2007 FORD FIESTA charging

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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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
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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
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GROUP
Electrical
SECTION TITLE PAGE
Climate Control System
.......................................................... Climate Control System . General Information 42-00
........................................................................\
................... Air Distribution and Filtering 412-01
........................................................................\
......................... Heating and Ventilation .41 2-02
........................................................................\
..................................... Air Conditioning .41 2.03
........................................................................\
............................. Control Components .41 2.04
i
Instrumentation and Warning Systems
.................................................................... Instrument Cluster and Panel Illumination -41 3-00
........................................................................\
................................. Instrument Cluster .41 3-01
........................................................................\
...................................................... Horn -41 3-06
Information and Message Center ........................................................................\
........... 41 3-08
........................................................................\
................................... Warning Devices -41 3-09
........................................................................\
............................................. Parking Aid 413-1 3
Battery and Charging System
Charging System . General Information ..................................................................... 14-00
........................................................................\
............... Battery, Mounting and Cables -41 4-01
........................................................................\
...................... Generator and Regulator .41 4-02
lnformation and Entertainment Systems
Information and Entertainment System . General Information ..................................... .41 5-00
Audio Unit ........................................................................\
.............................................. 15-01
........................................................................\
................................................. Antenna .41 5-02
Lighting
........................................................................\
.................................... Exterior Lighting .41 7.01
........................................................................\
..................................... Interior Lighting -41 7-02
Electrical Distribution
........................................................................\
......... Module Communications Network 18-00
........................................................................\
............................. Module Configuration 41 8-01
Electronic Feature Group
Anti-Theft - Active ........................................................................\
.................................. 419-OIA
........................................................................\
............................... Anti-Theft . Passive .4 I 9-0 I B
........................................................................\
.............................. Cellular Phone .........4 19-08
........................................................................\
........... Multifunction Electronic Modules 41 9-1 0
0512005 2006.0
Fiesta
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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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303-00-5 Engine System - General Information 303-00-5
DIAGNOSIS AND TESTING
Symptom
Oil consumption
Possible Sources Action
Use of the wrong type of
engine oil.
Faulty positive crankcase vent-
ilation (PCV) system.
- Hoses or ventilation or
breather valves are blocked.
This causes excessive
pressure in the crankcase
which causes more oil to
enter the combustion
chamber.
- PCV oil separator is faulty
and engine oil can enter the
combustion chamber
through the intake manifold.
Turbocharger seals (diesel
engine only).
DETERMINE the last type of
engine oil used and compare
with the specification. Change
the engine oil to the specifica-
tion.
CHECK if the PCV system is
operating correctly and repair
as necessary. REFER to:
Engine Emission Control (303-
08 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), Diagnosis and
Testing),
Engine Emission Control (303-
08 Engine Emission Control
- 2.OL Duratec-HE (M14),
Diagnosis and Testing),
Engine Emission Control
-
Vehicles With: Vacuum
Exhaust Gas Recirculation
(EGR) Valve (303-08 Engine
Emission Control
- 1.4L
Duratorq-TDCi (DV) Diesel,
Diagnosis and Testing),
Engine Emission Control (303-
08 Engine Emission Control
- 1.6L Duratorq-TDCi (DV)
Diesel, Description and
Operation).
INSTALL a new turbocharger.
REFER to:
Turbocharger (303-04 Fuel
Charging and Controls
-
Turbocharger - I .4L
Duratorq-TDCi (DV) Diesel,
Removal and lnstallation),
Turbocharger
- I .6L Duratorq-
TDCi (DV) Diesel (303-04
Fuel Charging and Controls
- Turbocharger - I .6L
Duratorq-TDCi (DV) Diesel,
Removal and lnstallation).
2006.0 Fiesta 1212006 GI 52554en
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303-00-1 0 Engine System - General Information 303-00-1 0
DIAGNOSIS AND TESTING
Symptom
Very poor power output or fuel
consumption too high or engine
running rough
Possible Sources Action
Fuel system. CHECK the fuel system.
REFER to:
Fuel Charging and Controls
(303-04 Fuel Charging and
Controls
- 1.25L Duratec-1 6V
(Sigma)/l.4L Duratec-I 6V
(Sigma)/l.GL Duratec-1 6V
(Sigma), Diagnosis and
I Testing),
Fuel Charging and Controls
(303-04 Fuel Charging and
Controls
- 1.3L Duratec-8V
(Rocam), Diagnosis and
Testing),
Fuel Charging and Controls
(303-04 Fuel Charging and
Controls
- I .4L Duratorq-
TDCi (DV) Diesel, Diagnosis and Testing),
Fuel Charging and Controls
(303-04 Fuel Charging and
Controls
- 1.6L Duratorq-
TDCi (DV) Diesel, Diagnosis
and Testing).
Engine intake air system. CHECK the intake air system.
REFER to: lntake Air Distribu-
tion and Filtering
(303-12
lntake Air Distribution and
Filtering, Diagnosis and
Testing).
Exhaust system blocked. I CHECK the exhaust system.
REFER to: Exhaust System
(309-00 Exhaust System,
Description and Operation).
Engine management system.
CHECK the engine manage-
ment system.
REFER to: Electronic Engine
Controls (303-1 4 Electronic
Engine Controls, Diagnosis
and Testing).
Fault in ignition system (petrol
engines only). CHECK the ignition system.
REFER to:
Engine lgnition (303-07 Engine
Ignition, Diagnosis and
Testing),
Engine lgnition (303-07 Engine
lgnition
- 2.OL Duratec-HE
(M14), Diagnosis and
Testing).
2006.0 Fiesta 1212006 GI 52554en
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303-00-1 I Engine System - General Information 303-00-1 I
DIAGNOSIS AND TESTING
Symptom Possible
Sources Action --
Turbocharger (diesel engine
only).
CHECK the turbocharger.
REFER to:
Turbocharger (303-04
Fuel
Charging and Controls -
Turbocharger - 1.4L
Duratorq-TDCi (DV) Diesel,
Diagnosis and Testing),
Turbocharger (303-04
Fuel
Charging and Controls -
Turbocharger - 1.6L
Duratorq-TDCi (DV) Diesel,
Diagnosis and Testing).
Incorrect valve timing. Timing
beltltiming sprocket or
pulleylsprocket damaged. CHECK
and adjust the
valve
timing. REFER to:
Timing
Belt (303101 Engine -
I .25L Duratec-1 6V
(Sigma)ll.4L Duratec-1 6V
(Sigma)ll .6L Duratec-1 6V
(Sigma), In-vehicle Repair),
Timing Chain (303-01 Engine
- 1.3L Duratec-8V (Rocam),
In-vehicle Repair),
Crankshaft
Pulley (303-01
Engine
- 2.OL Duratec-HE
(M14), In-vehicle Repair),
Timing
Belt (303-01 Engine -
1.4L Duratorq-TDCi (DV)
Diesel, In-vehicle Repair),
Timing
Belt (303-01 Engine -
1.6L Duratorq-TDCi (DV)
Diesel, In-vehicle Repair).
Ignition timing incorrect (petrol
engines only).
CHECK the electronic engine
controls.
REFER to: Electronic Engine
Controls (303-1 4 Electronic
Engine Controls, Diagnosis
and Testing).
2006.0 Fiesta 1212006 GI 52554en
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