general procedures FORD KUGA 2011 1.G Repair Manual

Action
Possible Sources
Symptom
• INSTALL a new brake mastercylinder.
REFER to: Brake Master
Cylinder - 2.5L Duratec
(147kW/200PS) - VI5 (206-06
Hydraulic Brake Actuation,
Removal and Installation).
• Leaking brake master cylinder
primary piston cup.
• FREE UP and ADJUST theparking brake cable.
REFER to: Parking Brake
Cable Adjustment (206-05
Parking Brake and Actuation,
General Procedures).
INSTALL new components as
necessary.
• Parking brake control not fully
released.
• REFER to:Anti-Lock Control
(206-09 Anti-Lock Control,
Diagnosis and Testing).
• Malfunctioning anti-lock braking
system (ABS).
• REFER to:Instrument Cluster
(413-01 Instrument Cluster,
Diagnosis and Testing).
• Shorted indicator circuit.
• INSTALL new brake shoes orbrake pads.
REFER to: Brake Pads (206-03
Front Disc Brake, Removal
and Installation).
• Grease or fluid on the brake
shoes or brake pads; glazed
linings.
• Vibration when the brakes are
applied
• INSTALL new brake shoes orbrake pads.
REFER to: Brake Pads (206-03
Front Disc Brake, Removal
and Installation).
• Worn or damaged brake shoes
or brake pads.
• TIGHTEN the caliper mountingbolt(s).
• Loose caliper mounting bolt(s).
•
• Excessive brake disc thickness
variation or brake disc runout.
• CHECK the tires. BALANCE orINSTALL new tires as neces-
sary.
REFER to: Wheels and Tires
(204-04 Wheels and Tires,
Diagnosis and Testing).
• Wheels and tires.
• TIGHTEN or INSTALL newwheel hub bolts as necessary.
• Loose or missing wheel hub
bolts.
• CARRY OUT a brake discrunout check.
• Worn or damaged brake drums
or brake discs.
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Action
Possible Sources
Symptom
• FILL the reservoir. CHECK thebrake and clutch system for
leaks including brake fluid in
the brake booster.
• Low brake fluid level.
• Pedal goes down fast
• REPAIR the leak. CHECK theentire hydraulic system. FILL
and BLEED the brake system.
REFER to: (206-00 Brake
System - General Information)
Brake System Bleeding (General Procedures),
Brake System Pressure Bleeding (General Proced-
ures),
Component Bleeding (General
Procedures).
• Leak in the hydraulic system.
• CHECK for leaks. BLEED thebrake system. REFER to: (206-
00 Brake System - General
Information)
Brake System Bleeding (General Procedures),
Brake System Pressure Bleeding (General Proced-
ures),
Component Bleeding (General
Procedures).
• Air in the system.
• CARRY OUT a brake discrunout check.
• Brake disc “brake knock back”
(Brake pads push the brake
caliper piston back into the
brake caliper. Caused by
excessive brake disc lateral
runout or loose wheel bear-
ings.)
• INSTALL new brake shoes orbrake pads.
REFER to: Brake Pads (206-03
Front Disc Brake, Removal
and Installation).
• Worn brake shoes or brake
pads.
• GO toPinpoint Test A.
• Worn brake master cylinder
piston cups or scored cylinder
bore.
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Action
Possible Sources
Symptom
• BLEED the brake system.REFER to: Brake System
Pressure Bleeding (206-00
Brake System - General
Information, General Proced-
ures).
REFER to: (206-00 Brake
System - General Information)
Brake System Bleeding (General Procedures),
Component Bleeding (General
Procedures).
• Air in the system.
• Pedal eases down slowly
• GO toPinpoint Test B.
• Malfunctioning brake master
cylinder.
• Low engine vacuum (stationary).
• INSTALL new brake shoes orbrake pads.
REFER to: Brake Pads (206-03
Front Disc Brake, Removal
and Installation).
• Worn brake shoes or brake
pads.
• Pedal is low or feels spongy
• CHECK for leaks. BLEED thebrake system. REFER to: (206-
00 Brake System - General
Information)
Brake System Bleeding (General Procedures),
Brake System Pressure Bleeding (General Proced-
ures),
Component Bleeding (General
Procedures).
• Air in the system.
• INSTALL new brake shoes orbrake pads.
REFER to: Brake Pads (206-03
Front Disc Brake, Removal
and Installation).
• Glazed or worn brake shoes or
brake pads.
• Brake lockup during light brake
pedal force
• GO toPinpoint Test C.
• Brake booster.
• Low engine vacuum.
• INSTALL new brake shoes orbrake pads.
REFER to: Brake Pads (206-03
Front Disc Brake, Removal
and Installation).
• Worn brake shoes or brake
pads.
• Excessive or erratic pedal
travel
• CARRY OUT a brake discrunout check.
• Wheel bearings
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Action
Possible Sources
Symptom
• ADJUST the parking brakecable or switch
REFER to: Parking Brake
Cable Adjustment (206-05
Parking Brake and Actuation,
General Procedures).
• Incorrectly adjusted parking
brake or brake pedal switch
• Brake drag
• REFER to brake booster opera-tion check in this procedure.
• Brake booster.
• INSTALL a new wheel cylinderor brake caliper.
REFER to: Brake Caliper (206-
03 Front Disc Brake,
Removal and Installation).
• Seized wheel cylinder or brake
caliper.
• INSTALL a new brake caliper.REFER to: Brake Caliper (206-
03 Front Disc Brake,
Removal and Installation).
• Seized brake caliper slide pins.
• INSTALL new parking brakecables.
REFER to: Parking Brake
Cable Adjustment (206-05
Parking Brake and Actuation,
General Procedures).
• Seized parking brake cables.
• Check the parking brake leaverposition and make sure there
are no obstructions.
• Parking brake not fully
released.
• Check all brake hose(s) forcorrect fitment.
REFER to: Rear Brake Flexible
Hose (206-04 Rear Disc
Brake, Removal and Installa-
tion)
/ Front Brake Flexible Hose
(206-03 Front Disc Brake,
Removal and Installation).
• Brake hose incorrectly fitted.
• INSTALL new brake shoes orbrake pads.
REFER to: Brake Pads (206-03
Front Disc Brake, Removal
and Installation).
• Worn or contaminated brake
shoes or brake pads.
• Excessive brake pedal effort
• INSTALL a new brake vacuumpump.
• Malfunctioning vacuum pump
(diesel).
• CONNECT or INSTALL a newbrake booster vacuum pipe as
necessary.
• Disconnected or damaged
brake booster vacuum pipe.
• GO toPinpoint Test D.
• Brake booster.
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Action
Possible Sources
Symptom
• INSTALL new brake shoes orbrake pads.
REFER to: Brake Pads (206-03
Front Disc Brake, Removal
and Installation).
• Worn or damaged brake shoes
or brake pads.
• Brake noise
• GO toPinpoint Test E.
• Brake booster.
• GO toPinpoint Test F.
• Brake booster.
• Seized brake pedal pivot.
• Slow or incomplete brake pedal
return
Pinpoint Tests
PINPOINT TEST A : PEDAL GOES DOWN FAST
DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
A1: PRESSURIZE THE SYSTEM
1 Pump the foot brake rapidly five times.
• Does the brake pedal height build up and then hold?
zYe s
CHECK parking brake adjustment and
ADJUST as necessary.
REFER to: Parking Brake Cable Adjustment
(206-05 Parking Brake and Actuation,
General Procedures).
If the condition still exists. BLEED the brake
system. REFER to: (206-00 Brake System -
General Information)
Brake System Bleeding (General Procedures),
Brake System Pressure Bleeding (General
Procedures),
Component Bleeding (General Procedures).
TEST the system for normal operation.
zNo
GO to A2.
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DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
A2: CHECK FOR BRAKE SYSTEM LEAKS
1 Check for external brake and clutch system
leaks. Refer to Brake Master Cylinder
Component Test in this procedure.
• Are any leaks present?
zYe s REPAIR as necessary. ADD fluid and BLEED
the brake system. REFER to: (206-00 Brake
System - General Information)
Brake System Bleeding (General Procedures),
Brake System Pressure Bleeding (General
Procedures),
Component Bleeding (General Procedures).
TEST the system for normal operation.
zNo
GO to A3.
A3: PERFORM A BRAKE MASTER CYLINDER BYPASS CONDITION TEST
1 Carry out a brake master cylinder bypass
Condition Test. Refer to the Brake Master
Cylinder Component Test in this procedure.
• Was a concern found?
zYe s 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).
TEST the system for normal operation.
zNo
VERIFY the customer concern.
PINPOINT TEST B : PEDAL EASES DOWN SLOWLY
DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
B1: CHECK THE BRAKE PEDAL OPERATION
1 Depress the brake pedal.
• Does the pedal ease down slowly?
zYe s GO to B2.
zNoRefer to the Brake Master Cylinder
Component Test in this procedure.
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DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
B2: CHECK FOR BRAKE SYSTEM LEAKS
1 Check for external brake system leaks.
• Are any leaks present?
zYe s REPAIR as necessary. ADD fluid and BLEED
the brake system. REFER to: (206-00 Brake
System - General Information)
Brake System Bleeding (General Procedures),
Brake System Pressure Bleeding (General
Procedures),
Component Bleeding (General Procedures).
TEST the system for normal operation.
zNo
GO to B3.
B3: PERFORM A BRAKE MASTER CYLINDER BYPASS CONDITION TEST
1 Carry out a brake master cylinder bypass
Condition Test. Refer to the Brake Master
Cylinder Component Test in this procedure.
• Was a concern found?
zYe s 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).
TEST the system for normal operation.
zNo
GO to B4.
B4: CHECK THE BRAKE BOOSTER CHECK VALVE
1 Disconnect the brake booster check valve
vacuum hose at the manifold.
2Blow into the hose attached to the brake booster
check valve.
• Does air pass through the valve?
zYe s INSTALL a new brake booster check valve.
zNoGO to B5.
B5: CHECK THE BRAKE BOOSTER CHECK VALVE VACUUM
1 Run the engine at idle.
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DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
E2: CHECK THE BRAKE BOOSTER
1 Check the brake booster push rod alignment
and travel.
• Is the push rod and pedal travel OK?
zYe s BLEED the brake system. REFER to: (206-00
Brake System - General Information)
Brake System Bleeding (General Procedures),
Brake System Pressure Bleeding (General
Procedures),
Component Bleeding (General Procedures).
TEST the system for normal operation.
zNo
INSTALL a new brake booster. TEST the
system for normal operation.
PINPOINT TEST F : SLOW OR INCOMPLETE BRAKE PEDAL RETURN
DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
F1: CHECK FOR BRAKE PEDAL RETURN
1 Run the engine at approximately 1200 rpm
whilst making several brake applications.
2Pull the brake pedal upwards with approximately
44.5 N (10 lbs) force.
3Release the brake pedal and measure the
distance to the floor panel and note the reading.
4Make a hard brake application.
5Release the brake pedal and measure the
distance to the floor panel and note the reading.
6Compare the measurements.
• Did the brake pedal return to its original posi- tion?
zYe s
VERIFY the customer concern.
zNoGO to F2.
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4. Remove the vacuum hose from the brakebooster. Manifold vacuum should be available
at the brake booster end of the hose with the
engine at idle speed and the transaxle in the
NEUTRAL position. Make sure that all unused
vacuum outlets are correctly capped, hose
connectors are correctly secured and vacuum
hoses are in good condition. When it is
established that manifold vacuum is available
to the brake booster, connect the vacuum hose
to the brake booster and repeat Step 3. If no
downward movement of the brake pedal is felt,
install a new brake booster.
5. Operate the engine a minimum of 10 seconds at approximately 1200 rpm. Stop the engine and
let the vehicle stand for 10 minutes. Then, apply
the brake pedal with approximately 89 N (20 lb)
force. The pedal feel (brake application) should
be the same as that noted with the engine
operating. If the brake pedal feels hard (no
power assist), install a new vacuum check valve
and then repeat the test. If the brake pedal still
feels hard, install a new brake booster. If the
brake pedal movement feels spongy, bleed the
brake system. REFER to: (206-00 Brake System
- General Information)
Brake System Bleeding (General Procedures),
Brake System Pressure Bleeding (General
Procedures),
Component Bleeding (General Procedures).
Brake Master Cylinder
Usually, the first and strongest indicator of anything
wrong with the braking system is a feeling through
the brake pedal. In diagnosing the condition of the
brake master cylinder, check pedal feel as
evidence of a brake concern. Check for the red
brake warning indicator illumination and the fluid
level in the master cylinder reservoir.
Normal Conditions
The following conditions are considered normal
and are not indications that the brake master
cylinder is in need of service.
– Modern brake systems are not designed to
produce as hard a pedal effort as in the past.
Complaints of light pedal efforts should be compared to pedal efforts of another vehicle, of
the same model and year.
– During normal operation of the brake pedal, the fluid level in the reservoir will rise during brake
pedal application and fall during release. The
net fluid level (i.e., after brake pedal application
and release) will remain unchanged.
– A trace of brake fluid will exists on the brake booster shell below the master cylinder
mounting flange. This results from the normal
lubricating action of the master cylinder bore
end seal.
– The fluid level will fall with brake shoe and lining wear.
Abnormal Conditions
NOTE: Prior to performing any diagnosis, make
sure the brake system warning indicator is
functional.
Changes in brake pedal feel or travel are indicators
that something could be wrong with the braking
system. The diagnostic procedure and techniques
use brake pedal feel, warning indicator illumination
and low brake fluid level as indicators in diagnosing
braking system concerns. The following conditions
are considered abnormal and indicate that the
brake master cylinder is in need of service.
– The brake pedal goes down fast. This could be caused by an external or internal leak.
– The brake pedal eases down slowly. This could be caused by an external or internal leak.
– The brake pedal is low and or feels spongy. This condition may be caused by no fluid in the brake
master cylinder reservoir, reservoir cap vent
holes clogged or air in the hydraulic system.
– The brake pedal effort is excessive. This may be caused by a bind or obstruction in the pedal
or linkage, clogged fluid control valve or
insufficient booster vacuum.
– The rear brakes lock up during light pedal force. This may be caused by incorrect tire pressures,
grease or fluid on the brake shoes and linings,
damaged brake shoes and linings, incorrectly
adjusted parking brake, or damaged or
contaminated brake pressure control valves.
– The brake pedal effort is erratic. This condition could be caused by a brake booster malfunction,
extreme caliper piston knock back or incorrectly
installed brake shoes and linings.
– The red brake warning indicator is ON. This may be caused by low fluid level, ignition wire routing
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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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