tires FORD KUGA 2011 1.G Repair Manual

Rear 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
E99425
1
2
3
G1001210en2008.50 Kuga8/2011
206-04- 5
Rear Disc Brake
206-04- 5
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

4.Loosen the parking brake cable adjustment
nut to the end of the parking brake cable
thread.
2.
E102067
2
P1
5.
Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
6. NOTE: This step requires the aid of another
technician.
1. Insert a 1.2 mm feeler gauge between the parking brake lever and the brake caliper
abutment, on both sides.
2. Tighten the parking brake cable adjustment nut until movement is observed on one of the
parking brake levers.
3. Remove the feeler gauges.
4. Rotate the rear wheels and tires and check for brake drag. If brake drag is felt, loosen
the parking brake cable adjustment nut to
the end of the parking brake cable thread,
clean the parking brake cables and repeat
the parking brake cable adjustment
procedure.
5. If brake drag is still felt after, repeat the adjustment using a 1.0 mm feeler gauge. If
brake drag is still felt, loosen the parking
brake adjustment nut and reduce the feeler
gauge measurement by 0.2 mm each time,
until no brake drag can be felt at the rear
wheels and tires.
E83778
1.2 mm
G1001211en2008.50 Kuga8/2011
206-05- 10
Parking Brake and Actuation
206-05- 10
GENERAL PROCEDURES
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Parking Brake Rear Cables
Removal
NOTE:Removal steps in this procedure may
contain installation details.
1. Fully release the parking brake control.
2.
E92650
3. Loosen the parking brake cable adjustment nut
to the end of the parking brake cable thread.
E92651
4.Refer to: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation).
4x4
5. Torque: 25Nm
E101187
x2
x4
1
2
3
4x2
6.Torque: 25Nm
E101189
x4
G1072319en2008.50 Kuga8/2011
206-05- 12
Parking Brake and Actuation
206-05- 12
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Front Wheel Speed Sensor
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. Torque: 5
Nm
E71878
Installation
1.To install, reverse the removal procedure.
G1001227en2008.50 Kuga8/2011
206-09B- 21
Anti-Lock Control - Stability Assist
206-09B- 21
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Rear Wheel Speed Sensor
Removal
NOTE:Removal steps in this procedure may
contain installation details.
4x2
1. Torque: 5Nm
E98809
4x4
2.Refer to: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation).
3. Torque: 5
Nm
E98810
All vehicles
4. NOTE: The O-ring seal is to be reused unless
damaged.
E98820
Installation
1. NOTE: Make sure that the sensor housing is
clean and free of foreign material.
NOTE: Make sure that the sensor ring is
correctly located.
To install, reverse the removal procedure.
G1001228en2008.50 Kuga8/2011
206-09B- 22
Anti-Lock Control - Stability Assist
206-09B- 22
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Steering System
Special Tool(s) / General EquipmentAlignment Pins, Subframe
205-316 (15-097A)
15097
Simulator, Driver and
Passenger Air Bags and Side
Air Curtains
501-073 (40-016)
501073
The Ford approved diagnostic tool
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanicalor electrical damage.
Visual Inspection Chart
Electrical
Mechanical
• Battery
• Battery cables
• Steering anglesensor electrical
connector
• Power steering pump control
module electrical
connectors
• Power steering pump control
module ground
cable
• Power steering pump control
module ground
cable retaining
screw
• Steering angle sensor warning
indicator
• Fuse(s)
• Tire pressure(s)
• Loose tie-rod end(s)
• Loose strut and
spring assemblies or
ball joints
• Loose pinch bolts on steering column
shaft flexible coup-
ling
• Wheels and tires
• Power steering line fluid leaks
• Steering gear bellows 3. If an obvious cause for an observed or reported
concern is found, correct the cause (if possible)
before proceeding to the next step.
4. If the cause is not visually evident, verify the symptom and refer to the diagnostic tab within
the Ford approved diagnostic tool.
Components Tests
Steering Linkage
1. Grasp the steering wheel firmly and move it upand down and to the left and right without
turning the steering wheel to check the steering
column bearing for wear, steering column shaft
for wear, steering wheel for looseness and
steering column for looseness. If the steering
column bearing or the steering column shaft is
worn install a new steering column. If the
steering wheel or the steering column is loose,
tighten the steering wheel or the steering column
retaining bolts.
2. With the road wheels in the straight ahead position, gently turn the steering wheel to the
left and the right to check for free play in the
steering linkage.
3. There should be no excessive free play at the steering wheel rim. If there is excessive free
play, CHECK the tie-rod inner and outer ball
joints, REFER to Tie-Rod Component Test in
this procedure. CHECK the steering column
universal joint, REFER to Steering Column
Universal Joint Component Test in this
procedure. If there is no free play in the tie-rod
and the steering column, install a new steering
gear.
Tie-Rod
CAUTION: Steering gear boots must be
handled carefully to avoid damage. Use
new steering boot clamps when installing
the steering gear boots.
NOTE: Noises such as knocks, which may appear
to originate from the steering linkage, may also be
generated by front suspension components.
REFER to: Noise, Vibration and Harshness (NVH)
(100-04 Noise, Vibration and Harshness,
Diagnosis and Testing).
G1059437en2008.50 Kuga8/2011
211-00- 2
Steering System - General Information
211-00- 2
DIAGNOSIS AND TESTING
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Power Steering Pressure Line and Return Line Assembly — 2.5LDuratec (147kW/200PS) - VI5(13 443 0)
General Equipment
Hose Clamp Remover/Installer
Removal
NOTE: Removal steps in this procedure may
contain installation details.
1. Refer to: Steering 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.
E98543
x7
4.
E99630
5.
E99631
6. WARNING: Be prepared to collect escaping fluid.
1. General Equipment: Hose ClampRemover/Installer
2. Torque: 30
Nm
E114706
1
2
7. Torque: 23Nm1.
2. Torque: 7
Nm
G1185534en2008.50 Kuga8/2011
211-02- 13
Power Steering
211-02- 13
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Power Steering Pump — 2.5L Duratec (147kW/200PS) -VI5(13 434 0)
General Equipment
Hose Clamp(s)
Hose Clamp Remover/Installer
Removal
NOTE: Removal steps in this procedure may
contain installation details.
1. Refer to: Steering 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.
E98543
x7
4.
E99630
5.
E99631
6. 1. WARNING: Be prepared to collect
escaping fluid.
General Equipment: Hose Clamp(s)
2. General Equipment: Hose Clamp Remover/Installer
E114163
12
7.1. WARNING: Be prepared to collect
escaping fluid.
Torque: 30Nm
3. General Equipment: Hose Clamp
Remover/Installer
4. Torque: 10
Nm
G1176952en2008.50 Kuga8/2011
211-02- 18
Power Steering
211-02- 18
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Power Steering Pump to Steering Gear Pressure Line — 2.5LDuratec (147kW/200PS) - VI5(13 440 0; 13 443 0)
General Equipment
Hose Clamp Remover/Installer
Removal
NOTE: Removal steps in this procedure may
contain installation details.
1. Refer to: Steering 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.
E98543
x7
4.
E99630
5.
E99631
6. WARNING: Be prepared to collect escaping fluid.
1. General Equipment: Hose ClampRemover/Installer
2. Torque: 30
Nm
E114706
1
2
7. Torque: 23Nm1.
2. Torque: 7
Nm
G1185535en2008.50 Kuga8/2011
211-02- 21
Power Steering
211-02- 21
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Steering Gear(13 116 0)
Special Tool(s) / General Equipment205-880
Alignment Pins, Subframe
E93105
211-020
Separator, Ball Joint
13006
Transmission Jack
Materials
Specification
Name
WSA-M2C195-A / 9U7J-
M2C195-AA
Power Steering Fluid IW
Removal
NOTE:
Removal steps in this procedure may
contain installation details.
1. Refer to: Steering System Health and Safety
Precautions (100-00 General Information,
Description and Operation).
2. CAUTION: Make sure that the steering wheel lock is engaged.
NOTE: Make sure that the road wheels are in
the straight ahead position.
E99259
3. Torque: 30Nm
E66155
4.On both sides.
Refer to: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation).
5. If equipped.
E98543
x7
6.If equipped.
Torque: 8
Nm
E75215
7. CAUTION: Make sure that the ball joint
ball does not rotate.
G1001271en2008.50 Kuga8/2011
211-02- 25
Power Steering
211-02- 25
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL