................\
...........................
206-05-2
Overview ........................................................................\
.....................................................
206-05-2
Parking brake cable ........................................................................\
....................................
206-05-3
Parking brake control ........................................................................\
..................................
DIAGNOSIS AND TESTING 206-05-4
Parking Brake ........................................................................\
.............................................
206-05-4
Inspection and Verification ........................................................................\
..........................
206-05-4
Symptom Chart ........................................................................\
...........................................
206-05-5
Pinpoint Tests ........................................................................\
.............................................
GENERAL PROCEDURES 206-05-9
Parking Brake Cable Adjustment ........................................................................\
................
REMOVAL AND INSTALLATION 206-05-11
(12 664 0)
Parking Brake Control ........................................................................\
............
206-05-12
Parking Brake Rear Cables ........................................................................\
........................
206-05-1
Parking Brake and Actuation
206-05- 1
.
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The following instructions must be followed when
removing, installing or renewing the parking brake
cable:
• If the parking brake cable is removed, installedor renewed, the parking brake must be adjusted
after the work is completed.
Refer to: Parking Brake Cable Adjustment
(206-05 Parking Brake and Actuation, General
Procedures).
Parking brake control
E103687
The following instructions must be followed when
removing, installing or renewing the parking brake
lever:
• If the parking brake lever is removed, installed or renewed, the parking brake must be adjusted
after the work is completed.
Refer to: Parking Brake Cable Adjustment
(206-05 Parking Brake and Actuation, General
Procedures).
G1058325en2008.50 Kuga8/2011
206-05- 3
Parking Brake and Actuation
206-05- 3
DESCRIPTION AND OPERATION
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Pinpoint Tests
PINPOINT TEST A : THE PARKING BRAKE WILL NOT APPLY
DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
A1: CHECK PARKING BRAKE CABLE ADJUSTMENT
1 Release the parking brake and measure the gap
between the lever and the caliper.
• Is the gap 1.2mm?
zYe s
E83778
1.2 mm
Vehicle OK
zNo REFER to: Parking Brake Cable Adjustment
(206-05 Parking Brake and Actuation,
General Procedures).
A2: CHECK FUNCTION OF PARKING BRAKE ON BRAKE CALIPER
1 Raise and support the vehicle on a lift with the
parking brake fully applied.
REFER to:
Lifting(100-02 Jacking and Lifting,
Description and Operation).
– With the aid of another technician, release the parking brake and check the operation of the
brake cables and levers.
• Are the left-hand (LH) and right-hand (RH) parking brake levers moving a similar distance?
zYe s
CHECK the other causes such as conventional
brake system components. REPAIR or
INSTALL new components as necessary.
zNoREFER to: Brake Caliper (206-04 Rear Disc
Brake, Removal and Installation).
TEST the system for normal operation.
G1063696en2008.50 Kuga8/2011
206-05- 5
Parking Brake and Actuation
206-05- 5
DIAGNOSIS AND TESTING
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Parking Brake Cable Adjustment
1.Fully apply the parking brake.
1.
2. Fully release the parking brake control.
2.
E92650
3. NOTE: This step is only necessary if the parking
brake cable was removed.
1. Torque: 2
Nm
E102065
21
G1001211en2008.50 Kuga8/2011
206-05- 9
Parking Brake and Actuation
206-05- 9
GENERAL PROCEDURES
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4.Loosen the parking brake cable adjustment
nut to the end of the parking brake cable
thread.
2.
E102067
2
P1
5.
Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
6. NOTE: This step requires the aid of another
technician.
1. Insert a 1.2 mm feeler gauge between the parking brake lever and the brake caliper
abutment, on both sides.
2. Tighten the parking brake cable adjustment nut until movement is observed on one of the
parking brake levers.
3. Remove the feeler gauges.
4. Rotate the rear wheels and tires and check for brake drag. If brake drag is felt, loosen
the parking brake cable adjustment nut to
the end of the parking brake cable thread,
clean the parking brake cables and repeat
the parking brake cable adjustment
procedure.
5. If brake drag is still felt after, repeat the adjustment using a 1.0 mm feeler gauge. If
brake drag is still felt, loosen the parking
brake adjustment nut and reduce the feeler
gauge measurement by 0.2 mm each time,
until no brake drag can be felt at the rear
wheels and tires.
E83778
1.2 mm
G1001211en2008.50 Kuga8/2011
206-05- 10
Parking Brake and Actuation
206-05- 10
GENERAL PROCEDURES
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Parking Brake Control(12 664 0)
Removal
1.Refer to: Floor Console (501-12 Instrument
Panel and Console, Removal and Installation).
2. Release the parking brake.
3.
3
33
2
1
4
E93308
Installation
1. Torque: 35Nm2.
3.NOTE: Only tighten the nut finger tight at this
stage.
2
22
3
4
1
E93328
2. Refer to: Parking Brake Cable Adjustment
(206-05 Parking Brake and Actuation, General
Procedures).
3. Refer to: Floor Console (501-12 Instrument
Panel and Console, Removal and Installation).
G1058318en2008.50 Kuga8/2011
206-05- 11
Parking Brake and Actuation
206-05- 11
REMOVAL AND INSTALLATION
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E101193
1
x43
2
Installation
1.To install, reverse the removal procedure.
2. Refer to: Parking Brake Cable Adjustment
(206-05 Parking Brake and Actuation, General
Procedures).
G1072319en2008.50 Kuga8/2011
206-05- 14
Parking Brake and Actuation
206-05- 14
REMOVAL AND INSTALLATION
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E114811
2
1
Installation
1.To install, reverse the removal procedure.
2. Refer to: Brake System Bleeding (206-00 Brake
System - General Information, General
Procedures).
Refer to: Brake System Pressure Bleeding
(206-00 Brake System - General Information,
General Procedures).
G1174985en2008.50 Kuga8/2011
206-06- 7
Hydraulic Brake Actuation
206-06- 7
REMOVAL AND INSTALLATION
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Brake Booster — 2.5L Duratec (147kW/200PS) - VI5, RHD4WD/RHD FWD(12 451 0)
Removal
NOTE: Removal steps in this procedure may
contain installation details.
1. Refer to: Brake System Health and Safety
Precautions (100-00 General Information,
Description and Operation).
2. Torque: 24
Nm
E69829
x4
1
2
3.Refer to: Air Conditioning (A/C) System
Recovery, Evacuation and Charging (412-00
Climate Control System - General Information,
General Procedures).
Refer to: Brake Master Cylinder - 2.5L Duratec
(147kW/200PS) - VI5 (206-06 Hydraulic Brake
Actuation, Removal and Installation).
Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
4.
E65299
5. Torque:
• Stage 1: 10
Nm
• Stage 2: 25Nm
E99866
x6
6.
G1185955en2008.50 Kuga8/2011
206-07- 2
Power Brake Actuation
206-07- 2
REMOVAL AND INSTALLATION
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Description
Item
Front wheel sensor, right-hand side
8Description
Item
9 ESP switch
Testing the brakes on a roller dynamometer
- 4X4 vehicles only
On 4X4 vehicles a brake test on a roller
dynamometer must only be performed under the
following conditions.
• The brake test must not exceed a duration of 1 minute.
• Ignition key in position 0.
• The roller speed must not exceed 5 km/h.
ABS/ESP module or hydraulic control
unit (HCU)
E96821
1
23
The ABS/ESP module or the hydraulic control unit
(HCU) is mounted on the left-hand side of the
bulkhead. Diagnosis is performed with the aid of
a diagnostic tester.
The following components can be replaced
separately or as a unit:
• Hydraulic Control Unit (HCU)
• ABS/ESP module
• Mounting Bracket
The following must be taken into account when
removing/installing or renewing the ABS/ESP
module or the hydraulic control unit (HCU):
• Only hydraulic control units (HCU) which are pre-filled with brake fluid are available for
service operations.
• After replacing the HCU it is not necessary to bleed the system via the diagnostic tester.
• After replacing the brake fluid it is also only necessary to perform standard bleeding.
• The blanking caps/plugs must not be removed until the brake tubes are ready to be connected. • If accidentally dropped or knocked install a new
hydraulic control unit (HCU) and module
assembly.
• When the ABS/ESP module is removed/installed or replaced, it is necessary to reconfigure the
ABS/ESP module with the aid of the diagnostic
tester once all of the installation work has been
performed.
Refer to: Module Configuration (418-01 Module
Configuration, General Procedures).
Combined yaw rate sensor and lateral
acceleration sensor / longitudinal
acceleration sensor
E96822
The sensor is attached to the floor crossmember
at the front right. For vehicles with 4x4 drive, a
longitudinal acceleration sensor is also integrated
in the same housing.
The following must be taken into account when
removing/installing or replacing the combined yaw
rate sensor and lateral/longitudinal acceleration
sensor:
• Ensure the correct installation position of the yaw rate sensor and lateral/longitudinal
acceleration sensor.
G1001303en2008.50 Kuga8/2011
206-09B- 4
Anti-Lock Control - Stability Assist
206-09B- 4
DESCRIPTION AND OPERATION
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