2007 FORD FIESTA maintenance

Handles, Locks, Latches and Entry Systems 501-14
Wipers and Washers 501-16
Bumpers 501-19
Safety Belt System 50
I -20A
Supplemental Restraint
System 501 -20B
Body Repairs
- General
Information 501 -25
Body Repairs
- Vehicle Specific
lnformation and Tolerance
Checks 501 -26
To the best of our knowledge, the illustrations,
technical information, data and descriptions in
this issue were correct at the time of going to
print. The right to change prices, specifications,
equipment and maintenance instructions at
any time without notice is reserved as part of
FORD policy of continuous development and
improvement for the benefit of our customers.
No part of this publication may be reproduced,
stored in a data processing system or
transmitted in any form, electronic, mechanical,
photocopy, recording, translation or by any
other means without prior permission of
Ford-Werke Aktiengesellschaft. No liability can
be accepted for any inaccuracies in this
publication, although every possible care has
been taken to make it as complete and
accurate as possible.
Copyright
O
FORD-WERKE AKTIENGESELLSCHAFT
Service training programs D-FIGT-1
Printed in Germany
- rewi druckhaus, Wissen -
Printed on environmentally friendly
chlorine-free paper. (GB) Front End Sheet Metal Repairs
50 1 -27
Roof Sheet Metal Repairs 50 1 -28
Side Panel Sheet Metal Repairs 501 -29
Rear End Sheet Metal Repairs 501
-30
Paint
- General Information 501
-36
Frame and Mounting
Uni-Body, Subframe and Mounting
System 502-00
0512005 2006.0 Fiesta
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100-00-6 General Information 100-00-6
DESCRIPTION AND OPERATION
Health and Safety Precautions
Introduction
Many of the procedures associated with vehicle
maintenance and repair involve physical hazards
or other risks to health. This subsection lists,
alphabetically, some of these hazardous operations
and the materials and equipment associated with
them. Precautions necessary to avoid these
hazards are identified.
The list is not exhaustive and all operations and
procedures, and the handling of materials, should
be carried out with health and safety in mind.
Before using any product the Materials Safety Data
Sheet supplied by the manufacturer or supplier
should be consulted.
Acids and Alkalis
See also Battery Acids.
For example caustic soda, sulphuric acid.
Used in batteries and cleaning materials.
Irritant and corrosive to the skin, eyes, nose and
throat. Cause burns. Can destroy ordinary
protective clothing.
Avoid splashes to the skin, eyes and clothing. Wear
suitable protective impervious apron, gloves and
goggles. Do not breath mists.
Make sure access to eye wash bottles, shower and
soap are readily available for splashing accidents.
Display Eye Hazard sign.
Air Bags
See also Fire, Chemical Materials.
Highly flammable, explosive
- observe No Smoking
policy.
Used as a safety restraint system mounted in the
steering wheel and passenger side of the instrument panel.
The inflator contains a high-energetic propellant
which, when ignited, produces a VERY HOT GAS
(2500°C).
The gas
generant used in air bags is Sodium Azide.
This material is hermetically sealed in the module
and is completely consumed during deployment.
No attempt should be made to open an air bag inflator
as this will lead to the risk of exposure to
( '.
Sodium Azide. If a gas generator is ruptured, full
protective clothing should be worn when dealing
with the spillage.
After normal deployment, gloves and safety goggles must be worn during the handling process.
Deployed air bags should be disposed of in a
plastic bag in accordance with local regulations at
an approved chemical waste site.
Following any direct contact with gas generant.
- wash affected areas thoroughly with water.
- seek medical assistance if necessary.
Air Bags
- Do's
- Do store modules in an upright position.
- Do keep modules dry.
- Do carry modules with the cover side pointing
away from the body.
- Do place modules with their cover side upwards.
- Do carefully inspect modules for damage.
- Do stand to one side when connecting modules.
- Do make sure all test equipment is properly
calibrated and maintained.
- Do wash hands after handling deployed air
bags.
Air Bags
- Do Nots
- Do not store highly flammable material together
with modules or gas generators.
- Do not store gas generators at temperatures
exceeding 80°C.
- Do not store modules upside down.
- Do not attempt to open a gas generator housing.
- Do not expose gas generators to open flame or
sources of heat.
- Do not place anything on top of a module cover.
- Do not use damaged modules.
- Do not touch a fired module or gas generator
for at least
10 minutes.
- Do not use any electrical probes on the wiring
circuit.
Air Conditioning Refrigerant (1,
See also Chlorofluorocarbon, Chemical Materials
Highly flammable, combustible
- observe No
Smoking policy.
2006.0 Fiesta iu200s GI 7372en
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100-00-1 1 General Information 100-00-1 1
DESCRIPTION AND OPERATION
First Aid
Apart from meeting any legal requirements it is
desirable for someone in the workshop to be
trained in First Aid procedures.
Splashes in the eye should be flushed carefully
with clean water for at least ten minutes.
Soiled skin should be washed with soap and water.
In case of cold burns, from alternative fuels, place
affected area in cool to cold water.
Individuals affected by inhalation of gases and
fumes should be removed to fresh air immediately.
If effects persist, consult a doctor.
If liquids are swallowed inadvertently, consult a
doctor giving him the information on the container
or label. Do not induce vomiting unless this action
is indicated on the label.
Fluoroelastomer
See Viton.
Foams - Polyurethane
See also Fire.
Used in sound and noise insulation. Cured foams
used in seat and trim cushioning.
Follow manufacturers instructions.
Unreacted components are irritating and may be
harmful to the skin and eyes. Wear gloves and
goggles.
Individuals with chronic respiratory diseases,
asthma, bronchial medical problems, or histories
of allergic diseases should not work in or near
uncured materials.
The components, vapors or spray mists can cause
direct irritation, sensitivity reactions and may be
toxic or harmful.
Vapors and spray mists must not be inhaled. These
materials must be applied with adequate ventilation
and respiratory protection. Do not remove the
respirator immediately after spraying; wait until the
vapors/mists have cleared.
Burning of the uncured components and the cured
foams can generate toxic and harmful fumes.
Smoking, naked flames or the use of electrical
equipment during foaming operations and until
vapors/mists have cleared should not be allowed.
Any heat cutting of cured foams or partially cured foams
should be conducted with extraction
ventilation. See also the vehicle Body Repair
Manual.
Freon
See Air Conditioning Refrigerant.
Fuels
See also, Fire, Legal Aspects, Chemicals and
Solvents.
Avoid skin contact with fuel where possible. Should
contact occur, wash the affected skin with soap
and water.
Gasoline (Petrol)
Highly flammable - observe No Smoking policy.
Swallowing can result in mouth and throat irritation
and absorption from the stomach can result in
drowsiness and unconsciousness. Small amounts
can be fatal to children. Aspiration of liquid into the
lungs, through vomiting, is a very serious hazard.
Gasoline dries the skin and can cause irritation
and dermatitis on prolonged or repeated contact.
Liquid in the eye causes severe smarting.
Motor gasoline may contain appreciable quantities
of benzene, which is toxic upon inhalation, and the
concentration of gasoline vapors must be kept very
low. High concentrations will cause eye, nose and
throat irritation, nausea, headache, depression and
symptoms of drunkenness. Very high
concentrations will result in rapid loss of
CO~SC~OUS~~SS.
Make sure there is adequate ventilation when
handling and using gasoline. Great care must be
taken to avoid the serious consequences of
inhalation in the event of vapor build up arising
from spillages in confined spaces.
Special precautions apply to cleaning and
maintenance operations on gasoline storage tanks.
Gasoline should not be used as a cleaning agent.
It must not be siphoned by mouth. See First Aid.
Gasoil (Diesel Fuel)
Com busti ble.
2006.0 Fiesta 1212006 GI 7372en
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303101 B-9 Engine - 2.OL Duratec-HE (M14) 303-01 B-9
DESCRIPTION AND OPERATION
The complete engine is made of cast aluminum
which, when combined with the plastic intake
manifold, gives a very light unit.
2.OL Duratec-HE (M14) engine
Emission standard
N0TE:Due to the fine tolerance in the bearing
clearances and bearing shells, no service
operations whatsoever are permitted on the crank
assembly. In the event of damage, the complete
cylinder block and crank assembly must be
changed. European
Emissions Standard Stage
IV (Stage II I, depending
on country)
Further design features include a ladder frame
incorporating the main bearing caps which support
the crankshaft in the cylinder block, and the
deep-drawn side walls of the cylinder block which
reduce engine vibration.
The camshafts are driven by a pinned link chain
which runs very quietly and is also
maintenance-free.
Cvlinder head
Item Description
1
2
The engine management for the 2.OL Duratec-HE
(M14) is provided by a Visteon system.
Item Description
Exhaust camshaft
Camshaft bearing cap
', This engine management systems controls the ' , sequential multipoint fuel injection (SFI) and the
I 1 (Enngine code I
3
4
wl~n~ine serial number I
Cam to identify cylinder No. 1
Intake camshaft
ele~tronically controlled coolant-cooled exhaust The design and the valve arrangement in the gas recirculation (EGR) valve.
cylinder head is similar to the head of the Zetec-SE
engines.
Enaine codes
5
The engine code and the engine serial number are
stamped on the right-hand side of the cylinder block
on the flywheel side of the engine. Camshaft sprockets
Cvlinder
head gasket
Item Description
I 1 I Cylinder head gasket I
1 2 1 Locating dowels 1
A four-layer laminated steel cylinder head gasket
is used.
The cylinder head gasket and cylinder head are
located with two locating dowels.
2006.0 Fiesta 1212006 G461395en
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303-01 B-I 0 Engine - 2.OL Duratec-HE (M14) 303-01 B-I 0 - -- --
DESCRIPTION AND OPERATION
Valve tappets Camshaft drive
Item Description
I 1 I Exhaust valve tappet I
1 2 1 Intake valve tappet I
Mechanical tappets are fitted without adjusting
shims.
Due to the special materials and the optimized
camshaft profiles, the wear in the area of the valve
gear is so minute that checking and adjustment of
the valve clearances is only necessary after the
engine has been in extensive service.
Different sizes of replacement valve tappets are
I ELE0023383
available in the event of wear or repairs to the valve ' '2
gear. Item Description
I 1 I Exhaust camshaft sprocket
1 2 I Timing chain I
1 3 1 Intake camshaft sprocket I
1 4 I ~imin~ chain guide I
1 5 1 Crankshaft sprocket I
1 6 1 Hydraulic timing chain tensioner I
1 7 1 ~imin~ chain tensioner arm 1 - -
The camshafts are driven by a low-noise,
maintenance-free pinned link timing chain.
The timing chain is lubricated by the engine oil
circuit.
An elongated timing chain guide and a timing chain
tensioner arm ensure optimum timing chain
guidance and silent running.
The timing chain is tensioned by a hydraulic timing
chain tensioner which is supplied from the engine
,.
oil circuit.
The timing chain tensioner can be used again after
removal.
The camshaft drive requires no maintenance.
2006.0 Fiesta 1212006 G461395en
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303-01 B-I 3 Engine - 2.OL Duratec-HE (M14) 303-01 B-I 3
DESCRIPTION AND OPERATION
Oil pump Oil Pump Drive I I I I
Item Description
I I I Oil pump I
1 2 1 Oil pump outer rotor I
1 3 1 Oil pump inner rotor I
A rotor oil pump is used for engine lubrication.
The rotor oil pump is a positive displacement pump
with an internally toothed outer rotor and an
externally toothed inner rotor.
The rotor pump works very evenly, can produce
high pressures and is therefore fundamental for
optimum engine lubrication.
Item Description -- -
I 1 I Crankshaft sprocket I
1 2 1 Oil pump chain tensioner I
1, 3 1 Oil pump sprocket I
1 4 1 Oil pump chain I
1 5 1 Oil pump chain guide I
The oil pump is mounted on the cylinder block, on
the engine front cover side at the bottom and driven
directly from the crankshaft by a separate driving
chain.
A oil pump chain guide and an oil pump
spring-loaded chain tensioner ensure quiet maintenance-free operation.
2006.0 Fiesta 12/2006 G461395en
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