steering linkage 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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100-04-13 Noise, Vibration and Harshness 100-04-13
DIAGNOSIS AND TESTING
Power Steering Mechanical Knock Noise 1. Turn the steering wheel to a steering lock and
(PAS on) return to center quickly.
2. Turn the steering wheel 90 degrees to the left
Test Condition and then 90 degrees to the right quickly.
Listen for steering knock noise with the engine
speed at idle in the following test conditions (power
assist).
Action
Certain amount of noise level
acceptable, not a safety critical
item.
Certain amount of noise level
acceptable, not a safety critical
item.
Symptom
Power steering system knock
noise - a heavy loud repeating
sound like a knock on a door that
occurs in several driving and
steering conditions.
Power Steering Hammer Knock (Hydraulic) 1. Turn the steering wheel to a steering lock
Noise position and return quickly.
Possible Sources
Power steering system knock
noise
- a damped, metallic knock
noise which only occurs at
steering condition with engine off
(very high efforts),
Tolerances in the steering gear
components.
Test Condition
Action
REFER to Steering System.
REFER to: Steering System (21
1 -
00, Diagnosis and Testing).
Symptom
Power steering system knock
noise - clear knock noise from
steering gear linkage area.
Listen for steering knock noise with the engine
speed at idle in the following test conditions (for
vehicles with hydraulic power assisted steering only, not electro-hydraulic power steering).
Possible Sources
Worn tie-rod ball joints (inner and
outer ball joints).
Symptom Possible Sources Action
hitting the suspension cross- Certain
amount of noise level
by pressure impulse in gear and
return line).
Power Steering Hydraulic KnocWClonk 1. Drive over cobbled roads at low speed 10-30
Noise kmlh (6-20 mph) with and without turning.
2. Drive over straight tar strips road rails or 25 mm
Test Condition tall harshness strips at low speed 10-30 kmlh
Listen for steering knocklclonk noise in the (6-20
mph) both driving straight and with
following test conditions with the windows closed. moderate turning.
2006.0 Fiesta 1212006 G37349en
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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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204-00-7 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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204-00-1 7 Suspension System - General Information 204-00-1 7
GENERAL PROCEDURES
Front Toe Adjustment(l4 11 7 0)
I
N0TE:Make sure that the vehicle is standing on a 4. Rotate the tie-rods an equal amount in either
level surface. a clockwise or a counterclockwise direction
1. Centralize the steering and lock it in position. to
adjust the toe setting.
For additional information, refer to:
Specifications
(204-00, Specifications).
2. Loosen the tie-rod end locknuts.
3. Remove the steering gear boot outer clamps.
5. Tighten the tie-rod end locknuts.
For additional information, refer to: Tie Rod
End (21
1-03 Steering Linkage, Removal and
Installation).
6. Install the steering gear boot outer clamps.
2006.0 Fiesta 1212006 GI 7387en
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211 -00-6 Steering System = General Information 21 1 =OO-6
DIAGNOSIS AND TESTING
Symptom Possible Sources Action
lncorrect wheel alignment. CHECK the wheel alignment
and adjust if necessary.
REFER to: (204-00 Suspension
System
- General Information) r
Specifications (Specifications), Front Toe Adjustment (General
Procedures).
lncorrect front axle cross-
member alignment.
Using the special tool, CHECK
the front axle crossmember
alignment.
Damaged or worn front wheel
bearings. CHECK and INSTALL new
front wheel bearings as neces-
sary.
REFER to: Front Wheel
Bearing (204-01 Front
Suspension, Removal and
Installation).
I CHECK the brake system. I
REFER to: Brake System (206-
00 Brake System
- General
Information, Diagnosis and
Testing).
CARRY OUT the steering
linkage component test.
REFER to Steering Linkage
Component Test in this
procedure.
CARRY OUT the steering
linkage component test.
REFER to Steering Linkage
Component Test in this
procedure.
Wheels and tires. I CHECK the wheels and tires. I
REFER to: Wheels and Tires
(204-04 Wheels and Tires,
Diagnosis and Testing).
Steering wheel 'off center Vehicle attitude incorrect (front
or rear is high or low). CHECK
for abnormal loading,
coil spring sag or non-standard
springs.
lncorrect wheel alignment. CHECK
the wheel alignment
and adjust if necessary.
REFER to: (204-00 Suspension
System
- General Information)
Specifications (Specifications),
Front Toe Adjustment (General
Procedures).
2006.0 Fiesta 1212006 GI 49906en
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21 1-00-7 Steering System - General Information 21 1-00-7
DIAGNOSIS AND TESTING
Symptom
Vibration
Possible Sources Action
Front suspension lower arm
ball joint. CHECK
and INSTALL new
suspension components as
necessary.
REFER to: Suspension System
(204-00 Suspension System
- General Information,
Diagnosis and Testing).
Steering linkage. CARRY OUT the steering
linkage component test. REFER to Steering Linkage
Component Test in this
procedure.
Steering gear. CARRY OUT the steering
linkage component test. REFER to Steering Linkage
Component Test in this
procedure.
Incorrect wheel alignment. CHECK the wheel alignment
and adjust if necessary.
REFER to: (204-00 Suspension
System
- General Information)
Specifications (Specifications), Front Toe Adjustment (General
Procedures).
Wheels and tires.
CHECK the wheels and tires.
BALANCE or INSTALL new
wheels and tires as necessary.
REFER to: Wheel and Tire
(204-04 Wheels and Tires,
Removal and
Installation).
Damaged or worn front wheel
bearings. CHECK
and INSTALL new
front wheel bearings as neces-
sary.
REFER to: Front Wheel
Bearing
(204-01 Front
Suspension, Removal and
Installation).
Front strut and spring assem-
blies. CHECK
and INSTALL new
suspension 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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21 1-00-8 Steering System - General Information 21 1-00-8
DIAGNOSIS AND TESTING
Symptom
Possible Sources Action
Damaged front suspension
lower arm(s).
CHECK and INSTALL new
suspension components as
necessary.
REFER to: Suspension System
(204-00 Suspension System
- General Information,
Diagnosis and Testing).
CARRY OUT the steering
linkage component test.
REFER to Steering Linkage
Component Test in this
procedure.
Steering effort is highllow Loose or worn accessory drive
belt.
CHECK the accessory drive
belt. REFER to: (303-05
Accessory Drive)
Power Steering Pump
Belt -
1.4L Duratec-1 6V
(Sigma)ll .6L Duratec-1 6V
(Sigma), Vehicles With: Air
Conditioning
(Removal and
Installation),
Accessory Drive Belt - 1.3L
Du ratec-8V (Rocam)
(Removal and lnstallation),
Accessory Drive Belt - I .4L
Duratec-I 6V
(Sigma)ll.6L
Duratec-1 6V (Sigma),
Vehicles Without: Air Condi-
tioning
(Removal and Installa-
tion),
Accessory Drive
Belt - 1.4L
Duratorq-TDCi (DV) Diesel
(Removal and lnstallation),
Accessory Drive Belt - 2.OL
Duratec-H E (M 14) (Removal
and lnstallation).
2006.0 Fiesta 1212006 GI 49906en
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