2007 FORD FIESTA gasket

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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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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100-00-12 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 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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206-00-31 Brake System - General Information 206-00-31
DIAGNOSIS AND TESTING
Type 1: An external leak may occur at the master
cylinder reservoir cap because of incorrect
( positioning of the gasket and cap. Reposition the
cap and gasket.
Type
2: An external leak may occur at the reservoir
mounting seals. Service such a leak by installing
new seals.
2006.0 Fiesta 1212006 G28494en
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206-07-8 Power Brake Actuation 206-07-8
REMOVAL AND INSTALLATION
Brake Booster - RHD(12 451 0)
Removal 2. Remove the brake booster actuating rod pin. (
1. Remove the brake master cylinder.
For additional information, refer to: Brake
Master Cylinder
- RHD (206-06 Hydraulic
Brake Actuation, Removal and Installation).
2. Disconnect the brake vacuum pipe from the
brake booster.
I. Unclip the brake vacuum pipe.
2. Disconnect the brake vacuum pipe.
3. Remove the instrument panel lower panel.
1. Remove the lower retaining screws.
2. Remove the upper retaining screws from the
stowage compartment.
3. Release the retaining clip. 5.
Remove
the brake booster.
Discard the gasket.
Installation
1. WARNINGS:
ADO not install an Emergency Brake Assist
(EBA) brake booster to a vehicle that is not
equipped with the Anti-lock Brake System
(ABS). Failure to follow this instruction may
result in personal injury.
ADO not use a damaged brake pedal.
Failure to follow this instruction may result
in personal injury.
4. Detach the brake booster actuating rod from CAUTIONS:
the brake pedal (accelerator pedal shown A Make sure that the brake booster gasket
removed for clarity).
is correctly positioned on the brake
I. Depress the clip. booster before installation. 41
A Do not drop or knock the brake pedal.
Failure to follow this instruction will cause
damage to the brake pedal decoupler
mechanism (if equipped).
2006.0 Fiesta 12/2006 G89214en
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206-07-9 Power Brake Actuation 206-07-9
REMOVAL AND INSTALLATION
N0TE:On vehicles equipped with EBA the brake
booster is identified by a white sticker showing a
( large letter "A.
N0TE:lnstall a new brake booster gasket.
To install, reverse the removal procedure.
2006.0 Fiesta 121~0o6 G89214en
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211 -02-24 Power Steering 211 -02-24
REMOVAL AND INSTALLATION
2. Disconnect the power steering pressure
(PSP) switch electrical connector. Support
the exhaust flexible pipe with a
support wrap or splint.
3. Detach the steering gear heat shield from 6. ACAUTION:Twisting the exhaust flexible the steering gear.
pipe more than two degrees may cause
4. N0TE:Note the position of the power steering
pump to steering gear pressure line to aid
installation.
Detach the power steering pump to steering
gear pressure line from the steering gear.
5m &AUTION:O~~~ bending of the exhaust
flexible pipe may cause damage resulting in
failure. damage
resulting in failure.
N0TE:Use a pry-bar to prevent the exhaust flexible
pipe from twisting when removing the exhaust
flexible pipe to catalytic converter retaining nuts.
Remove the exhaust flexible pipe to catalytic
converter retaining nuts.
Discard the exhaust flexible pipe to catalytic
converter gasket and retaining nuts.
7m &AUTION:T~~~ care when removing the
exhaust hanger insulator to prevent damage.
2006.0 Fiesta 1212006 G458165en
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