2007 FORD FIESTA engine

206-09A-14 Anti-Lock Control 206-09A-I 4
REMOVAL AND INSTALLATION
Anti-Lock Brake System (ABS) Module - Vehicles Built Up To: /.
Materials Remove
the brake master cylinder to
hydraulic control unit (HCU) brake tubes.
Name
S~ecification
I Super DOT 4 brake fluid 1 ESD-M6C57-A I
Removal
A CAUTI0N:Y brake fluid is spilt on the
paintwork, the affected area must be
immediately washed down with cold water.
1. Remove the brake master cylinder. For
additional information, refer to
Section
206-06 [Hydraulic Brake Actuation].
2. Detach the engine wiring harness electrical
connector from the wheelhouse assembly.
4m CAUTIONS:
3. CAUTIONS:
&ap the brake tubes to prevent fluid loss
or dirt ingress.
Aplug the hydraulic control unit (HCU)
ports to prevent fluid loss or dirt ingress.
N0TE:Make a note of the position of the brake
tubes, to aid installation.
&ap the brake tubes to prevent fluid loss
or dirt ingress.
Aplug the HCU ports to prevent fluid loss
or dirt ingress.
N0TE:Make a note of the position of the brake
tubes, to aid installation.
Disconnect the brake tubes from the HCU.
2006.0 Fiesta 1~12006 G327317en
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206-09A-I 7 Anti-Lock Control 206-09A-I 7
REMOVAL AND INSTALLATION
Anti-Lock Brake System (ABS) Module - Vehicles Built From:
0512004
Materials Remove
the brake master cylinder to HCU
brake tubes.
Name Specification
I Super DOT 4 brake fluid I ESD-M6C57-A I
Removal
All vehicles
A CAUTI0N:lf brake fluid is spilt on the
paintwork, the affected area must be
immediately washed down with cold water.
1. Detach the engine wiring harness electrical
connector from the wheelhouse assembly.
Left-hand drive vehicles
2. Remove the brake master cylinder.
For additional information, refer to: Brake
Master Cylinder
- LHD (206-06 Hydraulic
Brake Actuation, Removal and Installation).
3. CAUTIONS:
&ap the brake tubes to prevent fluid loss
or dirt ingress.
Aplug the hydraulic control unit (HCU)
ports to prevent fluid loss or dirt ingress.
N0TE:Make a note of the position of the brake
tubes to aid installation.
Right-hand drive vehicles
4. Remove the battery tray.
For additional information, refer to: Battery Tray (41 4-01 Battery, Mounting and Cables,
Removal and Installation).
5. CAUTIONS:
hap the brake tubes to prevent fluid loss
or dirt ingress.
nplug the hydraulic control unit (HCU)
ports to prevent fluid loss or dirt ingress.
N0TE:Make a note of the position of the brake
tubes to aid installation.
Disconnect the brake master cylinder to HCU
brake tubes from the HCU.
All vehicles
6. CAUTIONS:
2006.0 Fiesta 1212006 G406272en
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206-096-4 Anti-Lock Control - Stability Assist 206-096-4
REMOVAL AND INSTALLATION
Hydraulic Control Unit (HCU)
Materials Remove
the brake master cylinder to
hydraulic control unit (HCU) brake tubes.
Name Specification
I Super DOT4 brake fluid I ESD-M6C57-A 7
Removal
A CAUTI0N:lf brake fluid is spilt on the
paintwork, the affected area must be
immediately washed down with cold water.
1. Remove the brake master cylinder. For
additional information, refer to
Section
206-06 [Hydraulic Brake Actuation].
2. Detach the engine wiring harness electrical
connector from the wheelhouse assembly.
3. CAUTIONS:
hap the brake tubes to prevent fluid loss
or dirt ingress.
nplug the hydraulic control unit (HCU)
ports to prevent fluid loss or dirt ingress.
N0TE:Make a note of the position of the brake
tubes, to aid installation.
4. CAUTIONS:
&ap the brake tubes to prevent fluid loss
or dirt ingress.
Aplug the HCU ports to prevent fluid loss
or dirt ingress.
N0TE:Make a note of the position of the brake
tubes, to aid installation.
Disconnect the brake tubes from the HCU.
2006.0 Fiesta 1212006 ~327341 en
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206-09C-12 Anti-Lock Control - Stability Assist 206-096-1 2
REMOVAL AND INSTALLATION
Stability Assist Module ,/.. ,
Materials Remove
the brake master cylinder to
hydraulic control unit (HCU) brake tubes. C
Name Specification I I
I Super DOT 4 brake fluid I ESD-M6C57-A I
Removal
CAUTI0N:If brake fluid is spilt on the
paintwork, the affected area must be
immediately washed down with cold water.
I. Remove the brake master cylinder. For
additional information, refer to
Section
206-06 [Hydraulic Brake Actuation].
2. Detach the engine wiring harness electrical I
connector from the wheelhouse assembly. 4. CAUTIONS:
3. CAUTIONS:
hap the brake tubes to prevent fluid loss
or dirt ingress.
Dplug the hydraulic control unit (HCU)
ports to prevent fluid loss or dirt ingress.
N0TE:Make a note of the position of the brake
tubes, to aid installation.
hap the brake tubes to prevent fluid loss
or dirt ingress.
nplug the HCU ports to prevent fluid loss
or dirt ingress.
N0TE:Make a note of the position of the brake
tubes, to aid installation.
Disconnect the brake tubes from the HCU.
2006.0 Fiesta 1~12006 G327320en
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21 1-00-4 Steering System - General Information 21 1-00-4
DESCRIPTION AND OPERATION
Item Descri~tion
A
RHD with Duratec 16V engine and Air
1 I Conditioning (NC)
I B I LHD with Duratec 16V engine and NC I
I C I RHD with Duratec 16V engine without AM: I
I D I LHD with Duratec 16V engine without NC I
I E ( RHD with 1.4L Duratorq TDCi engine I
I F I LHD with 1.4L Duratorq TDCi engine I
I I I Steering gear I
1 2 1 Additional cooling loop I
Independent of the equipment level, all vehicles
have conventional power-assisted rack and pinion
steering with an additional cooling loop.
The steering gear is supplied with hydraulic fluid
by a hydraulic pump.
The hydraulic pump is driven by the accessory
drive belt and has a separate reservoir.
Vehicles with petrol engines have a Power Steering
Pressure (PSP) switch in the pressure line, which
opens as the power steering load increases, thus
signalling to the Powertrain Control Module (PCM)
that it should increase the idle speed.
- - -- - -
2006.0 Fiesta 1212006 G202090en
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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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211 -00-14 Steering System - General Information 21 1-00-1 4
DIAGNOSIS AND TESTING
Symptom
Engine stalls when parking with
engine speed at idle Possible
Sources Action
I Worn front suspension lower 1. CARRY OUT the suspension f-
ball joint inspection component'
test.
REFER to: Suspension System
(204-00 Suspension System
- General Information,
Diagnosis and Testing).
Steering gear bushings worn
or perished. CHECK
and INSTALL new
components as necessary.
REFER to: Steering Gear
Bushing (21 1-02 Power
Steering, Removal and
Installation).
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).
Loose steering column retaining bolts.
CHECK and INSTALL new
steering column retaining bolts as necessary.
REFER to: Specifications (21 1
-
04 Steering Column,
Specifications).
Loose steering column to
steering gear pinion retaining bolt. CHECK
and INSTALL a new
steering column to steering
gear pinion retaining bolt as
necessary.
REFER to: Specifications (21 1
-
02 Power Steering, specifica-
tions).
I Excessive steering gear back-
lash. CARRY
OUT the steering
linkage component test.
REFER to Steering Linkage
Component Test in this
procedure.
Power steering pressure (PSP)
or additional information, refer
switch or circuit.
1. I to WDS.
Components Tests
Steering Linkage
column bearing wear, steering column universal
joint free play, steering wheel or steering column
looseness. The steering column cannot be
repaired. Install a new steering column.
('- .,
1. Grasp the steering wheel firmly and move it up REFER to: Steering Column
(21 1-04 Steering "'
and down and to the left and right without Column, Removal and Installation).
turning the steering wheel, to check for steering
2006.0 Fiesta 1212006 Gl49906en
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21 1-00-1 6 Steering System - General Information 21 I -00-1 6
DIAGNOSIS AND TESTING
8m ACAUTION:T~ prevent damage to the
steering linkage, turn the steering wheel to
move the steering linkage to the steering
lock stop.
Turn the steering wheel to position the steering
linkage against the left-hand steering lock stop.
9. N0TE:To isolate the steering gear design
'clearance, check the left-hand
tiemrod with
the steering held against the left-hand
steering lock stop.
With the aid of another technician holding the
steering against the left-hand steering lock stop,
firmly grasp the left-hand road wheel and apply
a rocking motion to check for any free play in
the tie-rod.
IQ Detach the steering gear boot from the steering
gear body and check for free play at the tie-rod
inner ball joint.
11. If there is free play at the tie-rod inner ball joint,
install a new tie-rod.
REFER to: Tie Rod (211-03 Steering Linkage,
Removal and lnstallation).
I2 If there is free play at the tie-rod end, install a
new tie-rod end.
REFER to: Tie Rod End (21 1-03 Steering
Linkage, Removal and lnstallation).
Turning Effort Test
N0TE:Before carrying out this test, make sure that
the suspension components are serviceable.
N0TE:Before carrying out this test, make sure that
the steering column is serviceable.
N0TE:Before carrying out this test, make sure that
the front toe adjustment and tire pressures are
correct. 1.
Park the vehicle on a dry, even surface and
apply the parking brake.
/- ,
2. Remove the driver air bag module.
REFER to: Driver Air Bag Module (501 -20
Supplemental Restraint System, Removal and
Installation).
3. Remove the driver air bag module wiring
harness from the driver air bag module.
REFER to: Driver Air Bag Module Wiring
Harness (501 -20 Supplemental Restraint
System, Removal and Installation).
4. Connect the driver air bag module wiring
harness to the clockspring.
5. Connect the air bag simulators to the driver air
bag module wiring harness in place of the driver
air bag module at the top of the steering column.
6. Start the engine and turn the steering wheel
from lock to lock several times until the power
steering fluid has reached normal operating
temperature.
7. Using a suitable torque wrench and socket,
check the steering wheel turning effort.
8. If the steering wheel turning effort is greater than
the specification, install a new power steering -
pump. REFER to: i
Specifications (21 1-00 Steering System -
General Information, Specifications),
Power Steering Pump
- I .3L Duratec-8V
(Rocam) (21 1-02 Power Steering, Removal
and lnstallation),
Power Steering Pump
- 1.25L Duratec-1 6V
(Sigma)/l.4L Duratec-1 6V (Sigma)/l .6L
Duratec-l6V (Sigma), Vehicles With: Air
Conditioning (21 1-02 Power Steering,
Removal and lnstallation),
Power Steering Pump
- I .25L Duratec-I 6V
(Sigma)/l.4L Duratec-1 6V (Sigma)/l .6L
Duratec-I 6V (Sigma), Vehicles Without: Air
Conditioning (21 1-02 Power Steering, Removal and lnstallation),
Power Steering Pump
- 1.4L Duratorq-TDCi
(DV) Diesel (21 1-02 Power Steering, Removal
and lnstallation),
Power Steering Pump
- 2.OL Duratec-HE (M14)
(21 1-02 Power Steering, Removal and
Installation).
Disconnect the air bag simulators from the driver
air bag module wiring harness.
//
IQ Disconnect the driver air bag module wiring i,,.
harness from the clockspring.
2006.0 Fiesta 1212006 GI 49906en
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