parking brake FORD FIESTA 2007 Workshop Manual

2006.0 Fiesta
Workshop Manual
Table of Contents
GROUP 1 General lnformation
Service lnformation
General lnformation
Identification Codes
Jacking and Lifting
Noise, Vibration and
Harshness
Suspension
Suspension System - General
lnformation
Front Suspension
Rear Suspension
Wheels and Tires
Driveline
Front Drive Halfshafts
Brake System
Brake System - General
Information
Drum Brake
Front Disc Brake
Rear Disc Brake
Parking Brake and Actuation
Hydraulic Brake Actuation
Power Brake Actuation
Anti-Lock Control
Anti-Lock Control
- Traction
Control
Anti-Lock Control
- Stability
Assist
Steering System
Steering System - General
lnformation
Power Steering Steering Linkage
Steering Column
Steering Column Switches
Engine
Engine System - General
lnformation
Engine
- 1.25L Duratec-1 6V
(Sigma)/l.4L Duratec-1 6V
(Sigma)/l.GL Duratec-I 6V
(Sigma)
Engine
- 2.OL Duratec-HE
(MI41
Engine Cooling - 1.3L Duratec-8V
(Rocam)/l.25L Duratec-1 6V
(Sigma)/l.4L Duratec-1 6V
(Sigma)/l .6L Duratec-1 6V
(Sigma)
Engine Cooling
- 2.OL Duratec-HE
(MI41
Fuel Charging and Controls - 1.25L
Duratec-1 6V (Sigma)/l.4L
Duratec-16V (Sigma)/l.GL
Duratec-1 6V (Sigma)
Fuel Charging and Controls
- 2.OL
Duratec-HE (M14)
Accessory Drive
Starting System
Engine lgnition
Engine Ignition
- 2.OL Duratec-HE
(M14)
Engine Emission Control - 1.3L
Duratec-8V (Rocam)/l.25L
Duratec-1 6V (Sigma)/l.4L
Duratec-1 6V (Sigma)/l .6L
Duratec-1
6V (Sigma)
Engine Emission Control
- 2.OL
Duratec-HE (M14)
05/2005 2006.0 Fiesta
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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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100-00-1 9 General Information 100-00-1 9
DESCRIPTION AND OPERATION
Standard Workshop Practices
Vehicle in Workshop
When working on a vehicle in the workshop always
make sure that:
- the parking brake is applied or the wheels are
securely chocked to prevent the vehicle moving
forwards or backwards.
- the key is removed from key operated hood
locks before any work is carried out around the
front of the vehicle.
- if the engine is to be run, there is adequate
ventilation, or an extraction hose to remove
exhaust fumes.
- there is adequate room to raise the vehicle and
remove the wheels, if necessary.
- fender covers are always fitted if any work is to
be carried out in the engine compartment.
- the battery is disconnected if working on the
engine, underneath the vehicle, or if the vehicle
is raised.
Alternative Fuel - Dons
- Do work on the vehicle in a designated area,
that is well ventilated and with access restricted
to qualified personnel only.
- Install new warning labels to their original
locations.
- If possible always isolate the alternative fuel
tank, and run the vehicle on the alternative fuel
until it automatically switches to its normal fuel
prior to taking the vehicle into the workshop
service area.
- Only use tested and approved components and
pipes when repairing or servicing
LPG and CNG
systems.
Alternative Fuel - Do Nots
- Do not vent off LPG fuel.
- Do not use shop air pressure to force LPG fuel
from the fuel tank.
( A CAUTION:When electric arc welding on a - Do not use paint drying ovens above 40°C for vehicle, always disconnect the generator any alternative fuel vehicle. LPG and CNG fuel wiring to prevent the possibility of a surge tanks must be removed from the vehicle prior of current causing damage to the internal to being put into paint drying ovens above 40°C. components of the generator. - Do not modify the system or install new - if using welding equipment on the vehicle, a
components that are not designed for gas
suitable fire extinguisher is readily available.
vehicles.
Alternative Fuel
A WARNING:When servicing the fuel system
always follow the recommended
procedures. Failure to follow these
instructions may result in personal injury.
If the odor of liquefied petroleum gas (LPG) or
compressed natural gas
(CNG) is present in the
air in the workshop, warn all persons in the area
to:
- extinguish all flames and lighted tobacco.
- shut off electrical and air powered equipment.
- evacuate the area.
- ventilate the area.
- contact the fire control authorities.
- remove the vehicle to a dedicated, ventilated
area.
- Do not evacuate fuel tanks unless there is repair
that requires the removal of the fuel tank.
- Do not work on the fuel lines or system
components unless the alternative fuel has been
evacuated and the pressure in the system
reduced to atmospheric or less.
- Do not use anything other than the specified
leak detector fluid to trace fuel leaks.
Be aware of situations that may cause the
LPG or I
CNG fuel system to vent off fuel, such as: I
- extremely hot days.
- parking by a space heater.
- hoisting a vehicle up near a ceiling heater.
Only fully trained personnel, who are conversant
with local standards, are to work on alternative fuel
vehicles.
2006.0 Fiesta 1212006 GI 7373en
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100-00-23 General Information 100-00-23
DESCRIPTION AND OPERATION
RoadIRoller Testing
I Road or roller testing may be carried out for various
reasons and a procedure detailing pre-test checks,
engine starting and stopping, pre-driving checks,
on-test checks and final checks to be completed
on completion of the test is given below.
Unless complete vehicle performance is being
checked, the full road test procedure need not be
carried out. Instead, those items particularly
relevant to the
system(s) being checked can be
extracted.
Pre-Test Checks
A WARNING:lf the brake system hydraulic
fluid level is low, pedal travel is excessive
or a hydraulic leak is found, do not attempt
to road test the vehicle until the reason for
the low fluid level, excessive pedal travel
or hydraulic leak is found and rectified.
It is suggested that pre-test checks and functional
tests of those systems and circuits which affect the
safe and legal operations of the vehicle, such as
( , brakes, lights and steering, should always be
carried out before the road or roller test.
With the ignition switched off, check:
- the engine oil level.
- the engine coolant level.
- the tires, for correct pressure, compatible types
and tread patterns, and wear within limits.
- that there is sufficient fuel in the tank to
complete the test.
- all around the engine, transmission and under
the vehicle for oil, coolant, hydraulic and fuel
leaks. Make a note of any apparent leaks and
wipe off the surrounding areas to make it easier
to identify the extent of the leak on completion
of the test.
Starting the Engine
N0TE:On initial drive away from cold and within
the first 1.5 km (1 mile), do not depress the
accelerator pedal beyond half travel until the
vehicle has attained a minimum speed of
25 kmlh
(15 mileslh). Never operate at high engine speed
or with the accelerator pedal at full travel whilst the
engine is cold.
With the ignition switched off, check:
- that the parking brake is applied.
- that the gear lever is in the neutral position.
- that all instrument gauges (except fuel gauge)
read zero.
With the ignition switched on, check:
- that the ignition controlled warning lamps are
illuminated.
- that the engine temperature gauge registers a reading compatible with the engine temperature.
- that the fuel gauge registers a reading
appropriate to the fuel level in the tank.
- the operation of the parking brake warning lamp
and fluid level warning indicator.
Road or Roller Testing
A CAUTI0N:lf road testing, check the brake
operation while still traveling at low speed
before continuing with the test. If the
brakes pull to one side, or appear to be
otherwise faulty, do not continue with the
road test until the fault has been found and
rectified.
During the road or roller test, check:
- that the clutch pedal operation is not stiff or
heavy.
- that the initial gear engagement is smooth and
there is no evidence of clutch drag.
- that the parking brake control operates smoothly
and releases quickly and completely.
- that the clutch takes up the drive smoothly,
without slip or judder.
- that gear changing is smooth with no abnormal
noises or vibrations from the transmission.
- the engine power output is satisfactory, full
power is achieved, acceleration is smooth and
pedal operation is not stiff or heavy, and engine
speed returns to idle correctly.
- there is no excessive or abnormally colored
smoke from the engine under normal driving,
heavy load or overrun conditions.
- that steering operation, including power steering
(if equipped), is smooth, accurate, not
excessively heavy or with excessive free play
or vibration.
- that the steering does not pull to one side and
self centers smoothly after cornering.
2006.0 Fiesta 1212006 GI 7375en
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204-02-1 0 Rear Suspension 204-02-1 0
REMOVAL AND INSTALLATION
Beam Axle(l5 231 0)
f
General Equipment 5. Detach the parking brake cable from the (.
beam axle bracket on both sides. I Transmission jack
I Securing strap I
I Electric hand drill I
I Blind rivet gun I
Removal
Vehicles with rear drum brakes
1. Release the parking brake.
2. Remove the rear wheels and tires.
For additional information, refer to: Wheel
and Tire (204.04 Wheels and Tires, Removal 6. Remove the brake dIIlm and wheel spindle
and Installation). assembly
on both sides.
3. Detach the rear wheel speed sensor and
brake hose retaining bracket from the beam
axle on both sides.
Remove the retaining bolt.
7m &AUTION:S~~~~~~ the brake backing
plate, wheel cylinder and brake shoes
assembly to prevent load being placed on
the brake hose.
4. Disconnect the parking brake cable on both
Detach the brake backing plate, wheel
sides. cylinder and brake shoes assembly from the
beam axle on both sides.
2006.0 Fiesta 1212006 G183767en
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204-02-1 1 Rear Suspension 204-02-1 1
REMOVAL AND INSTALLATION
Using a suitable electric hand drill, remove
the rivets.
Vehicles with rear disc brakes
8. Remove the brake disc shield.
For additional information, refer to: Brake
Disc Shield
(206-04 Rear Disc Brake,
Removal and Installation).
9. Detach the parking brake cable from the
beam axle bracket on both sides.
All vehicles
10. Detach the parking brake cable from the
beam axle on both sides.
11. Remove the rear wheel speed sensor.
For additional information, refer to: Rear
Wheel Speed Sensor
(206-09 Anti-Lock
Control, Removal and Installation).
I*' AWARNING:M~~~ sure that the beam axle
is secured to the transmission jack. Failure
to follow this instruction may result in
personal injury.
Using a suitable securing strap, secure the
beam axle to a transmission jack.
13. Detach the shock absorber from the beam
axle on both sides.
14. Detach the spring from the lower spring
seat on both sides.
15. Remove the beam axle.
2006.0 Fiesta 1212006 GI 83767en
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204-02-1 3 Rear Suspension 204-02-1 3
REMOVAL AND INSTALLATION
8. Attach the parking brake cable to the beam Using a suitable blind rivet gun, install new
axle on both sides. rivets.
Vehicles with rear disc brakes 12. Install the brake drum and wheel spindle
assembly on both sides.
9. Attach the parking brake cable to the beam
axle bracket on both sides.
10. Install the brake disc shield.
For additional information, refer to: Brake
Disc Shield
(206-04 Rear Disc Brake,
Removal and Installation).
Vehicles with rear drum brakes
11. Attach the brake backing plate, wheel
cylinder and brake shoes assembly to the
beam axle on both sides.
13. Attach the parking brake cable to the beam
axle bracket on both sides.
2006.0 Fiesta 1212006 GI 83767en
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204-02-1 4 Rear Suspension 204102-14
REMOVAL AND INSTALLATION
14. Connect the parking brake cable on both 18. Tighten the shock absorber lower mounting
sides. bolt on both sides.
f
15. Attach the rear wheel speed sensor and 19. Adjust the parking brake cable.
brake hose retaining bracket to the beam
For additional information, refer to: Parking
axle on both sides.
Brake Cable Adjustment
- Vehicles With:
Install the retaining bolt. Rear Drum Brakes (206-05 Parking Brake
and Actuation, General Procedures).
16. Install the rear wheels and tires.
For additional information, refer to: Wheel
and Tire
(204-04 Wheels and Tires,
Removal and Installation).
All vehicles
17. Tighten the beam axle retaining bolts on
both sides.
2006.0 Fiesta 1212006 GI 83767en
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204-02-1 7 Rear Suspension 204-02-1 7
REMOVAL AND INSTALLATION
Rear Wheel Bearing
Special Tool(s)
General Equipment
17041
I Soft faced hammer I
Installer, Input Shaft Seal
307-2 1 0 (1 7-04 1 )
Vehicles with rear drum brakes
3. Release the parking brake.
4. Remove the brake drum and hub assembly.
Remove and discard the wheel hub retaining
nut.
I Wooden block I Vehicles with rear disc brakes
i , Removal

CAUTI0N:The brake drum and hub
assembly removal in this procedure is for
5. Remove the brake disc.
For additional information, refer to: Brake
Disc
(206-04 Rear Disc Brake, Removal and
Installation).
installing a new wheel bearing, not for
6. Remove the wheel hub.
access to brake system components.
Remove and discard the wheel hub retaining
nut.
All vehicles
1. Remove the dust cap.
2. Remove the wheel and tire.
For additional information, refer to: Wheel
and Tire
(204-04 Wheels and Tires, Removal
and installation).
2006.0 Fiesta 1212006 GI 83769en
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204-02-1 9 Rear Suspension 204-02-1 9
REMOVAL AND INSTALLATION
Using the special tool, install a new wheel
speed sensor ring (brake disc shown).
Vehicles with rear drum brakes
4. CAUTIONS:
AAvoid impact on the wheel speed sensor
ring.
AMake sure the wheel speed sensor ring
is clean.
AAvoid any contact between the wheel
, speed sensor ring and a magnetic surface.
' , A~otate the wheel hub assembly 10 times
counter-clockwise when tightening the wheel
hub retaining nut to prevent damage to the
wheel bearing.
N0TE:lnstall a new wheel hub retaining nut.
Install the brake drum and hub assembly.
5. Apply the parking brake.
Vehicles with rear disc brakes
6. CAUTIONS:
AAvoid impact on the wheel speed sensor
ring.
AMake sure the wheel speed sensor ring
is clean.
AAvoid any contact between the wheel
speed sensor ring and a magnetic surface.
A~otate the wheel hub assembly 10 times
counter-clockwise when tightening the wheel
hub retaining nut to prevent damage to the
wheel bearing.
N0TE:lnstall a new wheel hub retaining nut.
Install the wheel hub retaining nut.
7. lnstall the brake disc.
For additional information, refer to: Brake
Disc (206-04 Rear Disc Brake, Removal and
Installation).
All vehicles
8. Install the wheel and tire.
For additional information, refer to: Wheel
and Tire (204-04 Wheels and Tires, Removal
and Installation).
9. N0TE:lf the dust cap is damaged a new dust
cap must be installed.
Using a soft faced hammer and a wooden
block, install the dust cap.
2006.0 Fiesta 1212006 GI 83769en
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