Ford Kuga

 Service Manual

Brake System - General Information » Brake System
Pinpoint Tests

1. Pump the foot brake rapidly five times.

• Does the brake pedal height build up and then hold?

Yes CHECK parking brake adjustment and ADJUST as necessary.

REFER to: Parking Brake Cable Adjustment (206-05 Parking Brake and Actuation, General Procedures).

If the condition still exists. BLEED the brake system. REFER to: (206-00 Brake System - General Information) Brake System Bleeding (General Procedures), Brake System Pressure Bleeding (General Procedures), Component Bleeding (General Procedures).

TEST the system for normal operation.

No GO to A2.

1. Check for external brake and clutch system leaks. Refer to Brake Master Cylinder Component Test in this procedure.

Are any leaks present?

• Yes REPAIR as necessary. ADD fluid and BLEED the brake system. REFER to: (206-00 Brake System - General Information) Brake System Bleeding (General Procedures), Brake System Pressure Bleeding (General Procedures), Component Bleeding (General Procedures).

  TEST the system for normal operation.

• No GO to A3.

1. Carry out a brake master cylinder bypass Condition Test. Refer to the Brake Master Cylinder Component Test in this procedure.

• Was a concern found?

Yes INSTALL a new brake master cylinder.

REFER to: Brake Master Cylinder - 2.5L Duratec (147kW/200PS) - VI5 (206-06 Hydraulic Brake Actuation, Removal and Installation).

TEST the system for normal operation.

No VERIFY the customer concern.

1. Depress the brake pedal.

• Does the pedal ease down slowly?

Yes GO to B2.

No Refer to the Brake Master Cylinder Component Test in this procedure.

1. Check for external brake system leaks.

• Are any leaks present?

Yes REPAIR as necessary. ADD fluid and BLEED the brake system. REFER to: (206-00 Brake System - General Information) Brake System Bleeding (General Procedures), Brake System Pressure Bleeding (General Procedures), Component Bleeding (General Procedures).

TEST the system for normal operation.

No GO to B3.

1. Carry out a brake master cylinder bypass Condition Test. Refer to the Brake Master Cylinder Component Test in this procedure.

• Was a concern found?

Yes INSTALL a new brake master cylinder.

REFER to: Brake Master Cylinder - 2.5L Duratec (147kW/200PS) - VI5 (206-06 Hydraulic Brake Actuation, Removal and Installation).

TEST the system for normal operation.

No GO to B4.

1. Disconnect the brake booster check valve vacuum hose at the manifold.

2. Blow into the hose attached to the brake booster check valve.

• Does air pass through the valve?

Yes INSTALL a new brake booster check valve.

No GO to B5.

1. Run the engine at idle.
2. Using a suitable vacuum gauge, check the vacuum pressure.

• Is the vacuum pressure above 40.5 kPa (0.4 bar) with the brake booster non-operational?

Yes VERIFY the customer concern.

No INSTALL a new brake booster check valve vacuum hose. TEST the system for normal operation.

1. Check the brake booster push rod alignment and pedal travel.

• Is the push rod and pedal travel OK?

Yes TEST the brake pedal application. GO to Pinpoint Test D.

No INSTALL a new brake booster. TEST the system for normal operation.

1. With the engine off, apply and release the brake pedal five times to deplete all vacuum from the brake booster. Apply the brake pedal, hold with light pressure. Start the engine.

• Does the brake pedal hold?

Yes GO to D2.

No GO to D3.

1. Run the engine at approximately 1000 rpm, release the accelerator pedal and turn the engine off. Wait 90 seconds and apply the brakes. Two or more brake applications should be power assisted.

• Does the brake booster work?

Yes VERIFY the customer concern.

No GO to D4.

1. Disconnect the actuator rod from the pedal pin and fully depress the brake pedal.

• Did the pedal move freely?

Yes VERIFY the customer concern.

No INSTALL new brake pedal bushings. TEST the system for normal operation.

1. Disconnect the brake booster check valve vacuum hose at the manifold.

2. Blow into the hose attached to the brake booster check valve.

• Does air pass through the valve?

Yes INSTALL a new brake booster check valve.

TEST the system for normal operation.

No GO to D5.

1. Run the engine at idle.
2. Using a suitable vacuum gauge, check the vacuum pressure.

• Is the vacuum pressure above 40.5 kPa (0.4 bar) with the brake booster non-operational?

Yes GO to D6.

No INSTALL a new vacuum hose and fittings.

TEST the system for normal operation.

1. Check the brake booster. REFER to the Brake Booster Operation Check in this procedure.

• Is the brake booster OK?

Yes VERIFY the customer concer

No INSTALL a new brake booster. TEST the system for normal operation.

1. Run the engine at idle for 10 seconds or longer.

2. Apply the brake pedal and listen for noise.

3. Compare results with a known good system.

• Was a noise present?

Yes GO to E2.

No VERIFY the customer concern.

1. Check the brake booster push rod alignment and travel.

• Is the push rod and pedal travel OK?

Yes BLEED the brake system. REFER to: (206-00 Brake System - General Information) Brake System Bleeding (General Procedures), Brake System Pressure Bleeding (General Procedures), Component Bleeding (General Procedures).

TEST the system for normal operation.

No INSTALL a new brake booster. TEST the system for normal operation.

1. Run the engine at approximately 1200 rpm whilst making several brake applications.

2. Pull the brake pedal upwards with approximately 44.5 N (10 lbs) force.

3. Release the brake pedal and measure the distance to the floor panel and note the reading.

4. Make a hard brake application.

5. Release the brake pedal and measure the distance to the floor panel and note the reading.

6. Compare the measurements.

• Did the brake pedal return to its original position?

Yes VERIFY the customer concern.

No GO to F2.

1. Check the brake pedal for free operation.

• Did the brake pedal operate freely?

Yes INSTALL a new brake booster. TEST the system for normal operation.

No INSTALL new brake pedal bushings. TEST the system for normal operation.