tires 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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100-00-23 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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100-04-4 Noise, Vibration and Harshness 100-0414
DIAGNOSIS AND TESTING
Noise, Vibration and Harshness (NVH)
Inspection and Verification
1. Verify the customer concern. Identify the Condition
2. Visually inspect for obvious signs of mechanical NVH usually occur in four areas:
or electrical damage.
tires
3. If an obvious cause for an observed or reported
concern is found, correct the cause (if possible) engine accessories
before proceeding to the next step.
suspension
4. If the concern is not visually evident, verify the
symptom and REFER to the Symptom Chart.
How to Use this Diagnostic Procedure
Section
Noise, vibration and harshness (NVH) concerns
have become more important as
vehjcles have
become more sensitive to these vibrations. This
section is designed to aid in identifying these
concerns.
The section provides diagnostic procedures based on symptom. If the condition occurs at
high speed, for instance, the most likely place
to start is under Shake and Vibration While
Driving.
The road test procedure will tell how to sort the
conditions into categories and how to tell a
vibration from a shake.
A series of Road Test Quick Checks are
provided to make sure that a cause is either
pinpointed or eliminated.
Name the condition, proceed to the appropriate
section and locate the correct diagnosis. When
the condition is identified, the job is partly done.
Follow the diagnostic procedure as outlined.
Quick Checks are described within the step,
while more involved tests and adjustments are
outlined in General Procedures.
Always follow each step exactly and make notes
to recall important findings later.
driveline
It is important, therefore, that an NVH concern be
isolated into its specific
area(s) as soon as
possible. The easiest and quickest way to do this
is to carry out the Road Test as outlined. To assist
in the diagnosis and testing
procedure(s), use a
suitable approved NVH diagnosis tester.
Noise Diagnostic Procedure
Non-Axle Noise
The five most common sources of non-axle noise
are exhaust, tires, roof racks, trim panels and
( transmission.
Therefore, make sure that none of the following
conditions are the cause of the noise before
proceeding with a driveline
teardown and
diagnosis.
In certain conditions, the pitch of the exhaust
may sound very much like gear noise. At other
times, it can be mistaken for a wheel bearing
rumble.
Tires, especially snow tires, can have a high
pitched tread whine or roar, similar to gear
noise. Radial tires may have this characteristic.
Also, any non-standard tire with an unusual
tread construction may emit a roar or whine
noise.
Trim panels can also cause whistling or whining
noise.
Clunk may be a metallic noise heard when the
Customer Interview automatic transaxle is engaged in "R
(REVERSE) or "D" (DRIVE) or it may occur
The road test and customer interview (if available) when
the throttle is applied or released. It is
provide information that will help identify the caused
by backlash somewhere in the driveline.
,
concern and will provide direction to the correct Bearing rumble sounds like marbles being
starting point for diagnosis. (
tumbled. This condition is usually caused by a
damaged wheel bearing.
2006.0 Fiesta 1212006 G37349en
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100-04-5 Noise, Vibration and Harshness 100-04-5
DIAGNOSIS AND TESTING
Noise Conditions
Gear noise is typically a howling or whining due
to gear damage or incorrect bearing preload. It
can occur at various speeds and driving
conditions, or it can be continuous.
Chuckle is a particular rattling noise that sounds
like a stick against the spokes of a spinning
bicycle wheel. It occurs while decelerating from
64
kmlh (40 mph) and can usually be heard all
the way to a stop. The frequency varies with
vehicle speed.
Knock is very similar to chuckle, though it may
be louder and occurs on acceleration or
deceleration. The
teardown will disclose what
has to be corrected.
Clicking, popping or grinding noises may be caused
by the following:
worn, damaged or incorrectly installed wheel
bearing, suspension or brake component.
Check and rule out tires, exhaust and trim items
before disassembling the transmission to diagnose
and correct gear noise.
The noises described under Road Test usually
( have specific causes that can be diagnosed by
observation as the unit is disassembled. The initial
clues are the type of noise heard on the road test
and driving conditions.
Vibration Conditions
Vibration at highway speeds may be caused by
the following:
out-of-balance front or rear wheels.
out-of-round tires.
Shudder or vibration during acceleration may be
caused by the following:
damaged powertrainldrivetrain mounts.
excessively high constant velocity (CV) joint
operating angles caused by incorrect ride height.
Check ride height, verify correct spring rate and
check items under inoperative conditions.
Road Test
I A gear-driven unit will produce a certain amount
of noise. Some noise is acceptable and may be
audible at certain speeds or under various driving conditions,
as on a newly paved asphalt road. The
slight noise is in no way detrimental and must be
considered normal.
The road test and customer interview (if available)
provide information needed to identify the condition
-
and give direction to the correct starting point for
diagnosis.
1. Make notes throughout the diagnosis routine.
Make sure to write down even the smallest bit
of information, because it may turn out to be the
most important.
2. Do not touch anything until a road test and a
thorough visual inspection of the vehicle have been carried out. Leave the tire pressures and
vehicle load just where they were when the
condition was first observed. Adjusting tire
pressures, vehicle load or making other
adjustments may reduce the
condition(s)
intensity to a point where it cannot be identified
clearly. It may also inject something new into
the system, preventing correct diagnosis.
3. Make a visual inspection as part of the
preliminary diagnosis routine, writing down
anything that does not look right. Note tire
pressures, but do not adjust them yet. Note
leaking fluids, loose nuts and bolts, or bright
spots where components may be rubbing
against each other. Check the load space for
unusual loads.
4. Road test the vehicle and define the condition
by reproducing it several times during the road
test.
5. Carry out the Road Test Quick Checks as soon
as the condition is reproduced. This will identify
the correct diagnostic procedure. Carry out the
Road Test Quick Checks more than once to
verify they are providing a valid result.
Remember, the Road Test Quick Checks may
not tell where the concern is, but they will tell
where it is not.
Road Test Quick Checks
1. 24-80 kmlh (1 5-50 mph): with light acceleration,
a moaning noise is heard and possibly a
vibration felt in the front floor panel. It is usually
worse at a particular engine speed and at a
particular throttle setting during acceleration at
that speed. It may also produce a moaning
sound, depending on what component is
causing it. REFER to Tip-in Moan in the
Driveline Noise and Vibration Symptom Chart.
2006.0 Fiesta 1212006 G37349en
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100-04-6 Noise, Vibration and Harshness 100-04-6
DIAGNOSIS AND TESTING
2. AccelerationIDeceleration: With slow
acceleration and deceleration, a shake is
sometimes noticed in the steering
wheellcolumn,
seats, front floor panel, front door trim panel or
front end sheet metal. It is a low frequency
vibration (around
9-1 5 cycles per second). It
may or may not be increased by applying the
brakes lightly. REFER to
Idle
BoomIShakeNibration in the Driveline Noise
and Vibration Symptom Chart.
High Speed: A vibration is felt in the front floor
panel or seats with no visible shake, but with
an accompanying sound or rumble, buzz, hum,
drone or booming noise. Coast with the clutch
pedal depressed (manual transmission) or shift
control selector lever in "N" (NEUTRAL)
(automatic transmission) and engine idling. If
vibration is still evident, it may be related to
wheels, tires, front brake discs, wheel hubs or
front wheel bearings. REFER to Shake and
Vibration While Driving in the Driveline Noise
and Vibration Symptom Chart.
4. Engine rpm Sensitive: A vibration is felt
whenever the engine reaches a particular rpm.
It will disappear in neutral coasts. The vibration
can be duplicated by operating the engine at
the problem rpm while the vehicle is stationary.
It can be caused by any component, from the
accessory drive belt to the clutch or torque
converter which turns at engine speed when the
vehicle is stopped. REFER to Shake and
Vibration While Driving in the Driveline Noise
and Vibration Symptom Chart.
5. Noise and Vibration While Turning: Clicking,
popping or grinding noises may be due to the
following:
worn, damaged or incorrectly installed front
wheel bearing.
damaged
powertrainldrivetrain mounts.
Road Conditions
An experienced technician will always establish a
route that will be used for all NVH diagnosis road
tests. The road selected should be reasonably
smooth, level and free of undulations (unless a
particular condition needs to be identified). A
smooth asphalt road that allows driving over a
range of speeds is best. Gravel or bumpy roads
are unsuitable because of the additional road noise produced.
Once the route is established and
consistently used, the road noise variable is
eliminated from the test results.
N0TE:Some concerns may be apparent only on
smooth asphalt roads.
If a customer complains of a noise or vibration on
a particular road and only on a particular road, the
source of the concern may be the road surface. If
possible, try to test the vehicle on the same type
of road.
Vehicle Preparation
Carry out a thorough visual inspection of the
vehicle before carrying out the road test. Note
anything which is unusual. Do not repair or adjust
any condition until the road test is carried out,
unless the vehicle is inoperative or the condition
could pose a hazard to the technician. After
verifying that the condition has been corrected,
make sure all components removed have been
installed.
Power Steering Conditions
c !
Check for the noise in the following conditions to
verify the customer concern.
Check for the noise in several temperature
conditions.
Is the noise from when the vehicle was new?
Can the noise be repeated constantly or is it
random?
Check the condition of the vehicle age, mileage
and service record.
Interview the customer to find the operating
condition in which the noise will occur. Test the
vehicle based on the
detail(s) from the customer
interview.
Follow the power steering operation noise
condition tables below, to find which condition
the noise will occur.
Power Steering Operation Noise Check
Step 1 : Check for NVH concerns from non-steering
components, which may sound like noises coming
from the steering system.
I:. ':
2006.0 Fiesta 121zoo6 G37349en
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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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204-00-4 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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