brake system FORD KUGA 2011 1.G Repair Manual

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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Brake Disc Runout Check(12 221 0)
Special Tool(s) / General EquipmentDial Indicator Gauge (Metric)
205-069 (15-046)
15046
Holding Fixture, Dial Indicator
Gauge
205-070 (15-022A)
15022A
Holding Fixture, Dial Indicator
Gauge (Disc Brake)
206-003 (12-003)
12003
Micrometer 0-125 mm
Check
1. NOTE: The total dial indicator gauge readingshould not exceed 0.05 mm.
Using the special tools, measure the brake
disc runout on the inner face of the brake
disc (wheel and tire shown removed for
clarity).
1. Position the dial indicator gauge so that it contacts the brake disc approximately 10 mm
from the outer edge. 2. Slowly rotate the wheel and tire and note the
readings.
TIE0036133
2
206-0031
205-0701
205-0691
2. NOTE: Using paint or typing correction fluid,mark the position of the wheel in relation to
the wheel hub.
Remove the wheel and tire.
For additional information, refer to: Wheel
and Tire (204-04 Wheels and Tires, Removal
and Installation).
3. Remove the brake pads. For additional information, refer to:Brake
Caliper - Detach (206-03 Front Disc Brake,
Removal and Installation)
/ Brake Caliper -Detach (206-04 Rear Disc
Brake, Removal and Installation).
4. Install the wheel nuts and tighten the wheel nuts to 10 Nm, to hold the brake disc in
place.
5. NOTE: The total dial indicator gauge reading should not exceed 0.05 mm.
Using the special tools, measure the brake
disc runout on the inner and outer faces of
the brake disc (outer face measurement
shown).
1. Position the dial indicator gauge so that it contacts the brake disc approximately 10 mm
from the outer edge.
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2. Slowly rotate the brake disc and note thereadings.
TIE0035481
2
206-0031
205-0701
205-0691
6. NOTE: If any of the readings vary by morethan 0.015 mm or the brake disc thickness
is less than the specified minimum, a new
brake disc must be installed and the brake
disc runout re-checked.
Check the brake disc thickness variation.
For additional information, refer to:Specifications (206-00 Brake System -
General Information, Specifications).
• Using a suitable micrometer, measure the brake disc thickness at eight positions, 45
degrees apart and approximately 15 mm from
the outer edge of the brake disc.
MPU1201004
7. If all the brake disc runout measurementsand the thickness variation are within the
specifications, check the wheel balance.
8. If just the brake disc runout measurement with the wheel and tire fitted exceeds the
specification, the wheel and tire must be
rotated through 90 degrees in relation to the
brake disc and the brake disc runout
re-checked.
• If the brake disc runout measurement still exceeds the specification, repeat the wheel and tire rotation and checking process until
the measurement is within specification.
9. If the brake disc runout measurement without the wheel and tire fitted is outside the
specification, check the wheel hub face
runout.
10. NOTE: Using paint or typing correction fluid, mark the position of the brake disc in
relation to the wheel hub.
Remove the brake disc.
11. NOTE: Make sure that the wheel hub face is clean and free of rust and foreign
material.
NOTE: Re-position the dial indicator gauge so that
it contacts the wheel hub approximately 10 mm
from the outer edge of the wheel hub.
Check the wheel hub face runout.• Slowly rotate the wheel hub and note the readings.
TIE0035482
12. If the wheel hub runout exceeds 0.03 mm, install a new wheel hub.
For additional information, refer to: Wheel
Hub (204-01 Front Suspension, Removal
and Installation)
/ Wheel Bearing and Wheel Hub (204-02
Rear Suspension, Removal and
Installation).
13. If the wheel hub face runout is within specification, install a new brake disc.
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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
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5.
E139455
6.General Equipment: Fluid Container
E139454
7.Loosen: 180°
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E139456
8.Operate the brake pedal fully (pumping brake
fluid and air into the bleed jar) and allow the
brake pedal to return to the rest position. 9.
Continue operating the brake pedal until air-free
fluid is being pumped into the bleed jar.
10. Refer to: Specifications (206-00 Brake System
- General Information, Specifications).
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E139915
11 .With the brake pedal fully depressed tighten the
bleed nipple.
Torque: 9
Nm
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E139456
12.
E139455
13.
E86914
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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
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5.
E139455
6. CAUTION: Make sure that the pressurewithin the brake system does not
exceed 1 bar.
General Equipment: Fluid Container
E139454
7.Loosen: 180°
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