AIR CON FORD KUGA 2011 1.G Repair Manual

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.
G37349en2008.50 Kuga8/2011
100-04- 17
Noise, Vibration and Harshness
100-04- 17
DIAGNOSIS AND TESTING
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DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
D2: INSPECT THE WHEEL BEARINGS
1 Inspect the wheel bearings.
• Are the wheel bearings OK?
zYe s GO to D3 .
zNo
INSTALL new wheel bearings as necessary.
REFER to: Front Wheel Bearing (204-01 Front
Suspension, Removal and Installation).
ROAD TEST as necessary.
D3: INSPECT THE WHEEL AND TIRE RUNOUT
1 Inspect the wheel and tire runout.
• Is the wheel and tire runout OK?
zYe s Balance the wheels and tires. Refer to the
wheel balance equipment manufacturer's
instructions. ROAD TEST as necessary.
zNoINSTALL new wheels or tires as necessary.
REFER to: Wheel and Tire (204-04 Wheels
and Tires, Removal and Installation).
ROAD TEST as necessary.
PINPOINT TEST E : NON-AXLE NOISE
DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
E1: INSPECT THE VEHICLE TRIM
1 Check the radiator grille and trim panels to see
if they are the source of the noise.
• Are the vehicle trim components causing the noise?
zYe s
INSTALL new trim components or REPAIR as
necessary. ROAD TEST as necessary.
zNoGO to E2.
E2: CHECK THE AIR CONDITIONING (A/C) SYSTEM FOR NOISE
1 Ignition switch in position III.
2Ignition switch in position II.
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100-04-
18
Noise, Vibration and Harshness
100-04- 18
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DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
3 Check the A/C system components for noise by
turning the A/C system on and off.
• Is the A/C system causing the noise?
zYe s INSPECT the A/C system.
REFER to: Climate Control System (412-00
Climate Control System - General Informa-
tion, Diagnosis and Testing).
ROAD TEST as necessary.
zNo
GO to E3.
E3: CHECK NON-FACTORY FITTED ACCESSORIES
1 Check any non-factory installed accessories for
being the source of the noise. For example:
touch condition body-to-frame, antennas,
deflectors and fog lights.
• Are the accessories the cause of the noise?
zYe s ADJUST, REPAIR, or INSTALL new
accessories or fasteners as required. ROAD
TEST as necessary.
zNoVERIFY the customer concern.
G37349en2008.50 Kuga8/2011
100-04- 19
Noise, Vibration and Harshness
100-04- 19
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SECTION 204-00 Suspension System - General
Information
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
DIAGNOSIS AND TESTING
204-00-2
Suspension System ........................................................................\
....................................
204-00-2
Inspection and Verification ........................................................................\
..........................
204-00-2
Symptom Chart ........................................................................\
...........................................
204-00-5
Pinpoint Tests ........................................................................\
.............................................
204-00-12
Component Tests ........................................................................\
........................................
GENERAL PROCEDURES 204-00-15
(14 117 3)
Front Toe Adjustment ........................................................................\
.............
204-00-16
(15 211 3)
Rear Toe Adjustment ........................................................................\
..............
204-00-1
Suspension System - General Information
204-00- 1
.
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Suspension System
Special Tool(s)Alignment Pins, Subframe
205-316 (15-097A)
15097A
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanicaldamage.
Visual Inspection Chart
Mechanical
Tire pressure(s) Wheel and tires
Mechanical
Wheel knuckles Tie-rod ends
Front suspension lower arm ball joints Front suspension lower arm bushings Front strut and spring assemblies
Front and rear stabilizer bar and connecting links Rear springs
Rear shock absorbers
Rear suspension lower arms
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 Symptom Chart.
Symptom Chart
Symptom Chart
Action
Possible Sources
Symptom
• Vehicles without load levellingshock absorbers, CHECK for
abnormal loading, spring sag
or non-standard springs.
• Vehicles with load levelling shock absorbers, GO to
Pinpoint Test C.
• Vehicle attitude incorrect (front
or rear / left or right is high or
low).
• Drift left or right
• CHECK the steering system.REFER to: Steering System
(211-00 Steering System -
General Information,
Diagnosis and Testing).
• Steering gear or linkage worn
or damaged.
• CHECK the brake system.REFER to: Brake System (206-
00 Brake System - General
Information, Diagnosis and
Testing).
• Brake system.
• Using the special tool, CHECKthe front subframe alignment..
• Incorrect front crossmember
alignment.
• CHECK the wheel bearings.
• Worn front wheel bearings.
• GO toPinpoint Test A.
• Wheel and tires.
G1080717en2008.50 Kuga8/2011
204-00- 2
Suspension System - General Information
204-00- 2
DIAGNOSIS AND TESTING
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Condenser
General EquipmentCable TiesMaterials
Specification
Name
WSH-M1C231-B /
6U7J-M1C231-AA
Compressor Oil - Air
Conditioning
Removal
NOTE:
Removal steps in this procedure may
contain installation details. 1.
Refer to: Air Conditioning (A/C) System
Recovery, Evacuation and Charging (412-00
Climate Control System - General Information,
General Procedures).
2. CAUTION: Make sure that all openings are sealed. Use new blanking caps.
1. Torque: 5Nm
2. Torque: 8Nm
E100847
1
2
2
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412-01- 31
Climate Control
412-01- 31
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3.Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
4.
E98183
5.
E98184
Vehicles with automatic transmission
6. General Equipment: Cable Ties
E112626
1
2
1
2
All vehicles
7.Torque: 5Nm
G1022366en2008.50 Kuga8/2011
412-01- 32
Climate Control
412-01- 32
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8.
G1022366en2008.50 Kuga8/2011
412-01-33
Climate Control
412-01- 33
REMOVAL AND INSTALLATION
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1
2
1
11
E77215
E99948

Installation
1.To install, reverse the removal procedure.
2. Coat the O-ring seals on the refrigerant lines.
Material: Compressor Oil - Air Conditioning
(WSH-M1C231-B / 6U7J-M1C231-AA)
refrigerant oil
G1022366en2008.50 Kuga8/2011
412-01- 34
Climate Control
412-01- 34
REMOVAL AND INSTALLATION
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Clutch and Clutch Field Coil
General EquipmentPuller
Removal
1. Refer to: Air Conditioning (A/C) Compressor -
2.5L Duratec (147kW/200PS) - VI5 (412-01
Climate Control, Removal and Installation).
2. Torque: 13
Nm
E112210
3.General Equipment: Puller
E112211
4. NOTE: Note the position of the component
before removal.
E112212
Installation
1. NOTE: Make sure that the component is
installed to the position noted before removal.
To install, reverse the removal procedure.
2. Refer to: Air Conditioning (A/C) Clutch Air Gap
Adjustment (412-00 Climate Control System
- General Information, General Procedures).
G1158272en2008.50 Kuga8/2011
412-01- 35
Climate Control
412-01- 35
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL