lock FORD FIESTA 2007 Workshop Manual

2006.0 Fiesta
Workshop Manual
Table of Contents
GROUP 1 General lnformation
Service lnformation
General lnformation
Identification Codes
Jacking and Lifting
Noise, Vibration and
Harshness
Suspension
Suspension System - General
lnformation
Front Suspension
Rear Suspension
Wheels and Tires
Driveline
Front Drive Halfshafts
Brake System
Brake System - General
Information
Drum Brake
Front Disc Brake
Rear Disc Brake
Parking Brake and Actuation
Hydraulic Brake Actuation
Power Brake Actuation
Anti-Lock Control
Anti-Lock Control
- Traction
Control
Anti-Lock Control
- Stability
Assist
Steering System
Steering System - General
lnformation
Power Steering Steering Linkage
Steering Column
Steering Column Switches
Engine
Engine System - General
lnformation
Engine
- 1.25L Duratec-1 6V
(Sigma)/l.4L Duratec-1 6V
(Sigma)/l.GL Duratec-I 6V
(Sigma)
Engine
- 2.OL Duratec-HE
(MI41
Engine Cooling - 1.3L Duratec-8V
(Rocam)/l.25L Duratec-1 6V
(Sigma)/l.4L Duratec-1 6V
(Sigma)/l .6L Duratec-1 6V
(Sigma)
Engine Cooling
- 2.OL Duratec-HE
(MI41
Fuel Charging and Controls - 1.25L
Duratec-1 6V (Sigma)/l.4L
Duratec-16V (Sigma)/l.GL
Duratec-1 6V (Sigma)
Fuel Charging and Controls
- 2.OL
Duratec-HE (M14)
Accessory Drive
Starting System
Engine lgnition
Engine Ignition
- 2.OL Duratec-HE
(M14)
Engine Emission Control - 1.3L
Duratec-8V (Rocam)/l.25L
Duratec-1 6V (Sigma)/l.4L
Duratec-1 6V (Sigma)/l .6L
Duratec-1
6V (Sigma)
Engine Emission Control
- 2.OL
Duratec-HE (M14)
05/2005 2006.0 Fiesta
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Handles, Locks, Latches and Entry Systems 501-14
Wipers and Washers 501-16
Bumpers 501-19
Safety Belt System 50
I -20A
Supplemental Restraint
System 501 -20B
Body Repairs
- General
Information 501 -25
Body Repairs
- Vehicle Specific
lnformation and Tolerance
Checks 501 -26
To the best of our knowledge, the illustrations,
technical information, data and descriptions in
this issue were correct at the time of going to
print. The right to change prices, specifications,
equipment and maintenance instructions at
any time without notice is reserved as part of
FORD policy of continuous development and
improvement for the benefit of our customers.
No part of this publication may be reproduced,
stored in a data processing system or
transmitted in any form, electronic, mechanical,
photocopy, recording, translation or by any
other means without prior permission of
Ford-Werke Aktiengesellschaft. No liability can
be accepted for any inaccuracies in this
publication, although every possible care has
been taken to make it as complete and
accurate as possible.
Copyright
O
FORD-WERKE AKTIENGESELLSCHAFT
Service training programs D-FIGT-1
Printed in Germany
- rewi druckhaus, Wissen -
Printed on environmentally friendly
chlorine-free paper. (GB) Front End Sheet Metal Repairs
50 1 -27
Roof Sheet Metal Repairs 50 1 -28
Side Panel Sheet Metal Repairs 501 -29
Rear End Sheet Metal Repairs 501
-30
Paint
- General Information 501
-36
Frame and Mounting
Uni-Body, Subframe and Mounting
System 502-00
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GROUP
Chassis
SECTION TITLE PAGE
Suspension
Suspension
System . General Information .................................................................... 204-00
........................................................................\
................................. Front Suspension .201 4.0
........................................................................\
................................. Rear Suspension .20 4.02
........................................................................\
.................................. Wheels and Tires 204-04
Driveline
Front Drive Halfshafts ........................................................................\
............................ 205-04
' Brake System
Brake System . General Information ........................................................................\
...... 206-00
........................................................................\
.......................................... Drum Brake .20 6.02
Front Disc Brake
........................................................................\
................................... 206-03
Rear Disc Brake
........................................................................\
.................................... 206-04
Parking Brake and Actuation
........................................................................\
................. 206-05
Hydraulic Brake Actuation ........................................................................\
...................... 206-06
Power Brake Actuation
........................................................................\
.......................... 206-07
........................................................................\
.................................. An ti-Lock Control .20 6.09A
Anti-Lock Control . Traction Control ........................................................................\
....... 206-09B
Anti-Lock Control . Stability Assist ........................................................................\
......... 206-09C
Steering System
........................................................................\
. Steering System . General Information .21 1.00
........................................................................\
..................................... Power Steering -21 1-02
........................................................................\
.................................. Steering Linkage -21 1-03
Steering Column
........................................................................\
................................... 21 1-04
Steering Column Switches
........................................................................\
..................... 21 1-05
0512005 2006.0 Fiesta
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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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Fiesta
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100-00-1 9 General Information 100-00-1 9
DESCRIPTION AND OPERATION
Standard Workshop Practices
Vehicle in Workshop
When working on a vehicle in the workshop always
make sure that:
- the parking brake is applied or the wheels are
securely chocked to prevent the vehicle moving
forwards or backwards.
- the key is removed from key operated hood
locks before any work is carried out around the
front of the vehicle.
- if the engine is to be run, there is adequate
ventilation, or an extraction hose to remove
exhaust fumes.
- there is adequate room to raise the vehicle and
remove the wheels, if necessary.
- fender covers are always fitted if any work is to
be carried out in the engine compartment.
- the battery is disconnected if working on the
engine, underneath the vehicle, or if the vehicle
is raised.
Alternative Fuel - Dons
- Do work on the vehicle in a designated area,
that is well ventilated and with access restricted
to qualified personnel only.
- Install new warning labels to their original
locations.
- If possible always isolate the alternative fuel
tank, and run the vehicle on the alternative fuel
until it automatically switches to its normal fuel
prior to taking the vehicle into the workshop
service area.
- Only use tested and approved components and
pipes when repairing or servicing
LPG and CNG
systems.
Alternative Fuel - Do Nots
- Do not vent off LPG fuel.
- Do not use shop air pressure to force LPG fuel
from the fuel tank.
( A CAUTION:When electric arc welding on a - Do not use paint drying ovens above 40°C for vehicle, always disconnect the generator any alternative fuel vehicle. LPG and CNG fuel wiring to prevent the possibility of a surge tanks must be removed from the vehicle prior of current causing damage to the internal to being put into paint drying ovens above 40°C. components of the generator. - Do not modify the system or install new - if using welding equipment on the vehicle, a
components that are not designed for gas
suitable fire extinguisher is readily available.
vehicles.
Alternative Fuel
A WARNING:When servicing the fuel system
always follow the recommended
procedures. Failure to follow these
instructions may result in personal injury.
If the odor of liquefied petroleum gas (LPG) or
compressed natural gas
(CNG) is present in the
air in the workshop, warn all persons in the area
to:
- extinguish all flames and lighted tobacco.
- shut off electrical and air powered equipment.
- evacuate the area.
- ventilate the area.
- contact the fire control authorities.
- remove the vehicle to a dedicated, ventilated
area.
- Do not evacuate fuel tanks unless there is repair
that requires the removal of the fuel tank.
- Do not work on the fuel lines or system
components unless the alternative fuel has been
evacuated and the pressure in the system
reduced to atmospheric or less.
- Do not use anything other than the specified
leak detector fluid to trace fuel leaks.
Be aware of situations that may cause the
LPG or I
CNG fuel system to vent off fuel, such as: I
- extremely hot days.
- parking by a space heater.
- hoisting a vehicle up near a ceiling heater.
Only fully trained personnel, who are conversant
with local standards, are to work on alternative fuel
vehicles.
2006.0 Fiesta 1212006 GI 7373en
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100-00-20 General Information 100-00-20
DESCRIPTION AND OPERATION
Towing the Vehicle
an instance, the discharged battery must
be recharged immediately after jump
A WARN1NG:When the vehicle is being starting
to avoid permanent damage. ( towed, the ignition switch must be in - Always make sure that the jumper cables are
position ll (steering lock released and adequate for the task. Heavy duty cables must
warning lamps illuminated). Only then will be used.
the turn signal lamps, horn and - Always make sure that the slave battery is of stop lamps be operational. Failure to follow the same voltage as the vehicle battery. The these instructions may result in personal batteries must be connected in parallel. injury. - Always make sure that switched electric circuits
N0TE:The removable towing eye (if equipped),
are switched off before connecting jumper
has a left-hand thread and must be fully tightened cables. This reduces the risk of arcing occurring
before towing can commence.
when the final connection is made.
When towing is necessary, the vehicle towing eyes
should be used. The rope must be securely
fastened to the towing eyes and must also be
attached to the other vehicle such that the rope will
not foul the bodywork.
When a vehicle with automatic transmission is
towed, the gear selector must be in position
N
(Neutral). Never tow a vehicle with automatic
transmission at a speed greater than 30 mph (50
kmlh) or for a distance greater than 30 miles (50
km). If it is necessary to tow the vehicle a greater
distance, the drive wheels must be lifted clear off
the ground.
I A WARN1NG:Make sure that the ends of the Alternatively the vehicle can be transported on a jumper cables do not touch each other or low loader or a trailer. ground against the vehicle body at any
time while the cables are attached to the
Connectin a Slave Battery Using
73
battery. A fully charged battery, if shorted
Jumper Ca les through jumper cables, can discharge at
a rate well above
I000 amps causing
A WARNING:H the slave battery has recently violent arcing
and very rapid heating of the
been charged and is gassing, cover the jumper cables and
terminals, and can even
vent plugs or covers with a damp cloth to cause
the battery to explode. Failure to
reduce the risk of explosion should arcing follow
these instructions may result in
occur when connecting the jumper cables. personal injury.
Failure to follow these instructions may
Always connect the jumper cables in the following
result in personal injury. sequence:
CAUTIONS:
A A discharged battery condition may have
been caused by an electrical short circuit.
If this condition exists there will be an
apparently live circuit on the vehicle even
when all normal circuits are switched off.
This can cause arcing when the jumper
cables are connected.
A While it is not recommended that the
vehicle is jump started,
it is recognized
that this may occasionally be the only
practical way to mobilize a vehicle. In such
- Slave battery positive first and then vehicle
battery positive.
- Slave battery negative next and then vehicle
ground at least
12 inches (300 mm) from the
battery terminal, for example engine lifting eye.
Always reduce the engine speed to idle before
disconnecting the jumper cables.
Before removing the jumper cables from the vehicle
-
heater blower (high) or the heated rear window, to
that
had the discharged battery, switch on the
reduce the voltage peak when the cables are
removed.
2006.0 Fiesta 1~12006 GI 7373en
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100-02-5 Jacking and Lifting 100-02-5
DESCRIPTION AND OPERATION
Lifting
/' A WARNING:Only raise the vehicle at the A CAUTI0N:Place blocks underneath the
specified lifting points. hoist points
if a two-column hoist is used.
- -- --
2006.0 Fiesta 1212006 GI 67072en
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I 00-04-8 Noise, Vibration and Harshness 100-04-8
DIAGNOSIS AND TESTING
Steering system NVH concerns Power
assisted steering operating condition
I Steering System operation condition (column A to F) 1
Noise I Driving condition I A
Parking
Moan REFER
to
steering
system NVH
concerns
column A REFER
to
steering
system NVH
concerns
column
B
Driving
Whine REFER
to
steering
system NVH
concerns
column C
Vehicle stationary with engine off
Parking between lock stops, at engine idle and
also increased engine speed REFER
to
steering system
NVH concerns
column
D
REFER to steering
system NVH
concerns column E
X
Hiss REFER
to steering
system NVH
concerns column F
Driving, high engine rpm. Must be present from
1 new
0
b) Holding steering wheel against lock stops. Must
be present from new
a) Parking between lock
stops. Must be present
from new
X
Lock stop impact
knock a) Parking
at lock stop. Must be present from new
Mechanical knock
(power assisted
steering (PAS) off) b)
Parking between lock stops, engine OFF. Must
be present from new
Mechanical Knock c) Parking between lock stops, engine
ON (ball
(PAS on)
1 joint knock)
X
Hammer knock
Column knock
I f) Parking, driving. cobble stones and rough roads I X
- -
d) Parking into lock stop and release (vehicle
hydraulic power assisted steering (HPAS) only,
not for vehicles with electro-hydraulic power
assisted steering (EHPAS))
Hydraulic knock
(clonk)
Column rattle I Mainly driving on rough roads 1 0
e) Driving, cobble stones, rough road (clonk). Must
be present from new
Grinding
I When turning steering wheel I
Steering left and right at high frequency. Must be
present from new
Zip
I At engine start, -1 0°C only I X
X
X = Noise will most likely occur in this operating condition.
0 = Noise can possibly occur in this operating condition.
Blank = Noise is unlikely to occur in this operating condition.
2006.0 Fiesta 1212006 G37349en
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I 00-04-1 2 Noise, Vibration and Harshness I 00=04m12
DIAGNOSIS AND TESTING
Power Steering Hiss Noise
Test Condition
Listen for steering hiss noise with the vehicle
parked, transmission in neutral and all windows
-
closed in the following test conditions.
Power Steering Lock Stop Impact Knock 1. Turn the steering wheel to the left-hand and
Noise right-hand steering locks and listen for the
impact noise.
Test Condition
Listen for steering knock noise with the engine
speed at idle in the following test conditions (noise
also apparent with engine off).
Action
CHECK the installation and
potential damage of the floor seal.
Certain amount of noise level
acceptable, not a safety critical
item.
Certain amount of noise level
acceptable, not a safety critical
item.
Certain amount of noise level
acceptable, not a safety critical
item.
Symptom
N0TE:Engine speed at idle
turning the steering wheel slowly
lock to lock.
Power steering system hiss noise
- a high frequency, continuous
rush or swish noise like escaping
air from a balloon. Hiss occurs
while turning between the steering
lock stops, all steering angles.
Noise does not change with
engine rpm and is worse at high
operating temperatures.
N0TE:Engine speed at idle
holding the steering wheel against
a steering lock for three seconds.
Do not hold for more than five
seconds.
Power steering system hiss noise
- a continuous noise like escaping
air occurs while holding the
steering against a steering lock
stop.
Possible Sources
Floor seal.
Power steering gear valve design.
Power steering system hydraulic
design.
Power pump pressure
relief valve.
Power Steering Mechanical Knock Noise 1. Turn the steering wheel 90 degrees to the right,
(PAS off) hold and then quickly release.
2. Turn the steering wheel 90 degrees to the left, Test Condition hold and then quickly release.
Listen for steering knock noise with the engine off
in the following test conditions (no power assist).
2006.0 Fiesta 1212006 G37349en
Action
Certain amount of noise level
acceptable, not a safety critical
item.
Symptom
Power steering system knock
noise
- a heavy loud sound like a
knock on a door that occurs in
parking condition when hitting the
lock stop.
Possible Sources
Power steering gear mechanical
noise, metal to metal at end of
steering travel.
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100-04-13 Noise, Vibration and Harshness 100-04-13
DIAGNOSIS AND TESTING
Power Steering Mechanical Knock Noise 1. Turn the steering wheel to a steering lock and
(PAS on) return to center quickly.
2. Turn the steering wheel 90 degrees to the left
Test Condition and then 90 degrees to the right quickly.
Listen for steering knock noise with the engine
speed at idle in the following test conditions (power
assist).
Action
Certain amount of noise level
acceptable, not a safety critical
item.
Certain amount of noise level
acceptable, not a safety critical
item.
Symptom
Power steering system knock
noise - a heavy loud repeating
sound like a knock on a door that
occurs in several driving and
steering conditions.
Power Steering Hammer Knock (Hydraulic) 1. Turn the steering wheel to a steering lock
Noise position and return quickly.
Possible Sources
Power steering system knock
noise
- a damped, metallic knock
noise which only occurs at
steering condition with engine off
(very high efforts),
Tolerances in the steering gear
components.
Test Condition
Action
REFER to Steering System.
REFER to: Steering System (21
1 -
00, Diagnosis and Testing).
Symptom
Power steering system knock
noise - clear knock noise from
steering gear linkage area.
Listen for steering knock noise with the engine
speed at idle in the following test conditions (for
vehicles with hydraulic power assisted steering only, not electro-hydraulic power steering).
Possible Sources
Worn tie-rod ball joints (inner and
outer ball joints).
Symptom Possible Sources Action
hitting the suspension cross- Certain
amount of noise level
by pressure impulse in gear and
return line).
Power Steering Hydraulic KnocWClonk 1. Drive over cobbled roads at low speed 10-30
Noise kmlh (6-20 mph) with and without turning.
2. Drive over straight tar strips road rails or 25 mm
Test Condition tall harshness strips at low speed 10-30 kmlh
Listen for steering knocklclonk noise in the (6-20
mph) both driving straight and with
following test conditions with the windows closed. moderate turning.
2006.0 Fiesta 1212006 G37349en
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