2007 FORD FIESTA Light switch

100-00-1 7 General Information 100-00-1 7
DESCRIPTION AND OPERATION
The flame is bright, and eye protection should be - used, but the ultra-violet emission is much less
than that from arc welding, and lighter filters may
be used.
The process itself produces few toxic fumes, but
such fumes and gases may be produced from
coatings on the work, particularly during cutting
away of damaged body parts, and inhalation of the
fumes should be avoided.
In brazing, toxic fumes may be produced from the
metals in the brazing rod, and a severe hazard
may arise if brazing rods containing cadmium are
used. In this event particular care must be taken
2. Components or assemblies displaying the
to avoid inhalation of fumes and expert advice may
warning triangle with the 'electrified' arrow and
be required. open book symbol
give warning of inherent high
SPECIAL PRECAUTIONS MUST BE TAKEN voltages.
Never touch these with the engine
BEFORE ANY WELDING OR CUTTING TAKES running
or the ignition switched on. See Electric
PLACE ON VESSELS, WHICH HAVE Shock
in this subsection.
CONTAINED COMBUSTIBLE MATERIALS, FOR
EXAMPLE BOILING OR STEAMING OUT OF
FUEL TANKS.
Warning Symbols on Vehicles
( i Decals showing warning symbols will be found on
various vehicle components.
These decals must not be removed. The warnings
are for the attention of
owners/operators and
persons carrying out service or repair operations
on the vehicle.
3. Vehicles and replacement components which
The most commonly found decals are reproduced
contain asbestos are identified by this symbol.
below together with an explanation of the warnings.
See Asbestos in this subsection.
1. Components or assemblies displaying the
caution triangle and open book symbol advise
consultation of the relevant section of the owner
literature before touching or attempting
adjustments of any kind. 4. Components or assemblies displaying this
symbol give warning that the component
contains a corrosive substance. See Acids and
Alkalis in this subsection.
2006.0 Fiesta 1212006 GI 7372en
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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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100-00-23 General Information 100-00-23
DESCRIPTION AND OPERATION
RoadIRoller Testing
I Road or roller testing may be carried out for various
reasons and a procedure detailing pre-test checks,
engine starting and stopping, pre-driving checks,
on-test checks and final checks to be completed
on completion of the test is given below.
Unless complete vehicle performance is being
checked, the full road test procedure need not be
carried out. Instead, those items particularly
relevant to the
system(s) being checked can be
extracted.
Pre-Test Checks
A WARNING:lf the brake system hydraulic
fluid level is low, pedal travel is excessive
or a hydraulic leak is found, do not attempt
to road test the vehicle until the reason for
the low fluid level, excessive pedal travel
or hydraulic leak is found and rectified.
It is suggested that pre-test checks and functional
tests of those systems and circuits which affect the
safe and legal operations of the vehicle, such as
( , brakes, lights and steering, should always be
carried out before the road or roller test.
With the ignition switched off, check:
- the engine oil level.
- the engine coolant level.
- the tires, for correct pressure, compatible types
and tread patterns, and wear within limits.
- that there is sufficient fuel in the tank to
complete the test.
- all around the engine, transmission and under
the vehicle for oil, coolant, hydraulic and fuel
leaks. Make a note of any apparent leaks and
wipe off the surrounding areas to make it easier
to identify the extent of the leak on completion
of the test.
Starting the Engine
N0TE:On initial drive away from cold and within
the first 1.5 km (1 mile), do not depress the
accelerator pedal beyond half travel until the
vehicle has attained a minimum speed of
25 kmlh
(15 mileslh). Never operate at high engine speed
or with the accelerator pedal at full travel whilst the
engine is cold.
With the ignition switched off, check:
- that the parking brake is applied.
- that the gear lever is in the neutral position.
- that all instrument gauges (except fuel gauge)
read zero.
With the ignition switched on, check:
- that the ignition controlled warning lamps are
illuminated.
- that the engine temperature gauge registers a reading compatible with the engine temperature.
- that the fuel gauge registers a reading
appropriate to the fuel level in the tank.
- the operation of the parking brake warning lamp
and fluid level warning indicator.
Road or Roller Testing
A CAUTI0N:lf road testing, check the brake
operation while still traveling at low speed
before continuing with the test. If the
brakes pull to one side, or appear to be
otherwise faulty, do not continue with the
road test until the fault has been found and
rectified.
During the road or roller test, check:
- that the clutch pedal operation is not stiff or
heavy.
- that the initial gear engagement is smooth and
there is no evidence of clutch drag.
- that the parking brake control operates smoothly
and releases quickly and completely.
- that the clutch takes up the drive smoothly,
without slip or judder.
- that gear changing is smooth with no abnormal
noises or vibrations from the transmission.
- the engine power output is satisfactory, full
power is achieved, acceleration is smooth and
pedal operation is not stiff or heavy, and engine
speed returns to idle correctly.
- there is no excessive or abnormally colored
smoke from the engine under normal driving,
heavy load or overrun conditions.
- that steering operation, including power steering
(if equipped), is smooth, accurate, not
excessively heavy or with excessive free play
or vibration.
- that the steering does not pull to one side and
self centers smoothly after cornering.
2006.0 Fiesta 1212006 GI 7375en
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100-00-24 General Information 100-00-24
DESCRIPTION AND OPERATION
- that the speedometer, coolant temperature - oil, coolant, hydraulic, air and fuel leaks.
gauge and tachometer (if equipped) register the - abnormal temperature of any moving
correct readings and operate correctly.
components or assemblies, for example wheel
(
- that the switches and controls operate smoothly hubs, transmission and axle, which might
and positively, warning and indicator lamps
indicate over tightness or lack of lubrication.
operate correctly and the direction indicator
control self cancels when the steering is
returned to the straight ahead position.
- that the heating and ventilation systems operate
correctly and effectively.
- the brake operation and efficiency.
Brake Testing
A WARNING:When brake testing, avoid
breathing the fumes from hot brakes, this
may contain asbestos dust which is
hazardous to health. Failure to follow this
instruction may result in personal injury.
For additional information, refer to: Health
and Safety Precautions
(1 00-00 General
Information, Description and Operation).
CAUTIONS:
A Avoid brake testing on busy roads where
it may cause inconvenience or danger to
other road users.
A Brake testing which includes heavy brake
applications should not be carried out with
new brake
padsldiscs or liningsldrums
until the components have bedded-in. New
brake friction components will not reach
full efficiency until the bedding-in process
is complete.
Test the brakes at several speeds within the normal
operating range using both light and heavy pedal
pressure. Note any tendency to snatch, pull or
drag, and any undue delay in application or
release.
Allow the vehicle to coast and note any tendency
to pull to one side, or evidence that the brakes are
binding.
After stopping the vehicle (not immediately after a
period of heavy braking), carefully check the brake
temperature.
A brake disc or brake drum that feels
hot or is appreciably hotter than the others,
indicates that the brake is binding.
After completion of the test, check for:
2006.0 Fiesta 1212006 GI 7375en
procarmanuals.com

100-04-22 Noise, Vibration and Harshness I 00-04-22
DIAGNOSIS AND TESTING
PINPOINT TEST E : NON-AXLE NOISE
TEST CONDITIONS
DETAILSIRESULTSIACTIONS
I El : INSPECT THE VEHICLE TRIM I
Check the radiator grille and trim panels to see
if they are the source of the noise.
Are the vehicle trim components causing the
noise?
+ Yes INSTALL new trim components or REPAIR
as necessary. ROAD TEST as necessary.
I E2: CHECK THE AIR CONDITIONING (AIC) SYSTEM FOR NOISE I
I Ignition switch in position Ill. I
I lgnition switch in position II.
Check the NC system components for noise by
turning the
NC system on and off.
Is the
NC system causing the noise?
+ Yes
INSPECT the
NC system. REFER to: (412-
00 Climate Control System - General Informa-
tion)
Climate Control System (Diagnosis and Testing),
Climate Control System (Diagnosis and Testing).
ROAD TEST as necessary.
I E3: CHECK NO~FACTORY FITTED ACCESSORIES I
rn Check any non-factory installed accessories for
being the source of the noise. For example:
touch condition body-to-frame, antennas, deflectors and fog lights.
Are the accessories the cause of the noise?
+ Yes
ADJUST, REPAIR, or INSTALL new
accessories or fasteners as required. ROAD
TEST as necessary.
+ No
VERIFY the customer concern.
2006.0 Fiesta iuzoos G37349en
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206-00-9 Brake System - General Information 206-00-9
DIAGNOSIS AND TESTING
Symptom
Brakedrag
Excessive brake pedal effort
Brake noise
I
i
i
Slow or incomplete brake pedal
return Possible Sources
Action
Brake discs.
Brake booster.
Incorrectly adjusted brake light
switch. Brake pressure control valve.
Seized brake caliper or wheel
cylinder. Parking brake applied or
malfunction.
Seized parking brake cables.
Seized brake caliper slide pins.
Brake booster inoperative.
Worn or contaminated brake
shoes or brake pads.
Worn brake shoes or brake
pads.
Brake booster.
Brake booster.
Brake master cylinder.
GO to Pinpoint Test H.
GO to Pinpoint Test I.
ADJUST the brake light switch.
PERFORM a brake booster
functional test REFER to the
component tests.
INSTALL new brake shoes or
brake pads. REFER to:
Brake Shoes (206-02 Drum Brake, Removal and Installa-
tion),
Brake Pads (206-03 Front Disc
Brake, Removal and Installa-
tion),
Brake Pads (206-04 Rear Disc Brake, Removal and Installa-
tion).
GO to Pinpoint Test J.
INSTALL new brake shoes or
brake pads. REFER to:
Brake Shoes (206-02 Drum Brake, Removal and Installa-
tion),
Brake Pads (206-03 Front Disc
Brake, Removal and Installa-
tion),
Brake Pads (206-04 Rear Disc
Brake, Removal and Installa-
tion).
GO to Pinpoint Test K.
GO to Pinpoint Test L.
2006.0 Fiesta 1212006 G28494en
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Engine - 1.25L Duratec-1 6V (Sigma)lIl4L
Duratec-1 6V (Sigma)ll .6L Duratec-1 6V (Sigma)
REMOVAL
19. Disconnect the EVAP electrical connector. 22.
Disconnect the knock sensor (KS) electrical
connector.
20. Disconnect the low pressure evaporate
emission (EVAP) hose from the EVAP valve. 23.
Disconnect the generator electrical
connectors.
21. Detach the brake booster vacuum line from
the intake manifold. 24.
Remove the right-hand
headlamp assembly.
For additional information, refer to:
Headlamp Assembly (41 7-01 Exterior
Lighting, Removal and Installation).
25. Disconnect the air conditioning
(AIC)
lower-pressure cut-off switch electrical
connector.
2006.0 Fiesta 1212006 GI 131 63en
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303-01 A-I 29 Engine
- 1.25L Duratec-I
6V (Sigma)ll.4L
Duratec-I 6V (Sigma)/l .6L Duratec-1 6V (Sigma) 303-01A-129
INSTALLATION
45. Attach the power steering line to the power 48.
Connect the engine coolant temperature
i steering pump mounting bracket. (ECT) sensor electrical connector.
46, Install the engine wiring harness support 49.
Connect the generator electrical
brackets. connectors.
Connect the engine ground cable.
50. Connect the air conditioning (AIC)
47. Connect the electronic ignition (El) coil lower-pressure
cut-off switch electrical
electrical connector. connector.
51. Install the right-hand
headlamp assembly.
For additional information, refer to:
Headlamp Assembly (41 7-01 Exterior
Lighting, Removal and Installation).
2006.0 Fiesta 1212006 GI 131 64en
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