instrument panel FORD FIESTA 2007 Workshop Manual

Intake Air Distribution and
- Filtering
303-1 2
Evaporative Emissions 303-1 3
Electronic Engine Controls 303-14
Automatic Transmission/Transaxle
Automatic TransmissionlTransaxle -
Vehicles With: 4-Speed Automatic
Transmission
(AW81-40) 307-01
TransmissionlTransaxle Cooling -
Vehicles With: 4-Speed Automatic
Transmission
(AW81-40) 307-02
Automatic
TransmissionlTransaxle
External Controls - Vehicles With:
4-Speed Automatic Transmission
(AW8 1 -40) 307-05
Manual Transmissionrrransaxle, Clutch and
Transfer Case
Manual TransmissionlTransaxle and
Clutch
- General Information 308-00
Clutch 308-0 1
Clutch Controls 308-02
Manual
Transmission/Transaxle 308-03
Manual TransmissionlTransaxle
External Controls 308-06
Exhaust System
Exhaust System 309-00
Fuel System
Fuel System - General
Information 31 0-00
Fuel Tank and Lines
31 0-01
Acceleration Control - I .3L Duratec-8V
(Rocam)ll.25L Duratec-I 6V
Instrumentation and Warning Systems
lnstrument Cluster and Panel
(
Illumination 41 3-00
Instrument Cluster
413-01
Horn 41 3-06
lnformation and Message
Center 41 3-08
Warning Devices
4 1 3-09
Parking Aid 41 3-1 3
Battery and Charging System
Charging System - General
Information 4 14-00
Battery, Mounting and Cables 414-01
Generator and Regulator 41 4-02
lnformation and Entertainment Systems
lnformation and Entertainment System
- General Information 41 5-00
Audio Unit 41 5-01
Antenna 41 5-02
Lighting
Exterior Lighting 41 7-01
Interior Lighting 4 1 7-02
Electrical Distribution
Module Communications ( 'j
Network 41 8-00
Module Configuration 41 8-01
Electronic Feature Group
Anti-Theft - Active 419-01A
Anti-Theft
- Passive 41 9-01 B
Cellular Phone 41 9-08
Multifunction Electronic
Modules 41 9-1 0
Climate Control System
Climate Control System - General
Information
Air Distribution and Filtering
Heating and Ventilation
Air Conditioning
Control Components
(Sigma)ll.4L Duratec-I 6V
lnterior Trim and
Ornamentation
Exterior Trim and
Ornamentation
Rear View Mirrors
Seating
Glass, Frames and
Mechanisms
(Sigma)/l .6L Duratec-1 6V
Instrument Panel and Console 501 -1 2
0512005 2006.0 Fiesta
GROUP 5 Body and Paint
(Sigma) 3 1 0-02A
Acceleration Control
- 2.OL Duratec-HE Body and Paint
(M14) 31 0-028 Body System - General
Information 501 -00
GROUP 4 Electrical Front End Body Panels 50 1 -02
Body Closures 50 1 -03
procarmanuals.com

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
0512005 2006.0
Fiesta
procarmanuals.com

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
0512005 2006.0
Fiesta
procarmanuals.com

100-00-6 General Information 100-00-6
DESCRIPTION AND OPERATION
Health and Safety Precautions
Introduction
Many of the procedures associated with vehicle
maintenance and repair involve physical hazards
or other risks to health. This subsection lists,
alphabetically, some of these hazardous operations
and the materials and equipment associated with
them. Precautions necessary to avoid these
hazards are identified.
The list is not exhaustive and all operations and
procedures, and the handling of materials, should
be carried out with health and safety in mind.
Before using any product the Materials Safety Data
Sheet supplied by the manufacturer or supplier
should be consulted.
Acids and Alkalis
See also Battery Acids.
For example caustic soda, sulphuric acid.
Used in batteries and cleaning materials.
Irritant and corrosive to the skin, eyes, nose and
throat. Cause burns. Can destroy ordinary
protective clothing.
Avoid splashes to the skin, eyes and clothing. Wear
suitable protective impervious apron, gloves and
goggles. Do not breath mists.
Make sure access to eye wash bottles, shower and
soap are readily available for splashing accidents.
Display Eye Hazard sign.
Air Bags
See also Fire, Chemical Materials.
Highly flammable, explosive
- observe No Smoking
policy.
Used as a safety restraint system mounted in the
steering wheel and passenger side of the instrument panel.
The inflator contains a high-energetic propellant
which, when ignited, produces a VERY HOT GAS
(2500°C).
The gas
generant used in air bags is Sodium Azide.
This material is hermetically sealed in the module
and is completely consumed during deployment.
No attempt should be made to open an air bag inflator
as this will lead to the risk of exposure to
( '.
Sodium Azide. If a gas generator is ruptured, full
protective clothing should be worn when dealing
with the spillage.
After normal deployment, gloves and safety goggles must be worn during the handling process.
Deployed air bags should be disposed of in a
plastic bag in accordance with local regulations at
an approved chemical waste site.
Following any direct contact with gas generant.
- wash affected areas thoroughly with water.
- seek medical assistance if necessary.
Air Bags
- Do's
- Do store modules in an upright position.
- Do keep modules dry.
- Do carry modules with the cover side pointing
away from the body.
- Do place modules with their cover side upwards.
- Do carefully inspect modules for damage.
- Do stand to one side when connecting modules.
- Do make sure all test equipment is properly
calibrated and maintained.
- Do wash hands after handling deployed air
bags.
Air Bags
- Do Nots
- Do not store highly flammable material together
with modules or gas generators.
- Do not store gas generators at temperatures
exceeding 80°C.
- Do not store modules upside down.
- Do not attempt to open a gas generator housing.
- Do not expose gas generators to open flame or
sources of heat.
- Do not place anything on top of a module cover.
- Do not use damaged modules.
- Do not touch a fired module or gas generator
for at least
10 minutes.
- Do not use any electrical probes on the wiring
circuit.
Air Conditioning Refrigerant (1,
See also Chlorofluorocarbon, Chemical Materials
Highly flammable, combustible
- observe No
Smoking policy.
2006.0 Fiesta iu200s GI 7372en
procarmanuals.com

206-06-6 Hydraulic Brake Actuation 206-06-6
REMOVAL AND INSTALLATION
Brake Pedal - RHD(12 333 0)
Removal
All vehicles
A WARNING:ln the event of a frontal impact
to a vehicle equipped with a decoupler
brake pedal in which damage to, or
significant movement of, the instrument
panel or the brake booster has occurred,
a new brake pedal must be installed.
Failure to follow this instruction may result
in personal injury.
1. Remove the instrument panel lower panel.
1. Remove the lower retaining screws.
2. Remove the upper retaining screws from the
stowage compartment.
3. Release the clip.
2. Detach the brake booster actuating rod from
the brake pedal (accelerator pedal shown
removed for clarity).
I. Depress the clip.
2. Remove the brake booster actuating rod pin.

Vehicles with manual transaxle 1.
3. N0TE:From 0212004 the brake pedal will not
be equipped with the brake pedal decoupler
mechanism.
Remove the brake pedal.
1. Remove the pivot shaft nut.
2. Slide out the pedal pivot shaft.
3. Remove the brake pedal.
4. Remove the brake pedal bushings. ( ,:
Vehicles with automatic transaxle
5. N0TE:From 0212004 the brake. pedal will not
be equipped with the brake pedal decoupler
mechanism.
Remove the brake pedal.
1. Remove the pivot shaft nut.
2. Slide out the pedal pivot shaft.
2006.0 Fiesta 1212006 G89190en
procarmanuals.com

206-07-8 Power Brake Actuation 206-07-8
REMOVAL AND INSTALLATION
Brake Booster - RHD(12 451 0)
Removal 2. Remove the brake booster actuating rod pin. (
1. Remove the brake master cylinder.
For additional information, refer to: Brake
Master Cylinder
- RHD (206-06 Hydraulic
Brake Actuation, Removal and Installation).
2. Disconnect the brake vacuum pipe from the
brake booster.
I. Unclip the brake vacuum pipe.
2. Disconnect the brake vacuum pipe.
3. Remove the instrument panel lower panel.
1. Remove the lower retaining screws.
2. Remove the upper retaining screws from the
stowage compartment.
3. Release the retaining clip. 5.
Remove
the brake booster.
Discard the gasket.
Installation
1. WARNINGS:
ADO not install an Emergency Brake Assist
(EBA) brake booster to a vehicle that is not
equipped with the Anti-lock Brake System
(ABS). Failure to follow this instruction may
result in personal injury.
ADO not use a damaged brake pedal.
Failure to follow this instruction may result
in personal injury.
4. Detach the brake booster actuating rod from CAUTIONS:
the brake pedal (accelerator pedal shown A Make sure that the brake booster gasket
removed for clarity).
is correctly positioned on the brake
I. Depress the clip. booster before installation. 41
A Do not drop or knock the brake pedal.
Failure to follow this instruction will cause
damage to the brake pedal decoupler
mechanism (if equipped).
2006.0 Fiesta 12/2006 G89214en
procarmanuals.com

21 1 -04-5 Steering Column 2 I I -04-5
REMOVAL AND INSTALLATION
Steering Column(l3 542 0)
Removal Disconnect the electrical connector.
1. Remove the driver air-bag module.
For additional information, refer to: Driver
Air Bag Module (501-20 Supplemental
Restraint System, Removal and
Installation).
2. Remove the instrument panel lower panel.
1. Remove the lower retaining screws.
2. Remove the upper retaining screws from the
stowage compartment.
3. Release the clip.
3. Detach the audio control switch from the
steering column lower shroud (if equipped).
Using a thin bladed screwdriver, release the
locking tang.
4. Remove the audio control switch (if
equipped).
5. N0TE:Turn the steering wheel to gain access
to the steering column upper shroud
retaining clips.
Detach the steering column upper shroud
from the steering column lower shroud (steering wheel shown removed for clarity).
1 . Using a thin bladed screwdriver, release the
two clips, (one each side).
2. Detach the shroud.
6. Remove the steering column lower shroud
(steering wheel shown removed for clarity).
1. Remove the retaining screws.
2006.0 Fiesta 1212006 GI 05654en
procarmanuals.com

303-1 4-1 4 Electronic Engine Controls 303-1 4-1 4
DIAGNOSIS AND TESTING
Electronic Engine Controls
General Equipment
I Worldwide Diagnostic system (WDS)
Principles of Operation
For Principles of Operation on the electronic
accelerator control system
REFER to: Acceleration Control (31
0-02A,
Diagnosis and Testing).
European On-Board Diagnostics (EOBD)
EOBD is a diagnostic system integrated into the
powertrain control module (PCM). This system
continuously monitors vehicle emission
components. The system includes a malfunction
indicator lamp (MIL) which indicates when there is
a concern that can affect emissions or the system
malfunctions. Data stored within the module DTC
memory can be accessed using a generic scan
tool or WDS.
EOBD is mandated within European Union
regulations from the year 2000 for passenger
vehicles with petrol engines and from 2003 onwards for passenger vehicles with diesel
engines.
EOBD Functions:
Establishes when and how emissions control
faults must be indicated.
Actuates emission control malfunction indicator
lamp (MIL) and fault memory.
Indicates operating conditions in which the
concern occurred (freeze frame data).
Standardized output of operating data such as
engine speed, engine coolant temperature etc.
Standardized names and abbreviations for
components and systems.
Standardized
DTCs for all manufacturers.
Standardized communication with the diagnostic
equipment.
Standardized 16-pin data link connector (DLC)
in area of the instrument panel.
Concern display must be possible using a
generic scan tool.
EOBD consists of the following elements:
Warm-up Cycle C'
The warm-up cycle is an operation that consists of
key on, engine start and a coolant temperature
increase of
22"C, exceeding 71 OC on completion.
Drive Cycle
A drive cycle commences when the engine is
started (cold or warm) and ends when the engine
is switched off.
Trip
A trip begins when the engine is started and is
complete when all the EOBD monitors have
completed a self-test. This may take place over a
number of drive cycles. On diesel variants, the
information gathered from one drive cycle is not
carried over to a subsequent cycle or cycles.
When a concern has been rectified, particularly
after electronic engine control components have
been changed, the DTC memory, which is part of
the EEPROM must be cleared of all trouble codes.
When the DTC memory has been cleared, the code
.
PI000 (known as the readiness code) is set in the
PCM memory, which indicates that since the
EEPROM has been cleared, not all of the
monitoring systems have completed their tests.
PI000 can only be cleared by carrying out a trip,
which includes driving the vehicle under variable
conditions of speed, load and time so that all of the
monitors are completed. As
PI000 will not
illuminate the MIL it is not necessary to carry out
the trip before returning the vehicle to the customer.
Freeze Frame Data
When a concern is detected, various data is stored
depending on application including:
Diagnostic trouble code.
Vehicle speed.
Engine coolant temperature.
Engine speed.
Engine load.
Mixture formation trim value (trim value for
engine wear) (All except vehicles with diesel
engine).
State of oxygen sensor control (open and closed
loop) (All except vehicles with diesel engine).
Distance covered since the concern was first
registered.
2006.0 Fiesta 1212006 G384566en
procarmanuals.com

Automatic Transmission/Transaxle -
Vehicles With: 4-Speed Automatic
307-01 -36 Transmission (AW81-40) 307-01 -36
DESCRIPTION AND OPERATION
Actuation of the MIL warning lamp Warning tone request
The information required to actuate the
MIL The
driver's door is open.
warning lamp is sent the transmission control The instrument cluster passes on the warning tone unit to the instrument cluster.
request to the GEM. The GEM generates the
warning tone.
I I I
Actuation of the overdrive indicator lamp
I
The overdrive indicator lamp is located on the
instrument panel.
The MIL warning lamp
is actuated by the The transmission control unit sends
a warning tone
instrument cluster if there are serious faults in the request
to the instrument cluster if the following
transmission control or if the transmission fluid conditions are
met:
temperature is excessively high.
The selector lever is not in position "P",
The information required to actuate the overdrive
indicator lamp is sent from the transmission control
unit when the overdrive switch on the selector lever
is pressed.
2006.0 Fiesta 1u2oos G380530en
procarmanuals.com

- -
Automatic Transmission/Transaxle External
Controls -Vehicles With:
4Speed Automatic
307-05-8 Transmission
(AW81-40) 307-05-8
REMOVAL AND INSTALLATION
7. Attach a suitable length of draw cord to the 2. Using the draw cord, pull the selector lever
transaxle end of the selector lever cable and
cable through the floor panel.
secure
it to the transaxle. 3. Install the selector lever cable grommet.
8. Lower the vehicle.
9. Remove the floor console.
For additional information, refer to: Floor
Console
(501 -1 2 Instrument Panel and
Console, Removal and lnstallation).
10. Detach the selector lever cable from the
transmission selector lever.
1. Shift the selector lever to the "P" (PARK)
position.
2. Detach the selector lever cable.
3. Pull the selector lever cable locking pin and
detach the selector lever cable outer sleeve.
4. Attach the selector lever cable to the selector
lever.
11. Remove the selector lever cable grommet.
12. Remove the selector lever cable.
1. Shift the selector lever to the "P" (PARK)
position.
2. Attach the selector lever cable outer sleeve.
3. Attach the selector lever cable.
5. Install the floor console.
For additional information, refer to: Floor
Console
(501-12 lnstrument Panel and
Console, Removal and lnstallation).
6. Raise and support the vehicle.
For additional information, refer to: Lifting
(100-02 Jacking and Lifting, Description
and Operation).
Pull the cable and draw cord through the floor 7. Remove the draw cord.
panel. 8. Attach the selector lever cable to the manual
Installation
shift lever. f
1. Attach the selector lever cable to the selector''-
1. Attach the draw cord to the transaxle end of lever cable bracket.
the selector lever cable.
2006.0 Fiesta 1212006 G388013en
procarmanuals.com