2007 FORD FIESTA brake

I 00-00-21 General Information 1 00-00-21
DESCRIPTION AND OPERATION
Always disconnect the jumper cables in the reverse
order to the connecting sequence and do not short
i the ends of the cables.
Do not rely on the generator to restore a
discharged battery. For a generator to recharge a
battery, it would take in excess of eight hours
continuous driving with no additional loads placed
on the battery.
Component Cleaning
To prevent the ingress of dirt, accumulations of
loose dirt and greasy deposits should be removed
before disconnecting or dismantling components
or assemblies.
Components should be thoroughly cleaned before inspection prior to reassembly.
Cleaning Methods:
- Dry cleaning.
- Removal of loose dirt with soft or cable brushes.
- Scraping dirt off with a piece of metal or wood.
( ,- Wiping off with a rag.
A WARN1NG:Wear eye protection when
cleaning vehicle components with
compressed air, a steam cleaner or a
power washer. Failure to follow this
instruction may result in personal injury.
CAUTIONS:
A Compressed air is sometimes 'wet' so use
with caution, especially on hydraulic
systems.
A To prevent damage to the electrical
connectors in the engine compartment, do
not use a steam cleaner or a power washer
to clean the engine compartment.
- Blowing dirt off with compressed air.
- Removal of dry dust using vacuum equipment.
This method must always be used to remove
friction lining material dust (asbestos particles).
- Steam cleaning.
A WARN1NG:Most solvents require careful
handling and some are harmful. Refer to
Health and Safety Precautions and to the
manufacturers literature for the relevant
safety precautions. Failure to follow these
instructions may result in personal injury.
Various solvents are available which are suitable
for component cleaning. Some components, such
as brake hydraulic parts and electrical assemblies
should be cleaned only with recommended solvents
- refer to Solvents, Sealers and Adhesives or to
the section of the manual relevant to the
component.
Calibration of Essential Measuring
Equipment
A WARNING:Equipment, which requires
regular calibration, must be calibrated in
accordance with the manufacturers
instructions. Failure to follow this
instruction may result in personal injury
or damage to components.
It is of fundamental importance that certain
essential equipment, for example torque wrenches,
multimeters, exhaust gas analyzers or rolling roads,
are regularly calibrated in accordance with the
manufacturers instructions.
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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100-00-24 General Information 100-00-24
DESCRIPTION AND OPERATION
- that the speedometer, coolant temperature - oil, coolant, hydraulic, air and fuel leaks.
gauge and tachometer (if equipped) register the - abnormal temperature of any moving
correct readings and operate correctly.
components or assemblies, for example wheel
(
- that the switches and controls operate smoothly hubs, transmission and axle, which might
and positively, warning and indicator lamps
indicate over tightness or lack of lubrication.
operate correctly and the direction indicator
control self cancels when the steering is
returned to the straight ahead position.
- that the heating and ventilation systems operate
correctly and effectively.
- the brake operation and efficiency.
Brake Testing
A WARNING:When brake testing, avoid
breathing the fumes from hot brakes, this
may contain asbestos dust which is
hazardous to health. Failure to follow this
instruction may result in personal injury.
For additional information, refer to: Health
and Safety Precautions
(1 00-00 General
Information, Description and Operation).
CAUTIONS:
A Avoid brake testing on busy roads where
it may cause inconvenience or danger to
other road users.
A Brake testing which includes heavy brake
applications should not be carried out with
new brake
padsldiscs or liningsldrums
until the components have bedded-in. New
brake friction components will not reach
full efficiency until the bedding-in process
is complete.
Test the brakes at several speeds within the normal
operating range using both light and heavy pedal
pressure. Note any tendency to snatch, pull or
drag, and any undue delay in application or
release.
Allow the vehicle to coast and note any tendency
to pull to one side, or evidence that the brakes are
binding.
After stopping the vehicle (not immediately after a
period of heavy braking), carefully check the brake
temperature.
A brake disc or brake drum that feels
hot or is appreciably hotter than the others,
indicates that the brake is binding.
After completion of the test, check for:
2006.0 Fiesta 1212006 GI 7375en
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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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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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204-00-1 6 Suspension System - General Information 204-00-1 6
GENERAL PROCEDURES
Wheel Bearing Inspection
Special Tool(s)
General Equipment
I Dial indicator gauge I
bearing assembly. There should be no end (
play. If end play exists, install new wheel
bearings.
Check
1. N0TE:Do not to confuse lower arm ball joint
looseness with bearing looseness.
Raise and support the front of the vehicle. 6.
Install the front brake caliper anchor plate.
For additional information, refer to: (I 00-02)
For additional information, refer to: Brake
Jacking (Description and Operation),
Lifting (Description and Operation).
2. Check for loose front wheel bearings by
rocking the wheels at the top and bottom.
3. Spin the wheel quickly by hand and make
sure the wheel turns smoothly without noise
from the wheel bearings.
4. Remove the front brake caliper anchor plate.
For additional information, refer to: Brake
Caliper Anchor Plate (206-03, Removal and
Installation).
5. Position a suitable Dial indicator gauge
fixture or equivalent, against the wheel hub,
then push and pull the wheel hub. Measure
the end play of the wheel hub and front wheel Caliper
Anchor Plate (206-03, Removal and
Installation).
2006.0 Fiesta 1212006 ~25341 en
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204-01 -2 Front Suspension 204-01 -2
SPECIFICATIONS
I Top mount retaining nuts I 25 I 18 I - I
Torque Specifications
I Thrust bearing retaining nut I 48 I 35 I - I
Stabilizer bar connecting link to strut and spring
retaining nut Ib-in
I Wheel
knuckle to suspension strut pinch bolt I 85 I 63 I - I
Ib-ft Item Nm
Brake caliper anchor plate retaining bolts
Lower arm ball joint to wheel knuckle retaining nut
I Steering gear retaining bolts I 48 I 35 I - I
Tie-rod end retaining nut
Stabilizer bar clamp retaining bolts
Stabilizer bar to connecting link retaining nut
Fb.wer arm front retaining bolt I
70
48
I Lower arm rear clamp retaining bolts I 55 I 41 I - I
48
55
55
I Crossmember front retaining bolts I 70 I 52 I - I
52
35
I Crossmember rear retaining bolts 1 Iq5 1 85 I - I
-
-
35
41
41
I Crossmember inner and outer retaining bolts 1 175 1 129 1 - I
-
-
-
I Wheel hub retaining nut 1290 1214 1 - I
I Engine support insulator center bolt I 48 I 35 I - I
2006.0 Fiesta 1212006 GI 52539en
Wheel speed sensor retaining nut
a) Refer to the procedure in this section.
9 - 80
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