ECT FORD KUGA 2011 1.G Repair Manual

Power assisted steering operating conditionVehicle stationary with engine off
Driving
Parking
REFER to steering
system NVH
concerns column F
REFER to steering
system NVH
concerns column E
REFER to
steering system
NVH concerns
column D
REFER to
steering
system NVH
concerns
column C
REFER to
steering
system NVH
concerns
column B
REFER to
steering
system NVH
concerns
column A
Steering system NVH concerns
Steering System operation condition (column A to F) FEDCBA
Driving condition
Noise
OX
Parking between lock stops, at engine idle and
also increased engine speed
Moan
XXOO
Driving, high engine rpm. Must be present from
new
Whine
OOXX
a) Parking between lock stops. Must be present
from new
Hiss
X
b) Holding steering wheel against lock stops. Must
be present from new
X
X
a) Parking at lock stop. Must be present from new
Lock stop impact
knock
X
b) Parking between lock stops, engine OFF. Must
be present from new
Mechanical knock
(power assisted
steering (PAS) off)
X
c) Parking between lock stops, engine ON (ball
joint knock)
Mechanical Knock
(PAS on)
X
d) Parking into lock stop and release (vehicle with
hydraulic power assisted steering (HPAS) only,
not for vehicles with electro-hydraulic power
assisted steering (EHPAS))
Hammer knock
XO
e) Driving, cobble stones, rough road (clonk). Must
be present from new
Hydraulic knock
(clonk)
XXXOXX
f) Parking, driving. cobble stones and rough roads
Column knock
OXX
O
Mainly driving on rough roads
Column rattle
X
Steering left and right at high frequency. Must be
present from new
Toc-toc
XO
X
When turning steering wheel
Grinding
OX
At engine start, low temperatures below -10°C
only
Zip
• X = Noise will most likely occur in this operating condition.
• O = Noise can possibly occur in this operating condition.
• Blank = Noise is unlikely to occur in this operating condition.
Step 3: According to each identified operating
condition (Column A, B, C, D, E, F), check each possible Steering System NVH concern with the
detail symptom charts below.
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Before conducting a vehicle test to identify a NVH
concern carry out the following checks.
1. Check the tire pressures and adjust tospecification, as necessary.
2. Make sure the steering system fluid is correct, the system is free of leaks and is operating
correctly.
3. Make sure the vehicle steering system temperature is the same as described at the
customer interview.
4. All evaluations must take place in a relatively quiet location.
5. The heating - air conditioning (A/C) fan and radio must be turned off during evaluations and
the windows closed.Symptom Chart
Power Steering Moan Noise
Test Condition
Listen for steering moan noise with the vehicle
parked, transmission in neutral and all windows
closed in the following test conditions.
1. Engine speed at idle with no steering action.
2. Engine speed at idle with slow 90 degrees persecond turning of the steering wheel.
3. Engine speed at 1250 +/- 50 rpm with no steering action.
4. Engine speed at 1250 +/- 50 rpm with slow 90 degrees per second turning of the steering
wheel.
Action
Possible Sources
Symptom
• CHECK the routing of thepower steering lines.
• CHECK the power steering line clamps are secure.
• CHECK the power steering lines for clearance from the
vehicle body, front axle cross-
member and steering gear.
Power steering lines.
Power steering system moan
noise – A continuous low pitched
humming noise occurs when the
steering wheel is turned and the
steering system is loaded. Noise
frequency changes with engine
rpm changes. Particularly
annoying at lower engine speed. FLUSH the power steering
system.
REFER to:
Power Steering
System Flushing (211-00
Steering System - General
Information, General Proced-
ures).
Incorrect power steering fluid.
Pressure pulses from the power
steering pump. Certain amount
of noise level acceptable, not a
safety critical item.
Power steering pump.
Power Steering Whine Noise
Test Condition
Listen for steering whine noise with the vehicle
parked, transmission in neutral and all windows
closed in the following test conditions. 1. Engine speed at 1800 +/- 50 rpm with no
steering action.
2. Engine speed at 1800 +/- 50 rpm with slow 90 degrees turning of the steering wheel.
3. Engine speed at 3000 +/- 50 rpm with no steering action.
4. Engine speed at 3000 +/- 50 rpm with slow 90 degrees turning of the steering wheel.
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Action
Possible Sources
Symptom
BLEED the power steering
system.
REFER to:Power Steering
System Vacuum Bleeding (211-
00 Steering System - General
Information, General Proced-
ures).
Power steering fluid aeration.
Power steering system whine
noise – a high pitched buzzing
sound like an electric motor or
drill. Whine occurs at the higher
engine rpm, 1500 - 5000 rpm,
frequency does not change if
system is loaded or not loaded. FLUSH the power steering
system.
REFER to:
Power Steering
System Flushing (211-00
Steering System - General
Information, General Proced-
ures).
Incorrect power steering fluid.
FLUSH the power steering
system.
REFER to:Power Steering
System Flushing (211-00
Steering System - General
Information, General Proced-
ures).
Overheated power steering fluid.
Certain amount of noise level
acceptable, not a safety critical
item.
Hydraulic operating condition of
the power steering pump.
Power Steering Hiss Noise
Test Condition
Listen for steering hiss noise with the vehicle
parked, transmission in neutral and all windows
closed in the following test conditions.
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Action
Possible Sources
Symptom
Certain amount of noise level
acceptable, not a safety critical
item.
Power steering system knock
noise – a damped, metallic knock
noise which only occurs at
steering condition with engine off
(very high efforts).
Power steering system knock
noise – a heavy loud repeating
sound like a knock on a door that
occurs in several driving and
steering conditions.
Certain amount of noise level
acceptable, not a safety critical
item.
Tolerances in the steering gear
components.
Power Steering Mechanical Knock Noise
(PAS on)
Test Condition
Listen for steering knock noise with the engine
speed at idle in the following test conditions (power
assist). 1. Turn the steering wheel to a steering lock and
return to center quickly.
2. Turn the steering wheel 90 degrees to the left and then 90 degrees to the right quickly.
Action
Possible Sources
Symptom
REFER to Steering System.
REFER to:Steering System (211-
00 Steering System - General
Information, Diagnosis and
Testing).
Worn tie-rod ball joints (inner and
outer ball joints).
Power steering system knock
noise – clear knock noise from
steering gear linkage area.
Power Steering Hammer Knock (Hydraulic)
Noise
Test Condition
Listen for steering knock noise with the engine
speed at idle in the following test conditions (for vehicles with hydraulic power assisted steering
only, not electro-hydraulic power steering).
1. Turn the steering wheel to a steering lock
position and return quickly.
Action
Possible Sources
Symptom
Certain amount of noise level
acceptable, not a safety critical
item.
Hydraulic noise created by pres-
sure impulses.
Power steering system knock
noise – loud, metallic sound if
hitting the suspension cross-
member with a hammer (sounds
like metallic noise but is created
by pressure impulse in gear and
return line).
Power Steering Hydraulic Knock/Clonk
Noise
Test Condition
Listen for steering knock/clonk noise in the
following test conditions with the windows closed. 1. Drive over cobbled roads at low speed 10-30
km/h (6-20 mph) with and without turning.
2. Drive over straight tar strips road rails or 25 mm tall harshness strips at low speed 10-30 km/h
(6-20 mph) both driving straight and with
moderate turning.
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Action
Possible Sources
Symptom
Certain amount of noise level
acceptable, not a safety critical
item.
Power steering return lines.
Power steering system knock/
clonk noise – sounds almost
identical to column knock that
occurs when driving and
cornering over cobbled stones or
rough roads. Noise may appear
to emanate from a location closer
to the floor than that for column
knock (Sounds like metallic noise
but is created by pressure
impulse in gear and return line –
similar to a sound like quickly
turning off a water tap). Certain amount of noise level
acceptable, not a safety critical
item.
High power assist gain of power
steering gear valve (steering gear
design - no quality issue).
Certain amount of noise level
acceptable, not a safety critical
item.
High power steering pump flow
rate (by design).
Power Steering Column Knock Noise
Test Condition
Listen for steering knock noise in the following test
conditions with windows closed. 1. Drive over cobbled stones at low speed 16-40
km/h (10-25 mph) with and without steering
input carefully listening for knock sounds.
2. Drive over straight tar strips, road rails or 25 mm tall harshness strips at low speed 16-40 km/h
(10-25 mph) both driving straight and with
moderate cornering.
Action
Possible Sources
Symptom
CHECK the steering column
retaining bolts and attachments
to the steering column and
secure if necessary.
Steering column or steering
column shaft.
Power steering system column
knock noise – a loose sounding
rattle or vibration coming from the
column. Noticeable by hearing
and touch. Check steering column and
intermediate shaft for free play or
loose components.
REFER to:
Steering System (211-
00 Steering System - General
Information, Diagnosis and
Testing).
Power Steering Toc-Toc Noise
Test Condition
Listen for steering toc-toc noise with the engine
speed at idle and the vehicle parked, automatic
transmission in "P" (PARK) or manual transmission
in neutral and the windows closed. 1. Turn the steering wheel from left to right abruptly
changing direction.
2. Drive the vehicle for low speed parking manoeuvres constantly changing steering
direction.
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Action
Possible Sources
Symptom
Certain amount of noise level
acceptable, not a safety critical
item.
Steering gear (design tolerance
in steering rack).
Power steering system toc-toc
noise – a metallic noise created
when changing direction of
steering wheel rotation during
parking manoeuvre or at stand-
still.
Power Steering Grinding Noise
Test Condition
Listen for steering grinding noise with the engine
speed at idle and the vehicle parked, automatic transmission in "P" (PARK) or manual transmission
in neutral and the windows closed.
1. Slowly turn the steering wheel from lock to lock.
2. Tilt and extend the steering column in various
positions and slowly turn the steering wheel
from lock to lock.
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Action
Possible Sources
Symptom
GO toPinpoint Test C.
• Cable(s)/hose(s).
• Powertrain/drivetrain mounts.
• Exhaust system.
• Belt/pulleys.
Idle boom/shake/vibration/
shudder
Suspension Noise and Vibration
Action
Possible Sources
Symptom
GO toPinpoint Test D.
• Suspension.
• Wheel bearings.
Wheel end vibration analysis
GO toPinpoint Test E.
• Trim panels.
• Air conditioning (A/C) system.
• Accessories.
Non-axle noise
Pinpoint Tests
NOTE:
These Pinpoint Tests are designed to take
the technician through a step-by-step diagnosis
procedure to determine the cause of a condition.
It may not always be necessary to follow the chart
to its conclusion. Carry out only the pinpoint test steps necessary to correct the condition. Then
check the operation of the system to make sure
the condition has been corrected.
After verifying that the condition has been
corrected, make sure all components removed
have been installed.
PINPOINT TEST A : SHAKE AND VIBRATION WHILE DRIVING
DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
A1: NEUTRAL COAST
1 Carry out the neutral coast test.
• Does the vibration disappear during the neutral coast test?
zYe s
GO to A2.
zNoGO to Pinpoint Test D.
A2: CHECK THE POWERTRAIN/DRIVETRAIN MOUNTS
1 Carry out the powertrain/drivetrain mount neut-
ralizing procedure
• Are the mounts OK?
zYe s Vehicle condition corrected. ROAD TEST as
necessary.
zNoINSTALL new powertrain/drivetrain mounts
as necessary. ROAD TEST as necessary.
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PINPOINT TEST B : TIP-IN MOAN
DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
B1: CHECK THE AIR CLEANER
1 Check the condition of the air cleaner mounts,
inlet tube, outlet tube, resonators and all other
components associated with the air induction
system for correct installation and tightness of
all connections.
• Are the components OK?
zYe s GO to B2.
zNoREPAIR or INSTALL new components as
necessary. ROAD TEST as necessary.
B2: CHECK THE EXHAUST SYSTEM
1 Carry out the exhaust system neutralizing
procedure.
• Is the exhaust system OK?
zYe s GO to B3.
zNoREPAIR as necessary. ROAD TEST as
necessary.
B3: CHECK THE POWER STEERING
1 Remove the accessory drive belt and test for
tip-in moan. REFER to:
Accessory Drive Belt (303-05 Accessory Drive
- 2.5L Duratec (147kW/200PS) - VI5, Removal
and Installation),
• Is the tip-in moan OK?
zYe s REPAIR the power steering as necessary.
REFER to: Steering System (211-00 Steering
System - General Information, Diagnosis
and Testing).
zNo
GO to B4.
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DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
B4: CHECK THE POWERTRAIN/DRIVETRAIN MOUNTS
1 Carry out the powertrain/drivetrain mount neut-
ralizing procedure
• Are the powertrain/drivetrain mounts OK?
zYe s Vehicle condition corrected. ROAD TEST as
necessary.
zNoINSTALL new powertrain/drivetrain mounts
as necessary. ROAD TEST as necessary.
PINPOINT TEST C : IDLE BOOM/SHAKE/VIBRATION/SHUDDER
DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
C1: CHECK THE CABLE/HOSES
1 Check the engine compartment for any
component that may have a touch condition
between the engine and body or chassis. For
example: control cable, air conditioning (A/C)
hoses, acceleration cable.
• Are the components OK?
zYe s GO to C2 .
zNo
REPAIR or INSTALL new components as
necessary. ROAD TEST as necessary.
C2: CHECK THE ENGINE COOLING RADIATOR
1 Check the engine cooling radiator mountings
and bushings for security and condition. Check
the radiator installation for any component that
may have a touch condition.
• Is the installation and bushings OK?
zYe s GO to C3 .
zNo
REPAIR or INSTALL new components as
necessary. ROAD TEST as necessary.
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DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
C3: CHECK THE EXHAUST SYSTEM
1 Carry out the exhaust system neutralizing
procedure.
• Is the exhaust system OK?
zYe s GO to C4 .
zNo
REPAIR as necessary. ROAD TEST as
necessary.
C4: CHECK THE POWERTRAIN/DRIVETRAIN MOUNTS
1 Carry out the powertrain/drivetrain mount neut-
ralizing procedure
• Are the powertrain/drivetrain mounts OK?
zYe s Vehicle condition corrected. ROAD TEST as
necessary.
zNoINSTALL new powertrain/drivetrain mounts
as necessary. ROAD TEST as necessary.
PINPOINT TEST D : WHEEL END VIBRATION ANALYSIS
DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
D1: INSPECT THE WHEELS AND TIRES
1 Inspect the wheels and tires.
REFER to:
Wheels and Tires (204-04 Wheels
and Tires, Diagnosis and Testing).
• Are the wheels and tires OK?
zYe s GO to D2 .
zNo
INSTALL new wheels or tires as necessary.
REFER to: Wheel and Tire (204-04 Wheels
and Tires, Removal and Installation).
ROAD TEST as necessary.
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