all FORD KUGA 2011 1.G Workshop Manual

6.
E99208
7.Torque: 115Nm
E101643
8.Refer to: Wheel Bearing and Wheel Hub (204-02
Rear Suspension, Removal and Installation).
9. Refer to: Spring(204-02 Rear Suspension,
Removal and Installation).
G1000760en2008.50 Kuga8/2011
204-02- 24
Rear Suspension
204-02- 24
REMOVAL AND INSTALLATION
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Spring(15 621 0)
Special Tool(s)204-167
Compressor, Coil Spring
14042
204-215
Adapter for 204-167
15111
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. CAUTION: Make sure that the ball joint ball does not rotate.
Torque: 70Nm
E98878
3.Install the Special Tool(s): 204-167, 204-215
E98877
1
2
204-167
204-215
Installation
1.To install, reverse the removal procedure.
G1000236en2008.50 Kuga8/2011
204-02- 25
Rear Suspension
204-02- 25
REMOVAL AND INSTALLATION
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SECTION 204-04 Wheels and Tires
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
SPECIFICATIONS
204-04-2
Specifications ........................................................................\
..............................................
DESCRIPTION AND OPERATION 204-04-3
Wheels and Tires (Overview) ........................................................................\
.....................
204-04-3
Tire/wheel rim combinations ........................................................................\
.......................
204-04-3
Use of snow chains ........................................................................\
....................................
204-04-3
Tire repair kit ........................................................................\
...............................................
204-04-4
Run-Flat Tires (Overview) ........................................................................\
...........................
204-04-4
Tires with Run-flat Properties ........................................................................\
.....................
204-04-5
Tire Pressure Monitoring System (TPMS) (Overview) ........................................................
204-04-5
Description of operation ........................................................................\
..............................
DIAGNOSIS AND TESTING 204-04-6
Wheels and Tires ........................................................................\
........................................
204-04-6
Inspection and Verification ........................................................................\
..........................
204-04-7
Symptom Chart ........................................................................\
...........................................
REMOVAL AND INSTALLATION 204-04-11
Wheel and Tire........................................................................\
...........................................
204-04- 1
Wheels and Tires
204-04- 1
.
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Tyre pressures (cold tyres) - Up to 80 km/h (50
mph)
Full load
Normal load
Tyre
size
Variant
Rear
Front
Rear
Front
bar
(psi)
bar
(psi)
bar
(psi)
bar
(psi)
4.2
(61)
4.2
(61)
4.2
(61)
4.2 (61)
T135/
90 R 17
All
Tyre pressures (cold tyres) - Up to 160 km/h
(100 mph)
Full load
Normal load
Tyre
size
Variant
Rear
Front
Rear
Front
bar
(psi)
bar
(psi)
bar
(psi)
bar (psi)
2.8
(41)
2.4
(35)
2.3
(33)
2.2 (32)
215/
65
R16
All
2.8
(41)
2.4
(35)
2.3
(33)
2.2 (32)
215/
70
R16
All
2.8
(41)
2.4
(35)
2.3
(33)
2.2 (32)
235/
60
R16
All
2.8
(41)
2.4
(35)
2.3
(33)
2.2 (32)
235/
55
R17
All
2.8
(41)
2.4
(35)
2.3
(33)
2.2 (32)
235/
55
RF17
All
2.8
(41)
2.4
(35)
2.2
(32)
2.1 (31)
235/
50
R18
All
2.8
(41)
2.4
(35)
2.2
(32)
2.1 (31)
235/
45
R19
All Tyre pressures (cold tyres) - Continuous speed
in excess of 160 km/h (100 mph)
Full load
Normal load
Tyre
size
Variant
Rear
Front
Rear
Front
bar
(psi)
bar
(psi)
bar
(psi)
bar (psi)
2.8
(41)
2.4
(35)
2.3
(33)
2.3 (33)
215/
65
R16
All
2.8
(41)
2.4
(35)
2.3
(33)
2.3 (33)
215/
70
R16
All
2.8
(41)
2.4
(35)
2.3
(33)
2.3 (33)
235/
60
R16
All
2.8
(41)
2.4
(35)
2.3
(33)
2.3 (33)
235/
55
R17
All
2.8
(41)
2.4
(35)
2.3
(33)
2.3 (33)
235/
55
RF17
All
2.8
(41)
2.4
(35)
2.3
(33)
2.3 (33)
235/
50
R18
All
2.8
(41)
2.4
(35)
2.3
(33)
2.3 (33)
235/
45
R19
All
G1000248en2008.50 Kuga8/2011
204-04-
2
Wheels and Tires
204-04- 2
SPECIFICATIONS
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Run-Flat Tires – Overview
Tires with Run-flat Properties
E68867
2
1
3
2
4
1
3
BA
Description
Item
Standard tire after pressure loss
A
Tire with run-flat properties after pressure
loss
B
Wheel position with correct tire pressure
1Description
Item
Wheel position with insufficient tire
pressure
2
Tires
3
Reinforced sidewall
4
In addition to the standard tires, run-flattires are
also optionally available. These tires have a
reinforced sidewall and provide the advantage that
the tire maintains its shape to a large extent even
in the event of insufficient tire pressure. This
ensures that the vehicle handling remains stable.
Advantage:
• These tires maintain their shape to a large extent, even in the event of insufficient tire
pressure. This ensures that the vehicle handling
remains stable.
Special wheel rims (EH2) and a tire pressure
monitoring system are needed for run-flat tires.
Standard tires can also be installed on the EH2
(EH = Extended Hump) wheel rims. Tires with
run-flat properties have the same size code and
the same appearance as standard tires.
With some tires, the code RFfor run-flat is included
in the tire designation, e.g. 205/55 RF16. Tires with run-flat properties have various different
codes on the sidewall, depending on the
manufacturer.
• The RFT logo
• "RUNFLAT" as an additional designation
• The additional designation "RSC" (RSC =
Runflat System Component)
• The additional designation "SSR" (SSR = Self
S upporting Run-Flat-Tire)
• The additional designation "SST" (SST = Self
S upporting Run-Flat- Tire)
WARNING: If a tire with run-flat properties
is used without air then the vehicle speed
must not exceed 80 km/h and the vehicle
must not be driven for distances in excess
of 80 km.
Note: Vehicles equipped at the factory with run-flat
tires do not feature a tire repair kit or a spare wheel.
G1000256en2008.50 Kuga8/2011
204-04- 4
Wheels and Tires
204-04- 4
DESCRIPTION AND OPERATION
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Tire Pressure Monitoring System (TPMS) – Overview
Description of operation
The tire pressure monitoring system is able to
detect loss of air in a tire at an early stage and warn
the driver. Because it can only compare the
behavior of the tires with each other, it is not
possible to draw conclusions about the absolute
tire pressure. It is also not possible to monitor the
spare tire pressure. In order for the system to
operate correctly, the tire pressures must be
regularly checked and corrected and the system
subsequently initialized (see below).
The tire pressure monitoring system used here,
depending on the equipment level, is built into the
anti-lock braking system (ABS) as an extra function
and therefore does not have its own sensors.
The ABS module determines the loss of pressure
in the tires by calculation using the wheel speed
sensors of the ABS system. If a tire loses pressure,
its diameter decreases and the speed of the wheel
therefore increases. If the ABS module detects
such a loss in pressure, it sends a signal to the
instrument cluster via the CAN bus and a warning
message is displayed in the driver information
system. The warning threshold depends among
other things on the dimension of the tires being
used, the vehicle operating conditions and the
status at the last initialization. Since neither the
absolute tire pressure nor the position of the tire is
known, after a tire pressure warning the pressure
of all the tires must be checked and the system
re-initialized. If necessary, the cause of the loss of
pressure must be investigated.
Furthermore, regular pressure checks are
necessary. The system must be initialized after a
tire is changed, winter or summer tires fitted, the
pressures corrected or adjusted to suit the vehicle
load. This can be done by the driver using the
driver information system. For further information,
see: Owner’s Manual.
G1001290en2008.50 Kuga8/2011
204-04-5
Wheels and Tires
204-04- 5
DESCRIPTION AND OPERATION
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Wheels and Tires
Inspection and Verification
Visual Inspection Chart
MechanicalWheel(s)Tire(s)
Tire pressure(s) * Wheel nuts
Wheel studs
* Vehicles equipped with a tire deflation detection system (DDS) must be inspected for correct operation using the Ford approved diagnostic tool.
To maximize tire performance, inspect the tires for
signs of incorrect inflation and uneven wear which
may indicate a need for balancing, rotation or
suspension alignment. Tires should also be
checked frequently for cuts, stone bruises,
abrasions, blisters and for objects that may have
become embedded in the tread. More frequent
inspections are recommended when rapid or
extreme temperature changes occur or when road
surfaces are rough or occasionally littered with
foreign material.
As a further visible check of tire condition, tread
wear indicators are molded into the bottom of the
tread grooves. When these indicator bands become
visible, new tires must be installed.
Tire Wear Diagnosis
Uneven wear is usually caused by either excessive
camber or excessive toe on tires.
Sometimes incorrect toe settings or worn struts will
cause severe `cupping' or `scalloped' tire wear on
non-driven wheels.
Severely incorrect toe settings will also cause other
unusual wear patterns.
Tire Vibration Diagnosis
A tire vibration diagnostic procedure always begins
with a road test. The road test and customer
interview (if available) will provide much of the
information needed to find the source of a vibration. During the road test, drive the vehicle on a road
that is smooth and free of undulations. If vibration
is apparent, note and record the following:
– the speed at which the vibration occurs.
– what type of vibration occurs in each speed
range.
– mechanical or audible
– how the vibration is affected by changes in the following:
– engine torque
– vehicle speed
– engine speed
– type of vibration - sensitivity: – torque sensitive
– vehicle speed sensitive
– engine speed sensitive
The following explanations help isolate the source
of the vibration.
Torque Sensitive
This means that the condition can be improved or
made worse by accelerating, decelerating,
coasting, maintaining a steady vehicle speed or
applying engine torque.
Vehicle Speed Sensitive
This means that the vibration always occurs at the
same vehicle speed and is not affected by engine
torque, engine speed or the transmission gear
selected.
G1061329en2008.50 Kuga8/2011
204-04- 6
Wheels and Tires
204-04- 6
DIAGNOSIS AND TESTING
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Engine Speed Sensitive
This means that the vibration occurs at varying
vehicle speeds when a different transmission gear
is selected. It can sometimes be isolated by
increasing or decreasing engine speed with the
transmission in NEUTRAL or by stall testing with
the transmission in gear. If the condition is engine
speed sensitive, the cause is probably not related
to the tires.
If the road test indicates that there is tire whine,
but no shake or vibration, the noise originates with
the contact between the tire and the road surface.A thumping noise usually means that the tire is flat
or has soft spots making a noise as they slap the
roadway. Tire whine can be distinguished from axle
noise. Tire whine remains the same over a range
of speeds.
A complete road test procedure is described in
Section 100-04.
REFER to:
Noise, Vibration and Harshness (NVH)
(100-04 Noise, Vibration and Harshness,
Diagnosis and Testing).
Symptom Chart
Action
Possible Sources
Symptom
• ADJUST the tire pressure andreset the DDS. For additional
information REFER to the
owners guide.
• Loss of tire pressure.
• DDS warning lamp illuminated
• REFER to the DDS resetprocedure. For additional
information REFER to the
owners guide.
• The DDS reset procedure was
not carried out after adjustment
of the tire pressure.
• DDS warning lamp illuminated
with the correct tire pressure
• ADJUST the tire pressure andreset the DDS. For additional
information REFER to the
owners guide.
• The DDS reset procedure was
carried out under incorrect tire
conditions.
• DDS warning lamp not illumin-
ated when one or more tire(s)
have the incorrect tire pressure
• REFER to the DDS resetprocedure. For additional
information REFER to the
owners guide.
• The DDS reset procedure was
not completed.
• DDS reset command was not
confirmed
• REFER to the Ford approveddiagnostic tool.
• Anti-lock brake system (ABS)
module.
• DDS failure warning display
• ADJUST the tire pressure(s).
• Tire(s) under-inflated.
• Tire(s) show excess wear on
edge of tread
• CORRECT as necessary.
• Vehicle overloaded.
• ADJUST the wheel alignment.REFER to: Suspension System
(204-00 Suspension System
- General Information,
Diagnosis and Testing).
• Incorrect wheel alignment.
• ADJUST the tire pressure(s).
• Tire(s) over-inflated.
• Tire(s) show excess wear in
center of tread
• ADJUST the tire pressure(s).
• Incorrect tire pressure(s).
• Other excessive tire wear
concerns
G1061329en2008.50 Kuga8/2011
204-04- 7
Wheels and Tires
204-04- 7
DIAGNOSIS AND TESTING
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Action
Possible Sources
Symptom
• ROTATE the wheel and tireassemblies.
• Wheel and tire assemblies
need rotating.
• ADJUST the wheel alignment.REFER to: Suspension System
(204-00 Suspension System
- General Information,
Diagnosis and Testing).
• Incorrect wheel alignment.
• CORRECT as necessary.
• Vehicle overloaded.
• TIGHTEN or INSTALL newsuspension components as
necessary.
REFER to: Front Strut and
Spring Assembly (204-01
Front Suspension, Disas-
sembly and Assembly).
• Loose or leaking front strut and
spring assembly.
• INSTALL new wheel bearingsas necessary.
REFER to: Front Wheel
Bearing (204-01 Front
Suspension, Removal and
Installation).
• Wheel bearings worn.
• CHECK or INSTALL newsuspension components as
necessary.
• Suspension components,
bushings and ball joints.
• BALANCE the wheel and tireassemblies. Using a suitable
dial indicator gauge and holding
fixture, CHECK lateral and
radial runout of the wheel and
tire assemblies. INSTALL new
wheel and tire assemblies as
necessary.
REFER to: Wheel and Tire
(204-04 Wheels and Tires,
Removal and Installation).
• Excessive lateral or radial
runout of wheel or tire.
• INSPECT the wheel rims fordamage. BALANCE the wheel
and tire assemblies. Using a
suitable dial indicator gauge
and holding fixture, CHECK
lateral and radial runout of the
wheel and tire assemblies.
INSTALL new wheel and tire
assemblies as necessary.
REFER to: Wheel and Tire
(204-04 Wheels and Tires,
Removal and Installation).
• Damaged wheel.
• Wobble or shimmy affecting
wheel runout
G1061329en2008.50 Kuga8/2011
204-04- 8
Wheels and Tires
204-04- 8
DIAGNOSIS AND TESTING
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Action
Possible Sources
Symptom
• CHECK or INSTALL new wheelbearings as necessary.
REFER to: Front Wheel
Bearing (204-01 Front
Suspension, Removal and
Installation).
• Front wheel bearing.
• CHECK or INSTALL newsuspension components as
necessary.
• Suspension components.
• Excessive vehicle vibration,
rough steering
• ADJUST the tire pressure(s).
• Incorrect tire pressure(s).
• Vehicle vibrations from wheels
and tires
• BALANCE the wheel and tireassemblies.
• Wheel or tire imbalance.
• INSTALL a new tire(s) asnecessary.
REFER to: Wheel and Tire
(204-04 Wheels and Tires,
Removal and Installation).
• Uneven tire wear.
• CHECK the brake disc forforeign material.
• Brake disc imbalance.
• REMOVE the water.
• Water in tire(s).
• INSTALL a new wheel and tireassembly.
REFER to: Wheel and Tire
(204-04 Wheels and Tires,
Removal and Installation).
• Bent wheel.
• SPIN the wheel on the vehicle.EXAMINE the area where the
tire and the wheel meet. If that
section of the tire appears to
waver while being rotated, the
tire bead may not be correctly
seated on the wheel. REMOVE
the tire and CLEAN the bead
seat areas on both wheel and
tire.
• Incorrectly seated tire bead.
• BALANCE the wheel and tireassemblies. Using a suitable
dial indicator gauge and holding
fixture, CHECK the lateral and
radial runout of the wheel and
tire assemblies. INSTALL new
wheel and tire assemblies as
necessary.
REFER to: Wheel and Tire
(204-04 Wheels and Tires,
Removal and Installation).
• Excessive lateral or radial
runout of wheel or tire.
G1061329en2008.50 Kuga8/2011
204-04- 9
Wheels and Tires
204-04- 9
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