ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

ABOUT US
Steering System - 1.6L Duratorq-TDCi (DV) Diesel > < Steering System - 1.6L Duratorq-TDCi (DV) Diesel

Fiesta 2002.25 (11.2001-)

Steering System - General Information - Steering System Fiesta 2002.25 (11/2001-)
Diagnosis and Testing

Special Tool(s)

Alignment Pins, Subframe

205-524

Simulator, Driver and Passenger Air Bags and Side Air Curtains

501-073A

General Equipment
Worldwide Diagnostic System (WDS)

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.

Inspection and Verification

  1. Verify the customer concern.
  1. Visually inspect for obvious signs of mechanical or electrical damage.

Visual Inspection Chart

Mechanical Electrical
  • 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 coupling
  • Wheels and tires
  • Power steering line fluid leaks
  • Steering gear bellows
  • Power steering pressure (PSP) switch
  1. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
  1. 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
*
Vehicle attitude incorrect (front or rear is high or low).
*
CHECK for abnormal loading, coil spring sag or non-standard springs.
*
Incorrect wheel alignment.
*
CHECK the wheel alignment and adjust if necessary. REFER to: (204-00 Suspension System - General Information)
Specifications (Specifications),
Front Toe Adjustment (General Procedures).
*
Incorrect front axle crossmember alignment.
*
Using the special tool, CHECK the front axle crossmember alignment.
*
Damaged or worn front wheel bearings.
*
CHECK and INSTALL new front wheel bearings as necessary.
REFER to: Front Wheel Bearing (204-01 Front Suspension, Removal and Installation).
*
Brake system.
*
CHECK the brake system.
REFER to: Brake System (206-00 Brake System - General Information, Diagnosis and Testing).
*
Steering linkage.
*
CARRY OUT the steering linkage component test. REFER to Steering Linkage Component Test in this procedure.
*
Steering gear.
*
CARRY OUT the steering linkage component test. REFER to Steering Linkage Component Test in this procedure.
*
Wheels and tires.
*
CHECK the wheels and tires.
REFER to: Wheels and Tires (204-04 Wheels and Tires, Diagnosis and Testing).
Steering wheel off center
*
Vehicle attitude incorrect (front or rear is high or low).
*
CHECK for abnormal loading, coil spring sag or non-standard springs.
*
Incorrect wheel alignment.
*
CHECK the wheel alignment and adjust if necessary. REFER to: (204-00 Suspension System - General Information)
Specifications (Specifications),
Front Toe Adjustment (General Procedures).
*
Front suspension lower arm ball joint.
*
CHECK and INSTALL new suspension components as necessary.
REFER to: Suspension System (204-00 Suspension System - General Information, Diagnosis and Testing).
*
Steering linkage.
*
CARRY OUT the steering linkage component test. REFER to Steering Linkage Component Test in this procedure.
*
Steering gear.
*
CARRY OUT the steering linkage component test. REFER to Steering Linkage Component Test in this procedure.
Vibration
*
Incorrect wheel alignment.
*
CHECK the wheel alignment and adjust if necessary. REFER to: (204-00 Suspension System - General Information)
Specifications (Specifications),
Front Toe Adjustment (General Procedures).
*
Wheels and tires.
*
CHECK the wheels and tires. BALANCE or INSTALL new wheels and tires as necessary.
REFER to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation).
*
Damaged or worn front wheel bearings.
*
CHECK and INSTALL new front wheel bearings as necessary.
REFER to: Front Wheel Bearing (204-01 Front Suspension, Removal and Installation).
*
Front strut and spring assemblies.
*
CHECK and INSTALL new suspension components as necessary.
REFER to: Suspension System (204-00 Suspension System - General Information, Diagnosis and Testing).
*
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).
*
Steering linkage.
*
CARRY OUT the steering linkage component test. REFER to Steering Linkage Component Test in this procedure.
Steering effort is high/low
*
Loose or worn accessory drive belt.
*
CHECK the accessory drive belt. REFER to: (303-05 Accessory Drive)
Power Steering Pump Belt - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), Vehicles With: Air Conditioning (Removal and Installation),
Accessory Drive Belt - 1.3L Duratec-8V (Rocam) (Removal and Installation),
Accessory Drive Belt - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), Vehicles Without: Air Conditioning (Removal and Installation),
Accessory Drive Belt - 1.4L Duratorq-TDCi (DV) Diesel (Removal and Installation),
Accessory Drive Belt - 2.0L Duratec-HE (MI4) (Removal and Installation).
*
Power steering lines restriction.
*
CHECK the power steering lines for damage, kinks or restrictions. INSTALL new components as necessary. REFER to: (211-02 Power Steering)
Power Steering Pump to Steering Gear Pressure Line - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), Vehicles With: Air Conditioning (Removal and Installation),
Power Steering Pump to Steering Gear Pressure Line - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), Vehicles Without: Air Conditioning (Removal and Installation),
Power Steering Pump to Steering Gear Pressure Line - 1.3L Duratec-8V (Rocam) (Removal and Installation),
Power Steering Pump to Steering Gear Pressure Line - 1.4L Duratorq-TDCi (DV) Diesel (Removal and Installation),
Power Steering Pump to Steering Gear Pressure Line - 2.0L Duratec-HE (MI4) RHD (Removal and Installation),
Steering Gear to Power Steering Fluid Reservoir Return Line - 2.0L Duratec-HE (MI4) RHD (Removal and Installation),
Steering Gear to Fluid Cooler Return Hose (Removal and Installation).
*
Power steering fluid aeration.
*
BLEED the power steering system.
REFER to: Power Steering System Bleeding (211-00 Steering System - General Information, General Procedures).
*
Steering column.
*
CHECK if the floor covering is obstructing the steering gear pinion.
*
CHECK the installation of the steering gear bulkhead floor seal.
*
CARRY OUT the steering column universal joint component test. REFER to Steering Column Universal Joint Component Test in this procedure.
*
Steering linkage.
*
CARRY OUT the steering linkage component test. REFER to Steering Linkage Component Test in this procedure.
*
Steering gear.
*
CARRY OUT the steering linkage component test. REFER to Steering Linkage Component Test in this procedure.
*
Worn power steering pump.
*
INSTALL a new power steering pump. REFER to: (211-02 Power Steering)
Power Steering Pump - 1.3L Duratec-8V (Rocam) (Removal and Installation),
Power Steering Pump - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), Vehicles With: Air Conditioning (Removal and Installation),
Power Steering Pump - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), Vehicles Without: Air Conditioning (Removal and Installation),
Power Steering Pump - 1.4L Duratorq-TDCi (DV) Diesel (Removal and Installation),
Power Steering Pump - 2.0L Duratec-HE (MI4) (Removal and Installation).
Excessive noise
*
Power steering operation noise.
*
CARRY OUT the Power Steering Operation Noise Check.
REFER to: Noise, Vibration and Harshness (NVH) (100-04 Noise, Vibration and Harshness, Diagnosis and Testing).
*
Power steering fluid aeration.
*
BLEED the power steering system.
REFER to: Power Steering System Bleeding (211-00 Steering System - General Information, General Procedures).
*
Power steering lines.
*
CHECK the power steering line clamps are secure. REFER to: (211-02 Power Steering)
Power Steering Pump to Steering Gear Pressure Line - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), Vehicles With: Air Conditioning (Removal and Installation),
Power Steering Pump to Steering Gear Pressure Line - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), Vehicles Without: Air Conditioning (Removal and Installation),
Power Steering Pump to Steering Gear Pressure Line - 1.3L Duratec-8V (Rocam) (Removal and Installation),
Power Steering Pump to Steering Gear Pressure Line - 1.4L Duratorq-TDCi (DV) Diesel (Removal and Installation),
Power Steering Pump to Steering Gear Pressure Line - 2.0L Duratec-HE (MI4) RHD (Removal and Installation),
Steering Gear to Power Steering Fluid Reservoir Return Line - 2.0L Duratec-HE (MI4) RHD (Removal and Installation),
Steering Gear to Fluid Cooler Return Hose (Removal and Installation).
*
CHECK the power steering lines for clearance from the vehicle body, front axle crossmember and steering gear.
*
CHECK the steering gear transfer lines for clearance from the steering gear.
*
Steering gear bushings worn or perished.
*
CHECK and INSTALL new components as necessary.
REFER to: Steering Gear Bushing (211-02 Power Steering, Removal and Installation).
*
Loose steering gear retaining bolts.
*
CHECK and INSTALL new steering gear retaining bolts as necessary.
REFER to: Specifications (211-02 Power Steering, Specifications).
*
Worn power steering pump.
*
INSTALL a new power steering pump. REFER to: (211-02 Power Steering)
Power Steering Pump - 1.3L Duratec-8V (Rocam) (Removal and Installation),
Power Steering Pump - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), Vehicles With: Air Conditioning (Removal and Installation),
Power Steering Pump - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), Vehicles Without: Air Conditioning (Removal and Installation),
Power Steering Pump - 1.4L Duratorq-TDCi (DV) Diesel (Removal and Installation),
Power Steering Pump - 2.0L Duratec-HE (MI4) (Removal and Installation).
*
Worn tie-rod.
*
CARRY OUT the tie-rod component test. REFER to Tie-Rod Component Test in this procedure.
Steering does not vary with increased wheel rotation
*
Worn tie-rod ends.
*
INSTALL new components as necessary.
REFER to: Tie Rod End (211-03 Steering Linkage, Removal and Installation).
*
Worn front suspension bushings.
*
CHECK and INSTALL new components as necessary.
REFER to: Suspension System (204-00 Suspension System - General Information, Diagnosis and Testing).
*
Worn front suspension lower arm ball joints.
*
CARRY OUT the suspension 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 (211-02 Power Steering, Removal and Installation).
*
Loose steering gear retaining bolts.
*
CHECK and INSTALL new steering gear retaining bolts as necessary.
REFER to: Specifications (211-02 Power Steering, Specifications).
*
Loose steering column retaining bolts.
*
CHECK and INSTALL new steering column retaining bolts as necessary.
REFER to: Specifications (211-04 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 (211-02 Power Steering, Specifications).
*
Excessive steering gear backlash.
*
CARRY OUT the steering linkage component test. REFER to Steering Linkage Component Test in this procedure.
Engine stalls when parking with engine speed at idle
*
Power steering pressure (PSP) switch or circuit.
*
For additional information, refer to WDS.

Components Tests

Steering Linkage

  1. Grasp the steering wheel firmly and move it up and down and to the left and right without turning the steering wheel, to check for steering 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.
    REFER to: Steering Column (211-04 Steering Column, Removal and Installation).
  1. With the road wheels in the straight ahead position, gently turn the steering wheel to the left and the right to check free play in the steering linkage.
  1. There should be no excessive free play at the steering wheel rim. If there is excessive free play, CHECK the tie-rod inner and outer ball joints, REFER to Tie-Rod Component Test in this procedure. CHECK the steering column universal joint, REFER to Steering Column Universal Joint Component Test in this procedure. If there is no free play in the tie-rod and the steering column, install a new steering gear.
    REFER to: Steering Gear (211-02 Power Steering, Removal and Installation).

Tie-Rod

CAUTION:
CAUTION:The steering gear boots must be handled carefully to avoid damage. Use new steering gear boot clamps when installing the steering gear boots.
NOTE:
NOTE:Noises such as knocks, which may appear to originate from the steering linkage, may also be generated by front suspension components.
  1. Raise and support the vehicle. REFER to: (100-02 Jacking and Lifting)
    Jacking (Description and Operation),
    Lifting (Description and Operation).

  1. Firmly grasp the road wheel and apply a rocking motion to check for any free play in the wheel bearing or suspension components.

  1. CAUTION:
    CAUTION:To 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 right-hand steering lock stop.
  1. NOTE:
    NOTE:To isolate the steering gear design clearance, check the right-hand tie-rod with the steering held against the right-hand steering lock stop.
    With the aid of another technician holding the steering against the right-hand steering lock stop, firmly grasp the right-hand road wheel and apply a rocking motion to check for any free play in the tie-rod.

  1. Detach the steering gear boot from the steering gear body and check for free play at the tie-rod inner ball joint.
  1. 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 Installation).
  1. If there is free play at the tie-rod end, install a new tie-rod end.
    REFER to: Tie Rod End (211-03 Steering Linkage, Removal and Installation).
  1. CAUTION:
    CAUTION:To 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.
  1. NOTE:
    NOTE:To isolate the steering gear design clearance, check the left-hand tie-rod 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.

  1. Detach the steering gear boot from the steering gear body and check for free play at the tie-rod inner ball joint.
  1. 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 Installation).
  1. If there is free play at the tie-rod end, install a new tie-rod end.
    REFER to: Tie Rod End (211-03 Steering Linkage, Removal and Installation).

Turning Effort Test

NOTE:
NOTE:Before carrying out this test, make sure that the suspension components are serviceable.
NOTE:
NOTE:Before carrying out this test, make sure that the steering column is serviceable.
NOTE:
NOTE: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.
  1. Remove the driver air bag module.
    REFER to: Driver Air Bag Module (501-20B Supplemental Restraint System, Removal and Installation).
  1. Remove the driver air bag module wiring harness from the driver air bag module.
    REFER to: Driver Air Bag Module Wiring Harness (501-20B Supplemental Restraint System, Removal and Installation).
  1. Connect the driver air bag module wiring harness to the clockspring.
  1. 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.
  1. Start the engine and turn the steering wheel from lock to lock several times until the power steering fluid has reached normal operating temperature.
  1. Using a suitable torque wrench and socket, check the steering wheel turning effort.
  1. If the steering wheel turning effort is greater than the specification, install a new power steering pump. REFER to:
    Specifications (211-00 Steering System - General Information, Specifications),
    Power Steering Pump - 1.3L Duratec-8V (Rocam) (211-02 Power Steering, Removal and Installation),
    Power Steering Pump - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), Vehicles With: Air Conditioning (211-02 Power Steering, Removal and Installation),
    Power Steering Pump - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), Vehicles Without: Air Conditioning (211-02 Power Steering, Removal and Installation),
    Power Steering Pump - 1.4L Duratorq-TDCi (DV) Diesel (211-02 Power Steering, Removal and Installation),
    Power Steering Pump - 2.0L Duratec-HE (MI4) (211-02 Power Steering, Removal and Installation).
  1. Disconnect the air bag simulators from the driver air bag module wiring harness.
  1. Disconnect the driver air bag module wiring harness from the clockspring.
  1. Install a new driver air bag module wiring harness to the drive air bag module.
    REFER to: Driver Air Bag Module Wiring Harness (501-20B Supplemental Restraint System, Removal and Installation).
  1. Install the driver air bag module.
    REFER to: Driver Air Bag Module (501-20B Supplemental Restraint System, Removal and Installation).

Steering Column Shaft Universal Joint

  1. WARNING:
    WARNING:Install a new steering column shaft to steering gear pinion retaining bolt. Failure to follow this instruction may result in personal injury.
    Detach the steering column shaft from the steering gear pinion.
    • Discard the steering column shaft to steering gear pinion retaining bolt.

  1. Check for smooth movement of the steering column shaft universal joint.
    1. Hold the steering column shaft universal joint yoke.
    1. Articulate the free yoke in a figure of eight movement.
    • If the movement is not smooth or resistance is felt, renew the steering column.
      REFER to: Steering Column (211-04 Steering Column, Removal and Installation).
  1. Hold both of the steering column shaft universal joint yokes and then twist them clockwise and counterclockwise.
    • If any movement is felt, install a new steering column.
      REFER to: Steering Column (211-04 Steering Column, Removal and Installation).

Steering System - 1.6L Duratorq-TDCi (DV) Diesel > < Steering System - 1.6L Duratorq-TDCi (DV) Diesel