204 02 FORD FIESTA 2007 Workshop Manual

GROUP
Chassis
SECTION TITLE PAGE
Suspension
Suspension
System . General Information .................................................................... 204-00
........................................................................\
................................. Front Suspension .201 4.0
........................................................................\
................................. Rear Suspension .20 4.02
........................................................................\
.................................. Wheels and Tires 204-04
Driveline
Front Drive Halfshafts ........................................................................\
............................ 205-04
' Brake System
Brake System . General Information ........................................................................\
...... 206-00
........................................................................\
.......................................... Drum Brake .20 6.02
Front Disc Brake
........................................................................\
................................... 206-03
Rear Disc Brake
........................................................................\
.................................... 206-04
Parking Brake and Actuation
........................................................................\
................. 206-05
Hydraulic Brake Actuation ........................................................................\
...................... 206-06
Power Brake Actuation
........................................................................\
.......................... 206-07
........................................................................\
.................................. An ti-Lock Control .20 6.09A
Anti-Lock Control . Traction Control ........................................................................\
....... 206-09B
Anti-Lock Control . Stability Assist ........................................................................\
......... 206-09C
Steering System
........................................................................\
. Steering System . General Information .21 1.00
........................................................................\
..................................... Power Steering -21 1-02
........................................................................\
.................................. Steering Linkage -21 1-03
Steering Column
........................................................................\
................................... 21 1-04
Steering Column Switches
........................................................................\
..................... 21 1-05
0512005 2006.0 Fiesta
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100-04-20 Noise, Vibration and Harshness 100-04-20
DIAGNOSIS AND TESTING
TEST CONDITIONS DETAILSIRESULTSIACTIONS
C4: CHECK THE POWERTRAINIDRIVETRAIN MOUNTS
Carry out the powertrainldrivetrain mount neut-
ralizing procedure
Are the powertrainldrivetrain mounts OK?
+ Yes
Vehicle condition corrected. ROAD TEST as
necessary.
+ No
INSTALL new powertrainldrivetrain mounts
as necessary. ROAD TEST as necessary.
PINPOINT TEST D
: WHEEL END VIBRATION ANALYSIS
TEST CONDITIONS
DETAILSIRESU LTSIACTIONS
Dl: INSPECT THE WHEELS AND TIRES
Inspect the wheels and tires.
REFER to: Wheels and Tires (204-04 Wheels
and Tires, Diagnosis and Testing).
Are the wheels and tires OK?
+ Yes
GO to D2.
+ No
INSTALL new wheels or tires as necessary.
REFER to: Wheel and Tire (204-04 Wheels
and Tires, Removal and Installation).
ROAD TEST as necessary.
2006.0 Fiesta 1212006 G37349en
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100-04-21 Noise, Vibration and Harshness 100-04-21
DIAGNOSIS AND TESTING
TEST CONDITIONS DETAILSIRESULTSIACTIONS
I D2: INSPECT THE WHEEL BEARINGS
lnspect the wheel bearings.
REFER to: Wheel Bearing Inspection (204-00
Suspension System
- General Information,
General Procedures).
Are the wheel bearings OK?
+ Yes
GO to D3.
+ No
INSTALL new wheel bearings as necessary.
REFER to:
Wheel Bearing (204-01 Front Suspension,
Removal and lnstallation),
Wheel Bearing
- 2.OL Duratorq-DiITDDi (Puma)
Diesel12.0L Duratorq-TDCi (Puma) Diesel,
Vehicles With: 5-Speed Automatic Transaxle
(5F31 J) (204-01 Front Suspension, Removal
and lnstallation),
Wheel Hub (204-02 Rear Suspension, Removal
and lnstallation). ROAD TEST as necessary.
I D3: INSPECT THE WHEEL AND TIRE RUNOUT I
lnspect the wheel and tire runout.
Is the wheel and tire runout OK?
+ Yes
Balance the wheels and tires. Refer to the
wheel balance equipment manufacturer's
instructions. ROAD TEST as necessary.
+ No
INSTALL new wheels or tires as necessary.
REFER to: Wheel and Tire (204-04 Wheels
and Tires, Removal and Installation).
ROAD TEST as necessary.
2006.0 Fiesta 1212006 G37349en
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204-00-1 Suspension System - General Information 204-00-I
SECTION 204-00 Suspension System - General
lnformation
VEHICLE APPLICATION:2006.0 Fiesta
CONTENTS PAGE
SPECIFICATIONS
Specifications.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204-00-2
DIAGNOSIS AND TESTING
Suspension System ........................................................................\
.................................... 204-00-4
Inspection and Verification
........................................................................\
.......................... 204-00-4
Symptom Chart..
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204-00-4
Pinpoint Tests
........................................................................\
............................................. 204-00-8
Component Tests..
.... . . ...... .. .. . . .... .. . . .. .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204-00-1 4
GENERAL PROCEDURES
Wheel Bearing Inspection ....... . .. .. .. . . . . ...... .... .. . . . . . . . . . . . . . . ...... . . . . . . . . . . . . . . . . . . . . . . . . . . 204-00-1 6
Front Toe Adjustment ........................................................................\
......... (14 11 7 0) 204-00-1 7
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204-00-2 Suspension System - General Information 204-00-2
SPECIFICATIONS
Caster angle
Front Wheel Alignment (at curb weight)
Degrees and / 4'38'to 2'38' 1
minutes
Maximum Vari-
ance Left or Right
Description
I Camber angle I Degrees
and 1 0°36'to -1'54' 1 -0'39' I 1'15'
Decimal degrees
Tolerance Range
Setting or
Nominal
4.64" to 2.64"
Total toe
Degrees and minutes
Front Wheel Alignment (at curb weigh
Description
3.64"
minutes
Decimal degrees mm
Decimal degrees
Tolerance Range Setting or
I Nominal
1 .OOO
Maximum Vari-
ance Left or Right
0.60" to -1 .90°
3.1Toeink2.2
- 0'30' Toe in k 0'21'
0.50" Toe in k 0.35"
Caster angle
0'30 Toe in + 0°1 0'
Degrees and minutes -0.65"
3.1Toeink1.0
0.50"
Toe in k 0.1 7"
Decimal degrees
1.25"
-
-
Camber angle Degrees and
minutes
Decimal degrees
Total toe
Degrees and
minutes
0°09' Toe in k 0°20' 1 0°09' Toe in k 0°10'
Decimal degrees 0.15" Toe in k 0.34" ( 0.15" Toe in k 0.1 7"
Caster
angle
Front Wheel Alignment (at curb weight) - %Door Sport
Description
Camber angle
Degrees and minutes
Decimal degrees Degrees and
1 0'25' to -2'08' 1 -0'52'
minutes
Decimaldegrees
1 0.4I0to-2.13" 1 -0:86"
Maximum Vari-
ance Left or Right
Tolerance Range
4'39' to 2'34'
4.65"
to 2.57"
Total toe
Setting or
Nominal
Degrees and 0'30' Toe in k 0'21' 0'30 Toe in k 0°10'
minutes
3"37'
3.61"
I Decimal degrees 1 0.50" Toe in k 0.35" 1 0.50" Toe in k 0.17" 1 - I
1°00'
1
.OOO
2006.0 Fiesta 1212006 G149884en
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204-00-4 Suspension System - General Information 204-00-4
DIAGNOSIS AND TESTING
Suspension System
I I Alignment Pins, Subframe I
lnspection and Verification
Mechanical
Wheel knuckles
Tie-rod ends
Front suspension lower arm ball joints
Front suspension lower arm bushings
Front strut and spring assemblies
Front stabilizer bar and connecting links
Rear springs
Rear shock absorbers
Rear suspension beam axle and bushings
1.
Verify the customer concern.
I
2. Visually inspect for obvious signs of mechanical
damage.
3. If an obvious cause for an observed or reported Visual Inspection Chart concern is found, correct the cause (if possible)
I I Wheels and tires
Mechanical
Tire pressure(s)
Symptom Chart
before proceeding to the next step.
4. If the cause is not visually evident, verify the
symptom and refer to the Symptom Chart.
Symptom Chart
Symptom
Drift left or right
Possible Sources Action
Steering System (Diagnosis
and Testing),
Steering System
- 1.6L
Duratorq-TDCi (DV) Diesel
(Diagnosis and Testing).
Vehicle attitude incorrect (front
or rear is high or low).
Steering gear or linkage worn
or damaged.
I Brake system. I CHECK the brake system. I
CHECK for abnormal loading,
spring sag or non-standard
springs.
CHECK the steering system.
REFER to: (21 1-00 Steering
System
- General Information)
REFER to: Brake System (206-
00 Brake System
- General
Information, Diagnosis and
REFER to: Specifications (204-
'!
00 Suspension System -
i
General Information,
Specifications).
Incorrect wheel alignment.
2006.0 Fiesta 1212006 GI 49885en
Testing).
ADJUST the wheel alignment. ,'-
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204-00-5 Suspension System - General Information 204-00-5 --
DIAGNOSIS AND TESTING
Symptom Possible
Sources -
l ncorrect front crossmem ber
alignment.
Action
Using the special tool, CHECK
the front crossmember align- ment.
Worn front wheel bearings. CHECK
the wheel bearings.
REFER to: Wheel Bearing
lnspection (204-00 Suspen-
sion System
- General
Information, General Proced-
ures).
I Wheels and tires. I . GO to Pinpoint Test A. I
Steering wheel off-center Vehicle attitude incorrect (front
or rear is high or low).
Tracks incorrectly CHECK for abnormal loading,
spring sag or non-standard
springs.
-
Steering gear or linkage worn
or damaged. CHECK the steering system.
REFER to: (21 1-00 Steering
System
- General Information)
Steering System (Diagnosis and Testing),
Steering System
- 1.6L
Duratorq-TDCi (DV) Diesel
(Diagnosis and Testing).
Suspension lower arm ball
joint. CARRY
OUT the Ball Joint
lnspection component test in
this procedure.
lncorrect wheel alignment. ADJUST
the wheel alignment.
REFER to: Specifications (204-
00 Suspension System
-
General Information,
Specifications).
lncorrect front suspension toe,
castor or camber angles. CHECK
the wheel alignment.
REFER to: Specifications (204-
00 Suspension System
-
General Information,
Specifications).
INSTALL new suspension
components as necessary.
~ncorrecGar suspension toe
or camber angles. CHECK
the wheel alignment.
REFER to: Specifications (204-
00 Suspension System
-
General Information,
Specifications).
INSTALL new suspension
components as necessary.
2006.0 Fiesta 1212006 Gl49885en
Front or rear suspension
damage. INSTALL new
suspension
components as necessary.
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204-00-6 Suspension System - General Information 204-00-6
DIAGNOSIS AND TESTING
Possible Sources Action
Front strut
and spring assem-
blies.
Front stabilizer bar, connecting
links or bushings.
Front suspension lower arm
bushings.
- -
Rear suspension bushings.
Rear shock absorbers.
--
I Front strut and spring assembly
or rear shock absorber and
spring upper mounting bolts or
nuts loose or broken.
1 Shock absorbers leaking
Shock absorber performance
incorrect
I Stabilizer bar components
' Strut and spring assembly and
springs
Springs moving on spring
upper or lower seats
Suspension bushings
Lower arm ball joint 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).
CHECK and INSTALL new
suspension components as
necessary. REFER to: (204-01
Front Suspension)
Front Stabilizer Bar Bushing
(Removal and Installation),
Front Stabilizer Bar (Removal
and Installation).
INSTALL a new lower arm.
REFER to: Lower Arm (204-01
Front Suspension, Removal
and Installation).
CHECK and INSTALL new
components as necessary.
CARRY OUT the Strut or
Shock Absorber Testing
component test in this
procedure.
CHECK and INSTALL new
suspension components as
necessary.
GO to Pinpoint Test B.
GO to Pinpoint Test B. I
GO to Pinpoint Test B.
GO to Pinpoint Test B. I
GO to Pinpoint Test B.
GO to Pinpoint Test B. ' '
GO to pinpoint Test B. I
GO to Pinpoint Test B. I
2006.0 Fiesta 1212006 G149885en
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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
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204-00-8 Suspension System - General Information 204-00-8
DIAGNOSIS AND TESTING
Symptom Possible
Sources Action
Pinpoint Tests
Damaged front suspension
lower
arm(s).
PINPOINT TEST A : DRIFT LEFT OR RIGHT
TEST CONDITIONS
DETAILSIRESU LTSIACTIONS
INSTALL a new lower arm(s).
REFER to: Lower Arm (204-01
Front Suspension, Removal
and installation).
I
A WARNING:To avoid personal injury due to the loss of vehicle control, the inspection should
be carried out by two people to maintain safe driving conditions. Adequate grip should
always be maintained oh the steering wheel. Failure to follow these instructions may result
in personal injury.
N0TE:The following conditions must be met when evaluating the vehicle.
N0TE:The tire swapping procedures are for bi-directional rotating tires only.
Al: SWAP THE FRONT WHEEL AND TIRE ASSEMBLIES
Raise and support the vehicle. REFER to: (1 00-
02 Jacking and Lifting)
Jacking (Description and Operation), Lifting (Description and Operation).
- Swap the front left-hand wheel and tire
assembly with the front right-hand wheel and
tire assembly.
- Road test the vehicle.
Does the vehicle drift?
+ Yes
GO to A2.
+ No
Vehicle condition corrected.
2006.0 Fiesta 12/2006 G149885en
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