2011 FORD KUGA AIR CON

E96312
1
2
3
Description
Item
Reservoir
1
Hydraulic pump
2
Brushless DC motor with integral power
steering moduleRefertoComponentDescription:(page
11)
3
NOTE: The power steering pump must be filled
and vented as specified.
The electro-hydraulic power steering pump
comprises a brushless DC motor, the hydraulic
pump and the power steering fluid reservoir.
The hydraulic pump is a gear pump; a resonance
chamber incorporated into the pump body reduces
noise emissions.
The operating pressure is also regulated by means
of a pressure limiting valve which is integrated in
the pump housing. The pressure limiting valve
stabilizes the throughput to the steering gear to a
particular level independently of engine speed.
The pressure relief valve will operate if the
discharge from the pump is restricted, for example, steering held on full lock. If the output from the
pump is blocked, all output is recirculated through
the pump. As no fresh fluid from the reservoir is
drawn into the pump in the process, the
temperature of the power steering fluid in the pump
quickly increases. Consequently, periods of holding
the steering wheel at full lock should be kept to a
minimum to prevent overheating of the pump and
the power steering fluid within it.
The pressure limiting valve limits the pressure on
the outlet side to 120 bar.
Integrated steering angle sensor - vehicles
built up to 09/2009
G1001270en2008.50 Kuga8/2011
211-02-
10
Power Steering
211-02- 10
DESCRIPTION AND OPERATION
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1
2
3
45
6
7
8
9
10
E42460
Description
Item
Connector
1
Power steering module
2
Seal
3
Bearing
4
Shaft
5Description
Item
Cover
6
Rotor with magnets
7
Stator8
Distributor
9
Bearing
10
In the electrohydraulic power steering system, a
brushless 12 volt direct current motor drives the
hydraulic pump. Higher pumping rates are only
provided when they are required for steering
manoeuvres. This avoids unnecessary energy
consumption in the majority of phases in a drive
cycle.
Commutation in the motor is done electronically.
As a result, there are no brushes to wear away.
The entire system is designed for maintenance-free
operation.
In more than 85% of all driving situations, the
power steering pump operates at standby speed
and consumes less than 4A. However, pump speed
can quickly increase to full rotational speed if
emergency steering manoeuvres require it. The system has a continuously variable pump
rotational speed.
G1001270en2008.50 Kuga8/2011
211-02-
12
Power Steering
211-02- 12
DESCRIPTION AND OPERATION
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Power Steering Pressure Line and Return Line Assembly — 2.5LDuratec (147kW/200PS) - VI5(13 443 0)
General Equipment
Hose Clamp Remover/Installer
Removal
NOTE: Removal steps in this procedure may
contain installation details.
1. Refer to: Steering 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.
E98543
x7
4.
E99630
5.
E99631
6. WARNING: Be prepared to collect escaping fluid.
1. General Equipment: Hose ClampRemover/Installer
2. Torque: 30
Nm
E114706
1
2
7. Torque: 23Nm1.
2. Torque: 7
Nm
G1185534en2008.50 Kuga8/2011
211-02- 13
Power Steering
211-02- 13
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Power Steering Pump — 2.5L Duratec (147kW/200PS) -VI5(13 434 0)
General Equipment
Hose Clamp(s)
Hose Clamp Remover/Installer
Removal
NOTE: Removal steps in this procedure may
contain installation details.
1. Refer to: Steering 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.
E98543
x7
4.
E99630
5.
E99631
6. 1. WARNING: Be prepared to collect
escaping fluid.
General Equipment: Hose Clamp(s)
2. General Equipment: Hose Clamp Remover/Installer
E114163
12
7.1. WARNING: Be prepared to collect
escaping fluid.
Torque: 30Nm
3. General Equipment: Hose Clamp
Remover/Installer
4. Torque: 10
Nm
G1176952en2008.50 Kuga8/2011
211-02- 18
Power Steering
211-02- 18
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Power Steering Pump to Steering Gear Pressure Line — 2.5LDuratec (147kW/200PS) - VI5(13 440 0; 13 443 0)
General Equipment
Hose Clamp Remover/Installer
Removal
NOTE: Removal steps in this procedure may
contain installation details.
1. Refer to: Steering 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.
E98543
x7
4.
E99630
5.
E99631
6. WARNING: Be prepared to collect escaping fluid.
1. General Equipment: Hose ClampRemover/Installer
2. Torque: 30
Nm
E114706
1
2
7. Torque: 23Nm1.
2. Torque: 7
Nm
G1185535en2008.50 Kuga8/2011
211-02- 21
Power Steering
211-02- 21
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Steering Gear(13 116 0)
Special Tool(s) / General Equipment205-880
Alignment Pins, Subframe
E93105
211-020
Separator, Ball Joint
13006
Transmission Jack
Materials
Specification
Name
WSA-M2C195-A / 9U7J-
M2C195-AA
Power Steering Fluid IW
Removal
NOTE:
Removal steps in this procedure may
contain installation details.
1. Refer to: Steering System Health and Safety
Precautions (100-00 General Information,
Description and Operation).
2. CAUTION: Make sure that the steering wheel lock is engaged.
NOTE: Make sure that the road wheels are in
the straight ahead position.
E99259
3. Torque: 30Nm
E66155
4.On both sides.
Refer to: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation).
5. If equipped.
E98543
x7
6.If equipped.
Torque: 8
Nm
E75215
7. CAUTION: Make sure that the ball joint
ball does not rotate.
G1001271en2008.50 Kuga8/2011
211-02- 25
Power Steering
211-02- 25
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Steering Gear to Power Steering Fluid Reservoir Return Line —2.5L Duratec (147kW/200PS) - VI5(13 439 0)
General Equipment
Hose Clamp Remover/Installer
Removal
NOTE: Removal steps in this procedure may
contain installation details.
1. Refer to: Steering 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.
E98543
x7
4.
E99630
5.
E99631
6. WARNING: Be prepared to collect escaping fluid.
1. General Equipment: Hose ClampRemover/Installer
2. Torque: 30
Nm
E114706
1
2
7. Torque: 23Nm1.
2. Torque: 7
Nm
G1185536en2008.50 Kuga8/2011
211-02- 36
Power Steering
211-02- 36
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

SECTION 211-03 Steering Linkage
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
REMOVAL AND INSTALLATION
211-03-2
(13 273 0)
Tie Rod End ........................................................................\
............................
211-03-3
(13 263 0)
Tie Rod ........................................................................\
...................................
211-03-5
(13 134 0)
Steering Gear Boot ........................................................................\
.................
211-03-1
Steering Linkage
211-03- 1
.
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL