ABS FORD FIESTA 2007 User Guide

204-00-7 Suspension System - General Information 204-00-7
DIAGNOSIS AND TESTING
Possible Sources Action
1. Worn front wheel bearings I GO to Pinpoint Test B. I
I Wheels and tires I GO to Pinpoint Test B. I
Front or rear suspension
damage. CHECK and INSTALL new
suspension components as
necessary.
lncorrect wheel alignment. ADJUST the wheel alignment.
REFER to: Specifications (204-
00 Suspension System
-
General Information,
Specifications).
Damaged or worn front wheel
bearings. CHECK
the front wheel bear-
ings.
REFER to: Wheel Bearing
Inspection (204-00 Suspen-
sion System
- General
Information, General Proced-
ures).
Wheels and tires. CHECK the tires. BALANCE or
INSTALL new tires as neces-
sary.
I Incorrect wheel alignment. I ADJUST the wheel alignment.
REFER to: Specifications (204-
00 Suspension System
-
General Information,
Specifications).
Steering gear or linkage worn
or damaged. CHECK the steering system.
REFER to: (2
11 -00 Steering
System
- General Information)
Steering System (Diagnosis
and Testing),
Steering System
- I .6L
Duratorq-TDCi (DV) Diesel
(Diagnosis and Testing).
Front strut and spring assem-
1 blies. CARRY OUT
the Strut or
Shock 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).
2006.0 Fiesta 1212006 G149885en
procarmanuals.com

204-00-1 I Suspension System - General Information 204-00-1 I
DIAGNOSIS AND TESTING
PINPOINT TEST B : EXCESSIVE NOISE
1 TEST CONDITIONS DETAILSIRESU LTSIACTIONS
2006.0 Fiesta 1212006 Gl49885en
B1: INSPECT ALL STRUT AND SPRING ASSEMBLY AND SHOCK ABSORBER MOUNTING BOLTS
AND NUTS
lnspect the strut and spring assembly and shock
absorber mounting bolts and nuts.
Are the mounting bolts or nuts loose or
broken?
+ Yes
TIGHTEN or INSTALL new mounting bolts
and nuts. REFER to:
Specifications (204-0 1 Front Suspension, Specifications),
Specifications (204-02 Rear Suspension,
Specifications).
-, No
GO to B2.
B2: INSPECT THE STRUT AND SPRING ASSEMBLIES AND SHOCK ABSORBERS FOR LEAKS - --
N0TE:Make sure that the oil is not from another
source.
lnspect the strut and spring assemblies and
shock absorbers for signs of oil
weepage or
leaks. Refer to
weepage and leakage conditions
in the Strut or Shock Absorber Testing
component test in this procedure.
Are the struts or shock absorbers leaking?
+ Yes
INSTALL new struts or shock absorbers as
necessary. REFER to:
Front Strut and Spring Assembly (204-01 Front
Suspension, Removal and
Installation),
Rear Shock Absorber (204-02 Rear Suspension,
Removal and Installation).
+ No
GO to B3.
procarmanuals.com

204-00-1 2 Suspension System - General Information 204-00-12
DIAGNOSIS AND TESTING
TEST CONDITIONS DETAILSIRESULTSIACTIONS
1 83: INSPECT THE SPRINGS AND STABILIZER BAR(S) I
lnspect the springs and stabilizer bar(s) for
damage.
Are the springs or stabilizer bar(s) damaged?
-+ Yes
INSTALL new springs or stabilzer bar(s).
REFER to:
Front Strut and Spring Assembly (204-01 Front Suspension, Disassembly and Assembly),
Front Stabilizer Bar (204-01 Front Suspension,
Removal and Installation),
Spring (204-02 Rear Suspension, Removal and
Installation).
I B4: INSPECT THE SUSPENSION BUSHINGS I
lnspect the suspension bushings for excessive
wear or damage.
Are the bushings worn or damaged?
-+ Yes
INSTALL new components as necessary.
REFER to:
Front Stabilizer Bar Bushing (204-01 Front Suspension, Removal and lnstallation),
Lower Arm (204-01 Front Suspension, Removal
and Installation),
Front Strut and Spring Assembly (204-01 Front
Suspension, Removal and lnstallation),
Rear Shock Absorber (204-02 Rear Suspension,
Removal and lnstallation),
Trailing Arm Bushing (204-02 Rear Suspension,
Removal and Installation).
Carry out the Ball Joint Inspection component
test in this procedure.
Is the lower arm ball joint or gaiter damaged?
-+ Yes
INSTALL a new lower arm.
REFER to: Lower Arm (204-01 Front
Suspension, Removal and lnstallation).
2006.0 Fiesta iz1~006 GI 49885en
procarmanuals.com

204-00-1 3 Suspension System - General Information 204-00-1 3
DIAGNOSIS AND TESTING
TEST CONDITIONS DETAILSIRESU LTSIACTIONS
B6: INSPECT THE WHEEL BEARINGS
rn Check the wheel bearings.
REFER to: Wheel Bearing Inspection (204-00
Suspension System
- General Information,
General Procedures).
Are the wheel bearings damaged?
-+ Yes
INSTALL a new wheel bearing(s). REFER to:
Front Wheel Bearing (204-01 Front Suspension,
Removal and Installation),
Rear Wheel Bearing (204-02 Rear Suspension,
Removal and Installation).
-+ No
GO to B7.
B7: INSPECT THE WHEELS AND TIRES
rn Check the tires for uneven wear.
Is there uneven tire wear?
-+ Yes
REFER to the symptom chart.
-, No
GO to B8.
B8: INSPECT THE STRUT AND SPRING ASSEMBLY AND REAR SUSPENSION SPRING INTERFACE
Loosen the strut and spring assemblies and
shock absorbers top and bottom mounting bolts
and nuts. Tighten the mounting bolts and nuts.
REFER to:
Specifications (204-01 Front Suspension, Specifications),
Specifications (204-02 Rear Suspension,
Specifications).
- Carry out a road test.
REFER to:
RoadIRoller Testing (1 00-00
General Information, Description and Oper-
ation).
Is the concern still evident?
-+ Yes
GO to B9.
-+ No
Vehicle condition corrected.
B9: INSPECT THE STRUT AND SPRING ASSEMBLIES AND SHOCK ABSORBER COMPONENTS
rn Check that the spring is correctly located on the
spring seat and has not moved.
2006.0 Fiesta 1212006 G149885en
procarmanuals.com

204-00-1 4 Suspension System - General Information 204-00-1 4
DIAGNOSIS AND TESTING
TEST CONDITIONS DETAILSIRESU LTSIACTIONS
Component Tests
Raise and support the vehicle. REFER to: (1 00-02 Ball Joint Inspection
Jacking and Lifting)
1. Firmly grasp the outer end of the suspension
Jacking (Description and Operation), lower arm and
try to move it up and down,
Lifting (Description and Operation). watching and feeling for
any movement. Free
-
movement will usually be accompanied by an !
audible "click". There should be no free
movement.
(,';
B10: CARRY OUT A ROAD TEST
2006.0 Fiesta 1212006 Gl49885en
Disassemble the strut and spring and assembly
and inspect the individual components.
REFER to: Front Strut and Spring Assembly
(204-01 Front Suspension, Disassembly and
Assembly).
Inspect the shock absorber top mount for wear
or damage.
Carry out the Strut or Shock Absorber Testing
component test in this procedure.
Are any of the strut and spring assemblies or
shock absorber components damaged?
-+ Yes
INSTALL new components as necessary.
REFER to:
Front Strut and Spring Assembly (204-01 Front
Suspension, Disassembly and Assembly),
Rear Shock Absorber (204-02 Rear Suspension, Removal and Installation),
Spring (204-02 Rear Suspension, Removal and Installation).
-, No
REINSTALL the strut and spring assemblies
or shock absorbers. GO to
B10.
Carry out a road test.
REFER to:
RoadlRoller Testing (1 00-00 General
Information, Description and Operation).
Is the concern still evident?
-+ Yes
REFER to: Noise, Vibration and Harshness
(NVH) (1 00-04 Noise, Vibration and Harsh-
ness, Diagnosis and Testing).
-+ No
Vehicle condition corrected.
procarmanuals.com

204-00-1 5 Suspension System - General Information 204-00-1 5 1
DIAGNOSIS AND TESTING
2. If there is any free movement install a new lower 4. Compress and pull the piston rod in the vertical
arm. position. Feel if the resistance force at the point
REFER to: Lower Arm (204-01 Front
Suspension, Removal and Installation).
3. If a new lower arm is installed it will be
necessary to check and adjust the front wheel
alignment.
REFER to: Specifications (204-00 Suspension
System
- General Information, Specifications). 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, Disassembly and Assembly),
Front Strut and Spring Assembly (204-01 Front
Suspension, Removal and Installation),
Rear Shock Absorber (204-02 Rear Suspension,
Removal and Installation).
Strut or Shock Absorber Inspection
N0TE:lnspect 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
N0TE:Struts or shock absorbers must be tested
in the vertical position.
I. 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, Disassembly
and Assembly).
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.
2006.0 Fiesta 1212006 Gl49885en
procarmanuals.com

204-01 -3 Front Suspension 204-01 -3
DESCRIPTION AND OPERATION
Front Suspension
Overview
N0TE:During installation of the front wheel bearing
it is important to adhere to the specified installation
position, as the anti-lock brake system
( ABS )
sensor ring is located in the wheel bearing. A
coloured rubber ring is provided to indicate the
correct installation position. If the wheel bearing
were to be installed incorrectly then this would
cause failure of the ABS
.
A newly developed Mc-Pherson front suspension
with L-shaped lower arms is used. These lower
suspension arms are linked via large rubber
mountings to a reinforced and extremely rigid front
axle crossmember.
The ball head between the lower suspension arm
and the suspension strut is secured with three
rivets. Toe-in is adjusted via adjustable track rods.
The lower suspension arms can only be replaced as a complete unit.
2006.0 Fiesta IZIZOO~ GI 67080en
procarmanuals.com

204101 -4 Front Suspension 204-01 -4
DESCRIPTION
AND OPERATION
Item Description
The rear rubber mountings for the lower
suspension arms are enclosed in aluminium
brackets. This provides more vibration damping
than previously. Both the front and rear brackets
are arranged horizontally.
1
The suspension strut turret support bearings have
two separate routes for independently deflecting
the spring and shock absorber forces into the body.
This reduces the level of noise transmitted from
the road surface. Rear rubber
mounting
The correct installation position must be observed
when installing the suspension strut turret support
bearings. This is indicated by an arrow on the
suspension strut turret support bearing. The shock
absorbers are gas shock absorbers.
The spring travel has been increased by
6 mm,
and the track has been increased by
48 mm to
1477 mm.
2006.0 Fiesta 1212006 GI 67080en
procarmanuals.com

204-02-1 Rear Suspension 204-02-1
SECTION 204-02 Rear Suspension
VEHICLE APPLICATION:2006.0 Fiesta
CONTENTS
SPECIFICATIONS
Specifications.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DESCRIPTION AND OPERATION
Rear Suspension ........................................................................\
........................................
DIAGNOSIS AND TESTING
Rear Suspension ........................................................................\
........................................
REMOVAL AND INSTALLATION
Rear Shock Absorber ........................................................................\
.............
Spring ........................................................................\
.....................................
Beam Axle ........................................................................\
..............................
Wheel Spindle ........................................................................\
........................
' Rear Wheel Bearing ........................................................................\
............... '~ , Trailing Arm Bushing ........................................................................\
..............
PAGE
procarmanuals.com

204-02-2 Rear Suspension 204-02-2
SPECIFICATIONS
Torque Specifications
I Shock absorber upper mount retaining bolts I 25 I 18 I - I
Item
Shock absorber lower mount retaining bolt
I Trailing arm bushing retaining bolts I 125 1 92 I - I
Nm
115
I drum brakes I I I I
Beam axle retaining bolts
Wheel spindle retaining bolts
- Vehicles with rear
Wheel spindle retaining bolts
- Vehicles with rear
disc brakes
Ib-ft
85
I Wheel hub retaining nut 1 235 1 173 1 - I
I b-in
-
115
70
I Brake hose to brake caliper union I 15 I 11 I - I
I Brake tube to brake hose union I 15 I 11 I - I
85
52
I Wheel speed sensor retaining bolt I 9 I - I 80 I
-
-
2006.0 Fiesta 1212006 GI 52540en
procarmanuals.com