steering system FORD KUGA 2011 1.G Workshop Manual

SECTION 100-00 General Information
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
DESCRIPTION AND OPERATION
100-00-3
About This Manual ........................................................................\
......................................
100-00-3
Introduction ........................................................................\
.................................................
100-00-4
How to use Repair Procedures ........................................................................\
...................
100-00-4
Global Authoring Standards (GAS) Repair Procedures ..................................................
100-00-18
How to use Diagnosis and Testing procedures ..................................................................
100-00-19
Symbols Glossary ........................................................................\
.......................................
100-00-41
Steering System Health and Safety Precautions ................................................................
100-00-42
Health and Safety Precautions ........................................................................\
...................
100-00-42
Introduction ........................................................................\
.................................................
100-00-42
Acids and Alkalis ........................................................................\
........................................
100-00-42
Air Bags ........................................................................\
......................................................
100-00-42
Air Conditioning Refrigerant ........................................................................\
.......................
100-00-42
Adhesives and Sealers ........................................................................\
...............................
100-00-43
Antifreeze ........................................................................\
...................................................
100-00-43
Asbestos ........................................................................\
.....................................................
100-00-44
Battery Acids ........................................................................\
..............................................
100-00-44
Brake and Clutch Linings and Pads ........................................................................\
...........
100-00-44
Brake Fluids (Polyalkylene Glycols) ........................................................................\
...........
100-00-44
Brazing ........................................................................\
.......................................................
100-00-44
Chemical Materials ........................................................................\
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100-00-45
Chlorofluorocarbons (CFC) ........................................................................\
........................
100-00-45
Clutch Fluids ........................................................................\
...............................................
100-00-45
Clutch Linings and Pads ........................................................................\
.............................
100-00-45
Corrosion Protection Materials ........................................................................\
...................
100-00-45
Cutting ........................................................................\
....................................................... .
100-00-45
Dewaxing ........................................................................\
....................................................
100-00-45
Dusts ........................................................................\
..........................................................
100-00-45
Electric Shock ........................................................................\
.............................................
100-00-45
Engine Oils ........................................................................\
.................................................
100-00-46
Exhaust Fumes ........................................................................\
...........................................
100-00-46
Fibre Insulation ........................................................................\
...........................................
100-00-46
Fire ........................................................................\
.............................................................
100-00-46
First Aid
........................................................................\
......................................................
100-00-46
Fluoroelastomer ........................................................................\
..........................................
100-00-46
Foams

- Polyurethane ........................................................................\
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100-00-47
Freon ........................................................................\
..........................................................
100-00-47
Fuels ........................................................................\
...........................................................
100-00-47
Gas Cylinders ........................................................................\
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100-00-47
Gases ........................................................................\
.........................................................
100-00-47
Gaskets (Fluoroelastomer) ........................................................................\
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100-00-47
General Workshop Tools and Equipment ........................................................................\
...
100-00-48
High Pressure Air, Lubrication and Oil Test Equipment ......................................................
100-00-48
Halon ........................................................................\
..........................................................
100-00-48
Legal Aspects ........................................................................\
.............................................
100-00-1
General Information
100-00- 1
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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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Health and Safety Precautions
Introduction
Many of the procedures associated with vehicle
maintenance and repair involve physical hazards
or other risks to health. This subsection lists,
alphabetically, some of these hazardous operations
and the materials and equipment associated with
them. Precautions necessary to avoid these
hazards are identified.
The list is not exhaustive and all operations and
procedures, and the handling of materials, should
be carried out with health and safety in mind.
Before using any product the Materials Safety Data
Sheet supplied by the manufacturer or supplier
should be consulted.
Acids and Alkalis
See alsoBattery Acids.
For example caustic soda, sulphuric acid.
Used in batteries and cleaning materials.
Irritant and corrosive to the skin, eyes, nose and
throat. Cause burns. Can destroy ordinary
protective clothing.
Avoid splashes to the skin, eyes and clothing. Wear
suitable protective impervious apron, gloves and
goggles. Do not breath mists.
Make sure access to eye wash bottles, shower and
soap are readily available for splashing accidents.
Display Eye Hazard sign.
Air Bags
See also Fire, Chemical Materials.
Highly flammable, explosive – observe No Smoking
policy.
Used as a safety restraint system mounted in the
steering wheel and passenger side of the
instrument panel.
The inflator contains a high-energetic propellant
which, when ignited, produces a VERY HOT GAS
(2500°C).
The gas generant used in air bags is Sodium Azide.
This material is hermetically sealed in the module
and is completely consumed during deployment.
No attempt should be made to open an air bag inflator as this will lead to the risk of exposure to
Sodium Azide. If a gas generator is ruptured, full
protective clothing should be worn when dealing
with the spillage.
After normal deployment, gloves and safety
goggles must be worn during the handling process.
Deployed air bags should be disposed of in a
plastic bag in accordance with local regulations at
an approved chemical waste site.
For additional information, refer to:
Supplemental
Restraint System (SRS) Health and Safety
Precautions (100-00 General Information,
Description and Operation).
Air Conditioning Refrigerant
See also Chlorofluorocarbon, Chemical Materials
Highly flammable, combustible – observe No
Smoking policy.
Skin contact may result in frostbite.
Instructions given by the manufacturer must be
followed. Avoid naked lights, wear suitable
protective gloves and goggles.
If refrigerant comes into contact with the skin or
eyes, immediately rinse the affected areas with
water. Eyes should also be rinsed with an
appropriate irrigation solution and should not be
rubbed. SEEK MEDICAL ASSISTANCE IF
NECESSARY.
For additional information, refer to: Air Conditioning
(A/C) System Health and Safety Precautions
(100-00 General Information, Description and
Operation).
Adhesives and Sealers
See also Fire, Chemical Materials.
Highly flammable, flammable, combustible –
observe No Smoking policy.
Generally should be stored in No Smoking areas.
Cleanliness and tidiness in use should be
observed, for example disposable paper covering
benches; should be dispensed from applicators
where possible; containers, including secondary
containers, should be labeled appropriately.
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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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– that the speedometer, coolant temperaturegauge and tachometer (if equipped) register the
correct readings and operate correctly.
– that the switches and controls operate smoothly and positively, warning and indicator lamps
operate correctly and the direction indicator
control self cancels when the steering is
returned to the straight ahead position.
– that the heating and ventilation systems operate correctly and effectively.
– the brake operation and efficiency.
Brake Testing
WARNING: When brake testing, avoid
breathing the fumes from hot brakes, this
may contain asbestos dust which is
hazardous to health. Failure to follow this
instruction may result in personal injury.
For additional information, refer to: Health
and Safety Precautions (100-00 General
Information, Description and Operation).
CAUTIONS:
Avoid brake testing on busy roads where
it may cause inconvenience or danger to
other road users.
Brake testing which includes heavy brake
applications should not be carried out with
new brake pads/discs or linings/drums
until the components have bedded-in. New
brake friction components will not reach
full efficiency until the bedding-in process
is complete.
Test the brakes at several speeds within the normal
operating range using both light and heavy pedal
pressure. Note any tendency to snatch, pull or
drag, and any undue delay in application or
release.
Allow the vehicle to coast and note any tendency
to pull to one side, or evidence that the brakes are
binding.
After stopping the vehicle (not immediately after a
period of heavy braking), carefully check the brake
temperature. A brake disc or brake drum that feels
hot or is appreciably hotter than the others,
indicates that the brake is binding.
After completion of the test, check for: – oil, coolant, hydraulic, air and fuel leaks.
– abnormal temperature of any moving
components or assemblies, for example wheel
hubs, transmission and axle, which might
indicate over tightness or lack of lubrication.
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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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