206-00 FORD KUGA 2011 1.G User Guide

Action
Possible Sources
Symptom
• INSTALL new brake shoes orbrake pads.
REFER to: Brake Pads (206-03
Front Disc Brake, Removal
and Installation).
• Worn or damaged brake shoes
or brake pads.
• Brake noise
• GO toPinpoint Test E.
• Brake booster.
• GO toPinpoint Test F.
• Brake booster.
• Seized brake pedal pivot.
• Slow or incomplete brake pedal
return
Pinpoint Tests
PINPOINT TEST A : PEDAL GOES DOWN FAST
DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
A1: PRESSURIZE THE SYSTEM
1 Pump the foot brake rapidly five times.
• Does the brake pedal height build up and then hold?
zYe s
CHECK parking brake adjustment and
ADJUST as necessary.
REFER to: Parking Brake Cable Adjustment
(206-05 Parking Brake and Actuation,
General Procedures).
If the condition still exists. 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 A2.
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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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DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
B2: CHECK FOR BRAKE SYSTEM LEAKS
1 Check for external brake system leaks.
• 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 B3.
B3: 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
GO to B4.
B4: CHECK THE BRAKE BOOSTER CHECK VALVE
1 Disconnect the brake booster check valve
vacuum hose at the manifold.
2Blow into the hose attached to the brake booster
check valve.
• Does air pass through the valve?
zYe s INSTALL a new brake booster check valve.
zNoGO to B5.
B5: CHECK THE BRAKE BOOSTER CHECK VALVE VACUUM
1 Run the engine at idle.
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DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
2 Using a suitable vacuum gauge, check the
vacuum pressure.
• Is the vacuum pressure above 40.5 kPa (0.4 bar) with the brake booster non-operational?
zYe s
VERIFY the customer concern.
zNoINSTALL a new brake booster check valve
vacuum hose. TEST the system for normal
operation.
PINPOINT TEST C : BRAKE LOCK UP DURING LIGHT BRAKE PEDAL FORCE
DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
C1: CHECK THE BRAKE BOOSTER
1 Check the brake booster push rod alignment
and pedal travel.
• Is the push rod and pedal travel OK?
zYe s TEST the brake pedal application. GO to
Pinpoint Test D.
zNo
INSTALL a new brake booster. TEST the
system for normal operation.
PINPOINT TEST D : EXCESSIVE BRAKE PEDAL EFFORT
DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
D1: CHECK BRAKE APPLICATION
1 With the engine off, apply and release the brake
pedal five times to deplete all vacuum from the
brake booster. Apply the brake pedal, hold with
light pressure. Start the engine.
• Does the brake pedal hold?
zYe s GO to D2 .
zNo
GO to D3 .
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DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
D2: CHECK THE BRAKE BOOSTER FOR LEAKS
1 Run the engine at approximately 1000 rpm,
release the accelerator pedal and turn the
engine off. Wait 90 seconds and apply the
brakes. Two or more brake applications should
be power assisted.
• Does the brake booster work?
zYe s VERIFY the customer concern.
zNoGO to D4 .
D3: CHECK THE BRAKE PEDAL LINKAGE
1 Disconnect the actuator rod from the pedal pin
and fully depress the brake pedal.
• Did the pedal move freely?
zYe s VERIFY the customer concern.
zNoINSTALL new brake pedal bushings. TEST
the system for normal operation.
D4: CHECK THE BRAKE BOOSTER CHECK VALVE
1 Disconnect the brake booster check valve
vacuum hose at the manifold.
2Blow into the hose attached to the brake booster
check valve.
• Does air pass through the valve?
zYe s INSTALL a new brake booster check valve.
TEST the system for normal operation.
zNoGO to D5 .
D5: CHECK THE BRAKE BOOSTER CHECK VALVE VACUUM
1 Run the engine at idle.
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DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
2 Using a suitable vacuum gauge, check the
vacuum pressure.
• Is the vacuum pressure above 40.5 kPa (0.4 bar) with the brake booster non-operational?
zYe s
GO to D6 .
zNo
INSTALL a new vacuum hose and fittings.
TEST the system for normal operation.
D6: CHECK THE BRAKE BOOSTER
1 Check the brake booster. REFER to the Brake
Booster Operation Check in this procedure.
• Is the brake booster OK?
zYe s VERIFY the customer concern.
zNoINSTALL a new brake booster. TEST the
system for normal operation.
PINPOINT TEST E : BRAKE NOISE
DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
E1: CHECK FOR PEDAL NOISE
1 Run the engine at idle for 10 seconds or longer.
2Apply the brake pedal and listen for noise.
3Compare results with a known good system.
• Was a noise present?
zYe s GO to E2.
zNoVERIFY the customer concern.
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DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
E2: CHECK THE BRAKE BOOSTER
1 Check the brake booster push rod alignment
and travel.
• Is the push rod and pedal travel OK?
zYe s 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
INSTALL a new brake booster. TEST the
system for normal operation.
PINPOINT TEST F : SLOW OR INCOMPLETE BRAKE PEDAL RETURN
DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
F1: CHECK FOR BRAKE PEDAL RETURN
1 Run the engine at approximately 1200 rpm
whilst making several brake applications.
2Pull the brake pedal upwards with approximately
44.5 N (10 lbs) force.
3Release the brake pedal and measure the
distance to the floor panel and note the reading.
4Make a hard brake application.
5Release the brake pedal and measure the
distance to the floor panel and note the reading.
6Compare the measurements.
• Did the brake pedal return to its original posi- tion?
zYe s
VERIFY the customer concern.
zNoGO to F2.
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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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4. Remove the vacuum hose from the brakebooster. Manifold vacuum should be available
at the brake booster end of the hose with the
engine at idle speed and the transaxle in the
NEUTRAL position. Make sure that all unused
vacuum outlets are correctly capped, hose
connectors are correctly secured and vacuum
hoses are in good condition. When it is
established that manifold vacuum is available
to the brake booster, connect the vacuum hose
to the brake booster and repeat Step 3. If no
downward movement of the brake pedal is felt,
install a new brake booster.
5. Operate the engine a minimum of 10 seconds at approximately 1200 rpm. Stop the engine and
let the vehicle stand for 10 minutes. Then, apply
the brake pedal with approximately 89 N (20 lb)
force. The pedal feel (brake application) should
be the same as that noted with the engine
operating. If the brake pedal feels hard (no
power assist), install a new vacuum check valve
and then repeat the test. If the brake pedal still
feels hard, install a new brake booster. If the
brake pedal movement feels spongy, 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).
Brake Master Cylinder
Usually, the first and strongest indicator of anything
wrong with the braking system is a feeling through
the brake pedal. In diagnosing the condition of the
brake master cylinder, check pedal feel as
evidence of a brake concern. Check for the red
brake warning indicator illumination and the fluid
level in the master cylinder reservoir.
Normal Conditions
The following conditions are considered normal
and are not indications that the brake master
cylinder is in need of service.
– Modern brake systems are not designed to
produce as hard a pedal effort as in the past.
Complaints of light pedal efforts should be compared to pedal efforts of another vehicle, of
the same model and year.
– During normal operation of the brake pedal, the fluid level in the reservoir will rise during brake
pedal application and fall during release. The
net fluid level (i.e., after brake pedal application
and release) will remain unchanged.
– A trace of brake fluid will exists on the brake booster shell below the master cylinder
mounting flange. This results from the normal
lubricating action of the master cylinder bore
end seal.
– The fluid level will fall with brake shoe and lining wear.
Abnormal Conditions
NOTE: Prior to performing any diagnosis, make
sure the brake system warning indicator is
functional.
Changes in brake pedal feel or travel are indicators
that something could be wrong with the braking
system. The diagnostic procedure and techniques
use brake pedal feel, warning indicator illumination
and low brake fluid level as indicators in diagnosing
braking system concerns. The following conditions
are considered abnormal and indicate that the
brake master cylinder is in need of service.
– The brake pedal goes down fast. This could be caused by an external or internal leak.
– The brake pedal eases down slowly. This could be caused by an external or internal leak.
– The brake pedal is low and or feels spongy. This condition may be caused by no fluid in the brake
master cylinder reservoir, reservoir cap vent
holes clogged or air in the hydraulic system.
– The brake pedal effort is excessive. This may be caused by a bind or obstruction in the pedal
or linkage, clogged fluid control valve or
insufficient booster vacuum.
– The rear brakes lock up during light pedal force. This may be caused by incorrect tire pressures,
grease or fluid on the brake shoes and linings,
damaged brake shoes and linings, incorrectly
adjusted parking brake, or damaged or
contaminated brake pressure control valves.
– The brake pedal effort is erratic. This condition could be caused by a brake booster malfunction,
extreme caliper piston knock back or incorrectly
installed brake shoes and linings.
– The red brake warning indicator is ON. This may be caused by low fluid level, ignition wire routing
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too close to the fluid level indicator assembly,
or float assembly damage.
Bypass Condition Test
1. Check the fluid in the brake master cylinderreservoir. Fill the brake master cylinder reservoir
if low or empty.
2. Observe the fluid level in the brake master cylinder reservoir. If after several brake
applications, the fluid level remains the same,
measure the wheel turning torque required to
rotate the wheels with the brakes applied as
follows:
Place the transaxle in the NEUTRAL position.
Raise and support the vehicle. REFER to: (100-02
Jacking and Lifting) Jacking (Description and Operation),
Lifting (Description and Operation).
Apply the brakes with a minimum of 445 N (100
lb) and hold for approximately 15 seconds. With
the brakes still applied, exert a torque on the front
wheels of 10.1 Nm (75 lb ft). If either wheel rotates,
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).
Non-Pressure Leaks
Any empty brake master cylinder reservoir
condition may be caused by two types of
non-pressure external leaks.
Type 1: An external leak may occur at the brake
master cylinder reservoir cap because of incorrect
positioning of the gasket and cap. Reposition the
cap and gasket.
Type 2: An external leak may occur at the brake
master cylinder reservoir mounting seals. Service
such a leak by installing new seals.
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