steering wheel FORD KUGA 2011 1.G Workshop Manual

Description
Item
Steering wheel in straight ahead position
1
Steering column lock locked
2
Steering column lock unlocked
3
Turn the steering wheel to the 90° left
position
4Description
Item
Turn the steering wheel to the 90° right
position
5
Turn the steering wheel to the left-hand
end position
6
Turn the steering wheel to the right-hand
end position
7
E88971
6
3
12
4
5
78
9
11
10
Description
Item
3, 4, 5-door body style
1
Wagon body style
2Description
Item
Sports utility vehicle body style
3
Coupe body style
4
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Description
Item
Turn the component clockwise through
45°
1
Turn the component counterclockwise
through 45°
2
Turn the component clockwise through
90°
3
Turn the component counterclockwise
through 90°
4
Turn the component clockwise through
180°
5Description
Item
Turn the component counterclockwise
through 180°
6
Turn the component clockwise through 2
complete turns
7
Turn the component counterclockwise
through 2 complete turns
8
Steering Wheel Symbols
Steering wheel symbols are used to provide further
information to a required steering wheel position
or steering column lock status.
E123751
3
4
12
56
7
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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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Standard Workshop Practices
Vehicle in Workshop
When working on a vehicle in the workshop always
make sure that:
– the parking brake is applied or the wheels aresecurely chocked to prevent the vehicle moving
forwards or backwards.
– the key is removed from key operated hood locks before any work is carried out around the
front of the vehicle.
– if the engine is to be run, there is adequate ventilation, or an extraction hose to remove
exhaust fumes.
– there is adequate room to raise the vehicle and remove the wheels, if necessary.
– fender covers are always fitted if any work is to be carried out in the engine compartment.
– the battery is disconnected if working on the engine, underneath the vehicle, or if the vehicle
is raised.
CAUTION: When electric arc welding on a
vehicle, always disconnect the generator
wiring to prevent the possibility of a surge
of current causing damage to the internal
components of the generator.
– if using welding equipment on the vehicle, a suitable fire extinguisher is readily available.
Towing the Vehicle
WARNING: When the vehicle is being
towed, the ignition switch must be in
position II (steering lock released and
warning lamps illuminated). Only then will
the steering, turn signal lamps, horn and
stop lamps be operational. Failure to follow
these instructions may result in personal
injury.
NOTE: The removable towing eye (if equipped),
has a left-hand thread and must be fully tightened
before towing can commence.
When towing is necessary, the vehicle towing eyes
should be used. The rope must be securely
fastened to the towing eyes and must also be
attached to the other vehicle such that the rope will
not foul the bodywork.
When a vehicle with automatic transmission is
towed, the gear selector must be in position N (Neutral). Never tow a vehicle with automatic
transmission at a speed greater than 30 mph (50
km/h) or for a distance greater than 30 miles (50
km). If it is necessary to tow the vehicle a greater
distance, the drive wheels must be lifted clear off
the ground.
Alternatively the vehicle can be transported on a
low loader or a trailer.
Connecting a Slave Battery Using
Jumper Cables
WARNING: If the slave battery has recently
been charged and is gassing, cover the
vent plugs or covers with a damp cloth to
reduce the risk of explosion should arcing
occur when connecting the jumper cables.
Failure to follow these instructions may
result in personal injury.
CAUTIONS:
A discharged battery condition may have
been caused by an electrical short circuit.
If this condition exists there will be an
apparently live circuit on the vehicle even
when all normal circuits are switched off.
This can cause arcing when the jumper
cables are connected.
While it is not recommended that the
vehicle is jump started, it is recognized
that this may occasionally be the only
practical way to mobilize a vehicle. In such
an instance, the discharged battery must
be recharged immediately after jump
starting to avoid permanent damage.
– Always make sure that the jumper cables are adequate for the task. Heavy duty cables must
be used.
– Always make sure that the slave battery is of the same voltage as the vehicle battery. The
batteries must be connected in parallel.
– Always make sure that switched electric circuits are switched off before connecting jumper
cables. This reduces the risk of arcing occurring
when the final connection is made.
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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 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
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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Action
Possible Sources
Symptom
Certain amount of noise level
acceptable, not a safety critical
item.
Power steering system knock
noise – a damped, metallic knock
noise which only occurs at
steering condition with engine off
(very high efforts).
Power steering system knock
noise – a heavy loud repeating
sound like a knock on a door that
occurs in several driving and
steering conditions.
Certain amount of noise level
acceptable, not a safety critical
item.
Tolerances in the steering gear
components.
Power Steering Mechanical Knock Noise
(PAS on)
Test Condition
Listen for steering knock noise with the engine
speed at idle in the following test conditions (power
assist). 1. Turn the steering wheel to a steering lock and
return to center quickly.
2. Turn the steering wheel 90 degrees to the left and then 90 degrees to the right quickly.
Action
Possible Sources
Symptom
REFER to Steering System.
REFER to:Steering System (211-
00 Steering System - General
Information, Diagnosis and
Testing).
Worn tie-rod ball joints (inner and
outer ball joints).
Power steering system knock
noise – clear knock noise from
steering gear linkage area.
Power Steering Hammer Knock (Hydraulic)
Noise
Test Condition
Listen for steering knock noise with the engine
speed at idle in the following test conditions (for vehicles with hydraulic power assisted steering
only, not electro-hydraulic power steering).
1. Turn the steering wheel to a steering lock
position and return quickly.
Action
Possible Sources
Symptom
Certain amount of noise level
acceptable, not a safety critical
item.
Hydraulic noise created by pres-
sure impulses.
Power steering system knock
noise – loud, metallic sound if
hitting the suspension cross-
member with a hammer (sounds
like metallic noise but is created
by pressure impulse in gear and
return line).
Power Steering Hydraulic Knock/Clonk
Noise
Test Condition
Listen for steering knock/clonk noise in the
following test conditions with the windows closed. 1. Drive over cobbled roads at low speed 10-30
km/h (6-20 mph) with and without turning.
2. Drive over straight tar strips road rails or 25 mm tall harshness strips at low speed 10-30 km/h
(6-20 mph) both driving straight and with
moderate turning.
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