FORD FIESTA 2007 Workshop Manual

206-00-1 9 Brake System - General Information 206-00-1 9
DIAGNOSIS AND TESTING
PINPOINT TEST F : PEDAL IS LOW OR FEELS SPONGY
TEST CONDITIONS
DETAILSIRESU LTSIACTIONS I I F1: ROAD TEST THE VEHICLE
rn Road test the vehicle and apply the foot brake.
Did the brake pedal feel spongy?
1 Ehicle OK.
I F2: CHECK BRAKE FLUID LEVEL I
rn Check the brake master cylinder reservoir fluid
level.
Is the fluid level OK?
-+ Yes
GO to F3.
-, No
CHECK the brake master cylinder reservoir
sealing points. REFER to the component tests.
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). TEST the system for normal operation.
I F3: CHECK FILLER CAP VENT I
rn Check if the filler cap vent holes are clogged or
dirty.
Was a concern found?
-+ Yes
CLEAN as necessary. TEST the system for
normal operation.
2006.0 Fiesta 1212006 G28494en
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206-00-20 Brake System - General Information 206=00-20
DIAGNOSIS AND TESTING
TEST CONDITIONS
DETAILSIRESULTSIACTIONS
F4: BLEED THE BRAKE SYSTEM
rn Check for air in the brake system. Bleed the
brake system. REFER to: (206-00 Brake System
- General lnformation)
Brake System Bleeding (General Procedures),
Brake System Pressure Bleeding (General Procedures)
.
Is the condition still present?
+ Yes
GO to F5.
+ No
Vehicle OK.
F5: CHECK FRONT WHEEL HUB RETAINING NUT
Check the front wheel hub retaining nut for
looseness.
Is the front wheel hub retaining nut loose?
+ Yes
INSTALL a new front wheel hub retaining nut.
REFER to: Specifications (204-01 Front
Suspension, Specifications).
Do not reuse the
frontwheel hub retaining nut.
TEST the system for normal operation.
+ No
CHECK the parking bake adjustment. REFER
to: (206-05 Parking Brake and Actuation)
Parking Brake Cable Adjustment
- Vehicles With:
Rear Drum Brakes (General Procedures),
Parking Brake Cable Adjustment
- Vehicles With:
Rear Disc Brakes (General Procedures).
PINPOINT TEST G
: BRAKE LOCK UP DURING LIGHT BRAKE PEDAL FORCE
TEST CONDITIONS
DETAILSIRESULTSIACTIONS
I GI : ROAD TEST-THE VEHICLE I
Road test the vehicle and apply the brake pedal
lightly.
Do the rear brakes lock up?
+ Yes
GO to G2. GO to Pinpoint Test G.
+ No
Vehicle OK.
2006.0 Fiesta 12/2006 G28494en
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206-00-21 Brake System - General Information 206-00-21
DIAGNOSIS AND TESTING
TEST CONDITIONS DETAILSIRESU LTSIACTIONS
162: TIRE INSPECTION
rn Check for excessive tire wear or incorrect tire
pressures.
Are the tires in good order?
-+ Yes
GO to G3. GO to Pinpoint Test G.
-+ No
SUBSTITUTE known good tires. INFLATE to
the correct pressure. TEST the system for
normal operation.
163: BRAKE SHOES OR BRAKE PADS INSPECTION I
rn Inspect the brake shoes or brake pads are
correctly fitted and for grease or fluid contamin-
ation or wear concerns.
Are there any concerns?
-+ Yes
REPAIR or INSTALL new components as
necessary. TEST the system for normal
operation.
-+ No
GO to G4. GO to Pinpoint Test G.
1 64: CHECK PRESSURE CONSCIOUS REDUCING VALVE-RIGHT-HAND REAR I
rn Install pressure gauges in the left-hand front
and right-hand rear bleed nipples. Apply the brake to read 6895
kPa (1 000 psi) at the left-
hand front wheel.
- Read the pressure at the right-hand rear
wheel.
Does the pressure gauge read between 4692-
5164
kPa (680-750 psi) at the right-hand rear
wheel?
-+ Yes
TEST the brake booster. Go to Pinpoint Test
I.
-+ No
INSTALL a new right-hand rear brake pres-
sure control valve. BLEED the brake system.
REFER to: (206-00 Brake System
- General
Information)
Brake System Bleeding (General Procedures),
Brake System Pressure Bleeding (General
Procedures). TEST the system normal operation.
2006.0 Fiesta 12/2006 G28494en
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206-00-22 Brake System - General Information 206100-22
DIAGNOSIS AND TESTING
TEST CONDITIONS DETAILSIRESULTSIACTIONS
G5: CHECK PRESSURE CONSCIOUS REDUCING VALVE-LEFT-HAND REAR
Install pressure gauges in the right-hand front
and left-hand rear bleed nipples. Apply the brake
to read 6895
kPa (1000 psi) at the right-hand
front wheel.
- Read the pressure at the left-hand rear wheel.
Does the pressure gauge read between 4692-
5164
kPa (680-750 psi) at the lefl-hand rear
wheel?
-+ Yes
TEST the brake booster. Go to Pinpoint Test
I.
-+ No
INSTALL a new left-hand rear brake pressure
control valve. BLEED the brake system.
REFER to: (206-00 Brake System
- General
Information)
Brake System Bleeding (General Procedures),
Brake System Pressure Bleeding (General
Procedures).
TEST the system for normal operation.
PINPOINT TEST H
: EXCESSIVE OR ERRATIC BRAKE PEDAL TRAVEL
TEST CONDITIONS
DETAILS/RESULTSlACTIONS
HI : ROAD TEST THE VEHICLE
Road test the vehicle under rough road condi-
tions. Apply the brakes slowly.
Is the pedal travel OK?
-+ Yes
Vehicle OK.
+ No
GO to H2.
2006.0 Fiesta 12/2006 G28494en
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206-00-23 Brake System - General Information 206-00-23
DIAGNOSIS AND TESTING
TEST CONDITIONS DETAILSIRESULTSIACTIONS
H2: CHECK WHEEL BEARING
rn Check for loose front wheel bearings.
Are the front wheel bearings loose?
-, Yes
CHECK the front wheel hub retaining nut.
INSTALL a new front wheel
bearing(s) if worn
or damaged,
REFER to: Front Wheel Bearing (204-01 Front
Suspension, Removal and Installation).
TEST the system for normal operation.
-, No
CHECK the front brake disc(s) for thickness
variances.
REFER to: Specifications (206-03 Front Disc
Brake, Specifications).
INSTALL new components as necessary.
TEST the system for normal operation.
PINPOINT TEST I : BRAKES DRAG
TEST CONDITIONS
DETAILSIRESU LTSIACTIONS
11: CHECK BRAKE BOOSTER
rn Check the brake booster push rod alignment
and pedal travel.
Is the push rod and pedal travel OK?
-+ Yes
GO to 12.
+ No
INSTALL a new brake booster. REFER to:
(206-07 Power Brake Actuation)
Brake Booster
- LHD (Removal and Installation),
Brake Booster
- RHD (Removal and Installation).
TEST the system for normal operation.
2006.0 Fiesta 1212006 G28494en
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206-00-24 Brake System - General Information 206-00-24
DIAGNOSIS AND TESTING
TEST CONDITIONS DETAILSIRESU LTSIACTIONS
12: ROAD TEST THE VEHICLE
rn Road test the vehicle and apply the brakes.
Are the brakes functioning correctly?
-+ Yes
Vehicle OK.
+ No
INSPECT individual wheel cylinders or
calipers for binding or sticking components.
INSTALL new components as necessary.
BLEED the brake system. REFER to: (206-00
Brake System
- General Information)
Brake System Bleeding (General Procedures),
Brake System Pressure Bleeding (General Procedures).
TEST the system for normal operation.
PINPOINT TEST J
: EXCESSIVE BRAKE PEDAL EFFORT
TEST CONDITIONS
DETAILSIRESULTSIACTIONS
J1: CHECK BRAKE APPLICATION
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 J2.
+ No
GO to J6.
52: CHECK BRAKE BOOSTER FOR LEAKS
rn Run the engine at medium idle, 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
Vehicle OK.
-+ No
GO to
J3.
2006.0 Fiesta 1212006 G28494en
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206-00-25 Brake System - General Information 206-00-25
DIAGNOSIS AND TESTING
TEST CONDITIONS
53: CHECK BRAKE BOOSTER CHECK VALVE
rn Disconnect the vacuum hose, for the brake
booster check valve at the intake manifold. 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 J4.
54: CHECK BRAKE BOOSTER CHECK VALVE VACUUM
rn Disconnect the vacuum hose from the brake
booster check valve. Run the engine at idle.
Check the supply with a vacuum gauge.
Is the vacuum pressure above 40.5 kPa (12
in-Hg) with the brake booster non-operational?
+ Yes
GO to J5.
+ No
REPAIR or INSTALL a new vacuum hose and
fittings. TEST the system for normal operation.
55: CHECK BRAKE BOOSTER
rn Check the brake booster. GO to the component
test procedure in this section.
Is the brake booster OK?
+ Yes
GO to J6.
+ No
INSTALL a new brake booster. REFER to:
(206-07 Power Brake Actuation)
Brake Booster
- LHD (Removal and lnstallation),
Brake Booster
- RHD (Removal and lnstallation).
TEST the system for normal operation.
2006.0 Fiesta 1212006 G28494en
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206-00-26 Brake System - General Information 206-00-26
DIAGNOSIS AND TESTING
TEST CONDITIONS DETAILSIRESU LTSIACTIONS
I J6: CHECK BRAKE PEDAL LINKAGE If
rn Disconnect the actuator rod from the pedal pin
and apply the brake pedal fully.
Did the pedal move freely?
-+ Yes
GO to J7.
+ No
REPAIR or INSTALL new brake pedal bush-
ings. REFER to: (206-06 Hydraulic Brake
Actuation)
Brake Pedal
- LHD, Vehicles With: Manual
Transaxle (Removal and Installation),
Brake Pedal
- LHD, Vehicles With: 4-Speed
Automatic Transmission
(AW81-40), Vehicles
With: Automated Gearshift (Removal and
Installation),
Brake Pedal
- RHD (Removal and Installation).
TEST the system for normal operation.
157: CHECK BRAKE PRESSURE CONTROL VALVE I
rn Check the brake pressure control valve for
contamination.
Is the brake fluid contaminated?
+ Yes
INSTALL a new brake pressure control valve.
FILL the brake master cylinder reservoir.
BLEED the brake system. REFER to: (206-00
Brake System
- General Information)
1 Brake System Bleeding (General Procedures),
Brake System Pressure Bleeding (General
Procedures). TEST the system for normal operation.
1 * Ehicle OK.
2006.0 Fiesta 1212006 G28494en
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206-00-27 Brake System - General Information 206-00-27
DIAGNOSIS AND TESTING
PINPOINT TEST K : BRAKE NOISE
TEST CONDITIONS
DETAILSIRESU LTSIACTIONS
K1: CHECK FOR PEDAL NOISE
Inspect the brake pads and brake shoes for
excessive wear.
- Run the engine at idle for 10 seconds or
longer. Apply the brake pedal and listen for
noise. Compare results with a known good
system.
Was a noise present?
-+ Yes
GO to K2.
-+ No
Vehicle OK.
K2: CHECK PUSH ROD ALIGNMENT
Check the brake booster push rod alignment
and travel.
Is the push rod 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). TEST the system for normal operation.
-+ No
INSTALL a new brake booster. REFER to:
(206-07 Power Brake Actuation)
Brake Booster
- LHD (Removal and lnstallation),
Brake Booster
- RHD (Removal and Installation).
TEST the system for normal operation.
2006.0 Fiesta 1212006 G28494en
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206-00-28 Brake System - General Information 206-00-28
DIAGNOSIS AND TESTING
PINPOINT TEST L : SLOW OR INCOMPLETE BRAKE PEDAL RETURN
TEST CONDITIONS
DETAILSIRESU LTSIACTIONS /"'
I L1: CHECK FOR BRAKE PEDAL RETURN I[<.
Run the engine at fast idle while making several
brake applications. Pull the brake pedal rear-
ward with approximately 44.5 N
(1 0 lbs) force.
Release the brake pedal and measure the
distance to the floor pan. Make a hard brake
application. Release the brake pedal and
measure the brake pedal to floor pan distance.
The brake pedal should return to its original
position.
Did the brake pedal return to its original posi-
tion?
+ Yes
Vehicle OK.
+ No
GO to L2.
I L2: CHECK FOR BRAKE PEDAL BINDING
1 171 Check the brake pedal for free operation.
I Is the brake pedal operating freely?
+ Yes
I INSTALL a new brake booster. REFER to:
(206-07 Power Brake Actuation)
Brake Booster
- LHD (Removal and lnstallation),
Brake Booster
- RHD (Removal and lnstallation).
TEST the system for normal operation.
+ No
REPAIR or INSTALL new brake pedal bush-
ings. REFER to: (206-06 Hydraulic Brake
Actuation)
Brake Pedal
- LHD, Vehicles With: Manual
Transaxle (Removal and lnstallation),
Brake Pedal
- LHD, Vehicles With: 4-Speed
Automatic Transmission
(AW81-40), Vehicles
With: Automated Gearshift (Removal and
Installation),
Brake Pedal
- RHD (Removal and lnstallation).
TEST the system for normal operation.
Component Tests It is possible that all evidence of fluid leakage may
have washed off if the vehicle has been operated
in rain or snow, as brake fluid is water-soluble.
Hydraulic Leak Check Refill the system, bleed then apply the brakes
several times. Examine the system to verify that
NOTE:Thet-e is a common clutch and brake fluid
the reservoir fluid level is actually dropping. Locate
reservoir, therefore it is possible that a clutch leak
can lead to reduction in the reservoir level.
-- --
2006.0 Fiesta 1212006 G28494en
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