air bleeding FORD KUGA 2011 1.G User Guide

Component Bleeding
General EquipmentFluid Container
Bleeding
NOTE: Make sure that the vehicle is standing on
a level surface.
1. Refer to: Brake System Health and Safety
Precautions (100-00 General Information,
Description and Operation).
Vehicles with stability assist
2. Bleed the brake system using the
BleedMASTER function in the diagnostic tool.
Vehicles without stability assist
3.
E86914
4. CAUTION: The brake fluid reservoir
must remain full with new, clean brake
fluid at all times during bleeding.
Refer to: Specifications (206-00 Brake System
- General Information, Specifications).
E139915
G1464506en2008.50 Kuga8/2011
206-00- 22
Brake System - General Information
206-00- 22
GENERAL PROCEDURES
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Brake System Bleeding
General EquipmentFluid Container
NOTE: Make sure that the vehicle is standing on
a level surface.
1. Refer to: Brake System Health and Safety
Precautions (100-00 General Information,
Description and Operation).
Vehicles with stability assist
2. Bleed the brake system using the
BleedMASTER function in the diagnostic tool.
Vehicles without stability assist
3.
E86914
4. CAUTION: The brake fluid reservoir
must remain full with new, clean brake
fluid at all times during bleeding.
Refer to: Specifications (206-00 Brake System
- General Information, Specifications).
E139915
G1057428en2008.50 Kuga8/2011
206-00- 27
Brake System - General Information
206-00- 27
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E139456
Filling
23.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).
Refer to: Component Bleeding (206-00 Brake
System - General Information, General
Procedures).
G1420093en2008.50 Kuga8/2011
206-00- 34
Brake System - General Information
206-00- 34
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Brake System Pressure Bleeding
General EquipmentBrake/Clutch System Pressure Bleeder/Filler
NOTE: Make sure that the vehicle is standing on
a level surface.
1. Refer to: Brake System Health and Safety
Precautions (100-00 General Information,
Description and Operation).
Vehicles with stability assist
2. Bleed the brake system using the
BleedMASTER function in the diagnostic tool.
Vehicles without stability assist
3.
E86914
4.Refer to: Specifications (206-00 Brake System
- General Information, Specifications).
E139915
5. CAUTION: Make sure that the pressure within the brake system does not
exceed 1 bar.Using the brake/clutch system pressure
bleeder/filler, pressure bleed the system in
accordance with the manufacturer's instructions.
General Equipment: Brake/Clutch SystemPressure Bleeder/Filler
G1057429en2008.50 Kuga8/2011
206-00- 35
Brake System - General Information
206-00- 35
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Brake Caliper(12 243 0)
General EquipmentHose Clamp(s)
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: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation).
3. General Equipment: Hose Clamp(s)
Loosen: 90°
E94932
4.Refer to: Brake Pads (206-03 Front Disc Brake,
Removal and Installation).
5. Torque: 22,5
Nm
E95017
6. WARNING: Make sure that the brake
hose is not twisted and is correctly
located.
NOTE: This step is only necessary when
installing a new component.
Refer to: Front Brake Flexible Hose (206-03
Front Disc Brake, Removal and Installation).
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).
G1001204en2008.50 Kuga8/2011
206-03- 4
Front Disc Brake
206-03- 4
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Front Brake Flexible Hose
Removal
CAUTION:
Refer to:Brake System Health and Safety
Precautions (100-00 General Information,
Description and Operation).
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. WARNINGS:
Make sure that no load is placed on the
brake hose.
Be prepared to collect escaping fluid.
CAUTION: Make sure that all openings
are sealed.
1. Torque: 15
Nm
4. Torque: 23Nm
E99419
1
2
3
4
Installation
1. To install, reverse the removal procedure.
2. Refer to: Component Bleeding (206-00 Brake
System - General Information, General
Procedures).
G1001206en2008.50 Kuga8/2011
206-03- 5
Front Disc Brake
206-03- 5
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Brake Caliper(12 253 0)
General EquipmentHose Clamp(s)
Materials
Specification
Name
WSS-M6C57-A2
Brake Fluid - Super
DOT4
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: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation).
3.
E70112
1
2
4. General Equipment: Hose Clamp(s)
1.
2. Torque: 28
Nm
3. Torque: 35Nm
E70110
1
2
x2
3
5. CAUTION: Make sure that all openings
are sealed.
NOTE: Note the position of each component
before removal.
E70111
6. NOTE: This step is only necessary when
installing a new component.
Refer to: Rear Brake Flexible Hose (206-04
Rear Disc Brake, Removal and Installation).
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).
3.
CAUTION: Make sure that the mating
faces are clean and free of foreign
material.
Depress the brake pedal, check the brake fluid
level in the brake fluid reservoir and top up as
necessary with brake fluid.
Material: Brake Fluid - Super DOT4 (WSS-M6C57-A2) brake fluid
G1001208en2008.50 Kuga8/2011
206-04- 4
Rear Disc Brake
206-04- 4
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3.Torque: 28Nm
E99426
Installation
1.To install, reverse the removal procedure.
2. Refer to: Component Bleeding (206-00 Brake
System - General Information, General
Procedures).
G1001210en2008.50 Kuga8/2011
206-04- 6
Rear Disc Brake
206-04- 6
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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
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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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