2007 FORD FIESTA brake fluid

100-00-1 General Information 100-00-1
. SECTION 100-00 General lnformation
VEHICLE APPLICATION:2006.0 Fiesta
CONTENTS
DESCRIPTION AND OPERATION
About This Manual
........................................................................\
......................................
........................................................................\
................................................. Introduction
Special Tools
........................................................................\
..............................................
Important Safety Instructions ........................................................................\
......................
Warnings. Cautions and Notes in This Manual ..................................................................
How to Use This Manual ........................................................................\
............................
Special Tools and Torque Figures ........................................................................\
..............
Health and Safety Precautions ........................................................................\
...................
........................................................................\
................................................. Introduction
........................................................................\
........................................ Acids and Alkalis
Air Bags
........................................................................\
......................................................
Air Conditioning Refrigerant ........................................................................\
.......................
........................................................................\
............................... Adhesives and Sealers
........................................................................\
................................................... Antifreeze
........................................................................\
..................................................... Asbestos
Battery Acids
........................................................................\
..............................................
Brake and Clutch Linings and Pads ........................................................................\
...........
Brake Fluids (Polyalkylene Glycols) ........................................................................\
...........
........................................................................\
....................................................... Brazing
Chemical Materials
........................................................................\
.....................................
................................................................... Chlorofluorocarbons (CFC) ... ..........................
Clutch Fluids ........................................................................\
...............................................
Clutch Linings and Pads ........................................................................\
.............................
Corrosion Protection Materials ........................................................................\
...................
........................................................................\
........................................................ Cutting
........................................................................\
.................................................... Dewaxing
........................................................................\
.......................................................... Dusts
Electric Shock
........................................................................\
.............................................
Engine Oils ........................................................................\
.................................................
Exhaust Fumes ........................................................................\
...........................................
........................................................................\
........................................... Fibre Insulation
Fire
........................................................................\
.............................................................
First Aid ........................................................................\
......................................................
........................................................................\
.......................................... Fluoroelastomer
Foams
. Polyurethane ........................................................................\
................................
........................................................................\
.......................................................... Freon
........................................................................\
........................................................... Fuels
........................................................................\
.............................................. Gas Cylinders
........................................................................\
......................................................... Gases
Gaskets (Fluoroelastomer)
........................................................................\
.........................
General Workshop Tools and Equipment ........................................................................\
...
High Pressure Air. Lubrication and Oil Test Equipment ......................................................
........................................................................\
.......................................................... Halon
........................................................................\
............................................. Legal Aspects
PAGE
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General Information
........................................................................\
............................. Lubricants and Greases
Transmission Fluids
........................................................................\
....................................
........................................................................\
.......................................................... Noise
Noise Insulation Materials
........................................................................\
..........................
0-Rings (Fluoroelastomer) ........................................................................\
.........................
........................................................................\
.......................................................... Paints
........................................................................\
.............................. Pressurized Equipment . . ........................................................................\
......................................................... Solder
........................................................................\
...................................................... Solvents
Sound Insulation
........................................................................\
.........................................
Suspended Loads ........................................................................\
.......................................
Transmission Brake Bands ........................................................................\
.........................
........................................................................\
................................................... Underseal
........................................................................\
............................................................ Viton
........................................................................\
....................................................... Welding
........................................................................\
.................... Warning Symbols on Vehicles
........................................................................\
................................................. White Spirit
Standard Workshop Practices
........................................................................\
....................
Vehicle in Workshop ........................................................................\
...................................
Alternative Fuel ........................................................................\
...........................................
Alternative Fuel - Do's ........................................................................\
..............................
Alternative Fuel - Do Nots ........................................................................\
........................
Towing the Vehicle ........................................................................\
......................................
Connecting a Slave Battery Using Jumper Cables ............................................................
Component Cleaning ........................................................................\
..................................
Calibration of Essential Measuring Equipment ...................................................................
Solvents. Sealants and Adhesives ........................................................................\
.............
........................................................................\
................................................. Introduction
RoadlRoller Testing ........................................................................\
....................................
Pre-Test Checks ........................................................................\
.........................................
Starting the Engine ........................................................................\
.....................................
Road or Roller Testing ........................................................................\
................................
Brake Testing ........................................................................\
..............................................
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100=00=8 General Information 100=00=8
DESCRIPTION AND OPERATION
drowsiness. In extreme cases, loss of
consciousness may result. Long term exposure to
vapor concentrations may result in adverse health
effects.
Prolonged contact with the skin may have a
defatting effect which may lead to skin irritation
and in some cases, dermatitis.
Splashes entering the eye will cause discomfort
and possible damage.
Any spraying should preferably be carried out in
exhaust ventilated booths, removing vapors and
spray droplets from the breathing zone.
Wear appropriate gloves, eye and respiratory
protection. Asbestos dust
waste should be dampened, placed
in a sealed container and marked for safe disposal.
If any cutting or drilling is attempted on materials
(
containing asbestos the item should be dampened "
and only hand tools or low speed power tools used.
Battery Acids
See also Acids and Alkalis.
Gases released during charging are explosive.
Never use naked flames or allow sparks near
charging or recently charged batteries.
Make sure there is adequate ventilation.
Brake and Clutch Linings and Pads
Antifreeze
See Asbestos.
See also Fire, Solvents.
For example isopropanol, ethylene glycol,
methanol.
Highly flammable, flammable, combustible.
Used in vehicle coolant systems, brake air pressure
systems, screenwash solutions.
Vapors may be given off from coolant antifreeze
(glycol) when heated. Avoid breathing these
vapors.
Antifreeze may be absorbed through the skin in
toxic or harmful quantities. Antifreeze, if swallowed,
can be fatal and MEDICAL ATTENTION SHOULD
BE SOUGHT IMMEDIATELY.
These products must not be used in any cooling
or industrial water system that is connected or
linked to general, food preparation or drinking water
supplies.
Asbestos
See also Warning Symbols on Vehicles at the end
of this subsection.
Breathing asbestos dust may cause lung damage
or, in some cases, cancer.
Used in brake and clutch linings, transmission
brake bands and gaskets.
The use of drum cleaning units, vacuum cleaning
or damp wiping is preferred.
Brake Fluids (Polyal kylene Glycols)
See also Fire.
Splashes to the skin and eyes are slightly irritating.
Avoid skin and
eye'contact as far as possible.
Inhalation vapor hazards do not arise at ambient
temperatures because of the very low vapor
pressure.
Brazing
See Welding.
Chemical Materials
See also Legal Aspects.
Chemical materials such as solvents, sealers,
adhesives, paints, resin foams, battery acids,
antifreeze, brake fluids, fuels, oils and grease
should always be used with caution and stored and
handled with care. They may be toxic, harmful,
corrosive, irritant or highly flammable and give rise
to hazardous fumes and dusts.
The effects of excessive exposure to chemicals may be immediate or delayed; briefly experienced
or permanent; cumulative; superficial; life
threatening; or may reduce life expectancy.
2006.0 Fiesta 1212006 GI 7372en
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100-00-9 General Information 100-00-9
DESCRIPTION AND OPERATION
Chemical Materials - Do's
/ I - Do carefully read and observe hazard and
precaution warnings given on material
containers (labels) and in any accompanying
leaflets, posters or other instructions. Material
health and safety data sheets can be obtained
from manufacturers.
- Do remove chemical materials from the skin
and clothing as soon as practicable after soiling.
Change heavily soiled clothing and have it
cleaned.
- Do organize work practices and protective
clothing to avoid soiling of the skin and eyes;
breathing vapors, aerosols, dusts or fumes;
inadequate container labeling; fire and explosion
hazards.
- Do wash before job breaks, before eating,
smoking, drinking or using toilet facilities when
handling chemical materials.
- Do keep work areas clean, uncluttered and free
of spills.
- Do store chemical materials according to
national and local regulations.
- Do keep chemical materials out of the reach of
( ' children.
- Do not clean hands or clothing with chemicals.
Chemicals, particularly solvents and fuels, will
dry the skin and may cause irritation leading to
dermatitis or be absorbed through the skin in
toxic or harmful quantities.
- Do not use emptied containers for other
materials except when they have been cleaned
under supervised conditions.
- Do not sniff or smell chemical materials. Brief
exposure to high concentrations of fumes can
be toxic or harmful.
Chlorofluorocarbons (CFC)
There is concern in the scientific community that
CFCs and Halons are depleting the upper ozone
layer which filters out harmful ultraviolet radiation.
Decreased filtration of ultraviolet radiation may
result in increases in skin cancer, cataracts and
immune system suppression in humans, as well
as decreased productivity of crops and aquatic
systems.
CFCs are used primarily as refrigerants in vehicle
air conditioning systems and as aerosol
propellants. Halons are used as fire extinguishants.
Clutch Fluids
Chemical Materials - Do Nots
See Brake fluids.
- Do not mix chemical materials except under the
manufacturers instructions; some chemicals can
form other toxic or harmful chemicals, give off
toxic or harmful fumes or become explosive
when mixed together.
- Do not spray chemical materials, particularly
those based on solvents, in confined spaces,
for example when people are inside a vehicle.
- Do not apply heat or flame to chemical materials
except under the manufacturers instructions. Some are highly flammable and some may
release toxic or harmful fumes.
- Do not leave containers open. Fumes given off
can build up to toxic, harmful or explosive
concentrations. Some fumes are heavier than
air and will accumulate in confined areas such
as pits.
- Do not transfer chemical materials to unlabelled
containers.
Clutch Linings and Pads
See Asbestos.
Corrosion Protection Materials
See also Solvents, Fire.
Highly flammable, flammable
- observe No
Smoking policy.
These materials are varied and the manufacturers instructions must be followed. They may contain
solvents, resins or petroleum products. Skin and
eye contact should be avoided. They should only be sprayed in conditions of adequate ventilation
and not in confined spaces.
Cutting
See Welding.
2006.0 Fiesta 1212006 GI 7372en
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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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100-00-1 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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100-04-5 Noise, Vibration and Harshness 100-04-5
DIAGNOSIS AND TESTING
Noise Conditions
Gear noise is typically a howling or whining due
to gear damage or incorrect bearing preload. It
can occur at various speeds and driving
conditions, or it can be continuous.
Chuckle is a particular rattling noise that sounds
like a stick against the spokes of a spinning
bicycle wheel. It occurs while decelerating from
64
kmlh (40 mph) and can usually be heard all
the way to a stop. The frequency varies with
vehicle speed.
Knock is very similar to chuckle, though it may
be louder and occurs on acceleration or
deceleration. The
teardown will disclose what
has to be corrected.
Clicking, popping or grinding noises may be caused
by the following:
worn, damaged or incorrectly installed wheel
bearing, suspension or brake component.
Check and rule out tires, exhaust and trim items
before disassembling the transmission to diagnose
and correct gear noise.
The noises described under Road Test usually
( have specific causes that can be diagnosed by
observation as the unit is disassembled. The initial
clues are the type of noise heard on the road test
and driving conditions.
Vibration Conditions
Vibration at highway speeds may be caused by
the following:
out-of-balance front or rear wheels.
out-of-round tires.
Shudder or vibration during acceleration may be
caused by the following:
damaged powertrainldrivetrain mounts.
excessively high constant velocity (CV) joint
operating angles caused by incorrect ride height.
Check ride height, verify correct spring rate and
check items under inoperative conditions.
Road Test
I A gear-driven unit will produce a certain amount
of noise. Some noise is acceptable and may be
audible at certain speeds or under various driving conditions,
as on a newly paved asphalt road. The
slight noise is in no way detrimental and must be
considered normal.
The road test and customer interview (if available)
provide information needed to identify the condition
-
and give direction to the correct starting point for
diagnosis.
1. Make notes throughout the diagnosis routine.
Make sure to write down even the smallest bit
of information, because it may turn out to be the
most important.
2. Do not touch anything until a road test and a
thorough visual inspection of the vehicle have been carried out. Leave the tire pressures and
vehicle load just where they were when the
condition was first observed. Adjusting tire
pressures, vehicle load or making other
adjustments may reduce the
condition(s)
intensity to a point where it cannot be identified
clearly. It may also inject something new into
the system, preventing correct diagnosis.
3. Make a visual inspection as part of the
preliminary diagnosis routine, writing down
anything that does not look right. Note tire
pressures, but do not adjust them yet. Note
leaking fluids, loose nuts and bolts, or bright
spots where components may be rubbing
against each other. Check the load space for
unusual loads.
4. Road test the vehicle and define the condition
by reproducing it several times during the road
test.
5. Carry out the Road Test Quick Checks as soon
as the condition is reproduced. This will identify
the correct diagnostic procedure. Carry out the
Road Test Quick Checks more than once to
verify they are providing a valid result.
Remember, the Road Test Quick Checks may
not tell where the concern is, but they will tell
where it is not.
Road Test Quick Checks
1. 24-80 kmlh (1 5-50 mph): with light acceleration,
a moaning noise is heard and possibly a
vibration felt in the front floor panel. It is usually
worse at a particular engine speed and at a
particular throttle setting during acceleration at
that speed. It may also produce a moaning
sound, depending on what component is
causing it. REFER to Tip-in Moan in the
Driveline Noise and Vibration Symptom Chart.
2006.0 Fiesta 1212006 G37349en
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