2011 FORD KUGA wheel

Action
Possible Sources
Symptom
Certain amount of noise level
acceptable, not a safety critical
item.
Steering wheel to shroud interfer-
ence.
Power steering system grinding
noise – an abrasive noise (like
sand paper rubbing against
wood) occurs between moving
components such as steering
wheel and the steering column
shroud. Certain amount of noise level
acceptable, not a safety critical
item.
Steering column bearing.
CHECK if floor covering is
obstructing the steering gear
pinion.
Foreign material in contact with
the steering column shaft.
CHECK the installation of the
floor seal.
CHECK the clockspring and
secure if necessary.
REFER to:Clockspring (501-20
Supplemental Restraint
System, Removal and Installa-
tion).
Clockspring.
Power Steering Zip Noise
Action
Possible Sources
Symptom
Certain amount of noise level
acceptable, not a safety critical
item.
High viscosity of power steering
fluid at low temperature.
Power steering system zip noise
– occurs when hydraulic fluid
does not flow freely through the
power steering pump supply hose
from steering fluid reservoir to
power steering pump causing
cavitation at the pump. Zip is
primarily a cold weather start-up
phenomenon (below -10°C). BLEED the power steering
system.
REFER to:
Power Steering
System Vacuum Bleeding (211-
00 Steering System - General
Information, General Proced-
ures).
Aeration of the power steering
fluid.
Driveline Noise and Vibration
Action
Possible Sources
Symptom
GO toPinpoint Test A.
• Wheel end vibration.
• Engine/transmission.
Shake and vibration while driving
GO toPinpoint Test B.
• Air cleaner.
• Power assisted steering.
• Powertrain.
• Powertrain/drivetrain mounts.
• Exhaust system.
Tip-in moan
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Noise, Vibration and Harshness
100-04- 13
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Action
Possible Sources
Symptom
GO toPinpoint Test C.
• Cable(s)/hose(s).
• Powertrain/drivetrain mounts.
• Exhaust system.
• Belt/pulleys.
Idle boom/shake/vibration/
shudder
Suspension Noise and Vibration
Action
Possible Sources
Symptom
GO toPinpoint Test D.
• Suspension.
• Wheel bearings.
Wheel end vibration analysis
GO toPinpoint Test E.
• Trim panels.
• Air conditioning (A/C) system.
• Accessories.
Non-axle noise
Pinpoint Tests
NOTE:
These Pinpoint Tests are designed to take
the technician through a step-by-step diagnosis
procedure to determine the cause of a condition.
It may not always be necessary to follow the chart
to its conclusion. Carry out only the pinpoint test steps necessary to correct the condition. Then
check the operation of the system to make sure
the condition has been corrected.
After verifying that the condition has been
corrected, make sure all components removed
have been installed.
PINPOINT TEST A : SHAKE AND VIBRATION WHILE DRIVING
DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
A1: NEUTRAL COAST
1 Carry out the neutral coast test.
• Does the vibration disappear during the neutral coast test?
zYe s
GO to A2.
zNoGO to Pinpoint Test D.
A2: CHECK THE POWERTRAIN/DRIVETRAIN MOUNTS
1 Carry out the powertrain/drivetrain mount neut-
ralizing procedure
• Are the mounts OK?
zYe s Vehicle condition corrected. ROAD TEST as
necessary.
zNoINSTALL new powertrain/drivetrain mounts
as necessary. ROAD TEST as necessary.
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Noise, Vibration and Harshness
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DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
C3: CHECK THE EXHAUST SYSTEM
1 Carry out the exhaust system neutralizing
procedure.
• Is the exhaust system OK?
zYe s GO to C4 .
zNo
REPAIR as necessary. ROAD TEST as
necessary.
C4: CHECK THE POWERTRAIN/DRIVETRAIN MOUNTS
1 Carry out the powertrain/drivetrain mount neut-
ralizing procedure
• Are the powertrain/drivetrain mounts OK?
zYe s Vehicle condition corrected. ROAD TEST as
necessary.
zNoINSTALL new powertrain/drivetrain mounts
as necessary. ROAD TEST as necessary.
PINPOINT TEST D : WHEEL END VIBRATION ANALYSIS
DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
D1: INSPECT THE WHEELS AND TIRES
1 Inspect the wheels and tires.
REFER to:
Wheels and Tires (204-04 Wheels
and Tires, Diagnosis and Testing).
• Are the wheels and tires OK?
zYe s GO to D2 .
zNo
INSTALL new wheels or tires as necessary.
REFER to: Wheel and Tire (204-04 Wheels
and Tires, Removal and Installation).
ROAD TEST as necessary.
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Noise, Vibration and Harshness
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DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
D2: INSPECT THE WHEEL BEARINGS
1 Inspect the wheel bearings.
• Are the wheel bearings OK?
zYe s GO to D3 .
zNo
INSTALL new wheel bearings as necessary.
REFER to: Front Wheel Bearing (204-01 Front
Suspension, Removal and Installation).
ROAD TEST as necessary.
D3: INSPECT THE WHEEL AND TIRE RUNOUT
1 Inspect the wheel and tire runout.
• Is the wheel and tire runout OK?
zYe s Balance the wheels and tires. Refer to the
wheel balance equipment manufacturer's
instructions. ROAD TEST as necessary.
zNoINSTALL new wheels or tires as necessary.
REFER to: Wheel and Tire (204-04 Wheels
and Tires, Removal and Installation).
ROAD TEST as necessary.
PINPOINT TEST E : NON-AXLE NOISE
DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
E1: INSPECT THE VEHICLE TRIM
1 Check the radiator grille and trim panels to see
if they are the source of the noise.
• Are the vehicle trim components causing the noise?
zYe s
INSTALL new trim components or REPAIR as
necessary. ROAD TEST as necessary.
zNoGO to E2.
E2: CHECK THE AIR CONDITIONING (A/C) SYSTEM FOR NOISE
1 Ignition switch in position III.
2Ignition switch in position II.
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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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Description
Item
Instrument Cluster
1
PCM (powertrain control module)
2
EHPS (electro-hydraulic power steering)
control module
3
Audio unit
4
GEM (generic electronic module)
5
RCM (restraints control module)
6
PATS transceiver
7 Description
Item
Steering wheel lock module
8
Left-hand steering column switch
9
Fuel level sensor
10
Washer water level warning lamp switch
11
Accelerator pedal position sensor
12
CPP (clutch pedal position) sensor/BPP
(brake pedal position) sensor
13
Lighting control switch
14
System Operation
Instrument Cluster
The instrument cluster contains analog displays
as well as warning and control lamps for displaying
the system status; in addiiton, there is an LCD
indicator field for driver information.
The instrument cluster receives the following
signals from the PCM via the high speed CAN
(controller area network) Bus (HS-CAN):
• Vehicle speed – The PCM receives the necessary signalsfrom the ABS (anti-lock brake system) wheel
sensors from the ABS control unit on the
HS-CAN.
• Engine Coolant Temperature
• Engine oil pressure.
• Engine speed
The instrument cluster receives the following
signals from the GEM via the medium speed CAN
Bus (MS-CAN):
• Ambient temperature
• Brake fluid level
• Handbrake control
• Door latch control
• Liftgate latch control
• High beam control
• Headlamp flasher control
• Direction indicator control
The fuel level signal is sent by the two fuel level
sensors in the fuel pumps in the semitrailer tank,
which is wired to the instrument cluster. The
sensors are connected in series, and the total
resistance is determined from the two individual resistors. The instrument cluster converts the raw
fuel level signal into a damped fuel level value.
The odometer shows the total distance travelled
by the vehicle and is based on the same signal as
is processed for the daily mileage counter. The
value is recorded by the instrument cluster and
stored in a protected EEPROM (Electronically
Erasable Programmable Read Only Memory) area.
This area is a memory protected against
manipulation. If the instrument cluster detects an
error in this memory area, e.g. through damage,
the driver is notified with the "Odometer error"
message.
Message center
The message center is operated using the left-hand
switch on the steering column.
The SET/RESET button is activated to select a
submenu and change the settings. If signal tones
have been activated, a short acoustic signal will
sound each time a button is pressed.
By turning the rotary switch, the different menu
displays can be scrolled through or a setting
selected.
In this display, the navigation system can also
display direction and distance information.
In addition, safety and warning messages can be
displayed in this system, such as "Coolant
overheating", "Engine system error" or "Washer
fluid level too low". In addition to a safety message,
a general warning light (red/yellow) lights up.
G1030770en
2008.50 Kuga 8/2011 413-01-4
Instrument Cluster
413-01-4
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Instrument Cluster
Refer to
Wiring Diagrams Section 413-01, for
schematic and connector information. General Equipment
The Ford approved diagnostic tool
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical
or electrical damage.
Visual Inspection Chart Electrical
Mechanical
– Fuse(s)
– Wiring harness
– Electricalconnector(s)
– Instrument cluster
– Light emitting diode(s) (LED)(s)
– Engine oil filter
– Engine oil level
–
Engine coolant level
– Oil pressure switch
– Engine coolant level
– Coolant thermostat
– Engine coolant temperature (ECT)
sensor
– Fuel gauge
– Collapsed or damaged fuel tank
– Recirculation hose
– Fuel tank filler pipe/hose
– Indicated fuel level
– Fuel lines
– Fuel tank filler cap
– Fuel filter (external to the fuel tank)
– Fuel tank
– Door adjustment
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. NOTE: If none of the following warning indicators are operating correctly this may
indicate a concern with the central junction
box (CJB). If only one or two of the following
warning indicators are not operating
correctly this may indicate an instrument
cluster concern. Verify the following warning indicators are
working correctly:
• Charging.
• Turn signals.
• Headlamps.
5. If the cause is not visually evident, verify the symptom and refer to the diagnostic tab within
the Ford approved diagnostic tool.
Configuration of the Instrument Cluster
The instrument cluster is a programmable module,
which must be configured by selecting the
Programmable Module Installation Routine on the
Ford approved diagnostic tool.
NOTE: When the new instrument cluster has been
configured with the odometer value, its
configuration cannot be decreased or matched. A
new configuration will result in an increase in the
displayed odometer value by a minimum of two
units.
NOTE: The odometer value must be recorded from
the original instrument cluster before removal.
If the odometer value cannot be obtained from
the original instrument cluster (display failure)
the customer should supply the approximate
value.
The following features will need to be configured
when a new instrument cluster is installed:
• Anti-lock Brake System (ABS)
• All wheel drive
• Keyless vehicle entry
• Electronic power assisted steering
• Trip computer
• Voice control
• Parking aid
• Belt minder
• Safety belt not fastened
• Right hand drive
• Overspeed warning
• Reverse warning
• Turbocharger boost pressure
• Speed control
• Auxiliary heater
• Suspension control
• Washer fluid sensor G1054964en
2008.50 Kuga 8/2011 413-01-7
Instrument Cluster
413-01-7
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Horn
Principles of Operation
The horn system consists of a relay, a steering
wheel switch and either one or two horns. The
horn(s) receives voltage from the switched side of
the relay, and the relay switch is controlled on its
ground side by the steering wheel switch.
The horn relay, is located in the Battery junction
box (BJB) and is supplied with a permanent voltage
from the battery.
The steering wheel horn switch shares the steering
wheel clockspring circuit with the air-bag circuit.
Each of these systems work completely
independent of each other.
Inspection and Verification
1. Verify the customer concern.
2.
Visually inspect for obvious signs of mechanical
or electrical damage.
Visual Inspection Chart Electrical
• Fuse(s)
• Wiring harness
• Electrical connector(s)
• Horn switch
• Horn
• Clockspring
• Horn relay
• BJB
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 diagnostic tab within
the Ford approved diagnostic tool. G1055042en
2008.50 Kuga 8/2011 413-06-2
Horn
413-06-2
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