AIR CON FORD KUGA 2011 1.G Workshop Manual

DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
B2: INSPECT THE STRUT AND SPRING ASSEMBLIES AND SHOCK ABSORBERS FOR LEAKS
NOTE:Make sure that the oil is not from another
source.
1 Inspect the strut and spring assemblies and
shock absorbers for signs of oil weepage or
leaks. Refer to weepage and leakage conditions
in the Strut or Shock Absorber Testing
component test in this procedure.
• Are the struts or shock absorbers leaking?
zYe s INSTALL new struts or shock absorbers as
necessary.
REFER to: Front Strut and Spring Assembly
(204-01 Front Suspension, Removal and
Installation).
zNo
GO to B3.
B3: INSPECT THE SPRINGS AND STABILIZER BAR(S)
1 Inspect the springs and stabilizer bar(s) for
damage.
• Are the springs or stabilizer bar(s) damaged?
zYe s INSTALL new springs or stabilzer bar(s).
REFER to:
Front Strut andSpring Assembly (204-01 Front
Suspension, Removal and Installation),
Front Stabilizer Bar (204-01 Front Suspension,
Removal and Installation),
Rear Stabilizer Bar Link (204-02 Rear Suspen-
sion, Removal and Installation).
zNo
GO to B4.
G1080717en2008.50 Kuga8/2011
204-00- 9
Suspension System - General Information
204-00- 9
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DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
B4: INSPECT THE SUSPENSION BUSHINGS
1 Inspect the suspension bushings for excessive
wear or damage.
• Are the bushings worn or damaged?
zYe s INSTALL new components as necessary.
REFER to:
Lower Arm (204-01 Front Suspension, Removal
and Installation),
Front Strut and Spring Assembly (204-01 Front
Suspension, Removal and Installation),
Front Stabilizer Bar (204-01 Front Suspension,
Removal and Installation),
Rear Stabilizer Bar Link (204-02 Rear Suspen-
sion, Removal and Installation).
zNo
GO to B5.
B5: INSPECT THE SUSPENSIONS LOWER ARM BALL JOINTS
1 Carry out the Ball Joint Inspection component
test in this procedure.
• Is the lower arm ball joint or gaiter damaged?
zYe s INSTALL new lower arm.
REFER to: Lower Arm (204-01 Front
Suspension, Removal and Installation).
TEST the system for normal operation.
zNo
GO to B6.
B6: INSPECT THE WHEEL BEARINGS
1 Check the wheel bearings.
• Are the wheel bearings damaged?
zYe s INSTALL a new wheel hub(s).
REFER to: Wheel Hub (204-01 Front
Suspension, Removal and Installation).
zNo
GO to B7.
G1080717en2008.50 Kuga8/2011
204-00- 10
Suspension System - General Information
204-00- 10
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DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
B7: INSPECT THE WHEEL AND TIRES
1 Inspect the tires for uneven wear.
• Is there uneven wear?
zYe s REFER to the symptom chart.
zNoGO to B8.
B8: INSPECT THE STRUT AND SPRING ASSEMBLY AND REAR SUSPENSION SPRING INTERFACE
1 Loosen the strut and spring assemblies and
shock absorbers top and bottom mounting bolts
and nuts. Tighten the mounting bolts and nuts.
REFER to:
Specifications (204-01 Front Suspension,
Specifications),
Specifications (204-02 Rear Suspension,
Specifications).
• Is the concern still evident?
zYe s GO to B9.
zNoVehicle condition corrected.
B9: INSPECT THE STRUT AND SPRING ASSEMBLIES AND SHOCK ABSORBER COMPONENTS
1 Check that the spring is correctly located on the
spring seat and has not moved.
2Disassemble the strut and spring and assembly
and inspect the individual components.
REFER to:
Front Strut and Spring Assembly
(204-01 Front Suspension, Removal and
Installation).
3 Inspect the shock absorber top mount for wear
or damage.
G1080717en2008.50 Kuga8/2011
204-00-
11
Suspension System - General Information
204-00- 11
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DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
4 Carry out the Strut or Shock Absorber Testing
component test in this procedure.
• Are any of the strut and spring assemblies or shock absorber components damaged?
zYe s
INSTALL new components as necessary.
REFER to:
Front Strut and Spring Assembly (204-01 Front
Suspension, Removal and Installation),
Spring (204-02 Rear Suspension, Removal and
Installation).
zNo
REINSTALL the strut and spring assemblies
or shock absorbers. GO to C1.
PINPOINT TEST C : VEHICLE LEAN
DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
C1: VEHICLE LEAN
1 Detach the load levelling shock absorbers from
the wheel knuckles.
• Does the vehicle lean?
zYe s Install new rear springs.
REFER to: Spring(204-02 Rear Suspension,
Removal and Installation).
TEST the system for normal operation.
zNo
CARRY OUT the Load-Levelling Shock
Absorber Component Test in this section.
Component Tests
Raise and support the vehicle. REFER to: (100-02
Jacking and Lifting)
Jacking (Description and Operation),
Lifting (Description and Operation).
Ball Joint Inspection
1. Firmly grasp the outer end of the suspension
lower arm and try to move it up and down,
watching and feeling for any movement. Free
movement will usually be accompanied by an
audible "click''. There should be no free
movement. 2. If there is any free movement install a new lower
arm.
REFER to: Lower Arm (204-01 Front
Suspension, Removal and Installation).
G1080717en2008.50 Kuga8/2011
204-00- 12
Suspension System - General Information
204-00- 12
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3. If a new lower arm is installed it will benecessary to check and adjust the front wheel
alignment.
REFER to: Front Toe Adjustment (204-00
Suspension System - General Information,
General Procedures)
/ Rear Toe Adjustment (204-00 Suspension
System - General Information, General
Procedures).
Strut or Shock Absorber Inspection
NOTE: Inspect the struts or shock absorber for
signs of oil weepage or leaks. Make sure that the
oil is not from another source.
Weepage:
• deposits a thin film of oil on the strut and spring assembly or shock absorber.
• is normally noticed due to a collection of dust on the strut and spring assembly or shock
absorber.
• occurs during the normal running-in period of 4800 - 8050 km. After this period no new signs
of oil should be visible.
• does not require new struts or shock absorbers to be installed.
Leakage:
• covers the entire strut and spring assembly or shock absorber with oil.
• will drip oil onto the surrounding suspension components.
• requires new struts or shock absorbers to be installed.
Strut or Shock Absorber Testing
NOTE: Struts or shock absorbers must be tested
in the vertical position.
1. Remove both strut and spring assemblies or shock absorbers. The piston rods should extend.
• Disassemble the strut and spring assemblies.
REFER to: Front Strut and Spring Assembly
(204-01 Front Suspension, Removal and
Installation).
2. Compress the piston rods. Both piston rods should offer the same resistance when
compressing.
3. Compress and release the piston rods. The piston rods should extent equally. 4. Compress and pull the piston rod in the vertical
position. Feel if the resistance force at the point
of direction change-over is perceptible without
a lag. If a lag is perceptible it is an indication of
damper valve damage and new struts or shock
absorbers must be installed. REFER to:
Front Strut and Spring Assembly (204-01 Front
Suspension, Removal and Installation),
Spring (204-02 Rear Suspension, Removal and
Installation).
Load-Levelling Shock Absorber
1. With the vehicle unladen, measure and note the dimensions between the base of the wheel rim
and the top of the rear fender on both sides.
• The measurements on both sides should be approximately equal.
2. With a load of 4 average size adults and a 100 kg weight, measure and note the dimensions
between the base of the wheel rim and the top
of the rear fender on both sides.
3. NOTE: Due to the internal ratchet mechanism of the suspension components, the height
of the rear of the vehicle should rise during
the road test.
With a load of 4 average size adults and a 100
kg weight, drive the vehicle for 3 km on a road
of normal condition.
4. With a load of 4 average size adults and a 100 kg weight, measure and note the dimensions
between the base of the wheel rim and the top
of the rear fender on both sides.
5. If the dimensions on both sides are no longer approximately equal, install new load levelling
shock absorbers.
REFER to: Spring(204-02 Rear Suspension,
Removal and Installation).
6. NOTE: Due to the internal ratchet mechanism of the suspension components, the height
of the rear of the vehicle should rise during
the road test.
If the dimensions are approximately equal,
unload the vehicle and drive the vehicle for 3
km on a road of normal condition.
7. With the vehicle unladen, measure and note the dimensions between the base of the wheel rim
and the top of the rear fender on both sides.
Check the final dimensions with the original
dimensions taken in the unladen condition.
G1080717en2008.50 Kuga8/2011
204-00- 13
Suspension System - General Information
204-00- 13
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8. If the final dimensions do not approximatelyequal the original dimensions, install new load
levelling shock absorbers.
REFER to: Spring(204-02 Rear Suspension,
Removal and Installation).
9. If the final dimensions approximately equal the original dimensions, verify the customer
concern.
G1080717en2008.50 Kuga8/2011
204-00- 14
Suspension System - General Information
204-00- 14
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SECTION 204-01 Front Suspension
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
SPECIFICATIONS
204-01-2
Specifications ........................................................................\
..............................................
DESCRIPTION AND OPERATION 204-01-3
Front Suspension (Component Location) ........................................................................\
...
204-01-4
Front Suspension (Overview) ........................................................................\
.....................
204-01-4
Overview ........................................................................\
.....................................................
204-01-5
Spring and damper assembly ........................................................................\
.....................
204-01-6
Subframe ........................................................................\
....................................................
204-01-7
Stabilizer bar ........................................................................\
...............................................
REMOVAL AND INSTALLATION 204-01-8
(14 371 0)
Wheel Hub ........................................................................\
..............................
204-01-9
(14 411 0;
14 411 4;
Front Wheel Bearing
........................................................................\
...............
14 412 0;
14 414 4;
14 416 4)
204-01-13
(14 706 0;
14 707 0;
14 709 0)
Lower Arm
........................................................................\
..............................
204-01-15
(14 752 0)
Front Stabilizer Bar ........................................................................\
.................
204-01-20
(14 754 0;
14 754 4)
Front Stabilizer Bar Bushing
........................................................................\
...
204-01-21
(14 343 0)
Wheel Knuckle ........................................................................\
........................
204-01-26
(14 781 0;
14 782 0)
Front Strut and Spring Assembly
....................................................................
DISASSEMBLY AND ASSEMBLY 204-01-29
(14 783 4)
Front Strut and Spring Assembly ....................................................................
204-01-1
Front Suspension
204-01- 1
.
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Lower Arm(14 706 0; 14 707 0; 14 709 0)
Special Tool(s)204-605
Separator, Lower Arm Ball
Joint
E63772
204-609
Protection Cap, Ball Joint
Gaiter
E75372
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.
E98543
x7
3. Torque: 83Nm
E97635
4.If equipped.
Torque: 8
Nm
E75215
5.Special Tool(s): 204-605
E97732
204-605
G1000207en2008.50 Kuga8/2011
204-01- 13
Front Suspension
204-01- 13
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Front Stabilizer Bar(14 752 0)
Special Tool(s) / General Equipment205-316A
Alignment Pins, Subframe
15097A
Hydraulic Press
Transmission Jack
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.
E98543
x7
3. If equipped.
Torque: 8
Nm
E75215
4. CAUTION: Make sure that the ball joint
ball does not rotate.
On both sides.
Torque: 47.5
Nm
E91648
5. CAUTION: Make sure that the exhaustflexible pipe is not forcibly bent.
E98334
6.
E98346
G1000208en2008.50 Kuga8/2011
204-01- 15
Front Suspension
204-01- 15
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Wheel Knuckle(14 343 0)
Special Tool(s)204-052
Lever, Wheel Knuckle
14026A
204-602
Installer, Halfshaft
E62067
204-605
Separator, Lower Arm Ball
Joint
E63772
204-609
Protection Cap, Ball Joint
Gaiter
E75372
211-020
Separator, Ball Joint
13006
Removal
NOTE:Removal steps in this procedure may
contain installation details. 1.
E99184
2.
Refer to: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation).
3.
E99195
4.
E98543
x7
5. WARNING: Make sure that no load is placed on the brake hose.
Torque: 120Nm
G1000209en2008.50 Kuga8/2011
204-01- 21
Front Suspension
204-01- 21
REMOVAL AND INSTALLATION
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