wheel bolt torque FORD KUGA 2011 1.G Workshop Manual

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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Wheel Knuckle — LHD FWD/RHD FWD
Removal
1.Refer to: Spring(204-02 Rear Suspension,
Removal and Installation).
2. Refer to: Wheel Bearing and Wheel Hub (204-02
Rear Suspension, Removal and Installation).
3.
E101643
4.
E99208
5.
E93214
6.
E93206
Installation
1. Fabricate a spacer.
E69209
226
40
2. Torque: 120Nm1.
2.NOTE: Only tighten the bolt finger tight at
this stage.
E932621
2
G1000235en2008.50 Kuga8/2011
204-02- 19
Rear Suspension
204-02- 19
REMOVAL AND INSTALLATION
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Wheel Knuckle — LHD 4WD/RHD 4WD
Removal
1.Refer to: Spring(204-02 Rear Suspension,
Removal and Installation).
2. Refer to: Wheel Bearing and Wheel Hub (204-02
Rear Suspension, Removal and Installation).
3.
E101643
4.
E99208
5.
E93214
6.
E93206
Installation
1. Fabricate a spacer.
E69209
226
40
2. Torque: 120Nm1.
2.NOTE: Only tighten the bolt finger tight at
this stage.
E932621
2
G1000760en2008.50 Kuga8/2011
204-02- 22
Rear Suspension
204-02- 22
REMOVAL AND INSTALLATION
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All-wheel drive control unit
E100663
14
3
2
5
Description
Item
Electronic Control Unit
1
Control valve
2
Pressure/temperature sensor
3
Electrical connection CAN (controller area
network) databus
4
Electric feed pump connection
5
The all-wheel drive control unit is bolted directly to
the housing of the Haldex clutch.
It forms one unit made up of the control valve, a
pressure/temperature sensor, and a control
module. It receives signals from the PCM and from
the ABS control module via the CAN data bus. The
control module in the control unit uses these
signals to determine the fluid pressure that is
needed to actuate the clutch plates depending on
the requirement. This determines how much torque
should be transmitted to the rear wheels. All-wheel
drive is deactivated if a fault occurs in the all-wheel
drive control unit.
A preload of approx. 80 Nm is always present at
the Haldex clutch. The temperature sensor of the Haldex clutch is
installed near the control valve in the control unit
and is surrounded by the hydraulic fluid. The
temperature is transmitted to the control module
and is used for adaptation to the changing viscosity
of the hydraulic fluid. If the hydraulic fluid is cold,
the control valve has to be opened slightly more
than requested. This allowance has to be reduced
as the temperature increases. The normal working
temperature of the hydraulic fluid is between +40
°C and +60 °C. If the temperature rises above 100
°C, the clutch is depressurised; if the temperature
falls below 95 °C, the clutch is pressurised again.
All-wheel drive is deactivated and a diagnostic
trouble code set if a fault occurs in the temperature
sensor.
With Haldex Generations I and II, the control valve
was actuated via a stepper motor. With Haldex
Generation III, the stepper motor has been omitted.
The control valve is now actuated via a solenoid
valve. The solenoid valve is actuated by the control
module in the all-wheel drive control unit by means
of pulse width modulation. The pulse width
modulation determines the position of the
adjustment spindle and thus the opening cross
section of the return hole. This is how the pressure
at the working piston of the plates is determined.
If the return hole is fully closed, maximum pressure
is applied to the plates. If the return hole is fully
open, the plates are unpressurized.
Electric feed pump
The electric feed pump is installed in the clutch
unit. It works according to the gerotor principle.
The main purpose of the feed pump is to fill the
pressure accumulator and the space behind the
pump plunger with hydraulic fluid, thereby ensuring
a fast response time of the Haldex clutch. The feed
pump used in the third generation is designed to
achieve an even higher pressure than the base
pressure of 4 bar. It is supplied with current by the
control module in the all-wheel drive control unit
when the engine is running above approx. 400 rpm.
Pressure control - 3rd generation
Haldex clutch
G1076981en2008.50 Kuga8/2011
205-02-
10
Rear Drive Axle/Differential
205-02- 10
DESCRIPTION AND OPERATION
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Brake Pads(12 234 0)
Special Tool(s)206-005
Retractor, Brake Caliper
Piston
12014
Materials
Specification
Name
WSS-M6C57-A2
Brake Fluid - Super
DOT4
WSS-M12A4-A2 / 1C1J-
19584-BA
Lubricating Paste
Removal
NOTE:
Removal steps in this procedure may
contain installation details.
1. Refer to: Brake System Health and Safety
Precautions (100-00 General Information,
Description and Operation).
2. Refer to: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation).
3.
E100314
4. WARNING: The brake caliper housing Torx bolts must not be removed.
CAUTION: Make sure that no load is
placed on the brake hose.
Torque: 28
Nm
E94825
12
3
5.
E100312
6.
E100313
G1001203en2008.50 Kuga8/2011
206-03- 2
Front Disc Brake
206-03- 2
REMOVAL AND INSTALLATION
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firmly grasp the road wheel and apply a rocking
motion checking for any free play in the steering
linkage.
E56375
10. Detach the steering gear boot from the steeringgear body and check for free play at the tie-rod
inner ball joint.
11. If there is free play at the tie-rod inner ball joint, install a new tie-rod.
REFER to: Tie Rod(211-03 Steering Linkage,
Removal and Installation).
12. Check the tie-rod end for free play. Install a new tie-rod end if necessary.
REFER to: Tie Rod End (211-03 Steering
Linkage, Removal and Installation).
Turning Effort Test
NOTE: Before carrying out this test, make sure
that the suspension components are serviceable.
NOTE: Before carrying out this test, make sure
that the steering column is serviceable.
NOTE: Before carrying out this test, make sure
that the toe adjustment and tire pressures are
correct.
1. Park the vehicle on a dry, even surface and apply the parking brake.
2. Remove the driver air bag module.
REFER to: Driver Air Bag Module (501-20
Supplemental Restraint System, Removal and
Installation).
3. Connect the air bag simulators to the sub-harnesses in place of the driver air bag
module at the top of the steering column.
4. Start the engine and turn the steering wheel from lock to lock several times until the power
steering fluid has reached normal operating
temperature. 5. Using a suitable torque wrench and socket,
check the steering wheel turning effort.
6. If the steering wheel turning effort is greater than the specification, install a new steering gear.
Steering Column Universal Joint
1.WARNING: Install a new steering column
to steering gear pinion retaining bolt. Failure
to follow this instruction may result in
personal injury.
Detach the steering column from the steering
gear pinion.• Discard the steering column to steering gear pinion retaining bolt.
TIE45919
1
2
2
2. Check for smooth movement of the steeringcolumn universal joint.
1. Hold the steering column universal joint yoke.
2. Articulate the free yoke in a figure of eight movement.
• If the movement is not smooth or resistance is felt, install a new steering column.
REFER to: Steering Column (211-04 Steering
Column, Removal and Installation).
TIE45918
3. Hold both of the steering column universal joint yokes and twist them clockwise and
counterclockwise.
G1059437en2008.50 Kuga8/2011
211-00- 4
Steering System - General Information
211-00- 4
DIAGNOSIS AND TESTING
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Installation
1.Special Tool(s): 303-1181
E64891
303-1181
Vehicles with manual transmission
2. CAUTIONS:
Make sure that new bolts are installed.
Make sure that no excess sealant
residue is evident.
NOTE: Make sure that the locating pin on the
crankshaft is aligned with the guide hole in the
flywheel or flexplate.
Special Tool(s): 303-254
Torque:
• Stage 1: 45
Nm
• Stage 2: 65°
E124911
1
2
3
4
5
67
8
9
10
3.
Vehicles with automatic transmission
4. CAUTIONS:
Make sure that new bolts are installed.
Make sure that no excess sealant
residue is evident. NOTE:
Make sure that the locating pin on the
crankshaft is aligned with the guide hole in the
flywheel or flexplate.
Special Tool(s): 303-254
Torque:
• Stage 1: 45
Nm
• Stage 2: 50°
E124911
1
2
3
4
5
67
8
9
10
5. Refer to: Transmission (307-01 Automatic
Transmission/Transaxle - Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD,
Removal).
G1268481en2008.50 Kuga8/2011
303-01- 57
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
57
REMOVAL AND INSTALLATION
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Engine Accessories(21 139 4)
Installation
Special Tool(s)303-122
Lifting Bracket, Engine
21068A
303-254
Locking Tool, Flywheel
21135
303-435
Mounting Stand
21187
303-435-06
Mounting Bracket for 303-435
21031B
303-435-14B
Mounting Plate for
303-435-06
E62805
1.Torque: 17Nm•
E68407
12
2.Torque: 48Nm
E84148
x4
Vehicles with manual transmission
3. CAUTIONS:
Make sure that new bolts are installed.
Make sure that no excess sealant
residue is evident.
G1079026en2008.50 Kuga8/2011
303-01- 11 2
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
11 2
INSTALLATION
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NOTE:Make sure that the locating pin on the
crankshaft is aligned with the guide hole in the
flywheel or flexplate.
Special Tool(s): 303-254
Torque:
• Stage 1: 45
Nm
• Stage 2: 65°
E124911
1
2
3
4
5
67
8
9
10
Vehicles with automatic transmission
4. CAUTIONS:
Make sure that new bolts are installed.
Make sure that no excess sealant
residue is evident.
NOTE: Make sure that the locating pin on the
crankshaft is aligned with the guide hole in the
flywheel or flexplate.
Special Tool(s): 303-254
Torque:
• Stage 1: 45
Nm
• Stage 2: 50°
E124911
1
2
3
4
5
67
8
9
10
All vehicles
5. Torque: 17Nm
E68412
6.
E67909
7.Torque: 24Nm
x12
E66830
G1079026en2008.50 Kuga8/2011
303-01- 11 3
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
11 3
INSTALLATION
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