2007 FORD FIESTA air suspension

100-04-16 Noise, Vibration and Harshness 100-04-1 6
DIAGNOSIS AND TESTING
Driveline Noise and Vibration
Suspension Noise and Vibration
Action
GO to Pinpoint Test A.
GO to Pinpoint Test
B.
GO to Pinpoint Test C.
Symptom
Shake and vibration while driving
Tip-in moan
Idle boomlshake/vibration/
shudder
Pinpoint Tests steps necessary to correct the condition. Then
check the operation of the system to make sure
N0TE:These Pinpoint Tests are designed to take the
condition has been corrected.
the technician through
a step-by-step diagnosis ~fi~~ verifying that the condition has been procedure to determine the cause of a condition. corrected, make sure all components removed It may not always be necessary to follow the chart have been installed. to its conclusion. Carry out only the pinpoint test
PINPOINT TEST A : SHAKE AND VIBRATION WHILE DRIVING
TEST CONDITIONS
DETAILSIRESU LTSIACTIONS 1
Possible Sources
Wheel end vibration.
. Engine/transmissiOnm
Air cleaner.
Power assisted steering.
Powertrain.
Powertrainldrivetrain mounts.
Exhaust system.
Cable(s)lhose(s).
Powertrainldrivetrain mounts.
Exhaust system.
Belt/ pulleys.
I A1 : NEUTRAL COAST I
Action
GO to Pinpoint Test D.
GO to Pinpoint Test E,
Symptom
Wheel end vibration analysis
Nan-axle noise
Carry out the neutral coast test.
Does the vibration disappear during the neutral
coast test?
+ Yes
GO to A2.
+ No
GO to Pinpoint Test D.
Possible Sources
Suspension.
. Wheel bearings,
Trim panels.
Air conditioning (A/C) system.
Accessories.
- --
2006.0 Fiesta 1212006 G37349en
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205-0414 Front Drive Halfshafts 205-04-4
DIAGNOSIS AND TESTING
Front Drive Halfshafts
Inspection and Verification 3. If an obvious cause for an observed or reported
concern is found, correct the cause (if possible) c.# '
1. Verify the customer concern. before proceeding
to the next step.
2. Visually inspect for obvious signs of mechanical
or electrical damage.
Symptom Chart - Front Drive Halfshafts
Symptom Chart
Symptom
Possible Sources Action
Clicking, Popping or Grinding
Noises While Turning Inadequate or contaminated INSPECT, CLEAN and
I lubricant in the inner or outer I LUBRICATE as necessary.
I Outer Constant Velocity (CV)
I Joint Boot - in this section.
front drive halfshaft constant
velocity (CV) joint.
REFER to Constant
Velocity (CV) Joint Boot -
Wheel bearings, brakes,
suspension or steering
components.
Another component contacting
front drive halfshaft assembly.
--
INSPECT and REPAIR as
necessary. REFER to
Section 204-00 [Suspension
System
- General Information]
1 206-00 [Brake System -
General Information] I 21 1-00
[Steering System
- General
Information].
INSPECT and REPAIR as
necessary.
- --
Vibration at Highway Speeds
Shudder Vibration During
Acceleration. Out of balance front wheels or
tires. Balance wheels and tires as
necessary.
I Incorrectly seated outer I REPAIR or INSTALL new as I
Out-of-round tires.
constant velocity (CV) joint in necessary.
front wheel hub.
I REFER to Halfshaft LH -
REPAIR or INSTALL new as
necessary.
I I I Halfshaft RH - in this section. I
Excessively high CV joint
operating angles caused by
incorrect ride height. CHECK the ride height,
VERIFY correct spring rate.
CHECK items under Halfshaft
Joint Pullout. REPAIR or INSTALL
new as necessary.
Excessively worn or damaged
I inner or outer front drive half-
- - - - --
2006.0 Fiesta 1212006 G25403en
INSPECT and INSTALL new
as necessary.
shaft constant velocity (CV)
joint. REFER
to Halfshaft LH
-
I Halfshaft RH - in this sectionk 1;
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205-04-5 Front Drive Halfshafts 205-04-5
DIAGNOSIS AND TESTING
Possible Sources Action
Halfshaft Joint Pullout Outer front drive halfshaft INSPECT
and REPAIR or
retainer circlip missing or not
I I INSTALL new as necessary.
Front suspension components
worn or damaged.
correctly seated differential
side. CHECK
for worn bushings or
bent components (front stabil-
izer bar, front suspension lower
arm). REPAIR or INSTALL new
as necessary. REFER to
Section
204-01 [Front
Suspension]. REFER to Halfshaft
LH
-
1 Halfshaft RH - in this section.
Engineltransaxle assembly
misalignment. CHECK engine mounts for
damage or wear. REPAIR or
INSTALL new as necessary.
Frame rail or strut tower out of
position or damaged. CHECK underbody dimen-
sions. REFER to Section
501 -
00 [Body System - General
Information].
-- - --
2006.0 Fiesta 1212006 G25403en
procarmanuals.com

206-004 Brake System - General Information 206-00-4
DIAGNOSIS AND TESTING
Symptom Chart - -
Symptom
Brakes pull or drift
Possible Sources Action
Worn or damaged brake shoes
or brake pads and linings. INSTALL
new brake shoes or ,
brake pads. REFER to:
Brake Shoes (206-02 Drum
Brake, Removal and Installa-
tion),
Brake Pads (206-03 Front Disc
Brake, Removal and Installa-
tion),
Brake Pads (206-04 Rear Disc Brake, Removal and Installa-
tion).
Abnormal wear or distortion of
brake discs.
INSTALL a new brake discs.
REFER to: Brake Disc (206-04
Rear Disc Brake, Removal
and Installation).
lncorrect rear brake adjust-
ment. PERFORM
a parking brake
cable adjustment. REFER to:
(206-05 Parking Brake and
Actuation)
Parking Brake Cable Adjust-
ment
- Vehicles With: Rear
Drum Brakes (General
Procedures),
Parking Brake Cable Adjust-
ment
- Vehicles With: Rear
Disc Brakes (General
Procedures).
lncorrect wheel alignment
adjustment. PERFORM a
wheel alignment
adjustment.
REFER to: Front Toe Adjust-
ment (204-00 Suspension
System
- General Informa-
tion, General Procedures).
l ncorrect wheel bearing preload
adjustment. ADJUST or INSTALL a new
wheel bearing. REFER to:
Front Wheel Bearing (204-01 Front Suspension, Removal
and Installation),
Rear Wheel Bearing (204-02 Rear Suspension, Removal
and Installation).
2006.0 Fiesta 1212006 G28494en
Unequal air pressure in the
tires. INFLATE the tires to the correct
pressure.
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206-00-20 Brake System - General Information 206=00-20
DIAGNOSIS AND TESTING
TEST CONDITIONS
DETAILSIRESULTSIACTIONS
F4: BLEED THE BRAKE SYSTEM
rn Check for air in the brake system. Bleed the
brake system. REFER to: (206-00 Brake System
- General lnformation)
Brake System Bleeding (General Procedures),
Brake System Pressure Bleeding (General Procedures)
.
Is the condition still present?
+ Yes
GO to F5.
+ No
Vehicle OK.
F5: CHECK FRONT WHEEL HUB RETAINING NUT
Check the front wheel hub retaining nut for
looseness.
Is the front wheel hub retaining nut loose?
+ Yes
INSTALL a new front wheel hub retaining nut.
REFER to: Specifications (204-01 Front
Suspension, Specifications).
Do not reuse the
frontwheel hub retaining nut.
TEST the system for normal operation.
+ No
CHECK the parking bake adjustment. REFER
to: (206-05 Parking Brake and Actuation)
Parking Brake Cable Adjustment
- Vehicles With:
Rear Drum Brakes (General Procedures),
Parking Brake Cable Adjustment
- Vehicles With:
Rear Disc Brakes (General Procedures).
PINPOINT TEST G
: BRAKE LOCK UP DURING LIGHT BRAKE PEDAL FORCE
TEST CONDITIONS
DETAILSIRESULTSIACTIONS
I GI : ROAD TEST-THE VEHICLE I
Road test the vehicle and apply the brake pedal
lightly.
Do the rear brakes lock up?
+ Yes
GO to G2. GO to Pinpoint Test G.
+ No
Vehicle OK.
2006.0 Fiesta 12/2006 G28494en
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211 -00-5 Steering System - General Information 211 -00-5
DIAGNOSIS AND TESTING
Steering System
/ Special Tool(s)
Alignment Pins, Subframe
205-524
Simulator, Driver and
passenger ~ir Bags and Side
Air Curtains 50
1 -073A
General Eaui~ment
I Worldwide Diagnostic System (WDS) I
Principles of Operation
The steering wheel rotational movement is
transferred to the steering gear through the steering
column shaft. The steering gear converts this
rotational movement, through the action of the rack
and pinion gear into lateral movement. This
movement in turn is transferred to the wheel
knuckles through the tie-rods and tie-rod ends.
Hydraulic fluid under pressure is supplied to the
steering gear by the power steering pump. As the
steering wheel is rotated, the hydraulic fluid is
allowed to pass through the steering gear valve to
one side of a double acting piston, dependent on
which direction the steering wheel is rotated. The
fluid moves the piston, which forms part of the
steering gear, giving power assistance to the effort
required to rotate the steering wheel.
Vehicles with petrol engines, due to the extra load
on the engine imposed by the power steering
pump, have a power steering pressure (PSP)
switch. The switch, which is normally closed, sends a signal
to the powertrain control module (PCM)
during low speed parking manoeuvres. The PCM
responds by maintaining the engine idle speed.
lnspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical
or electrical damage.
Visual lnspection Chart
I Mechanical I Electrical I
Tire pressure(s)
Accessory drive belt
Tie-rod ends
Tie-rod (s)
Steering gear housing
Front strut and
spring assemblies
Front suspension
lower arm ball joints
Front suspension
lower arm bushings
Pinch bolt on
steering column
shaft flexible coup-
ling Power
steering pres-
sure (PSP) switch
Wheels and tires
Power steering line
fluid leaks
Steering gear
bellows
3. If an obvious cause for an observed or reported
concern is found, correct the cause (if possible)
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 Possible Sources Action
Drift left or right
2006.0 Fiesta 1212006 Gl49906en
Vehicle attitude incorrect (front
or rear is high or low). CHECK for abnormal loading,
coil spring sag or non-standard
springs.
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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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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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