Ford Fiesta 2007 User Manual

2007 WQ Fiesta CONTENTS

(including XR4)

Repair Manual

Registered at the National Library,

Canberra, ACT Australia

ISBN 1 921140	151	(Set)
ISBN 1 921140	16X	(Volume 1)
ISBN 1 921140	178	(Volume 2)
ISBN 1 921140 186		(Volume 3)

O 2007 Ford Motor Company of Australia Ltd.

RegisteredOffice: CAMPBELLFIELD,VICTORIA

A.B.N. 30 004 116 223

Reproduction in whole or in part is prohibited without written approval.

PRINTED IN AUSTRALIA. May 2007

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-16V (Sigma)/l.4L Duratec-16V (Sigma)/l.GL Duratec-I6V (Sigma)

Engine - 2.OL Duratec-HE

(MI41

Engine Cooling - 1.3L Duratec-8V (Rocam)/l.25L Duratec-16V (Sigma)/l.4L Duratec-16V (Sigma)/l .6L Duratec-16V (Sigma)

Engine Cooling - 2.OL Duratec-HE

(MI41

Fuel Charging and Controls - 1.25L Duratec-16V (Sigma)/l.4L Duratec-16V (Sigma)/l.GL Duratec-16V (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-16V (Sigma)/l.4L

Duratec-16V (Sigma)/l .6L Duratec-16V (Sigma)

Engine Emission Control - 2.OL Duratec-HE (M14)

05/2005 2006.0 Fiesta

	IntakeAir Distribution and
-	Filtering	303-12
	Evaporative Emissions	303-13
	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
	(AW81-40)	307-05
	ManualTransmissionrrransaxle,Clutch and
	Transfer Case
	Manual TransmissionlTransaxle and
	Clutch - General Information	308-00
	Clutch	308-01
	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	310-00
	Fuel Tank and Lines	310-01
	Acceleration Control - I.3L Duratec-8V
	(Rocam)ll.25L Duratec-I6V
	(Sigma)ll.4L Duratec-I6V
	(Sigma)/l .6L Duratec-16V
	(Sigma)	310-02A
	Acceleration Control - 2.OL Duratec-HE
	(M14)	310-028

GROUP 4 Electrical

Climate Control System

Climate Control System - General

Information

Air Distributionand Filtering

Heating and Ventilation

Air Conditioning

Control Components

Instrumentation and Warning Systems		(
lnstrument Cluster and Panel
Illumination	413-00
Instrument Cluster	413-01
Horn	413-06
lnformation and Message
Center	413-08
Warning Devices	413-09
Parking Aid	413-13
Battery and Charging System
Charging System - General
Information	414-00
Battery, Mounting and Cables	414-01
Generator and Regulator	414-02
lnformation and Entertainment Systems
lnformation and Entertainment System
- General Information	415-00
Audio Unit	415-01
Antenna	415-02
Lighting
Exterior Lighting	417-01
Interior Lighting	417-02	( 'j
Electrical Distribution
Module Communications
Network	418-00
Module Configuration	418-01
Electronic Feature Group
Anti-Theft - Active	419-01A
Anti-Theft - Passive	419-01B
Cellular Phone	419-08
MultifunctionElectronic
Modules	419-10
GROUP 5 Body and Paint
Body and Paint
Body System - General	501-00
Information
Front End Body Panels	501-02
Body Closures	501-03
lnterior Trim and
Ornamentation
Exterior Trim and
Ornamentation
Rear View Mirrors
Seating
Glass, Frames and
Mechanisms
Instrument Panel and Console	501-12

0512005 2006.0 Fiesta

501-14

501-16

501-19

50I-20A

501-20B

501-25

Handles, Locks, Latches and Entry Systems

Wipers and Washers Bumpers

Safety Belt System Supplemental Restraint

System

Body Repairs - General Information

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 rightto change prices, specifications, equipment and maintenance instructions at any time without notice is reserved as part of FORD policy of continuous development and improvementfor the benefit of our customers.

No part of this publicationmay 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-WerkeAktiengesellschaft. No liabilitycan 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-WERKEAKTIENGESELLSCHAFT

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	501-27
Roof Sheet Metal Repairs	501-28
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

GROUP

General Information

SECTION TITLE	PAGE
Service Information
General Information.....................................................................................................	100-00
Identification Codes.....................................................................................................	100-01
Jacking and Lifting.......................................................................................................	100-02
Noise, Vibration and Harshness................................................................................	100-04

0562005 2006.0 Fiesta

GROUP

Chassis

SECTION TITLE	PAGE
Suspension
Suspension System .General Information....................................................................	204-00
Front Suspension..........................................................................................................	24.0 1
Rear Suspension..........................................................................................................	204.02
Wheels and Tires..........................................................................................................	204-04
Driveline
Front Drive Halfshafts....................................................................................................	205-04
' Brake System
Brake System .General Information..............................................................................	206-00
Drum Brake..................................................................................................................	206.02
Front Disc Brake...........................................................................................................	206-03
Rear Disc Brake............................................................................................................	206-04
Parking Brake and Actuation.........................................................................................	206-05
Hydraulic Brake Actuation..............................................................................................	206-06
Power Brake Actuation..................................................................................................	206-07
Anti-Lock Control..........................................................................................................	206.09A
Anti-Lock Control .Traction Control...............................................................................	206-09B
Anti-Lock Control .Stability Assist.................................................................................	206-09C
Steering System
Steering System .General Information.........................................................................	211.00
Power Steering.............................................................................................................	- 211-02
Steering Linkage..........................................................................................................	- 211-03
Steering Column...........................................................................................................	211-04
Steering Column Switches.............................................................................................	211-05

0512005 2006.0 Fiesta

GROUP

Powertrain

SECTION TITLE	PAGE
Engine
Engine System .General Information............................................................................	303-00
Enginel.25L Duratec-I6V (Sigma)ll.4L Duratec-16V (Sigma)ll .6L Duratec-I6V	-303-0IA
(Sigma)......................................................................................................................
Engine2.0L Duratec-HE (M14).......................................................................................	303-01B
Engine Cooling1.3L Duratec-8V (Rocam)ll.25L Duratec-I6V (Sigma)ll.4L
Duratec-16V (Sigma)ll.6L Duratec-16V (Sigma)......................................................	303-03A
Engine Cooling2.0L Duratec-HE (M14)..........................................................................	303-038
Fuel Charging and Controlsl.25L Duratec-16V (Sigma)ll.4L Duratec-16V
(Sigma)ll .6L Duratec-16V (Sigma)...........................................................................	.303-0414
Fuel Charging and Controls2.0L Duratec-HE (M14).......................................................	303-04B
Accessory Drive............................................................................................................	.303-05
Starting System..............................................................................................................	303-06
Engine Ignition...............................................................................................................	303-07A
Engine Ignition2.01Duratec-HE (M14)...........................................................................	303-07B
Engine EmissionControll.3L Duratec-8V (Rocam)ll.25L Duratec-16V (Sigma)ll.4L
Duratec-16V (Sigma)ll.6L Duratec-16V (Sigma)......................................................	303-08A
Engine Emission Control2.0L Duratec-HE (M14)...........................................................	303-088
Intake Air Distributionand Filtering................................................................................	303-12
Evaporative Emissions..................................................................................................	303-13
Electronic Engine Controls............................................................................................	330-14
Automatic Transmission/Transaxle
Automatic Transmission/TransaxleVehiclesWith: 4-Speed Automatic Transmission
(AW81.40) .................................................................................................................	37.0 1
Transmission/Transaxle CoolingVehicles With: 4-Speed Automatic Transmission
(AW81-40)..................................................................................................................	307-02
Automatic TransmissionlTransaxle External ControlsVehiclesWith: 4-Speed
Automatic Transmission (AW81-40)..........................................................................	307.05
Manual Transmission/Transaxle. Clutch and Transfer Case
Manual Transmission/Transaxleand Clutch .General Information...............................	308-00
Clutch............................................................................................................................	38.0 1
Clutch Controls.............................................................................................................	308.02
Manual TransmissionlTransaxle....................................................................................	308-03
Manual TransmissionlTransaxle External Controls........................................................	308-06

0512005 2006.0 Fiesta

Exhaust System

( I

Exhaust System.............................................................................................................	309-00
Fuel System
Fuel System - General Information............................................................................	3 1 0 - 0 0
Fuel Tank and Lines...................................................................................................... .310-01
Acceleration Controll.3L Duratec-8V (Rocam)ll.25L Duratec-16V (Sigma)ll.4L
Duratec-16V (Sigma)ll.6L Duratec-16V (Sigma).......................................................	310-02A
Acceleration Control2.0L Duratec-HE (M14)..............................................................	3 0 - 0 2 B

0512005 2006.0 Fiesta

GROUP

Electrical

	SECTION TITLE	PAGE
	Climate Control System	4 2 - 0 0
	Climate Control System .General Information..........................................................
	Air Distributionand Filtering...........................................................................................	412-01
	Heating and Ventilation.................................................................................................	412-02
	Air Conditioning.............................................................................................................	412.03
	Control Components.....................................................................................................	412.04
i	Instrumentationand Warning Systems	-413-00
	Instrument Cluster and Panel Illumination....................................................................
	Instrument Cluster.........................................................................................................	413-01
	Horn..............................................................................................................................	-413-06
	Information and Message Center...................................................................................	413-08
	Warning Devices...........................................................................................................	-413-09
	Parking Aid.....................................................................................................................	413-13
	Battery and Charging System
	Charging System .General Information.....................................................................	1 4 - 0 0
	Battery, Mounting and Cables.......................................................................................	-414-01
	Generator and Regulator..............................................................................................	414-02
	lnformation and Entertainment Systems
	Information and Entertainment System .General Information.....................................	415-00
	Audio Unit......................................................................................................................	1 5 - 0 1
	Antenna.........................................................................................................................	415-02
	Lighting	417.01
	Exterior Lighting............................................................................................................
	Interior Lighting.............................................................................................................	-417-02
	Electrical Distribution	1 8 - 0 0
	Module Communications Network.................................................................................
	Module Configuration.....................................................................................................	418-01
	Electronic Feature Group
	Anti-Theft - Active..........................................................................................................	419-OIA
	Anti-Theft .Passive.......................................................................................................	4I9-0IB
	Cellular Phone...............................................................................................................	4 19-08
	Multifunction Electronic Modules...................................................................................	419-10

0512005 2006.0 Fiesta

GROUP

Body and Paint

SECTION TITLE	PAGE
Body and Paint
Body System .General Information............................................................................	.501.00
Front End Body Panels.................................................................................................	.501.02
Body Closures................................................................................................................	501-03
Interior Trim and Ornamentation....................................................................................	501-05
Exterior Trim and Ornamentation..................................................................................	.501-08
Rear View Mirrors..........................................................................................................	501-09
Seating...........................................................................................................................	501-10
Glass, Frames and Mechanisms...................................................................................	S1O-11
Instrument Panel and Console.......................................................................................	5 10-12
Handles, Locks, Latches and Entry Systems...............................................................	-501-14
Wipers and Washers.....................................................................................................	-501-16
Bumpers.........................................................................................................................	501-19
Safety Belt System.........................................................................................................	50I-2OA
Supplemental Restraint System.....................................................................................	50I-2OB
Body Repairs - General Information..............................................................................	501-25
Body Repairs - Vehicle Specific Information and Tolerance Checks.............................	501-26
Front End Sheet Metal Repairs.....................................................................................	501-27
Roof Sheet Metal Repairs.............................................................................................	-50I-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

100-00-1

General Information

100-00-1

. SECTION 100-00 General lnformation

VEHICLE APPLICATION:2006.0 Fiesta
CONTENTS	PAGE
DESCRIPTIONAND 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.....................................................................................................................

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......................................................................................................................

100-00-3

General Information

100-00-3

DESCRIPTION AND OPERATION

About This Manual

-- . Introduction

This manual has been written in a format that is designed to meet the needs of technicians worldwide. The objective isto use common formats and include similar content in each manual.

This manual provides general descriptions for accomplishing diagnosis and testing, service and repair work with tested, effective techniques. Following them will help assure reliability.

Special Tools

The special tool(s) table provided at the beginning of each procedureshows all special tools required to carry out a repair. Where possible, illustrations are providedto assist in identifyingthe special tool required.

Important Safety Instructions

Appropriate service methods and correct repair --.!procedures are essential for the safe, reliable

operation of all motor vehicles as well as the personal safety of the individual carrying out the work.

This manual cannot possibly anticipate all such variations and provide advice or cautions as to each. Anyone who departs from the instructions provided in this manual must first establish that he compromises neither his personal safety nor the vehicle integrity by his choice of methods, tools or components.

Warnings, Cautions and Notes in This

Manual

A WARN1NG:Warnings are used to indicate that failure to follow a procedurecorrectly may result in personal injury.

A CAUTI0N:Cautions are used to indicate that failure to follow a procedurecorrectly may result in damage to the vehicle or equipment being used.

,, N0TE:Notes are used to provide additional

essential information required to carry out a complete and satisfactory repair.

AS YOU read through this manual, YOU will come across WARNINGS, CAUTIONS and NOTES.

A warning, caution or note is placed at the beginningof a series of steps if it applies to multiple steps. If the warning, caution or note only applies to one step, it is placed at the beginning of the specific step (after the step number).

How to Use This Manual

This manual covers diagnosis and testing, service and repair procedures.

This manual is structuredinto groups and sections, with specific system sections collected together under their relevant group.

A group covers a specific portion of the vehicle. The manual is divided into five groups, General Information, Chassis, Powertrain, Electrical and Body and Paint. The number of the group is the first number of a section number.

Pages at the start of the manual list all sections available. Eachsection has a contents listdetailing Specifications, Description and Operation, Diagnosis and Testing, In Vehicle Repairs, Disassembly and Assembly, Removal and Installation.

If components need to be removed or disassembled in sequence, the sequence will be identified numerically in a graphic and the corresponding text will be numbered accordingly.

All left and right-hand referencesto the vehicle are taken from a position sitting in the driver seat looking forward.

All left and right-hand referencesto the engine are taken from a position at the flywheel looking towards the front camshaft pulley.

Where appropriate, instructions will be given for the use of the diagnostic tool.

Overview Procedures

Overview procedures contain an exploded view illustration(s). The numbered sequence within the illustration(s) indicatethe order to be followed when removingldisassembling or when

installinglassembling a component. Additional information,symbol(s) or a torque figure, may also

be shown alonaside the com~onent.

There are ten symbols used to give additional

informationwhen removina/disassemblincror when

/"itallinglac&ponent. V

2006.0 Fiesta 1212006

GI 7371en

100-00-4

General Information

100=00=4

DESCRIPTION AND OPERATION

Item	Designation	Description
1	Special tool	A special tool is required for this component. There will also
		be a removal or installation symbol alongside the special
		tool symbol.
2	Install new component	Discard the old component and install a new component.
3	lnspect	Check the component for damage.
4	Apply sealant	Apply sealant to the component as specified in the mate-
		rials table.
5	Apply petroleumjelly	Apply petroleumjelly to the component as specified in the
		materials table.
6	Apply oil	Apply oil to the componentas specified in the materialstable.
7	Apply fluid	Apply fluid to the component as specified in the materials
		table.
8	Apply grease	Apply grease to the component as specifiedin the mate-rials
		table.
9	Removal or Disassembly	Go to the removal or disassembly detail for additional
	detail	information to remove or disassemble a component
10	Installation or Assembly	Go to the installation or assembly detail for additional
	detail	information to install or assemble a component

lnspection and Verification

Visual lnspection Charts, Symptom Charts and other information charts (such as diagnostic routines) or supplement test procedureswith technical specifications will navigate the user to a specific test procedure.

Symptom Chart

The symptom chart indicates symptoms, sources and actions to address a condition.

Pinpoint Tests

For electricalsystems, pinpointtest steps are used to identify the source of a concern in a logical, step-by-step manner. pinpoint tests have two columns: CONDITIONS and DETAILSIRESULTSIACTIONS.

The CONDITIONS column is used exclusively for graphics and icons (with or without captions) and the DETAILSIRESULTSIACTIONScolumn provides direction to another test step or specific corrective actions.

The boxed numbers indicatethe order in which the described action is to be performed.

2006.0 Fiesta 1212006

G I7371en

100-00-5 General Information 100-00-5

DESCRIPTIONAND OPERATION

Component Tests

'A component test is used when a component is tested in multiple pinpoint tests, or if a procedure is too complicated to be formatted within a single page of the pinpoint test.

Graphics

Test graphics show the measurement or test to be performed in a test step.

A representative tester graphic is used for voltmeters and ohmmeters.

If multiple measurements are made in a single graphic, the test leads are drawn with a solid line until the test lead splits to indicate the multiple measurements,at which point dashed lines are used.

Breakout box-type testers are represented by a double circle test pin. Test pins are labeled with the pin number.

Special Tools and Torque Figures

Any requirement for special tools will picture the tool, showing it in use and with its tool number

(\	'shown. Torque settingswill be given at the relevant
	point in the procedure.

2006.0 Fiesta 1212006

GI 7371en

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 hazardousoperations 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 productthe Materials Safety Data Sheet supplied by the manufacturer or supplier should be consulted.

Acids and Alkalis

See also BatteryAcids.

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 splashesto 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.

Highlyflammable, 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 SodiumAzide. 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 beworn 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 moduleswith 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 highlyflammable materialtogether 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 Fiestaiu200s

GI 7372en

100-00-7

General Information

100-00-7

DESCRIPTION AND OPERATION

Skin contact may result in frostbite.

Instructions given by the manufacturer must be followed. Avoid naked lights, wear suitable protective gloves and goggles.

If refrigerant comes into contact with the skin or eyes, immediately rinse the affected areas with water. Eyes should also be rinsed with an appropriate irrigation solution and should not be rubbed. SEEK MEDICAL ASSISTANCE IF NECESSARY.

Air Conditioning Refrigerant - Do Nots

-Do not expose refrigerant bottles to sunlight or heat.

-Do not stand refrigerant bottles upright; when filling, hold them with the valve downwards.

-Do not expose refrigerant bottles to frost.

-Do not drop refrigerant bottles.

-Do not vent refrigerantto atmosphere under any circumstance.

-Do not mix refrigerants, for example R12 (Freon) and R134a.

Hot Melt Adhesives

Inthe solid state, they are safe. Inthe moltenstate they may cause burns and health hazards may arise from the inhalation of toxic fumes.

Use appropriate protective clothing and a thermostatically controlled heater with a thermal cut-out and adequate extraction.

Resin-based AdhesiveslSealers,for example Epoxide and Formaldehyde Resin-based

Mixing should be carried out in well ventilated areas, as harmful or toxic volatile chemicals may be released.

Skin contact with uncured resins and hardeners can result in irritation, dermatitis, and absorption of toxic or harmful chemicals through the skin.

Splashes can damage the eyes.

Provide adequate ventilation and avoid skin and eye contact.

Adhesives and Sealers

See also Fire, Chemical Materials.

Highly flammable, flammable, combustible - observe No Smoking policy.

Generally should be stored in No Smoking areas. Cleanliness and tidiness in use should be observed, for example disposable paper covering benches; should be dispensed from applicators where possible; containers, including secondary containers, should be labeled appropriately.

Solvent-basedAdhesivesISealers - See

Solvents

Follow manufacturers instructions.

Water-based Adhesives1Sealers

Those based On polymeremulsionsand rubber latexes may contain small amounts of volatile toxic

and harmful chemicals. Skin and eye contact should be avoided and adequate ventilation provided during use.

Anaerobic, Cyanoacrylate (super-glues)

and other Acrylic Adhesives

Many are irritant, sensitizing or harmful to the skin and respiratory tract. Some are eye irritants.

Skin and eye contact should be avoided and the manufacturersinstructions followed.

Cyanoacrylateadhesives (super-glues) MUST NOT contact the skin or eyes. If skin or eye tissue is bonded, cover with a clean moist pad and SEEK IMMEDIATE MEDICAL ATTENTION. Do not attempt to pull tissue apart. Use in well ventilated areas as vapors can cause irritationto the nose and eyes.

For two-pack systems see Resin-based and lsocyanate AdhesivesISealers.

lsocyanate (Polyurethane) Adhesives1Sealers

See also Resin-basedAdhesives.

Individuals suffering from asthma or respiratory allergies should not work with or near these materials as sensitivity reactions can occur.

Over exposure is irritating to the eyes and respiratorysystem. Excessiveconcentrationsmay produce effects on the nervous system including

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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.

Antifreeze

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 MEDICALATTENTION SHOULD BE SOUGHT IMMEDIATELY.

These products must not be used in any cooling or industrial water system that is connected or linkedto general, food preparationor drinkingwater 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.

Asbestos dust waste should be dampened, placed in a sealed container and markedfor safe disposal. If any cutting or drilling is attempted on materials ( containingasbestosthe item should be dampened " and only handtools 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

See Asbestos.

Brake Fluids (Polyalkylene Glycols)

See also Fire.

Splashes to the skin and eyes are slightly irritating. Avoid skin and eye'contactas far as possible. Inhalationvapor 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 usedwith caution and stored and handled with care. They may be toxic, harmful, corrosive, irritant or highlyflammable and give rise to hazardousfumes 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.

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Chemical Materials - Do's

-Do carefully read and observe hazard and

precautionwarnings 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; inadequatecontainer labeling;fire and explosion hazards.

-Do wash beforejob breaks, before eating, smoking, drinking or using toilet facilities when handling chemical materials.

-Do keep work areas clean, unclutteredand 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. Decreasedfiltration 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. Halonsare used as fire extinguishants.

Chemical Materials - Do Nots

-Do not mix chemical materialsexcept underthe manufacturersinstructions;some chemicalscan 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 chemicalmaterialsto unlabelled containers.

Clutch Fluids

See Brake fluids.

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.

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Dewaxing	Engine Oils
See Solvents and Fuels (Kerosene).	See Lubricants and Grease.

Dusts

Powder, dusts or clouds may be irritant, harmful or toxic. Avoid breathing dusts from powdery chemical materials or those arising from dry abrasion operations. Wear respiratory protection if ventilation is inadequate.

Fine dusts of combustible material can present an explosion hazard. Avoid explosive limits and sources of ignition.

Electric Shock

Electric shock can result from the use of faulty electrical equipment or from the misuse of equipment in good condition.

Make sure that electrical equipment is maintained in good condition and frequently tested. Faulty equipment should be labeled and preferably removed from the workstation.

Make sure that flexes, cables, plugs and sockets are not frayed, kinked, cut, cracked or otherwise damaged.

Make sure that electrical equipment and flexes do not come into contact with water.

Make sure that electrical	is protected
by the correct rated fuse.

Never misuse electrical equipment and never use equipment that is in any way faulty. The results could be fatal.

Make sure that the cables of mobile electrical equipmentcannot get trapped and damaged, such as in a vehicle hoist.

Make sure that the designated electrical workers are trained in basic First Aid.

In cases of electrocution:

-switch off the power supply before approaching the victim.

-if this is not possible push or drag the victim from the source of electricity using dry non-conductive material.

-commence resuscitation if trained to do so.

-SUMMON MEDICAL ASSISTANCE.

Exhaust Fumes

These contain asphyxiating, harmful and toxic chemicals and particles such as carbon oxides, nitrogen oxides, aldehydes, lead and aromatic hydrocarbons. Engines should be run only under conditions of adequate exhaust extraction or general ventilation and not in confined spaces.

Gasoline (petrol) engine

There may not be adequate warning of odor or of irritationbeforetoxic or harmfuleffectsarise. These may be immediate or delayed.

Diesel engine

Soot, discomfort and irritation usually give

adequate warning of hazardousfume concentrations.

Fibre

See also Dusts.

Used in noise and sound insulation.

The fibrous nature of surfaces and cut edges can cause skin irritation. This is usually a physical and not a chemical effect.

Precautions should be taken to avoid excessive skin contact through careful organization of work practices and the ;se of gloves.

-.

Fire

See also Welding, Foams, Legal Aspects.
Many of the materials found on or associated with
the repair of vehicles are highly flammable. Some
give off toxic or harmful fumes if burnt.
Observestrictfire safety when storing and handling
flammable materials or solvents, particularly near
electrical equipment or welding processes.	/ \
Make sure, before using electrical or welding	'L '
equipment, that there is no fire hazard present.
Have a suitable fire extinguisher available when
using welding or heating equipment.

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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 alternativefuels, place affected area in cool to cold water.

Individuals affected by inhalation of gases and fumes should be removedto 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.

Individualswith 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 mistscan cause direct irritation, sensitivity reactions and may be toxic or harmful.

Vapors and spray mists must not be inhaled.These materials must be appliedwith adequate ventilation and respiratory protection. Do not remove the respiratorimmediatelyafter spraying; wait untilthe vapors/mists have cleared.

Burningof 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 contactwith 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 drowsinessand 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.

Motorgasoline may contain appreciable quantities of benzene, which is toxic upon inhalation, and the concentration of gasoline vapors must be kept very low. High concentrationswill cause eye, nose and throat irritation, nausea, headache,depression and symptoms of drunkenness. Very high concentrations will result in rapid loss of

C O ~ S C ~ O U S ~ ~ S S .

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 maintenanceoperationson 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)

Combustible.

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Gross or prolonged skin contact with high boiling point gas oils may also cause serious skin disorders including skin cancer.

Ifthe fuel tank isto be removedfor service or repair the fuel must be evacuated using dedicated equipment and following the specified procedures.(

Kerosene (Paraffin)

Used also as heating fuel, solvent and cleaning agent.

Flammable- observe No Smoking policy.

Irritationof 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 irritationor dermatitis. Splashes in the eye may be slightly irritating.

In normal circumstancesthe low volatility does not give rise to harmful vapors. Exposureto 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

Highlyflammable. Observe "NO SMOKING"signs.

Make sure there is adequate ventilation when working on alternativefuelled 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 concentrationsmay 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 LPGICNGfuel system components.

LPGICNGfuel 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.

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 mechanicaldamageto 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 usetools or equipmentfor any purposeother than that for which they were designed. Never overload equipment such as hoists,jacks, axle and chassis stands or liftingslings. Damage caused by overloading is not always immediately apparent and may result in a fatal failure the next time that the equipment is used.

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Do not use damaged or defective tools or equipment, particularlyhigh-speedequipmentsuch as grindingwheels. A damaged grinding wheel can disintegrate without warning and cause serious injury.

Wear suitable eye protectionwhen using grinding, chiseling or sand blasting equipment.

Wear a suitable breathing mask when using abrasive blasting equipment, working with asbestos-based materials or using spraying equipment.

Make sure there is adequate ventilation to control dusts, mists and fumes.

High Pressure Air, Lubrication and Oil

Test Equipment

See also Lubricants and Greases.

Always keep high-pressure equipment in good condition, and regularly maintained, particularly at joints and unions.

Never direct a high-pressure nozzle, for example diesel injector, at the skin as the fluid may

,penetrate to the underlying tissue, and cause serious injury.

Halon

See CFCs.

Legal Aspects

There are many laws and regulations relating to health and safety in the use and disposal of materials and equipment in a workshop.

For a safe working environment and to avoid environmental pollution, workshops should be familiar, in detail, with the many health and safety laws and regulationswithin their country, published by both national and local authorities.

Lubricants and Greases

Avoid all prolonged and repeated contact with mineral oils. All lubricants and greases may be irritating to the eyes and skin.

Transmission Fluids

Safety instructions

Certain Transmission and Power Steering fluids supplied to Ford may contain additiveswhich have the potential to cause skin disease (dermatitis) to exposed persons. The dermatitis may be irritant or allergic in nature. Risks are higher where prolonged or repeated skin contact with a fluid may occur. These fluids are used for vehicle initial fill and service purposes. This sub-section is to:

Inform Service personnel who may come into contact with these vehicle fluids (hazard communication).

Summarise appropriate workplace control measures and personal protective equipment requirements.

Draw attention to the existence of Material Safety Datasheets (MSDS's)for the fluids (availablefrom Ford CustomerService Division). These MSDS'scontain detailed information on hazards and appropriate controls.

Control measures

Workplace risk assessments made under national chemical control regulations should identify operations involving the fluids as potentially hazardous and specify workplace control and worker awareness measures. In such circumstances, the relevant Material Safety Datasheet (see the details specified below) which specifies hazards and control measures in detail should be made available for guidance.

Avoid unprotectedskin contact with the fluids, and in particular, avoid prolonged or repeated skin contact. Work practices should be organised so as to minimisethe potentialfor skin contact. This may include the use of drip trays, absorbents, correct fluid handling equipment (funnels etc), and workplace housekeeping measures such as the cleaning of contaminated surfaces.

Personnel engaged in operations where skin contact could occur (such as fluid draining or filling) should wear impervious gloves made from nitrile rubber, certified to a chemical protectionstandard, e.g. Europe Standard EN374. This glove type is widely availablefrom reputablesuppliers of gloves for chemical protection[includingthe manufacturers Ansell-Admont (Solvex Range), North Safety products (North Nitrile Latex Gloves range), and

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Marigold Industrial (Blue Nitrile range)]. If gloves become torn or contaminated on the inside they should be replaced. Eye protection with safety glasses is appropriate. Use of an impervious apron and arm protectors may be necessary if more extensive exposure is possible. Use of skin barrier creams suitable for work with mineral oil products may offer some supplementaryprotection,but such barrier creams should not be used in place of protective clothing.

If accidental skin contact occurs with the fluids, wash the area thoroughly with soap or skin cleanser and water.

Accidental eye contact should be dealt with as per normalfirst aid practices, by flushing the eyes with an eye wash or clean cool water for 10 minutes, after which medical attention should be obtained.

Remove and launder clothing which becomes contaminatedwith the fluids. Do not place rags contaminatedwith fluid in clothing pockets.

Do not employ used engine oils as lubricants or for any applicationwhere appreciable skin contact is likely to occur.

Environmental Precautions

Burning used engine oil in small space heaters or boilers can be recommended only for units of . approved design. If in doubt check with the appropriate local authority and manufacturer of approved appliances.

Dispose of used oil and used oil filters through authorized waste disposal contractors or licensed waste disposal sites, or to the waste oil reclamation trade. If in doubt, contact the relevant local authority for advice on disposal facilities.

It is illegal to pour used oil on to the ground, down sewers or drains, or into watercourses.

Wash thoroughlyafter completingoperations where skin exposure may have occurred.

It is important that personnel do not smoke, eat or drink whilst handling the fluids or affected transmissions. These measures are designed to limit the risk from accidental ingestion.

Labelany decantedfluid properlylusean equivalent label to that on original product containers.

Clean up any spills promptly using an inert absorbent and wash down contaminatedsurfaces with detergent and water.

Dispose of any waste fluids safely as hazardous waste.

Noise

Some operations may produce high noise levels, which could, in time, damage hearing. In these cases, suitable ear protection must be worn.

Noise Insulation Materials

See Foams, Fibre Insulation.

0-Rings (Fluoroelastomer)

See Viton.

Safety Data Sheets

Safety Data Sheets, which detail specific material handling instructionsand precautionsare available from the respective national sales company, and via internet www.msds.ford .corn.

Used Engine Oil

Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants, which may cause skin cancer. Adequate means of skin protection and washing facilities must be provided.

Paints

See also Solvents, Chemical Materials.

Highly flammable, flammable - observe No Smoking policy

One Pack

Can contain harmful or toxic pigments, driers and other components as well as solvents. Spraying should be carried out only with adequate ventilation.

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