Ford 2007 WQ Fiesta Manuals

Manuals and User Guides for Ford 2007 WQ Fiesta. We have 1 Ford 2007 WQ Fiesta manual available for free PDF download: Repair Manual

Ford 2007 WQ Fiesta Repair Manual (1226 pages)

2007 WQ Fiesta

Brand: Ford | Category: Automobile | Size: 63.11 MB

Contents
1
Table of Contents
3
General Information
7
Chassis
9
Powertrain
11
Electrical
13
Body and Paint
15
Section 100-00 General Lnformation
17
Table of Contents
17
General Information
18
Description and Operation
19
About this Manual
19
Warnings, Cautions and Notes in this Manual
19
How to Use this Manual
19
Introduction
19
Special Tools
19
Important Safety Instructions
19
Lnspection and Verification
20
Symptom Chart
20
Pinpoint Tests
20
Component Tests
21
Graphics
21
Special Tools and Torque Figures
21
Health and Safety Precautions
22
Acids and Alkalis
22
Air Bags
22
Air Conditioning Refrigerant
22
Introduction
22
Air Conditioning Refrigerant-Do Nots
23
Adhesives and Sealers
23
Hot Melt Adhesives
23
Anaerobic, Cyanoacrylate (Super-Glues) and Other Acrylic Adhesives
23
Antifreeze
24
Asbestos
24
Battery Acids
24
Chemical Materials
24
Brake and Clutch Linings and Pads
24
Brake Fluids (Polyalkylene Glycols)
24
Brazing
24
Chemical Materials-Do's
25
Chemical Materials-Do Nots
25
Chlorofluorocarbons (CFC)
25
Corrosion Protection Materials
25
Clutch Fluids
25
Clutch Linings and Pads
25
Cutting
25
Electric Shock
26
Exhaust Fumes
26
Fibre Insulation
26
Fire
26
Dewaxing
26
Dusts
26
Engine Oils
26
First Aid
27
Fuels
27
Gasoline (Petrol)
27
Fluoroelastomer
27
Foams . Polyurethane
27
Freon
27
Kerosene (Paraffin)
28
Alternative Fuel
28
Gas Cylinders
28
General Workshop Tools and Equipment
28
Gases
28
Gaskets (Fluoroelastomer)
28
High Pressure Air, Lubrication and Oil Test Equipment
29
Legal Aspects
29
Transmission Fluids
29
Control Measures
29
Halon
29
Safety Data Sheets
30
Used Engine Oil
30
Environmental Precautions
30
Noise
30
Two Pack
31
Solder
31
Solvents
31
Suspended Loads
31
Viton
32
Resistance Welding
32
Arc Welding
32
Gas Welding (and Cutting)
32
Warning Symbols on Vehicles
33
Standard Workshop Practices
35
Vehicle in Workshop
35
Alternative Fuel-Do's
35
Alternative Fuel-Do Nots
35
Towing the Vehicle
36
Connectin a Slave Battery Using Jumper Cables
36
Component Cleaning
37
Cleaning Methods
37
Calibration of Essential Measuring Equipment
37
Solvents, Sealants and Adhesives
38
Road/Roller Testing
39
Pre-Test Checks
39
Starting the Engine
39
Road or Roller Testing
39
Brake Testing
40
Section 100-01 Ldentification Codes
41
Ldentification Codes
42
VIN (an Example of VIN Shown)
43
Vehicle Certification Label (Typical) or VIN Plate
45
Section 100-02 Jacking and Lifting
51
Jacking
52
Adapters for Jacking Points
54
Lifting
55
Noise, Vibration and Harshness (NVH)
58
Diagnostic Theory
58
Know the System
58
Diagnostic Charts
58
Description and Operation
58
Know the History of the System
58
Know the History of the Condition
58
Know the Probability of Certain Conditions Developing
58
Do Not Cure the Symptom and Leave the Cause
58
Be Positive the Cause Is Found
58
Inspection and Verification
60
How to Use this Diagnostic Procedure Section
60
Identify the Condition
60
Non-Axle Noise
60
Diagnosis and Testing
60
Noise. Vibration and Harshness (NVH)
60
Noise Conditions
61
Vibration Conditions
61
Road Test Quick Checks
61
Road Conditions
62
Vehicle Preparation
62
Power Steering Operation Noise Check
62
NVH Concerns from Other Components
63
Steering System NVH Concerns
64
Power Steering Moan Noise
65
Test Condition
65
Symptom Chart
65
Power Steering Whine Noise
66
Power Steering Hiss Noise
68
Power Steering Lock Stop Impact Knock Noise
68
Power Steering Mechanical Knock Noise (PAS Off)
68
Power Steering Mechanical Knock Noise (PAS On)
69
Power Steering Hammer Knock (Hydraulic) Noise
69
Power Steering Hydraulic Knock/Clonk Noise
69
Power Steering Column Knock Noise
70
Power Steering Toc-Toc Noise
70
Power Steering Grinding Noise
71
Power Steering Zip Noise
71
Driveline Noise and Vibration
72
Suspension Noise and Vibration
72
Pinpoint Test A: Shake and Vibration While Driving
72
Pinpoint Test B: Tip-In Moan
73
Pinpoint Test C: Idle Boom/Shake/Vibration/Shudder
75
Pinpoint Test D: Wheel End Vibration Analysis
76
Pinpoint Test E: Non-Axle Noise
78
Powertrain/Drivetrain Mount Neutralizing (14 001 0)
79
General Procedures
79
Section 204-00 Suspension System-General Information
81
Front Wheel Alignment (at Curb Weight)
82
Front Wheel Alignment (at Curb Weight)-ST150
82
Front Wheel Alignment (at Curb Weight)-3-Door Sport
82
Specifications
82
Rear Wheel Alignment (at Curb Weight)-All Vehicles Except ST150
83
Rear Wheel Alignment (at Curb Weight)-ST150
83
Suspension System
84
Diagnosis and Testing
84
Symptom Chart
84
Pinpoint Test A: Drift Left or Right
88
Pinpoint Test B: Excessive Noise
91
Ball Joint Inspection
94
Component Tests
94
Strut or Shock Absorber Inspection
95
Strut or Shock Absorber Testing
95
Wheel Bearing Inspection
96
General Procedures
96
Front Toe Adjustment (14 117 0)
97
Section 204-01 Front Suspension
99
Front Suspension Overview
101
Front Stabilizer Bar Bushing (14 754 0)
104
Lower Arm (14 706 0)
105
Install the Heat Shield
106
Front Stabilizer Bar (14 752 0)
107
Wheel Knuckle (14 343 0)
111
Front Strut and Spring Assembly (14 781 0)
117
Front Wheel Bearing (14 411 0)
119
Front Strut/Spring Assembly DISASSEMBLY/ASSEMBLY
121
Section 204-02 Rear Suspension
123
Rear Suspension
125
Rear Shock Absorber (15 791 0)
128
Spring (15 621 0)
130
Beam Axle (15 231 0)
132
Vehicles with Rear Drum Brakes
132
Vehicles with Rear Disc Brakes
133
Wheel Spindle (15 366 0)
137
Wrtg
138
Rear Wheel Bearing
139
Trailing Arm Bushing REMOVAL/INSTALLATION
142
Section 204-04 Wheels and Tires
145
Wheel and Tire Assembly Runout Specifications
146
Wheels and Tires
147
Tire Wear Diagnosis
147
Tire Vibration Diagnosis
147
Torque Sensitive
147
Diagnosis and Testing
147
Engine Speed Sensitive
148
Wheel and Tire
152
Removal
152
Installation
152
Section 205-04 Front Drive Halfshafts
153
Lubricants, Fluids, Sealers and Adhesives
154
Constant Velocity (CV) Joint Boot Capacities
154
Torque Specifications
154
Front Drive Halfshafts
155
Driveshafts
155
Symptom Chart-Front Drive Halfshafts
156
Inspection and Verification
156
Diagnosis and Testing
157
Removal and Installation
158
Front Halfshaft LH (14 320 0)
158
Special Tool(S)
158
All Vehicles
158
Vehicles with Automatic Transaxle
159
Vehicles with Manual Transaxle
159
Install the Wheel Hub Retaining Nut
160
Front Halfshaft RH (14 321 0)
162
Intermediate Shaft
165
Remove the Intermediate Shaft
165
Inner Constant Velocity (CV) Joint Boot (L4 336 0)
167
Outer Constant Velocity (CV) Joint Boot (L4 338 0)
170
Section 206-00 Brake System-General Information
173
Brake System
174
Overview
174
Visual Inspection Chart
175
Road Test
175
Pinpoint Test A: Brakes Pull or Drift
182
Pinpoint Test B: Brake Warning Indicator Always on
184
Pinpoint Test C: Vibration When Brakes Are Applied
185
Pinpoint Test D: Pedal Goes down Fast
187
Pinpoint Test E: Pedal EASES down Slowly
189
Pinpoint Test F: Pedal Is Low or Feels Spongy
191
Pinpoint Test G: Brake Lock up During Light Brake Pedal Force
192
Pinpoint Test H: Excessive or Erratic Brake Pedal Travel
194
Pinpoint Test I: Brakes Drag
195
Pinpoint Test J: Excessive Brake Pedal Effort
196
Pinpoint Test K: Brake Noise
199
Pinpoint Test L: Slow or Incomplete Brake Pedal Return
200
Hydraulic Leak Check
200
Brake System Check
201
Brake Pedal Reserve Check
201
Brake Booster Functional Test
201
Brake Booster Operation Check
201
Normal Conditions
202
Abnormal Conditions
202
Bypass Condition Test
202
Non-Pressure Leaks
202
Brake System Bleeding (12 141 0)
204
Bleeding
204
Vehicles with Anti-Lock Brakes
204
Brake System Pressure Bleeding (12 141 0)
205
Section 206-02 Drum Brake
207
Drum Brake Specification
208
Drum Brake
209
Description and Operation
209
Overview
209
Diagnosis and Testing
211
Drum Brake
211
Brake Drum (12 275 0)
212
Removal and Installation
212
Brake Shoes (12 285 0)
213
Wheel Cylinder (12 305 0)
215
Brake Backing Plate (12 31 3 0)
216
Section 206-03' Front Disc Brake
217
Front Disc Brake Specification
218
Front Disc Brake
219
Description and Operation
219
Overview
219
Diagnosis and Testing
220
Front Disc Brake
220
Brake Pads (12 234 0)
221
Removal and Installation
221
Brake Caliper (12 243 0)
223
Section 206-04 Rear Disc Brake
225
Brake Disc S~Ecification
226
Specifications
226
Rear Wheel Hub and Disc Brake Assembly
227
Description and Operation
227
Brake Caliper and Brake Caliper Anchor Plate Assembly
228
Diagnosis and Testing
229
Rear Disc Brake
229
Brake Pads (12 238 0)
230
Removal and Installation
230
Brake Caliper (12 253 0)
232
Brake Disc (12 225 0)
234
Brake Disc Shield
235
Section 206-05 Parking Brake and Actuation
237
Parking Brake
239
Layout
240
Function
240
Pinpoint Test A: the Parking Brake will Not Apply
241
Pinpoint Test B: the Parking Brake will Not Release
243
Parking Brake Cable Adjustment-Vehicles With: Rear Drum Brakes (12 662 0)
245
General Procedures
246
Parking Brake Cable Adjustment-Vehicles With: Rear Disc Brakes (12 662 0)
247
Parking Brake Cable-Vehicles With: Rear Drum Brakes (12 675 0)
249
Parking Brake Cable-Vehicles With: Rear Disc Brakes (12 675 0)
251
Parking Brake Control (12 664 0)
253
Section 206-06 Hydraulic Brake Actuation
255
Specifications
256
Description and Operation
257
Hydraulic Brake Actuation - Vehicles Built up To: 01/2004
257
Brake Pedal
257
Diagnosis and Testing
259
Hydraulic Brake Actuation
259
Brake Pedal-RHD (12 333 0)
260
Removal and Installation
260
Brake Master Cylinder-RHD (12 343 0)
262
Section 206-07 Power Brake Actuation
265
Brake Booster
267
Emergency Brake Assistant (EBA)
267
Components
267
Normal Braking
268
Active Brake Assistant
269
Release of the Brake Assistant
270
Service
270
Brake Booster-RHD (12 451 0)
272
Section 206-09A Anti-Lock Control
275
Specifications
276
Anti-Lock Control
277
Description and Operation
277
206-09A-3
277
Valve Block
278
Pump Motor
278
ABS Regulating Cycle
278
MK70 Anti-Lock Brake System (ABS)
279
Mk60 Abs
279
Anti-Lock Control
279
Wheel Speed Sensors
280
Diagnosis and Testing
281
Anti-Lock Control
281
206-09A-7
281
Inspection and Verification
281
Hydraulic Control Unit (HCU)-Vehicles Built up To: 05/2004
282
Removal and Installation
282
206-09A-8
282
206-09A-11
283
Hydraulic Control Unit (HCU)
285
Vehicles Built From: 05/2004
285
Anti-Lock Brake System (ABS) Module-Vehicles Built up To: 05/2004
288
Anti-Lock Brake System (ABS) Module-Vehicles Built From: 05/2004
291
Vehicles Built From: 0512004 .......................... 206-09A-17
291
Rear Wheel Speed Sensor (12 785 0) 206-09A-20
294
Rear Wheel Speed Sensor Ring ................................................................... (12 788 0) 206-09A-22
296
Front Wheel Speed Sensor ............................................................................ (12 784 0) 206-09A-24
298
Section 206-09B Anti-Lock Control Traction Control
299
Anti-Lock Control
301
Traction Control 206-09B-1
301
Traction Control
301
Diagnosis and Testing
301
206-09B-3
301
Removal and Installation
302
Rear Wheel Speed Sensor Ring
302
Rear Wheel Speed Sensor
303
Hydraulic Control Unit (HCU)
304
Anti-Lock Brake System (ABS) Module
305
Section 206-09C Anti-Lock Control-Stability Assist
307
Anti-Lock Control - Stability Assist
310
Removal and Installation
310
Hydraulic Control Unit (HCU)
310
Rear Wheel Speed Sensor
313
Yaw Rate Sensor and Accelerometer
314
Steering Wheel Rotation Sensor
316
Rear Wheel Speed Sensor Ring
317
Stability Assist Module
318
Section 211-00 Steering System General Information
321
Turning Circle
322
Steering Wheel Alignment
322
Turning Effort
322
Specifications
322
Steering System
323
Description and Operation
323
Overview
323
Principles of Operation
325
Diagnosis and Testing
325
Steering System
325
Components Tests
334
Steering Linkage
334
Tie-Rod
335
Turning Effort Test
336
Steering Column Shaft Universal Joint
337
General Equipment
338
Tie-Rods
338
Check for Power Steering Fluid Leaks
338
Steering Gear Checks after a Collision 21 1-00-1
338
Power Steering System Filling (13 002 0)
340
General Procedures
340
Power Steering System Bleeding (13 416 1)
341
Power Steering System Flushing 1.25L Duratec-16V(Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma)(13 001 0)
343
Power Steering System Flushing 2.0L Duratec-HE (MI4) (13 001 0)
346
Section 211-02 Power Steering
349
Power Steering Pump-1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), Vehicles With: Air Conditioning (13 434 0)
353
Power Steering Pump-1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), Vehicles Without: Air Conditioning (13 434 0)
356
Power Steering Pump-2.0L Duratec-HE (MI4)
358
Removal Details
360
Installation Details
360
Power Steering Pump to Steering Gear Pressure Line-1.25L Duratec 16V (Sigma)/1.4 Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), Vehicles With: Air Cond
362
Power Steering Pump to Steering Gear Pressure Line-1.25L Duratec 16V (Sigma)/1.4 Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), Vehicles Without: Air C
365
Power Steering Pump to Steering Gear Pressure Line-2.0L Duratec-HE (MI4) RHD
368
Power Steering
370
Power Steering Pump Pulley
371
Power Steering Pump to Steering Gear Pressure Line Bracket to Intake Manifold Retaining Bolt
371
Power Steering Pump to Steering Gear Pressure Line
371
Steering Gear to Power Steering Fluid Reservoir Return Line-2.0L Duratec-HE (MI4) RHD
378
Steering Gear to Power Steering Fluid Reservoir Return Line Upper Retaining Clip
380
Steering Gear to Power Steering Fluid Reservoir Return Line Support Bracket to Generator Retaining Nut
380
Steering Gear Heat Shield
380
Cable Ties
381
Steering Gear to Power Steering Fluid Reservoir Return Line
382
Steering Gear (13 11 6 0)
386
Steering Gear to Fluid Cooler Return Hose (13 439 0)
394
Left-Hand Drive Vehicles
394
Power Steering Fluid Cooler (13 444 0)
396
Steering Gear Bushing
397
Section 211-03 Steering Linkage
399
Tie Rod End (13 273 0)
402
Steering Gear Boot (13 134 0)
404
Tie Rod (13 263 0)
406
Section 211-04 Steering Column
409
Steering Wheel (13 524 0)
412
Steering Column (13 542 0)
413
Steering Column DISASSEMBLY/ASSEMBLY
416
Steering Column (13 543 4)
416
Section 211-05 Steering Column Switches
419
Ignition Switch (36 424 0)
420
Section 303-00 Engine System-General Lnformation
423
Engine/Transmission Combinations
425
Engine-Oil Leaks
436
Ultraviolet (UV) Testing
436
Measure the Compression Pressure
436
Measure the Compression Pressure 1.4L Duratorq-Tdci (DV) Diesel)
437
Measure the Compression Pressure 1.6L Duratorq-Tdci (DV) Diesel)
439
Measure the Compression Pressure (Engine-1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma))
442
Measure the Compression Pressure (Engine-1.3L Duratec-8V (Rocam))
444
Measure the Compression Pressure (Engine-2.0L Duratec-HE (MI4))
445
Measure the Oil Pressure (Engine-1.4L Duratorq-Tdci (DV) Diesel)
447
Measure the Oil Ressure (Engine-1.6L Duratorq-Tdci (DV) Diesel)
448
Measure the Oil Pressure (Engine-1.25L Durater-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma))
449
Duratec-1 6V (Sigma)/L .6L Duratec-1 6V (Sigma)
449
Measure the Oil Pressure (Engine-1.3L Duratec-8V (Rocam))
450
Measure the Oil Pressure (Engine-2.0L Duratec-HE (MI4))
452
Valve Train Analysis-Static (Engine Off)
453
Camshaft Bearing Journal Diameter
454
Camshaft Bearing Journal Clearance
455
Camshaft End Play
456
Camshaft Surface Inspection
457
Camshaft Lobe Lift
458

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