2007 FORD FIESTA Intake

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
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
0512005 2006.0 Fiesta
procarmanuals.com

206-00-2 Brake System - General Information 206-00-2
DESCRIPTION AND OPERATION
Brake System
Overview
A Brake system without Anti-lock
Brake
I I system (ABS)
I B I Brake system with ABS I
I 1 I Brake master cylinder I -
1 2 1 Reservoir I
1 4 1 Brake pedal I
1 5 1 Brake pressure reduction valve I
1 6 1 Rear drum brake I
171t disk brake I
8 ABS hydraulic unit with integrated control
1 1 unit
1 9 I Wheel speed sensors I
Vehicles without ABS are equipped with brake
pressure reduction valves for the rear wheel
brakes. They are located in the corresponding
brake circuits at the brake master cylinder.
Vehicles with ABS do not need brake pressure
reduction valves because they are equipped with
electronic brake distribution (EBD).
The handbrake is cable operated on the rear
brakes.
On vehicles with a petrol engine the necessary
vacuum for the brake booster is generated by the
intake manifold.
On vehicles with a diesel engine, a vacuum pump
driven by the engine provides the necessary
vacuum for the brake booster.
2006.0 Fiesta lu2006 G281357en
procarmanuals.com

206-00-25 Brake System - General Information 206-00-25
DIAGNOSIS AND TESTING
TEST CONDITIONS
53: CHECK BRAKE BOOSTER CHECK VALVE
rn Disconnect the vacuum hose, for the brake
booster check valve at the intake manifold. Blow
into the hose attached to the brake booster
check valve.
Does air pass through the valve?
+ Yes
INSTALL a new brake booster check valve.
TEST the system for normal operation.
+ No
GO to J4.
54: CHECK BRAKE BOOSTER CHECK VALVE VACUUM
rn Disconnect the vacuum hose from the brake
booster check valve. Run the engine at idle.
Check the supply with a vacuum gauge.
Is the vacuum pressure above 40.5 kPa (12
in-Hg) with the brake booster non-operational?
+ Yes
GO to J5.
+ No
REPAIR or INSTALL a new vacuum hose and
fittings. TEST the system for normal operation.
55: CHECK BRAKE BOOSTER
rn Check the brake booster. GO to the component
test procedure in this section.
Is the brake booster OK?
+ Yes
GO to J6.
+ No
INSTALL a new brake booster. REFER to:
(206-07 Power Brake Actuation)
Brake Booster
- LHD (Removal and lnstallation),
Brake Booster
- RHD (Removal and lnstallation).
TEST the system for normal operation.
2006.0 Fiesta 1212006 G28494en
procarmanuals.com

206-00-29 Brake System - General Information 206-00-29
DIAGNOSIS AND TESTING
and repair the external leak. If the fluid level drops
and no external leak can be found, check for a
brake master cylinder bore end seal leak.
Brake System Check
Brake Pedal Reserve Check
Where a low brake pedal or the feel of a
bottomed-out condition exists, check for brake
pedal reserve.
1. Operate the engine at idle with the transaxle in
NEUTRAL.
2. Apply the brake pedal lightly three or four times.
3. Allow 15 seconds for vacuum to replenish the
brake booster.
N0TE:This increased resistance may feel like
something has bottomed out.
4. Apply the brake pedal until it stops moving
downward or an increased resistance to the
pedal travel occurs.
5. Hold the brake pedal in the applied position and
raise the engine speed to approximately 2000
rpm.
N0TE:The additional movement of the brake pedal
is the result of the increased engine intake manifold
vacuum which exerts more force on the brake
booster during engine rundown. This means that
additional stroke is available in the brake master
cylinder and the brake system is not bottoming out.
6. Release the accelerator pedal and observe that
the brake pedal moves downward as the engine
returns to idle speed.
Brake Booster Functional Test
lnspect all hoses and connections. All unused
vacuum connectors should be capped. Hoses and
their connections should be correctly secured and
in good condition with no holes and no collapsed 2.
With the transaxle in NEUTRAL, stop the engine
and apply the parking brake. Apply the brake
pedal several times to exhaust all vacuum in
the system.
3. With the engine turned off and all vacuum in the
system exhausted, apply the brake pedal and hold it down. Start the engine. If the vacuum
system is operating, the brake pedal will tend
to move downward under constant foot
pressure. If no motion is felt, the vacuum
booster system is not functioning.
4. Remove the vacuum hose from the brake
booster.
Intake manifold vacuum should be
available at the brake booster end of the hose
with the engine at idle speed and the transaxle
in NEUTRAL. Make sure that all unused vacuum
outlets are correctly capped, hose connectors
are correctly secured and vacuum hoses are in
good condition. When it is established that
manifold vacuum is available to the brake
booster, connector the vacuum hose to the
brake booster and repeat Step
3. If no
downward movement of the brake pedal is felt,
install a new brake booster. REFER to: (206-07
Power Brake Actuation)
Brake Booster
- LHD (Removal and lnstallation),
Brake Booster
- RHD (Removal and lnstallation).
5. Operate the engine a minimum of 10 seconds
at fast idle. Stop the engine and let the vehicle
stand for
10 minutes. Then, apply the brake
pedal with approximately 89
N (20 lb) force. The
pedal feel (brake application) should be the
same as that noted with the engine operating.
If the brake pedal feels hard (no power assist),
install a new vacuum check valve and then
repeat the test. If the brake pedal still feels hard,
install a new brake booster. REFER to: (206-07
Power Brake Actuation)
Brake Booster
- LHD (Removal and Installation),
Brake Booster
- RHD e em oval and installation).
If the brake pedal movement feels spongy, bleed
the brake system. REFER to: (206-00 Brake
System
- General Information)
areas. Inspect the check valve on the brake booster Brake System Bleeding (General Procedures),
for damage. Brake
System Pressure Bleeding (General
Procedures).
Brake Booster Operation Check
Brake Master Cylinder
1. Check the hydraulic brake system for leaks or
low fluid. Usually,
the first and strongest indicator of anything
wrong with the braking system is a feeling through
the brake pedal. In diagnosing the condition of the
brake master cylinder, check pedal feel as
2006.0 Fiesta 1212006 G28494en I
i
procarmanuals.com

21 1-02-1 0 Power Steering 21 1-02-1 0
REMOVAL AND INSTALLATION
Power Steering Pump - 2.OL Duratec-HE (M14)
f
I I Remover, Power Steering I
1 I Installer, Camshaft Pulley 1
7 I Removerllnstaller, Cooling I
1. Remove the right-hand headlamp assembly.
For additional information, refer to:
Headlamp Assembly (41 7-01 Exterior
Lighting, Removal and Installation).
2. Remove the accessory drive belt.
For additional information, refer to:
Accessory Drive Belt
- 2.OL Duratec-HE
(M14) (303-05 Accessory Drive, Removal
and Installation).
I
3. Detach the power steering pump to steering
, gear pressure line from the intake manifold. I
1 4. Lower the vehicle.
5. Remove the components in the order
indicated in the following
illustration(s) and
table(s).
2006.0 Fiesta 1212006 G428496en
procarmanuals.com

21 1-02-20 Power Steering 211 -02-20
REMOVAL AND INSTALLATION
Power Steering Pump to Steering Gear Pressure Line - 2.OL
Duratec-HE (M14) RHD
Special Tool(s)
I
- -
I Remover, Power Steering I
General Equipment 3.
Remove the air cleaner intake pipe resonator.
1. Remove the air cleaner intake pipe duct
retaining bolts.
2. Remove the air cleaner intake pipe and air
cleaner intake pipe duck assembly.
3. Detach the air cleaner intake pipe resonator
from the radiator grille opening panel.
Transmission jack
1. Remove the right-hand headlamp assembly. 5. N0TE:Make sure that the road wheels are in
For additional information, refer to: the
straight ahead position.
4.
Remove the battery tray.
Materials
Headlamp Assembly (41 7-01 Exterior
Lighting, Removal and Installation). For additional information, refer
to: Battery
2. Remove the air cleaner.
For additional information, refer to: Air
Cleaner
- 2.OL Duratec-HE (M14) (303-1 2
Intake Air Distribution and Filtering,
Removal and Installation).
Name
Specification Tray
- 2.OL Duratec-HE (M14) (414-01
Battery, Mounting and Cables, Removal
2006.0 Fiesta 1212006 G458165en
1 Grease I SA-M 1 C9 1 07-A and Installation).
procarmanuals.com

21 1-02-22 Power Steering 211 -02-22
REMOVAL AND INSTALLATION
Item Description
2 Power steering pump to steering gear
I I pressure line retaining clips
1
Item Description
Power steering pump pulley
See Removal Detail
See Installation Detail I I~ee Removal Detail I
5 Power steering pump to steering gear
pressure line
See Removal Detail
See lnstallation Detail
3 10. To install, reverse the removal procedure.
(
Power steering pump to steering gear
pressure line bracket to transaxle retaining
bolt
4
2006.0 Fiesta 1212006 G458165en
Power steering pump to steering gear
pressure line bracket to intake manifold
retaining bolt
procarmanuals.com