air FORD KUGA 2011 1.G Workshop Manual

Hydraulic Control Unit (HCU)
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. Refer to: Battery(414-01 Battery, Mounting and
Cables, Removal and Installation).
3. Torque: 12
Nm
E100290
4. Connect one end of a suitable piece of clear
plastic pipe to the brake caliper bleed nipple
1.
and place the other end into a suitable
container.
2. Loosen the bleed nipple.
3. Depress the brake pedal until all the brake fluid is drained from the brake fluid reservoir.
4. Tighten the bleed nipple.
5. Repeat the draining procedure on the opposite side brake caliper.
E86914
Left-hand drive vehicles
5. NOTE: Make sure that the seal is correctly
located.
Torque: 18
Nm
E69767
Right-hand drive vehicles
6.
E66148
7. Torque: 18Nm
G1001225en2008.50 Kuga8/2011
206-09B- 16
Anti-Lock Control - Stability Assist
206-09B- 16
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E101093
All vehicles
8. NOTE:Make sure that the seal is correctly
located.
2. Torque: 18
Nm
3. Torque: 9Nm
G1001225en2008.50 Kuga8/2011
206-09B- 17
Anti-Lock Control - Stability Assist
206-09B- 17
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E99307
x4
1
2
3
9.Torque: 9Nm
E69769
x3
10.Refer to: Stability Assist Module (206-09
Anti-Lock Control - Stability Assist, Removal
and Installation).
Installation
1. CAUTION: If accidentally dropped or knocked install a new hydraulic control
unit (HCU) and module.
The blanking caps/plugs must not be
removed until the brake tubes are ready to
be connected. 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).
G1001225en2008.50 Kuga8/2011
206-09B- 18
Anti-Lock Control - Stability Assist
206-09B- 18
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Stability Assist Module
General EquipmentFord approved diagnostic tool
Pneumatic Vacuum GunMaterials
Specification
Name
WSK-M2G342-A /
2U7J-M2G400-AA
Metal Adhesive Kit - 2
Component
Removal
1.
Refer to: Hydraulic Control Unit (HCU) (206-09
Anti-Lock Control - Stability Assist, Removal
and Installation).
2.
E101091
1
2
3. Clean the HCU contact surface.
Material: Metal Adhesive Kit - 2 Component
(WSK-M2G342-A / 2U7J-M2G400-AA) cleaner
4. Remove all traces of the cleaner and foreign
material.
General Equipment: Pneumatic Vacuum GunInstallation
1. WARNING: Make sure that the module
is correctly located on the hydraulic
control unit (HCU).
CAUTION: If accidentally dropped or
knocked install a new hydraulic control
unit (HCU) and module.
Take extra care not to damage the seal.
G1001226en2008.50 Kuga8/2011
206-09B- 19
Anti-Lock Control - Stability Assist
206-09B- 19
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NOTE:Make sure that the seal is correctly
located. Torque: 5,5Nm
E101092
2.
Refer to: Hydraulic Control Unit (HCU) (206-09
Anti-Lock Control - Stability Assist, Removal
and Installation).
3. Configure the stability assist program.
General Equipment: Ford approved diagnostic
tool
4. Carry out the stability assist program Function
Test.
General Equipment: Ford approved diagnostic
tool
5. Carry out a road test.
Refer to: Road/Roller Testing (100-00 General
Information, Description and Operation).
G1001226en2008.50 Kuga8/2011
206-09B- 20
Anti-Lock Control - Stability Assist
206-09B- 20
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Front Wheel Speed Sensor
Removal
NOTE:Removal steps in this procedure may
contain installation details.
1. Refer to: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation).
2. Torque: 5
Nm
E71878
Installation
1.To install, reverse the removal procedure.
G1001227en2008.50 Kuga8/2011
206-09B- 21
Anti-Lock Control - Stability Assist
206-09B- 21
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Rear Wheel Speed Sensor
Removal
NOTE:Removal steps in this procedure may
contain installation details.
4x2
1. Torque: 5Nm
E98809
4x4
2.Refer to: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation).
3. Torque: 5
Nm
E98810
All vehicles
4. NOTE: The O-ring seal is to be reused unless
damaged.
E98820
Installation
1. NOTE: Make sure that the sensor housing is
clean and free of foreign material.
NOTE: Make sure that the sensor ring is
correctly located.
To install, reverse the removal procedure.
G1001228en2008.50 Kuga8/2011
206-09B- 22
Anti-Lock Control - Stability Assist
206-09B- 22
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Yaw Rate Sensor
Removal
NOTE:Removal steps in this procedure may
contain installation details.
1. Refer to: Front Seat (501-10 Seating, Removal
and Installation).
2.
E99493
3.
E99496
4. Torque: 9Nm
E99499
Installation
1.To install, reverse the removal procedure.
G1058755en2008.50 Kuga8/2011
206-09B- 23
Anti-Lock Control - Stability Assist
206-09B- 23
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SECTION 211-00 Steering System - General
Information
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
DIAGNOSIS AND TESTING
211-00-2
Steering System ........................................................................\
.........................................
211-00-2
Inspection and Verification ........................................................................\
..........................
211-00-2
Components Tests ........................................................................\
......................................
211-00-6
Steering Gear Checks After a Collision ........................................................................\
......
GENERAL PROCEDURES 211-00-8
Power Steering System Flushing ........................................................................\
...............
211-00-9
Power Steering System Filling ........................................................................\
....................
211-00-10
Power Steering System Vacuum Bleeding ........................................................................\
.
211-00-1
Steering System - General Information
211-00- 1
.
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Steering System
Special Tool(s) / General EquipmentAlignment Pins, Subframe
205-316 (15-097A)
15097
Simulator, Driver and
Passenger Air Bags and Side
Air Curtains
501-073 (40-016)
501073
The Ford approved diagnostic tool
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanicalor electrical damage.
Visual Inspection Chart
Electrical
Mechanical
• Battery
• Battery cables
• Steering anglesensor electrical
connector
• Power steering pump control
module electrical
connectors
• Power steering pump control
module ground
cable
• Power steering pump control
module ground
cable retaining
screw
• Steering angle sensor warning
indicator
• Fuse(s)
• Tire pressure(s)
• Loose tie-rod end(s)
• Loose strut and
spring assemblies or
ball joints
• Loose pinch bolts on steering column
shaft flexible coup-
ling
• Wheels and tires
• Power steering line fluid leaks
• Steering gear bellows 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 diagnostic tab within
the Ford approved diagnostic tool.
Components Tests
Steering Linkage
1. Grasp the steering wheel firmly and move it upand down and to the left and right without
turning the steering wheel to check the steering
column bearing for wear, steering column shaft
for wear, steering wheel for looseness and
steering column for looseness. If the steering
column bearing or the steering column shaft is
worn install a new steering column. If the
steering wheel or the steering column is loose,
tighten the steering wheel or the steering column
retaining bolts.
2. With the road wheels in the straight ahead position, gently turn the steering wheel to the
left and the right to check for free play in the
steering linkage.
3. There should be no excessive free play at the steering wheel rim. If there is excessive free
play, CHECK the tie-rod inner and outer ball
joints, REFER to Tie-Rod Component Test in
this procedure. CHECK the steering column
universal joint, REFER to Steering Column
Universal Joint Component Test in this
procedure. If there is no free play in the tie-rod
and the steering column, install a new steering
gear.
Tie-Rod
CAUTION: Steering gear boots must be
handled carefully to avoid damage. Use
new steering boot clamps when installing
the steering gear boots.
NOTE: Noises such as knocks, which may appear
to originate from the steering linkage, may also be
generated by front suspension components.
REFER to: Noise, Vibration and Harshness (NVH)
(100-04 Noise, Vibration and Harshness,
Diagnosis and Testing).
G1059437en2008.50 Kuga8/2011
211-00- 2
Steering System - General Information
211-00- 2
DIAGNOSIS AND TESTING
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