FORD FIESTA 2007 User Guide

GROUP
Powertrain
SECTION TITLE PAGE
Engine
Engine System . General Information ........................................................................\
.... 303-00
Enginel.25L Duratec-I 6V (Sigma)ll.4L Duratec-1 6V (Sigma)ll . 6L Duratec-I 6V
........................................................................\
.............................................. (Sigma) -303-0 I A
........................................................................\
............... Engine2.0L Duratec-HE (M14) .30 3-01 B
Engine
Cooling1.3L Duratec-8V (Rocam)ll.25L Duratec-I 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)ll . 6L Duratec-1 6V (Sigma) ...................................................... .30 3-03A
Engine
Cooling2.0L Duratec-HE (M14) ........................................................................\
.. 303-038
Fuel Charging and Controlsl.25L Duratec-1 6V (Sigma)ll.4L Duratec-1 6V
........................................................................\
... (Sigma)ll . 6L Duratec-1 6V (Sigma) .30 3-0414
Fuel Charging
and Controls2.0L Duratec-HE (M14) ....................................................... 303-04B
........................................................................\
.................................... Accessory Drive .30 3-05
Starting System
........................................................................\
...................................... 303-06
Engine Ignition
........................................................................\
....................................... 303-07A
Engine Ignition2.01 Duratec-HE (M14) ........................................................................\
... 303-07B
Engine Emission
Controll.3L Duratec-8V (Rocam)ll.25L Duratec-1 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)ll . 6L Duratec-1 6V (Sigma) ...................................................... .30 3-08A
Engine Emission
Control2.0L Duratec-HE (M14) ........................................................... 303-088
........................................................................\
........ Intake Air Distribution and Filtering 303-1 2
........................................................................\
.......................... Evaporative
Emissions .30 3-13
........................................................................\
.................... Electronic Engine Controls .304 3-1
Automatic Transmission/Transaxle
Automatic Transmission/TransaxleVehicles With: 4-Speed Automatic Transmission
........................................................................\
......................................... (AW8 1 .40) .301 7.0
Transmission/Transaxle CoolingVehicles With: 4-Speed Automatic Transmission
........................................................................\
.......................................... (AW81-40) 307-02
Automatic
TransmissionlTransaxle External ControlsVehicles With: 4-Speed
........................................................................\
.. Automatic Transmission (AW81-40) .30 7.05
Manual Transmission/Transaxle. Clutch and Transfer Case
Manual Transmission/Transaxle and Clutch . General Information ............................... 308-00
........................................................................\
.................................................... Clutch .301 8.0
........................................................................\
..................................... Clutch Controls .30 8.02
Manual
TransmissionlTransaxle ........................................................................\
............ 308-03
Manual
TransmissionlTransaxle External Controls ........................................................ 308-06
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Exhaust System (I
Exhaust System ........................................................................\
..................................... 309-00
Fuel System
Fuel System
- General Information ........................................................................\
.... 310-00
Fuel Tank and Lines..
........................................................................\
............................ .310-01
Acceleration Controll.3L Duratec-8V (Rocam)ll.25L Duratec-1 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)ll .6L Duratec-1 6V (Sigma) ....................................................... 310-02A
Acceleration
Control2.0L Duratec-HE (M14) .............................................................. 30-02B
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GROUP
Electrical
SECTION TITLE PAGE
Climate Control System
.......................................................... Climate Control System . General Information 42-00
........................................................................\
................... Air Distribution and Filtering 412-01
........................................................................\
......................... Heating and Ventilation .41 2-02
........................................................................\
..................................... Air Conditioning .41 2.03
........................................................................\
............................. Control Components .41 2.04
i
Instrumentation and Warning Systems
.................................................................... Instrument Cluster and Panel Illumination -41 3-00
........................................................................\
................................. Instrument Cluster .41 3-01
........................................................................\
...................................................... Horn -41 3-06
Information and Message Center ........................................................................\
........... 41 3-08
........................................................................\
................................... Warning Devices -41 3-09
........................................................................\
............................................. Parking Aid 413-1 3
Battery and Charging System
Charging System . General Information ..................................................................... 14-00
........................................................................\
............... Battery, Mounting and Cables -41 4-01
........................................................................\
...................... Generator and Regulator .41 4-02
lnformation and Entertainment Systems
Information and Entertainment System . General Information ..................................... .41 5-00
Audio Unit ........................................................................\
.............................................. 15-01
........................................................................\
................................................. Antenna .41 5-02
Lighting
........................................................................\
.................................... Exterior Lighting .41 7.01
........................................................................\
..................................... Interior Lighting -41 7-02
Electrical Distribution
........................................................................\
......... Module Communications Network 18-00
........................................................................\
............................. Module Configuration 41 8-01
Electronic Feature Group
Anti-Theft - Active ........................................................................\
.................................. 419-OIA
........................................................................\
............................... Anti-Theft . Passive .4 I 9-0 I B
........................................................................\
.............................. Cellular Phone .........4 19-08
........................................................................\
........... Multifunction Electronic Modules 41 9-1 0
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GROUP
Body and Paint
SECTION TITLE PAGE
Body and Paint
........................................................................\
.... Body System . General Information .50 1.00
........................................................................\
......................... Front End Body Panels .50 1.02
........................................................................\
........................................ Body Closures 501 -03
Interior Trim and Ornamentation ........................................................................\
............ 501-05
........................................................................\
.......... Exterior Trim and Ornamentation .50 1-08
........................................................................\
.................................. Rear View Mirrors 50 1 -09
........................................................................\
................................................... Seating 501 -10
........................................................................\
........... Glass, Frames and Mechanisms .SO1 1-1
........................................................................\
............... Instrument Panel and Console 502 1-1
............................................................... Handles, Locks, Latches and Entry Systems -501 -1 4
........................................................................\
............................. Wipers and Washers -501 -1 6
Bumpers ........................................................................\
................................................. 501 -1 9
........................................................................\
................................. Safety Belt System 50 I -2OA
........................................................................\
............. Supplemental Restraint System .50 I -2OB
Body Repairs - General Information ........................................................................\
...... 501-25
Body Repairs - Vehicle Specific Information and Tolerance Checks ............................. 501-26
........................................................................\
............. Front End Sheet Metal Repairs .50 1-27
........................................................................\
..................... Roof Sheet Metal Repairs -50 I -28
Side Panel Sheet Metal Repairs ........................................................................\
............ 501-29
........................................................................\
.............. Rear End Sheet Metal Repairs 50 1-30
........................................................................\
.................... Paint - General Information 501 -36
Frame and Mounting
Uni-Body, Subframe and Mounting System ................................................................... 502-00
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100-00-1 General Information 100-00-1
. SECTION 100-00 General lnformation
VEHICLE APPLICATION:2006.0 Fiesta
CONTENTS
DESCRIPTION AND OPERATION
About This Manual
........................................................................\
......................................
........................................................................\
................................................. Introduction
Special Tools
........................................................................\
..............................................
Important Safety Instructions ........................................................................\
......................
Warnings. Cautions and Notes in This Manual ..................................................................
How to Use This Manual ........................................................................\
............................
Special Tools and Torque Figures ........................................................................\
..............
Health and Safety Precautions ........................................................................\
...................
........................................................................\
................................................. Introduction
........................................................................\
........................................ Acids and Alkalis
Air Bags
........................................................................\
......................................................
Air Conditioning Refrigerant ........................................................................\
.......................
........................................................................\
............................... Adhesives and Sealers
........................................................................\
................................................... Antifreeze
........................................................................\
..................................................... Asbestos
Battery Acids
........................................................................\
..............................................
Brake and Clutch Linings and Pads ........................................................................\
...........
Brake Fluids (Polyalkylene Glycols) ........................................................................\
...........
........................................................................\
....................................................... Brazing
Chemical Materials
........................................................................\
.....................................
................................................................... Chlorofluorocarbons (CFC) ... ..........................
Clutch Fluids ........................................................................\
...............................................
Clutch Linings and Pads ........................................................................\
.............................
Corrosion Protection Materials ........................................................................\
...................
........................................................................\
........................................................ Cutting
........................................................................\
.................................................... Dewaxing
........................................................................\
.......................................................... Dusts
Electric Shock
........................................................................\
.............................................
Engine Oils ........................................................................\
.................................................
Exhaust Fumes ........................................................................\
...........................................
........................................................................\
........................................... Fibre Insulation
Fire
........................................................................\
.............................................................
First Aid ........................................................................\
......................................................
........................................................................\
.......................................... Fluoroelastomer
Foams
. Polyurethane ........................................................................\
................................
........................................................................\
.......................................................... Freon
........................................................................\
........................................................... Fuels
........................................................................\
.............................................. Gas Cylinders
........................................................................\
......................................................... Gases
Gaskets (Fluoroelastomer)
........................................................................\
.........................
General Workshop Tools and Equipment ........................................................................\
...
High Pressure Air. Lubrication and Oil Test Equipment ......................................................
........................................................................\
.......................................................... Halon
........................................................................\
............................................. Legal Aspects
PAGE
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General Information
........................................................................\
............................. Lubricants and Greases
Transmission Fluids
........................................................................\
....................................
........................................................................\
.......................................................... Noise
Noise Insulation Materials
........................................................................\
..........................
0-Rings (Fluoroelastomer) ........................................................................\
.........................
........................................................................\
.......................................................... Paints
........................................................................\
.............................. Pressurized Equipment . . ........................................................................\
......................................................... Solder
........................................................................\
...................................................... Solvents
Sound Insulation
........................................................................\
.........................................
Suspended Loads ........................................................................\
.......................................
Transmission Brake Bands ........................................................................\
.........................
........................................................................\
................................................... Underseal
........................................................................\
............................................................ Viton
........................................................................\
....................................................... Welding
........................................................................\
.................... Warning Symbols on Vehicles
........................................................................\
................................................. White Spirit
Standard Workshop Practices
........................................................................\
....................
Vehicle in Workshop ........................................................................\
...................................
Alternative Fuel ........................................................................\
...........................................
Alternative Fuel - Do's ........................................................................\
..............................
Alternative Fuel - Do Nots ........................................................................\
........................
Towing the Vehicle ........................................................................\
......................................
Connecting a Slave Battery Using Jumper Cables ............................................................
Component Cleaning ........................................................................\
..................................
Calibration of Essential Measuring Equipment ...................................................................
Solvents. Sealants and Adhesives ........................................................................\
.............
........................................................................\
................................................. Introduction
RoadlRoller Testing ........................................................................\
....................................
Pre-Test Checks ........................................................................\
.........................................
Starting the Engine ........................................................................\
.....................................
Road or Roller Testing ........................................................................\
................................
Brake Testing ........................................................................\
..............................................
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100-00-3 General Information 100-00-3
DESCRIPTION AND OPERATION
About This Manual
-- . Introduction
This manual has been written in a format that is
designed to meet the needs of technicians
worldwide. The objective is to use common formats
and include similar content in each manual.
This manual provides general descriptions for accomplishing diagnosis and testing, service and
repair work with tested, effective techniques.
Following them will help assure reliability.
Special Tools
The special tool(s) table provided at the beginning
of each procedure shows all special tools required
to carry out a repair. Where possible, illustrations
are provided to assist in identifying the special tool
required.
Important Safety Instructions
Appropriate service methods and correct repair
--.! procedures are essential for the safe, reliable
operation of all motor vehicles as well as the
personal safety of the individual carrying out the
work.
This manual cannot possibly anticipate all such
variations and provide advice or cautions as to
each. Anyone who departs from the instructions
provided in this manual must first establish that he
compromises neither his personal safety nor the
vehicle integrity by his choice of methods, tools or
components.
Warnings, Cautions and Notes in This
Manual
A WARN1NG:Warnings are used to indicate
that failure to follow a procedure correctly
may result in personal injury.
A warning, caution or note is placed at the
beginning of a series of steps if it applies to multiple
steps. If the warning, caution or note only applies
to one step, it is placed at the beginning of the
specific step (after the step number).
How to Use This Manual
This manual covers diagnosis and testing, service
and repair procedures.
This manual is structured into groups and sections,
with specific system sections collected together
under their relevant group.
A group covers a specific portion of the vehicle.
The manual is divided into five groups, General
Information, Chassis, Powertrain, Electrical and
Body and Paint. The number of the group is the
first number of a section number.
Pages at the start of the manual list all sections
available. Each section has a contents list detailing
Specifications, Description and Operation,
Diagnosis and Testing, In Vehicle Repairs,
Disassembly and Assembly, Removal and
Installation.
If components need to be removed or
disassembled in sequence, the sequence will be
identified numerically in a graphic and the
corresponding text will be numbered accordingly.
All left and right-hand references to the vehicle are
taken from a position sitting in the driver seat
looking forward.
All left and right-hand references to the engine are
taken from a position at the flywheel looking
towards the front camshaft pulley.
Where appropriate, instructions will be given for
the use of the diagnostic tool.
Overview Procedures
Overview procedures contain an exploded view
A CAUTI0N:Cautions are used to indicate illustration(s). The numbered sequence within the
that failure to follow a procedure correctly illustration(s) indicate the order to be followed when
may result in damage to the vehicle or removingldisassem bling or when
equipment being used. installinglassembling a component. Additional
information,
symbol(s) or a torque figure, may also
, , N0TE:Notes are used to provide additional
be shown alonaside the com~onent.
essential information required to carry out a
complete and satisfactory repair. There are
ten symbols used to give additional
information when
removina/disassemblincr or when V AS YOU read through this manual, YOU will come /"itallinglassembling a c&ponent.
across WARNINGS, CAUTIONS and NOTES.
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100-00-4 General Information 100=00=4
DESCRIPTION AND OPERATION
lnspection and Verification
Visual lnspection Charts, Symptom Charts and
other information charts (such as diagnostic
routines) or supplement test procedures with
technical specifications will navigate the user to a
specific test procedure.
Symptom Chart
The symptom chart indicates symptoms, sources
and actions to address a condition.
Item
1
2
3
4
5
6
7
8
9
10
Pinpoint Tests
For electrical systems, pinpoint test steps are used
to identify the source of a concern in a logical,
step-by-step manner. pinpoint tests have two
columns: CONDITIONS and
DETAILSIRESULTSIACTIONS.
Designation
Special tool
Install new component
l nspect
Apply sealant
Apply petroleum jelly Apply oil
Apply fluid
Apply grease
Removal or Disassembly
detail
Installation or Assembly
detail
The CONDITIONS column is used exclusively for
graphics and icons (with or without captions) and
the
DETAILSIRESULTSIACTIONS column
provides direction to another test step or specific
corrective actions.
The boxed numbers indicate the order in which the
described action is to be performed.
Description
A special tool is required for this component. There will also
be a removal or installation symbol alongside the special
tool symbol.
Discard the old component and install a new component.
Check the component for damage.
Apply sealant to the component as specified in the mate-
rials table.
Apply petroleum jelly to the component as specified in the
materials table.
Apply oil to the component as specified in the materials table.
Apply fluid to the component as specified in the materials
table.
Apply grease to the component as specified in the mate-rials
table.
Go to the removal or disassembly detail for additional
information to remove or disassemble a component
Go to the installation or assembly detail for additional
information to install or assemble a component
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