2007 FORD FIESTA air condition

100-00-12 General Information 100-00-12
DESCRIPTION AND OPERATION
Gross or prolonged skin contact with high boiling
point gas oils may also cause serious skin
disorders including skin cancer.
Kerosene (Paraffin)
Used also as heating fuel, solvent and cleaning
agent.
Flammable
- observe No Smoking policy.
Irritation of the mouth and throat may result from
swallowing. The main hazard from swallowing
arises if liquid aspiration into the lungs occurs.
Liquid contact dries the skin and can cause
irritation or dermatitis. Splashes in the eye may be
slightly irritating.
In normal circumstances the low volatility does not
give rise to harmful vapors. Exposure to mists and
vapors from kerosene at elevated temperature
should be avoided (mists may arise in dewaxing).
Avoid skin and eye contact and make sure there
is adequate ventilation.
Alternative Fuel
Highly flammable. Observe "NO SMOKING" signs.
Make sure there is adequate ventilation when
working on alternative fuelled vehicles. Great care
must be taken to avoid the serious consequences
of inhalation in the event of vapor build up in
confined spaces.
Inhalation in high concentrations may cause
dizziness, headache, nausea and loss of
co-ordination. Very high concentrations may result
in loss of consciousness.
Contact with liquefied petroleum gas (LPG) or
compressed natural gas (CNG) to the skin may
cause cold burns and frost bite.
Long sleeved cotton overalls, steel toe capped
safety boots and rubber neoprene gloves should
be worn during removal and installation of
LPGICNG fuel system components.
LPGICNG fuel leaks could cause a fire and be a
hazard to health that can lead to personal injury,
illness or even death.
If a leak is detected, under no circumstances
attempt to seal the leak by tightening the
unionlconnection until the fuel in the system or
component is depressurized. Once tightened the
system should be checked for integrity following
the specified procedures. If
the fuel tank is to be removed for service or repair
the fuel must be evacuated using dedicated
equipment and following the specified
procedures. (
Gas Cylinders
See also Fire.
Gases such as oxygen, acetylene, argon and
propane are normally stored in cylinders at
pressures of up to
138 bar (2000 psi) and great
care should be taken in handling these cylinders
to avoid mechanical damage to them or to the valve
gear attached. The contents of each cylinder
should be clearly identified by appropriate
markings.
Cylinders should be stored in well-ventilated
enclosures, and protected from ice and snow, or
direct sunlight. Fuel gases, for example acetylene
and propane, should not be stored in close
proximity to oxygen cylinders.
Care should be exercised to prevent leaks from
gas cylinders and lines, and to avoid sources of
ignition.
Only trained personnel should undertake work
involving gas cylinders.
Gases
See Gas Cylinders.
Gaskets (Fluoroelastomer)
See Viton.
General Workshop Tools and
Equipment
It is essential that all tools and equipment are
maintained in good condition and that the correct
safety equipment is used where required.
Never use tools or equipment for any purpose other
than that for which they were designed. Never
overload equipment such as hoists, jacks, axle and
chassis stands or
lifting slings. Damage caused by
overloading is not always immediately apparent
and may result in a fatal failure the next time that
the equipment is used.
2006.0 Fiesta 1212006 GI 7372en
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100-00-1 3 General Information 100-00-1 3
DESCRIPTION AND OPERATION
Do not use damaged or defective tools or
equipment, particularly high-speed equipment such
i as grinding wheels. A damaged grinding wheel can
disintegrate without warning and cause serious
injury.
Wear suitable eye protection when using grinding,
chiseling or sand blasting equipment.
Wear a suitable breathing mask when using
abrasive blasting equipment, working with
asbestos-based materials or using spraying
equipment.
Make sure there is adequate ventilation to control
dusts, mists and fumes.
High Pressure Air, Lubrication and Oil
Test Equipment
See also Lubricants and Greases.
Always keep high-pressure equipment in good
condition, and regularly maintained, particularly at
joints and unions.
Never direct a high-pressure nozzle, for example
diesel injector, at the skin as the fluid may
, penetrate to the underlying tissue, and cause
serious injury.
Halon
See CFCs.
Legal Aspects
There are many laws and regulations relating to
health and safety in the use and disposal of
materials and equipment in a workshop.
For a safe working environment and to avoid
environmental pollution, workshops should be
familiar, in detail, with the many health and safety
laws and regulations within their country, published
by both national and local authorities.
Lubricants and Greases
Avoid all prolonged and repeated contact with
mineral oils. All lubricants and greases may be
irritating to the eyes and skin.
'
Transmission Fluids
Safety instructions
Certain Transmission and Power Steering fluids
supplied to Ford may contain additives which have
the potential to cause skin disease (dermatitis) to
exposed persons. The dermatitis may be irritant
or allergic in nature. Risks are higher where
prolonged or repeated skin contact with a fluid may
occur. These fluids are used for vehicle initial
fill
and service purposes. This sub-section is to:
Inform Service personnel who may come into
contact with these vehicle fluids (hazard
communication).
Summarise appropriate workplace control
measures and personal protective equipment
requirements.
Draw attention to the existence of Material
Safety Datasheets (MSDS's) for the fluids
(available from Ford Customer Service Division).
These MSDS's contain detailed information on
hazards and appropriate controls.
Control measures
Workplace risk assessments made under national
chemical control regulations should identify
operations involving the fluids as potentially
hazardous and specify workplace control and
worker awareness measures. In such
circumstances, the relevant Material Safety
Datasheet (see the details specified below) which
specifies hazards and control measures in detail
should be made available for guidance.
Avoid unprotected skin contact with the fluids, and
in particular, avoid prolonged or repeated skin
contact. Work practices should be organised so as
to minimise the potential for skin contact. This may
include the use of drip trays, absorbents, correct
fluid handling equipment (funnels etc), and
workplace housekeeping measures such as the
cleaning of contaminated surfaces.
Personnel engaged in operations where skin
contact could occur (such as fluid draining or filling)
should wear impervious gloves made from
nitrile
rubber, certified to a chemical protection standard,
e.g. Europe Standard EN374. This glove type is
widely available from reputable suppliers of gloves
for chemical protection [including the manufacturers
Ansell-Admont
(Solvex Range), North Safety
products (North
Nitrile Latex Gloves range), and
2006.0 Fiesta 1212006 GI 7372en
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General Information
DESCRIPTION AND OPERATION
Two Pack
Can also contain harmful and toxic unreacted
resins and resin hardening agents. The
manufacturers instructions should be followed. See
also Resin-based Adhesives and
Isocyanate
Adhesives and Sealers under Adhesives and
Sealers.
Spraying should preferably be carried out in
exhausted ventilated booths removing vapor and
spray mists from the breathing zone. Individuals
working in booths should wear appropriate
respiratory protection. Those doing small-scale
repair work in the open workshop should wear
air-fed respirators.
Pressurized Equipment
See High Pressure Air, Lubrication and Oil Test
Equipment.
Solder
Solders are mixtures of metals such that the
melting point of the mixture is below that of the
constituent metals (normally lead and tin). Solder
application does not normally give rise to toxic lead
fumes, provided a
gaslair flame is used.
Oxy-acetylene flames should not be used, as they
are much hotter and will cause lead fumes to be
produced.
Some fumes may be produced by the application
of any flame to surfaces coated with grease, and
inhalation of these should be avoided.
Removal of excess solder should be undertaken
with care, to make sure that fine lead dust is not
produced, which can give toxic effects if inhaled.
Respiratory protection may be necessary.
Solder spillage and filings should be collected and
removed promptly to prevent general air
contamination by lead.
High standards of personal hygiene are necessary
in order to avoid ingestion of lead or inhalation of
solder dust from clothing.
Solvents
See also Chemical Materials, Fuels (Kerosene),
Fire.
For example acetone, white spirit, toluene, xylene,
trichloroethane.
2006.0 Fiesta 1212006
Used in cleaning and dewaxing materials, paints,
plastics, resins and thinners.
Some may be highly flammable or flammable.
Skin contact will degrease the skin and may result
in irritation and dermatitis following repeated or
prolonged contact. Some can be absorbed through
the skin in toxic or harmful quantities.
Splashes in the eye may cause severe irritation
and could lead to loss of vision.
Brief exposure of high concentrations of vapors or
mists will cause eye and throat irritation,
drowsiness, dizziness, headaches and, in the worst
circumstances, unconsciousness.
Repeated or prolonged exposure to excessive but
lower concentrations of vapors or mists, for which
there might not be adequate warning indications,
can cause more serious toxic or harmful effects.
Aspiration into the lungs, for example through
vomiting, is the most serious consequence of
swallowing.
Avoid splashes to the skin, eyes and clothing. Wear
protective gloves, goggles and clothing if
necessary.
Make sure there is good ventilation when in use,
avoid breathing fumes, vapors and spray mists and
keep containers tightly sealed. Do not use in
confined spaces.
When spraying materials containing solvents, for
example paints, adhesive, coatings, use extraction
ventilation or personal respiratory protection in the
absence of adequate general ventilation.
Do not apply heat or flame except under specific
and detailed manufacturers instructions.
Sound Insulation
See Fibre Insulation, Foams.
Suspended Loads
A CAUTI0N:Never improvise lifting tackle.
There is always a danger when loads are lifted or
suspended. Never work under an unsupported,
suspended or raised load, for example a
suspended engine.
Always make sure that lifting equipment such as
jacks, hoists, axle stands and slings are adequate
and suitable for the job, in good condition and
regularly maintained.
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100-00-1 6 General Information 100-00-1 6 '
DESCRIPTION AND OPERATION
Transmission Brake Bands
See Asbestos.
Underseal Welding
See
also Fire, Electric Shock, Gas Cylinders. (
Welding processes include Resistance Welding
(Spot Welding), Arc Welding and Gas Welding.
See Corrosion Protection.
Resistance Welding
Viton
In common with many other manufacturers
vehicles, some components have O-rings, seals
or gaskets, which contain a material known as
'Viton'.
Viton is a fluoroelastomer, that is a synthetic rubber
type material, which contains Fluorine. It is
commonly used for O-rings, gaskets and seals of
all types. Although Viton is the most well known
fluoroelastomer, there are others, including
Fluorel
and Tecmoflon.
When used under design conditions
fluoroelastomers are perfectly safe. If, however,
they are exposed to temperatures in excess of
400°C, the material will not burn, but will
decompose, and one of the products formed is
hydrofluoric acid.
This acid is extremely corrosive and may be
absorbed directly, through contact, into the general
body system.
O-rings, seals or gaskets which have been exposed
to very high temperatures will appear charred or
as a black sticky substance.
DO NOT; under any circumstances touch them or
the attached components.
Enquiries should be made to determine whether
Viton or any other fluoroelastomer has been used
in the affected O-ring, seal or gasket. If they are of
natural rubber or
nitrile there is no hazard. If in
doubt, be cautious, as the material may be Viton
or any fluoroelastomer.
If Viton or any other fluoroelastomers have been
used, the affected area should be decontaminated
before the commencement of work.
Disposable heavy duty plastic gloves should be
worn at all times, and the affected area washed
down using wire wool and a limewater (calcium
hydroxide) solution to neutralize the acid before
disposing of the decomposed Viton residue and
final cleaning of the area. After use, the plastic
gloves should be discarded carefully and safely. This process may cause particles of molten metal
to
be emitted at a high velocity, and the eyes and
skin must be protected.
Arc Welding
This process emits a high level of ultra-violet radiation, which may cause arc-eye, and skin burns
to the operator and to other persons nearby.
Gas-shielded welding processes are particularly
hazardous in this respect. Personal protection must
be worn, and screens used to shield other
~eo~le. . .
CONTACT LENS WEARERS ARE ADVISED TO
REVERT TO ORDINARY SPECTACLES WHEN
ARC WELDING as the arc spectrum is believed to
emit microwaves which dry out the fluid between
the lens and the eye. This may result in blindness
when the lens is removed from the eve.
Metal spatter will also occur, and appropriate eye
and skin protection is necessary.
The heat of the welding arc will produce fumes and
gases from the metals being welded, the rods and
from any applied coatings or contamination on the
surfaces being worked on. These gases and fumes
may be toxic and inhalation of these should be
avoided. The use of extraction ventilation to remove
the fumes from the working area may be necessary
particularly in cases where the general ventilation
is poor, or where considerable welding work is
anticipated. In extreme cases or confined spaces
where adequate ventilation cannot be provided,
air-fed respirators may be necessary.
Gas Welding (and Cutting)
Oxy-acetylene torches may be used for welding
and cutting, and special care must be taken to
prevent leakage of these gases, with consequent
risk of fire and explosion.
("
The process will produce metal spatter and eye "
and skin protection is necessary.
2006.0 Fiesta 1212006 GI 7372en
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100-04-2 Noise, Vibration and Harshness 100-04-2
DESCRIPTION AND OPERATION
Noise, Vibration and Harshness (NVH)
Noise, vibration and harshness (NVH) is becoming
more important as vehicles become more '
Know the History of the Condition
sophisticated and passenger comfort levels
increase. This section is designed to aid in the
- Did it start suddenly or appear gradually?
diagnosis and testing and repair of NVH concerns.
- Was it related to some other occurrence such
- Noise is defined as sounds not associated with
as a collision or previous part replacement?
the operation of passenger compartment
- Know how the condition made itself known; it
equipment that interface with customer
may be an important clue to the cause.
satisfaction.
- Vibration is defined as impulses felt by the
customer that are not caused by road surface Know the Probability of Certain
changes. Conditions Develop~ng
- Harshness is a ride quality issue where the - Look for the simple rather than the complex.
customer feels that the vehicle response to the
road surface is sharply transmitted to the
- For example:
customer.
- Electrical conditions usually occur at
connections rather than components.
Diagnostic Theory - An engine no-start is more likely to be caused
by a loose wire or small adjustment rather
than a sheared-off
camshafi. Diagnosis is more than just following a series of
interrelated steps in order to find the solution to the - Know the difference between impossible and
specific condition. It is a way of looking at systems improbable. Certain failures
in a system can be
that are not functioning the way they should and improbable
but still happen.
finding out why. Also it is knowing how the system
- New parts are just that, new. It does not mean
should work and whether it is working correctly. they are always
good functioning parts.
There are basic rules for diagnosis. If these rules
are followed, the cause of the condition is usually
Do Not Cure the Symptom and Leave
found the first time through the system. the Cause
Know the System
- Know how the parts go together. Lowering
the pressure in a front tire may correct
the condition of a vehicle leaning to one side, but
it does not correct the original condition.
- Know how the system operates as well as its
limits and what happens when the system goes
Be Positive the Cause is Found
wrong.
- Sometimes this means checking the system - Double check findings.
against one that is known to be working
- What caused a worn component?
correctly.
- A loose transmission or engine mount could
indicate that other mounts are also loose.
Know the History of the System
Diagnostic Charts
A clue in any one of these areas may save time:
- How old or new is the system? Charts are a simple
way of expressing the
relationship between basic logic and a physical
- What kind of treatment has it had?
system of components. They help discover the ,.
- Has it been serviced in the past in such a
cause of a condition in the least time. Diagnostic (,-
manner that might relate to the present
charts combine many areas of diagnosis into one
condition? visual display:
- What is the service history?
2006.0 Fiesta 12/2006 G28448en
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100-04-6 Noise, Vibration and Harshness 100-04-6
DIAGNOSIS AND TESTING
2. AccelerationIDeceleration: With slow
acceleration and deceleration, a shake is
sometimes noticed in the steering
wheellcolumn,
seats, front floor panel, front door trim panel or
front end sheet metal. It is a low frequency
vibration (around
9-1 5 cycles per second). It
may or may not be increased by applying the
brakes lightly. REFER to
Idle
BoomIShakeNibration in the Driveline Noise
and Vibration Symptom Chart.
High Speed: A vibration is felt in the front floor
panel or seats with no visible shake, but with
an accompanying sound or rumble, buzz, hum,
drone or booming noise. Coast with the clutch
pedal depressed (manual transmission) or shift
control selector lever in "N" (NEUTRAL)
(automatic transmission) and engine idling. If
vibration is still evident, it may be related to
wheels, tires, front brake discs, wheel hubs or
front wheel bearings. REFER to Shake and
Vibration While Driving in the Driveline Noise
and Vibration Symptom Chart.
4. Engine rpm Sensitive: A vibration is felt
whenever the engine reaches a particular rpm.
It will disappear in neutral coasts. The vibration
can be duplicated by operating the engine at
the problem rpm while the vehicle is stationary.
It can be caused by any component, from the
accessory drive belt to the clutch or torque
converter which turns at engine speed when the
vehicle is stopped. REFER to Shake and
Vibration While Driving in the Driveline Noise
and Vibration Symptom Chart.
5. Noise and Vibration While Turning: Clicking,
popping or grinding noises may be due to the
following:
worn, damaged or incorrectly installed front
wheel bearing.
damaged
powertrainldrivetrain mounts.
Road Conditions
An experienced technician will always establish a
route that will be used for all NVH diagnosis road
tests. The road selected should be reasonably
smooth, level and free of undulations (unless a
particular condition needs to be identified). A
smooth asphalt road that allows driving over a
range of speeds is best. Gravel or bumpy roads
are unsuitable because of the additional road noise produced.
Once the route is established and
consistently used, the road noise variable is
eliminated from the test results.
N0TE:Some concerns may be apparent only on
smooth asphalt roads.
If a customer complains of a noise or vibration on
a particular road and only on a particular road, the
source of the concern may be the road surface. If
possible, try to test the vehicle on the same type
of road.
Vehicle Preparation
Carry out a thorough visual inspection of the
vehicle before carrying out the road test. Note
anything which is unusual. Do not repair or adjust
any condition until the road test is carried out,
unless the vehicle is inoperative or the condition
could pose a hazard to the technician. After
verifying that the condition has been corrected,
make sure all components removed have been
installed.
Power Steering Conditions
c !
Check for the noise in the following conditions to
verify the customer concern.
Check for the noise in several temperature
conditions.
Is the noise from when the vehicle was new?
Can the noise be repeated constantly or is it
random?
Check the condition of the vehicle age, mileage
and service record.
Interview the customer to find the operating
condition in which the noise will occur. Test the
vehicle based on the
detail(s) from the customer
interview.
Follow the power steering operation noise
condition tables below, to find which condition
the noise will occur.
Power Steering Operation Noise Check
Step 1 : Check for NVH concerns from non-steering
components, which may sound like noises coming
from the steering system.
I:. ':
2006.0 Fiesta 121zoo6 G37349en
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100-04-9 Noise, Vibration and Harshness 1 00-04-9
DIAGNOSIS AND TESTING
Step 3: According to each identified operating
condition (Column A, B,
C, D, E, F), check each
possible Steering System
NVH concern with the
detail symptom charts below.
Before conducting a vehicle test to identify a
NVH
concern carry out the following checks.
1. Check the tire pressures and adjust to
specification, as necessary.
2. Make sure the steering system fluid is correct,
the system is free of leaks and is operating
correctly.
3. Make sure the vehicle steering system
temperature is the same as described at the
customer interview.
4. All evaluations must take place in a relatively
quiet location.
5. The heating
- air conditioning (AIC) fan and
radio must be turned off during evaluations and
the windows closed.
Symptom Chart
Power Steering Moan Noise
Test Condition
Listen for steering moan noise with the vehicle
parked, transmission in neutral and all windows
closed in the following test conditions.
1. Engine speed at idle with no steering action.
2. Engine speed at idle with slow 90 degrees per
second turning of the steering wheel.
3. Engine speed at 1250 +I- 50 rpm with no
steering action.
4. Engine speed at 1250 +I- 50 rpm with slow 90
degrees per second turning of the steering
wheel.
2006.0 Fiesta 12/2006 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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