FORD FIESTA 2007 Workshop Manual

211 -00-1 I Steering System - General Information 211 -00-11
DIAGNOSIS AND TESTING
Action
Symptom Possible Sources
CARRY OUT the Power
Steering Operation Noise
Check.
Excessive noise
REFER to: Noise, Vibration and
Harshness (NVH) (1 00-04
Noise, Vibration and Harsh-
ness, Diagnosis and Testing).
Power
steering operation noise.
Power steering fluid aeration. BLEED the power steering
system.
REFER to: Power Steering
System Bleeding (21 1-00
Steering System
- General
lnformation, General Proced-
u res).
2006.0 Fiesta 1212006 GI 49906en
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211 -00-12 Steering System - General Information 211-00-12
DIAGNOSIS AND TESTING
Symptom Possible Sources Action
Power steering lines.
Steering gear bushings worn
or perished.
2006.0 Fiesta 12/2006 Gl49906en
CHECK the power steering lin
clamps are secure. REFER to:
(21 1-02 Power Steering)
Power Steering Pump to
Steering Gear Pressure Line
- 1.25L Duratec-1 6V
(Sigma)/l.4L Duratec-1 6V
(Sigma)/l .6L Duratec-1 6V
(Sigma), Vehicles With: Air
Conditioning
(Removal and
Installation),
Power Steering Pump to
Steering Gear Pressure Line
- 1.25L Duratec-1 6V
(Sigma)/l.4L Duratec-1 6V
(Sigma)/l .6L Duratec-1 6V
(Sigma), Vehicles Without:
Air Conditioning
(Removal
and Installation),
Power Steering Pump to
Steering Gear Pressure Line
- I .3L Duratec-8V (Rocam)
(Removal and Installation),
Power Steering Pump to
Steering Gear Pressure Line
- I .4L Duratorq-TDCi (DV)
Diesel (Removal and Installa-
tion),
Power Steering Pump to
Steering Gear Pressure Line
- 2.OL Duratec-HE (M14) RHD
(Removal and Installation),
Steering Gear to Power
Steering
Fluid Reservoir
Return Line
- 2.OL Duratec-
HE
(M14) RHD (Removal and
Installation),
Steering Gear to Fluid Cooler
Return Hose (Removal and
Installation).
CHECK the power steering
lines for clearance from the
vehicle body, front axle cross-
member and steering gear.
CHECK the steering gear
transfer
lines for clearance from
the steering gear.
CHECK and INSTALL new
components as necessary.
I REFER to: Steering Gear
Bushing (21 1-02 Power
Steering,
Removal and
Installation).
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21 1 -00-1 3 Steering System - General Information 211-00-13
DIAGNOSIS AND TESTING
Steering does not vary with
increased wheel rotation Possible Sources
Action
Loose steering gear retaining
bolts.
CHECK and INSTALL new
steering gear retaining bolts as
necessary.
REFER to: Specifications
(21 1 -
02 Power Steering, Specifica-
tions).
Worn power steering pump. INSTALL
a new power steering
pump. REFER to:
(21 1-02
Power Steering)
Power Steering Pump
- I .3L
Duratec-8V
(Rocam)
(Removal and lnstallation),
Power Steering Pump
- I .25L
Duratec-16V (Sigma)/l.4L
Duratec-1 6V (Sigma)/l .6L
Duratec-1
6V (Sigma),
Vehicles With: Air Condi-
tioning (Removal and Installa-
tion),
Power Steering Pump
- 1.25L
Duratec-I 6V (Sigma)/l.4L
Duratec-I 6V (Sigma)/l.GL
Duratec-I 6V (Sigma),
Vehicles Without: Air Condi-
tioning (Removal and Installa-
tion),
Power Steering Pump
- 1.4L
Duratorq-TDCi (DV) Diesel
(Removal and lnstallation),
Power Steering Pump
- 2.OL
Duratec-HE (M14) (Removal
and lnstallation).
Worn tie-rod. CARRY
OUT the tie-rod
component test. REFER to Tie-
Rod Component Test in this
procedure.
Worn tie-rod ends. INSTALL new
components as
necessary.
REFER to: Tie Rod End
(21 1-
03 Steering Linkage, Removal and Installation).
Worn front suspension bush-
ings. CHECK and INSTALL new
components as necessary.
REFER to: Suspension System
(204-00 Suspension System
- General Information,
Diagnosis and Testing).
2006.0 Fiesta 1212006 GI 49906en
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211 -00-14 Steering System - General Information 21 1-00-1 4
DIAGNOSIS AND TESTING
Symptom
Engine stalls when parking with
engine speed at idle Possible
Sources Action
I Worn front suspension lower 1. CARRY OUT the suspension f-
ball joint inspection component'
test.
REFER to: Suspension System
(204-00 Suspension System
- General Information,
Diagnosis and Testing).
Steering gear bushings worn
or perished. CHECK
and INSTALL new
components as necessary.
REFER to: Steering Gear
Bushing (21 1-02 Power
Steering, Removal and
Installation).
Loose steering gear retaining
bolts. CHECK and INSTALL new
steering gear retaining bolts as
necessary.
REFER to: Specifications (21 1
-
02 Power Steering, specifica-
tions).
Loose steering column retaining bolts.
CHECK and INSTALL new
steering column retaining bolts as necessary.
REFER to: Specifications (21 1
-
04 Steering Column,
Specifications).
Loose steering column to
steering gear pinion retaining bolt. CHECK
and INSTALL a new
steering column to steering
gear pinion retaining bolt as
necessary.
REFER to: Specifications (21 1
-
02 Power Steering, specifica-
tions).
I Excessive steering gear back-
lash. CARRY
OUT the steering
linkage component test.
REFER to Steering Linkage
Component Test in this
procedure.
Power steering pressure (PSP)
or additional information, refer
switch or circuit.
1. I to WDS.
Components Tests
Steering Linkage
column bearing wear, steering column universal
joint free play, steering wheel or steering column
looseness. The steering column cannot be
repaired. Install a new steering column.
('- .,
1. Grasp the steering wheel firmly and move it up REFER to: Steering Column
(21 1-04 Steering "'
and down and to the left and right without Column, Removal and Installation).
turning the steering wheel, to check for steering
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21 1-00-1 5 Steering System - General Information 21 I -00-1 5
DIAGNOSIS AND TESTING
2. With the road wheels in the straight ahead
position, gently turn the steering wheel to the
1 left and the right to check free play in the
steering linkage.
3. There should be no excessive free play at the
steering wheel rim. If there is excessive free
play, CHECK the tie-rod inner and outer ball
joints, REFER to Tie-Rod Component Test in
this procedure. CHECK the steering column
universal joint, REFER to Steering Column
Universal Joint Component Test in this
procedure. If there is no free play in the tie-rod
and the steering column, install a new steering
gear.
REFER to: Steering Gear (211-02 Power
Steering, Removal and installation).
Tie-Rod
A CAUTI0N:The steering gear boots must be
handled carefully to avoid damage. Use
new steering gear boot clamps when
installing the steering gear boots.
N0TE:Noises such as knocks, which may appear
to originate from the steering linkage, may also be
( , generated by front suspension components.
1. Raise and support the vehicle. REFER to:
(1 00-02 Jacking and Lifting)
Jacking (Description and Operation),
Lifting (Description and Operation).
3m ACAUTION:T~ prevent damage to the
steering linkage, turn the steering wheel to move the steering linkage to the steering
lock stop.
Turn the steering wheel to position the steering
linkage against the right-hand steering lock stop.
4. N0TE:To isolate the steering gear design
clearance, check the right-hand tie-rod with
the steering held against the right-hand
steering lock stop.
With the aid of another technician holding the
steering against the right-hand steering lock
stop, firmly grasp the right-hand road wheel and
apply a rocking motion to check for any free play
in the tie-rod.
5. Detach the steering gear boot from the steering
gear body and check for free play at the tie-rod
inner ball joint.
2. Firmly grasp the road wheel and apply a rocking 6. If there is free play at the tie-rod inner ball joint,
motion to check for any free play in the wheel
install a new tie-rod.
bearing or suspension components.
REFER to: Tie Rod (211-03 Steering Linkage,
Removal and installation).
7. If there is free play at the tie-rod end, install a
new tie-rod end.
REFER to: Tie Rod End (21 1-03 Steering
Linkage, Removal and Installation).
2006.0 Fiesta 1212006 GI 49906en
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21 1-00-1 6 Steering System - General Information 21 I -00-1 6
DIAGNOSIS AND TESTING
8m ACAUTION:T~ prevent damage to the
steering linkage, turn the steering wheel to
move the steering linkage to the steering
lock stop.
Turn the steering wheel to position the steering
linkage against the left-hand steering lock stop.
9. N0TE:To isolate the steering gear design
'clearance, check the left-hand
tiemrod with
the steering held against the left-hand
steering lock stop.
With the aid of another technician holding the
steering against the left-hand steering lock stop,
firmly grasp the left-hand road wheel and apply
a rocking motion to check for any free play in
the tie-rod.
IQ Detach the steering gear boot from the steering
gear body and check for free play at the tie-rod
inner ball joint.
11. If there is free play at the tie-rod inner ball joint,
install a new tie-rod.
REFER to: Tie Rod (211-03 Steering Linkage,
Removal and lnstallation).
I2 If there is free play at the tie-rod end, install a
new tie-rod end.
REFER to: Tie Rod End (21 1-03 Steering
Linkage, Removal and lnstallation).
Turning Effort Test
N0TE:Before carrying out this test, make sure that
the suspension components are serviceable.
N0TE:Before carrying out this test, make sure that
the steering column is serviceable.
N0TE:Before carrying out this test, make sure that
the front toe adjustment and tire pressures are
correct. 1.
Park the vehicle on a dry, even surface and
apply the parking brake.
/- ,
2. Remove the driver air bag module.
REFER to: Driver Air Bag Module (501 -20
Supplemental Restraint System, Removal and
Installation).
3. Remove the driver air bag module wiring
harness from the driver air bag module.
REFER to: Driver Air Bag Module Wiring
Harness (501 -20 Supplemental Restraint
System, Removal and Installation).
4. Connect the driver air bag module wiring
harness to the clockspring.
5. Connect the air bag simulators to the driver air
bag module wiring harness in place of the driver
air bag module at the top of the steering column.
6. Start the engine and turn the steering wheel
from lock to lock several times until the power
steering fluid has reached normal operating
temperature.
7. Using a suitable torque wrench and socket,
check the steering wheel turning effort.
8. If the steering wheel turning effort is greater than
the specification, install a new power steering -
pump. REFER to: i
Specifications (21 1-00 Steering System -
General Information, Specifications),
Power Steering Pump
- I .3L Duratec-8V
(Rocam) (21 1-02 Power Steering, Removal
and lnstallation),
Power Steering Pump
- 1.25L Duratec-1 6V
(Sigma)/l.4L Duratec-1 6V (Sigma)/l .6L
Duratec-l6V (Sigma), Vehicles With: Air
Conditioning (21 1-02 Power Steering,
Removal and lnstallation),
Power Steering Pump
- I .25L Duratec-I 6V
(Sigma)/l.4L Duratec-1 6V (Sigma)/l .6L
Duratec-I 6V (Sigma), Vehicles Without: Air
Conditioning (21 1-02 Power Steering, Removal and lnstallation),
Power Steering Pump
- 1.4L Duratorq-TDCi
(DV) Diesel (21 1-02 Power Steering, Removal
and lnstallation),
Power Steering Pump
- 2.OL Duratec-HE (M14)
(21 1-02 Power Steering, Removal and
Installation).
Disconnect the air bag simulators from the driver
air bag module wiring harness.
//
IQ Disconnect the driver air bag module wiring i,,.
harness from the clockspring.
2006.0 Fiesta 1212006 GI 49906en
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211 -00-1 7 Steering System - General Information 21 1 -00-1 7
DIAGNOSIS AND TESTING
11. Install a new driver air bag module wiring
harness to the drive air bag module. If the
movement is not smooth or resistance
is felt, renew the steering column.
REFER to: Driver Air Bag Module Wiring REFER
to: Steering Column (21 1-04 Steering
Harness (501 -20 Supplemental Restraint Column,
Removal and Installation).
System, Removal and lnstallation).
12 Install the driver air bag module.
3. Hold both of the steering column shaft universal
joint yokes and then twist them clockwise and
REFER to: Driver Air Bag Module (501-20 counterclockwise.
Supplemental Restraint System, Removal and If
any movement is felt, install a new steering
installation). column.
REFER to: Steering Column (21 1-04 Steering
Column, Removal and lnstallation).
Steering Column Shaft Universal Joint

la AwARNING:~~~~~~~ a new steering column
shaft to steering gear pinion retaining bolt.
Failure to follow this instruction may result
in personal injury.
Detach the steering column shaft from the
steering gear pinion.
Discard the steering column shaft to steering
gear pinion retaining bolt.
2. Check for smooth movement of the steering
column shaft universal joint.
1. Hold the steering column shaft universal joint
yoke.
2. Articulate the free yoke in a figure of eight
movement.
2006.0 Fiesta 1212006 GI 49906en
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211 -00-1 8 Steering System - General Information 211 -00-1 8
DIAGNOSIS AND TESTING
Steering Gear Checks After a Collision
f
system REFER to: Steering Gear (211-02 Power
The following list of steering gear conditions and
Steering, Removal and Installation).
the methods
of testing should be taken into ~CCOU~~ 2. Check the tightening torque of the tiemrod end when carrying out checks to the steering system:
to wheel knuckle nut.
General
Equipment TIE-RODS (.
If
the steering gear has no faults after
REFER to: Tie Rod End (21 1-03 Steering
completing the following checks, do not install
Linkage, Removal and Installation).
a new steering gear.
3. Check the tightening torque of the tie-rod end
Surface corrosion and marks on the tie-rod are
locking nut.
acceptable.
When checking for turning effort torque peaks REFER to: Tie
Rod End
(211-03 Steering
in the steering gear, turn the steering wheel from Linkage,
Removal and lnstallation).
Feeler gauge
Straight edge
steering lock-stop to steering lock
stop in CHECK FOR TURNING EFFORT TORQUE
approximately 15 seconds. PEAKS
IN THE STEERING GEAR
1.
Using a straight edge and feeler gauge, check
the tie-rods to see if they are straight. If the
distance between the tie-rod and straight edge
A steady increase of turning effort torque from
steering center to steering lock stop is
acceptable.
When checking for power steering fluid leaks,
turn the steering wheel to the steering lock stop
in approximately
10 seconds.
Noises from the power steering, for example
the power steering pump relief valve, are
acceptable. is
greater than 0.5 mm, install a new steering
Items to be observed when checking the steering gear.
STEERING GEAR HOUSING
I. Raise and support the vehicle.
REFER to: Lifting
(1 00-02 Jacking and Lifting,
Description and Operation).
2. Visually inspect the steering gear housing for
cracks and damage. If the steering gear housing
is cracked or damaged, install a new steering
gear.
REFER to: Steering Gear
(21 1-02 Power
Steering, Removal and lnstallation).
1. Lower and support the vehicle making sure that
the road wheels are just clear of the floor.
2. With the ignition switch in position
I, slowly turn
the steering wheel from steering lock stop to
steering lock stop. If a turning effort torque peak
or judder is felt while turning the steering wheel,
detach the tie-rods from the wheel knuckles.
3. Slowly turn the steering wheel from steering
lock stop to steering lock stop. If a turning effort
torque peak or judder is felt while turning the
steering wheel, install a new steering gear.
REFER to: Steering Gear
(211-02 Power
Steering, Removal and lnstallation).
CHECK FOR POWER STEERING FLUID LEAKS
1. Lower the vehicle.
2. Run the engine at a fast idle and slowly turn the
steering wheel to the left-hand steering lock
stop. Hold the steering wheel in this position for
5 seconds with a turning effort torque of
15 Nm
at the steering wheel rim.
3. Turn the steering wheel away from the left-hand
steering lock stop for 30 seconds.
4. Run the engine at a fast idle and slowly turn the
steering wheel to the right-hand steering lock
stop. Hold the steering wheel in this position for
5 seconds with a turning effort torque of
15 Nm '
at the steering wheel rim. (\,
2006.0 Fiesta 1212006 ~538091 en
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211-00-19 Steering System - General Information 21 1-00-1 9
DIAGNOSIS AND TESTING
5. Turn the steering wheel away from the
right-hand steering lock stop.
I 6. Check for power steering fluid leaks at the
steering gear housing and the power steering
line connections to the steering gear. If there is
a power steering fluid leak at the steering gear,
install a new steering gear.
REFER to: Steering Gear
(211-02 Power
Steering, Removal and Installation).
2006.0 Fiesta 1212006 ~538091 en
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21 1 -00-20 Steering System - General Information 21 1-00-20
GENERAL PROCEDURES
Power Steering System Filling(l3 002 0)
Special Tool(s)
Adapter, Power Steering
Bleeding
211-189 (13-016)
I ( Hand Vacuum
Refill
"%s a3
1. N0TE:When filling the power steering fluid
reservoir, make sure that the power steering
fluid is clean and not agitated prior to use.
The power steering fluid should be poured
slowly into the reservoir to minimize the
possibility of aeration. The power steering
fluid level should be checked with the power
steering fluid cold.
PumpIPressure Pump
41 6-DO01 (23-036A)
Fill the power steering fluid reservoir to the
MAX mark with the appropriate power
steering fluid.
For additional information, refer to:
Specifications (211-00 Steering System
-
General Information, Specifications).
2. Raise and support the vehicle making sure
that the road wheels are just clear of the
floor. For additional information, refer to:
(1 00-02 Jacking and Lifting)
Jacking (Description and Operation),
Lifting (Description and Operation).
3.
N0TE:Do not start the engine at this stage.
N0TE:Make sure that the power steering fluid in
the power steering fluid reservoir does not fall
below the MIN mark,
as air could enter the system.
Slowly turn the steering wheel from lock to
lock and add power steering fluid until the
power steering fluid in the power steering
fluid reservoir stops dropping. 4.
N0TE:Make sure that
the power steering fluid \.
in the power steering fluid reservoir does
not fall below the MIN mark, as air could
enter the system.
Start the engine and slowly turn the steering
wheel from lock to lock and add power
steering fluid until the power steering fluid
in the power steering fluid reservoir stops
dropping.
5. Switch the engine OFF and using the special
tools, create a vacuum of
62cm-Hg - 75cm-Hg
for 30 seconds.
6. Observe the vacuum gauge reading.
If the vacuum decreases by more than
5cm-Hg
in 5 minutes, the system should be
checked for leaks.
7. Remove the special tools. Fill the power
steering fluid reservoir to the
MAX mark with
the appropriate power steering fluid as
necessary.
For additional information, refer to:
Specifications (211 -00 Steering System
-
General Information, Specifications).
8. Lower the vehicle.
2006.0 Fiesta 1212006 GI 7562en
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