wheel alignment FORD KUGA 2011 1.G Workshop Manual

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
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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 is high or low).
• Steering wheel off center
• CHECK the steering system.REFER to: Steering System
(211-00 Steering System -
General Information,
Diagnosis and Testing).
• Steering gear or linkage worn
or damaged.
• CARRY OUT the Ball JointInspection Component Test in
this procedure.
• Suspension lower arm ball joint.
• ADJUST the wheel alignment.REFER to: Front Toe Adjust-
ment (204-00 Suspension
System - General Informa-
tion, General Procedures)
/ Rear Toe Adjustment (204-00
Suspension System - General
Information, General Proced-
ures).
• Incorrect wheel alignment.
• CARRY OUT the Strut orShock Absorber Testing
component test in this
procedure.
• CHECK and INSTALL new suspension components as
necessary.
REFER to: Front Strut and
Spring Assembly (204-01
Front Suspension, Disas-
sembly and Assembly).
• Front strut and spring assem-
blies.
• Rough ride
• CHECK and INSTALL newsuspension components as
necessary. REFER to:
Front Strut and Spring Assembly (204-01 Front
Suspension, Disassembly
and Assembly),
Rear Stabilizer Bar (204-02
Rear Suspension, Removal
and Installation).
• Front or rear stabilizer bar
connecting links or bushings.
G1080717en2008.50 Kuga8/2011
204-00- 3
Suspension System - General Information
204-00- 3
DIAGNOSIS AND TESTING
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Action
Possible Sources
Symptom
• INSTALL a new lower arm.REFER to: Lower Arm (204-01
Front Suspension, Removal
and Installation).
• Front suspension lower arm
bushings.
• CHECK and INSTALL newcomponents as necessary.
REFER to: Rear Stabilizer Bar
Bushing (204-02 Rear
Suspension, Removal and
Installation).
• Rear suspension arm bushings.
• CARRY OUT the Strut orShock Absorber Testing
component test in this
procedure.
• CHECK and INSTALL new suspension components as
necessary.
• Rear shock absorbers.
• GO toPinpoint Test B.
• Front strut and spring assembly
or rear shock absorber and
spring upper mounting bolts or
nuts loose or broken.
• Excessive noise
• GO toPinpoint Test B.
• Shock absorbers leaking.
• GO toPinpoint Test B.
• Shock absorbers performance
incorrect.
• GO toPinpoint Test B.
• Stabilizer bar components.
• GO toPinpoint Test B.
• Strut and spring assembly and
springs.
• GO toPinpoint Test B.
• Springs moving on springs
upper or lower seats.
• GO toPinpoint Test B.
• Suspension bushings.
• GO toPinpoint Test B.
• Lower arm ball joint.
• GO toPinpoint Test B.
• Worn front wheel bearings
• GO toPinpoint Test B.
• Wheels and tires.
• CHECK and INSTALL newsuspension components as
necessary.
• Front or rear suspension
damage.
• Incorrect tire wear
• ADJUST the wheel alignment.REFER to: Front Toe Adjust-
ment (204-00 Suspension
System - General Informa-
tion, General Procedures)
/ Rear Toe Adjustment (204-00
Suspension System - General
Information, General Proced-
ures).
• Incorrect wheel alignment.
G1080717en2008.50 Kuga8/2011
204-00-
4
Suspension System - General Information
204-00- 4
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3. If a new lower arm is installed it will benecessary to check and adjust the front wheel
alignment.
REFER to: Front Toe Adjustment (204-00
Suspension System - General Information,
General Procedures)
/ Rear Toe Adjustment (204-00 Suspension
System - General Information, General
Procedures).
Strut or Shock Absorber Inspection
NOTE: Inspect the struts or shock absorber for
signs of oil weepage or leaks. Make sure that the
oil is not from another source.
Weepage:
• deposits a thin film of oil on the strut and spring assembly or shock absorber.
• is normally noticed due to a collection of dust on the strut and spring assembly or shock
absorber.
• occurs during the normal running-in period of 4800 - 8050 km. After this period no new signs
of oil should be visible.
• does not require new struts or shock absorbers to be installed.
Leakage:
• covers the entire strut and spring assembly or shock absorber with oil.
• will drip oil onto the surrounding suspension components.
• requires new struts or shock absorbers to be installed.
Strut or Shock Absorber Testing
NOTE: Struts or shock absorbers must be tested
in the vertical position.
1. Remove both strut and spring assemblies or shock absorbers. The piston rods should extend.
• Disassemble the strut and spring assemblies.
REFER to: Front Strut and Spring Assembly
(204-01 Front Suspension, Removal and
Installation).
2. Compress the piston rods. Both piston rods should offer the same resistance when
compressing.
3. Compress and release the piston rods. The piston rods should extent equally. 4. Compress and pull the piston rod in the vertical
position. Feel if the resistance force at the point
of direction change-over is perceptible without
a lag. If a lag is perceptible it is an indication of
damper valve damage and new struts or shock
absorbers must be installed. REFER to:
Front Strut and Spring Assembly (204-01 Front
Suspension, Removal and Installation),
Spring (204-02 Rear Suspension, Removal and
Installation).
Load-Levelling Shock Absorber
1. With the vehicle unladen, measure and note the dimensions between the base of the wheel rim
and the top of the rear fender on both sides.
• The measurements on both sides should be approximately equal.
2. With a load of 4 average size adults and a 100 kg weight, measure and note the dimensions
between the base of the wheel rim and the top
of the rear fender on both sides.
3. NOTE: Due to the internal ratchet mechanism of the suspension components, the height
of the rear of the vehicle should rise during
the road test.
With a load of 4 average size adults and a 100
kg weight, drive the vehicle for 3 km on a road
of normal condition.
4. With a load of 4 average size adults and a 100 kg weight, measure and note the dimensions
between the base of the wheel rim and the top
of the rear fender on both sides.
5. If the dimensions on both sides are no longer approximately equal, install new load levelling
shock absorbers.
REFER to: Spring(204-02 Rear Suspension,
Removal and Installation).
6. NOTE: Due to the internal ratchet mechanism of the suspension components, the height
of the rear of the vehicle should rise during
the road test.
If the dimensions are approximately equal,
unload the vehicle and drive the vehicle for 3
km on a road of normal condition.
7. With the vehicle unladen, measure and note the dimensions between the base of the wheel rim
and the top of the rear fender on both sides.
Check the final dimensions with the original
dimensions taken in the unladen condition.
G1080717en2008.50 Kuga8/2011
204-00- 13
Suspension System - General Information
204-00- 13
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Front Toe Adjustment(14 117 3)
General EquipmentWheel Alignment System
NOTE: Make sure that the vehicle is standing on
a level surface.
1. CAUTION: Make sure that the steering wheel lock is engaged.
NOTE: Make sure that the road wheels are in
the straight ahead position.
E99259
2. Check the toe setting on both sides.
General Equipment: Wheel Alignment System
3. Loosen on both sides.
Torque: 69
Nm
1.
2.NOTE: Make sure that the boot is correctly
located.
Rotate the tie-rods an equal amount in either
a clockwise or a counterclockwise direction
to adjust the toe setting on both sides.
2
E67410
1
2
G1000721en2008.50 Kuga8/2011
204-00- 15
Suspension System - General Information
204-00- 15
GENERAL PROCEDURES
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Rear Toe Adjustment(15 211 3)
General EquipmentWheel Alignment System
NOTE: Make sure that the vehicle is standing on
a level surface.
1. Check the toe setting.
Refer to: Specifications (204-02 Rear
Suspension, Specifications).
General Equipment: Wheel Alignment System
2. Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
3. Loosen the rear lower arm adjustment cam nut
on both sides.
Torque: 18
Nm
E69309
4.Lower the vehicle.
5. Bounce the vehicle to make sure that the
suspension is in its normal resting position.
6. Adjust the toe setting.
E69678
7. NOTE: Only tighten the nuts and bolts when the
suspension is in the normal drive position.
Torque: 90
Nm
E69309
G1000722en2008.50 Kuga8/2011
204-00- 16
Suspension System - General Information
204-00- 16
GENERAL PROCEDURES
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Front Wheel Alignment 2WD (at curb weight)
MaximumVari-
ance
Left or Right
Setting
or
Nominal
Toler-
ance
Range
Measurem
ents
Descri
ption
1°00'
4°26'
3°26'
to
5°26'
Degrees
and
minutes
Caster
angle
1.00°
4.44°
3.44°
to
5.44°
Decimal
degrees
1°15'
-0°48'
-2°03'
to
+0°27'
Degrees
and
minutes
Camber
angle
1.25°
-0.80°
-2.05°
to -
0.45°
Decimal
degrees
-1.5
Toe-in ±1.1
1.5
Toe-in ±2.6
mm
To t a l
toe
-
0°12'
Toe-in
± 0°09'
0°12'
Toe-in
± 0°21'
Degrees
and
minutes
-
0.20°
Toe-in
± 0.15°
0.20°
Toe-in
± 0.35°
Decimal
degrees Front Wheel Alignment 4WD (at curb weight)Maximum
Vari-
ance
Left or Right
Setting
or
Nominal
Toler-
ance
Range
Measurem
ents
Descri
ption
1°00'
4°22'
3°22'
to
5°22'
Degrees
and
minutes
Caster
angle
1.00°
4.37°
3.37°
to
5.37°
Decimal
degrees
1°15'
-0°47'
-2°02'
to
+0°28'
Degrees
and
minutes
Camber
angle
1.25°
-0.78°
-2.03°
to -
0.47°
Decimal
degrees
-1.5
Toe-in ±1.1
1.5
To e - i n ±2.6
mm
To t a l
toe
-
0°12'
Toe-in
± 0°09'
0°12'
To e - i n
±0°21'
Degrees
and
minutes
-
0.20°
Toe-in
± 0.15°
0.20°
To e - i n
±0.35°
Decimal
degrees
G1000726en2008.50 Kuga8/2011
204-01- 2
Front Suspension
204-01- 2
SPECIFICATIONS
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Front Stabilizer Bar(14 752 0)
Special Tool(s) / General Equipment205-316A
Alignment Pins, Subframe
15097A
Hydraulic Press
Transmission Jack
Removal
NOTE:Removal steps in this procedure may
contain installation details.
1. Refer to: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation).
2.
E98543
x7
3. If equipped.
Torque: 8
Nm
E75215
4. CAUTION: Make sure that the ball joint
ball does not rotate.
On both sides.
Torque: 47.5
Nm
E91648
5. CAUTION: Make sure that the exhaustflexible pipe is not forcibly bent.
E98334
6.
E98346
G1000208en2008.50 Kuga8/2011
204-01- 15
Front Suspension
204-01- 15
REMOVAL AND INSTALLATION
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Rear Wheel Alignment 2WD
MaximumVari-
ance
Left or Right
Setting
or
Nominal
Toler-
ance
Range
Measurem
ents
Descri
ption
1°15'
-1°32'
-2°47'
to -
0°17'
Degrees
and
minutes
Camber
angle
1.25°
-1.54°
-2.79°
to -
0.29°
Decimal
degrees
-1.4
Toe-in ±0.6
1.4 ±
1.3
mm
Single
wheel toe
-
0°11'
Toe-in
± 0°05'
0°11' ±
0°10'
Degrees
and
minutes
-
0.19°
Toe-in
± 0.08°
0.19° ±
0.18°
Decimal
degrees
-2.8
Toe-in ±1.1
2.8 ±
2.6
mm
To t a l
toe
-
0°23'
Toe-in
± 0°09'
0°23' ±
0°21'
Degrees
and
minutes
-
0.38°
Toe-in
± 0.15°
0.38° ±
0.35°
Decimal
degrees Rear Wheel Alignment 4WDMaximum
Vari-
ance
Left or Right
Setting
or
Nominal
Toler-
ance
Range
Measurem
ents
Descri
ption
1°15'
-1°32'
-2°.47'
to -
0°17'
Degrees
and
minutes
Camber
angle
1.25°
-1.54°
-2.79°
to -
0.29°
Decimal
degrees
-1.4
Toe-in ±0.6
1.4 ±
1.3
mm
Single
wheel toe
-
0°11'
Toe-in
± 0°05'
0°11' ±
0°10'
Degrees
and
minutes
-
0.19°
Toe-in
± 0.08°
0.19° ±
0.18°
Decimal
degrees
-2.8
Toe-in ±1.1
2.8 ±
2.6
mm
To t a l
toe
-
0°23'
Toe-in
± 0°09'
0°23' ±
0°21'
Degrees
and
minutes
-
0.38°
Toe-in
± 0.15°
0.38° ±
0.35°
Decimal
degrees
Torque Specifications
lb-in
lb-ft
Nm
Item
160
14
18
Rear Shock Absorber - Upper Fixing
1018
85
11 5
Rear Shock Absorber - Lower Fixing
G1000727en2008.50 Kuga8/2011
204-02- 2
Rear Suspension
204-02- 2
SPECIFICATIONS
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Wheels and Tires
Inspection and Verification
Visual Inspection Chart
MechanicalWheel(s)Tire(s)
Tire pressure(s) * Wheel nuts
Wheel studs
* Vehicles equipped with a tire deflation detection system (DDS) must be inspected for correct operation using the Ford approved diagnostic tool.
To maximize tire performance, inspect the tires for
signs of incorrect inflation and uneven wear which
may indicate a need for balancing, rotation or
suspension alignment. Tires should also be
checked frequently for cuts, stone bruises,
abrasions, blisters and for objects that may have
become embedded in the tread. More frequent
inspections are recommended when rapid or
extreme temperature changes occur or when road
surfaces are rough or occasionally littered with
foreign material.
As a further visible check of tire condition, tread
wear indicators are molded into the bottom of the
tread grooves. When these indicator bands become
visible, new tires must be installed.
Tire Wear Diagnosis
Uneven wear is usually caused by either excessive
camber or excessive toe on tires.
Sometimes incorrect toe settings or worn struts will
cause severe `cupping' or `scalloped' tire wear on
non-driven wheels.
Severely incorrect toe settings will also cause other
unusual wear patterns.
Tire Vibration Diagnosis
A tire vibration diagnostic procedure always begins
with a road test. The road test and customer
interview (if available) will provide much of the
information needed to find the source of a vibration. During the road test, drive the vehicle on a road
that is smooth and free of undulations. If vibration
is apparent, note and record the following:
– the speed at which the vibration occurs.
– what type of vibration occurs in each speed
range.
– mechanical or audible
– how the vibration is affected by changes in the following:
– engine torque
– vehicle speed
– engine speed
– type of vibration - sensitivity: – torque sensitive
– vehicle speed sensitive
– engine speed sensitive
The following explanations help isolate the source
of the vibration.
Torque Sensitive
This means that the condition can be improved or
made worse by accelerating, decelerating,
coasting, maintaining a steady vehicle speed or
applying engine torque.
Vehicle Speed Sensitive
This means that the vibration always occurs at the
same vehicle speed and is not affected by engine
torque, engine speed or the transmission gear
selected.
G1061329en2008.50 Kuga8/2011
204-04- 6
Wheels and Tires
204-04- 6
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