2007 FORD FIESTA trim

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
Body and Paint
SECTION TITLE PAGE
Body and Paint
........................................................................\
.... Body System . General Information .50 1.00
........................................................................\
......................... Front End Body Panels .50 1.02
........................................................................\
........................................ Body Closures 501 -03
Interior Trim and Ornamentation ........................................................................\
............ 501-05
........................................................................\
.......... Exterior Trim and Ornamentation .50 1-08
........................................................................\
.................................. Rear View Mirrors 50 1 -09
........................................................................\
................................................... Seating 501 -10
........................................................................\
........... Glass, Frames and Mechanisms .SO1 1-1
........................................................................\
............... Instrument Panel and Console 502 1-1
............................................................... Handles, Locks, Latches and Entry Systems -501 -1 4
........................................................................\
............................. Wipers and Washers -501 -1 6
Bumpers ........................................................................\
................................................. 501 -1 9
........................................................................\
................................. Safety Belt System 50 I -2OA
........................................................................\
............. Supplemental Restraint System .50 I -2OB
Body Repairs - General Information ........................................................................\
...... 501-25
Body Repairs - Vehicle Specific Information and Tolerance Checks ............................. 501-26
........................................................................\
............. Front End Sheet Metal Repairs .50 1-27
........................................................................\
..................... Roof Sheet Metal Repairs -50 I -28
Side Panel Sheet Metal Repairs ........................................................................\
............ 501-29
........................................................................\
.............. Rear End Sheet Metal Repairs 50 1-30
........................................................................\
.................... Paint - General Information 501 -36
Frame and Mounting
Uni-Body, Subframe and Mounting System ................................................................... 502-00
0512005 2006.0
Fiesta
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100-00-1 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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100-01 -5 Identification Codes 1 00-01-5
DESCRIPTION AND OPERATION
Vehicle Certification Label (Typical) or VIN Plate
Item Description
I 1 I National or whole vehicle type approval I
1 3 1 Gross vehicle mass (GVM) I
1 4 1 Gross train mass (GTM) I
1 5 1 Maximum permissible front axle mass I
~l~aximum permissible rear axle mass I
1 7 1 Smoke value (diesel only) I
1 8 1 Model body or type I
1 9 1 Model type I
Item Description
1 1 0 1 Door combination I
I 11 I Exhaust emission level codes I
112 1 Body color codes I
1 13 1 Interior trim codes I
1 14 1 Transaxle final drive ratio I
1 15 1 Transaxle codes I
1 16 1 Engine codes I
Items 1 to 6: Vehicle Certification Label
--
17
18 Hand
of drive
Axle mounting (Transit only)
--
2006.0 Fiesta 1212006 G413286en
Item
ltem 1: National or whole vehicle type approval
Item 2: VIN
Item 3: GVM
Details
A unique code required by legislation in certain
territories.
Vehicle identification number.
Indicates maximum legal laden mass, in territories
where this is required.
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100-01-7 Identification Codes 100-01 -7
DESCRIPTION AND OPERATION
Item 13: lnterior Trim Codes
Code
R
U
W
Z
1
2
3
6
7
8
Body Color
Honour Green
Neptune Green
Ink Blue
Flare
Sublime
Aquarius Vitro
Moondust Silver
Machine Silver
Deep Navy
2006.0 Fiesta 1212006 G413286en
For vehicles built in continental plants, the second digit of the paint code, on the VIN label, denotes the original model year of
the color's introduction,
('O1=color introduction in 2000 model year).
Code
AT
BR
DC
DM
FB
FC
FP FT
GM
HH
IW
JH
LM MI
MT
NM
QB QL
QM
QZ
Q2 Interior
Trim
Dogtooth - Mamara Blue
Compass
- Blue
Cord
- Dark Flint
Mirage
- Plum
Bussac - Medium Flint
Cord
- Medium Flint
Metropolitan
- Medium Flint
Dogtooth - Medium Flint
Mirage
- Green
Humy
- Dark Flint - Dark Flint
Wire
- lnfra Red
Humy
- Dark Flint - Ebony
Mirage
- Medium Light Flint
lntro
- Midnight Black
Dogtooth - Midnight Black
Mirage
- Tan
Bussac - Ebony
Leather
- Ebony
Mirage
- Ebony
Leather
- Ebony
Leather
- Ebony
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I 00-01 -8 Identification Codes 100-01 -8
DESCRIPTION AND OPERATION
I Code I Interior Trim I
I TB I Bussac - Light Stone I
RK
RR
I TL I Leather - Light Stone 1
- -
Compass - Red
Compass
- Red
I VK I Compass - Silver I
ltem 14: Transaxle Final Drive Ratio
ltem 15: Transaxle Codes Code
A
B
M
R 3
4
Transaxle Final Drive Ratio
3.37
4.06
4.05
4.25
4.375
3.82
Code Transaxle
5-Speed Manual Transaxle (iB5)
I A I 1.3L Duratec-8V (Rocam) (60PS) I
B
C
ltem 16: Engine Codes
I H I 1.6L Duratorq-TDCi (DV) Diesel (90PS) I
5-Speed Manual Transaxle (iB5) Automated Shift Manual
4-Speed Automatic Transaxle
(AW81- 40LE)
Code Engine
I Y I 1.6L Duratec-1 6V (Sigma) (1 OOPS) 1
U
X
I 6 I 1.4L DuraTorq-TDCi (DV) (68PS) I
1.25L Duratec-1 6V (Sigma) (75PS)
1.4L Duratec-1 6V (Sigma) (80PS)
I 7 I 1.25L Duratec-I 6V (Sigma) (70PS) I
I 9 I 1.3L Duratec-8V (Rocam) (70PS) I
ltem 17: Hand of Drive
(I
Code
1
2
3
2006.0 Fiesta 1212006 G413286en
Drive
Left-hand drive
Right-hand drive Left-hand drive
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100-04-4 Noise, Vibration and Harshness 100-0414
DIAGNOSIS AND TESTING
Noise, Vibration and Harshness (NVH)
Inspection and Verification
1. Verify the customer concern. Identify the Condition
2. Visually inspect for obvious signs of mechanical NVH usually occur in four areas:
or electrical damage.
tires
3. If an obvious cause for an observed or reported
concern is found, correct the cause (if possible) engine accessories
before proceeding to the next step.
suspension
4. If the concern is not visually evident, verify the
symptom and REFER to the Symptom Chart.
How to Use this Diagnostic Procedure
Section
Noise, vibration and harshness (NVH) concerns
have become more important as
vehjcles have
become more sensitive to these vibrations. This
section is designed to aid in identifying these
concerns.
The section provides diagnostic procedures based on symptom. If the condition occurs at
high speed, for instance, the most likely place
to start is under Shake and Vibration While
Driving.
The road test procedure will tell how to sort the
conditions into categories and how to tell a
vibration from a shake.
A series of Road Test Quick Checks are
provided to make sure that a cause is either
pinpointed or eliminated.
Name the condition, proceed to the appropriate
section and locate the correct diagnosis. When
the condition is identified, the job is partly done.
Follow the diagnostic procedure as outlined.
Quick Checks are described within the step,
while more involved tests and adjustments are
outlined in General Procedures.
Always follow each step exactly and make notes
to recall important findings later.
driveline
It is important, therefore, that an NVH concern be
isolated into its specific
area(s) as soon as
possible. The easiest and quickest way to do this
is to carry out the Road Test as outlined. To assist
in the diagnosis and testing
procedure(s), use a
suitable approved NVH diagnosis tester.
Noise Diagnostic Procedure
Non-Axle Noise
The five most common sources of non-axle noise
are exhaust, tires, roof racks, trim panels and
( transmission.
Therefore, make sure that none of the following
conditions are the cause of the noise before
proceeding with a driveline
teardown and
diagnosis.
In certain conditions, the pitch of the exhaust
may sound very much like gear noise. At other
times, it can be mistaken for a wheel bearing
rumble.
Tires, especially snow tires, can have a high
pitched tread whine or roar, similar to gear
noise. Radial tires may have this characteristic.
Also, any non-standard tire with an unusual
tread construction may emit a roar or whine
noise.
Trim panels can also cause whistling or whining
noise.
Clunk may be a metallic noise heard when the
Customer Interview automatic transaxle is engaged in "R
(REVERSE) or "D" (DRIVE) or it may occur
The road test and customer interview (if available) when
the throttle is applied or released. It is
provide information that will help identify the caused
by backlash somewhere in the driveline.
,
concern and will provide direction to the correct Bearing rumble sounds like marbles being
starting point for diagnosis. (
tumbled. This condition is usually caused by a
damaged wheel bearing.
2006.0 Fiesta 1212006 G37349en
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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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