power steering FORD KUGA 2011 1.G Workshop Manual

Steering System Health and Safety Precautions
WARNINGS:
When handling the power steering fluid,
always wear protective goggles and gloves
made of nitril.
EYE CONTACT: Power steering fluid
contains long chain alkyl amine
thiophosphate. Avoid contact with the
eyes. Wash hands thoroughly after
handling. If power steering fluid comes into
contact with the eyes, flush the eyes with
plenty of cold running water for 15
minutes. Seek medical attention for any
persistent eye irritation or abnormality.
SKIN CONTACT: If power steering fluid
comes into contact with the skin, remove
contaminated clothing. Wash affected
areas of skin with soap and water. Seek
medical attention for any persistent skin
irritation or abnormality.
INHALED: If oil mist is inhaled, move a
victim to fresh air. Keep a victim warm and
at rest. Seek immediate medical attention
in cases of throat irritation or coughing.
SWALLOWED: Power steering fluid
contains long chain alkyl amine
thiophosphate. If swallowed, drink plenty
of water. Seek immediate medical attention.
CAUTION: If the power steering fluid is
spilled on the paintwork, the affected area
must be immediately washed down with
cold water.
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Make sure there is adequate ventilation to control
dusts, mists and fumes.
High Pressure Air, Lubrication and Oil
Test Equipment
See alsoLubricants and Greases.
Always keep high-pressure equipment in good
condition, and regularly maintained, particularly at
joints and unions.
Never direct a high-pressure nozzle, for example
diesel injector, at the skin as the fluid may
penetrate to the underlying tissue, and cause
serious injury.
Halon
See CFCs.
Legal Aspects
There are many laws and regulations relating to
health and safety in the use and disposal of
materials and equipment in a workshop.
For a safe working environment and to avoid
environmental pollution, workshops should be
familiar, in detail, with the many health and safety
laws and regulations within their country, published
by both national and local authorities.
Lubricants and Greases
Avoid all prolonged and repeated contact with
mineral oils. All lubricants and greases may be
irritating to the eyes and skin.
Transmission Fluids
Safety instructions
Certain Transmission and Power Steering fluids
supplied to Ford may contain additives which have
the potential to cause skin disease (dermatitis) to
exposed persons. The dermatitis may be irritant
or allergic in nature. Risks are higher where
prolonged or repeated skin contact with a fluid may
occur. These fluids are used for vehicle initial fill
and service purposes. This sub-section is to: • Inform Service personnel who may come into
contact with these vehicle fluids (hazard
communication).
• Summarise appropriate workplace control measures and personal protective equipment
requirements.
• Draw attention to the existence of Material Safety Datasheets (MSDS's) for the fluids
(available from Ford Customer Service Division).
These MSDS's contain detailed information on
hazards and appropriate controls.
Control measures
Workplace risk assessments made under national
chemical control regulations should identify
operations involving the fluids as potentially
hazardous and specify workplace control and
worker awareness measures. In such
circumstances, the relevant Material Safety
Datasheet (see the details specified below) which
specifies hazards and control measures in detail
should be made available for guidance.
Avoid unprotected skin contact with the fluids, and
in particular, avoid prolonged or repeated skin
contact. Work practices should be organised so as
to minimise the potential for skin contact. This may
include the use of drip trays, absorbents, correct
fluid handling equipment (funnels etc), and
workplace housekeeping measures such as the
cleaning of contaminated surfaces.
Personnel engaged in operations where skin
contact could occur (such as fluid draining or filling)
should wear impervious gloves made from nitrile
rubber, certified to a chemical protection standard,
e.g. Europe Standard EN374. This glove type is
widely available from reputable suppliers of gloves
for chemical protection [including the manufacturers
Ansell-Admont (Solvex Range), North Safety
products (North Nitrile Latex Gloves range), and
Marigold Industrial (Blue Nitrile range)]. If gloves
become torn or contaminated on the inside they
should be replaced. Eye protection with safety
glasses is appropriate. Use of an impervious apron
and arm protectors may be necessary if more
extensive exposure is possible. Use of skin barrier
creams suitable for work with mineral oil products
may offer some supplementary protection, but such
barrier creams should not be used in place of
protective clothing.
If accidental skin contact occurs with the fluids,
wash the area thoroughly with soap or skin
cleanser and water.
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Road/Roller Testing
Road or roller testing may be carried out for various
reasons and a procedure detailing pre-test checks,
engine starting and stopping, pre-driving checks,
on-test checks and final checks to be completed
on completion of the test is given below.
Unless complete vehicle performance is being
checked, the full road test procedure need not be
carried out. Instead, those items particularly
relevant to the system(s) being checked can be
extracted.
Pre-Test Checks
WARNING: If the brake system hydraulic
fluid level is low, pedal travel is excessive
or a hydraulic leak is found, do not attempt
to road test the vehicle until the reason for
the low fluid level, excessive pedal travel
or hydraulic leak is found and rectified.
It is suggested that pre-test checks and functional
tests of those systems and circuits which affect the
safe and legal operations of the vehicle, such as
brakes, lights and steering, should always be
carried out before the road or roller test.
With the ignition switched off, check:
– the engine oil level.
– the engine coolant level.
– the tires, for correct pressure, compatible types and tread patterns, and wear within limits.
– that there is sufficient fuel in the tank to complete the test.
– all around the engine, transmission and under the vehicle for oil, coolant, hydraulic and fuel
leaks. Make a note of any apparent leaks and
wipe off the surrounding areas to make it easier
to identify the extent of the leak on completion
of the test.
Starting the Engine
NOTE: On initial drive away from cold and within
the first 1.5 km (1 mile), do not depress the
accelerator pedal beyond half travel until the
vehicle has attained a minimum speed of 25 km/h
(15 miles/h). Never operate at high engine speed
or with the accelerator pedal at full travel whilst the
engine is cold.
With the ignition switched off, check: – that the parking brake is applied.
– that the gear lever is in the neutral position.
– that all instrument gauges (except fuel gauge)
read zero.
With the ignition switched on, check:
– that the ignition controlled warning lamps are illuminated.
– that the engine temperature gauge registers a reading compatible with the engine temperature.
– that the fuel gauge registers a reading appropriate to the fuel level in the tank.
– the operation of the parking brake warning lamp and fluid level warning indicator.
Road or Roller Testing
CAUTION: If road testing, check the brake
operation while still traveling at low speed
before continuing with the test. If the
brakes pull to one side, or appear to be
otherwise faulty, do not continue with the
road test until the fault has been found and
rectified.
During the road or roller test, check:
– that the clutch pedal operation is not stiff or heavy.
– that the initial gear engagement is smooth and there is no evidence of clutch drag.
– that the parking brake control operates smoothly and releases quickly and completely.
– that the clutch takes up the drive smoothly, without slip or judder.
– that gear changing is smooth with no abnormal noises or vibrations from the transmission.
– the engine power output is satisfactory, full power is achieved, acceleration is smooth and
pedal operation is not stiff or heavy, and engine
speed returns to idle correctly.
– there is no excessive or abnormally colored smoke from the engine under normal driving,
heavy load or overrun conditions.
– that steering operation, including power steering (if equipped), is smooth, accurate, not
excessively heavy or with excessive free play
or vibration.
– that the steering does not pull to one side and self centers smoothly after cornering.
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SECTION 100-04 Noise, Vibration and Harshness
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
DIAGNOSIS AND TESTING
100-04-2
Noise, Vibration and Harshness (NVH) ........................................................................\
......
100-04-2
Inspection and Verification ........................................................................\
..........................
100-04-2
Noise Diagnostic Procedure ........................................................................\
.......................
100-04-3
Road Test ........................................................................\
...................................................
100-04-3
Road Test Quick Checks........................................................................\
............................
100-04-4
Road Conditions ........................................................................\
.........................................
100-04-4
Vehicle Preparation ........................................................................\
....................................
100-04-4
Power Steering Conditions ........................................................................\
.........................
100-04-4
Power Steering Operation Noise Check ........................................................................\
.....
100-04-7
Symptom Chart ........................................................................\
...........................................
100-04-14
Pinpoint Tests ........................................................................\
.............................................
100-04-1
Noise, Vibration and Harshness
100-04- 1
.
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sometimes noticed in the steering wheel/column,
seats, front floor panel, front door trim panel or
front end sheet metal. It is a low frequency
vibration (around 9-15 cycles per second). It
may or may not be increased by applying the
brakes lightly. REFER to Idle
Boom/Shake/Vibration in the Driveline Noise
and Vibration Symptom Chart.
3. High Speed: A vibration is felt in the front floor panel or seats with no visible shake, but with
an accompanying sound or rumble, buzz, hum,
drone or booming noise. Coast with the clutch
pedal depressed (manual transmission) or shift
control selector lever in "N" (NEUTRAL)
(automatic transmission) and engine idling. If
vibration is still evident, it may be related to
wheels, tires, front brake discs, wheel hubs or
front wheel bearings. REFER to Shake and
Vibration While Driving in the Driveline Noise
and Vibration Symptom Chart.
4. Engine rpm Sensitive: A vibration is felt whenever the engine reaches a particular rpm.
It will disappear in neutral coasts. The vibration
can be duplicated by operating the engine at
the problem rpm while the vehicle is stationary.
It can be caused by any component, from the
accessory drive belt to the clutch or torque
converter which turns at engine speed when the
vehicle is stopped. REFER to Shake and
Vibration While Driving in the Driveline Noise
and Vibration Symptom Chart.
5. Noise and Vibration While Turning: Clicking, popping or grinding noises may be due to the
following:
• worn, damaged or incorrectly installed front wheel bearing.
• damaged powertrain/drivetrain mounts.
Road Conditions
An experienced technician will always establish a
route that will be used for all NVH diagnosis road
tests. The road selected should be reasonably
smooth, level and free of undulations (unless a
particular condition needs to be identified). A
smooth asphalt road that allows driving over a
range of speeds is best. Gravel or bumpy roads
are unsuitable because of the additional road noise
produced. Once the route is established and consistently used, the road noise variable is
eliminated from the test results.
NOTE:
Some concerns may be apparent only on
smooth asphalt roads.
If a customer complains of a noise or vibration on
a particular road and only on a particular road, the
source of the concern may be the road surface. If
possible, try to test the vehicle on the same type
of road.
Vehicle Preparation
Carry out a thorough visual inspection of the
vehicle before carrying out the road test. Note
anything which is unusual. Do not repair or adjust
any condition until the road test is carried out,
unless the vehicle is inoperative or the condition
could pose a hazard to the technician. After
verifying that the condition has been corrected,
make sure all components removed have been
installed.
Power Steering Conditions
Check for the noise in the following conditions to
verify the customer concern.
• Check for the noise in several temperature conditions.
• Is the noise from when the vehicle was new?
• Can the noise be repeated constantly or is it random?
• Check the condition of the vehicle age, mileage and service record.
• Interview the customer to find the operating condition in which the noise will occur. Test the
vehicle based on the detail(s) from the customer
interview.
• Follow the power steering operation noise condition tables below, to find which condition
the noise will occur.
Power Steering Operation Noise Check
Step 1: Check for NVH concerns from non-steering
components, which may sound like noises coming
from the steering system.
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Power assisted steering operating conditionDriving
Parking
Cornering condition
Driving straight ahead
Steering at a steering
lock stop
Steering central/slightly
off center
REFER to NVH
concerns from other
components column D
REFER to NVH
concerns from other
components column C
REFER to NVH
concerns from other
components column B
REFER to NVH
concerns from other
components column A
NVH concerns from other components
NVH concerns from other condition (column A to D) DCBA
Driving Condition
Noise
XOXX
Drive off, stop driving and slow cornering
over uneven roads
Pedal box knocking
XOOX
Drive off, driving and cornering
Stabilizer bar link
knocking
X
X
Drive off, driving, acceleration and
deceleration
Engine support insu-
lator knocking
OOXX
Engine on, activate switch for air condi-
tioning
Air conditioning
knocking
XO
X
Drive off, driving, cornering, acceleration
and deceleration
Suspension knocking
(Subframe, Springs)
X
OX
Drive off, driving, cornering, acceleration
and deceleration
Constant velocity (CV)
joint knocking
X
O
Deceleration, acceleration and single
impact
Washer bottle
XO
O
All driving conditions
Loose suspension
bolts
XXXX
All driving conditions. Engine rpm
dependant
Instrument panel
rattle/squeak
• 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 2: Check for steering system NVH concerns
according to operation condition described at the
customer interview.
Power assisted steering operating condition
Vehicle stationary with engine off
Driving
Parking
Steering at a
steering lock stop
Steering central/
slightly off centre
Steering at a
steering lock
stop
Steering
central/slightly
off center
Steering at a
steering lock
stop
Steering
central/
slightly off
center
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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
CHECK the installation and
potential damage of the floor
seal.
Floor seal.
NOTE:
Engine speed at idle
turning the steering wheel slowly
lock to lock.
Power steering system hiss noise
– a high frequency, continuous
rush or swish noise like escaping
air from a balloon. Hiss occurs
while turning between the
steering lock stops, all steering
angles. Noise does not change
with engine rpm and is worse at
high operating temperatures. Certain amount of noise level
acceptable, not a safety critical
item.
Power steering gear valve
design.
Certain amount of noise level
acceptable, not a safety critical
item.
Power steering system hydraulic
design.
Certain amount of noise level
acceptable, not a safety critical
item.
Power steering pump pressure
relief valve.
NOTE:
Engine speed at idle
holding the steering wheel
against a steering lock for three
seconds. Do not hold for more
than five seconds.
Power steering system hiss noise
– a continuous noise like
escaping air occurs while holding
the steering against a steering
lock stop.
Power Steering Lock Stop Impact Knock
Noise
Test Condition
Listen for steering knock noise with the engine
speed at idle in the following test conditions (noise
also apparent with engine off). 1. Turn the steering wheel to the left-hand and
right-hand steering locks and listen for the
impact noise.
Action
Possible Sources
Symptom
Certain amount of noise level
acceptable, not a safety critical
item.
Power steering gear mechanical
noise, metal to metal at end of
steering travel.
Power steering system knock
noise – a heavy loud sound like
a knock on a door that occurs in
parking condition when hitting the
lock stop.
Power Steering Mechanical Knock Noise
(PAS off)
Test Condition
Listen for steering knock noise with the engine off
in the following test conditions (no power assist). 1. Turn the steering wheel 90 degrees to the right,
hold and then quickly release.
2. Turn the steering wheel 90 degrees to the left, hold and then quickly release.
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