Fiesta ST 150 Manual de Taller

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FORD FIESTA ST150 2005.25 WRM
2005.25 Ford Fiesta ST150 South Africa

Workshop Manual Main Index
Group 1 General Information
GI
Group 2 Chassis
CH
Group 3 Powertrain
PT
Group 4 Electrical
EL
Group 5 Body and Paint
BP

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Group
General Information
SECTION TITLE
1
PAGE
Service Information
General Information ..............................................................................................................
Identification Codes...............................................................................................................
Jacking and Lifting ................................................................................................................
Noise, Vibration and Harshness ............................................................................................
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SECTION 100-00 General Information

VEHICLE APPLICATION: 2005.25 Fiesta
CONTENTS
PAGE
DESCRIPTION AND OPERATION

About This Manual ............................................................................................................
Introduction ......................................................................................................................
Special Tools ...................................................................................................................
Important Safety Instructions............................................................................................
Warnings, Cautions and Notes in This Manual .................................................................
How to Use This Manual ..................................................................................................
Special Tools and Torque Figures....................................................................................
Health and Safety Precautions..........................................................................................
Introduction ......................................................................................................................
Acids and Alkalis ..............................................................................................................
Air Bags ...........................................................................................................................
Air Conditioning Refrigerant .............................................................................................
Adhesives and Sealers.....................................................................................................
Antifreeze.........................................................................................................................
Asbestos ..........................................................................................................................
Battery Acids....................................................................................................................
Brake and Clutch Linings and Pads..................................................................................
Brake Fluids (Polyalkylene Glycols) .................................................................................
Brazing.............................................................................................................................
Chemical Materials...........................................................................................................
Chlorofluorocarbons (CFC) ..............................................................................................
Clutch Fluids ....................................................................................................................
Clutch Linings and Pads...................................................................................................
Corrosion Protection Materials .........................................................................................
Cutting .............................................................................................................................
Dewaxing .........................................................................................................................
Dusts................................................................................................................................
Electric Shock ..................................................................................................................
Engine Oils.......................................................................................................................
Exhaust Fumes ................................................................................................................
Fibre Insulation.................................................................................................................
Fire...................................................................................................................................
First Aid............................................................................................................................
Fluoroelastomer ...............................................................................................................
Foams - Polyurethane ......................................................................................................
Freon ...............................................................................................................................
Fuels ................................................................................................................................
Gas Cylinders ..................................................................................................................
Gases ..............................................................................................................................
Gaskets (Fluoroelastomer) ...............................................................................................
General Workshop Tools and Equipment .........................................................................
High Pressure Air, Lubrication and Oil Test Equipment ....................................................
Halon ...............................................................................................................................
Legal Aspects ..................................................................................................................
Lubricants and Greases ...................................................................................................
Transmission Fluids .........................................................................................................
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Noise ................................................................................................................................
Noise Insulation Materials.................................................................................................
O-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.......................................................................................................................
Road/Roller Testing...........................................................................................................
Pre-Test Checks ...............................................................................................................
Starting the Engine ...........................................................................................................
Road or Roller Testing ......................................................................................................
Brake Testing ...................................................................................................................
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About This Manual
Introduction
This manual has been written in a format that is
designed to meet the needs of technicians
worldwide. The objective is to use common
formats and include similar content in each
manual.
A warning, caution or note is placed at the

beginning of 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).
This manual provides general descriptions for

accomplishing diagnosis and testing, service and
repair work with tested, effective techniques.
Following them will help assure reliability.
How to Use This Manual
Special Tools
This manual is structured into groups and sections,

with specific system sections collected together
under their relevant group.
The special tool(s) table provided at the beginning

of each procedure shows all special tools required
to carry out a repair. Where possible, illustrations
are provided to assist in identifying the 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
WARNING: Warnings are used to indicate
that failure to follow a procedure
correctly may result in personal injury.
CAUTION: Cautions are used to indicate
that failure to follow a procedure
correctly may result in damage to the
vehicle or equipment being used.
NOTE: Notes are used to provide additional
essential information required to carry out a
complete and satisfactory repair.
This manual covers diagnosis and testing, service

and repair procedures.
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. Each section has a contents list
detailing 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 references to the vehicle are
taken from a position sitting in the driver seat
looking forward.
All left and right-hand references to 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) indicate the order to be followed
when removing/disassembling or when
installing/assembling a component. Additional
information, symbol(s) or a torque figure, may also
be shown alongside the component.
As you read through this manual, you will come

across WARNINGS, CAUTIONS and NOTES.
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DESCRIPTION AND OPERATION (Continued)

There are ten symbols used to give additional
information when removing/disassembling or
when installing/assembling a component.
Item
1
Designation
Special tool
2
3
4
Install new component

Inspect
Apply sealant
Apply petroleum jelly
Apply oil
Apply fluid
Apply grease
Removal or Disassembly
detail
Installation or Assembly
detail
10
Description
A special tool is required for this component. There will also
be a removal or installation symbol alongside the special tool
symbol.
Discard the old component and install a new component.
Check the component for damage.
Apply sealant to the component as specified in the mate-rials
table.
Apply petroleum jelly to the component as specified in the
materials table.
Apply oil to the component as specified in the materials table.
Apply fluid to the component as specified in the materials
table.
Apply grease to the component as specified in the mate-rials
table.
Go to the removal or disassembly detail for additional information to remove or disassemble a component
Go to the installation or assembly detail for additional information to install or assemble a component
Inspection and Verification
Visual Inspection Charts, Symptom Charts and

other information charts (such as diagnostic
routines) or supplement test procedures with
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 electrical systems, pinpoint test steps are

used to identify the source of a concern in a logical,
step-by-step manner. pinpoint tests have two
columns: CONDITIONS and
DETAILS/RESULTS/ACTIONS.
The CONDITIONS column is used exclusively for
graphics and icons (with or without captions) and
the DETAILS/RESULTS/ACTIONS column
provides direction to another test step or specific
corrective actions.
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The boxed numbers indicate the order in which

the described action is to be performed.
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.
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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 settings will be given at the
relevant point in the procedure.
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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.
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.
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.
Deployed air bags should be disposed of in a

plastic bag in accordance with local regulations at
an approved chemical waste site.
Before using any product the Materials Safety

Data Sheet supplied by the manufacturer or
supplier should be consulted.
Following any direct contact with gas generant.
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.
After normal deployment, gloves and safety

goggles must be worn during the handling
process.
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
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
(2500C).
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
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Do not store highly flammable material
together with modules or gas generators.
Do not store gas generators at temperatures
exceeding 80C.
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
See also Chlorofluorocarbon, Chemical Materials
Highly flammable, combustible observe No
Smoking policy.
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-based Adhesives/Sealers - See Solvents
Follow manufacturers instructions.

Water-based Adhesives/Sealers
Those based on polymer emulsions and 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.
Hot Melt Adhesives
Skin contact may result in frostbite.
In the solid state, they are safe. In the molten state

they may cause burns and health hazards may
arise from the inhalation of toxic fumes.
Instructions given by the manufacturer must be

followed. Avoid naked lights, wear suitable
protective gloves and goggles.
Use appropriate protective clothing and a

thermostatically controlled heater with a thermal
cut-out and adequate extraction.
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 refrigerant to atmosphere under
any circumstance.
Do not mix refrigerants, for example R12
(Freon) and R134a.
Adhesives and Sealers
See also Fire, Chemical Materials.
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Resin-based Adhesives/Sealers, 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.
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
manufacturers instructions followed.
Cyanoacrylate adhesives (super-glues) MUST
NOT contact the skin or eyes. If skin or eye tissue
is bonded, cover with a clean moist pad and SEEK
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IMMEDIATE MEDICAL ATTENTION. Do not
attempt to pull tissue apart. Use in well ventilated
areas as vapors can cause irritation to the nose
and eyes.
to general, food preparation or drinking water

supplies.
For two-pack systems see Resin-based and

Isocyanate Adhesives/Sealers.
Asbestos
Isocyanate (Polyurethane) Adhesives/Sealers
See also Resin-based Adhesives.

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
respiratory system. Excessive concentrations may
produce effects on the nervous system including
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.
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 marked for safe disposal.
If any cutting or drilling is attempted on materials
containing asbestos the item should be dampened
and only hand tools or low speed power tools
used.
Battery Acids
See also Acids and Alkalis.
Gases released during charging are explosive.
Never use naked flames or allow sparks near
charging or recently charged batteries.
Make sure there is adequate ventilation.
Brake and Clutch Linings and Pads
See Asbestos.
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 MEDICAL
ATTENTION SHOULD BE SOUGHT
IMMEDIATELY.
These products must not be used in any cooling or
industrial water system that is connected or linked
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Brake Fluids (Polyalkylene Glycols)

See also Fire.
Splashes to the skin and eyes are slightly irritating.
Avoid skin and eye contact as far as possible.
Inhalation vapor hazards do not arise at ambient
temperatures because of the very low vapor
pressure.
Brazing
See Welding.
Chemical Materials
See also Legal Aspects.
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Chemical materials such as solvents, sealers,
adhesives, paints, resin foams, battery acids,
antifreeze, brake fluids, fuels, oils and grease
should always be used with caution and stored
and handled with care. They may be toxic, harmful,
corrosive, irritant or highly flammable and give rise
to hazardous fumes and dusts.
The effects of excessive exposure to chemicals
may be immediate or delayed; briefly experienced
or permanent; cumulative; superficial; life
threatening; or may reduce life expectancy.
Chemical Materials - Do's
Do carefully read and observe hazard and

precaution warnings 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;
inadequate container labeling; fire and
explosion hazards.
Do wash before job breaks, before eating,
smoking, drinking or using toilet facilities when
handling chemical materials.
Do keep work areas clean, uncluttered and
free of spills.
Do store chemical materials according to
national and local regulations.
Do keep chemical materials out of the reach of
children.
Chemical Materials - Do Nots
Do not mix chemical materials except under

the manufacturers instructions; some
chemicals can 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 chemical materials to
unlabelled containers.
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.
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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.
Decreased filtration 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. Halons are used as fire
extinguishants.
Clutch Fluids
See Brake fluids.
Clutch Linings and Pads
See Asbestos.
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 equipment 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.
See also Solvents, Fire.
Make sure that the cables of mobile electrical

equipment cannot get trapped and damaged,
such as in a vehicle hoist.
Highly flammable, flammable observe No

Smoking policy.
Make sure that the designated electrical workers

are trained in basic First Aid.
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.
In cases of electrocution:
Corrosion Protection Materials
Cutting
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.
See Welding.
Engine Oils
Dewaxing
See Lubricants and Grease.
See Solvents and Fuels (Kerosene).
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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

irritation before toxic or harmful effects arise.
These may be immediate or delayed.
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.
Diesel engine
Soot, discomfort and irritation usually give

adequate warning of hazardous fume
concentrations.
See Viton.
Fibre Insulation
Foams - Polyurethane
See also Dusts.
See also Fire.
Used in noise and sound insulation.
Used in sound and noise insulation. Cured foams

used in seat and trim cushioning.
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 use 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.
Observe strict fire safety when storing and
handling flammable materials or solvents,
particularly near electrical equipment or welding
processes.
Make sure, before using electrical or welding
equipment, that there is no fire hazard present.
Have a suitable fire extinguisher available when
using welding or heating equipment.
First Aid
Apart from meeting any legal requirements it is
desirable for someone in the workshop to be
trained in First Aid procedures.
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Fluoroelastomer
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.
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Freon
Kerosene (Paraffin)
See Air Conditioning Refrigerant.
Used also as heating fuel, solvent and cleaning

agent.
Fuels
Flammable - observe No Smoking policy.
See also, Fire, Legal Aspects, Chemicals and

Solvents.
Irritation of the mouth and throat may result from

swallowing. The main hazard from swallowing
arises if liquid aspiration into the lungs occurs.
Avoid skin contact with fuel where possible.

Should contact occur, wash the affected skin with
soap and water.
Liquid contact dries the skin and can cause

irritation or dermatitis. Splashes in the eye may be
slightly irritating.
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
consciousness.
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.
Gas-oil (Diesel Fuel)
Combustible.
Gross or prolonged skin contact with high boiling
point gas oils may also cause serious skin
disorders including skin cancer.
G17372 en
In normal circumstances the low volatility does not

give rise to harmful vapors. Exposure to mists and
vapors from kerosene at elevated temperature
should be avoided (mists may arise in dewaxing).
Avoid skin and eye contact and make sure there is
adequate ventilation.
Alternative Fuel
Highly flammable. Observe ``NO SMOKING"

signs.
Make sure there is adequate ventilation when
working on alternative fuelled vehicles. Great care
must be taken to avoid the serious consequences
of inhalation in the event of vapor build up in
confined spaces.
Inhalation in high concentrations may cause
dizziness, headache, nausea and loss of
co-ordination. Very high concentrations may result
in loss of consciousness.
Contact with liquefied petroleum gas (LPG) or
compressed natural gas (CNG) to the skin may
cause cold burns and frost bite.
Long sleeved cotton overalls, steel toe capped
safety boots and rubber neoprene gloves should
be worn during removal and installation of
LPG/CNG fuel system components.
LPG/CNG fuel leaks could cause a fire and be a
hazard to health that can lead to personal injury,
illness or even death.
If a leak is detected, under no circumstances
attempt to seal the leak by tightening the
union/connection until the fuel in the system or
component is depressurized. Once tightened the
system should be checked for integrity following
the specified procedures.
If the fuel tank is to be removed for service or
repair the fuel must be evacuated using dedicated
equipment and following the specified procedures.
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Gas Cylinders
See also Fire.
Gases such as oxygen, acetylene, argon and
propane are normally stored in cylinders at
pressures of up to 138 bar (2000 psi) and great
care should be taken in handling these cylinders
to avoid mechanical damage to them or to the
valve gear attached. The contents of each cylinder
should be clearly identified by appropriate
markings.
Cylinders should be stored in well-ventilated
enclosures, and protected from ice and snow, or
direct sunlight. Fuel gases, for example acetylene
and propane, should not be stored in close
proximity to oxygen cylinders.
Care should be exercised to prevent leaks from
gas cylinders and lines, and to avoid sources of
ignition.
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.
Only trained personnel should undertake work

involving gas cylinders.
Halon
Gases
Legal Aspects
See Gas Cylinders.
There are many laws and regulations relating to

health and safety in the use and disposal of
materials and equipment in a workshop.
Gaskets (Fluoroelastomer)
See CFCs.
General Workshop Tools and Equipment
For a safe working environment and to avoid

environmental pollution, workshops should be
familiar, in detail, with the many health and safety
laws and regulations within their country,
published by both national and local authorities.
It is essential that all tools and equipment are

maintained in good condition and that the correct
safety equipment is used where required.
Lubricants and Greases
See Viton.
Never use tools or equipment for any purpose

other than that for which they were designed.
Never overload equipment such as hoists, jacks,
axle and chassis stands or lifting slings. Damage
caused by overloading is not always immediately
apparent and may result in a fatal failure the next
time that the equipment is used.
Avoid all prolonged and repeated contact with

mineral oils. All lubricants and greases may be
irritating to the eyes and skin.
Do not use damaged or defective tools or

equipment, particularly high-speed equipment
such as grinding wheels. A damaged grinding
wheel can disintegrate without warning and cause
serious injury.
Safety instructions
Wear suitable eye protection when using grinding,

chiseling or sand blasting equipment.
Wear a suitable breathing mask when using
abrasive blasting equipment, working with
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Transmission Fluids
Certain Transmission and Power Steering fluids

supplied to Ford may contain additives which 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:
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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
(available from Ford Customer Service
Division). These MSDS's contain 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 unprotected skin contact with the fluids, and
in particular, avoid prolonged or repeated skin
contact. Work practices should be organised so as
to minimise the potential for 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 protection
standard, e.g. Europe Standard EN374. This
glove type is widely available from reputable
suppliers of gloves for chemical protection
[including the manufacturers Ansell-Admont
(Solvex Range), North Safety products (North
Nitrile Latex Gloves range), and 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 supplementary protection, but such
barrier creams should not be used in place of
protective clothing.
G17372 en
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
normal first 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
contaminated with the fluids. Do not place rags
contaminated with fluid in clothing pockets.
Wash thoroughly after completing operations
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.
Label any decanted fluid properly/use an
equivalent label to that on original product
containers.
Clean up any spills promptly using an inert
absorbent and wash down contaminated surfaces
with detergent and water.
Dispose of any waste fluids safely as hazardous
waste.
Safety Data Sheets
Safety Data Sheets, which detail specific material

handling instructions and precautions are
available from the respective national sales
company, and via internet www.msds.ford.com.
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.
Do not employ used engine oils as lubricants or for
any application where 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.
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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.
Pressurized Equipment
It is illegal to pour used oil on to the ground, down

sewers or drains, or into watercourses.
Solder
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.
See High Pressure Air, Lubrication and Oil Test

Equipment.
Solders are mixtures of metals such that the

melting point of the mixture is below that of the
constituent metals (normally lead and tin). Solder
application does not normally give rise to toxic
lead fumes, provided a gas/air flame is used.
Oxy-acetylene flames should not be used, as they
are much hotter and will cause lead fumes to be
produced.
Some fumes may be produced by the application
of any flame to surfaces coated with grease, and
inhalation of these should be avoided.
See Viton.
Removal of excess solder should be undertaken

with care, to make sure that fine lead dust is not
produced, which can give toxic effects if inhaled.
Respiratory protection may be necessary.
Paints
Solder spillage and filings should be collected and

removed promptly to prevent general air
contamination by lead.
O-Rings (Fluoroelastomer)
See also Solvents, Chemical Materials.

Highly flammable, flammable - observe No
Smoking policy
High standards of personal hygiene are necessary

in order to avoid ingestion of lead or inhalation of
solder dust from clothing.
One Pack
Solvents
Can contain harmful or toxic pigments, driers and

other components as well as solvents. Spraying
should be carried out only with adequate
ventilation.
See also Chemical Materials, Fuels (Kerosene),

Fire.
Two Pack
Can also contain harmful and toxic unreacted

resins and resin hardening agents. The
manufacturers instructions should be followed.
See also Resin-based Adhesives and Isocyanate
Adhesives and Sealers under Adhesives and
Sealers.
Spraying should preferably be carried out in
exhausted ventilated booths removing vapor and
spray mists from the breathing zone. Individuals
working in booths should wear appropriate
respiratory protection. Those doing small-scale
repair work in the open workshop should wear
air-fed respirators.
G17372 en
For example acetone, white spirit, toluene, xylene,

trichloroethane.
Used in cleaning and dewaxing materials, paints,
plastics, resins and thinners.
Some may be highly flammable or flammable.
Skin contact will degrease the skin and may result
in irritation and dermatitis following repeated or
prolonged contact. Some can be absorbed
through the skin in toxic or harmful quantities.
Splashes in the eye may cause severe irritation
and could lead to loss of vision.
Brief exposure of high concentrations of vapors or
mists will cause eye and throat irritation,
drowsiness, dizziness, headaches and, in the
worst circumstances, unconsciousness.
Repeated or prolonged exposure to excessive but
lower concentrations of vapors or mists, for which
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there might not be adequate warning indications,
can cause more serious toxic or harmful effects.
Aspiration into the lungs, for example through
vomiting, is the most serious consequence of
swallowing.
Avoid splashes to the skin, eyes and clothing.
Wear protective gloves, goggles and clothing if
necessary.
Make sure there is good ventilation when in use,
avoid breathing fumes, vapors and spray mists
and keep containers tightly sealed. Do not use in
confined spaces.
When spraying materials containing solvents, for
example paints, adhesive, coatings, use
extraction ventilation or personal respiratory
protection in the absence of adequate general
ventilation.
Do not apply heat or flame except under specific
and detailed manufacturers instructions.
Sound Insulation
See Fibre Insulation, Foams.
Suspended Loads
CAUTION: Never improvise lifting tackle.
There is always a danger when loads are lifted or
suspended. Never work under an unsupported,
suspended or raised load, for example a
suspended engine.
Viton is a fluoroelastomer, that is a synthetic

rubber type material, which contains Fluorine. It is
commonly used for O-rings, gaskets and seals of
all types. Although Viton is the most well known
fluoroelastomer, there are others, including
Fluorel and Tecmoflon.
When used under design conditions
fluoroelastomers are perfectly safe. If, however,
they are exposed to temperatures in excess of
400C, the material will not burn, but will
decompose, and one of the products formed is
hydrofluoric acid.
This acid is extremely corrosive and may be
absorbed directly, through contact, into the
general body system.
O-rings, seals or gaskets which have been
exposed to very high temperatures will appear
charred or as a black sticky substance.
DO NOT; under any circumstances touch them or
the attached components.
Enquiries should be made to determine whether
Viton or any other fluoroelastomer has been used
in the affected O-ring, seal or gasket. If they are of
natural rubber or nitrile there is no hazard. If in
doubt, be cautious, as the material may be Viton
or any fluoroelastomer.
If Viton or any other fluoroelastomers have been
used, the affected area should be decontaminated
before the commencement of work.
Always make sure that lifting equipment such as

jacks, hoists, axle stands and slings are adequate
and suitable for the job, in good condition and
regularly maintained.
Disposable heavy duty plastic gloves should be

worn at all times, and the affected area washed
down using wire wool and a limewater (calcium
hydroxide) solution to neutralize the acid before
disposing of the decomposed Viton residue and
final cleaning of the area. After use, the plastic
gloves should be discarded carefully and safely.
Transmission Brake Bands
Welding
See Asbestos.
See also Fire, Electric Shock, Gas Cylinders.
Underseal
Welding processes include Resistance Welding

(Spot Welding), Arc Welding and Gas Welding.
See Corrosion Protection.
Resistance Welding
Viton
This process may cause particles of molten metal

to be emitted at a high velocity, and the eyes and
skin must be protected.
In common with many other manufacturers

vehicles, some components have O-rings, seals
or gaskets, which contain a material known as
`Viton'.
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Arc Welding
This process emits a high level of ultra-violet

radiation, which may cause arc-eye, and skin
burns to the operator and to other persons nearby.
Gas-shielded welding processes are particularly
hazardous in this respect. Personal protection
must be worn, and screens used to shield other
people.
CONTACT LENS WEARERS ARE ADVISED TO
REVERT TO ORDINARY SPECTACLES WHEN
ARC WELDING as the arc spectrum is believed to
emit microwaves which dry out the fluid between
the lens and the eye. This may result in blindness
when the lens is removed from the eye.
Metal spatter will also occur, and appropriate eye
and skin protection is necessary.
The heat of the welding arc will produce fumes
and gases from the metals being welded, the rods
and from any applied coatings or contamination
on the surfaces being worked on. These gases
and fumes may be toxic and inhalation of these
should be avoided. The use of extraction
ventilation to remove the fumes from the working
area may be necessary particularly in cases
where the general ventilation is poor, or where
considerable welding work is anticipated. In
extreme cases or confined spaces where
adequate ventilation cannot be provided, air-fed
respirators may be necessary.
avoid inhalation of fumes and expert advice may

be required.
SPECIAL PRECAUTIONS MUST BE TAKEN
BEFORE ANY WELDING OR CUTTING TAKES
PLACE ON VESSELS, WHICH HAVE
CONTAINED COMBUSTIBLE MATERIALS, FOR
EXAMPLE BOILING OR STEAMING OUT OF
FUEL TANKS.
Warning Symbols on Vehicles
Decals showing warning symbols will be found on
various vehicle components.
These decals must not be removed. The warnings
are for the attention of owners/operators and
persons carrying out service or repair operations
on the vehicle.
The most commonly found decals are reproduced
below together with an explanation of the
warnings.
Gas Welding (and Cutting)
Oxy-acetylene torches may be used for welding

and cutting, and special care must be taken to
prevent leakage of these gases, with consequent
risk of fire and explosion.
The process will produce metal spatter and eye
and skin protection is necessary.
The flame is bright, and eye protection should be
used, but the ultra-violet emission is much less
than that from arc welding, and lighter filters may
be used.
1. Components or assemblies displaying the

caution triangle and open book symbol advise
consultation of the relevant section of the
owner literature before touching or attempting
adjustments of any kind.
The process itself produces few toxic fumes, but

such fumes and gases may be produced from
coatings on the work, particularly during cutting
away of damaged body parts, and inhalation of the
fumes should be avoided.
In brazing, toxic fumes may be produced from the
metals in the brazing rod, and a severe hazard
may arise if brazing rods containing cadmium are
used. In this event particular care must be taken to
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2. Components or assemblies displaying the
warning triangle with the `electrified' arrow
and open book symbol give warning of
inherent high voltages. Never touch these with
the engine running or the ignition switched on.
See Electric Shock in this subsection.
3. Vehicles and replacement components which

contain asbestos are identified by this symbol.
See Asbestos in this subsection.
4. Components or assemblies displaying this

symbol give warning that the component
contains a corrosive substance. See Acids
and Alkalis in this subsection.
of naked lights or flames within the immediate

vicinity due to the presence of highly
flammable or explosive liquids or vapors. See
Fire in this subsection.
6. Displaying this symbol (normally in

conjunction with 5 above) warn of the
presence of potentially explosive matter within
the immediate vicinity.
7. Displaying this symbol warn that children

should not be allowed in the immediate vicinity
unsupervised.
White Spirit
See Solvents.
5. Displaying the caution circle with a deleted

lighted match symbol, caution against the use
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Standard Workshop Practices
Vehicle in Workshop
When working on a vehicle in the workshop
always make sure that:
the parking brake is applied or the wheels are
securely chocked to prevent the vehicle
moving forwards or backwards.
the key is removed from key operated hood
locks before any work is carried out around the
front of the vehicle.
if the engine is to be run, there is adequate
ventilation, or an extraction hose to remove
exhaust fumes.
there is adequate room to raise the vehicle
and remove the wheels, if necessary.
fender covers are always fitted if any work is to
be carried out in the engine compartment.
the battery is disconnected if working on the
engine, underneath the vehicle, or if the
vehicle is raised.
CAUTION: When electric arc welding on a
vehicle, always disconnect the generator
wiring to prevent the possibility of a
surge of current causing damage to the
internal components of the generator.
If using welding equipment on the vehicle, a
suitable fire extinguisher is readily available.
Alternative Fuel
WARNING: When servicing the fuel
system always follow the recommended
procedures. Failure to follow these
instructions may result in personal injury.
If the odor of liquefied petroleum gas (LPG) or
compressed natural gas (CNG) is present in the
air in the workshop, warn all persons in the area
to:
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extinguish all flames and lighted tobacco.

shut off electrical and air powered equipment.
evacuate the area.
ventilate the area.
contact the fire control authorities.
remove the vehicle to a dedicated, ventilated
area.
extremely hot days.

parking by a space heater.
hoisting a vehicle up near a ceiling heater.
Only fully trained personnel, who are conversant
with local standards, are to work on alternative
fuel vehicles.
Towing the Vehicle
Alternative Fuel Do's

Do work on the vehicle in a designated area
that is well ventilated and with access
restricted to qualified personnel only.
Install new warning labels to their original
locations.
If possible always isolate the alternative fuel
tank, and run the vehicle on the alternative fuel
until it automatically switches to its normal fuel
prior to taking the vehicle into the
workshop/service area.
Only use tested and approved components
and pipes when repairing or servicing LPG
and CNG systems.
Alternative Fuel Do Nots
Do not vent off LPG fuel.
Do not use shop air pressure to force LPG fuel
from the fuel tank.
Do not use paint drying ovens above 40C for
any alternative fuel vehicles. LPG and CNG
fuel tanks must be removed from the vehicles
prior to being put into paint drying ovens above
40C.
Do not modify the system or install new
components that are not designed for gas
vehicles.
Do not evacuate fuel tanks unless there is
repair that requires the removal of the fuel
tank.
Do not work on the fuel lines or system
components unless the alternative fuel has
been evacuated and the pressure in the
system reduced to atmospheric or less.
Do not use anything other than the specified
leak detector fluid to trace fuel leaks.
Be aware of situations that may cause the LPG or
CNG fuel system to vent off fuel, such as:
G17373 en
WARNING: When the vehicle is being

towed the ignition switch must be in
position II (steering lock released and
warning lamps illuminated). Only then
will the steering, turn signal lamps, horn
and stop lamps be operational. Failure to
follow these instructions may result in
personal injury.
NOTE: The removable towing eye (if equipped),
has a left-hand thread and must be fully tightened
before towing can commence.
When towing is necessary, the vehicle towing
eyes should be used. The rope must be securely
fastened to the towing eyes and must also be
attached to the other vehicle such that the rope
will not foul the bodywork.
When a vehicle with automatic transmission is
towed, the gear selector must be in position N
(Neutral). Never tow a vehicle with automatic
transmission at a speed greater than 30 mph (50
km/h) or for a distance greater than 30 miles (50
km). If it is necessary to tow the vehicle a greater
distance, the drive wheels must be lifted clear off
the ground.
Alternatively the vehicle can be transported on a
low loader or a trailer.
Connecting a Slave Battery Using Jumper
Cables
WARNING: If the slave battery has
recently been charged and is gassing,
cover the vent plugs or covers with a
damp cloth to reduce the risk of
explosion should arcing occur when
connecting the jumper cables. Failure to
personal injury.
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CAUTION: A discharged battery condition

may have been caused by an electrical
short circuit. If this condition exists there
will be an apparently live circuit on the
vehicle even when all normal circuits are
switched off. This can cause arcing when
the jumper cables are connected.
CAUTION: While it is not recommended
that the vehicle is jump started, it is
recognized that this may occasionally be
the only practical way to mobilize a
vehicle. In such an instance, the
discharged battery must be recharged
immediately after jump starting to avoid
permanent damage.
Always make sure that the jumper cables are
adequate for the task. Heavy duty cables must
be used.
Always make sure that the slave battery is of
the same voltage as the vehicle battery. The
batteries must be connected in parallel.
Always make sure that switched electric
circuits are switched off before connecting
jumper cables. This reduces the risk of arcing
occurring when the final connection is made.
Slave battery positive first and then vehicle

battery positive.
Slave battery negative next and then vehicle
ground at least 12 inches (300 mm) from the
battery terminal, for example engine lifting
eye.
Always reduce the engine speed to idle before
disconnecting the jumper cables.
Before removing the jumper cables from the
vehicle that had the discharged battery, switch on
the heater blower (high) or the heated rear window,
to reduce the voltage peak when the cables are
removed.
Always disconnect the jumper cables in the
reverse order to the connecting sequence and do
not short the ends of the cables.
Do not rely on the generator to restore a
discharged battery. For a generator to recharge a
battery, it would take in excess of eight hours
continuous driving with no additional loads placed
on the battery.
Component Cleaning
To prevent ingress of dirt, accumulations of loose
dirt and greasy deposits should be removed
before disconnecting or dismantling components
or assemblies.
Components should be thoroughly cleaned before
inspection prior to reassembly.
Cleaning Methods:
WARNING: Make sure that the ends of the

jumper cables do not touch each other or
ground against the vehicle body at any
time while the cables are attached to the
battery. A fully charged battery, if shorted
through jumper cables, can discharge at
a rate well above 1000 amps causing
violent arcing and very rapid heating of
the jumper cables and terminals, and can
even cause the battery to explode. Failure
to follow these instructions may result in
personal injury.
Dry cleaning.
Removal of loose dirt with soft or cable
brushes.
Scraping dirt off with a piece of metal or wood.
Wiping off with a rag.
CAUTION: Compressed air is sometimes
'wet' so use with caution, especially on
hydraulic systems.
Always connect the jumper cables in the following

sequence:
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Blowing dirt off with compressed air. Eye
protection must be worn when using this
method.
Removal of dry dust using vacuum equipment.
This method should always be used to remove
friction lining material dust (asbestos
particles).
Steam cleaning.
WARNING: Most solvents require careful
handling and some are harmful. Refer to
Health and Safety Precautions and to the
manufacturers literature for safety
precautions. Failure to follow these
Various solvents are available which are suitable
for component cleaning. Some components such
as brake hydraulic parts and electrical assemblies
should be cleaned only with recommended
solvents refer to Solvents, Sealers and
Adhesives or to the section of the manual relevant
to the component.
Calibration of Essential Measuring Equipment
WARNING: Failure to follow these
instructions may result in personal injury
or damage to components.
It is of fundamental importance that certain
essential equipment, for example torque
wrenches, multimeters, exhaust gas analyzers or
rolling roads, are regularly calibrated in
accordance with the manufacturers instructions.
G17373 en
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General Information
100-00-23

Solvents, Sealants and Adhesives
Introduction
WARNING: Always handle all solvents,
sealers and adhesives with extreme care.
Some contain chemicals or give off
fumes which can be dangerous to health.
Always follow the manufacturers
instructions. If in doubt about any
substance, particularly a solvent, DO
NOT use it.
CAUTION: If in doubt about the suitability
of any proprietary solvent or sealer for a
particular application, contact the
manufacturer of the product for
information regarding storage, handling
and application.
The Health and Safety Precautions subsection
refers to some commonly used chemicals and
materials, hazards associated with their use, and
safety measures to be taken.
G17374 en
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General Information
100-00-24

Road/Roller Testing
Road or roller testing may be carried out for
various reasons and a procedure detailing pre-test
checks, engine starting and stopping, pre-driving
checks, on-test checks and final checks to be
completed on completion of the test is given
below.
Unless complete vehicle performance is being
checked, the full road test procedure need not be
carried out. Instead, those items particularly
relevant to the system(s) being checked can be
extracted.
Pre-Test Checks
WARNING: If the brake system hydraulic
fluid level is low, pedal travel is excessive
or a hydraulic leak is found, do not
attempt to road test the vehicle until the
reason for the low fluid level, excessive
pedal travel or hydraulic leak is found
and rectified.
It is suggested that pre-test checks and functional
tests of those systems and circuits which affect
the safe and legal operations of the vehicle, such
as brakes, lights and steering, should always be
carried out before the road or roller test.
With the ignition switched off, check:
the engine oil level.

the engine coolant level.
the tires, for correct pressure, compatible
types and tread patterns, and wear within
limits.
that there is sufficient fuel in the tank to
complete the test.
all around the engine, transmission and under
the vehicle for oil, coolant, hydraulic and fuel
leaks. Make a note of any apparent leaks and
wipe off the surrounding areas to make it
easier to identify the extent of the leak on
completion of the test.
Starting the Engine
NOTE: On initial drive away from cold and within
the first 1.5 km (1 mile), do not depress the
accelerator pedal beyond half travel until the
vehicle has attained a minimum speed of 25 km/h
(15 miles/h). Never operate at high engine speed
or with the accelerator pedal at full travel whilst the
engine is cold.
With the ignition switched off, check:
that the parking brake is applied.
that the gear lever is in the neutral position.
that all instrument gauges (except fuel gauge)
read zero.
With the ignition switched on, check:
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General Information
100-00-25

that the ignition controlled warning lamps are
illuminated.
that the engine temperature gauge registers a
reading compatible with the engine
temperature.
that the fuel gauge registers a reading
appropriate to the fuel level in the tank.
the operation of the parking brake warning
lamp and fluid level warning indicator.
Road or Roller Testing
CAUTION: If road testing, check the brake
operation while still traveling at low
speed before continuing with the test. If
the brakes pull to one side, or appear to
be otherwise faulty, do not continue with
the road test until the fault has been
found and rectified.
During the road or roller test, check:
that the clutch pedal operation is not stiff or
heavy.
that the initial gear engagement is smooth and
there is no evidence of clutch drag.
that the parking brake control operates
smoothly and releases quickly and completely.
that the clutch takes up the drive smoothly,
without slip or judder.
that gear changing is smooth with no abnormal
noises or vibrations from the transmission.
the engine power output is satisfactory, full
power is achieved, acceleration is smooth and
pedal operation is not stiff or heavy, and
engine speed returns to idle correctly.
there is no excessive or abnormally colored
smoke from the engine under normal driving,
heavy load or overrun conditions.
that steering operation, including power
steering (if equipped), is smooth, accurate, not
excessively heavy or with excessive free play
or vibration.
that the steering does not pull to one side and
self centers smoothly after cornering.
that the speedometer, coolant temperature
gauge and tachometer (if equipped) register
the correct readings and operate correctly.
that the switches and controls operate
smoothly and positively, warning and indicator
lamps operate correctly and the direction
indicator control self cancels when the
G17375 en
steering is returned to the straight ahead

position.
that the heating and ventilation systems
operate correctly and effectively.
the brake operation and efficiency.
Brake Testing
WARNING: When brake testing, avoid
breathing the fumes from hot brakes, this
may contain asbestos dust which is
hazardous to health. Failure to follow this
instruction may result in personal injury.
For additional information, refer to Health
and Safety Precautions in this section.
CAUTION: Avoid brake testing on busy
roads where it may cause inconvenience
or danger to other road users.
CAUTION: Brake testing which includes
heavy brake applications should not be
carried out with new brake pads/discs or
linings/drums until the components have
bedded-in. New brake friction
components will not reach full efficiency
until the bedding-in process is complete.
Test the brakes at several speeds within the
normal operating range using both light and heavy
pedal pressure. Note any tendency to snatch, pull
or drag, and any undue delay in application or
release.
Allow the vehicle to coast and note any tendency
to pull to one side, or evidence that the brakes are
binding.
After stopping the vehicle (not immediately after a
period of heavy braking), carefully check the brake
temperature. A brake disc or brake drum that feels
hot or is appreciably hotter than the others,
indicates that the brake is binding.
After completion of the test, check for:
oil, coolant, hydraulic, air and fuel leaks.
abnormal temperature of any moving
components or assemblies, for example wheel
hubs, transmission and axle, which might
indicate over tightness or lack of lubrication.
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100-01-1
Identification Codes
100-01-1
SECTION 100-01 Identification Codes

CONTENTS
PAGE

Identification Codes ..........................................................................................................
VIN (an example of VIN shown) .......................................................................................
Vehicle Certification Label (Typical) or VIN Plate .............................................................
100-01-2
100-01-3
100-01-4
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100-01-2

The vehicle identification plate (VIN plate) is
located on the right-hand B-pillar. The codes
stamped or printed on the VIN plate during
production enable the precise details of the
vehicle build specification to be established. The
Item
Part
Number
Visible VIN
VIN on the suspension strut

top mount
VIN plate
G413286 en
vehicle identification number (VIN) may also be

viewed through the windshield or in the engine
compartment where it is stamped onto the
suspension strut top mount.
Description
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100-01-3
100-01-3
VIN (an example of VIN shown)
Item
Part
Number
VIN Position 1, 2 and 3 World manufacturer identifier
VIN Position 5 and 6 - Constant X
VIN Position 7 and 8 Product source company and

assembly plant
Description
Item
Part
Number
VIN Position 11 - Year of

manufacture
VIN Position 12 - Month of

manufacture
VIN Positions 13 to 17 - Vehicle serial number
VIN Position 4 and 10 - Body

type
VIN Position 9 - Model
Description
VIN Position 1, 2 and 3 - World Manufacturer Identifier

Codes
World Manufacturer
WF0
Ford-Werke AG Germany (European vehicles)
VIN Position 4 and 10 - Body Type
Code
C
D
H
U
G413286 en
Body Type
3-door van (Fiesta)
3-door (Fiesta)
5-door (Fiesta)
5-door (Fusion)
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100-01-4

VIN Position 5 and 6 Constant X
VIN Position 7 and 8 - Product Source Company and Assembly Plant
Code
Product Source Company and Assembly Plant
GA
Cologne/Germany
WP
Valencia/Spain
VIN Position 9 - Model
Code
J
VIN Position 11 - Year of Manufacture
Code
2
3
4
5
6
7
VIN Position 12 - Month of Manufacture
Month
2002
2003
January
L
C
February
Y
K
March
S
D
April
T
E
May
J
L
June
U
Y
July
M
S
August
P
T
September
B
J
October
R
U
November
A
M
December
G
P
VIN Positions 13 to 17 - Vehicle Serial Number
Five Digit Number
G413286 en
Model
Fiesta/Fusion
Year of Manufacture
2002
2003
2004
2005
2006
2007
2004
B
R
A
G
C
K
D
E
L
Y
S
T
2005
J
U
M
P
B
R
A
G
C
K
D
E
2006
L
Y
S
T
J
U
M
P
B
R
A
G
2007
C
K
D
E
L
Y
S
T
J
U
M
P
Vehicle Certification Label (Typical) or VIN

Plate
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100-01-5
100-01-5
Item
Part
Number
Model type
10
Door combination
11
Exhaust emission level

codes
12
Body color codes
13
Interior trim codes
14
Transaxle final drive ratio
Maximum permissible rear

axle mass
15
Transaxle codes
16
Engine codes
Item
Part
Number
Description
National or whole vehicle

type approval
VIN
Gross vehicle mass (GVM)
Gross train mass (GTM)
Maximum permissible front

axle mass
Description
Smoke value (diesel only)
17
Hand of drive
Model body or type
18
Axle mounting (Transit only)
Items 1 to 6: Vehicle Certification Label

Item
Item 1: National or whole vehicle type approval
Item 2: VIN
G413286 en
Details
A unique code required by legislation in certain
territories.
Vehicle identification number.
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100-01-6
100-01-6

Item
Item 3: GVM
Item 4: GTM
Item 5: Maximum permissible front axle mass
Item 6: Maximum permissible rear axle mass
Item 7: Smoke Value (Diesel only)

Number
Item 8 Model Body or Type

Code
JC3
JD3
JH1
JU2
Item 9: Model Type
Code
Item 10: Door Combination
Code
Item 11: Exhaust Emission Level Codes
Code
S
7
Item 12: Body Color Codes
Code
B
D
G
J
K
L
M
Q
R
U
W
Z
1
2
G413286 en
Details
Indicates maximum legal laden mass, in territories
where this is required.
Indicates the maximum combined mass of vehicle
and trailer or caravan.
Maximum permissible loading on the front wheels
of the vehicle.
Maximum permissible loading on the rear wheels of
the vehicle.
Smoke Value
Per meter
Model Body or Type

3-door van (Fiesta)
3-door (Fiesta)
5-door (Fiesta)
5-door (Fusion)
Model Type
-
Door Combination
-
Exhaust Emissions
2000 EEC (Stage III)
Stage IV requirements
Body Color
Diamond White
Panther Black
Performance Blue
Tonic
Colorado Red
Deep Rosso Red
Magnum Grey
Oyster Silver
Honour Green
Neptune Green
Ink Blue
Flare
Sublime
Aquarius
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100-01-7
100-01-7

Code
3
6
7
8
Body Color
Vitro
Moondust Silver
Machine Silver
Deep Navy
For vehicles built in continental plants, the second digit of the paint code, on the VIN label, denotes the original
model year of the colors introduction, (0=color introduction in 2000 model year).
Item 13: Interior Trim Codes

Code
AT
BR
DC
FC
FP
FT
HH
JH
LM
MI
MT
QB
QL
QM
QZ
Q2
RK
RR
TB
TL
VK
Interior Trim
Dogtooth - Mamara Blue
Compass - Blue
Cord - Dark Flint
Cord - Medium Flint
Metropolitan - Medium Flint
Dogtooth - Medium Flint
Humy - Dark Flint - Dark Flint
Humy - Dark Flint - Ebony
Mirage - Medium Light Flint
Intro - Midnight Black
Dogtooth - Midnight Black
Bussac - Ebony
Leather - Ebony
Mirage - Ebony
Leather - Ebony
Leather - Ebony
Compass - Red
Compass - Red
Bussac - Light Stone
Leather - Light Stone
Compass - Silver
Item 14: Transaxle Final Drive Ratio

Code
A
B
M
R
3
4
Transaxle Final Drive Ratio

3.37
4.06
4.05
4.25
4.375
3.82
Item 15: Transaxle Codes

Code
A
B
C
Item 16: Engine Codes
Code
A
G413286 en
Transaxle
5-Speed Manual Transaxle (iB5)
5-Speed Manual Transaxle (iB5) Automated Shift Manual
4-Speed Automatic Transaxle (AW81- 40LE)
Engine
1.3L Duratec-8V (Rocam) (60PS)
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100-01-8

Code
H
U
X
Y
4
6
7
9
Item 17: Hand of Drive
Code
1
2
3
4
N
P
Q
R
G413286 en
Engine
1.6L Duratorq-TDCi (DV) Diesel (90PS)
1.25L Duratec-16V (Sigma) (75PS)
2.0L Duratec-HE (MI4) (150PS)
1.4L DuraTorq-TDCi (DV) (68PS)
1.3L Duratec-8V (Rocam) (70PS)
Drive
Left-hand drive
Right-hand drive
Left-hand drive
Right-hand drive
Left-hand drive
Right-hand drive
Left-hand drive
Right-hand drive
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100-02-1
Jacking and Lifting
100-02-1
SECTION 100-02 Jacking and Lifting

CONTENTS
PAGE

Jacking .............................................................................................................................
Lifting ................................................................................................................................
100-02-2
100-02-3
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Jacking and Lifting
100-02-2

Jacking
WARNING: Only the specified jacking

points may be used for jacking up and
supporting the vehicle.
G167070 en
CAUTION: Park the vehicle on a flat, level

and stable surface. If the vehicle must be
lifted on a soft surface, the supporting
forces must be spread by using a suitable
base under the jack. Place a wheel chock
against the wheel opposite the jack.
Injury may occur if these instructions are
not followed !
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Jacking and Lifting
100-02-3

Lifting
WARNING: Only raise the vehicle at the

specified lifting points.
G167072 en
CAUTION: Place blocks underneath the

hoist points if a two-column hoist is used.
11/2004 2005.25 Fiesta

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100-04-1
Noise, Vibration and Harshness
100-04-1
SECTION 100-04 Noise, Vibration and Harshness

CONTENTS
PAGE

Noise, Vibration and Harshness (NVH) .............................................................................
Diagnostic Theory ............................................................................................................
Know the System .............................................................................................................
Know the History of the System .......................................................................................
Know the History of the Condition ....................................................................................
Know the Probability of Certain Conditions Developing ....................................................
Do Not Cure the Symptom and Leave the Cause.............................................................
Be Positive the Cause is Found .......................................................................................
Diagnostic Charts.............................................................................................................
100-04-2
100-04-2
100-04-2
100-04-2
100-04-2
100-04-2
100-04-2
100-04-3
100-04-3
DIAGNOSIS AND TESTING

Noise, Vibration and Harshness (NVH) .............................................................................
Inspection and Verification ...............................................................................................
Noise Diagnostic Procedure .............................................................................................
Road Test ........................................................................................................................
Road Test Quick Checks..................................................................................................
Road Conditions...............................................................................................................
Vehicle Preparation..........................................................................................................
Power Steering Conditions ...............................................................................................
Power Steering Operation Noise Check ...........................................................................
Symptom Chart ................................................................................................................
Pinpoint Tests ..................................................................................................................
100-04-4
100-04-4
100-04-4
100-04-5
100-04-6
100-04-6
100-04-7
100-04-7
100-04-7
100-04-9
100-04-14
GENERAL PROCEDURES
Powertrain/Drivetrain Mount Neutralizing ...................................................... (14 001 0)
100-04-19
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100-04-2

Noise, Vibration and Harshness (NVH)
Noise, vibration and harshness (NVH) is
becoming more important as vehicles become
more sophisticated and passenger comfort levels
increase. This section is designed to aid in the
diagnosis and testing and repair of NVH concerns.
Noise is defined as sounds not associated with
the operation of passenger compartment
equipment that interface with customer
satisfaction.
Vibration is defined as impulses felt by the
customer that are not caused by road surface
changes.
Harshness is a ride quality issue where the
customer feels that the vehicle response to the
road surface is sharply transmitted to the
customer.
Diagnostic Theory
Diagnosis is more than just following a series of
interrelated steps in order to find the solution to
the specific condition. It is a way of looking at
systems that are not functioning the way they
should and finding out why. Also it is knowing how
the system should work and whether it is working
correctly.
There are basic rules for diagnosis. If these rules
are followed, the cause of the condition is usually
found the first time through the system.
Know the System
Know how the parts go together.
Know how the system operates as well as its
limits and what happens when the system
goes wrong.
Sometimes this means checking the system
against one that is known to be working
correctly.
How old or new is the system?

What kind of treatment has it had?
Has it been serviced in the past in such a
manner that might relate to the present
condition?
What is the service history?
Know the History of the Condition
Did it start suddenly or appear gradually?
Was it related to some other occurrence such
as a collision or previous part replacement?
Know how the condition made itself known; it
may be an important clue to the cause.
Know the Probability of Certain Conditions
Developing
Look for the simple rather than the complex.
For example:
- Electrical conditions usually occur at
connections rather than components.
- An engine no-start is more likely to be
caused by a loose wire or small adjustment
rather than a sheared-off camshaft.
Know the difference between impossible and
improbable. Certain failures in a system can
be improbable but still happen.
New parts are just that, new. It does not mean
they are always good functioning parts.
Do Not Cure the Symptom and Leave the
Cause
Lowering the pressure in a front tire may correct
the condition of a vehicle leaning to one side, but it
does not correct the original condition.
Know the History of the System

A clue in any one of these areas may save time:
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100-04-3

Be Positive the Cause is Found
Double check findings.
What caused a worn component?
A loose transmission or engine mount could
indicate that other mounts are also loose.
Diagnostic Charts
Charts are a simple way of expressing the
relationship between basic logic and a physical
system of components. They help discover the
cause of a condition in the least time. Diagnostic
charts combine many areas of diagnosis into one
visual display:
Probability of certain things occurring in a
system.
Speed of checking certain components or
functions before others.
Simplicity of performing certain tests before
others.
Elimination of checking huge portions of a
system by performing simple tests.
Certainty of narrowing down the search to a
small portion before performing in-depth
testing.
The fastest way to find a condition is to work with
the tools that are available. This means working
with proven diagnostic charts and the correct
special equipment for the system.
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100-04-4

Noise, Vibration and Harshness (NVH)
1. Verify the customer concern.
2. Visually inspect for obvious signs of
mechanical or electrical damage.
3. If an obvious cause for an observed or
reported concern is found, correct the cause
(if possible) before proceeding to the next
step.
4. If the concern is not visibly evident, verify the
symptom and REFER to the Symptom Chart.
tires
engine accessories
suspension
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
How To Use This Diagnostic Procedure Section
Noise, vibration and harshness (NVH)

concerns have become more important as
vehicles 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 is
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.
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.
Customer Interview
The road test and customer interview (if available)

provide information that will help identify the
concern and will provide direction to the correct
starting point for diagnosis.
Identify the Condition
NVH usually occur in four areas:

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100-04-5
DIAGNOSIS AND TESTING (Continued)

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
automatic transaxle is engaged in REVERSE
or DRIVE, or it may occur when the throttle is
applied or released. It is caused by backlash
somewhere in the driveline.
Bearing rumble sounds like marbles being
tumbled. This condition is usually caused by a
damaged wheel bearing.
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 km/h (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.
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 powertrain/drivetrain 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
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.
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 transaxle 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 the driving conditions.
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100-04-6

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. At a speed of 24-80 km/h (15-50 mph): With
light acceleration, a moaning noise is heard
and possibly a vibration is felt in the front floor
pan. 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 Symptom Chart.
2. Acceleration/Deceleration: With slow
acceleration and deceleration, a shake is
sometimes noticed in the steering
wheel/column, seats, front floor pan, front
door trim panel or front end sheet metal. It is a
low frequency vibration (around 9-15 cycles
per second). It may or may not be increased
G17381 en
3.
4.
5.
by applying the brakes lightly. REFER to Idle

Boom/Shake/Vibration in the Symptom Chart.
High Speed: A vibration is felt in the front floor
pan or seats with no visible shake, but with an
accompanying sound or rumble, buzz, hum,
drone or booming noise. Coast with the clutch
pedal depressed (manual transmission) or
shift control selector lever in neutral
(automatic transmission) and engine idling. If
vibration is still evident, it may be related to
wheels, tires, front brake discs, wheel hubs or
front wheel bearings. REFER to Shake and
Vibration While Driving in the Symptom Chart.
Engine rpm Sensitive: A vibration is felt
whenever the engine reaches a particular rpm.
It will disappear in neutral coasts. The
vibration can be duplicated by operating the
engine at the problem rpm while the vehicle is
stationary. It can be caused by any
component, from the accessory drive belt to
the clutch or torque converter which turns at
engine speed when the vehicle is stopped.
REFER to Shake and Vibration While Driving
in the Symptom Chart.
Noise and Vibration While Turning: Clicking,
popping, or grinding noises may be due to the
following:
worn, damaged, or incorrectly installed front
wheel bearing
damaged powertrain/drivetrain mounts
Road Conditions
An experienced technician will always establish a
route that will be used for all NVH diagnosis road
tests. The road selected should be reasonably
smooth, level and free of undulations (unless a
particular condition needs to be identified). A
smooth asphalt road that allows driving over a
range of speeds is best. Gravel or bumpy roads
are unsuitable because of the additional road
noise produced. Once the route is established and
consistently used, the road noise variable is
eliminated from the test results.
NOTE: Some concerns may be apparent only on
smooth asphalt roads.
If a customer complains of a noise or vibration on
a particular road and only on a particular road, the
source of the concern may be the road surface. If
possible, try to test the vehicle on the same type of
road.
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Vehicle Preparation
Carry out a thorough visual inspection of the
vehicle before carrying out the road test. Note
anything which is unusual. Do not repair or adjust
any condition until the road test is carried out,
unless the vehicle is inoperative or the condition
could pose a hazard to the technician.
After verifying that the condition has been
corrected, make sure all components removed
have been installed.
Power Steering Conditions
Check for the noise in the following conditions to
verify the customer concern.
Check for the noise in several temperature

conditions.
Is the noise from when the vehicle was new?
Can the noise be repeated constantly or is it
random?
Check the condition of the vehicle age,
mileage and service record.
Interview the customer to find the operating
condition in which the noise will occur. Test the
vehicle based on the detail(s) from the
customer interview.
Follow the power steering operation noise
condition tables below, to find which condition
the noise will occur.
Power Steering Operation Noise Check
Step 1: Check for NVH concerns from
non-steering components, which may sound like
noises coming from the steering system.
Power assisted steering operating condition

Parking
Driving
Steering central/slightly Steering at a steering
Driving straight ahead
Cornering condition
off center
lock stop
REFER to NVH conREFER to NVH conREFER to NVH conREFER to NVH concerns from other comcerns from other comcerns from other comcerns from other components column D
ponents column C
ponents column B
ponents column A
NVH concerns from other components
NVH concerns from other condition (column A to D)
Noise
Driving Condition
A
B
Pedal box knocking
Drive off, stop driving and slow cornering
X
X
over uneven roads
Stabilizer bar link
Drive off, driving and cornering
X
O
knocking
Engine support insuDrive off, driving, acceleration and deX
lator knocking
celeration
Air conditioning
Engine on, activate switch for air condiX
X
knocking
tioning
Suspension knocking Drive off, driving, cornering, acceleration
X
(Subframe, Springs)
and deceleration
Constant velocity joint Drive off, driving, cornering, acceleration
X
O
knocking
and deceleration
Washer bottle
Deceleration, acceleration and single
O
impact
Loose suspension
All driving conditions
O
bolts
Instrument panel rat- All driving conditions. Engine RPM deX
X
tle/squeak
pendant
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C
O
D
X
X
O
X
X
X
O
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Noise
NVH concerns from other condition (column A to D)

Driving Condition
A
B
X = Noise will most likely occur in this operating condition.

O = Noise can possibly occur in this operating condition.
Blank = Noise is unlikely to occur in this operating condition.
Step 2: Check for steering system NVH concerns
according to operation condition described at the
customer interview.
Power assisted steering operating condition
Parking
Driving
Vehicle stationary with engine off
Steering at a Steering cen- Steering at a
Steering cenSteering at a
Steering
steering lock tral/slightly off steering lock
tral/slightly off censteering lock stop
censtop
center
stop
tre
tral/slightly
off center
REFER to steering REFER to steering
REFER to
REFER to
REFER to
REFER to
steering sys- steering sys- steering system system NVH con- system NVH consteering
cerns column F
NVH concerns cerns column E
tem NVH
system NVH tem NVH
column D
concerns
concerns
concerns
column C
column B
column A
Steering system NVH concerns
Steering System operation condition (column A to F)
Noise
Driving condition
A
B
Moan
Parking between lock stops, at engine idle and
X
O
also increased engine speed
Whine
Driving, high engine RPM. Must be present from
O
O
new
Hiss
a) Parking between lock stops. Must be present
X
X
from new
X
b) Holding steering wheel against lock stops. Must
be present from new
Lock Stop Impact a) Parking at lock stop. Must be present from new
X
Knock
Mechanical Knock b) Parking between lock stops, engine off. Must be
(PAS off)
present from new
Mechanical Knock c) Parking between lock stops, engine on (ball joint X
(PAS on)
knock)
Hammer Knock
d) Parking into lock stop and release (vehicle with
X
hydraulic power assisted steering (HPAS) only,
not for vehicles with electro-hydraulic power assisted steering (EHPAS))
Hydraulic Knock
e) Driving, cobble stones, rough road (clonk). Must
(clonk)
be present from new
Column Knock
f) Parking, driving. cobble stones and rough roads X
X
Column rattle
Mainly driving on rough roads
O
Toc-toc
Steering left and right at high frequency. Must be
X
present from new
Grinding
When turning steering wheel
X
Zip
At engine start, low temperatures below -10 C
X
O
only
G17381 en
X
X
O
X
X
X
X
O
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100-04-9
Noise
Steering System operation condition (column A to F)

Driving condition
A
B
X = Noise will most likely occur in this operating condition.

O = Noise can possibly occur in this operating condition.
Blank = Noise is unlikely to occur in this operating condition.
Step 3: According to each identified operating
condition (Column A, B, C, D, E, F), check each
possible Steering System NVH concern with the
detail symptom charts below.
Before conducting vehicle a test to identify a NVH
concern inspect the vehicle.
1. Check the tire pressures and adjust to
specification, as necessary.
2. Make sure the steering system fluid is correct,
the system is free of leaks and is operating
correctly.
3. Make sure the vehicle steering system
temperature is the same as described at the
customer interview.
4. All evaluations must take place in a relatively
quiet location.
5. The heating - A/C fan and radio must be
turned off during evaluations and the windows
closed.
1. Engine speed at idle with no steering action.

2. Engine speed at idle with slow 90 degrees/sec
turning of the steering wheel.
3. Engine speed at 1250 +/- 50 RPM with no
steering action.
4. Engine speed at 1250 +/- 50 RPM with slow
90 degrees/sec turning of the steering wheel.
Symptom Chart
Power Steering Moan Noise
Test Condition
Listen for steering moan noise with the vehicle

parked, transmission in neutral and all windows
closed in the following test conditions.
Symptom
Possible Sources
Power steering system moan

Power steering lines.
noise A continuous low pitched
humming noise occurs when the
steering wheel is turned and the
steering system is loaded. Noise
frequency changes with engine
RPM changes. Particularly anIncorrect power steering fluid.
noying at lower engine speed.
Power steering pump.
G17381 en
Action
CHECK the routing of the
power steering lines.
CHECK the power steering
line clamps are secure.
CHECK the power steering
lines for clearance from the
vehicle body, front axle
crossmember and steering
gear.
FLUSH the power steering system.
Pressure pulses from the power
steering pump. Certain amount of
noise level acceptable, not a
safety critical item.
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steering action.
Power Steering Whine Noise
Test Condition
90 degrees turning of the steering wheel.
Listen for steering whine noise with the vehicle
steering action.
90 degrees turning of the steering wheel.
Symptom
Possible Sources
Action
Power steering fluid aeration.
Bleed the power steering system.
Power steering system whine
noise a high pitched buzzing
FLUSH the power steering sysIncorrect power steering fluid.
sound like an electric motor or
tem.
drill. Whine occurs at the higher
FLUSH the power steering sysOverheated power steering fluid.
engine RPM, 1500-5000 RPM,
tem.
frequency does not change if
Hydraulic operating condition of Certain amount of noise level acsystem is loaded or not loaded. the power steering pump.
ceptable, not a safety critical item.
Power Steering Hiss Noise
Test Condition
Listen for steering hiss noise with the vehicle

Symptom
Possible Sources
Action
CHECK the installation and poNOTE: Engine speed at idle
Floor seal.
tential damage of the floor seal.
turning the steering wheel slowly
Certain amount of noise level
lock to lock.
Power
steering
gear
valve
design.
acceptable, not a safety critical
Power steering system hiss noise
item.
a high frequency, continuous
rush or swish noise like escaping
air from a balloon. Hiss occurs
while turning between the steerPower steering system hydraulic
ing lock stops, all steering angles.
design.
item.
Noise does not change with engine RPM and is worse at high
operating temperatures.
NOTE: Engine speed at idle
holding the steering wheel against
a steering lock for three seconds.
Do not hold for more than five
Power steering pump pressure
seconds.
Power steering system hiss noise relief valve.
item.
a continuous noise like escaping air occurs while holding the
steering against a steering lock
stop.
Power Steering Lock Stop Impact Knock Noise

Test Condition
1. Turn the steering wheel to the left-hand and

right-hand steering locks and listen for the
impact noise.
Listen for steering knock noise with the engine

speed at idle in the following test conditions (noise
also apparent with engine off).
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Symptom
Possible Sources
Power steering system knock
noise a heavy loud sound like a Power steering gear mechanical
noise, metal to metal at end of
knock on a door that occurs in
parking condition when hitting the steering travel.
lock stop.
Power Steering Mechanical Knock Noise (PAS off)
Test Condition
Test Condition

item.
1. Turn the steering wheel 90 degrees to the

right, hold and then quickly release.
2. Turn the steering wheel 90 degrees to the left,
hold and then quickly release.
Listen for steering knock noise with the engine off

in the following test conditions (no power assist).
Symptom
Possible Sources
noise a damped, metallic knock
noise which only occurs at steernoise a heavy loud repeating
ing condition with engine off (very
sound like a knock on a door that
high efforts).
occurs in several driving and
steering conditions.
Tolerances in the steering gear
components.
Power Steering Mechanical Knock Noise (PAS on)
Action
Action
item.
item.
1. Turn the steering wheel to a steering lock and

return to center quickly.
2. Turn the steering wheel 90 degrees to the left
and then 90 degrees to the right quickly.

speed at idle in the following test conditions
(Power assist).
Symptom
Possible Sources
Action
Worn tie-rod ball joints (inner and
REFER to Steering System.
noise clear knock noise from
outer ball joints).
steering gear linkage area.
vehicles with hydraulic power assisted steering
(HPAS) only, not electro hydraulic power assisted
Power Steering Hammer Knock (Hydraulic) Noise
steering (EHPAS)).
Test Condition
1. Turn the steering wheel into steering lock

position and return quickly.
speed at idle in the following test conditions (for
Symptom
Possible Sources
Action
noise loud, metallic sound if hitCertain amount of noise level
ting the suspension crossmember
Hydraulic noise created by presacceptable, not a safety critical
with a hammer (sounds like mesure impulses.
item.
tallic noise but is created by
pressure impulse in gear and return line).
Power Steering Hydraulic Knock/Clonk Noise
Test Condition
Listen for steering knock/clonk noise in the

following test conditions with the windows closed.
G17381 en
1. Drive over cobbled roads at low speed

(6-20mph / 10-30km/h) with and without
turning.
2. Drive over straight tar strips, road rails, or
25mm tall harshness strips at low speed
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(6-20mph / 10-30km/h) both driving straight
and with moderate turning.
Symptom
Possible Sources
Power steering system
knock/clonk noise sounds alPower steering return lines.
most identical to column knock
that occurs when driving and
High power assist gain of power
cornering over cobbled stones or steering gear valve (steering gear
rough roads. Noise may appear to design - no quality issue).
emanate from a location closer to
the floor than that for column
knock (Sounds like metallic noise
High power steering pump flow
but is created by pressure imrate (by design).
pulse in gear and return line
similar to a sound like quickly
turning off a water tap).
Action
item.
item.
item.
1. Drive over cobbled stones at low speed

(10-25 mph) with and without steering input
Power Steering Column Knock Noise
carefully listening for knock sounds.
Test Condition
2. Drive over straight tar strips, road rails, or 25
Listen for steering knock noise in the following test
mm tall harshness strips at low speed (10-25
conditions with windows closed.
mph) both driving straight and with moderate
cornering.
Symptom
Possible Sources
Action
CHECK the steering column retaining bolts and attachments to
Power steering system column
the steering column and secure if
knock noise a loose sounding
Steering column or steering
necessary.
rattle or vibration coming from the
column shaft.
column. Noticeable by hearing
Check steering column and inand touch.
termediate shaft for lash, free play
or loose components.
Power Steering Toc-Toc Noise
Test Condition
1. Turn the steering wheel from left to right

abruptly changing direction.
2. Drive the vehicle for low speed parking
manoeuvres constantly changing steering
direction.
Listen for steering toc-toc noise the engine speed

at idle and the vehicle parked, transmission in
park or neutral and the windows closed.
Symptom
Possible Sources
Action
Power steering system toc-toc
noise a metallic noise created
Steering gear (design tolerance in
when changing direction of
steering rack).
steering wheel rotation during
item.
parking manoeuvre or at standstill.
Power Steering Grinding Noise
Test Condition
Listen for steering grinding noise the engine

speed at idle and the vehicle parked, transmission
in park or neutral and the windows closed.
G17381 en
1. Slowly turn the steering wheel from lock to

lock.
2. Tilt and extend the steering column in various
positions and slowly turn the steering wheel
from lock to lock.
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Symptom
Possible Sources
Steering wheel to shroud interference.
Power steering system grinding

noise an abrasive noise (like
sand paper rubbing against
wood) occurs between moving
components such as steering
wheel and the steering column
shroud.
Steering column bearing.

Foreign material in contact with
the steering column shaft.
Clockspring.
Action
item.
item.
CHECK if floor covering is obstructing the steering gear pinion.CHECK the installation of the
floor seal.
CHECK the clockspring and secure if necessary.
Power Steering Zip Noise
Symptom
Power steering system zip noise
occurs when hydraulic fluid
does not flow freely through the
power steering pump supply hose
from steering fluid reservoir to
power steering pump causing
cavitation at the pump. Zip is
primarily a cold weather start-up
phenomenon (below -10C).
Possible Sources
High viscosity of power steering
fluid at low temperature.
Aeration of the power steering

fluid.
Action
item.
Bleed the power steering system.
Driveline Noise and Vibration
Symptom
Shake and vibration while driving
Tip-in moan
Idle boom/shake/vibration, or
shudder
Possible Sources
Wheel end vibration.

Engine/transmission.
Air cleaner.
Power assisted steering
(PAS).
Powertrain.
Powertrain/drivetrain mounts.
Exhaust system.
Cable(s)/hose(s).
Powertrain/drivetrain mounts.
Exhaust system.
Belt/pulleys.
Action
GO to Pinpoint Test A
GO to Pinpoint Test B
GO to Pinpoint Test C
Suspension Noise and Vibration
Symptom
Wheel end vibration analysis
G17381 en
Possible Sources
Suspension.
Wheel bearings.
Action
GO to Pinpoint Test D
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Symptom
Non-axle noise
Possible Sources
Action
Trim panels.
Air conditioning (A/C) system.
Accessories.
Pinpoint Tests
After verifying that the condition has been corrected, make sure all components removed have
been installed.
NOTE: These pinpoint tests are designed to take

the technician through a step-by-step diagnosis
procedure to determine the cause of a condition. It
may not always be necessary to follow the chart to
its conclusion. Carry out only the pinpoint test
steps necessary to correct the condition. Then
check the operation of the system to make sure
the condition has been corrected.
PINPOINT TEST A: SHAKE AND VIBRATION WHILE DRIVING
TEST CONDITIONS
A1: NEUTRAL COAST
DETAILS/RESULTS/ACTIONS
1 Carry out the neutral coast test.
Does the vibration disappear during the neutral

coast test?
Yes
GO to A2
No
A2: CHECK THE POWERTRAIN/DRIVETRAIN MOUNTS
1 Visually check the hydraulic powertrain/drivetrain mounts for leaks and condition.
Are the powertrain/drivetrain mounts OK?
Yes
GO to A3
No
A3: CHECK THE POWERTRAIN/DRIVETRAIN MOUNT NEUTRALIZATION
1 Carry out the powertrain/drivetrain mount neutralizing procedure in this section.
Is the shake and vibration OK?
Yes
Vehicle condition corrected. CARRY OUT a
road test.
No
VERIFY the customer concern.
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PINPOINT TEST B: TIP-IN MOAN
TEST CONDITIONS
B1: CHECK THE AIR CLEANER

1 Check the condition of the air cleaner mounts,
inlet tube, outlet tube, resonators and all other
components associated with the air induction
system for correct installation and tightness of
all connections.
Are the air cleaner and associated components
OK?
Yes
GO to B2
No
CORRECT the condition. REPEAT the Road
Test as outlined.
B2: CHECK THE EXHAUST SYSTEM
1 Check the exhaust system mounts.
Are the exhaust system mounts OK?
Yes
GO to B3
No
INSTALL new mounts as necessary.
REPEAT the Road Test as outlined.
B3: CHECK THE POWER STEERING
1 Remove the auxiliary drive belt and test for
tip-in moan.
Is the tip-in moan OK?
Yes
REPAIR the power steering as necessary.
No
GO to B4
B4: CHECK THE POWERTRAIN/DRIVETRAIN MOUNTS
Yes
GO to B5
No
B5: CHECK THE POWERTRAIN/DRIVETRAIN MOUNT NEUTRALIZATION
Is the tip-in moan OK?
Yes
Vehicle condition corrected. REPEAT the
Road Test as outlined.
No
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TEST CONDITIONS
PINPOINT TEST C: IDLE BOOM/SHAKE/VIBRATION/SHUDDER

TEST CONDITIONS
C1: CHECK CABLE/HOSES

1 Check the engine compartment for any component that may have a touch condition between the engine and body or chassis. For
example: control cable, air conditioning (A/C)
hoses, and acceleration cable.
Are the engine compartment components OK?
Yes
GO to C2
No
CORRECT the condition. REPEAT the Road
Test as outlined.
C2: CHECK THE ENGINE COOLING RADIATOR
1 Check the engine cooling radiator mountings
and bushings for security and condition. Check
the radiator installation for any component that
may have a touch condition.
Is the engine cooling radiator installation and
bushings OK?
Yes
GO to C3
No
REPAIR or INSTALL new components as
necessary. REPEAT the Road Test as outlined.
C3: CHECK THE EXHAUST SYSTEM
1 Check the exhaust system mounts.
Are the exhaust system mounts OK?
Yes
GO to C4
No
C4: CHECK THE POWERTRAIN/DRIVETRAIN MOUNTS
Yes
GO to C5
No
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TEST CONDITIONS
C5: CHECK THE POWERTRAIN/DRIVETRAIN MOUNT NEUTRALIZATION

Is the boom/shake/vibration/shudder OK?
Yes
Vehicle condition corrected. REPEAT the
Road Test as outlined.
No
PINPOINT TEST D: WHEEL END VIBRATION ANALYSIS
TEST CONDITIONS
D1: INSPECT THE TIRES
1 Inspect the wheels and tires.
Are the wheels and tires OK?
Yes
GO to D2
No
INSTALL new wheels and tires as necessary. REPEAT the Road Test as outlined.
D2: INSPECT WHEEL AND TIRE RUNOUT

1 Inspect the wheel and tire runout.
Is the wheel and tire runout OK?
Yes
GO to D3
No
REPAIR as necessary. REPEAT the Road
Test as outlined.
D3: INSPECT THE WHEEL BEARINGS
1 Inspect the wheel bearings.
Are the wheel bearings OK?
Yes
No
INSTALL new wheel bearings/wheel hub as
necessary. REPEAT the Road Test as outlined
PINPOINT TEST E: NON-AXLE NOISE
TEST CONDITIONS
E1: INSPECT THE VEHICLE TRIM
1 Check the radiator grille and trim panels to see
if they are the source of the noise.
Are the vehicle trim components causing the
noise?
Yes
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TEST CONDITIONS
INSTALL new trim components or REPAIR
as necessary.
No
GO to E2
E2: CHECK THE HEATING AND VENTILATION SYSTEM FOR NOISE
1 Ignition switch in position III.
2 Ignition switch in position II.
3 Check the heating and ventilation system
components for noise by turning the heating and
ventilation system ON and OFF.
Is the heating and ventilation system causing
the noise?
Yes
DIAGNOSE the heating and ventilation system.
No
GO to E3
E3: CHECK THE AIR CONDITIONING (A/C) SYSTEM FOR NOISE
1 Check the A/C system components for noise by
turning the A/C system ON and OFF.
Is the A/C system causing the noise?
Yes
DIAGNOSE the A/C system.
No
GO to E4
E4: CHECK NON-FACTORY ACCESSORIES
1 Check any accessories for being the source of
the noise. Example: grounding body-to-frame,
antennas, visors, deflectors and fog lights.
Are the accessories the cause of the noise?
Yes
ADJUST, REPAIR or INSTALL new accessories or fasteners as required.
No
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GENERAL PROCEDURES
Powertrain/Drivetrain Mount Neutralizing (14 001 0)
NOTE: There is no procedure for neutralizing the
powertrain/drivetrain mounts. To check the
alignment of the powertrain mounts visually,
proceed as follows.
1. Loosen the rear support insulator retaining
bolts (if equipped).
2. Loosen the powertrain/drivetrain mount
retaining bolts.
3. NOTE: Support the powertrain/drivetrain in an
approximate position and height.
NOTE: Make sure that the right-hand mount and
left-hand insulator align over the studs on the
powertrain and drivetrain to allow the fixings to be
assembled through the large holes in the support
insulator bracket without overstraining.
Check the powertrain/drivetrain mount
alignment.
4. Tighten the powertrain/drivetrain mount to
powertrain/drivetrain mount bracket
retaining bolts.
5. Tighten the powertrain/drivetrain mount to
body retaining bolts.
6. Tighten the rear support insulator retaining
bolts (if equipped).
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11/2004 2005.25 Fiesta
BACK TO MAIN INDEX

TO MODEL INDEX
Group
Chassis
SECTION TITLE
PAGE
Suspension
Suspension System - General Information ............................................................................ 204-00-1
Front Suspension .................................................................................................................. 204-01-1
Rear Suspension................................................................................................................... 204-02-1
Wheels and Tires .................................................................................................................. 204-04-1
Driveline
Front Drive Halfshafts............................................................................................................ 205-04-1
Brake System
Brake System - General Information ..................................................................................... 206-00-1
Drum Brake........................................................................................................................... 206-02-1
Front Disc Brake ................................................................................................................... 206-03-1
Rear Disc Brake .................................................................................................................... 206-04-1
Parking Brake and Actuation ................................................................................................. 206-05-1
Hydraulic Brake Actuation ..................................................................................................... 206-06-1
Power Brake Actuation.......................................................................................................... 206-07-1
Anti-Lock Control................................................................................................................... 206-09A-1
Anti-Lock Control - Traction Control ...................................................................................... 206-09B-1
Anti-Lock Control - Stability Assist......................................................................................... 206-09C-1
Steering System
Steering System - General Information ................................................................................. 211-00-1
Power Steering...................................................................................................................... 211-02-1
Steering Linkage ................................................................................................................... 211-03-1
Steering Column ................................................................................................................... 211-04-1
Steering Column Switches .................................................................................................... 211-05-1
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204-00-1
Suspension System - General Information
204-00-1
SECTION 204-00 Suspension System - General

Information
CONTENTS
PAGE
SPECIFICATIONS
Specifications....................................................................................................................
204-00-2

Suspension System ..........................................................................................................
Symptom Chart ................................................................................................................
Pinpoint Tests ..................................................................................................................
Component Tests.............................................................................................................
204-00-4
204-00-4
204-00-4
204-00-6
204-00-8
GENERAL PROCEDURES
Wheel Bearing Inspection .................................................................................................
Front Toe Adjustment.................................................................................... (14 117 0)
204-00-9
204-00-10
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204-00-2
SPECIFICATIONS
Front Wheel Alignment (at curb weight)

Setting or
Nominal
325'
Description
Tolerance Range
Caster angle
Degrees and min432' to 218'
utes
Decimal degrees
4.54 to 2.30
3.42
Camber angle
Degrees and min039' to -207'
-044'
utes
Decimal degrees
0.65 to -2.11
-0.73
Total toe
mm
3.1 Toe in 2.2
3.1 Toe in 1.0
Degrees and min- 030' Toe in 021' 030 Toe in 010'
utes
Decimal degrees 0.50 Toe in 0.35 0.50 Toe in 0.17
Maximum
Variance Left or
Right
100'
1.00
115'
1.25
-
Front Wheel Alignment (at curb weight) Vehicles with 2.0L engine
Setting or
Nominal
347'
Description
Tolerance Range
Caster angle
Degrees and min447' to 247'
utes
Decimal degrees
4.78 to 2.78
3.78
Camber angle
-113'
utes
Decimal degrees
0.03 to -2.47
-1.22
Total toe
mm
1.1 Toe in 2.4
1.1 Toe in 1.2
Degrees and min- 009' Toe in 020' 009' Toe in 010'
utes
Decimal degrees 0.15 Toe in 0.34 0.15 Toe in 0.17
Maximum
Variance Left or
Right
100'
1.00
115'
1.25
-
Rear Wheel Alignment (at curb weight)

Description
Tolerance Range
Camber angle
utes
Decimal degrees
0.12 to -2.40
Total toe
mm
3.2 Toe in 2.1
Degrees and min- 031' Toe in 020'
utes
Decimal degrees 0.52 Toe in 0.34
Setting or
Nominal
-108'
Maximum
Variance Left or
Right
115'
-1.14
3.2
031'
1.25
-
0.52
Rear Wheel Alignment (at curb weight) Vehicles with 2.0L engine
Description
Camber angle
Degrees and minutes
Decimal degrees
Total toe
mm
G149884 en
Tolerance Range
006' to -224'
Setting or
Nominal
-109'
Maximum
Variance Left or
Right
115'
0.10 to -2.40
3.6 Toe in 2.4
-1.15
3.6
1.25
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204-00-3

TO MODEL INDEX
204-00-3
SPECIFICATIONS (Continued)
Tolerance Range
Description
Degrees and min- 031' Toe in 020'
utes
Decimal degrees 0.51 Toe in 0.34
Torque Specifications
Item
Tie-rod end locknut
G149884 en
Nm
63
Setting or
Nominal
031'
Maximum
Variance Left or
Right
-
0.51
lb-ft
46
lb-in
-
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204-00-4

TO MODEL INDEX
204-00-4

Suspension System
Mechanical
Special Tool(s)
Alignment Pins, Subframe
205-524 (15-122)

mechanical damage.
Visual Inspection Chart
- Tire pressure(s)
- Wheels and tires
- Wheel knuckles
- Tie-rod ends
- Front suspension lower arm ball joints
- Front suspension lower arm bushings
- Front strut and spring assemblies
- Front stabilizer bar and connecting links
- Rear springs
- Rear shock absorbers
- Rear suspension beam axle and bushings
step.
4. If the cause is not visually evident, verify the
symptom and refer to the Symptom Chart.
Symptom Chart
Symptom
Drift left or right
Possible Sources
Vehicle attitude incorrect (front
or rear is high or low).
Action
CHECK for abnormal loading,
coil spring sag or non-standard
springs.
Steering gear or linkage worn or CHECK the steering system.

REFER to Section 211-00.
damaged.
Steering wheel off-center
Brake system.
CHECK the brake system.

Incorrect wheel alignment.
ADJUST the wheel alignment.

REFER to Specifications in this
section.
Incorrect front crossmember

alignment.
Using the special tool, CHECK

the front crossmember alignment.
Worn front wheel bearings.
CHECK the wheel bearings.

REFER to Wheel Bearing Inspection in this section.
Wheels and tires.


springs.

damaged.
Suspension lower arm ball joint. CARRY OUT the Ball Joint
Component Test in this section.
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204-00-5

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204-00-5

Symptom
Tracks incorrectly
Possible Sources
Action

section.
Incorrect front suspension toe,

castor or camber angles.
CHECK the wheel alignment.

section. INSTALL new suspension components as necessary.
Incorrect rear suspension toe or CHECK the wheel alignment.

camber angles.
section. INSTALL new suspension components as necessary.
Rough ride
Excessive noise
G149885 en
Front or rear suspension damage.
CHECK and INSTALL new

suspension components as
necessary. REFER to Section
204-01 / 204-02.
Front strut and spring assemblies.

204-01.
Front stabilizer bar, connecting

links or bushings.

204-01.
Front suspension lower arm

bushings.

204-01.
Rear suspension bushings.

components as necessary.
Rear shock absorbers.

204-02.
Front strut and spring assembly CHECK and INSTALL new

upper mounting bolts loose or
broken.
204-01.

204-01.
Worn front wheel bearings.
CHECK the wheel bearings.

REFER to Wheel Bearing Inspection in this section.
11/2004 2005.25 Fiesta
204-00-6

TO MODEL INDEX
204-00-6

Possible Sources
Symptom
Action
Front suspension lower arm

bushings.

204-01.
Suspension lower arm ball joint. CARRY OUT the Ball Joint
Component test in this Section
Incorrect tire wear
Vibration
Wheels and tires.
CHECK the tires. BALANCE or

INSTALL new tires as necessary. REFER to Section 204-04.
Front or rear suspension damage.

204-01 / 204-02.

section.
Damaged or worn front wheel

bearings.
CHECK the front wheel bearings. REFER to Wheel Bearing

Inspection in this section.
Wheels and tires.
CHECK the tires. BALANCE or

INSTALL new tires as necessary. REFER to Section 204-04.

section.

damaged.

204-01.
Damaged front suspension lower CHECK and INSTALL new

arm(s).
204-01.
Pinpoint Tests
PINPOINT TEST A: DRIFT LEFT OR RIGHT
TEST CONDITIONS
WARNING: To avoid personal injury due to the loss of vehicle control, the inspection should
be carried out by two people to maintain safe driving conditions. Adequate grip should always be maintained on the steering wheel. Failure to follow these instructions may result in
personal injury.
NOTE: The following conditions must be met when evaluating the vehicle.
NOTE: The tire swapping procedures are for bi-directional rotating tires only.
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204-00-7

TEST CONDITIONS
A1: SWAP THE FRONT WHEEL AND TIRE ASSEMBLIES

1 Raise and support the vehicle.
- Swap the front left-hand wheel and tire
assembly with the front right-hand wheel and
tire assembly.
- Road test the vehicle.
Does the vehicle drift?
Yes
GO to A2
No
The concern has been corrected.
A2: SWAP THE REAR WHEEL AND TIRE ASSEMBLIES
- Swap the rear left-hand wheel and tire
assembly with the rear right-hand wheel and
tire assembly.
Yes
GO to A3
No
A3: SWAP THE LEFT-HAND WHEEL AND TIRE ASSEMBLIES
assembly with the rear left-hand wheel and tire
assembly.
Yes
GO to A4
No
A4: SWAP THE RIGHT-HAND WHEEL AND TIRE ASSEMBLIES
- Swap the front right-hand wheel and tire
tire assembly.
Yes
GO to A5
No
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204-00-8

TEST CONDITIONS
A5: SWAP THE FRONT LEFT-HAND WHEEL AND TIRE ASSEMBLY

tire assembly.
Yes
GO to A6
No
A6: SWAP THE FRONT RIGHT-HAND WHEEL AND TIRE ASSEMBLY
- Swap the front right-hand wheel and tire
assembly with the rear left-hand wheel and tire
assembly.
Yes
GO to A7
No
A7: INSTALL NEW TIRES
NOTE: Install new tires only once.
1 Install new tires to the four road wheels. TEST
the system for normal operation.
Yes
Verify possible sources, refer to the Symptom Chart.
No
Component Tests
Ball Joint Inspection
G149885 en
1. Raise and support the vehicle.

2. Firmly grasp the outer end of the suspension
lower arm and try to move it up and down,
watching and feeling for any movement. Free
movement will usually be accompanied by an
audible "click''. There should be no free
movement.
3. If there is any free movement install a new
lower arm. REFER to Section 204-01.
4. If a new lower arm is installed it will be
necessary to check and adjust the front wheel
alignment. REFER to Specifications in this
section.
11/2004 2005.25 Fiesta

TO MODEL INDEX
204-00-9
204-00-9
GENERAL PROCEDURES
Wheel Bearing Inspection
Special Tool(s)
Holding Fixture, Dial Indicator
Gauge
205-044 (15-008)
5. Position a suitable Dial indicator gauge

fixture or equivalent, against the wheel hub,
then push and pull the wheel hub. Measure
the end play of the wheel hub and front
wheel bearing assembly. There should be
no end play. If end play exists, install new
wheel bearings.
General Equipment
Dial indicator gauge
Check
1. NOTE: Do not to confuse lower arm ball joint
looseness with bearing looseness.
Raise and support the front of the vehicle.
For additional information, refer to Section
100-02.
2. Check for loose front wheel bearings by
rocking the wheels at the top and bottom.
6. Install the front brake caliper. For

additional information, refer to Section
206-03.
3. Spin the wheel quickly by hand and make

sure the wheel turns smoothly without
noise from the wheel bearings.
4. Remove the front brake caliper and anchor
plate. For additional information, refer to
Section 206-03.
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204-00-10

TO MODEL INDEX
204-00-10
GENERAL PROCEDURES
Front Toe Adjustment (14 117 0)
NOTE: The checking and subsequent adjustment
of the front toe setting should be carried out on a
flat surface and in accordance with the
manufacturers instructions for the wheel
alignment equipment used.
1. Centralize the steering and lock it in position.
4. Rotate the tie-rods an equal amount in either a clockwise or a counterclockwise direction to adjust the toe setting.
5. Tighten the tie-rod end locknuts. For additional information, refer to Section 211-03.
2. Loosen the tie-rod end locknuts.
6. Install the steering gear boot outer clamps.

3. Remove the steering gear boot outer
clamps.
7. Check the toe setting.

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204-01-1
Front Suspension
204-01-1
SECTION 204-01 Front Suspension

CONTENTS
PAGE
SPECIFICATIONS
Specifications....................................................................................................................
204-01-2

Front Suspension..............................................................................................................
204-01-3

Front Suspension..............................................................................................................
204-01-5
REMOVAL AND INSTALLATION

Stabilizer Bar Bushing...................................................................................
Lower Arm ....................................................................................................
Stabilizer Bar ................................................................................................
Wheel Knuckle ..............................................................................................
Strut and Spring Assembly............................................................................
Wheel Bearing ..............................................................................................
(14 754 0)
(14 706 0)
(14 752 0)
(14 343 0)
(14 781 0)
(14 411 0)
204-01-6
204-01-7
204-01-9
204-01-13
204-01-19
204-01-22
Strut and Spring Assembly............................................................................ (14 783 4)
204-01-24
DISASSEMBLY AND ASSEMBLY
11/2004 2005.25 Fiesta
204-01-2

TO MODEL INDEX
Front Suspension
204-01-2
SPECIFICATIONS
Item
Top mount retaining nuts
Thrust bearing retaining nut
Stabilizer bar connecting link to strut and spring
retaining nut
Wheel knuckle to suspension strut pinch bolt
Brake caliper anchor plate retaining bolts
Lower arm ball joint to wheel knuckle retaining nut
Tie-rod end retaining nut
Stabilizer bar clamp retaining bolts
Stabilizer bar to connecting link retaining nut
Steering gear retaining bolts
Lower arm front retaining bolt
Lower arm rear clamp retaining bolts
Crossmember front retaining bolts
Crossmember rear retaining bolts
Crossmember inner and outer retaining bolts
Wheel hub retaining nut
Engine support insulator center bolt
Wheel speed sensor retaining nut
Nm
25
48
48
lb-ft
18
35
35
lb-in
-
85
70
48
48
55
55
48
a)
55
70
115
175
290
48
9
63
52
35
35
41
41
35
41
52
85
129
214
35
-
80
a) Refer to the procedure in this section.
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11/2004 2005.25 Fiesta
204-01-3

TO MODEL INDEX
Front Suspension
204-01-3

Front Suspension
Overview
NOTE: During installation of the front wheel

bearing it is important to adhere to the specified
installation position, as the anti-lock brake system
( ABS ) sensor ring is located in the wheel bearing.
A coloured rubber ring is provided to indicate the
correct installation position. If the wheel bearing
were to be installed incorrectly then this would
cause failure of the ABS .
A newly developed Mc-Pherson front suspension
with L-shaped lower arms is used. These lower
suspension arms are linked via large rubber
mountings to a reinforced and extremely rigid front
axle crossmember.
The ball head between the lower suspension arm
and the suspension strut is secured with three
rivets. Toe-in is adjusted via adjustable track rods.
The lower suspension arms can only be replaced
as a complete unit.
Item
Part
Number
Description
Rear rubber mounting
The rear rubber mountings for the lower

suspension arms are enclosed in aluminium
brackets. This provides more vibration damping
than previously. Both the front and rear brackets
are arranged horizontally.
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Front Suspension
204-01-4

The suspension strut turret support bearings have
two separate routes for independently deflecting
the spring and shock absorber forces into the
body. This reduces the level of noise transmitted
from the road surface.
The correct installation position must be observed
when installing the suspension strut turret support
bearings. This is indicated by an arrow on the
suspension strut turret support bearing. The shock
absorbers are gas shock absorbers.
The spring travel has been increased by 6 mm,
and the track has been increased by 48 mm to
1477 mm.
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204-01-5

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Front Suspension
204-01-5

Front Suspension
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204-01-6

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Front Suspension
204-01-6

Stabilizer Bar Bushing (14 754 0)
Removal
1. Remove the stabilizer bar. For additional
information, refer to Stabilizer Bar in this
section.
2. Remove the stabilizer bar bushings on
both sides.
2. Install the stabilizer bar. For additional

information, refer to Stabilizer Bar in this
section.
Installation
1.
CAUTION: Do not lubricate the

stabilizer bar bushings.
CAUTION: The stabilizer bar bushings
must be positioned with the slot facing
forwards of the stabilizer bar.
CAUTION: The stabilizer bar bushings

must be positioned as shown.
NOTE: The location of the stabilizer bar bushings
should be measured from the center mark on the
stabilizer bar.
Install the stabilizer bar bushings.
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Front Suspension
204-01-7

Lower Arm (14 706 0)
Removal
4. Remove the lower arm.
1. Remove the wheel and tire. For additional

information, refer to Section 204-04.
2.
CAUTION: Protect the ball joint seal

using a soft cloth to prevent damage.
Detach the lower arm ball joint from the
wheel knuckle.
Remove the heat shield.
Installation
1. NOTE: Do not fully tighten the lower arm to
crossmember retaining bolts at this stage.
Install the lower arm.
3. Remove the crossmember outer retaining
bolt.
2. Install the crossmember outer retaining

bolt.
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204-01-8

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Front Suspension
204-01-8
REMOVAL AND INSTALLATION (Continued)

3.
CAUTION: Make sure the heat shield is

installed to prevent damage to the ball
joint.
Install the heat shield.
4.
6. NOTE: The lower arm to crossmember

retaining bolts must be tightened with the
vehicle weight on the road wheels.
Tighten the lower arm to crossmember
retaining bolts.
1. Tighten the bolt in two stages.
Stage 1: 80 Nm.
Stage 2: 55 degrees.
2. Tighten the bolts.
CAUTION: The lower arm pinch bolt

must be installed from the rear of the
wheel knuckle.
Attach the lower arm ball joint to the wheel
knuckle.
7. Check the toe setting and adjust as

necessary. For additional information,
refer to Section 204-00.
5. Install the wheel and tire. For additional

G183757 en
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204-01-9
Front Suspension
204-01-9

Stabilizer Bar (14 752 0)
Special Tool(s)
205-524 (15-122)

4. NOTE: Use a 5 mm Allen key to prevent the ball
joint from rotating.
Detach the stabilizer bar connecting link
from the stabilizer bar on both sides.
General Equipment
Transmission jack
Wooden block
Removal
1. NOTE: Make sure the road wheels are in the
straight ahead position.
Centralize the steering and lock it in position.
2. Detach the steering column shaft from the

steering gear pinion.
Discard the retaining bolt.
G183758 en
5. Remove the engine support insulator.
6. Detach the exhaust system from the exhaust hanger insulator.
11/2004 2005.25 Fiesta
204-01-10

TO MODEL INDEX
Front Suspension
204-01-10

7. Using a suitable transmission jack and a
wooden block, support the crossmember.
8. Remove the crossmember retaining bolts
on both sides.
9. Lower the crossmember to gain access to

the stabilizer bar.
10. Remove the stabilizer bar clamp on both
sides.
3. NOTE: Do not fully tighten the stabilizer bar

clamp retaining bolts at this stage.
Install the stabilizer bar clamp on both
sides.
4.
WARNING: When installing the

stabilizer bar, the measurement must
be taken in a vertical plane between
the crossmember and the stabilizer bar.
Failure to follow this instruction may
result in personal injury.
Set the stabilizer bar to the installation
setting.
Using cable ties, support the stabilizer bar
on both sides.
11. Remove the stabilizer bar.

12. Remove the stabilizer bar bushings. For
additional information, refer to Stabilizer
Bar Bushing in this section.
Installation
1. Install the stabilizer bar bushings. For
additional information, refer to Stabilizer
Bar Bushing in this section.
2. Position the stabilizer bar on the
crossmember.
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204-01-11

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Front Suspension
204-01-11
5. Install the stabilizer bar.

Tighten the bolts in two stages.
Stage 1: 10 Nm.
Stage 2: 55 Nm.
6. Remove the cable ties.

7. Using the transmission jack and the
wooden block, position the crossmember.
8. NOTE: Use the inner crossmember retaining
bolt to locate the special tools.
9.
CAUTION: While tightening the

crossmember retaining bolts, make
sure the crossmember does not move.
Install the crossmember retaining bolts on
both sides.
10. Remove the special tools.

11. Install the crossmember inner retaining
bolts on both sides.
Install the special tools on both sides.
12. Remove the transmission jack and

wooden block.
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Front Suspension
204-01-12
13. Attach the exhaust system to the exhaust

hanger insulator.
17.
WARNING: Install a new steering

column to steering gear pinion
retaining bolt. Failure to follow this
instruction may result in personal
injury.
Attach the steering column shaft to the
14. Install the engine support insulator.

refer to Section 204-00.[Suspension
System - General Information,
SPECIFICATIONS, Specifications]
For additional information, refer to
Section 204-00.[Suspension System General Information, GENERAL
PROCEDURES, Front Toe Adjustment]
15. NOTE: Use a 5 mm Allen key to prevent the
ball joint from rotating.
Attach the stabilizer bar connecting link
to the stabilizer bar on both sides.
16. Lower the vehicle.
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204-01-13
Front Suspension
204-01-13

Wheel Knuckle (14 343 0)
2. Loosen the strut and spring assembly top
mount retaining nuts by five turns.
Special Tool(s)
Lever, Wheel Knuckle
204-159 (14-039)
Installer, Halfshaft
204-161 (14-041)
Separator, Ball Joint

211-020 (13-006)
General Equipment
Three leg puller
Removal

[Wheels and Tires, REMOVAL AND
INSTALLATION, Wheel and Tire]
4. NOTE: Make a note of the position of the brake
hose, to aid installation.
Detach the brake hose from the brake hose
support bracket.
Remove the retaining clip.
All vehicles
1. Loosen the wheel hub retaining nut.
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11/2004 2005.25 Fiesta
204-01-14

TO MODEL INDEX
Front Suspension
204-01-14

All vehicles
5.
CAUTION: Suspend the brake caliper

and anchor plate to prevent load being
placed on the brake hose.
Detach the brake caliper and anchor plate
from the wheel knuckle.
CAUTION: Leave the tie-rod end

retaining nut in place to protect the
ball joint stud.
NOTE: Use a 5 mm Allen key to prevent the ball
joint stud from rotating.
8.
Loosen the tie-rod end retaining nut.
6. Remove the brake disc.

Remove and discard the retaining washer (if
equipped).
9.

Using the special tool, detach the tie-rod
end from the wheel knuckle.
1. Release the tie-rod end.
2. Remove and discard the tie rod end retaining nut.
Vehicles with anti-lock brakes

7. Detach the wheel speed sensor from the
wheel knuckle.
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11/2004 2005.25 Fiesta
204-01-15

TO MODEL INDEX
Front Suspension
204-01-15
10.

wheel knuckle.
11. Remove and discard the wheel hub retaining nut.
13. NOTE: Support the halfshaft. The inner joint

must not be bent more than 18 degrees. The
outer joint must not be bent more than 45
degrees.
Using a suitable three leg puller, detach
the wheel hub from the halfshaft.
14. Using the special tool, remove the wheel

knuckle.
12. Remove the wheel knuckle to suspension

strut pinch bolt.
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11/2004 2005.25 Fiesta
204-01-16

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Front Suspension
204-01-16
3.
Installation
All vehicles
1. Install the wheel knuckle.
2.
CAUTION: Make sure the halfshaft is

completely installed into the wheel
hub.
Using the special tool, attach the wheel hub
to the halfshaft.
G183759 en

joint.
4.

wheel knuckle.
knuckle.
11/2004 2005.25 Fiesta
204-01-17

TO MODEL INDEX
Front Suspension
204-01-17
5.
WARNING: Install a new tie-rod end

retaining nut. Failure to follow this
injury.
8.
CAUTION: Do not twist the brake hose

when attaching the brake caliper to
prevent damage to the brake hose.
Attach the brake caliper and anchor plate
to the wheel knuckle.
Attach the tie-rod end to the wheel knuckle.
9.
6. Attach the wheel speed sensor to the wheel
knuckle.
CAUTION: Make sure the brake hose is

correctly located in the brake hose
support bracket to prevent damage to
the brake hose.
CAUTION: Make sure the brake hose
retaining clip is located on the underside
of the brake hose support bracket to
Attach the brake hose to the brake hose
support bracket.
All vehicles
7. Install the brake disc.
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11/2004 2005.25 Fiesta
204-01-18

TO MODEL INDEX
Front Suspension
204-01-18
10.
WARNING: Install a new wheel hub

injury.
13. Tighten the strut and spring assembly top

mount retaining nuts.
With the aid of another technician, apply

the brakes and pre-load the wheel bearing
by installing the wheel hub retaining nut.

information, refer to Section
204-04.[Wheels and Tires, REMOVAL AND
12. Tighten the wheel hub retaining nut.
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204-01-19
Front Suspension
204-01-19

Strut and Spring Assembly (14 781 0)
4.
Special Tool(s)
Lever, Wheel Knuckle
204-159 (14-039)

and anchor plate to prevent load being
placed on the brake hose.
Detach the brake caliper and anchor plate
from the wheel knuckle.
Removal
hose, to aid installation.
support bracket.
Remove the retaining clip.

Remove and discard the retaining washer (if
equipped).

from the strut and spring assembly.
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11/2004 2005.25 Fiesta
204-01-20

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Front Suspension
204-01-20
6.

wheel knuckle.
7. Remove the wheel knuckle to strut and

spring assembly pinch bolt.
8. NOTE: Support the halfshaft. The inner joint

must not be bent more than 18 degrees. The
outer joint must not be bent more than 45
degrees.
Using the special tool, detach the wheel
knuckle from the strut and spring assembly.
9.
CAUTION: With the aid of another

technician, support the strut and
spring assembly.
Remove the strut and spring assembly.
Installation
joint.
CAUTION: The lower arm pinch bolt must
be installed from the rear of the wheel
knuckle.
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11/2004 2005.25 Fiesta
204-01-21

TO MODEL INDEX
Front Suspension
204-01-21

when installing the brake caliper to
CAUTION: Make sure the brake hose is
correctly located in the brake hose
support bracket to prevent damage to the
brake hose.
CAUTION: Make sure the brake hose
1. To install, reverse the removal procedure.
G183760 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
204-01-22
Front Suspension
204-01-22

Wheel Bearing (14 411 0)
Removal
Special Tool(s)
Collet for 205-295
204-158 (14-038)
Adapter for 204-158 (Thrust

Pad)
204-158-01 (14-038-01)
1. Remove the wheel knuckle. For additional

information, refer to Wheel Knuckle in this
section.
2. NOTE: When removing the wheel hub from the
wheel knuckle the bearing will be destroyed.
The bearing inner ring will be on the wheel hub
and the bearing outer ring will be in the wheel
knuckle.
Using the special tool, remove the wheel
hub.
Installer, Front Wheel Bearing

204-160 (14-040)
Adapter for 205-074

205-074-01 (15-064)
Installer, Rear Hub Oil Seal

205-075 (15-036)
Remover, Bearing (Main

Tool)
205-295 (15-050A)
3.
CAUTION: The special tools must be

used to prevent damage to the wheel
hub. If the wheel hub is damaged a
new wheel hub must be installed.
CAUTION: Do not use heat to remove the
bearing inner ring.
Using the special tools, remove the bearing
inner ring.
Installer/Aligner, Crankshaft
Rear Oil Seal
303-172-03 (21-102-03)
Name
Engine oil
G189095 en
Specification
WSS-M2C913-A
11/2004 2005.25 Fiesta
204-01-23

TO MODEL INDEX
Front Suspension
204-01-23

4. Using the special tools, remove the bearing
outer ring and speed sensor ring.
Installation
2. Using the special tools, install the wheel

hub.
3. Install the wheel knuckle. For additional

information, refer to Wheel Knuckle in this
section.
CAUTION: Avoid any impact on the wheel

speed sensor ring.
CAUTION: Make sure the wheel speed
sensor ring is clean.
CAUTION: Avoid any contact between the
wheel speed sensor ring and a magnetic
surface.
1.
CAUTION: Make sure the wheel bearing

is installed into the wheel knuckle with
the wheel speed sensor ring, colored
black, towards the inner face of the
wheel knuckle.
CAUTION: Make sure the wheel bearing is

completely installed in the wheel knuckle.
NOTE: Lubricate the bore of the wheel knuckle
with clean engine oil.
Using the special tool, install the new
wheel bearing.
G189095 en
11/2004 2005.25 Fiesta
204-01-24

TO MODEL INDEX
Front Suspension
204-01-24

Strut and Spring Assembly (14 783 4)
2.
Special Tool(s)
Compressor, Coil Spring
204-167 (14-042)
CAUTION: Use an Allen key to prevent

the piston rod from rotating.
Loosen the thrust bearing retaining nut.
Adaptors for 204-167

204-167-01 (14-042-01)
Disassembly
1.
WARNING: The spring is under extreme

tension; care must be taken at all times.
Using the special tools, compress the
spring.
G183766 en
11/2004 2005.25 Fiesta
204-01-25

TO MODEL INDEX
Front Suspension
204-01-25
DISASSEMBLY AND ASSEMBLY (Continued)

3. NOTE: When access to the strut or spring only
is required, remove items two through five as a
complete assembly.
Disassemble the strut and spring
assembly.
1. Remove the thrust bearing retaining nut.
2. Remove the top mount.
3. Remove the thrust bearing and spring seat
assembly.
4. Remove the boot.
5. Remove the bump stop.
6. Remove the spring.
7. Remove the insulator pad.
G183766 en
Assembly
1.
CAUTION: The ends of the spring must

locate correctly in the spring seats.
To assemble, reverse the disassembly
procedure.
11/2004 2005.25 Fiesta

TO MODEL INDEX
204-02-1
Rear Suspension
204-02-1
SECTION 204-02 Rear Suspension

CONTENTS
PAGE
SPECIFICATIONS
Specifications....................................................................................................................
204-02-2

Rear Suspension ..............................................................................................................
204-02-3

Rear Suspension ..............................................................................................................
204-02-5

Shock Absorber ............................................................................................ (15 791 0)
Spring ........................................................................................................... (15 621 0)
Beam Axle .................................................................................................... (15 231 0)
Wheel Spindle............................................................................................... (15 366 0)
Wheel Bearing ..................................................................................................................
Trailing Arm Bushing..................................................................................... (15 730 0)
204-02-6
204-02-8
204-02-10
204-02-15
204-02-17
204-02-21
11/2004 2005.25 Fiesta
204-02-2

TO MODEL INDEX
Rear Suspension
204-02-2
SPECIFICATIONS
Item
Shock absorber lower mount retaining bolt
Shock absorber upper mount retaining bolts
Trailing arm bushing retaining bolts
Beam axle retaining bolts
Wheel spindle retaining bolts - Vehicles with rear
drum brakes
Wheel spindle retaining bolts - Vehicles with rear
disc brakes
Brake hose to brake caliper union
Brake tube to brake hose union
Wheel speed sensor retaining bolt
G152540 en
Nm
115
25
125
115
70
lb-ft
85
18
92
85
52
lb-in
-
66
49
235
15
15
9
173
11
11
-
80
11/2004 2005.25 Fiesta
204-02-3

TO MODEL INDEX
Rear Suspension
204-02-3

Rear Suspension
Overview
The rear suspension is a semi-independent

suspension. The track has been increased by 71
mm to 1444 mm.
In addition, the diameter of the longitudinal
members has been increased to increase stability
and to reduce unwanted movements of the vehicle
around the longitudinal axis.
G167083 en
11/2004 2005.25 Fiesta
204-02-4

TO MODEL INDEX
Rear Suspension
204-02-4
Item
Part
Number
Description
Brake drum
Anti-lock brake system

(ABS ) wheel sensor pick-up
ring
Stub axle
Brake back plate assembly

with brake
Bracket
Spring
Shock absorber
The shock absorbers are single-tube gas shock

absorbers.
It is important that the correct installation
orientation is adhered to when assembling the
support bearings, as otherwise the geometry of
the rear suspension will not be correct. The
installation orientation of the support bearing is
indicated with an arrow.
A significant modification is the replacement of the

previous Mc-Pherson suspension struts with
separate spring and shock absorber elements.
This results in more space in the area of the
suspension strut turrets, thus increasing the
volume of the luggage compartment. In addition,
the forces from the spring and shock absorber
elements are now dissipated separately and have
been individually optimised.
G167083 en
11/2004 2005.25 Fiesta
204-02-5

TO MODEL INDEX
Rear Suspension
204-02-5

Rear Suspension
G17411 en
11/2004 2005.25 Fiesta
204-02-6

TO MODEL INDEX
Rear Suspension
204-02-6

Shock Absorber (15 791 0)
General Equipment
5. Remove the shock absorber.
Transmission jack
Removal
2. Detach the fender splash shield from the
fender.
Installation
1. Attach the shock absorber to the body.
3. Using a suitable transmission jack,

support the beam axle.
4. Detach the shock absorber from the beam
axle.
2. NOTE: Do not fully tighten the shock absorber

lower mounting bolt at this stage.
Install the shock absorber.
G89134 en
11/2004 2005.25 Fiesta
204-02-7

TO MODEL INDEX
Rear Suspension
204-02-7

3. Attach the fender splash shield to the
fender.

5. NOTE: The final tightening of the shock
absorber lower mounting bolt should be carried
out when the vehicle weight is on the road
wheels.
Tighten the shock absorber lower mounting bolt.
G89134 en
11/2004 2005.25 Fiesta
204-02-8

TO MODEL INDEX
Rear Suspension
204-02-8

Spring (15 621 0)
axle.
Special Tool(s)
Compressor, Coil Spring
204-167 (14-042)
Adapters for 204-167

204-215 (15-111)
Removal
1. Raise and support the vehicle. For
100-02.
2.
WARNING: As the spring is under

extreme tension care must be taken at
all times. Failure to follow this
injury.
Using the special tools, compress the
spring.
4.
WARNING: As the spring is under

extreme tension care must be taken at
all times. Failure to follow this
injury.
Remove the spring.
Installation
1. NOTE: Make sure the top seat mounting is
installed, and the spring ends butt correctly
against the upper and lower spring seats.
Install the spring.
lower mounting bolt at this stage.
Attach the shock absorber to the beam
axle.

G89135 en
11/2004 2005.25 Fiesta
204-02-9

TO MODEL INDEX
Rear Suspension
204-02-9

4. NOTE: The final tightening of the shock
absorber lower mounting bolt should be carried
out when the vehicle weight is on the road
wheels.
Tighten the shock absorber lower mounting bolt.
G89135 en
11/2004 2005.25 Fiesta
204-02-10

TO MODEL INDEX
Rear Suspension
204-02-10

Beam Axle (15 231 0)
General Equipment
5. Detach the parking brake cable from the

beam axle bracket on both sides.
Transmission jack
Securing strap
Electric hand drill
Blind rivet gun
Removal
Vehicles with rear drum brakes
1. Release the parking brake.
2. Remove the rear wheels and tires. For
3. Detach the rear wheel speed sensor and
brake hose retaining bracket from the
beam axle on both sides.
Remove the retaining bolt.
6. Remove the brake drum and wheel spindle

assembly on both sides.
4. Disconnect the parking brake cable on

both sides.
G183767 en
11/2004 2005.25 Fiesta
204-02-11

TO MODEL INDEX
Rear Suspension
204-02-11
7.
CAUTION: Suspend the brake backing

plate, wheel cylinder and brake shoes
assembly to prevent load being placed
on the brake hose.
All vehicles
Detach the brake backing plate, wheel

cylinder and brake shoes assembly from
the beam axle on both sides.
Using a suitable electric hand drill, remove
the rivets.
11. Remove the rear wheel speed sensor. For

206-09.[Anti-Lock Control, REMOVAL
AND INSTALLATION, Rear Wheel Speed
Sensor]
12.
Vehicles with rear disc brakes
8. Remove the brake disc shield. For
206-04.[Rear Disc Brake, REMOVAL AND
INSTALLATION, Brake Disc Shield]
G183767 en
WARNING: Make sure that the beam

axle is secured to the transmission
jack. Failure to follow this instruction
may result in personal injury.
Using a suitable securing strap, secure

the beam axle to a transmission jack.
axle on both sides.
11/2004 2005.25 Fiesta
204-02-12

TO MODEL INDEX
Rear Suspension
204-02-12

14. Detach the spring from the lower spring
seat on both sides.
2. NOTE: Do not fully tighten the beam axle

retaining bolts at this stage.
Install the beam axle.
Install the beam axle retaining bolts on both
sides.
15. Remove the beam axle.

Remove the beam axle retaining bolts on
both sides.
3. Attach the spring to the lower spring seat
on both sides.
Installation
All vehicles
NOTE: Final tightening of the beam axle
components should be carried out when the
vehicle weight is on the road wheels.
1. Using a suitable transmission jack, locate
the beam axle.
G183767 en

Attach the shock absorber to the beam axle
on both sides.
11/2004 2005.25 Fiesta
204-02-13

TO MODEL INDEX
Rear Suspension
204-02-13

5. Remove the securing strap.
6. Lower and remove the transmission jack.
7. Install the rear wheel speed sensor. For
206-09.[Anti-Lock Control, REMOVAL AND
INSTALLATION, Rear Wheel Speed Sensor]
8. Attach the parking brake cable to the beam
axle on both sides.

11. Attach the brake backing plate, wheel
cylinder and brake shoes assembly to the
Using a suitable blind rivet gun, install new
rivets.
12. Install the brake drum and wheel spindle

assembly on both sides.
axle bracket on both sides.
13. Attach the parking brake cable to the

10. Install the brake disc shield. For
206-04.[Rear Disc Brake, REMOVAL AND
INSTALLATION, Brake Disc Shield]
G183767 en
11/2004 2005.25 Fiesta
204-02-14

TO MODEL INDEX
Rear Suspension
204-02-14

14. Connect the parking brake cable on both
sides.
15. Attach the rear wheel speed sensor and

brake hose retaining bracket to the beam
axle on both sides.
Install the retaining bolt.
18. Tighten the shock absorber lower

mounting bolt on both sides.
19. Adjust the parking brake cable. For

206-05.[Parking Brake and Actuation,
GENERAL PROCEDURES, Parking Brake
Cable Adjustment - Vehicles With: Rear
Drum Brakes]
16. Install the rear wheels and tires. For

All vehicles
17. Tighten the beam axle retaining bolts on
both sides.
G183767 en
11/2004 2005.25 Fiesta
204-02-15

TO MODEL INDEX
Rear Suspension
204-02-15

Wheel Spindle (15 366 0)
Removal
4. Remove the wheel spindle.
All vehicles
1. Remove the dust cap.

2. Remove the brake drum. For additional
information, refer to Section 206-02.[Drum
Brake, REMOVAL AND INSTALLATION,
Brake Drum]
wheel spindle.
G183768 en

5. Remove the brake disc. For additional
information, refer to Section 206-04.[Rear
Disc Brake, REMOVAL AND
INSTALLATION, Brake Disc]
6. Remove the wheel hub.
Remove and discard the wheel hub retaining nut.
11/2004 2005.25 Fiesta
204-02-16

TO MODEL INDEX
Rear Suspension
204-02-16

wheel spindle.
8. Remove the wheel spindle.
Installation
NOTE: Install a new wheel hub retaining nut.
G183768 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
204-02-17
Rear Suspension
204-02-17

Wheel Bearing
Special Tool(s)
Installer, Differential Bearing
205-062
4. Remove the brake drum and hub assembly.

Installer, Input Shaft Seal

307-210 (17-041)
General Equipment
Soft faced hammer
Wooden block
Removal
CAUTION: The brake drum and hub
assembly removal in this procedure is for
installing a new wheel bearing, not for
access to brake system components.
All vehicles


G183769 en
11/2004 2005.25 Fiesta
204-02-18

TO MODEL INDEX
Rear Suspension
204-02-18

All vehicles
7. Remove and discard the wheel speed
sensor ring (brake disc shown).
Installation
All vehicles
1.
CAUTION: Support the wheel hub

assembly on the wheel mounting face
and not on the wheel nut studs.
Using the special tool, install the new
wheel bearing (brake disc shown).
8. Remove the circlip (brake disc shown).
2. Install the circlip (brake disc shown).
9. Using the special tool, remove and discard

the wheel bearing (brake disc shown).
G183769 en
11/2004 2005.25 Fiesta
204-02-19

TO MODEL INDEX
Rear Suspension
204-02-19
3.

sensor ring is not knocked, damaged
and kept free from metal fragments.
CAUTION: Protect the face of the wheel
speed sensor ring with a non-ferrous flat
block to prevent damage.
CAUTION: Make sure the wheel hub or
brake drum is adequately supported and
do not allow it to rest on the wheel studs..
sensor ring is pressed on slowly and
squarely until fully seated.
CAUTION: Do not exceed a maximum load
of 10 kN.

4.
CAUTION: Avoid impact on the wheel

speed sensor ring.
surface.
CAUTION: Rotate the wheel hub assembly

10 times counter-clockwise when
tightening the wheel hub retaining nut to
prevent damage to the wheel bearing.
Install the brake drum and hub assembly.
Using the special tool, install a new wheel

speed sensor ring (brake disc shown).
5. Apply the parking brake.
G183769 en
11/2004 2005.25 Fiesta
204-02-20

TO MODEL INDEX
Rear Suspension
204-02-20

6.
CAUTION: Avoid impact on the wheel

speed sensor ring.
9. NOTE: If the dust cap is damaged a new dust

cap must be installed.
Using a soft faced hammer and a wooden
block, install the dust cap.

surface.
CAUTION: Rotate the wheel hub assembly
10 times counter-clockwise when
tightening the wheel hub retaining nut to
prevent damage to the wheel bearing.
Install the wheel hub retaining nut.
7. Install the brake disc. For additional

All vehicles
G183769 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
204-02-21
Rear Suspension
204-02-21

Trailing Arm Bushing (15 730 0)
General Equipment
Transmission jack
Special Tool(s)
Remover/Installer, Rear Axle
Housing Bushings
205-035 (15-003B)
Adapter for 205-074
205-074-01 (15-064)
Removal
2. Disconnect the wheel speed sensor electrical connector.
Remover/Installer, Pivot
Bushing
205-297 (15-086)
Bushing
205-342 (15-110)

Adapter for 205-342

205-342-01 (15-110-01)
Adapter for 205-342

205-342-02 (15-110-02)
Receiving Cup, Axle Bushing

205-510 (15-116)
4. Using a suitable transmission jack, support

the beam axle.
Adapter for 303-171

303-172-01 (21-102-01)
G289770 en
11/2004 2005.25 Fiesta
204-02-22

TO MODEL INDEX
Rear Suspension
204-02-22

5. Remove the beam axle retaining bolts on
both sides.
6. Lower the beam axle sufficiently to gain

access to the trailing arm bushing.
7. Mark the bushing housing adjacent to the
locating tang on the bushing, to aid installation.
9. Using the special tools, remove and discard the trailing arm bushing.
Installation
1. NOTE: Install a new trailing arm bushing.
NOTE: Align the mark on the bushing housing
with the locating tang on the trailing arm bushing.
Using the special tools, install the new
trailing arm bushing.
8. Remove the trailing arm bushing retaining

nut and bolt.
2. Fabricate a 32 mm high by 60 mm long
spacer.
G289770 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
204-02-23
Rear Suspension
204-02-23

3. NOTE: Final tightening of the trailing arm
bushing retaining nut and bolt must be carried
out at the installation setting.
NOTE: The spacer must be positioned exactly as
illustrated.
6. Install the beam axle retaining bolts on

both sides.
Using the fabricated spacer, set the beam

axle bracket to the installation setting.
7. Lower and remove the transmission jack.

axle on both sides.
4. NOTE: Final tightening of the trailing arm

bushing retaining nut and bolt must be carried
out at the installation setting.
Install the trailing arm bushing retaining
nut and bolt.
Remove the spacer.
9. Connect the wheel speed sensor electrical

connector.
5. Raise the beam axle.
G289770 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
204-04-1
Wheels and Tires
204-04-1
SECTION 204-04 Wheels and Tires

CONTENTS
PAGE
SPECIFICATIONS
Specifications....................................................................................................................
204-04-2

Wheels and Tires ..............................................................................................................
Symptom Chart ................................................................................................................
204-04-3
204-04-3
204-04-4

Wheel and Tire..................................................................................................................
204-04-7
11/2004 2005.25 Fiesta
204-04-2

TO MODEL INDEX
Wheels and Tires
204-04-2
SPECIFICATIONS
Description
Wheel nuts
G17434 en
Nm
85
lb-ft
63
lb-in
-
11/2004 2005.25 Fiesta
204-04-3

TO MODEL INDEX
Wheels and Tires
204-04-3

Wheels and Tires
To maximize tire performance, inspect the tires for
signs of incorrect inflation and uneven wear which
may indicate a need for balancing, rotation or
suspension alignment. Tires should also be
checked frequently for cuts, stone bruises,
abrasions, blisters, and for objects that may have
become embedded in the tread. More frequent
inspections are recommended when rapid or
extreme temperature changes occur or when road
surfaces are rough or occasionally littered with
foreign material.
- engine torque
- vehicle speed
- engine speed
type of vibration - sensitivity: torque sensitive,
vehicle speed sensitive or engine speed
sensitive.
The following explanations help isolate the source
of the vibration.
Torque Sensitive
As a further visible check of tire condition, tread

wear indicators are molded into the bottom of the
tread grooves. When these indicator bands
become visible, new tires must be installed.
This means that the condition can be improved or

made worse by accelerating, decelerating,
coasting, maintaining a steady vehicle speed or
applying engine torque.
Tire Wear Diagnosis
Vehicle Speed Sensitive
Uneven wear is usually caused by either

excessive camber or excessive toe on tires.
This means that the vibration always occurs at the

same vehicle speed and is not affected by engine
torque, engine speed or the transmission gear
selected.
Sometimes incorrect toe settings or worn struts

will cause severe `cupping' or `scalloped' tire wear
on non-driven wheels.
Severely incorrect toe settings will also cause
other unusual wear patterns.
Tire Vibration Diagnosis
A tire vibration diagnostic procedure always

begins with a road test. The road test and
customer interview (if available) will provide much
of the information needed to find the source of a
vibration.
During the road test, drive the vehicle on a road
that is smooth and free of undulations. If vibration
is apparent, note and record the following:
the speed at which the vibration occurs.
what type of vibration occurs in each speed
range.
- mechanical or audible
how the vibration is affected by changes in the
following:
G25362 en
Engine Speed Sensitive
This means that the vibration occurs at varying

vehicle speeds when a different transmission gear
is selected. It can sometimes be isolated by
increasing or decreasing engine speed with the
transmission in NEUTRAL or by stall testing with
the transmission in gear. If the condition is engine
speed sensitive, the cause is probably not related
to the tires.
If the road test indicates that there is tire whine,
but no shake or vibration, the noise originates with
the contact between the tire and the road surface.
A thumping noise usually means that the tire is flat
or has soft spots making a noise as they slap the
roadway. Tire whine can be distinguished from
axle noise. Tire whine remains the same over a
range of speeds.
A complete road test procedure is described in
Section 100-04. REFER to Section 100-04.
11/2004 2005.25 Fiesta
204-04-4

TO MODEL INDEX
Wheels and Tires
204-04-4
Symptom Chart
Symptom
Possible Sources
Action
Tires show excess wear on edge Tires under-inflated.

of tread
ADJUST the tire pressure.
Vehicle overloaded.
CORRECT as necessary.
Tires show excess wear in cen- Tires over-inflated.

ter of tread
Other excessive tire wear concerns
Incorrect tire pressure.
Tires need rotating.
ROTATE the tires.
Vehicle overloaded.
CORRECT as necessary.
Loose or leaking front strut and

spring assembly.
TIGHTEN or INSTALL new

204-01.
Wheel bearings worn.
INSTALL new wheel bearings as

204-01/ 204-02.
Suspension components, bush- CHECK or INSTALL new susings and ball joints.
pension components as necessary.
Excessive lateral or radial runout CHECK the wheel and tire radial
runout. REFER to Section
of wheel or tire.
204-00.
Wheel mounting is difficult
Incorrect application or mismatched parts, including wheel

studs and nuts.
FOLLOW manufacturers specifications.
Wheel rust or corrosion
Poor maintenance.
CLEAN and PROTECT with

paint.
Wobble or shimmy affecting

wheel runout
Damaged wheel.
INSPECT wheel rims for damage. INSTALL new parts as

necessary.
Front wheel bearing.
CHECK or INSTALL new wheel

bearings as necessary.
Excessive vehicle vibration,

rough steering
Suspension components.
CHECK or INSTALL new parts.

Vehicle vibrations from wheels

and tires
Incorrect tire pressure.
Wheel or tire imbalance.
BALANCE the tire and wheel

assembly.
G25362 en
11/2004 2005.25 Fiesta
204-04-5

TO MODEL INDEX
Wheels and Tires
204-04-5

Symptom
Possible Sources
Action
Uneven tire wear.
INSTALL a new tire(s) as necessary.
Brake disc imbalance.
CHECK the brake disc for foreign material.
Water in tires.
REMOVE the water.
Bent wheel.
INSTALL a new wheel. Attempts

to straighten a wheel can cause
fractures in the wheel and
weaken the wheels strength.
Incorrectly seated tire bead.
SPIN the wheel on the vehicle.

EXAMINE the area where the
tire and the wheel meet. If that
section of the tire appears to
waver while being rotated, the
tire bead may not be correctly
seated on the wheel. REMOVE
the tire and CLEAN the bead
seat areas on both wheel and
tire.
Radial runout of wheel or tire.
Using a suitable dial indicator

gauge and holding fixture,
CHECK the radial runout of both
the wheel and the tire.
Wheel stud, wheel nut or

enlarged stud holes.
CHECK or INSTALL new parts

as necessary.
Foreign material between wheel CLEAN mounting surfaces.

mounting face and hub mounting
surface.
Lateral runout of wheel or tire.
Using a suitable dial indicator

gauge and holding fixture,
CHECK the radial runout of both
the wheel and the tire.
Front wheel bearing.
CHECK or INSTALL a new

wheel bearing as necessary.
Cracks develop in rim base back Overloading or abusive use.

(rim bead seat)
Incorrect use of tools.
G25362 en
INSTALL a new wheel. CHECK

loading and operating conditions. AVOID over inflation of
tires. CHECK the specifications
for the rim load capacity, working
load, tire size, ply rating and tire
construction.
CHECK mounting, demounting,
and maintenance procedures.
11/2004 2005.25 Fiesta
204-04-6

TO MODEL INDEX
Wheels and Tires
204-04-6

Symptom
Possible Sources
Action
Damaged wheel studs
Sliding wheel across wheel studs INSTALL new wheel studs as

during assembly.
necessary. INSTALL a new
wheel as necessary.
Loose brake drum
Wheel studs too long.
INSTALL new wheel studs of the

correct length as necessary.
Broken wheel studs
Loose wheel nuts.
INSTALL new wheel studs and

nuts. TIGHTEN to specification.
Overloading.
INSTALL new wheel studs.

TIGHTEN to specification.
Compare actual load against
vehicle load ratings.
Excessive tightening.
INSTALL new wheel studs and

nuts. TIGHTEN to specification.
Stripped wheel stud threads
Rust streaks from the wheel stud Wheel nuts.

holes in the wheel
CHECK complete assembly. If

parts are damaged INSTALL
new parts. TIGHTEN to specification.
Damaged wheel nuts
Wheel assembly.
INSTALL new wheel nuts.

TIGHTEN to specification.
Over tightened wheel nuts.
FOLLOW correct tightening

procedure.
Corrosion.
CAUTION: Do not permit lubricant to get on cone sets of stud

holes or on cone angle of wheel
nuts. If corrosion is slight, wire
brush away. If corrosion is excessive, INSTALL new wheel
studs and nuts. If the condition
persists, LUBRICATE the first
three threads of each wheel stud
with a graphite-based lubricant.
Overloading
REDUCE weight.
Seized wheel nuts
G25362 en
11/2004 2005.25 Fiesta
204-04-7

TO MODEL INDEX
Wheels and Tires
204-04-7

Wheel and Tire
Removal
CAUTION: Do not use heat to loosen a
seized wheel nut. Heat may damage the
wheel and wheel hub.
1. Loosen the wheel nuts.
100-02.
3. Remove the wheel and tire assembly.
Installation
1.
WARNING: Remove the corrosion or

dirt from the mounting surfaces of the
wheel, wheel hub, brake drum or brake
disc, as this may cause the wheel nuts
to loosen and the wheel to come off
while the vehicle is in motion. Failure
to follow this instruction may result in
personal injury.
Clean the wheel hub and mounting

surfaces.
2. Install the wheel and tire assembly.
4. Tighten the wheel nuts in a diagonally opposed pattern.
G17437 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
205-04-1
Front Drive Halfshafts
205-04-1
SECTION 205-04 Front Drive Halfshafts

CONTENTS
PAGE
SPECIFICATIONS
Specifications....................................................................................................................
205-04-2

Front Drive Halfshafts .......................................................................................................
Driveshafts ......................................................................................................................
205-04-3
205-04-3

Front Drive Halfshafts .......................................................................................................
Symptom Chart Front Drive Halfshafts ..........................................................................
205-04-4
205-04-4
205-04-4

Halfshaft LH .................................................................................................. (14 320 0)
Halfshaft RH ................................................................................................. (14 321 0)
Intermediate Shaft.............................................................................................................
Inner Constant Velocity (CV) Joint Boot ........................................................ (14 336 0)
Outer Constant Velocity (CV) Joint Boot ....................................................... (14 338 0)
205-04-6
205-04-11
205-04-15
205-04-17
205-04-20
11/2004 2005.25 Fiesta
205-04-2

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205-04-2
SPECIFICATIONS
Lubricants, Fluids, Sealers and Adhesives

Description
Manual transmission fluid
Grease, outer constant velocity (CV) joint
Grease, inner constant velocity (CV) joint
Specifications
WSD-M2C200-C
WSS-M1C259-A1
WSS-M1C259-A1
Constant Velocity (CV) Joint Boot Capacities

Description
Outer constant velocity (CV) joint boot
Inner constant velocity (CV) joint boot
Item
Lower arm ball joint pinch bolt nut
Intermediate shaft center bearing cap retaining nuts
Strut and spring assembly top mount retaining nuts
CV joint boot clamps
G113103 en
Grams
90
100
Nm
48
25
290
25
21
lb-ft
35
18
214
18
15
lb-in
-
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205-04-3
205-04-3

Driveshafts
Conventional driveshafts are used on the front
axle. For servicing purposes it is important to
note that the inner tripod joints are pressed onto
the shaft. This has made it possible to reduce
noise levels when the vehicle is pulling away from
standing.
driveshaft. This is required to prevent the grease

in the bearing from overheating as a result of the
closeness to the catalytic converter.
The outer joint has not been approved for service

repairs, so in the event of a fault it is necessary to
replace the complete shaft and outer joint
assembly. The inner joints are dismantled with
the aid of a puller. The driveshaft needs to be
removed first.
In order to install a new boot on the outer joint, it is
first necessary to remove the driveshaft and then
disassemble the inner joint. A special service kit
is available in service for this purpose, consisting
of the inner and outer boot and the necessary
small parts.
The same amount of grease is used to pack the
inner and outer joints.
The PAC nut used for securing the driveshaft to
the wheel hub must not be reused.
Item
Part
Number
Description
Securing clip for bearings
Heat shield (only for vehicles

with a petrol engine)
Securing pin
It should also be noted that vehicles with a petrol

engine have an additional heat shield on the
bearing of the intermediate shaft of the right-hand
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205-04-4

step.
Symptom Chart Front Drive Halfshafts
Symptom
Clicking, Popping or Grinding
Noises While Turning
Possible Sources
Action
Inadequate or contaminated lu- INSPECT, CLEAN and

bricant in the inner or outer front LUBRICATE as necessary.
drive halfshaft constant velocity REFER to Inner Constant Ve(CV) joint.
locity (CV) Joint Boot
/ Outer Constant Velocity (CV)
Joint Boot in this section.
Another component contacting
front drive halfshaft assembly.
INSPECT and REPAIR as necessary.
Wheel bearings, brakes, sus INSPECT and REPAIR as necpension or steering components. essary. REFER to Section
204-00 / 206-00 / 211-00.
Vibration at Highway Speeds
Out of balance front wheels or

tires.
Balance wheels and tires as

necessary.
Out-of-round tires.
REPAIR or INSTALL new as

necessary.
Incorrectly seated outer constant REPAIR or INSTALL new as

velocity (CV) joint in front wheel necessary. REFER to Halfshaft
hub.
LH / Halfshaft RH in this section.
Shudder Vibration During Acceleration.
Excessively high CV joint oper- CHECK the ride height, VERIFY

ating angles caused by incorrect correct spring rate.
ride height.
CHECK items under Halfshaft Joint Pullout. REPAIR
or INSTALL new as necessary.
Excessively worn or damaged
INSPECT and INSTALL new as
inner or outer front drive halfshaft necessary. REFER to Halfshaft
LH / Halfshaft RH in this section.
constant velocity (CV) joint.
Halfshaft Joint Pullout
G25403 en
Outer front drive halfshaft retainer circlip missing or not correctly seated differential side.
INSPECT and REPAIR or

INSTALL new as necessary.
REFER to Halfshaft LH
/ Halfshaft RH in this section.
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205-04-5

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205-04-5

Symptom
Possible Sources
Front suspension components
worn or damaged.
Action
CHECK for worn bushings or
bent components (front stabilizer
bar, front suspension lower arm).
REPAIR or INSTALL new as
204-01.
Engine/transaxle assembly mis- CHECK engine mounts for

alignment.
damage or wear. REPAIR or
INSTALL new as necessary.
Frame rail or strut tower out of
position or damaged.
G25403 en
CHECK underbody dimensions.

11/2004 2005.25 Fiesta

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205-04-6
205-04-6

Halfshaft LH (14 320 0)
All vehicles
mount retaining nuts by three turns.
Special Tool(s)
204-161 (14-041)
Remover, Halfshaft
308-256 (16-089)
General Equipment
Four leg puller
2.
Tire Lever
Name
Manual transmission
fluid
Specification
WSD-M2C200-C
CAUTION: Use a socket to loosen the

wheel hub retaining nut to prevent
damage.
Remove the wheel hub retaining nut.
Discard the wheel hub retaining nut.
Removal
WARNING: Refer to the Material Safety
Data Sheets for the Automatic
Transmission Fluid E-AW. Failure to
follow this instruction may result in
personal injury. Certain Transmission
and Power Steering fluids supplied to
Ford contain additives which may cause
skin irritation or other skin reactions after
contact. For additional information, refer
to Section 100-00.[General Information,
DESCRIPTION AND OPERATION, Health
and Safety Precautions]
See - Transmission Fluids.
G113104 en

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205-04-7
4.

wheel knuckle.
Vehicles with automatic transaxle

6.
CAUTION: Support the halfshaft. The

inner joint must not be bent more than
18 degrees. The outer joint must not be
bent more than 45 degrees.
CAUTION: Do not damage the halfshaft oil

seal.
NOTE: Plug the transaxle to prevent oil loss or dirt
ingress. For additional information, refer to
Section 100-00.[General Information,
DESCRIPTION AND OPERATION, Health and
Safety Precautions] See - Transmission Fluids.
5.

Using a suitable tire lever, remove the

halfshaft.
Discard the snap ring.
Allow the oil to drain into a suitable container. For additional information, refer to
and Safety Precautions] See - Transmission
Fluids.
Using a suitable four leg puller, detach the

halfshaft from the wheel hub.
Secure the halfshaft to one side.
G113104 en
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205-04-8

Vehicles with manual transaxle
Installation
7.
All vehicles

1.

seal.
ingress.
Using the special tool, remove the
halfshaft.
Allow the oil to drain into a suitable container.

seal.
CAUTION: Make sure the snap ring is

correctly seated.
NOTE: Install a new snap ring.
Attach the left hand halfshaft to the transaxle.
2.

hub.
Using the special tool, install the halfshaft.
G113104 en
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205-04-9
3. NOTE: Install a new wheel hub retaining nut.

NOTE: Do not fully tighten the wheel hub retaining
nut at this stage.
5.
4.
CAUTION: Make sure that the heat

shield is installed to prevent damage
to the ball joint.

wheel knuckle.
knuckle.

7.
CAUTION: Use a socket to tighten the

damage.
Tighten the wheel hub retaining nut.
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205-04-10


9. With the vehicle on a level surface, fill the
transaxle with transmission fluid until the
oil level is just below the bottom of the filler
hole.
10. Check the transmission fluid level and top
up with clean automatic transmission oil.
Section 307-01.[Automatic
Transmission/Transaxle - Vehicles With:
4-Speed Automatic Transaxle (AW81-40),
GENERAL PROCEDURES, Transmission
Fluid Drain and Refill]
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205-04-11
205-04-11

Halfshaft RH (14 321 0)
Special Tool(s)
204-161 (14-041)
4.

wheel knuckle.
General Equipment
Four leg puller
Removal
mount retaining nuts by three turns.
5.

Using a suitable four leg puller, detach the
halfshaft from the wheel hub.
Secure the halfshaft to one side.
2.
CAUTION: Use a socket to loosen the

damage.
Remove the wheel hub retaining nut.
Discard the wheel hub retaining nut.
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205-04-12

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205-04-12
6.

NOTE: Do not damage the inner constant velocity
(CV) joint boot.
NOTE: Discard the grease.
Remove the halfshaft.
Remove and discard the constant velocity
(CV) joint boot clamp.
Installation
1.
CAUTION: The total amount of grease

must not exceed 100 grams.
3. NOTE: Do not damage the inner constant

velocity (CV) joint boot.
NOTE: Make sure that the intermediate shaft
mating surface for the joint boot is clean.
Install the inner constant velocity (CV) joint
boot (halfshaft shown removed for clarity).
1. Slide a small screwdriver under the boot
seat to allow the air to escape.
2. Insert the constant velocity (CV) joint in as
far as it will go, then pull it back approximately 20 mm.
4. NOTE: Install a new CV joint boot clamp.

Using a suitable grip wrench, install the
inner CV joint boot clamp.
Apply grease to the intermediate shaft.

2.

Attach the halfshaft to the intermediate
shaft.
G113105 en
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205-04-13

TO MODEL INDEX
205-04-13
5.

hub.
7.
Using the special tool, install the halfshaft.
6. NOTE: Install a new wheel hub retaining nut.

NOTE: Do not fully tighten the wheel hub retaining
nut at this stage.

to the ball joint.
8.

wheel knuckle.
knuckle.

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TO MODEL INDEX
205-04-14
10.
CAUTION: Use a socket to tighten the

damage.
Tighten the wheel hub retaining nut.

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205-04-15

Intermediate Shaft
Name
Manual transmission
fluid
Specification
WSD-M2C200-C
Removal
WARNING: Refer to the Material Safety
Data Sheets for the Automatic
Transmission Fluid E-AW. Failure to
personal injury. Certain Transmission
and Power Steering fluids supplied to
Ford contain additives which may cause
skin irritation or other skin reactions after
contact. For additional information, refer
See - Transmission Fluids.
1. Remove the right-hand halfshaft. For
additional information, refer to Halfshaft
RH in this section.
2. Remove the intermediate shaft center
bearing cap.
1. Remove and discard the locknuts.
2. Detach the heatshield from the bearing cap.
3. Remove and discard the center bearing
cap.
G152541 en
CAUTION: Do not damage the halfshaft

oil seal.
ingress. For additional information, refer to
DESCRIPTION AND OPERATION, Health and
Safety Precautions] See - Transmission Fluids.
3.
Remove the intermediate shaft.

Allow the oil to drain into a suitable
container. For additional information, refer
and Safety Precautions] See - Transmission
Fluids.
Slide the heatshield off the intermediate
shaft.
11/2004 2005.25 Fiesta
205-04-16

TO MODEL INDEX
205-04-16

Installation
All vehicles
1.

oil seal.
Install the intermediate shaft.
Slide the heatshield onto the intermediate
shaft.

5. Check the transmission fluid level and top
up with clean automatic transmission oil.
307-01.[Automatic Transmission/Transaxle
- Vehicles With: 4-Speed Automatic
Transaxle (AW81-40), GENERAL
PROCEDURES, Transmission Fluid Drain
and Refill]
2. NOTE: Install a new intermediate shaft center

bearing cap and locknuts.
Install the intermediate shaft center
bearing cap.
1. Install the center bearing cap.
2. Attach the heatshield to the bearing cap.
3. Install the locknuts.
3. Install the right-hand halfshaft. For

RH in this section.
4. With the vehicle on the level surface, fill the
oil level is just below the bottom of the filler
hole.
G152541 en
11/2004 2005.25 Fiesta

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205-04-17
205-04-17

Inner Constant Velocity (CV) Joint Boot (14 336 0)
3.
Special Tool(s)
Clamping Tool, Boot
Retaining Clamp
204-169 (14-044)
Remover, Bearing/Gear
205-310 (15-091
Remover, Bearing/Gear
205-311 (15-092)
CAUTION: Do not bent the inner

constant velocity (CV) joint more than
18 degrees and the outer CV joint more
than 45 degrees.
CAUTION: Use vise jaw protectors for all

operations in a vise.
NOTE: Secure the halfshaft in a vise.
Detach the inner CV joint housing from the
halfshaft.
1. Remove and discard the CV joint boot
retaining clamps.
2. Remove the CV joint housing and discard
the grease.
Installer, Extension Housing

Bushing/Oil Seal
308-046 (16-016)
Name
Grease
Specification
WSS-M1C259-A1
4. Remove and discard the spider circlip.
Removal
RH in this section.
2. Remove the left-hand halfshaft. For
additional information, refer to Halfshaft LH
in this section.
G152548 en
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205-04-18

TO MODEL INDEX
205-04-18

5. Using the special tool, remove the spider.
2. NOTE: Install a new CV joint boot retaining

clamp.
Using the special tool, install the CV joint
boot retaining clamp.
6. Remove the inner CV joint boot.

Mark the halfshaft were the CV joint boot is
located.
3. NOTE: Install the spider with the chamfer facing
towards the halfshaft.
Using the special tool, install the spider.
Installation
1. NOTE: Make sure that the inner constant
velocity (CV) joint boot is installed to the marks
on the halfshaft.
4. NOTE: Install a new spider circlip.

Install the spider circlip.
Install the inner CV joint boot.
G152548 en
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205-04-19

TO MODEL INDEX
205-04-19
5.

in the inner CV joint must not exceed
85 grams.
Apply grease to the inner CV joint boot.
6. Attach the inner CV joint housing to the

halfshaft (left hand side shown for clarity).
1. Use a suitable screwdriver under the CV
joint boot to allow air to escape.
2. Install the CV joint boot housing and pull it
backwards 20 mm.
G152548 en
7. NOTE: Install a new CV joint boot retaining

clamp.
NOTE: Make sure that the CV joint boot is
clamped at the measured postion.
Using a special tool, install the CV joint
boot retaining clamp.

RH in this section.
9. Install the left-hand halfshaft. For
additional information, refer to Halfshaft LH
in this section.
11/2004 2005.25 Fiesta

TO MODEL INDEX
205-04-20
205-04-20

Outer Constant Velocity (CV) Joint Boot (14 338 0)
2.
Special Tool(s)
Clamping Tool, Boot
Retaining Clamp
204-169 (14-044)
Name
Grease
CAUTION: Use vise jaw protectors for all

operations in a vise.
NOTE: Secure the halfshaft in a vise.
NOTE: Mark the halfshaft were the CV joint boot is
located.
Specification
Remove the outer CV joint boot.

Remove and discard the CV joint boot
retaining clamps.
Remove and discard the grease.
WSS-M1C259-A1
Removal
1.
CAUTION: Do not bent the inner CV

joint more than 18 degrees and the
outer CV joint more than 45 degrees.
CAUTION: The outer constant velocity

(CV) joint is a press fit. Do not
disassemble. Failure to follow this
instruction may result in damage to the
outer CV joint.
Remove the inner CV joint boot. For
additional information, refer to Inner
Constant Velocity (CV) Joint Boot in this
section.
Installation
1.

in the inner constant velocity (CV) joint
must not exceed 85 grams.
Apply grease to the outer CV joint boot.
G152549 en
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TO MODEL INDEX
205-04-21

2. Install the outer CV joint boot.
Use a suitable screwdriver under the boot to
allow air to escape.
3. NOTE: Make sure that the outer CV joint boot is

installed to the marks on the halfshaft.
NOTE: Install a new inner CV joint boot retaining
clamp.
Using the special tool, install the inner CV
joint boot retaining clamp.
G152549 en
4. NOTE: Install a new outer CV joint boot

retaining clamp.
Using the special tool, install the outer CV
joint boot retaining clamp.
5. Install the inner CV joint boot. For

additional information, refer to Inner
Constant Velocity (CV) Joint Boot in this
section.
11/2004 2005.25 Fiesta

TO MODEL INDEX
206-00-1
Brake System - General Information
206-00-1
SECTION 206-00 Brake System - General Information

CONTENTS
PAGE

Brake System ...................................................................................................................
Overview ..........................................................................................................................
206-00-2
206-00-2

Brake System ...................................................................................................................
Road Test ........................................................................................................................
Pinpoint Tests ..................................................................................................................
Component Tests.............................................................................................................
Brake System Check........................................................................................................
Brake Booster Functional Test .........................................................................................
206-00-4
206-00-4
206-00-4
206-00-10
206-00-23
206-00-23
206-00-24
GENERAL PROCEDURES
Brake System Bleeding................................................................................. (12 141 0)
Brake System Pressure Bleeding.................................................................. (12 141 0)
206-00-27
206-00-28
11/2004 2005.25 Fiesta
206-00-2

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206-00-2

Brake System
Overview
Item
Part
Number
Description
Brake system without
Anti-lock Brake System
(ABS)
Item
Part
Number
Description
ABS hydraulic unit with integrated control unit
Wheel speed sensors
Vehicles without ABS are equipped with brake

pressure reduction valves for the rear wheel
brakes. They are located in the corresponding
brake circuits at the brake master cylinder.
Brake system with ABS
Brake master cylinder
Reservoir
Brake servo
Brake pedal
Vehicles with ABS do not need brake pressure

reduction valves because they are equipped with
electronic brake distribution (EBD).
Brake pressure reduction

valve
The handbrake is cable operated on the rear

brakes.
Rear drum brake
Front disk brake
On vehicles with a petrol engine the necessary

vacuum for the brake booster is generated by the
intake manifold.
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206-00-3

On vehicles with a diesel engine, a vacuum pump
driven by the engine provides the necessary
vacuum for the brake booster.
G281357 en
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206-00-4

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206-00-4

Brake System
The brakes system operates by transferring effort
applied to the brake pedal by the driver to the
brakes at each wheel.
The braking effort is distributed to each wheel,
using a hydraulic system. The system is assisted
using a vacuum brake booster that reduces pedal
effort and increases hydraulic pressure.
The parking brake operates on the rear wheels
and is applied using a hand operated control.
NOTE: Before carrying out any diagnosis, make
sure that the brake system warning indicator is
functional.
mechanical damage.
Mechanical
3.
Tire pressure
Wheels and tires
Fluid leak from brake line(s)
If an obvious cause for an observed or
reported concern is found, correct the case (if
possible) before proceeding to the next step.
4. If the cause if not visually evident, verify the
Road Test
Perform a road test to compare actual vehicle
braking performance with the performance
standards expected by the driver. The ability of the
test driver to make valid comparisons and detect
performance deficiencies will depend on
experience.
The driver should have a thorough knowledge of
the brake system operation and accepted general
performance guidelines to make good
comparisons and detect performance concerns.
An experienced technician will always establish a
route that will be used for all brake diagnosis road
G28494 en
tests. The road selected will be reasonably

smooth and level. Gravel or bumpy roads are not
suitable because the surface does not allow the
tires to grip the road equally. Crowned roads
should be avoided because of the large amount of
weight shifted to the low set of wheels on this type
of road. Once the route is established and
consistently used, the road surface variable can
be eliminated from the test results.
Before a road test, get a complete description of
the customer concerns or suspected condition.
From the description, the technician will be able to
match possible causes with symptoms. Certain
components will be identified as possible sources
while others will be eliminated by the evidence.
More importantly, the customer description can
reveal unsafe conditions which should be checked
or corrected before a road test. The description
will also help form the basic approach to the road
test by narrowing the concern to specific
components, vehicle speed or conditions.
Begin the road test with a general brake
performance check. Using the description of the
concern, test the brakes at different vehicle
speeds using both light and heavy pedal pressure.
Determine if the concern is in the front or rear
braking system. First use the foot brake and then
the parking brake. If the condition (i.e. pull,
vibration, pulsation) occurs only on operation of
the parking brake, the concern is in the rear brake
system. If the condition occurs when the foot
brake is depressed, the concern is in the front
brake system.
Avoid locking the brakes and sliding the tires. This
condition will not indicate brake efficiency. A
heavily braked but turning wheel will stop the
vehicle in a shorter distance than locked wheels.
If the concern becomes evident during this check,
make sure it fits the description given before the
road test. If the concern is not evident, attempt to
duplicate the condition using the information from
the description.
If a concern exists, use the Brake System Symptom Chart in order to isolate it to a specific
sub-system and condition description. From this
description, a list of possible sources can be used
to further narrow the cause to a specific component or condition.
11/2004 2005.25 Fiesta
206-00-5

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206-00-5

Symptom Chart
Symptom
Brakes pull or drift
Possible Sources
Action
Worn or damaged brake shoes

or brake pads and linings.
INSTALL new brake shoes or

brake pads. REFER to Section
206-02.[Drum Brake, REMOVAL
AND INSTALLATION, Brake
Shoes] REFER to Section
206-03.[Front Disc Brake,
REMOVAL AND
INSTALLATION, Brake Pads]
REFER to Section 206-04.[Rear
Abnormal wear or distortion of

brake discs.
INSTALL a new brake discs.

Incorrect rear brake adjustment. PERFORM a parking brake cable adjustment. REFER to Section 206-05.[Parking Brake and
Actuation, GENERAL
PROCEDURES, Parking Brake
Cable Adjustment - Vehicles
With: Rear Drum Brakes]
REFER to Section
206-05.[Parking Brake and Actuation, GENERAL
With: Rear Disc Brakes]
Incorrect wheel alignment adjustment.
PERFORM a wheel alignment

adjustment. REFER to Section
204-00.[Suspension System General Information, GENERAL
Incorrect wheel bearing preload ADJUST or INSTALL a new

wheel bearing. REFER to Secadjustment.
tion 204-01.[Front Suspension,
REMOVAL AND
INSTALLATION, Wheel Bearing]
Suspension, REMOVAL AND
Unequal air pressure in the tires. INFLATE the tires to the correct
pressure.
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206-00-6

Symptom
Brake warning indicator always

on
G28494 en
Possible Sources
Action
Grease or fluid on the brake

shoes or brake pads; glazed
linings.

REMOVAL AND
Stuck or seized calipers.
GO to Pinpoint Test A.
Low brake fluid level.
FILL the reservoir. CHECK the

brake and clutch system for
leaks including brake fluid in the
brake booster.
Leaking brake master cylinder

primary piston cup.
INSTALL a new brake master

cylinder. REFER to Section
206-06.[Hydraulic Brake Actuation, REMOVAL AND
INSTALLATION, Brake Master
Cylinder - RHD]
Parking brake control not fully

released.
FREE UP and ADJUST the

parking brake cable. REFER to
Section 206-05.[Parking Brake
and Actuation, DIAGNOSIS AND
TESTING, Parking Brake]
[Parking Brake and Actuation, GENERAL
With: Rear Drum Brakes]
[Parking Brake and Actuation, GENERAL
With: Rear Disc Brakes]
INSTALL new components as
necessary.
Shorted indicator circuit.
GO to Pinpoint Test B.
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206-00-7

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206-00-7

Symptom
Vibration when the brakes are
applied
Pedal goes down fast
G28494 en
Possible Sources
Action
Grease or fluid on the brake

shoes or brake pads; glazed
linings.

REMOVAL AND
Worn or damaged brake shoes

or brake pads.

Shoes REFER to Section
REMOVAL AND
Loose caliper mounting bolt(s).
TIGHTEN the caliper mounting

bolt(s). REFER to Section
SPECIFICATIONS, Specifications] REFER to Section
206-04.[Rear Disc Brake,
Insufficient grease on sliding

parts.
APPLY grease where necessary.
Damaged brake drum contact

surface.
INSTALL a new brake drum.

REFER to Section 206-02.[Drum
Brake, REMOVAL AND
INSTALLATION, Brake Drum]
Loose or missing rear wheel

spindle bolts.
TIGHTEN or INSTALL new rear

wheel spindle bolts. REFER to
Section 204-02.[Rear
Suspension, SPECIFICATIONS,
Specifications]
Go to Pinpoint Test C.
Leak in the hydraulic system.
REPAIR the leak. CHECK the

entire hydraulic system. FILL
and BLEED the brake system.
REFER to Brake System
Bleeding / Brake System Pressure Bleeding in this section.
11/2004 2005.25 Fiesta
206-00-8

TO MODEL INDEX
206-00-8

Symptom
Pedal eases down slowly
Pedal is low or feels spongy
Brake lockup during light brake

pedal force
G28494 en
Possible Sources
Action
Air in the system.
CHECK for leaks. BLEED the

brake system. REFER to Brake
System Bleeding / Brake System
Pressure Bleeding in this section.
Worn brake master cylinder

piston cups or scored cylinder
bore.
INSTALL a new brake master

cylinder. REFER to Section
206-06.[Hydraulic Brake Actuation, REMOVAL AND
INSTALLATION, Brake Master
Cylinder - RHD]
Brake disc brake `knock back'

(Brake pads push the brake
caliper piston back into brake
caliper. Caused by excessive
brake disc lateral runout or loose
wheel bearings.)
Install a new brake disc. REFER

to Section 206-04.[Rear Disc
Brake, REMOVAL AND
Worn brake shoes or brake

pads.

REMOVAL AND
GO to Pinpoint Test D.
Air in the system.
BLEED the brake system.

REFER to Brake System
Bleeding / Brake System Pressure Bleeding in this section.
Malfunctioning brake master

cylinder.
GO to Pinpoint Test E.

pads.

REMOVAL AND
Hydraulic system.
GO to Pinpoint Test F.
Incorrect tire pressures.
INFLATE the tires to the correct

pressure.
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Symptom
Possible Sources
Action
Tires worn.
INSTALL new tires.
Glazed or worn brake shoes or

brake pads.
Brake booster.

REMOVAL AND
GO to Pinpoint Test G.
Excessive or erratic pedal travel Worn brake shoes or brake

pads.

REMOVAL AND
Brake discs.
GO to Pinpoint Test H.
Brake drag
Brake booster.
Incorrectly adjusted brake light
switch.
Brake pressure control valve.
Seized brake caliper or wheel
cylinder.
Parking brake applied or
malfunction.
Seized parking brake cables.
Seized brake caliper slide pins.
GO to Pinpoint Test I.
ADJUST the brake light switch.
Excessive brake pedal effort
Brake booster inoperative.
PERFORM a brake booster

functional test REFER to the
component tests.
Worn or contaminated brake

shoes or brake pads.

REMOVAL AND
GO to Pinpoint Test J.
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Possible Sources
Symptom
Brake noise
Action

pads.

REMOVAL AND
Brake booster.
GO to Pinpoint Test K.
Slow or incomplete brake pedal Brake booster.

return
Brake master cylinder.
GO to Pinpoint Test L.
Pinpoint Tests
PINPOINT TEST A: BRAKES PULL OR DRIFT
TEST CONDITIONS
A1: ROAD TEST THE VEHICLE
1 Road test the vehicle and apply the brake
pedal.
Does the vehicle pull or drift?
Yes
GO to A2
No
Vehicle OK.
A2: TIRE INSPECTION

1 Check for excessive wear or incorrect tire
pressures.
Are the tires in good condition?
Yes
GO to A3
No
INFLATE the tires to the correct pressure.
INSTALL new tires if excessively worn. TEST
A3: BRAKE SHOE OR BRAKE PADS AND LINING INSPECTION
1 Inspect the brake shoes or brake pads for
grease or fluid on the linings and or wear concerns.
Are any concerns present?
Yes
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TEST CONDITIONS
INSTALL new brake shoes or brake pads.
REFER to Section 206-02.[Drum Brake,
REMOVAL AND INSTALLATION, Brake
Shoes] REFER to Section 206-03.[Front Disc
Brake Pads] REFER to Section 206-04.[Rear
INSTALLATION, Brake Pads] TEST the
system for normal operation.
No
GO to A4
A4: CHECK PRESSURE CONTROL VALVERIGHT-HAND REAR
1 Install pressure gauges in the left-hand front
and right-hand rear bleed nipples. Apply the
brake to read 6895 kPa (1000 psi) at the
left-hand front wheel.
- Read the pressure at right-hand rear wheel.
Does the pressure gauge read between
4692-5164 kPa (680-750 psi) at the right-hand
rear wheel?
Yes
INSPECT the brake calipers and INSTALL
new components as required. GO to A5
No
INSTALL a new right-hand rear brake pressure control valve. BLEED the brake system.
REFER to Brake System Bleeding / Brake
System Pressure Bleeding in this section.
TEST the system for normal operation.
A5: CHECK PRESSURE CONTROL VALVELEFT-HAND REAR
1 Install pressure gauges in the right-hand front
and left-hand rear bleed nipples. Apply the
right-hand front wheel.
- Read the pressure at left-hand rear wheel.
4692-5164 kPa (680-750 psi) at the left-hand rear
wheel?
Yes
INSPECT the brake calipers and INSTALL
new components as required. REFER to
Section 206-02.[Drum Brake, REMOVAL
AND INSTALLATION, Brake Shoes]
REFER to Section 206-03.[Front Disc Brake,
Pads] REFER to Section 206-04.[Rear Disc
Brake Pads] TEST the system for normal
operation.
No
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TEST CONDITIONS
INSTALL a new left-hand rear brake pressure control valve. BLEED the brake system.
PINPOINT TEST B: BRAKE WARNING INDICATOR ALWAYS ON

TEST CONDITIONS
B1: CHECK BRAKE WARNING INDICATOR

NOTE: The brake warning indicator should only illuminate when the ignition switch is in the START or
RUN position and the parking brake is applied.
2 Release the parking brake.
- Check the fluid level in the reservoir is at the
MAX mark.
Does the brake warning indicator illuminate?
Yes
REFER to Section 413-01.[Instrument
Cluster, DIAGNOSIS AND TESTING, Instrument Cluster]
No
GO to B2
B2: CHECK BRAKE SYSTEM FOR LEAKAGE
1 Check the brake master cylinder reservoir
sealing points and external brake and clutch
system for leaks. Refer to the brake master
cylinder component tests in this section.
Does the system leak?
Yes
REPAIR as necessary. ADD fluid and
BLEED the brake system. REFER to Brake
System Bleeding / Brake System Pressure
Bleeding in this section. TEST the system for
normal operation.
No
GO to B3
B3: CHECK BRAKE WARNING SWITCH OR WIRING
2 Remove the brake master cylinder reservoir
filler cap or switch. Allow the float to rest at its
lowest point.
Does the brake warning indicator illuminate?
Yes
The switch or wiring is OK. TEST the system
for normal operation.
No
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PINPOINT TEST C: VIBRATION WHEN BRAKES ARE APPLIED
TEST CONDITIONS
C1: ROAD TEST THE VEHICLE

1 Road test the vehicle without applying the
brakes at 40-80 km/h (25-50 mph).
Is a vibration present?
Yes
REFER to Section 100-04.[Noise, Vibration
and Harshness, DIAGNOSIS AND
TESTING, Noise, Vibration and Harshness
(NVH)] After servicing, TEST the system for
normal operation.
No
GO to C2
C2: CHECK FOR REAR BRAKE VIBRATION
NOTE: With a manual release parking brake control, hold the parking brake control release button in the
release position during parking brake control application.
1 Road test the vehicle at 40-80 km/h (25-50
mph) with a medium application on the parking
brake control.
Yes
CHECK the rear brake drums or discs for
excessive wear. INSTALL new components
as necessary. REFER to Section
206-02.[Drum Brake, REMOVAL AND
INSTALLATION, Brake Drum]
REFER to Section 206-02.[Drum Brake,
Shoes] REFER to Section 206-04.[Rear Disc
Brake Pads] REFER to Section 206-04.[Rear
No
GO to C3
C3: CHECK FOR FRONT BRAKE VIBRATION
1 Road test the vehicle at 40-80 km/h (25-50
mph) with light and medium application of the
foot brake.
Yes
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TEST CONDITIONS
CHECK the front brake discs for excessive
wear or cracks. INSTALL new components
206-03.[Front Disc Brake, REMOVAL AND
INSTALLATION, Brake Pads] REFER to
Section 206-03.[Front Disc Brake,
Caliper] TEST the system for normal operation.
No
Vehicle OK.
PINPOINT TEST D: PEDAL GOES DOWN FAST

TEST CONDITIONS
D1: ROAD TEST THE VEHICLE

1 Road test the vehicle and apply the foot brake.
Was the brake pedal effort normal?
Yes
Vehicle OK.
No
GO to D2
D2: CHECK BRAKE FLUID LEVEL
1 Check the brake master cylinder reservoir fluid
level.
Is the fluid level acceptable?
Yes
GO to D3
No
CHECK the brake master cylinder reservoir
sealing points for leaks. REFER to the brake
master cylinder component tests in this section. ADD fluid and BLEED the brake system.
D3: PRESSURIZE THE SYSTEM
1 Pump the foot brake rapidly five times.
Does the brake pedal height build up and then
hold?
Yes
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TEST CONDITIONS
CHECK parking brake adjustment and
ADJUST as necessary. REFER to Section
Cable Adjustment - Vehicles With: Rear
Drum Brakes] REFER to Section
Cable Adjustment - Vehicles With: Rear Disc
Brakes] If the condition still exists. BLEED
the brake system. REFER to Brake System
Bleeding / Brake System Pressure Bleeding
in this section. TEST the system for normal
operation.
No
GO to D4
D4: CHECK FOR BRAKE SYSTEM LEAKS

1 Check for external brake and clutch system
leaks. REFER to the component tests.
Are any leaks found?
Yes
normal operation.
No
GO to D5
D5: PERFORM A BRAKE MASTER CYLINDER BYPASS CONDITION CHECK
1 Test for a brake master cylinder bypass.
REFER to the component tests.
Was a concern found?
Yes
INSTALL a new brake master cylinder.
REFER to Section 206-06.[Hydraulic Brake
Actuation, REMOVAL AND INSTALLATION,
Brake Master Cylinder - RHD]
ADD fluid and BLEED the brake system.
No
System OK.
PINPOINT TEST E: PEDAL EASES DOWN SLOWLY
TEST CONDITIONS
E1: CHECK BRAKE PEDAL OPERATION

1 Check if the condition occurs when applying the
brake pedal while the vehicle is moving.
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TEST CONDITIONS
Does the condition occur with the vehicle stationary?
Yes
GO to E2
No
REFER to the component tests.
E2: CHECK FOR BRAKE SYSTEM LEAKS

1 Check for external brake system leaks.
Refer to the component tests.
Are any leaks found?
Yes
normal operation.
No
GO to E3
E3: PERFORM A BRAKE MASTER CYLINDER BYPASS TEST
1 Test for a brake master cylinder bypass.
Refer to the component tests.
Yes
INSTALL a new brake master cylinder.
REFER to Section 206-06.[Hydraulic Brake
Actuation, REMOVAL AND INSTALLATION,
Brake Master Cylinder - RHD]
ADD fluid and BLEED the bake system.
No
System OK. TEST the system for normal
operation.
PINPOINT TEST F: PEDAL IS LOW OR FEELS SPONGY
TEST CONDITIONS
F1: ROAD TEST THE VEHICLE
1 Road test the vehicle and apply the foot brake.
Did the brake pedal feel spongy?
Yes
GO to F2
No
Vehicle OK.
F2: CHECK BRAKE FLUID LEVEL

1 Check the brake master cylinder reservoir fluid
level.
Is the fluid level OK?
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TEST CONDITIONS
Yes
GO to F3
No
CHECK the brake master cylinder reservoir
sealing points. REFER to the component
tests. ADD fluid and BLEED the brake system. REFER to Brake System Bleeding /
Brake System Pressure Bleeding in this
section. TEST the system for normal operation.
F3: CHECK FILLER CAP VENT

1 Check if the filler cap vent holes are clogged or
dirty.
Yes
CLEAN as necessary. TEST the system for
normal operation.
No
GO to F4
F4: BLEED THE BRAKE SYSTEM
1 Check for air in the brake system. Bleed the
brake system. REFER to Brake System
Bleeding / Brake System Pressure Bleeding in
this section.
Is the condition still present?
Yes
GO to F5
No
Vehicle OK.
F5: CHECK FRONT WHEEL HUB RETAINING NUT
1 Check the front wheel hub retaining nut for
looseness.
Is the front wheel hub retaining nut loose?
Yes
INSTALL a new front wheel hub retaining
nut. REFER to Section 204-01.[Front Suspension, SPECIFICATIONS, Specifications]Do not reuse the front wheel hub retaining nut. TEST the system for normal operation.
No
CHECK the parking bake adjustment.
REFER to Section 206-05.[Parking Brake
and Actuation, GENERAL PROCEDURES,
Parking Brake Cable Adjustment - Vehicles
With: Rear Drum Brakes] REFER to Section
Cable Adjustment - Vehicles With: Rear Disc
Brakes]
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PINPOINT TEST G: BRAKE LOCK UP DURING LIGHT BRAKE PEDAL FORCE
TEST CONDITIONS
G1: ROAD TEST THE VEHICLE

1 Road test the vehicle and apply the brake pedal
lightly.
Do the rear brakes lock up?
Yes
GO to G2 GO to Pinpoint Test G
No
Vehicle OK.
G2: TIRE INSPECTION
1 Check for excessive tire wear or incorrect tire
pressures.
Are the tires in good order?
Yes
No
SUBSTITUTE known good tires. INFLATE to
the correct pressure. TEST the system for
normal operation.
G3: BRAKE SHOES OR BRAKE PADS INSPECTION
1 Inspect the brake shoes or brake pads are
correctly fitted and for grease or fluid contamination or wear concerns.
Are there any concerns?
Yes
REPAIR or INSTALL new components as
necessary. TEST the system for normal operation.
No
G4: CHECK PRESSURE CONSCIOUS REDUCING VALVERIGHT-HAND REAR
1 Install pressure gauges in the left-hand front
and right-hand rear bleed nipples. Apply the
left-hand front wheel.
- Read the pressure at the right-hand rear
wheel.
4692-5164 kPa (680-750 psi) at the right-hand
rear wheel?
Yes
TEST the brake booster. Go to Pinpoint Test
I.
No
INSTALL a new right-hand rear brake pressure control valve. BLEED the brake system.
TEST the system normal operation.
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TEST CONDITIONS
G5: CHECK PRESSURE CONSCIOUS REDUCING VALVELEFT-HAND REAR

1 Install pressure gauges in the right-hand front
and left-hand rear bleed nipples. Apply the
right-hand front wheel.
- Read the pressure at the left-hand rear wheel.
4692-5164 kPa (680-750 psi) at the left-hand rear
wheel?
Yes
TEST the brake booster.
Go to Pinpoint Test I.
No
INSTALL a new left-hand rear brake pressure control valve. BLEED the brake system.
PINPOINT TEST H: EXCESSIVE OR ERRATIC BRAKE PEDAL TRAVEL
TEST CONDITIONS
H1: ROAD TEST THE VEHICLE
1 Road test the vehicle under rough road conditions. Apply the brakes slowly.
Is the pedal travel OK?
Yes
Vehicle OK.
No
GO to H2
H2: CHECK WHEEL BEARING

1 Check for loose front wheel bearings.
Are the front wheel bearings loose?
Yes
CHECK the front wheel hub retaining nut.
INSTALL a new front wheel bearing(s) if
worn or damaged, REFER to Section
204-01.[Front Suspension, REMOVAL AND
INSTALLATION, Wheel Bearing] TEST the
No
CHECK the front brake disc(s) for thickness
variances. REFER to Section 206-03.[Front
Disc Brake, SPECIFICATIONS, Specifications] INSTALL new components as necessary. TEST the system for normal operation.
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PINPOINT TEST I: BRAKES DRAG
TEST CONDITIONS
I1: CHECK BRAKE BOOSTER

1 Check the brake booster push rod alignment
and pedal travel.
Is the push rod and pedal travel OK?
Yes
GO to I2
No
INSTALL a new brake booster. REFER to
Section 206-07.[Power Brake Actuation,
Booster - RHD] TEST the system for normal
operation.
I2: ROAD TEST THE VEHICLE
1 Road test the vehicle and apply the brakes.
Are the brakes functioning correctly?
Yes
Vehicle OK.
No
INSPECT individual wheel cylinders or calipers for binding or sticking components.
INSTALL new components as necessary.
normal operation.
PINPOINT TEST J: EXCESSIVE BRAKE PEDAL EFFORT
TEST CONDITIONS
J1: CHECK BRAKE APPLICATION

1 With the engine off, apply and release the brake
pedal five times to deplete all vacuum from the
brake booster. Apply the brake pedal, hold with
light pressure. Start the engine.
Does the brake pedal hold?
Yes
GO to J2
No
GO to J6
J2: CHECK BRAKE BOOSTER FOR LEAKS
1 Run the engine at medium idle, release the
accelerator pedal and turn the engine off. Wait
90 seconds and apply the brakes. Two or more
brake applications should be power assisted.
Does the brake booster work?
Yes
Vehicle OK.
No
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TEST CONDITIONS
GO to J3
J3: CHECK BRAKE BOOSTER CHECK VALVE

1 Disconnect the vacuum hose, for the brake
booster check valve at the intake manifold. Blow
into the hose attached to the brake booster
check valve.
Does air pass through the valve?
Yes
INSTALL a new brake booster check valve.
No
GO to J4
J4: CHECK BRAKE BOOSTER CHECK VALVE VACUUM
1 Disconnect the vacuum hose from the brake
booster check valve. Run the engine at idle.
Check the supply with a vacuum gauge.
Is the vacuum pressure above 40.5 kPa (12
in-Hg) with the brake booster non-operational?
Yes
GO to J5
No
REPAIR or INSTALL a new vacuum hose
and fittings. TEST the system for normal
operation.
J5: CHECK BRAKE BOOSTER
1 Check the brake booster. GO to the component
test procedure in this section.
Is the brake booster OK?
Yes
GO to J6
No
operation.
J6: CHECK BRAKE PEDAL LINKAGE
1 Disconnect the actuator rod from the pedal pin
and apply the brake pedal fully.
Did the pedal move freely?
Yes
GO to J7
No
REPAIR or INSTALL new brake pedal
bushings. REFER to Section
206-06.[Hydraulic Brake Actuation,
Pedal - RHD] TEST the system for normal
operation.
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TEST CONDITIONS
J7: CHECK BRAKE PRESSURE CONTROL VALVE

1 Check the brake pressure control valve for
contamination.
Is the brake fluid contaminated?
Yes
INSTALL a new brake pressure control
valve. FILL the brake master cylinder reservoir. BLEED the brake system. REFER to
Brake System Bleeding / Brake System
Pressure Bleeding in this section. TEST the
No
Vehicle OK.
PINPOINT TEST K: BRAKE NOISE
TEST CONDITIONS
K1: CHECK FOR PEDAL NOISE

1 Inspect the brake pads and brake shoes for
excessive wear.
- Run the engine at idle for 10 seconds or
longer. Apply the brake pedal and listen for
noise. Compare results with a known good
system.
Was a noise present?
Yes
GO to K2
No
Vehicle OK.
K2: CHECK PUSH ROD ALIGNMENT
1 Check the brake booster push rod alignment
and travel.
Is the push rod OK?
Yes
normal operation.
No
operation.
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PINPOINT TEST L: SLOW OR INCOMPLETE BRAKE PEDAL RETURN
TEST CONDITIONS
L1: CHECK FOR BRAKE PEDAL RETURN

1 Run the engine at fast idle while making several
brake applications. Pull the brake pedal rearward with approximately 44.5 N (10 lbs) force.
Release the brake pedal and measure the distance to the floor pan. Make a hard brake application. Release the brake pedal and measure
the brake pedal to floor pan distance. The brake
pedal should return to its original position.
Did the brake pedal return to its original position?
Yes
Vehicle OK.
No
GO to L2
L2: CHECK FOR BRAKE PEDAL BINDING
1 Check the brake pedal for free operation.
Is the brake pedal operating freely?
Yes
operation.
No
REPAIR or INSTALL new brake pedal
bushings. REFER to Section
Pedal - RHD] TEST the system for normal
operation.
Component Tests
Brake System Check
Hydraulic Leak Check
Brake Pedal Reserve Check
NOTE: There is a common clutch and brake fluid

reservoir, therefore it is possible that a clutch leak
can lead to reduction in the reservoir level.
Where a low brake pedal or the feel of a

bottomed-out condition exists, check for brake
pedal reserve.
It is possible that all evidence of fluid leakage may

have washed off if the vehicle has been operated
in rain or snow, as brake fluid is water-soluble.
Refill the system, bleed then apply the brakes
several times. Examine the system to verify that
the reservoir fluid level is actually dropping.
Locate and repair the external leak. If the fluid
level drops and no external leak can be found,
check for a brake master cylinder bore end seal
leak.
1. Operate the engine at idle with the transaxle in

NEUTRAL.
2. Apply the brake pedal lightly three or four
times.
3. Allow 15 seconds for vacuum to replenish the
brake booster.
NOTE: This increased resistance may feel like
something has bottomed out.
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4. Apply the brake pedal until it stops moving
downward or an increased resistance to the
pedal travel occurs.
5. Hold the brake pedal in the applied position
and raise the engine speed to approximately
2000 rpm.
NOTE: The additional movement of the brake
pedal is the result of the increased engine intake
manifold vacuum which exerts more force on the
brake booster during engine rundown. This means
that additional stroke is available in the brake
master cylinder and the brake system is not
bottoming out.
6. Release the accelerator pedal and observe
that the brake pedal moves downward as the
engine returns to idle speed.
Brake Booster Functional Test
Inspect all hoses and connections. All unused
vacuum connectors should be capped. Hoses and
their connections should be correctly secured and
in good condition with no holes and no collapsed
areas. Inspect the check valve on the brake
booster for damage.
Brake Booster Operation Check
1. Check the hydraulic brake system for leaks or

low fluid.
2. With the transaxle in NEUTRAL, stop the
engine and apply the parking brake. Apply the
brake pedal several times to exhaust all
vacuum in the system.
3. With the engine turned off and all vacuum in
the system exhausted, apply the brake pedal
and hold it down. Start the engine. If the
vacuum system is operating, the brake pedal
will tend to move downward under constant
foot pressure. If no motion is felt, the vacuum
booster system is not functioning.
4. Remove the vacuum hose from the brake
booster. Intake manifold vacuum should be
available at the brake booster end of the hose
with the engine at idle speed and the transaxle
in NEUTRAL. Make sure that all unused
vacuum outlets are correctly capped, hose
connectors are correctly secured and vacuum
hoses are in good condition. When it is
established that manifold vacuum is available
to the brake booster, connector the vacuum
hose to the brake booster and repeat Step 3. If
no downward movement of the brake pedal is
felt, install a new brake booster. REFER to
G28494 en

Booster - RHD]
5. Operate the engine a minimum of 10 seconds
at fast idle. Stop the engine and let the vehicle
stand for 10 minutes. Then, apply the brake
pedal with approximately 89 N (20 lb) force.
The pedal feel (brake application) should be
the same as that noted with the engine
operating. If the brake pedal feels hard (no
power assist), install a new vacuum check
valve and then repeat the test. If the brake
pedal still feels hard, install a new brake
booster. REFER to Section 206-07.[Power
Brake Actuation, REMOVAL AND
INSTALLATION, Brake Booster - RHD]
If the brake pedal movement feels spongy,
bleed the brake system. REFER to Brake
Bleeding in this section.
Brake Master Cylinder
Usually, the first and strongest indicator of

anything wrong with the braking system is a
feeling through the brake pedal. In diagnosing the
condition of the brake master cylinder, check
pedal feel as evidence of a brake concern. Check
for the brake warning indicator illumination and the
fluid level in the master cylinder reservoir.
Normal Conditions
The following conditions are considered normal

and are not indications that the brake master
cylinder is in need of service.
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Modern brake systems are not designed to
produce as hard a pedal effort as in the past.
Complaints of light pedal efforts should be
compared to pedal efforts of another vehicle,
of the same model and year.
During normal operation of the brake the fluid
level in the reservoir will rise during brake
application and fall during release. The net
fluid level (i.e., after brake application and
release) will remain unchanged.
A trace of brake fluid will exists on the brake
booster shell below the master cylinder
mounting flange. This results from the normal
lubricating action of the master cylinder bore
end seal.
The fluid level will fall with brake shoe and
lining wear.
Abnormal Conditions
NOTE: Prior to performing any diagnosis, make

sure the brake system warning indicator is
functional.
Changes in brake pedal feel or travel are
indicators that something could be wrong with the
braking system. The diagnostic procedure and
techniques use brake pedal feel, warning indicator
illumination and low brake fluid level as indicators
in diagnosing braking system concerns. The
following conditions are considered abnormal and
indicate that the brake master cylinder is in need
of service.
The brake pedal goes down fast. This could be

caused by an external or internal leak.
The brake pedal eases down slowly. This
could be caused by an external or internal
leak.
The brake pedal is low and or feels spongy.
This condition may be caused by no fluid in the
brake master cylinder reservoir, reservoir cap
vent holes clogged or air in the hydraulic
system.
The brake pedal effort is excessive. This may
be caused by a bind or obstruction in the pedal
or linkage, clogged fluid control valve or
insufficient booster vacuum.
The rear brakes lock up during light pedal
force. This may be caused by incorrect tire
pressures, grease or fluid on the brake shoes
and linings, damaged brake shoes and linings,
incorrectly adjusted parking brake, or
damaged or contaminated brake pressure
control valves.
The brake pedal effort is erratic. This condition
could be caused by a brake booster
malfunction, extreme caliper piston knock
back or incorrectly installed brake shoes and
linings.
The brake warning indicator is ON. This may
be caused by low fluid level, ignition wire
routing too close to the fluid level indicator
assembly, or float assembly damage.
Bypass Condition Test
1. Check the fluid in brake master cylinder. Fill

the brake master cylinder reservoir if low or
empty.
2. Observe the fluid level in the brake master
cylinder reservoir. If after several brake
applications, the fluid level remains the same,
measure the wheel turning torque required to
rotate the wheels with the brakes applied as
follows:
Place the transaxle in NEUTRAL and raise and
support the vehicle.
Apply the brakes with a minimum of 445 N (100 lb)
and hold for approximately 15 seconds. With the
brakes still applied, exert a torque on the front
wheels of 10.1 Nm (75 lb.ft). If either wheel rotates,
install a new brake master cylinder. REFER to
Section 206-06.[Hydraulic Brake Actuation,
REMOVAL AND INSTALLATION, Brake Master
Cylinder - RHD]
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Non-Pressure Leaks
Any empty brake master cylinder reservoir

condition may be caused by two types of
non-pressure external leaks.
Type 1: An external leak may occur at the master
cylinder reservoir cap because of incorrect
positioning of the gasket and cap. Reposition the
cap and gasket.
Type 2: An external leak may occur at the
reservoir mounting seals. Service such a leak by
installing new seals.
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GENERAL PROCEDURES
Brake System Bleeding (12 141 0)
General Equipment
Worldwide Diagnostic System (WDS)
Bleeding
All Vehicles
WARNING: Brake fluid contains
polyglycol ethers and polyglycols. Avoid
contact with the eyes. Wash hands
thoroughly after handling. If brake fluid
contacts the eyes, flush the eyes for 15
minutes with cold running water. Get
medical attention if irritation persists. If
taken internally, drink water and induce
vomiting. Get medical attention
immediately. Failure to follow these
CAUTION: If brake fluid is spilt on the
paintwork, the affected area must be
immediately washed down with cold
water.
NOTE: Make sure that the vehicle is standing on a
level surface.
NOTE: The system consists of separate circuits
for each front and diagonally opposite rear wheel.
Each circuit can be bled independently.
1.
7. Continue operating the brake pedal until

air-free fluid is being pumped into the bleed
jar.
8. With the brake pedal fully depressed
tighten the bleed nipple.
9.
CAUTION: Make sure that the bleed

nipple cap is installed after bleeding
the brake line(s). This will prevent
corrosion to the bleed nipple. Failure
the bleed nipple becoming seized.
Repeat the procedure for the remaining

brake lines.
10. NOTE: This step is only necessary when
changing the brake fluid to remove the used
brake fluid from the hydraulic control unit
(HCU).
Using WDS, bleed the brake system.
CAUTION: The brake fluid reservoir

must remain full with new, clean brake
fluid at all times during bleeding.
Install the bleed tube to the bleed nipple.

2. Immerse the end of the bleed tube in a
bleed jar containing a small quantity of
approved brake fluid.
3. Position the bleed jar base at least 300 mm
above the bleed nipple to maintain fluid
pressure and prevent air leaking past the
threads of the bleed nipple.
4. Loosen the bleed nipple by one-half turn.
5. Operate the brake pedal fully (pumping
brake fluid and air into the bleed jar) and
allow the brake pedal to return to the rest
position.
6. Fill the brake fluid reservoir to the MAX
mark.
G17458 en
11/2004 2005.25 Fiesta
206-00-28

TO MODEL INDEX
206-00-28
GENERAL PROCEDURES
Brake System Pressure Bleeding (12 141 0)
General Equipment
Bleeding
All vehicles
3.
CAUTION: Make sure that the bleed

nipple cap is installed after bleeding
the brake line(s). This will prevent
corrosion to the bleed nipple. Failure
the bleed nipple becoming seized.
Fill the brake fluid reservoir to the MAX

mark as necessary.
4. NOTE: This step is only necessary when
changing the brake fluid to remove the used
brake fluid from the hydraulic control unit
(HCU).
Using WDS, bleed the brake system.

water.
NOTE: Make sure that the vehicle is standing on a
level surface.
NOTE: The system consists of separate circuits
for each front and diagonally opposite rear wheel.
Each circuit can be bled independently.
1. Fill the brake fluid reservoir to the MAX
mark.
2.
CAUTION: Make sure that the pressure

within the brake system does not
exceed 1 bar.
CAUTION: Make sure that the pressure
bleeding equipment is filled with new
brake fluid to the correct specification.
Using suitable pressure bleeding
equipment, pressure bleed the system in
accordance with the manufacturer's
instructions.
G17459 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
206-02-1
Drum Brake
206-02-1
SECTION 206-02 Drum Brake

CONTENTS
PAGE
SPECIFICATIONS
Specifications....................................................................................................................
Drum Brake Specification.................................................................................................
206-02-2
206-02-2

Drum Brake.......................................................................................................................
Overview ..........................................................................................................................
206-02-3
206-02-3

Drum Brake.......................................................................................................................
206-02-5

Brake Drum...................................................................................................
Brake Shoes .................................................................................................
Wheel Cylinder..............................................................................................
Brake Backing Plate......................................................................................
(12 275 0)
(12 285 0)
(12 305 0)
(12 313 0)
206-02-6
206-02-8
206-02-10
206-02-11
11/2004 2005.25 Fiesta
206-02-2

TO MODEL INDEX
Drum Brake
206-02-2
SPECIFICATIONS

Specification
ESA-M1C171-A
SAM-1C1024-A
ESD-M6C57-A
Silicon dielectric compound

Grease - brake shoe adjuster
Super DOT 4 brake fluid
Drum Brake Specification
New brake drum nominal diameter
Worn brake drum discard diameter *
Brake shoe width
Worn brake shoe lining discard thickness *
203 mm
204 mm
36 mm
1 mm
* When the discard diameter/thickness has been reached, install a new brake drum/brake shoes.
Description
Wheel spindle retaining bolts
Wheel cylinder retaining bolts
Brake hose to wheel cylinder union
G22863 en
Nm
235
70
10
10
17
lb-ft
173
52
13
lb-in
89
89
-
11/2004 2005.25 Fiesta

TO MODEL INDEX
206-02-3
Drum Brake
206-02-3

Drum Brake
Overview
Item
Part
Number
Description
Brake shoe
Brake cylinder
Automatic adjuster
G250944 en
Item
Part
Number
Description
Bi-metallic strip
Return spring
11/2004 2005.25 Fiesta
206-02-4

TO MODEL INDEX
Drum Brake
206-02-4

The drum brake is equipped with an automatic
adjuster which adjusts the brake shoes towards
the brake drum when lining wear occurs.
The adjustment mechanism is equipped with a
bi-metallic strip which prevents undesired
adjustment of the brake shoes when the brakes
are run hot.
The heat generated during braking is passed to
the bi-metallic strip. If the heat exceeds a critical
point, the bi-metallic strip bends upwards into the
corresponding nib and prevents further
adjustment.
After the brake has cooled again, the bi-metallic
strip returns to the initial position. Adjustment is
now possible again.
G250944 en
11/2004 2005.25 Fiesta
206-02-5

TO MODEL INDEX
Drum Brake
206-02-5

Drum Brake
G17465 en
11/2004 2005.25 Fiesta
206-02-6

TO MODEL INDEX
Drum Brake
206-02-6

Brake Drum (12 275 0)
Removal
1. Remove the parking brake control trim
panel.
2. Loosen the parking brake cable adjustment

nut to the end of the thread.
Discard the retaining clip.
5. NOTE: If the dust cap is damaged on removal a

new dust cap must be installed during
installation.
Remove the dust cap.
6. Remove the brake drum.

1. Remove and discard the wheel hub
retaining nut.
2. Remove the drum.

Installation
1.
CAUTION: Rotate the drum ten times in

the opposite direction when tightening
the wheel hub retaining nut to prevent
damage to the bearing.
NOTE: Install a new parking brake cable retaining
clip.
To install, reverse the removal procedure.
G149886 en
11/2004 2005.25 Fiesta
206-02-7

TO MODEL INDEX
Drum Brake
206-02-7

206-05.
G149886 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
206-02-8
Drum Brake
206-02-8

Brake Shoes (12 285 0)
Name
Specification
Silicon dielectric compound
ESA-M1C171-A
Grease - brake shoe

adjuster
SAM-1C1024-A

backing plate.
Removal
panel.
6. Remove the brake drum.

7. Remove the hold down springs.

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11/2004 2005.25 Fiesta
206-02-9

TO MODEL INDEX
Drum Brake
206-02-9
8.
CAUTION: Do not damage the wheel

cylinder boots.
NOTE: Hold the wheel cylinder pistons in place
with a rubber band.
11. Disconnect the parking brake cable from

the brake shoe.
Detach the brake shoes from the wheel

cylinder.
12. Remove the brake shoes.
Installation
9. Remove the brake shoe return springs.
1. NOTE: Make sure that the brake shoe adjuster

is fully released.
NOTE: Install a new parking brake cable retaining
clip.
Apply grease to the brake shoe adjuster
strut.
Clean the backing plate and apply silicon
dieletic compound to the brake shoe contact
points.
206-05.
10. Remove the brake shoe adjuster from the

brake shoes.
G149887 en
11/2004 2005.25 Fiesta
206-02-10

TO MODEL INDEX
Drum Brake
206-02-10

Wheel Cylinder (12 305 0)
Installation
General Equipment
Brake hose clamp

2. Bleed the brake system. For additional
Removal
water.
1. Remove the brake shoes. For additional
information, refer to Brake Shoes in this
section.
2.
CAUTION: Cap the brake tube to

prevent fluid loss or dirt ingress.
Disconnect the brake tube from the wheel
cylinder.
1. Using a suitable brake hose clamp, clamp
the brake hose.
2. Disconnect the brake tube.
3. Remove the wheel cylinder.
G149888 en
11/2004 2005.25 Fiesta
206-02-11

TO MODEL INDEX
Drum Brake
206-02-11

Brake Backing Plate (12 313 0)
Installation
General Equipment
Electric hand drill
Blind rivet gun-hand

Using a suitable blind rivet gun-hand, install
new rivets.
Removal
1. Remove the wheel cylinder. For additional
information, refer to Wheel Cylinder in this
section.
backing plate.
1. Depress the retaining clip.
2. Detach the cable.
3. Remove the brake backing plate.

Using a suitable electric hand drill remove
the rivets
G149889 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
206-03-1
Front Disc Brake
206-03-1
SECTION 206-03 Front Disc Brake

CONTENTS
PAGE
SPECIFICATIONS
Specifications....................................................................................................................
Front Disc Brake Specification .........................................................................................
206-03-2
206-03-2

Front Disc Brake ...............................................................................................................
Overview ..........................................................................................................................
206-03-3
206-03-3

Front Disc Brake ...............................................................................................................
206-03-4

Brake Pads ................................................................................................... (12 234 0)
Brake Caliper ................................................................................................ (12 243 0)
206-03-5
206-03-7
11/2004 2005.25 Fiesta
206-03-2

TO MODEL INDEX
Front Disc Brake
206-03-2
SPECIFICATIONS

Specification
ESD-M6C57-A
Brake Fluid - Super DOT 4

Front Disc Brake Specification
Description
Brake disc diameter
Brake disc diameter - Vehicles with 2.0L Duratec-HE
New brake disc nominal thickness
New brake disc nominal thickness - Vehicles with 2.0L Duratec-HE
Worn brake disc discard thickness *
Worn brake disc discard thickness - Vehicles with 2.0L Duratec-HE *
Maximum brake disc thickness variation
Worn brake pad discard thickness **
Worn brake pad discard thickness - Vehicles with 2.0L Duratec-HE **
mm
258
278
22
25
20
23
0.025
1.5
2.0
* When the discard thickness has been reached, install a new brake disc and new brake pads.
** When the discard thickness has been reached, install new brake pads.
Description
Brake caliper anchor plate retaining bolts - Vehicles
with 2.0L Duratec-HE
Brake caliper retaining bolts
Brake hose to brake caliper union
G17354 en
Nm
70
80
lb-ft
52
59
lb-in
-
30
17
22
13
11/2004 2005.25 Fiesta

TO MODEL INDEX
206-03-3
Front Disc Brake
206-03-3

Front Disc Brake
Overview
Item
Part
Number
Description
Brake disc
Brake back plate assembly
Retaining spring clip
Brake pads
Brake caliper
The front brake system has internally ventilated

brake discs and a single-piston floating caliper.
The front disc brakes are the same on all vehicles,
irrespective of the vehicle specifications.
Please refer to the "General Specifications"
section for the dimensions of the brake discs.
The piston of the brake caliper has a diameter of
54 mm.
G250945 en
11/2004 2005.25 Fiesta
206-03-4

TO MODEL INDEX
Front Disc Brake
206-03-4

Front Disc Brake
G17475 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
206-03-5
Front Disc Brake
206-03-5

Brake Pads (12 234 0)
Special Tool(s)
Retractor, Brake Caliper
Piston
206-005
Name
Silicone Grease
Brake Fluid - Super
DOT4

hose to aid installation.
support bracket.
Remove the brake hose retaining clip.
Specification
ESE-M1C171-A
ESD-M6C57-A
Removal
water.
2. Remove the brake caliper retaining clip.
G149890 en
4.
CAUTION: Suspend the brake caliper to

prevent load being placed on the brake
hose.
Detach the brake caliper from the brake
caliper anchor plate.
1. Remove the brake caliper retaining bolt
covers (if equipped).
2. Remove the brake caliper retaining bolts.
11/2004 2005.25 Fiesta
206-03-6

TO MODEL INDEX
Front Disc Brake
206-03-6

5. Remove the brake pads.
2.

when installing the brake caliper to
CAUTION: Make sure that the brake hose
is correctly located in the brake hose
support bracket to prevent damage to the
brake hose.
CAUTION: Make sure that the brake hose
Installation
1.
CAUTION: When the brake caliper

piston is retracted into the piston
housing, brake fluid will be displaced
into the brake fluid reservoir.

Apply grease to the brake pad contact
points.
3. Fully depress and release the brake pedal.
4. Check the fluid level in the brake fluid
reservoir and top up if necessary with
brake fluid.
CAUTION: Support the brake caliper

during brake caliper piston retraction.
Using the special tool, retract the brake
caliper piston.
G149890 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
206-03-7
Front Disc Brake
206-03-7

Brake Caliper (12 243 0)
CAUTION: Cap the brake hose to
NOTE: Use a wrench to prevent the brake hose
from rotating.
3.
General Equipment
Brake hose clamp
Name
Silicone Grease
Specification
ESE-M1C171-A
Removal
Disconnect the brake hose from the brake

caliper.
1. Using a brake hose clamp, clamp the brake
hose.
2. Disconnect the brake hose.

water.
2. Remove the brake caliper retaining clip.
4. Remove the brake caliper.

1. Remove the brake caliper retaining bolt
covers (if equipped).
2. Remove the brake caliper retaining bolts.
G149891 en
11/2004 2005.25 Fiesta
206-03-8

TO MODEL INDEX
Front Disc Brake
206-03-8

Installation
1.

when connecting the brake hose to the
brake caliper to prevent damage to the
brake hose.

Apply grease to the brake pad contact
points.
information, refer to Section 206-00.[Brake
System - General Information, GENERAL
PROCEDURES, Brake System Bleeding]
206-00.[Brake System - General
Information, GENERAL PROCEDURES,
Brake System Pressure Bleeding]
G149891 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
206-04-1
Rear Disc Brake
206-04-1
SECTION 206-04 Rear Disc Brake

CONTENTS
PAGE
SPECIFICATIONS
Specifications....................................................................................................................
Brake Disc Specification...................................................................................................
206-04-2
206-04-2

Rear Disc Brake................................................................................................................
206-04-3

Rear Disc Brake................................................................................................................
206-04-5

Brake Pads ................................................................................................... (12 238 0)
Brake Caliper ................................................................................................ (12 253 0)
Brake Disc .................................................................................................... (12 225 0)
Brake Disc Shield..............................................................................................................
206-04-6
206-04-8
206-04-10
206-04-11
11/2004 2005.25 Fiesta

TO MODEL INDEX
206-04-2
Rear Disc Brake
206-04-2
SPECIFICATIONS

Item
Brake Fluid - Super DOT 4
Specification
ESD-M6C57-A
Brake Disc Specification

Description
mm
280
10.15
8
0.02
1.50
34
Brake disc diameter

New brake disc nominal thickness
Worn brake disc discard thickness*
Maximum brake disc thickness variation
Worn brake pad discard thickness*
Brake caliper piston diameter
*When the discard thickness has been reached, install a new brake disc/brake pads.
Item
Wheel spindle retaining bolts
Brake caliper retaining bolts
Brake tube to brake caliper union
G427692 en
Nm
66
60
35
15
lb-ft
49
44
26
11
lb-in
-
11/2004 2005.25 Fiesta

TO MODEL INDEX
206-04-3
Rear Disc Brake
206-04-3

Rear Disc Brake
Rear Wheel Hub and Disc Brake Assembly
Item
Part
Number
Beam axle
Brake disc shield
Brake caliper and brake

caliper anchor plate assembly
Dust cap
Brake disc
Wheel hub
Wheel speed sensor ring
Wheel spindle
G427693 en
Description
11/2004 2005.25 Fiesta
206-04-4

TO MODEL INDEX
Rear Disc Brake
206-04-4
Brake Caliper and Brake Caliper Anchor Plate Assembly
Item
Part
Number
Brake caliper anchor plate
Brake pads
Brake caliper
G427693 en
Description
11/2004 2005.25 Fiesta
206-04-5

TO MODEL INDEX
Rear Disc Brake
206-04-5

Rear Disc Brake
REFER to Section 206-00.[Brake System General Information, DIAGNOSIS AND TESTING,
Brake System]
G427694 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
206-04-6
Rear Disc Brake
206-04-6

Brake Pads (12 238 0)
4.
Special Tool(s)
Retractor, Rear Brake Caliper
Piston
206-012
Name
Brake Fluid - Super
DOT4
CAUTION: Suspend the brake caliper to

prevent load being placed on the brake
hose.
Detach the brake caliper from the brake
Specification
ESD-M6C57-A
Removal
water.
3. Detach the brake hose from the brake hose
support bracket.
G427695 en
11/2004 2005.25 Fiesta
206-04-7

TO MODEL INDEX
Rear Disc Brake
206-04-7

Installation
1.
CAUTION: When the brake caliper

piston is retracted into the brake
caliper piston housing, brake fluid will
be displaced into the brake fluid
reservoir.
CAUTION: Support the brake caliper
during brake caliper piston retraction.
Using the special tool, retract the brake
caliper piston.
2. NOTE: Make sure that the brake pad contact

points are clean and free from contamination.
3. Fully depress and release the brake pedal.
reservoir and top up if necessary with
brake fluid.
G427695 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
206-04-8
Rear Disc Brake
206-04-8

Brake Caliper (12 253 0)
4. Using a brake hose clamp, clamp the brake
hose.
Special Tool(s)
Retractor, Rear Brake Caliper
Piston
206-012
General Equipment
Brake hose clamp
Name
Brake Fluid - Super
DOT4
Specification
ESD-M6C57-A
Removal
water.
brake caliper.
1. Pull back the brake caliper lever.
2. Disconnect the parking brake cable from the
brake caliper lever.
brake caliper.
G427696 en
5.
CAUTION: Cap the brake hose to

Disconnect the brake tube from the brake
caliper.
6. Detach the brake caliper from the brake

11/2004 2005.25 Fiesta
206-04-9

TO MODEL INDEX
Rear Disc Brake
206-04-9


8. Remove the brake caliper anchor plate.
Installation
1. Using the special tool, retract the brake
caliper piston.
2. NOTE: Make sure that the brake pad contact

points are clean and free from contamination.
G427696 en
11/2004 2005.25 Fiesta
206-04-10

TO MODEL INDEX
Rear Disc Brake
206-04-10

Brake Disc (12 225 0)
Removal
3. Detach the brake hose from the brake hose
support bracket.

Remove the brake disc retaining clip (if
equipped).
Installation
4.

and brake caliper anchor plate
assembly to prevent load being placed
on the brake hose.
Detach the brake caliper and brake caliper
anchor plate assembly from the wheel
spindle (parking brake cable shown removed for clarity).
G427697 en
11/2004 2005.25 Fiesta
206-04-11

TO MODEL INDEX
Rear Disc Brake
206-04-11

Brake Disc Shield
General Equipment
Electric hand drill
4. Remove the brake disc shield.

Using an electric hand drill, remove the rivets.
Blind rivet gun
Removal
information, refer to Brake Disc in this
section.
wheel spindle.
Installation
1.
CAUTION: Make sure that the mating

faces are clean and free from rust and
foreign material.
NOTE: Using a blind rivet gun, install new rivets.
3. Remove the wheel spindle and wheel hub

assembly.
G427698 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
206-05-1
Parking Brake and Actuation
206-05-1
SECTION 206-05 Parking Brake and Actuation

CONTENTS
PAGE
SPECIFICATIONS
Specifications....................................................................................................................
206-05-2

Parking Brake ...................................................................................................................
Overview ..........................................................................................................................
206-05-3
206-05-3

Parking Brake ...................................................................................................................
Symptom Chart ................................................................................................................
Pinpoint Tests ..................................................................................................................
206-05-5
206-05-5
206-05-5
206-05-5
GENERAL PROCEDURES
Parking Brake Cable Adjustment Vehicles With: Rear Drum Brakes......... (12 662 0)
Parking Brake Cable Adjustment Vehicles With: Rear Disc Brakes .......... (12 662 0)
206-05-8
206-05-10

Parking Brake Cable Vehicles With: Rear Drum Brakes ........................... (12 675 0)
Parking Brake Cable Vehicles With: Rear Disc Brakes............................. (12 675 0)
Parking Brake Control ................................................................................... (12 664 0)
206-05-12
206-05-14
206-05-16
11/2004 2005.25 Fiesta
206-05-2

TO MODEL INDEX
206-05-2
SPECIFICATIONS
Description
Parking brake cable adjustment nut
Parking brake control retaining nuts
G28517 en
Nm
4
24
lb-ft
18
lb-in
35
-
11/2004 2005.25 Fiesta

TO MODEL INDEX
206-05-3
206-05-3

Parking Brake
Overview
Item
Part
Number
Handbrake lever
Handbrake adjusting nut
Front handbrake cable
G250946 en
Description
Item
Part
Number
Description
Equaliser
Handbrake cables
Sleeve connection
Rear handbrake cable

11/2004 2005.25 Fiesta
206-05-4

TO MODEL INDEX
206-05-4

Layout
The handbrake cable mechanism consists of

three sections: the front handbrake cable, the two
handbrake cables underneath the vehicle and the
two rear handbrake cables leading to the brakes.
The front handbrake cable is connected to the
handbrake lever via a threaded piece and a nut.
This nut is used to adjust the handbrake cable.
The two handbrake cables underneath the vehicle
are both connected via a threaded piece and a nut
to the equaliser and therefore the front handbrake
cable. They are connected to the rear handbrake
cables via a sleeve connection.
The rear handbrake cables in turn link into the
lever mechanism of the rear brakes.
Function
When the handbrake lever is operated, the front

handbrake cable acts via the equaliser onto the
two handbrake cables underneath the vehicle. Via
the sleeve connection pieces these then act onto
the rear handbrake cables and, via the lever
mechanism, onto the brake.
G250946 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
206-05-5
206-05-5

Parking Brake

step.
4. If the concern is not visually evident, verify the
1. Verify the customer concern by operating the

parking brake system.
Mechanical
Parking brake
control
Cable and conduit
Electrical
Parking brake
warning circuit.
Symptom Chart
Symptom
Possible Sources
Action
The parking brake will not apply Parking brake control.

Cable and conduit.
The parking brake will not release
Parking brake control.

Cable and conduit.
Pinpoint Tests
PINPOINT TEST A: THE PARKING BRAKE WILL NOT APPLY
TEST CONDITIONS
A1: CHECK FOR MISADJUSTED REAR PARKING BRAKE CABLE
1 Operate the parking brake control several times
to adjust the cable.
Does the parking brake now engage correctly?
Yes
Vehicle OK
No
GO to A2
A2: CHECK FOR WORN BRAKE SHOES OR PADS
1 Inspect the brake shoes or pads for excessive
wear.
Are the brake shoe linings or brake pads OK?
Yes
GO to A3
No
INSTALL new brake shoes or pads.
A3: CHECK FOR DAMAGED PARKING BRAKE CABLES
1 Inspect the parking brake cables and conduits
for damage, rust or fraying.
Are the parking brake cables and conduits OK?
Yes
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11/2004 2005.25 Fiesta
206-05-6

TO MODEL INDEX
206-05-6

TEST CONDITIONS
CHECK for other causes such as loose
parking brake control or conventional brake
system components.
No
REPAIR or INSTALL cables and conduit as
necessary. TEST the system for normal operation.
PINPOINT TEST B: THE PARKING BRAKE WILL NOT RELEASE

TEST CONDITIONS
B1: CHECK PARKING BRAKE CONTROL

1 Raise and support the vehicle on a lift with the
parking brake fully applied.
- With the aid of another technician, release the
parking brake and check the operation of the
brake cables and levers.
Did the parking brake release?
Yes
CHECK the other causes such as conventional brake system components. REPAIR or
No
GO to B2
B2: CHECK PARKING BRAKE CABLES
1 Loosen the parking brake cable tension.
- Rotate the rear wheels by hand.
Did the rear wheels turn freely?
Yes
INSTALL a new parking brake control. TEST
No
GO to B3
B3: CHECK FRONT PARKING BRAKE CABLE
1 Disconnect the parking brake front cable and
conduit from the rear brake cable and conduit at
the equalizer.
- Rotate the rear wheels by hand.
Did the rear wheels turn freely?
Yes
INSTALL a new front parking brake cable
and conduit. TEST the system for normal
operation.
No
GO to B4
B4: CHECK REAR PARKING BRAKE CABLES
1 Disconnect the parking brake at the rear
brakes, one at a time.
- Rotate the wheel affected by the disconnected
parking brake.
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206-05-7

TO MODEL INDEX
206-05-7

TEST CONDITIONS
Did the wheel turn freely?
Yes
INSTALL a new parking brake control lever
on the rear drum brakes or caliper assembly
on rear disc brakes. TEST the system
No
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11/2004 2005.25 Fiesta
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TO MODEL INDEX
206-05-8
GENERAL PROCEDURES
Parking Brake Cable Adjustment Vehicles With: Rear Drum Brakes (12 662 0)
panel.

5. NOTE: Prior to carrying out the adjustment to a

new or relocated parking brake cable, settle the
Settle the parking brake system in five
stages.
Stage 1: Raise the parking brake control
four notches.
Stage 2: Tighten the adjustment nut until
increased torque is detected.
Stage 3: Operate the parking brake control
firmly ten times.
Stage 4: Loosen the adjustment nut to the
end of the thread.
Stage 5: Depress the brake pedal firmly
fifteen times.
7. Remove the brake backing plate inspection
cover on both sides (left-hand side shown).

4. Make sure that the parking brake cable is
correctly located.
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206-05-9
GENERAL PROCEDURES (Continued)

8. NOTE: Make sure that the parking brake control
is fully released.
Adjust the parking brake cable in two
stages .
Stage 1: With the aid of another technician,
tighten the parking brake cable adjustment
nut until the parking brake levers operate
(left-hand side shown).
Stage 2: When movement is observed on
both levers, tighten the parking brake cable
adjustment nut two full turns.
10. Check the parking brake cable adjustment

in two stages.
Stage 1: Raise and release the parking
brake control and check that it returns to the
fully released position. If the parking brake
control does not fully release, repeat the
adjustment procedure.
Stage 2: Rotate the rear wheels and check
for brake drag. If brake drag is felt, loosen
the parking brake cable adjustment nut two
full turns and repeat the adjustment
procedure.
11. Install a new parking brake cable adjustment nut retaining clip.
9. Install the brake backing plate inspection

cover on both sides (left-hand side shown).
12. Install the parking brake control trim
panel.
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206-05-10
GENERAL PROCEDURES
Parking Brake Cable Adjustment Vehicles With: Rear Disc Brakes (12 662 0)
panel.

5. NOTE: Prior to carrying out adjustment to a new

or relocated parking brake cable, settle the
Settle the parking brake system in 5 stages.
Stage 1: Raise the parking brake control 4
notches.
Stage 2: Tighten the parking brake cable
adjustment nut until increased torque is
detected.
Stage 3: Operate the parking brake control
firmly 10 times.
Stage 4: Loosen the parking brake cable
adjustment nut to the end of the thread.
Stage 5: Depress the brake pedal firmly 15
times.
8. NOTE: Make sure that the parking brake control
is fully released.
Adjust the parking brake cable in 2 stages.
Stage 1: With the aid of another technician,
tighten the parking brake cable adjustment
nut until both the parking brake actuating
levers start to move (left-hand parking brake
actuating lever shown).
Stage 2: Tighten the parking brake cable
adjustment nut until the total movement
between both the parking brake actuating
levers and the stops, when added together,
is between 0.5 mm and 2.0 mm (left-hand
parking brake actuating lever shown).

4. Make sure that the parking brake cable is
correctly located.
9. Check the parking brake cable adjustment

in 2 stages.
Stage 1: Raise and release the parking
brake control and check that it returns to the
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206-05-11

fully released position. If the parking brake
control does not fully release, repeat the
adjustment procedure.
Stage 2: Rotate the rear wheels and check
for brake drag. If brake drag is felt, loosen
the parking brake cable adjustment nut 2 full
turns and repeat the adjustment procedure.
11. Install a new parking brake cable adjustment nut retaining clip.
12. Install the parking brake control trim

panel.
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TO MODEL INDEX
206-05-12
206-05-12

Parking Brake Cable Vehicles With: Rear Drum Brakes (12 675 0)
Name
Lubricant
Specification
5. Disconnect the parking brake cable on

both sides.
ESE-M99B144-B
Removal
3.
CAUTION: Take care when removing

the exhaust hanger insulators to
prevent damage.
Detach the exhaust rear muffler from the
exhaust hanger insulators.
4. Detach the center section of the exhaust

system heat shield from the floor panel.
7. Detach the parking brake cables from the
parking brake cable equalizer.
parking brake cable support bracket.
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206-05-13


floor panel crossmember on both sides.
10. Remove the parking brake cable.
Installation
1.
CAUTION: Take care when installing

prevent damage.
NOTE: Check the exhaust hanger insulators for
damage. Install new exhaust hanger insulators if
required.
2. Adjust the parking brake. For additional
information, refer to Parking Brake Cable
Adjustment - Vehicles With: Rear Drum
Brakes in this section.
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206-05-14

Parking Brake Cable Vehicles With: Rear Disc Brakes (12 675 0)
Removal
3.

prevent damage.
NOTE: Support the rear muffler.

brake caliper on both sides.
1. Pull back the parking brake actuating lever.
2. Disconnect the parking brake cable from the
parking brake actuating lever.
brake caliper bracket.
Detach the rear muffler from the exhaust

hanger insulators.
6.
4. Detach the center section of the exhaust

system heat shield from the floor pan.
CAUTION: Do not apply excessive force

when releasing the parking brake
cable clip locking tangs from the
parking brake cable clip support
bracket. Failure to follow this
instruction may result in damage to the
clip.
NOTE: The parking brake cable clip is secured to
the parking brake cable support bracket by a
locking tang on either side of the clip.
Detach the parking brake cable from the
Release the locking tangs.
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206-05-15

Detach the parking brake cables from the
parking brake cable support bracket.
Installation
1.

prevent damage.
NOTE: Check the exhaust hanger insulators for
damage. Install new exhaust hanger insulators if
required.
Adjustment - Vehicles With: Rear Disc


floor pan on both sides.
10. Remove the parking brake cable.
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206-05-16

Parking Brake Control (12 664 0)
Removal
panel.
2. Disconnect the parking brake warning indicator switch electrical connector.

5. Remove the parking brake control.
Installation
Adjustment - Vehicles With: Rear Drum
3. Disconnect the parking brake cable from

the parking brake control.
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206-06-1
Hydraulic Brake Actuation
206-06-1
SECTION 206-06 Hydraulic Brake Actuation

CONTENTS
PAGE
SPECIFICATIONS
Specifications....................................................................................................................
206-06-2

Hydraulic Brake Actuation.................................................................................................
206-06-3

Brake Pedal RHD ..................................................................................... (12 333 0)
Brake Master Cylinder RHD ..................................................................... (12 343 0)
206-06-4
206-06-6
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206-06-2
SPECIFICATIONS

Item
Description
Brake master cylinder brake tube unions
Pressure conscious reducing valve unions
Brake master cylinder retaining nuts
Brake pedal cross-shaft mounting bracket nuts
G327704 en
Specification
ESD-M6C57-A
Nm
17
26
25
25
lb-ft
13
19
18
18
lb-in
-
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206-06-3

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206-06-4

Brake Pedal RHD (12 333 0)
Removal
All vehicles
WARNING: In the event of a frontal impact
to a vehicle equipped with a decoupler
brake pedal in which damage to, or
significant movement of, the instrument
panel or the brake booster has occurred,
a new brake pedal must be installed.
1. Remove the instrument panel lower panel.
1. Remove the lower retaining screws.
2. Remove the upper retaining screws from
the stowage compartment.
3. Release the clip.

3. NOTE: From 02/2004 the brake pedal will not
be equipped with the brake pedal decoupler
mechanism.
Remove the brake pedal.
1. Remove the pivot shaft nut.
2. Slide out the pedal pivot shaft.
3. Remove the brake pedal.
4. Remove the brake pedal bushings.
2. Detach the brake booster actuating rod

from the brake pedal (accelerator pedal
shown removed for clarity).
1. Depress the clip.
2. Remove the brake booster actuating rod
pin.
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5. NOTE: From 02/2004 the brake pedal will not
be equipped with the brake pedal decoupler
mechanism.
Remove the brake pedal.
1. Remove the pivot shaft nut.
2. Slide out the pedal pivot shaft.
3. Remove the brake pedal.
6. Remove the brake pedal bushings.
Installation
1.
CAUTION: Do not drop or knock the

brake pedal. Failure to follow this
instruction will cause damage to the
brake pedal decoupler mechanism (if
equipped).
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206-06-6

Brake Master Cylinder RHD (12 343 0)
Removal
All vehicles
5. NOTE: It will be necessary to carry out this step

on both sides in order to completely drain the
brake fluid reservoir.

water.
1. Disconnect the brake vacuum pipe from
the brake booster.
1. Unclip the brake vacuum pipe.
2. Disconnect the brake vacuum pipe.
2. Disconnect the battery ground cable.

414-01.
3. Remove the windshield wiper motor
assembly.
For additional information,
4.
Drain the brake fluid reservoir.

1. Connect one end of a suitable piece of clear
plastic pipe to the bleed nipple and place
the other end into a suitable container.
2. Loosen the bleed nipple.
3. Depress the brake pedal until all the fluid is
drained from the brake fluid reservoir.
4. Tighten the bleed nipple.
6. Install the brake fluid reservoir cap.

7.
CAUTION: Cap the brake tubes to

Disconnect the brake tubes from the brake
master cylinder.
CAUTION: The brake fluid reservoir cap

must not become contaminated.
Remove the brake fluid reservoir cap.
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206-06-7

8.

10. Detach the brake master cylinder from the

brake booster.
Disconnect the brake tubes from the brake

master cylinder.
11. Disconnect the low brake fluid warning

indicator switch electrical connector.
All vehicles
9.
CAUTION: Cap the clutch master

cylinder feed hose to prevent fluid loss
or dirt ingress.
Disconnect the clutch master cylinder feed
hose from the brake fluid reservoir.
12. Remove the brake master cylinder and

brake fluid reservoir assembly.
Installation
CAUTION: Make sure the brake master
cylinder vacuum seal is correctly
positioned before installation.
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206-07-1
Power Brake Actuation
206-07-1
SECTION 206-07 Power Brake Actuation

CONTENTS
PAGE
SPECIFICATIONS
Specifications....................................................................................................................
206-07-2

Brake Booster ...................................................................................................................
Emergency brake assistant (EBA).....................................................................................
206-07-3
206-07-3

Power Brake System.........................................................................................................
206-07-7

Brake Booster RHD .................................................................................. (12 451 0)
206-07-8
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206-07-2
SPECIFICATIONS
Description
Brake booster retaining nuts
Brake master cylinder retaining nuts
G28531 en
Nm
25
25
lb-ft
18
18
lb-in
-
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206-07-3

Brake Booster
Emergency brake assistant (EBA)
As ABS braking systems have become
widespread, it has emerged that because of
incorrect use of the brakes, many drivers are
losing the safety benefit which ABS provides.
Drivers are applying the brakes too timidly.
Because of this, the Anti-lock Braking System
(ABS) does not engage, and the maximum
braking effect is not achieved.
The EBA recognises from the driver's manner of
braking that an emergency situation is occurring,
and automatically applies full braking power.
This occurs in a matter of milliseconds, which is
faster than the driver could do it.
Furthermore, it was observed that after the first
heavy application of the brake pedal, the driver
releases the pressure on the pedal too early.
The EBA ensures that the ABS effect still
continues when the pedal pressure would
normally lie below the ABS range of control. The
system is available as an option depending on
market and vehicle variant.
Depending on driving manner, EBA results in a
reduction in braking distance of 15% for
experienced drivers, to over 40% for average
drivers.
Item
Part
Number
Description
EBA
EBA operates purely mechanically, and is

completely integral with the brake servo.
Brake servo units with and without EBA are
externally identical. For identification purposes,
brake servo units with EBA carry a white sticker
showing a large letter "A".
The tandem master cylinder is the same for
vehicles with or without EBA.
Function
In normal braking situations, the brake servo with

EBA operates in the same way as a conventional
brake servo unit. This means that the driver can
always modulate the brakes.
If an activation threshold defined by a
characteristic curve is exceeded during braking,
the EBA operates.
Determination of the activation threshold is based
on the pedal movement parameters, which are a
function of the pressure on the brake pedal and
the speed of movement of the pedal.
The characteristic curve is separately defined for
each vehicle model.
Because EBA decelerates the vehicle up to the

wheel locking limit, emergency brake assist is only
used in vehicles with ABS.
The mechanical EBA uses the fact that in a brake

servo unit, the valve piston moves ahead of the
control housing when a braking operation starts.
Components
Because of this, there is a relative travel distance

between the control housing and the valve piston
which can vary depending on the force applied to
the brake pedal and the pedal speed.
The relative travel distance is small when the
pedal moves slowly with low force applied to it.
The relative travel distance is larger when the
pedal moves faster with higher force applied to it.
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206-07-4
Item
Part
Number
Description
Relative travel distance
Item
Part
Number
Description
Control housing
Valve piston
Item
Part
Number
Description
Lock sleeve
Ball cage
Normal braking
Item
Part
Number
Ball sleeve
Control housing
Valve piston
Ball
G163289 en
Description
In a normal braking operation, pedal operation

causes the relative travel distance to remain so
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206-07-5
206-07-5

small that the distance required for engagement is
not exceeded.
The lock sleeve is held in its rest position by the

force applied by the spring, the ball cage remains
free to move axially and the balls remain free to
move radially.
Active brake assistant
Item
Part
Number
Description
Relative travel distance
Disc valve
Key
If the activation threshold level is exceeded

because of an emergency braking situation, i.e.
the relative travel distance of the valve piston is so
great that the balls are moved in over the slope of
G163289 en
the ball sleeve, then the lock sleeve can move

completely to its end position.
The balls are now locked, and the ball sleeve can
no longer be moved in the closing direction of the
disc valve.
The EBA is now active, the brake pressure is
increased up to the wheel locking limit, and the
brake pedal can be moved to its maximum
pressure point without effort.
The brake pressure remains at the ABS control
limit until the EBA is completely released again.
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206-07-6
Release of the brake assistant
Item
Part
Number
Description
Lock sleeve
Key
Vacuum cylinder
To release EBA, the brake pedal must be fully

released, i.e. it must be returned to its rest
position.
When this occurs, the control housing together
with the valve piston move back into the rest
position. The key is pressed against the stop on
the vacuum cylinder and by this the lock sleeve is
slid back into its rest position.
The balls can again be moved outward by the ball
sleeve, and the ball cage is again free to move
axially and the balls free to move radially.
Service
It is not possible to repair the EBA. A new brake

servo unit must be installed.
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206-07-7

Power Brake System
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206-07-8

Brake Booster RHD (12 451 0)
Removal
1. Remove the brake master cylinder. For
Master Cylinder - RHD]
2. Disconnect the brake vacuum pipe from
the brake booster.
1. Unclip the brake vacuum pipe.
2. Disconnect the brake vacuum pipe.
4. Detach the brake booster actuating rod

from the brake pedal (accelerator pedal
1. Depress the clip.
2. Remove the brake booster actuating rod
pin.
5. Remove the brake booster.

Discard the gasket.

3. Release the retaining clip.
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206-07-9

Installation
1.
WARNING: Do not install an Emergency

Brake Assist (EBA) brake booster to a
vehicle that is not equipped with the
Anti-lock Brake System (ABS). Failure
personal injury.
WARNING: Do not use a damaged brake
pedal. Failure to follow this instruction
CAUTION: Make sure that the brake
booster gasket is correctly positioned on
the brake booster before installation.
CAUTION: Do not drop or knock the brake

pedal. Failure to follow this instruction
will cause damage to the brake pedal
decoupler mechanism (if equipped).
NOTE: On vehicles equipped with EBA the brake
booster is identified by a white sticker showing a
large letter "A".
NOTE: Install a new brake booster gasket.
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206-09A-1
Anti-Lock Control
206-09A-1
SECTION 206-09A Anti-Lock Control

CONTENTS
PAGE
SPECIFICATIONS
Specifications...................................................................................................................
206-09A-2

Anti-Lock Control .............................................................................................................
Overview .........................................................................................................................
Function ..........................................................................................................................
MK70 Anti-lock Brake System (ABS)..............................................................................
MK60 ABS .....................................................................................................................
206-09A-3
206-09A-3
206-09A-3
206-09A-5
206-09A-5
206-09A-5

Inspection and Verification ..............................................................................................
206-09A-7
206-09A-7

Hydraulic Control Unit (HCU) Vehicles Built Up To: 05/2004 .......................................
Hydraulic Control Unit (HCU) Vehicles Built From: 05/2004.........................................
Anti-Lock Brake System (ABS) Module Vehicles Built Up To: 05/2004 ........................
Anti-Lock Brake System (ABS) Module Vehicles Built From: 05/2004 .........................
Rear Wheel Speed Sensor............................................................................ (12 785 0)
Rear Wheel Speed Sensor Ring ................................................................... (12 788 0)
206-09A-8
206-09A-11
206-09A-14
206-09A-17
206-09A-20
206-09A-22
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TO MODEL INDEX
Anti-Lock Control
206-09A-2
SPECIFICATIONS

Specifications
ESDM6C57A

Item
Hydraulic control unit (HCU) to support bracket
retaining bolts
HCU support bracket retaining bolts
Brake tube to HCU unions
Wheel speed sensor retaining bolts
Anti-lock brake system (ABS) module to HCU retaining bolts
G112960 en
Nm
9
lb-ft
-
lb-in
80
20
18
9
5
15
13
-
80
44
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206-09A-3
Anti-Lock Control
206-09A-3

Anti-Lock Control
Overview
Description
Electronic brake force distribution is integrated in

the software of the ABS control unit, which
electronically regulates and optimises the
pressure applied to the wheel brakes on the front
and rear axles in accordance with the operating
conditions.
Item
Part
Number
Anti-lock brake system (ABS)

hydraulic unit with integrated
control unit
Data Link Connector (DLC)
Wheel speed sensors
Function
Ignition lock
Stoplamp switch
ABS warning lamp in the instrument cluster
The ABS is a closed loop control system in the

brake system which prevents the wheels from
locking up under braking and therefore maintains
steerability and driving stability in extreme
situations.
In addition to the conventional brake system with

two diagonally split brake circuits, the ABS
consists of an ABS hydraulic unit with integrated
control unit, four wheel sensors and the ABS
warning lamp in the instrument cluster.
G163290 en
ABS control unit
The ABS control unit continuously compares

stored physical deceleration values with those
detected by the wheel sensors. This allows the
lock-up tendency of each wheel to be detected
separately.
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Anti-Lock Control
206-09A-4

If the ABS control unit detects that a wheel is
threatening to lock up, then the corresponding
hydraulic valves in the valve block are either
closed or opened.
manner to achieve the greatest possible

deceleration.
The ABS control unit then also passes on the

vehicle speed signal obtained from the wheel
sensors to the Powertrain Control Module (PCM).
The warning lamp in the instrument cluster is
actuated by the ABS control unit after switching on
the ignition. It remains on up to the end of the ABS
self-test, and is also actuated in the event of
system errors.
It continuously monitors the system for possible
faults and stores these as and when they occur.
The corresponding trouble codes can be
interrogated with the aid of WDS via the DLC .
The ABS control unit is directly connected via a
diagnostic data link to the DLC.
Valve block
The valve block contains four inlet valves and four

outlet valves. There is one inlet valve and one
outlet valve for each wheel.
When there is no electrical supply the inlet valves
are open and the outlet valves are closed.
The valve block also contains the low-pressure
reservoir and sound damping chambers.
Pump motor
In the event of an ABS intervention the pump

motor ensures that the pressure can be provided
to the regulating channels independently of the
brake master cylinder.
ABS regulating cycle
An ABS regulating cycle has three phases:

Phase 1 - holding pressure
The inlet valve is closed, and the brake
pressure to the wheel brake cannot be
increased any further, even if the actuation
pressure (brake pedal) is increased further.
Phase 2 - pressure reduction
The outlet valve is temporarily opened, and
the brake pressure to the wheel brake is
reduced in a controlled manner.
Phase 3 - pressure build-up
The inlet valve is opened in stages, and the
brake pressure is increased in a controlled
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206-09A-5

TO MODEL INDEX
Anti-Lock Control
206-09A-5

Anti-Lock Control
MK70 Anti-lock Brake System (ABS)
The MK70 ABS is similar to the MK60 in
construction and design. The main differences
are:
New ABS control unit
New hydraulic lines through a revised valve
block
New wiring harness and electrical connector
(fewer occupied pins)
The MK70 ABS system will be installed from
05/2004 in vehicles which only have one ABS
function.
Item
Part
Number
Description
Pump motor
Valve block
ABS control unit
The MK60 ABS has been designed specifically for

small to medium size vehicles. Compared to the
MK20 ABS system, it has been possible to reduce
the size of the hydraulic and electric components
(e.g. hydraulic valves and solenoids) and the
housing.
As a result, the overall weight of the ABS hydraulic
unit has been significantly reduced.
Vehicles with ESP/Brake Traction Control System

(BTCS) will continue to be equipped with the
MK60.
The hydraulic unit consists of the pump motor, the

valve block with 8 hydraulic valves and the
electronic control unit.
MK60 ABS
The ABS control unit actuates the ABS warning

lamp in the instrument cluster via the CAN
databus.
The MK60 ABS is a 4/3 system. This means that
the wheel speed is measured individually for each
wheel (4 wheel speed sensors).
ABS controlled braking is provided individually for
the front wheels and jointly for the two rear wheels
(3 control channels; select-low control), i.e. the
ABS control for the rear wheels is governed by the
wheel closest to locking up.
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Anti-Lock Control
206-09A-6

Wheel speed sensors
Item
Part
Number
Description
Sensor
Installation position.
NOTE: The wheel speed sensors must not be

checked for voltage with an ohmmeter.
It also supplies the vehicle speed signal, which is

calculated from the wheel speed sensor signals.
This is transmitted via the CAN bus to the
Powertrain Control Module (PCM)
The ABS control unit can be diagnosed via the
Data Link Connector (DLC).
The hydraulic unit is pre-filled for service.
The wheel speed sensors are active sensors.

They are supplied with a voltage from the ABS
control unit after the ignition is switched on.
The pulses are picked up from a mechanically
encoded ring, which is built into the wheel
bearings on the front wheels while for the rear
wheels it is a metal ring which is mounted on the
stub axle.
The registered wheel speed is converted into a
digital (square-wave) signal by the electronics
integrated in the sensor and is then transmitted to
the ABS control unit.
Data transmissions to the ABS control unit take
place via a 2-stranded connecting cable.
G163291 en
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206-09A-7
Anti-Lock Control
206-09A-7

Anti-Lock Control
Refer to Wiring Diagrams Section 206-09A for
schematic and connector information.
General Equipment
Worldwide diagnostic system (WDS)

Mechanical
Electrical
Wheel speed
Fuse(s)
sensor(s)
Electrical
Wheel speed sensor
connector(s)
ring(s)
Wiring harness(s).
step.
4. If the cause is not visually evident, connect the
diagnostic tool to the data link connector and
select the vehicle to be tested from the
diagnostic tool menu.
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206-09A-8
Anti-Lock Control
206-09A-8

Hydraulic Control Unit (HCU) Vehicles Built Up To: 05/2004
Name
Super DOT 4 brake
fluid
Specification
ESD-M6C57-A
Removal
3.

CAUTION: Plug the hydraulic control unit

(HCU) ports to prevent fluid loss or dirt
ingress.
NOTE: Make a note of the position of the brake
tubes, to aid installation.

water.
206-06.
2. Detach the engine wiring harness electrical
connector from the wheelhouse assembly.
Remove the brake master cylinder to hydraulic control unit (HCU) brake tubes.
4.

CAUTION: Plug the HCU ports to prevent

fluid loss or dirt ingress.
Disconnect the brake tubes from the HCU.
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TO MODEL INDEX
Anti-Lock Control
206-09A-9

5. Detach the brake tubes from the bulkhead.
6. Disconnect the anti-lock brake system

(ABS) module electrical connector.

100-02.
8. Remove the HCU and ABS module support
bracket lower retaining bolt.
10. Remove the HCU and ABS module assembly and the support bracket.
11. Detach the HCU and ABS module assembly from the support bracket.
12. Remove the HCU to ABS module retaining

bolts.
13. Remove the HCU.

Installation
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TO MODEL INDEX
Anti-Lock Control
206-09A-10

G183774 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
206-09A-11
Anti-Lock Control
206-09A-11

Hydraulic Control Unit (HCU) Vehicles Built From: 05/2004
Name
Super DOT 4 brake
fluid
Specification
ESD-M6C57-A
Removal
All vehicles
water.
Left-hand drive vehicles

2. Remove the brake master cylinder.
G406271 en
3.


ingress.
tubes to aid installation.
Remove the brake master cylinder to HCU
brake tubes.
Right-hand drive vehicles

4. Remove the battery tray. For additional
414-01.[Battery, Mounting and Cables,
REMOVAL AND INSTALLATION, Battery
Tray]
11/2004 2005.25 Fiesta
206-09A-12

TO MODEL INDEX
Anti-Lock Control
206-09A-12
5.


ingress.
Disconnect the brake master cylinder to
HCU brake tubes from the HCU.
All vehicles
6.

7.
CAUTION: Cap the anti-lock brake

system (ABS) module electrical
connector and socket to prevent dirt
and fluid ingress.
Disconnect the ABS module electrical
connector.
1. Depress the locking tangs.
2. Release the retainer.


Detach the brake tubes from the bulkhead.
G406271 en
11/2004 2005.25 Fiesta
206-09A-13

TO MODEL INDEX
Anti-Lock Control
206-09A-13


13. Remove the HCU.
Installation
G406271 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
206-09A-14
Anti-Lock Control
206-09A-14

Anti-Lock Brake System (ABS) Module Vehicles Built Up To: 05/2004
Name
Super DOT 4 brake
fluid
Specification
ESD-M6C57-A
Removal
3.


ingress.

water.
206-06.
4.


G327317 en
11/2004 2005.25 Fiesta
206-09A-15

TO MODEL INDEX
Anti-Lock Control
206-09A-15

6. Disconnect the anti-lock brake system

(ABS) module electrical connector.

100-02.
12. Remove the HCU to ABS module retaining

bolts.
13. Remove the ABS module.

Installation
G327317 en
11/2004 2005.25 Fiesta
206-09A-16

TO MODEL INDEX
Anti-Lock Control
206-09A-16

G327317 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
206-09A-17
Anti-Lock Control
206-09A-17

Anti-Lock Brake System (ABS) Module Vehicles Built From: 05/2004
Name
Super DOT 4 brake
fluid
Specification
ESD-M6C57-A
Removal
All vehicles
water.

2. Remove the brake master cylinder.
G406272 en
3.


ingress.
Remove the brake master cylinder to HCU
brake tubes.

Tray]
11/2004 2005.25 Fiesta
206-09A-18

TO MODEL INDEX
Anti-Lock Control
206-09A-18
5.


ingress.
Disconnect the brake master cylinder to
HCU brake tubes from the HCU.
All vehicles
6.

7.
CAUTION: Cap the anti-lock brake

system (ABS) module electrical
connector and socket to prevent dirt
and fluid ingress.
Disconnect the ABS module electrical
connector.
2. Release the retainer.


Detach the brake tubes from the bulkhead.
G406272 en
11/2004 2005.25 Fiesta
206-09A-19

TO MODEL INDEX
Anti-Lock Control
206-09A-19


13. Remove the ABS module.
Installation
G406272 en
11/2004 2005.25 Fiesta
206-09A-20

TO MODEL INDEX
Anti-Lock Control
206-09A-20

Rear Wheel Speed Sensor (12 785 0)
Removal
All vehicles
wheel spindle on both sides.
4. Detach the wheel speed sensor wiring

harness from the wheel speed sensor wiring harness support bracket on both sides.
All vehicles
5. Disconnect the wheel speed sensor electrical connector.
wheel spindle on both sides.
6. Detach the wheel speed sensor support

bracket and wheel speed sensor wiring
harness from the beam axle.
Discard the retaining clips.
G183775 en
11/2004 2005.25 Fiesta
206-09A-21

TO MODEL INDEX
Anti-Lock Control
206-09A-21

harness from the wheel speed sensor
support bracket.
Discard the retaining clips.

harness from the beam axle on both sides.
9. Remove the rear wheel speed sensor.
Installation
1. NOTE: Install new retaining clips.
G183775 en
11/2004 2005.25 Fiesta
206-09A-22

TO MODEL INDEX
Anti-Lock Control
206-09A-22

Rear Wheel Speed Sensor Ring (12 788 0)
Special Tool(s)
Installer, ABS Sensor Ring
206-083

General Equipment
Soft faced hammer
Removal
1. Remove the brake drum. For additional
Brake Drum]
All vehicles
5. Remove and discard the wheel speed
sensor ring (brake disc shown).

G183776 en
11/2004 2005.25 Fiesta
206-09A-23

TO MODEL INDEX
Anti-Lock Control
206-09A-23

Installation
All vehicles
2.
1.

sensor ring is not knocked, damaged
and kept free from metal fragments.
CAUTION: Avoid any impact on the

wheel speed sensor ring.
CAUTION: Protect the face of the wheel

speed sensor ring with a non-ferrous flat
block to prevent damage.

surface.
CAUTION: Make sure the wheel hub or

brake drum is adequately supported and
do not allow it to rest on the wheel studs.
CAUTION: Rotate the hub assembly 10

times counter-clockwise when tightening
the wheel hub retaining nut to prevent
damage to the wheel bearing.

sensor ring is pressed on slowly and
squarely until fully seated.
Install the wheel hub.
CAUTION: Do not exceed a maximum load

of 10 kN.
Using the special tool, install a new wheel
speed sensor ring (brake disc shown).
3. Install the brake disc. For additional

4. NOTE: If the dust cap is damaged a new dust
cap must be installed.
Using a soft faced hammer and a wooden
block, install the dust cap.
G183776 en
11/2004 2005.25 Fiesta
206-09A-24

TO MODEL INDEX
Anti-Lock Control
206-09A-24

5.
CAUTION: Avoid any impact on the

wheel speed sensor ring.
surface.
Install the brake drum. For additional
Brake Drum]
G183776 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
206-09B-1
Anti-Lock Control - Traction Control
206-09B-1
SECTION 206-09B Anti-Lock Control - Traction

Control
CONTENTS
PAGE
SPECIFICATIONS
Specifications...................................................................................................................
206-09B-2

Anti-Lock Control - Traction Control .................................................................................
206-09B-3

Hydraulic Control Unit (HCU) ...........................................................................................
Anti-Lock Brake System (ABS) Module ............................................................................
206-09B-4
206-09B-5
206-09B-6
206-09B-7
11/2004 2005.25 Fiesta
206-09B-2

TO MODEL INDEX
206-09B-2
SPECIFICATIONS

Specifications
ESD-M6C57-A

Item
Hydraulic control unit (HCU) support bracket retaining bolts
HCU retaining bolts
Brake tube to HCU union
G89252 en
Nm
23
lb-ft
17
lb-in
-
10
13
9
10
-
89
80
11/2004 2005.25 Fiesta
206-09B-3

TO MODEL INDEX
206-09B-3

REFER to Section 206-09A / 206-09B / 206-09C.
G17539 en
11/2004 2005.25 Fiesta
206-09B-4

TO MODEL INDEX
206-09B-4

206-09A/ 206-09B/ 206-09C.
G89259 en
11/2004 2005.25 Fiesta
206-09B-5

TO MODEL INDEX
206-09B-5

Removal
1. For additional information, refer to Section
206-09A / 206-09B / 206-09C.
G17542 en
11/2004 2005.25 Fiesta
206-09B-6

TO MODEL INDEX
206-09B-6

Hydraulic Control Unit (HCU)
Removal
1. NOTE: The traction control function is only
available on vehicles equipped with the MK60
anti-lock brake system (ABS) and the stability
assist program.
206-09C.[Anti-Lock Control - Stability
Assist, REMOVAL AND INSTALLATION,
Hydraulic Control Unit (HCU)]
G410616 en
11/2004 2005.25 Fiesta
206-09B-7

TO MODEL INDEX
206-09B-7

Anti-Lock Brake System (ABS) Module
Removal
1. NOTE: The traction control function is only
available on vehicles equipped with the MK60
anti-lock brake system (ABS) and the stability
assist program.
206-09C.[Anti-Lock Control - Stability
Assist, REMOVAL AND INSTALLATION,
Stability Assist Module]
G410617 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
206-09C-1
Anti-Lock Control - Stability Assist
206-09C-1
SECTION 206-09C Anti-Lock Control - Stability Assist

CONTENTS
PAGE
SPECIFICATIONS
Specifications...................................................................................................................
206-09C-2

Anti-Lock Control - Stability Assist....................................................................................
206-09C-3

Hydraulic Control Unit (HCU) ...........................................................................................
Yaw Rate Sensor and Accelerometer ..............................................................................
Steering Wheel Rotation Sensor ......................................................................................
Stability Assist Module .....................................................................................................
206-09C-4
206-09C-7
206-09C-8
206-09C-10
206-09C-11
206-09C-12
11/2004 2005.25 Fiesta
206-09C-2

TO MODEL INDEX
206-09C-2
SPECIFICATIONS

Specifications
ESD-M6C57-A

Description
Hydraulic control unit (HCU) to support bracket
retaining bolts
HCU support bracket retaining bolts
Brake tube to HCU unions
Wheel speed sensor retaining bolts
Stability assist module to HCU retaining bolts
Yaw rate sensor and accelerometer assembly retaining bolts
Yaw rate sensor and accelerometer assembly
cover retaining bolts
G314562 en
Nm
9
lb-ft
-
lb-in
80
20
18
9
5
5
15
13
-
80
44
44
35
11/2004 2005.25 Fiesta
206-09C-3

TO MODEL INDEX
206-09C-3

REFER to Section 206-09A / 206-09B / 206-09C.
G37415 en
11/2004 2005.25 Fiesta
206-09C-4

TO MODEL INDEX
206-09C-4

Hydraulic Control Unit (HCU)
Name
Super DOT 4 brake
fluid
Specification
ESD-M6C57-A
Removal
3.


ingress.

water.
206-06.
4.


G327341 en
11/2004 2005.25 Fiesta
206-09C-5

TO MODEL INDEX
206-09C-5

6. Disconnect the stability assist module

electrical connector.

100-02.
8. Remove the HCU and stability assist module support bracket lower retaining bolt.
10. Remove the HCU and stability assist

module assembly and the support
bracket.
11. Detach the HCU and stability assist module assembly from the support bracket.
12. Remove the HCU to stability assist module retaining bolts.
13. Remove the HCU.

Installation
G327341 en
11/2004 2005.25 Fiesta
206-09C-6

TO MODEL INDEX
206-09C-6

G327341 en
11/2004 2005.25 Fiesta
206-09C-7

TO MODEL INDEX
206-09C-7

Removal
206-09A / 206-09B / 206-09C.
G17542 en
11/2004 2005.25 Fiesta
206-09C-8

TO MODEL INDEX
206-09C-8

Yaw Rate Sensor and Accelerometer
Removal
NOTE: The yaw rate sensor and accelerometer
are one assembly and cannot be seperated.
1. Remove the left-hand front seat. For
501-10.
2. Remove the scuff plate trim panels.
5. NOTE: Make a note of the position of the bolts,

to aid installation.
Remove the yaw rate sensor and accelerometer assembly cover.
6. NOTE: Make a note of the position of the bolts,

to aid installation.
3. Remove the B-pillar trim panel. For
501-05.
4. Locally detach the carpet.
G327319 en
Remove the yaw rate sensor and

accelerometer assembly.
1. Disconnect the electrical connector.
2. Remove the bracket retaining bolts.
11/2004 2005.25 Fiesta
206-09C-9

TO MODEL INDEX
206-09C-9

Installation
1.
WARNING: Do not use a damaged yaw

rate sensor and accelerometer
assembly. Failure to follow this
injury.
WARNING: Make sure the yaw rate sensor
and accelerometer assembly is correctly
positioned. Failure to follow this
CAUTION: The yaw rate sensor and
accelerometer assembly will be damaged
if dropped.
CAUTION: Make sure the correct bolts are
used for the yaw rate sensor and
accelerometer assembly. Failure to follow
this instruction will result in damaged
threads.
CAUTION: Make sure the correct bolts are
used for the yaw rate sensor and
accelerometer assembly cover. Failure to
follow this instruction will result in
damaged threads.
G327319 en
11/2004 2005.25 Fiesta
206-09C-10

TO MODEL INDEX
206-09C-10

Steering Wheel Rotation Sensor
Removal
1. NOTE: The steering wheel rotation sensor and
the clockspring cannot be separated.
Remove the clockspring. For additional
information, refer to Section 501-20A /
501-20B.
Installation
1.
WARNING: The stability assist program

must be re-configured following
installation. Failure to follow this
injury.
Install the clockspring. For additional
501-20B.
G289888 en
11/2004 2005.25 Fiesta
206-09C-11

TO MODEL INDEX
206-09C-11

Removal
206-09A / 206-09B / 206-09C.
G314570 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
206-09C-12
206-09C-12

Stability Assist Module
Name
Super DOT 4 brake
fluid
Specification
ESD-M6C57-A
Removal
3.


ingress.

water.
206-06.
4.


G327320 en
11/2004 2005.25 Fiesta
206-09C-13

TO MODEL INDEX
206-09C-13

6. Disconnect the stability assist module


100-02.
8. Remove the HCU and stability assist module support bracket lower retaining bolt.
10. Remove the HCU and stability assist

module assembly and the support
bracket.
11. Detach the HCU and stability assist module assembly from the support bracket.
12. Remove the HCU to stability assist module retaining bolts.
13. Remove the stability assist module.

Installation
G327320 en
11/2004 2005.25 Fiesta
206-09C-14

TO MODEL INDEX
206-09C-14

G327320 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
211-00-1
Steering System - General Information
211-00-1
SECTION 211-00 Steering System - General

Information
CONTENTS
PAGE
SPECIFICATIONS
Specifications....................................................................................................................
211-00-2

Steering System................................................................................................................
Overview ..........................................................................................................................
211-00-3
211-00-3

Steering System................................................................................................................
Principles of Operation .....................................................................................................
Components Tests ...........................................................................................................
211-00-5
211-00-5
211-00-5
211-00-13
GENERAL PROCEDURES
Power Steering System Filling ......................................................................
Power Steering System Bleeding ..................................................................
Power Steering System Flushing 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) ..............................................
Power Steering System Flushing 2.0L Duratec-HE (MI4) .........................
(13 002 0)
(13 416 1)
(13 001 0)
(13 001 0)
211-00-17
211-00-18
211-00-20
211-00-23
11/2004 2005.25 Fiesta

TO MODEL INDEX
211-00-2
211-00-2
SPECIFICATIONS

Description
Power steering fluid
Hydraulic fluid, vehicles with 1.6L Duratorq-TDCi (DV) Diesel
Specifications
WSA-M2C195-A
WSS-M2C204-A2
Turning Circle
Description
Meters
10.37
11.65
Wall to wall
Wall to wall, vehicles with 2.0L Duratec-HE (MI4)
Steering Wheel Alignment
Description
Maximum allowable steering wheel misalignment
Degrees
3.00
Turning Effort
Description
Turning effort
G112928 en
Nm
8
lb-in
71
11/2004 2005.25 Fiesta
211-00-3

TO MODEL INDEX
211-00-3

Steering System
Overview
G202090 en
11/2004 2005.25 Fiesta
211-00-4

TO MODEL INDEX
211-00-4

Item
Part
Number
Description
RHD with Duratec 16V engine and Air Conditioning

(A/C)
LHD with Duratec 16V engine and A/C
RHD with Duratec 16V engine without A/C
LHD with Duratec 16V engine without A/C
RHD with 1.4L Duratorq

TDCi engine
LHD with 1.4L Duratorq TDCi

engine
Steering gear
Additional cooling loop
Independent of the equipment level, all vehicles

have conventional power-assisted rack and pinion
steering with an additional cooling loop.
The steering gear is supplied with hydraulic fluid
by a hydraulic pump.
The hydraulic pump is driven by the accessory
drive belt and has a separate reservoir.
Vehicles with petrol engines have a Power
Steering Pressure (PSP) switch in the pressure
line, which opens as the power steering load
increases, thus signalling to the Powertrain
Control Module (PCM) that it should increase the
idle speed.
G202090 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
211-00-5
211-00-5

Steering System
(PCM) during low speed parking manoeuvres.

The PCM responds by maintaining the engine idle
speed.
Special Tool(s)
205-524
Simulator, Driver and

Passenger Air Bags and Side
Air Curtains
501-073A

Mechanical
General Equipment

Principles of Operation
The steering wheel rotational movement is

transferred to the steering gear through the
steering column shaft. The steering gear converts
this rotational movement, through the action of the
rack and pinion gear into lateral movement. This
movement in turn is transferred to the wheel
knuckles through the tie-rods and tie-rod ends.
Hydraulic fluid under pressure is supplied to the

steering gear by the power steering pump. As the
steering wheel is rotated, the hydraulic fluid is
allowed to pass through the steering gear valve to
one side of a double acting piston, dependent on
which direction the steering wheel is rotated. The
fluid moves the piston, which forms part of the
steering gear, giving power assistance to the effort
required to rotate the steering wheel.
Vehicles with petrol engines, due to the extra load
on the engine imposed by the power steering
pump, have a power steering pressure (PSP)
switch. The switch, which is normally closed,
sends a signal to the powertrain control module
Symptom Chart
Symptom
Drift left or right
G149906 en
3.
4.
Electrical
Tire pressure(s)
Power steering
pressure (PSP)
Accessory drive belt
switch
Tie-rod ends
Tie-rod(s)
Steering gear
housing
Front strut and
spring assemblies
Front suspension
lower arm ball joints
Front suspension
lower arm bushings
Pinch bolt on
steering column
shaft flexible
coupling
Wheels and tires
Power steering line
fluid leaks
Steering gear bellows
step.
If the cause is not visually evident, verify the
Possible Sources
Action
springs.
11/2004 2005.25 Fiesta
211-00-6

TO MODEL INDEX
211-00-6

Symptom
Possible Sources
Action
CHECK the wheel alignment and
adjust if necessary. REFER to
Section 204-00.[Suspension
Incorrect front axle crossmember Using the special tool, CHECK

alignment.
the front axle crossmember
alignment.
Steering wheel off center
G149906 en

bearings.
CHECK and INSTALL new front

wheel bearings as necessary.
REFER to Section 204-01.[Front
Brake system.
CHECK the brake system.

REFER to Section
Information, DIAGNOSIS AND
TESTING, Brake System]
Steering linkage.
CARRY OUT the steering linkage component test. REFER to

Steering Linkage Component
Test in this procedure.
Steering gear.

Wheels and tires.
CHECK the wheels and tires.

REFER to Section
204-04.[Wheels and Tires,
DIAGNOSIS AND TESTING,
Wheels and Tires]


springs.

11/2004 2005.25 Fiesta
211-00-7

TO MODEL INDEX
211-00-7

Symptom
Possible Sources
Action
Front suspension lower arm ball CHECK and INSTALL new

joint.
204-00.[Suspension System General Information,
Suspension System]
Vibration
G149906 en
Steering linkage.

Steering gear.


Wheels and tires.
CHECK the wheels and tires.

BALANCE or INSTALL new
wheels and tires as necessary.
REFER to Section
204-04.[Wheels and Tires,
REMOVAL AND
INSTALLATION, Wheel and
Tire]

bearings.
CHECK and INSTALL new front

wheel bearings as necessary.
REFER to Section 204-01.[Front

Suspension System]
11/2004 2005.25 Fiesta
211-00-8

TO MODEL INDEX
211-00-8

Symptom
Possible Sources
Action
Damaged front suspension lower CHECK and INSTALL new

arm(s).
Suspension System]
Steering effort is high/low
G149906 en
Steering linkage.

Loose or worn accessory drive

belt.
CHECK the accessory drive belt.

REFER to Section
303-05.[Accessory Drive,
REMOVAL AND
INSTALLATION, Power Steering
Pump Belt - 1.4L Duratec-16V
(Sigma)/1.6L Duratec-16V
(Sigma), Vehicles With: Air
Conditioning] REFER to Section
REMOVAL AND
INSTALLATION, Accessory
Drive Belt - 1.4L Duratec-16V
(Sigma), Vehicles Without: Air
Conditioning]
REFER to Section
REMOVAL AND
INSTALLATION, Accessory
Drive Belt - 2.0L Duratec-HE
(MI4)]
11/2004 2005.25 Fiesta
211-00-9

TO MODEL INDEX
211-00-9

Symptom
Possible Sources
Action
Power steering lines restriction. CHECK the power steering lines

for damage, kinks or restrictions.
211-02.[Power Steering,
REMOVAL AND
Pump to Steering Gear Pressure
Line - 1.25L Duratec-16V
REMOVAL AND
Conditioning]
REFER to Section
REMOVAL AND
INSTALLATION, Steering Gear
to Power Steering Fluid Reservoir Return Line - 2.0L Duratec-HE (MI4) RHD]
REFER to Section
REMOVAL AND
to Fluid Cooler Return Hose]
G149906 en
BLEED the power steering system. REFER to Power Steering

System Bleeding in this section.
Steering column.
CHECK if the floor covering is

obstructing the steering gear
pinion.
CHECK the installation of the
steering gear bulkhead floor
seal.
CARRY OUT the steering column universal joint component
test. REFER to Steering Column
Universal Joint Component Test
in this procedure.
Steering linkage.

11/2004 2005.25 Fiesta
211-00-10

TO MODEL INDEX
211-00-10

Symptom
Excessive noise
G149906 en
Possible Sources
Action
Steering gear.

Worn power steering pump.
INSTALL a new power steering

pump. REFER to Section
REMOVAL AND
Pump - 1.25L Duratec-16V
REMOVAL AND
Conditioning]
BLEED the power steering system. REFER to Power Steering

11/2004 2005.25 Fiesta
211-00-11

TO MODEL INDEX
211-00-11

Symptom
Possible Sources
Power steering lines.
Action
CHECK the power steering line
clamps are secure. REFER to
Section 211-02.[Power Steering,
REMOVAL AND
REMOVAL AND
Conditioning]
REFER to Section
REMOVAL AND
to Power Steering Fluid
Reservoir Return Line - 2.0L
Duratec-HE (MI4) RHD]
REFER to Section
REMOVAL AND
to Fluid Cooler Return Hose]
CHECK the power steering lines
for clearance from the vehicle
body, front axle crossmember
and steering gear.
CHECK the steering gear
transfer lines for clearance from
the steering gear.
Steering gear bushings worn or CHECK and INSTALL new

perished.
REFER to Section
REMOVAL AND
Bushing]
Loose steering gear retaining
bolts.
G149906 en

steering gear retaining bolts as
11/2004 2005.25 Fiesta
211-00-12

TO MODEL INDEX
211-00-12

Symptom
Steering does not vary with increased wheel rotation
Possible Sources
Action
Worn power steering pump.
INSTALL a new power steering

pump. REFER to Section
REMOVAL AND
Conditioning] REFER to Section 211-02.[Power Steering,
REMOVAL AND
Conditioning]
Worn tie-rod.
CARRY OUT the tie-rod component test. REFER to Tie-Rod

Component Test in this procedure.
Worn tie-rod ends.

211-03.[Steering Linkage,
REMOVAL AND
INSTALLATION, Tie-Rod End]
Worn front suspension bushings. CHECK and INSTALL new

REFER to Section
Suspension System]
Worn front suspension lower arm CARRY OUT the suspension
ball joints.
ball joint inspection component
test. REFER to Section
Suspension System]
Steering gear bushings worn or CHECK and INSTALL new
perished.
REFER to Section
REMOVAL AND
Bushing]
G149906 en
11/2004 2005.25 Fiesta
211-00-13

TO MODEL INDEX
211-00-13

Symptom
Possible Sources
Loose steering gear retaining
bolts.
Action
steering gear retaining bolts as
Loose steering column retaining CHECK and INSTALL new

bolts.
steering column retaining bolts
211-04.[Steering Column,
Loose steering column to steer- CHECK and INSTALL a new
ing gear pinion retaining bolt.
steering column to steering gear
pinion retaining bolt as necessary. REFER to Section
Excessive steering gear backlash.

Engine stalls when parking with Power steering pressure (PSP) For additional information, refer
engine speed at idle
switch or circuit.
to WDS.
Universal Joint Component Test in this
procedure. If there is no free play in the tie-rod
and
the steering column, install a new steering
Components Tests
gear. REFER to Section 211-02.[Power
Steering, REMOVAL AND INSTALLATION,
Steering Linkage
Steering Gear]
1. Grasp the steering wheel firmly and move it up
and down and to the left and right without
Tie-Rod
turning the steering wheel, to check for
steering column bearing wear, steering
CAUTION: The steering gear boots must
column universal joint free play, steering
be handled carefully to avoid damage.
wheel or steering column looseness. The
Use new steering gear boot clamps when
steering column cannot be repaired. Install a
installing the steering gear boots.
new steering column. REFER to Section
NOTE: Noises such as knocks, which may appear
211-04.[Steering Column, REMOVAL AND
to originate from the steering linkage, may also be
INSTALLATION, Steering Column]
generated by front suspension components.
2. With the road wheels in the straight ahead
position, gently turn the steering wheel to the
left and the right to check free play in the
steering linkage.
3. There should be no excessive free play at the
steering wheel rim. If there is excessive free
play, CHECK the tie-rod inner and outer ball
joints, REFER to Tie-Rod Component Test in
this procedure. CHECK the steering column
universal joint, REFER to Steering Column
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211-00-14

4. With the aid of another technician holding the

steering against the right-hand steering lock
stop, firmly grasp the right-hand road wheel
and apply a rocking motion to check for any
free play in the tie-rod.
2. Firmly grasp the road wheel and apply a

rocking motion to check for any free play in the
wheel bearing or suspension components.
5. Detach the steering gear boot from the
steering gear body and check for free play at
the tie-rod inner ball joint.
6. If there is free play at the tie-rod inner ball joint,
install a new tie-rod. REFER to Section
211-03.[Steering Linkage, REMOVAL AND
INSTALLATION, Tie-Rod]
7. If there is free play at the tie-rod end, install a
new tie-rod end. REFER to Section
CAUTION: To prevent damage to the
steering linkage, turn the steering wheel
to move the steering linkage to the
steering lock stop.
3. Turn the steering wheel to position the
steering linkage against the right-hand
steering lock stop.
NOTE: To isolate the steering gear design
clearance, check the right-hand tie-rod with the
steering held against the right-hand steering lock
stop.
G149906 en

steering linkage, turn the steering wheel
to move the steering linkage to the
steering lock stop.
8. Turn the steering wheel to position the
steering linkage against the left-hand steering
lock stop.
NOTE: To isolate the steering gear design
clearance, check the left-hand tie-rod with the
steering held against the left-hand steering lock
stop.
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9. With the aid of another technician holding the
steering against the left-hand steering lock
stop, firmly grasp the left-hand road wheel and
apply a rocking motion to check for any free
play in the tie-rod.
10. Detach the steering gear boot from the

steering gear body and check for free play at
the tie-rod inner ball joint.
11. If there is free play at the tie-rod inner ball joint,
install a new tie-rod. REFER to Section
INSTALLATION, Tie-Rod]
12. If there is free play at the tie-rod end, install a
new tie-rod end. REFER to Section
Turning Effort Test
NOTE: Before carrying out this test, make sure

that the suspension components are serviceable.
that the steering column is serviceable.
that the front toe adjustment and tire pressures
are correct.
1. Park the vehicle on a dry, even surface and

apply the parking brake.
2. Remove the driver air bag module. REFER to
Section 501-20B.[Supplemental Restraint
System, REMOVAL AND INSTALLATION,
Driver Air Bag Module]
3. Remove the driver air bag module wiring
harness from the driver air bag module.
REFER to Section 501-20B.[Supplemental
Restraint System, REMOVAL AND
INSTALLATION, Driver Air Bag Module
Wiring Harness]
4. Connect the driver air bag module wiring
harness to the clockspring.
5. Connect the air bag simulators to the driver air
bag module wiring harness in place of the
driver air bag module at the top of the steering
column.
6. Start the engine and turn the steering wheel
from lock to lock several times until the power
steering fluid has reached normal operating
temperature.
7. Using a suitable torque wrench and socket,
check the steering wheel turning effort.
8. If the steering wheel turning effort is greater
than the specification, install a new power
steering pump. REFER to Specifications in
this section.REFER to Section 211-02.[Power
Steering, REMOVAL AND INSTALLATION,
Power Steering Pump - 1.25L Duratec-16V
(Sigma)/1.4L Duratec-16V (Sigma)/1.6L
Duratec-16V (Sigma), Vehicles With: Air
211-02.[Power Steering, REMOVAL AND
INSTALLATION, Power Steering Pump 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V
(Sigma)/1.6L Duratec-16V (Sigma), Vehicles
Without: Air Conditioning]
9. Disconnect the air bag simulators from the
driver air bag module wiring harness.
10. Disconnect the driver air bag module wiring
harness from the clockspring.
11. Install a new driver air bag module wiring
harness to the drive air bag module. REFER
to Section 501-20B.[Supplemental Restraint
Driver Air Bag Module Wiring Harness]
12. Install the driver air bag module. REFER to
Section 501-20B.[Supplemental Restraint
Driver Air Bag Module]
Steering Column Shaft Universal Joint
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WARNING: Install a new steering column

shaft to steering gear pinion retaining
bolt. Failure to follow this instruction may
Discard the steering column shaft to
steering gear pinion retaining bolt.
2. Check for smooth movement of the steering

column shaft universal joint.
1. Hold the steering column shaft universal
joint yoke.
2. Articulate the free yoke in a figure of eight
movement.
If the movement is not smooth or resistance
is felt, renew the steering column. REFER
to Section 211-04.[Steering Column,
REMOVAL AND INSTALLATION, Steering
Column]
3. Hold both of the steering column shaft
universal joint yokes and then twist them
clockwise and counterclockwise.
If any movement is felt, install a new
steering column. REFER to Section
211-04.[Steering Column, REMOVAL AND
INSTALLATION, Steering Column]
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GENERAL PROCEDURES
Power Steering System Filling (13 002 0)
Special Tool(s)
Adapter, Power Steering
Bleeding
211-189 (13-016)
5. Switch the engine OFF and using the special tools, create a vacuum of 62cm-Hg 75cm-Hg for 30 seconds.
Hand Vacuum
Pump/Pressure Pump
416-D001 (23-036A)
Refill
1. NOTE: When filling the power steering fluid
reservoir, make sure that the fluid is clean and
not agitated prior to use. The fluid should be
poured slowly into the reservoir to minimize the
possibility of aeration. The fluid level should be
checked with the fluid cold.
Fill the power steering fluid reservoir to the
MAX mark with the appropriate fluid. For
additional information, refer to
Specifications in this section.
2. Raise and support the vehicle making sure
that the road wheels are just clear of the
floor.
3. NOTE: Do not start the engine at this stage.
NOTE: Make sure that the power steering fluid in
the power steering fluid reservoir does not fall
below the MIN mark, as air could enter the
system.
6. Observe the vacuum gauge reading.

If the vacuum decreases by more than
5cm-Hg in 5 minutes, the system should be
checked for leaks.
7. Remove the special tools. Fill the reservoir
to the MAX mark with the appropriate fluid
as necessary. For additional information,
refer to Specifications in this section.
Slowly turn the steering wheel from lock to

lock and add the power steering fluid until
the power steering fluid in the power
steering fluid reservoir stops dropping.
4. NOTE: Make sure that the power steering fluid
in the power steering fluid reservoir does not
fall below the MIN mark, as air could enter the
system.
Start the engine and slowly turn the
steering wheel from lock to lock and add
the power steering fluid until the power
steering fluid in the power steering fluid
reservoir stops dropping.
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GENERAL PROCEDURES
Power Steering System Bleeding (13 416 1)
Special Tool(s)
Adapter, Power Steering
Bleeding
211-189 (13-016)
Hand Vacuum
Pump/Pressure Pump
416-D001 (23-036A)
Bleeding
reservoir, make sure that the fluid is clean and
not agitated prior to use. The fluid should be
poured slowly into the reservoir to minimize the
possibility of aeration. The fluid level should be
checked with the fluid cold.
Fill the power steering reservoir to the MAX
mark with the appropriate fluid. For
2. Raise and support the vehicle making sure
that the road wheels are just clear of the
floor.
3. NOTE: Do not start the engine at this stage.
NOTE: Make sure that the power steering fluid in
the reservoir does not fall below the MIN mark, as
air could enter the system.
Slowly turn the steering wheel from lock to
lock and add the power steering fluid until
the power steering fluid in the power
steering fluid reservoir stops dropping.
4. Check the fluid level. Fill the power
steering fluid reservoir to the MAX mark
with the appropriate fluid. For additional
information, refer to Specifications in this
section.
G17560 en
5. NOTE: When bleeding the power steering

system the vacuum will decrease. Maintain a
sufficient vacuum of 38cm-Hg, using the
special tools. If the vacuum decreases by more
than 5cm-Hg in 5 minutes, the system should
be checked for leaks.
Using the special tools, bleed the power
steering system in the following sequence.
1. Slowly turn the steering wheel from lock to
lock once; then turn the steering wheel to
the right, just off the stop.
2. Using the special tools, create a vacuum of
38cm-Hg. Maintain the vacuum until the air
is evacuated from the system (minimum of
five minutes).
3. Release the vacuum.
4. Repeat the power steering bleeding procedure, turning the steering wheel to the left,
just off the stop.
6. Remove the special tools. Fill the power

steering reservoir to the MAX mark with the
appropriate fluid if necessary. For
7. NOTE: Make sure that the power steering fluid
in the power steering fluid reservoir does not
fall below the MIN mark, as air could enter the
system.
Start the engine and slowly turn the
steering wheel from lock to lock and add
the power steering fluid until the power
reservoir does not drop.
8. Switch OFF the engine and examine the
hose connections, steering gear boots,
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211-00-19

valve body and power steering pump for
external leaks.
9. Check the fluid level. Fill the power
steering fluid reservoir to the MAX mark
with the appropriate steering fluid. For
10. NOTE: When bleeding the power steering
system the vacuum will decrease. Using the
special tools, maintain a sufficient vacuum of
38cm-Hg. If the vacuum decreases by more
than 5cm-Hg in 5 minutes, the system should
be checked for leaks.
14. If the noise level is still unacceptable,

leave the vehicle standing overnight then
repeat the power steering system
bleeding procedure.
Using the special tools, bleed the power

steering system in the following
sequence.
1. Start the engine and slowly turn the steering
wheel from lock to lock once; then turn the
steering wheel to the right, just off the stop.
2. Switch OFF the engine.
3. Using the special tools, create a vacuum of
38cm-Hg. Maintain the vacuum until the air
is evacuated from the system (minimum of
five minutes).
4. Release the vacuum.
5. Repeat the power steering bleeding procedure, turning the steering wheel to the left,
just off the stop.
11. Remove the special tools. Fill the power

steering reservoir to the MAX mark with
the appropriate steering fluid if necessary.
12. Start the engine, turn the steering wheel
from lock to lock. If excessive noise is
apparent, repeat the power steering
bleeding procedure.
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211-00-20
GENERAL PROCEDURES
Power Steering System Flushing 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V
(Sigma)/1.6L Duratec-16V (Sigma) (13 001 0)
3. NOTE: Using a suitable blanking cap, cap the
end of the hose from the power steering fluid
reservoir.
Special Tool(s)
Socket, Spark Plug
303-499 (21-202)

2. Disconnect the crankshaft position (CKP)
sensor electrical connector.
Disconnect the power steering fluid

reservoir return hose quick release
coupling.
1. Press the power steering fluid reservoir
return hose quick release coupling locking
tangs.
2. Disconnect the power steering fluid
coupling.
Allow the fluid to drain into a suitable container.
4. Place the end of the power steering fluid

reservoir return hose into a suitable
container.
5. Lower the vehicle until the wheels are clear
of the floor to allow the steering wheel to
be rotated from lock to lock.
6. Remove the air cleaner.
1. Disconnect the air cleaner outlet pipe.
2. Disconnect the air cleaner inlet pipe.
3. Remove the retaining bolts.
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211-00-21
7. Disconnect the spark plug wires.
10.
CAUTION: Do not continuously crank

the engine for more than 30 seconds,
as damage to the starter motor may
result.
NOTE: When flushing the power steering system,
make sure that the power steering fluid in the
reservoir does not fall below the minimum mark.
While cranking the engine for no more
than 30 seconds turn the steering wheel
from lock to lock.
With the aid of another technician add 1 liter
of clean power steering fluid.
11. Wait 60 seconds to allow the starter motor
to cool.
8. Using the special tool, remove the spark

plugs.

reservoir, make sure that the power steering
fluid is clean and not agitated prior to use. The
fluid should be poured slowly into the reservoir
to minimize the possibility of aeration. The fluid
level should be checked with the fluid cold.
12.

the engine for more than 30 seconds,
as damage to the starter motor may
result.
NOTE: When flushing the power steering system,
make sure that the power steering fluid in the
reservoir does not fall below the minimum mark.
While cranking the engine for a further 30
seconds turn the steering wheel from lock
to lock.
With the aid of another technician add a
further 1 liter of clean power steering fluid.
13. When all the fluid has been used, turn the
ignition switch to the OFF position.
14. Using the special tool, install the spark
plugs.
Fill the power steering reservoir to the MAX

mark with the appropriate fluid. For
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211-00-22

15. Connect the spark plug wires.
16. Install the air cleaner.

1. Install the retaining bolts.
2. Connect the air cleaner inlet pipe.
3. Connect the air cleaner outlet pipe.
19. Connect the CKP sensor electrical connector.

21. Fill and bleed the power steering system.
For additional information, refer to Power
Steering System Filling / Power Steering

18. NOTE: Make sure that the collar on the hose is
inserted fully into the quick release coupling.
Remove the blanking cap and connect the
power steering fluid reservoir return hose
quick release coupling.
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GENERAL PROCEDURES
Power Steering System Flushing 2.0L Duratec-HE (MI4) (13 001 0)
Special Tool(s)
Remover/Installer, Hose
Clamp
303-397
Socket, Spark Plug

303-499
Pliers, Valve Stem Seal

303-508
4. Using the special tool, disconnect the
spark plug wires.
1. NOTE: Cap the power steering fluid reservoir to
Using the special tool, disconnect the
steering gear to power steering fluid
reservoir return line from the power
steering fluid reservoir.
Allow the fluid to drain into a container.

plugs.
2. Place the end of the steering gear to power

steering fluid reservoir return line into a
container.
6. Raise the vehicle until the road wheels are

clear of the floor. Support the vehicle.
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211-00-24

reservoir, make sure that the steering fluid is
clean and not agitated prior to use. The
steering fluid must be poured slowly into the
power steering fluid reservoir to minimize the
possibility of aeration. The steering fluid level
must be checked with the steering fluid cold.
Fill the power steering fluid reservoir to the
MAX mark with the appropriate steering
fluid. For additional information, refer to
8.

the engine for more than 30 seconds.
CAUTION: When flushing the power

steering system, make sure that the
reservoir does not fall below the MIN
mark.
NOTE: When filling the power steering fluid
reservoir, make sure that the steering fluid is clean
and not agitated prior to use. The steering fluid
must be poured slowly into the power steering
fluid reservoir to minimize the possibility of
aeration.
While cranking the engine turn the steering
wheel from lock to lock.
With the aid of another technician, add 1
liter of clean steering fluid to the power
9. Wait 60 seconds to allow the starter motor
to cool.
G458163 en
10.

the engine for more than 30 seconds.
CAUTION: When flushing the power

steering system, make sure that the
reservoir does not fall below the MIN
mark.
NOTE: When filling the power steering fluid
reservoir, make sure that the steering fluid is clean
and not agitated prior to use. The steering fluid
must be poured slowly into the power steering
fluid reservoir to minimize the possibility of
aeration.
While cranking the engine turn the
steering wheel from lock to lock.
With the aid of another technician, add a
further 1 liter of clean steering fluid to the
power steering fluid reservoir.
11. When the clean steering fluid has been
added to the power steering fluid
reservoir, turn the ignition switch to the
OFF position.
13. Using the special tool, connect the
steering gear to power steering fluid reservoir return line to the power steering
fluid reservoir.
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211-00-25

plugs.
15. Using the special tool, connect the spark

plug wires.

Fill the power steering fluid reservoir to
the MAX mark with the appropriate
steering fluid. For additional information,
18. Start the engine and slowly turn the
steering wheel from lock to lock.
19. Switch OFF the engine.
Check the steering fluid level. Fill the
power steering fluid reservoir to the MAX
mark with the appropriate steering fluid
as necessary. For additional information,
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211-02-1
Power Steering
211-02-1
SECTION 211-02 Power Steering

CONTENTS
PAGE
SPECIFICATIONS
Specifications....................................................................................................................
211-02-2

Power Steering .................................................................................................................
211-02-4

Power Steering Pump 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V
(13 434 0)
(Sigma)/1.6L Duratec-16V (Sigma), Vehicles With: Air Conditioning ............
Power Steering Pump 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V
(13 434 0)
(Sigma)/1.6L Duratec-16V (Sigma), Vehicles Without: Air Conditioning .......
Power Steering Pump to Steering Gear Pressure Line 1.25L Duratec-16V (Sigma)/1.4L
Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), Vehicles With: Air Conditioning ...........
Power Steering Pump to Steering Gear Pressure Line 1.25L Duratec-16V (Sigma)/1.4L
Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), Vehicles Without: Air Conditioning.......
Steering Gear to Power Steering Fluid Reservoir Return Line 2.0L Duratec-HE (MI4)
RHD .................................................................................................................................
Steering Gear ............................................................................................... (13 116 0)
Steering Gear to Fluid Cooler Return Hose................................................... (13 441 0)
Power Steering Fluid Cooler ......................................................................... (13 444 0)
Steering Gear Bushing......................................................................................................
211-02-5
211-02-8
211-02-11
211-02-14
211-02-17
211-02-25
211-02-34
211-02-36
211-02-37
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Power Steering
211-02-2
SPECIFICATIONS
Description
Steering gear mounting bolts
Power steering line to steering gear valve body
clamp retaining bolt
Power steering line bracket to steering gear retaining bolt
Power steering line to cylinder head support
bracket retaining bolt (Duratec)
Power steering line to accessory drive belt support
bracket retaining bolt (Duratec)
Power steering lines to transaxle bracket retaining
bolt - vehicles with 1.6L Duratorq-TDCi (DV) Diesel
Power steering supply hose to engine block (rear)
Power steering line to transmission housing retaining bolt
Power steering line to engine block (front) - vehicles
with 1.4L Duratorq-TDCi (DV) Diesel without air
conditioning
Power steering line to power steering pump union vehicles with 1.3L Duratec-8V (Rocam)
Power steering line to power steering pump union vehicles with 1.4L Duratec-16V (Sigma), 1.6L Duratec-16V (Sigma) or 2.0L Duratec-HE (MI4)
Power steering line to power steering pump union vehicles with 1.4L Duratorq-TDCi (DV) Diesel
Power steering line to power steering pump union vehicles with 1.6L Duratorq-TDCi (DV) Diesel
Power steering pump to steering gear pressure line
support bracket to inlet manifold retaining nut - vehicles with 2.0L Duratec-HE (MI4)
Power steering pump retaining bolts - vehicles with
1.3L Duratec-8V (Rocam)
1.4L Duratec-16V (Sigma), 1.6L Duratec-16V
(Sigma) or 2.0L Duratec-HE (MI4)
1.4L Duratorq-TDCi (DV) Diesel
Power steering pump retaining nuts - vehicles with
1.6L Duratorq-TDCi (DV) Diesel
Power steering fluid cooler line to front bumper
left-hand retaining bolt
Power steering fluid cooler line to front bumper
right-hand retaining bolt
Power steering fluid reservoir retaining screws vehicles with 2.0L Duratec-HE (MI4)
Steering gear to power steering fluid reservoir return line support bracket to generator retaining nut vehicles with 2.0L Duratec-HE (MI4)
Steering column shaft to steering gear pinion retaining bolt
G105647 en
Nm
48
18
lb-ft
35
13
lb-in
-
14
10
25
18
25
18
10
89
25
30
18
22
25
18
40
30
65
48
40
30
33
24
11
25
18
25
18
23
17
80
3.5
31
80
80
11
48
28
35
21
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Power Steering
211-02-3
Description
Exhaust heat shield to steering gear retaining bolts
Exhaust flexible pipe to muffler and tailpipe assembly retaining nuts - vehicles with 1.6L Duratorq-TDCi (DV) Diesel
Stabilizer bar link to stabilizer bar retaining nut
Front crossmember rear retaining bolts
Front crossmember inner and outer retaining bolts
Front crossmember front retaining bolts
Engine support insulator retaining bolts
G105647 en
Nm
14
47
lb-ft
10
35
lb-in
-
48
115
175
70
48
35
85
129
52
35
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Power Steering
211-02-4

Power Steering
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211-02-5
Power Steering
211-02-5

Power Steering Pump 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L
Duratec-16V (Sigma), Vehicles With: Air Conditioning (13 434 0)
2. Detach the power steering line from the
power steering pump mounting bracket.
Special Tool(s)
Expander, Teflon Seal
211-188 (13-015)
Wrench, Hydraulic Line Union

Nut
211-269 (13-027)
Clamp
303-397 (24-003)
3. Detach the power steering line bracket

from the cylinder head.
Removal
1. Detach the coolant expansion tank from
the wheelhouse assembly and position it to
one side.
1. Remove the retaining bolt.
4. Remove the accessory drive belt. For

303-05.[Accessory Drive, REMOVAL AND
INSTALLATION, Power Steering Pump Belt
- 1.4L Duratec-16V (Sigma)/1.6L
Conditioning]
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Power Steering
211-02-6

coupling, from either the power steering
fluid cooler or the power steering reservoir
return hose.
tangs.
coupling.
7.
CAUTION: Do not disconnect the power

steering pump pressure adapter from
the power steering pump.
power steering line from the power
steering pump pressure adapter.
Allow the fluid to drain into a suitable
container.
Discard the O-ring seal.
8. Remove the power steering pump.

power steering fluid supply hose from the
power steering pump.
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Power Steering
211-02-7

Installation
1. NOTE: If installing a new power steering pump,
the power steeing line union supplied with the
new pump should be removed and retained for
further use.
Using the special tool, install a new O-ring
seal onto the power steering line to power
steering pump union.
1. Push the O-ring seal onto the special tool.
2. Locate the special tool onto the union and
install the O-ring seal.
2. NOTE: Make sure the collar on the hose is

211-00.[Steering System - General
Power Steering System Filling]
Power Steering System Bleeding]
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Power Steering
211-02-8

Power Steering Pump 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L
Duratec-16V (Sigma), Vehicles Without: Air Conditioning (13 434 0)
Special Tool(s)
211-188 (13-015)

Nut
211-269 (13-027)

coupling, from either the power steering
fluid cooler or the power steering reservoir
return hose.
tangs.
coupling.
Clamp
303-397 (24-003)
Removal
INSTALLATION, Accessory Drive Belt 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V
Conditioning]
G397031 en

power steering fluid supply hose from the
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Power Steering
211-02-9
4.


container.
Installation
1. NOTE: If installing a new power steering pump,
the power steeing pressure line union supplied
with the new pump should be removed and
retained for further use.
from the engine block.

2. NOTE: Make sure the collar on the hose is

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Power Steering
211-02-10

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211-02-11
Power Steering
211-02-11

Power Steering Pump to Steering Gear Pressure Line 1.25L Duratec-16V
(Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), Vehicles With: Air
Conditioning
2. NOTE: Note the position of the power steering
line to aid installation.
Special Tool(s)
211-188 (13-015)
Detach the power steering line bracket

from the power steering pump mounting
bracket.
Socket, Hydraulic Line Union

Nut
211-269 (13-027)
Removal
All vehicles
the wheelhouse assembly and position it to
one side.

Detach the power steering line brackets
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Power Steering
211-02-12
5.


7. Detach the steering gear return hose from
the pressure line.

container.

Detach the power steering line from the
steering gear.
6. Disconnect the power steering pressure

(PSP) switch electrical connector.

Detach the power steering line from the
steering gear.
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Power Steering
211-02-13

All vehicles
10. Disconnect the power steering lines from
the steering gear valve body.
2. Rotate the clamp plate.
container.
Discard the O-ring seals.

2. Using the special tool, install a new O-ring

1. Push the new O-ring seal onto the special
tool.
3. Install new O-ring seals onto the power

steering lines.
Remove the power steering pump to

steering gear pressure line.
Installation
1. If a new fluid line is being installed, push
the new line into the new union until it clips
into place.

G91965 en
11/2004 2005.25 Fiesta
211-02-14

TO MODEL INDEX
Power Steering
211-02-14

Power Steering Pump to Steering Gear Pressure Line 1.25L Duratec-16V
(Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), Vehicles Without: Air
Conditioning
Special Tool(s)
211-188 (13-015)

Detach the power steering line brackets
from the transaxle.
Socket, Hydraulic Line Union

Nut
211-269 (13-027)
Removal
from the transaxle.
All vehicles
4.

container.
G397028 en
11/2004 2005.25 Fiesta
211-02-15

TO MODEL INDEX
Power Steering
211-02-15



from the engine block.

from the steering gear.


from the steering gear.

7. Detach the steering gear return hose from
the pressure line.
G397028 en
11/2004 2005.25 Fiesta
211-02-16

TO MODEL INDEX
Power Steering
211-02-16

All vehicles
container.

2. Using the special tool, install a new O-ring

1. Push the new O-ring seal onto the special
tool.

steering lines.
Remove the power steering pump to

steering gear pressure line.
Installation
1. If a new fluid line is being installed, push
the new line into the new union until it clips
into place.

G397028 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
211-02-17
Power Steering
211-02-17

Steering Gear to Power Steering Fluid Reservoir Return Line 2.0L Duratec-HE
(MI4) RHD
Special Tool(s)
205-524

Discard the steering column shaft to steering gear pinion retaining bolt.
Clamp
303-397
General Equipment
Transmission jack
Name
Specification
Grease
SA-M1C9107-A
1. NOTE: Make sure that the road wheels are in
the straight ahead position.
G458167 en
3. Remove the front wheels and tires. For

5. Remove the components in the order
indicated in the following illustration(s) and
table(s).
11/2004 2005.25 Fiesta
211-02-18

TO MODEL INDEX
Power Steering
211-02-18
Item
Part
Number
G458167 en
Description
Steering gear to power
steering fluid reservoir return
line upper retaining clip
See Removal Detail
line support bracket to
generator retaining nut
See Removal Detail
Item
Part
Number
Description
Steering gear heat shield

See Removal Detail
See Installation Detail

line support bracket to
steering gear retaining bolt
11/2004 2005.25 Fiesta

TO MODEL INDEX
211-02-19
Power Steering
211-02-19

Item
Part
Number
Description
Cable ties
See Removal Detail

line
See Removal Detail

Removal Details
Item 1 : Steering gear to power steering fluid
reservoir return line upper retaining clip
1.
2. Detach the steering gear to power steering

fluid reservoir return line from the generator wiring harness shield.

reservoir return line support bracket to
generator retaining nut
1. NOTE: Note the position of the steering gear to
power steering fluid reservoir return line
support bracket to aid installation.
Detach the generator wiring harness from
the steering gear to power steering fluid
reservoir return line support bracket.
CAUTION: Cap the steering gear to

power steering fluid reservoir return
line to prevent fluid loss or dirt
ingress.
CAUTION: Cap the power steering fluid
reservoir to prevent fluid loss or dirt
ingress.
Allow the power steering fluid to drain into a
container.
G458167 en
Item 3 : Steering gear heat shield

11/2004 2005.25 Fiesta
211-02-20

TO MODEL INDEX
Power Steering
211-02-20
2. Detach the steering gear heat shield from

the steering gear.
2.
CAUTION: Twisting the exhaust flexible

pipe more than two degrees may
cause damage resulting in failure.
NOTE: Use a pry-bar to prevent the exhaust
flexible pipe from twisting when removing the
catalytic converter to muffler and tailpipe
assembly retaining nuts.
Remove the exhaust flexible pipe to
catalytic converter retaining nuts.
Discard the exhaust flexible pipe to catalytic
converter gasket and retaining nuts.
Item 5 : Cable ties

1.
CAUTION: Over bending of the exhaust

flexible pipe may cause damage
resulting in failure.
Support the exhaust flexible pipe with a
support wrap or splint.
3.

the exhaust hanger insulator to
prevent damage.
Remove the exhaust hanger insulator.
G458167 en
11/2004 2005.25 Fiesta
211-02-21

TO MODEL INDEX
Power Steering
211-02-21

stabilizer bar link ball joint from rotating.
Detach the stabilizer bar link from the stabilizer bar on both sides.

fluid reservoir return line from the power
steering pump to steering gear pressure
line.

reservoir return line
1.
CAUTION: Cap the steering gear valve

body inlet port and outlet port to
Disconnect the power steering lines from
1. Remove the power steering lines clamp
plate retaining bolt.
2. Rotate the power steering lines clamp plate.
container.
6. Using a transmission jack and a wooden

block, support the front axle crossmember.
7. Remove the front axle crossmember retaining bolts on both sides.
8. Lower the front axle crossmember

approximately 100 mm.
G458167 en
11/2004 2005.25 Fiesta
211-02-22

TO MODEL INDEX
Power Steering
211-02-22

2. Remove and discard the power steering
lines O-ring seals.
Item 5 : Cable ties

1. Attach the steering gear to power steering
fluid reservoir return line to the power
steering pump to steering gear pressure
line.
Installation Details
reservoir return line
steering lines.
2. NOTE: Use the front axle crossmember rear

inner retaining bolts to locate the special tools.
NOTE: Do not fully tighten the front axle
crossmember rear inner retaining bolts at this
stage.
Using a transmission jack, wooden block
and the special tools, position and align the
front axle crossmember.
2. Connect the power steering lines to the

steering gear valve body.
1. Rotate the power steering lines clamp plate.
2. Install the power steering lines clamp plate
retaining bolt.
G458167 en
11/2004 2005.25 Fiesta
211-02-23

TO MODEL INDEX
Power Steering
211-02-23
3.
CAUTION: While tightening the front

axle crossmember front retaining bolts
and the front axle crossmember rear
outer retaining bolts, make sure that
the front axle crossmember does not
move.
5. Install the front axle crossmember rear inner retaining bolts on both sides.
Install the front axle crossmember front

retaining bolts and the front axle crossmember rear outer retaining bolts on both
sides.
6. Lower and remove the transmission jack

and wooden block.
4. Remove the front axle crossmember rear

inner retaining bolt and the special tool on
both sides.

stabilizer bar link ball joint from rotating.
Attach the stabilizer bar link to the stabilizer bar on both sides.
G458167 en
11/2004 2005.25 Fiesta
211-02-24

TO MODEL INDEX
Power Steering
211-02-24
9.

flexible pipe from twisting when installing the
exhaust flexible pipe to catalytic converter
retaining nuts.
NOTE: Install a new exhaust flexible pipe to
catalytic converter gasket and retaining nuts.
11.
CAUTION: Over bending of the

exhaust flexible pipe may cause
damage resulting in failure.
Remove the exhaust flexible pipe support
wrap or splint.
Install the exhaust flexible pipe to catalytic

converter retaining nuts.
Item 3 : Steering gear heat shield

1. Attach the steering gear heat shield to the
steering gear.
10.

prevent damage.
NOTE: Check the exhaust hanger insulator for
damage. Install a new exhaust hanger insulator if
required.
Install the exhaust hanger insulator.
G458167 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
211-02-25
Power Steering
211-02-25

Steering Gear (13 116 0)
Special Tool(s)
205-524 (15-122)


211-020 (13-006)
General Equipment
Transmission jack
Name
Grease
Specification
SA-M1C9107-A
Removal
All vehicles
G105648 en
3. Remove the wheels and tires. For

coupling.
tangs.
coupling.
11/2004 2005.25 Fiesta
211-02-26

TO MODEL INDEX
Power Steering
211-02-26
5.

6.

prevent damage.
G105648 en
Vehicles with 1.25L, 1.4L or 1.6L engine

7. Detach the exhaust flexible pipe from the
catalytic converter.
Vehicles with diesel engine

muffler and tailpipe assembly.
Discard the exhaust flexible pipe to muffler
and tail pipe assembly retaining nuts.
11/2004 2005.25 Fiesta
211-02-27

TO MODEL INDEX
Power Steering
211-02-27
Vehicles with 2.0L engine

11.

end from the wheel knuckle on both
sides.
2. Remove and discard the tie-rod end retaining nut.
All vehicles
retaining nuts in place to protect the
ball joint studs.
10.
Loosen the tie-rod end retaining nut on

both sides.
G105648 en

stabilizer bar connecting link ball joint stud from
rotating.
11/2004 2005.25 Fiesta
211-02-28

TO MODEL INDEX
Power Steering
211-02-28


container.

steering gear (left-hand drive shown).
17. Using a transmission jack and a wooden

block, support the front axle
crossmember.
18. Remove the front axle crossmember retaining bolts on both sides.
15. Detach the power steering lines from the

19. Lower the front axle crossmember to gain

access to the steering gear.
G105648 en
11/2004 2005.25 Fiesta
211-02-29

TO MODEL INDEX
Power Steering
211-02-29

20. Remove the steering gear.
Installation
All vehicles
1. Install the exhaust heat shield.
21. Remove and discard the steering gear

bulkhead floor seal.
2. Install a new steering gear bulkhead floor

seal.
22. Remove the exhaust heat shield.

3. Install the steering gear.
G105648 en
11/2004 2005.25 Fiesta
211-02-30

TO MODEL INDEX
Power Steering
211-02-30

4. NOTE: Use the front axle crossmember inner
retaining bolts to locate the special tools.
7. Install the front axle crossmember inner

retaining bolts on both sides.
Using a transmission jack, wooden block

and the special tools, position and align the
front axle crossmember.
8. Remove the transmission jack and wooden

block.
9. NOTE: Install new O-ring seals.
5.
CAUTION: While tightening the front

axle crossmember retaining bolts,
make sure that the crossmember does
not move.
Connect the power steering lines to the

steering gear valve body.
2. Install the retaining bolt.
Install the front axle crossmember retaining bolts on both sides.
10. Attach the power steering lines to the

G105648 en
11/2004 2005.25 Fiesta
211-02-31

TO MODEL INDEX
Power Steering
211-02-31

11. Attach the power steering line to the

14. NOTE: Coat the exhaust flexible pipe studs
with grease.
NOTE: Install new exhaust flexible pipe to muffler
and tailpipe assembly retaining nuts.
Attach the exhaust flexible pipe to the

with grease.
with grease.
G105648 en
11/2004 2005.25 Fiesta
211-02-32

TO MODEL INDEX
Power Steering
211-02-32
All vehicles
16.

prevent damage.
Check the exhaust hanger insulator for
damage. Install a new exhaust hanger
insulator if required..
17.

wrap or splint.
G105648 en
18.
WARNING: Install new tie-rod end

retaining nuts. Failure to follow this
injury.
NOTE: Use a 5 mm Allen key to prevent the
tie-rod end ball joint stud from rotating.
Attach the tie-rod end to the wheel
knuckle on both sides.
19. NOTE: Use a 5mm Allen key to prevent the

stabilizer bar connecting link ball joint stud from
rotating.
11/2004 2005.25 Fiesta
211-02-33

TO MODEL INDEX
Power Steering
211-02-33

Connect the power steering fluid reservoir return hose quick release coupling.

21. Install the wheels and tires. For additional

22.

column to steering gear pinion
injury.
Attach the steering column shaft to the

Section 211-00.[Steering System General Information, GENERAL
PROCEDURES, Power Steering System
Filling]
For
G105648 en
11/2004 2005.25 Fiesta
211-02-34

TO MODEL INDEX
Power Steering
211-02-34

Steering Gear to Fluid Cooler Return Hose (13 441 0)
Removal
All vehicles
1. Remove the front right-hand wheel and tire.
2. Disconnect the steering gear to power
steering fluid cooler return hose quick
release coupling, from either the power
steering fluid cooler or the power steering
reservoir return hose.
1. Press the power steering fluid cooler hose
quick release coupling locking tangs.
2. Disconnect the power steering fluid cooler
hose quick release coupling.

power steering fluid cooler return hose to aid
installation.
Detach the steering gear to power steering
fluid cooler return hose bracket from the
steering gear.

fluid cooler return hose clips from the
steering gear.

installation.
fluid cooler return hose clips from the
crankshaft pulley splash shield.
G91967 en
11/2004 2005.25 Fiesta
211-02-35

TO MODEL INDEX
Power Steering
211-02-35

fluid cooler return hose from the power
steering line.
All vehicles
container.

7. Remove the steering gear heat shield.
10. Remove the steering gear to power

steering fluid cooler return hose.
Installation

installation.
fluid cooler return hose bracket from the
steering gear.
G91967 en

fully inserted into the quick release coupling.
NOTE: Check the power steering lines to steering
gear valve body O-ring seals for damage or
fatigue. Install new O-ring seals as necessary.
11/2004 2005.25 Fiesta
211-02-36

TO MODEL INDEX
Power Steering
211-02-36

Power Steering Fluid Cooler (13 444 0)
Removal
quick release couplings.
1. Press the power steering fluid cooler hose
quick release coupling locking tangs.
hose quick release coupling.
5. Remove the power steering fluid cooler.

2. Lower the power steering fluid cooler.
Installation
3. Remove the radiator splash shield.

G91972 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
211-02-37
Power Steering
211-02-37

Steering Gear Bushing
3. Using the special tools remove the steering
gear insulator bushing on both sides.
Special Tool(s)
Installer, Wheel Hub
204-148 (14-037)
Bushing
205-297 (15-086)
Name
Rubber Suspension
Insulator Lubricant
Specification
E25J-19553-A
Installation
Removal
1. Remove the steering gear. For additional
information, refer to Steering Gear in this
section.
2.
1. Lubricate the steering bushing with

Rubber Suspension Insulator Lubricant
prior to installation.
2. Using the special tools install the steering
gear insulator bushing on both sides.
CAUTION: Make sure vise jaw

protectors are used.
CAUTION: Clamp the steering gear
reinforcement boss. Do not clamp the
steering gear body.
Secure the steering gear in a vise.
3. Install the steering gear. For additional

information, refer to Steering Gear in this
section.
G91973 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
211-03-1
Steering Linkage
211-03-1
SECTION 211-03 Steering Linkage

CONTENTS
PAGE
SPECIFICATIONS
Specifications....................................................................................................................
211-03-2

Steering Linkage ...............................................................................................................
211-03-3

Tie-Rod End.................................................................................................. (13 273 0)
Steering Gear Boot ....................................................................................... (13 134 0)
Tie-Rod......................................................................................................... (13 263 0)
211-03-4
211-03-6
211-03-8
11/2004 2005.25 Fiesta
211-03-2

TO MODEL INDEX
Steering Linkage
211-03-2
SPECIFICATIONS
Description
Tie-rod to steering gear
Tie-rod end locknut
G105649 en
Nm
110
63
48
lb-ft
81
46
35
lb-in
-
11/2004 2005.25 Fiesta
211-03-3

TO MODEL INDEX
Steering Linkage
211-03-3

Steering Linkage
G17594 en
11/2004 2005.25 Fiesta
211-03-4

TO MODEL INDEX
Steering Linkage
211-03-4

Tie-Rod End (13 273 0)
3.
Special Tool(s)
211-020 (13-006)

end from the wheel knuckle.
2. Remove and discard the tie-rod end retaining nut.
Removal
1. Remove the wheel and tire.For additional
retaining nut in place to protect the
ball joint stud.
2.
Loosen the tie-rod end locknut and the

tie-rod end retaining nut.
1. Loosen the locknut.
2. Loosen the retaining nut.
G105650 en
4. NOTE: Make a note of the number of turns used

to remove the tie-rod end.
Remove the tie-rod end.
11/2004 2005.25 Fiesta
211-03-5

TO MODEL INDEX
Steering Linkage
211-03-5

Installation
1. NOTE: Install the tie-rod end using the same
number of turns used to remove it.
Install the tie-rod end.
2.
WARNING: Install a new tie-rod end

injury.
Attach the tie-rod end to the wheel knuckle.
1. Tighten the retaining nut.
2. Tighten the locknut.
3. Install the wheel and tire.For additional

G105650 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
211-03-6
Steering Linkage
211-03-6

Steering Gear Boot (13 134 0)
Installation
General Equipment
1. NOTE: Lubricate the steering gear boot.
Pincers
Install the steering gear boot.

Name
Grease
Specification
ESB-M1C119-B
Removal
1. Remove the tie-rod end. For additional
information, refer to Tie-Rod End in this
section.
2. Remove the tie-rod end locknut.
2. Using a suitable pair of pincers, install a

new steering gear boot inner clamp.
3. NOTE: Make sure the tie-rod is clean before

removing the steering gear boot.
Remove the steering gear boot.
Discard the clamps.
3. NOTE: Make sure the steering gear boot outer
clamp is located over the recess in the tie-rod.
Using a suitable pair of pincers, install a
new steering gear boot outer clamp.
G105651 en
11/2004 2005.25 Fiesta
211-03-7

TO MODEL INDEX
Steering Linkage
211-03-7

4. Install the tie-rod end locknut.
5. Install the tie-rod end. For additional

information, refer to Tie-Rod End in this
section.
G105651 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
211-03-8
Steering Linkage
211-03-8

Tie-Rod (13 263 0)
3. Remove and discard the steering gear boot
clamps.
Special Tool(s)
Socket, Tie-Rod End,
Steering Gear
211-245 (13-025)
General Equipment
Pipe wrench
Vise jaw protectors
Pincers
Name
Grease
Specification
ESB-M1C119-B
4. Remove and discard the steering gear

boot.
Removal
1. Remove the steering gear.
For
211-02.
2. NOTE: Make a note of the number of turns used
to remove the tie-rod end.
Remove the tie-rod end and the tie-rod end
locknut.
1. Remove the tie-rod end.
2. Remove the tie-rod end locknut.
5. Rotate the steering gear pinion to expose
the rack.
G91976 en
11/2004 2005.25 Fiesta
211-03-9

TO MODEL INDEX
Steering Linkage
211-03-9
6.
CAUTION: Do not clamp the steering

rack on exposed hydraulic sealing
surfaces.
2. NOTE: Lubricate the steering gear boot.

Install a new steering gear boot.
CAUTION: Make sure vise jaw protectors

are used.
CAUTION: To counter the extensive
torque forces required to remove the
tie-rod, clamp the steering rack teeth in a
suitable vise. Do not clamp the steering
gear body.
Secure the steering rack in a vise and using a suitable
pipe wrench remove the
tie-rod.
3. Using a suitable pair of
pincers, install a
new steering gear boot inner clamp.
Installation
1. Using the special tool, install the tie-rod.
4. NOTE: Make sure the steering gear boot outer

clamp is located over the recess in the tie-rod.
Using a suitable pair of
pincers, install a
new steering gear boot outer clamp.
G91976 en
11/2004 2005.25 Fiesta
211-03-10

TO MODEL INDEX
Steering Linkage
211-03-10

5. NOTE: Install the tie-rod end using the same
number of turns used to remove it.
Install the tie-rod end and the tie tie-rod end
locknut.
6. Install the steering gear.

For additional
G91976 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
211-04-1
Steering Column
211-04-1
SECTION 211-04 Steering Column

CONTENTS
PAGE
SPECIFICATIONS
Specifications....................................................................................................................
211-04-2

Steering Column ...............................................................................................................
211-04-3

Steering Wheel ............................................................................................. (13 524 0)
Steering Column ........................................................................................... (13 542 0)
211-04-4
211-04-5

Steering Column ........................................................................................... (13 543 4)
211-04-8
11/2004 2005.25 Fiesta
211-04-2

TO MODEL INDEX
Steering Column
211-04-2
SPECIFICATIONS
Description
Steering wheel retaining bolt
Steering column retaining nuts
Steering column shaft to steering gear pinion retaining bolt
G105652 en
Nm
45
24
28
lb-ft
33
18
21
lb-in
-
11/2004 2005.25 Fiesta
211-04-3

TO MODEL INDEX
Steering Column
211-04-3

Steering Column
G91977 en
11/2004 2005.25 Fiesta
211-04-4

TO MODEL INDEX
Steering Column
211-04-4

Steering Wheel (13 524 0)
Removal
1. Remove the driver air bag module. For
501-20B.[Supplemental Restraint System,
REMOVAL AND INSTALLATION, Driver Air
Bag Module]
3. Remove the steering wheel.
Installation
G105653 en
11/2004 2005.25 Fiesta
211-04-5

TO MODEL INDEX
Steering Column
211-04-5

Steering Column (13 542 0)
Removal
1. Remove the driver air-bag module. For
501-20B.[Supplemental Restraint System,
REMOVAL AND INSTALLATION, Driver Air
Bag Module]
3. Release the clip.
4. Remove the audio control switch (if

equipped).
Disconnect the electrical connector.
5. NOTE: Turn the steering wheel to gain access

to the steering column upper shroud retaining
clips.
3. Detach the audio control switch from the

steering column lower shroud (if
equipped).
Using a thin bladed screwdriver, release the
locking tang.
G105654 en
Detach the steering column upper shroud

from the steering column lower shroud
(steering wheel shown removed for clarity).
1. Using a thin bladed screwdriver, release the
two clips, (one each side).
2. Detach the shroud.
11/2004 2005.25 Fiesta
211-04-6

TO MODEL INDEX
Steering Column
211-04-6

6. Remove the steering column lower shroud
1. Remove the retaining screws.
2. Release the steering column locking lever.


G105654 en
9. Disconnect the ignition switch and turn

signal electrical connectors.
Depress the locking tangs.
10. Disconnect the passive anti-theft system

(PATS) transceiver, windshield
wiper/washer switch and clockspring
electrical connectors.
11. Remove the steering column.

Discard the retaining nuts.
11/2004 2005.25 Fiesta
211-04-7

TO MODEL INDEX
Steering Column
211-04-7

Installation
1.

column shaft to steering gear pinion
injury.
WARNING: Make sure that the steering
column locking lever is in the locked
position. Failure to follow this instruction
WARNING: Install new steering column
retaining nuts. Failure to follow this
G105654 en
11/2004 2005.25 Fiesta
211-04-8

TO MODEL INDEX
Steering Column
211-04-8

Steering Column (13 543 4)
Disassembly
All vehicles
1. Remove the steering wheel.
2.
CAUTION: Make sure the clockspring is

not allowed to rotate. Secure in the
central position with a piece of suitable
tape.
3. Remove the clockspring.

1. Remove the retaining screw.
2. Release the locking tangs.
4. Remove the ignition switch.

Remove the multifunction switches.

2. Lift the switches upwards.
5. Remove the passive anti-theft system

(PATS) transceiver.
G91978 en
11/2004 2005.25 Fiesta
211-04-9

TO MODEL INDEX
Steering Column
211-04-9

6. Remove the ignition lock cylinder.
1. Insert and turn the ignition key to position 1.
2. Using a thin bladed screwdriver, depress
the detent.

1. Insert and turn the ignition key to position 1.
2. Using a thin bladed screwdriver, depress
the detent on both sides.
Assembly
1. To assemble, reverse the disassembly
procedure.
G91978 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
211-05-1
Steering Column Switches
211-05-1
SECTION 211-05 Steering Column Switches

CONTENTS
PAGE

Ignition Switch............................................................................................... (36 424 0)
211-05-2
11/2004 2005.25 Fiesta
211-05-2

TO MODEL INDEX
211-05-2

Ignition Switch (36 424 0)
Removal
414-01.
equipped).
locking tang.

equipped).
G105656 en
4. NOTE: Turn the steering wheel to access the

steering column upper shroud retaining clips.
two clips (one each side).

11/2004 2005.25 Fiesta
211-05-3

TO MODEL INDEX
211-05-3

6. Disconnect the ignition switch electrical
connector.
7. Remove the ignition switch.

Installation
G105656 en
11/2004 2005.25 Fiesta
BACK TO MAIN INDEX

TO MODEL INDEX
Group
Powertrain
3
PAGE
SECTION TITLE
Engine
Engine System - General Information.................................................................................... 303-00-1
Engine - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma). 303-01A-1
Engine - 2.0L Duratec-HE (MI4) ............................................................................................ 303-01B-1
Engine Cooling - 1.25L Duratec-16V (Sigma)/1.3L Duratec-8V (Rocam)/1.4L Duratec-16V 303-03A-1
(Sigma)/1.6L Duratec-16V (Sigma).....................................................................................
Engine Cooling - 2.0L Duratec-HE (MI4) ............................................................................... 303-03B-1
Fuel Charging and Controls - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L
303-04A-1
Duratec-16V (Sigma)..........................................................................................................
Fuel Charging and Controls - 2.0L Duratec-HE (MI4) ............................................................ 303-04B-1
Accessory Drive .................................................................................................................... 303-05-1
Starting System..................................................................................................................... 303-06-1
Engine Ignition ...................................................................................................................... 303-07A-1
Engine Ignition - 2.0L Duratec-HE (MI4)................................................................................ 303-07B-1
Engine Emission Control - 1.25L Duratec-16V (Sigma)/1.3L Duratec-8V (Rocam)/1.4L
303-08A-1
Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma)................................................................
Engine Emission Control - 2.0L Duratec-HE (MI4) ................................................................ 303-08B-1
Intake Air Distribution and Filtering........................................................................................ 303-12-1
Evaporative Emissions .......................................................................................................... 303-13-1
Electronic Engine Controls .................................................................................................... 303-14-1
Manual Transmission/Transaxle, Clutch and Transfer Case
Manual Transmission/Transaxle and Clutch - General Information........................................ 308-00-1
Clutch.................................................................................................................................... 308-01-1
Clutch Controls...................................................................................................................... 308-02-1
Manual Transmission/Transaxle............................................................................................ 308-03-1
Manual Transmission/Transaxle External Controls................................................................ 308-06-1
Exhaust System
Exhaust System .................................................................................................................... 309-00-1
Fuel System
Fuel System - General Information........................................................................................ 310-00-1
Fuel Tank and Lines.............................................................................................................. 310-01-1
Acceleration Control - 1.25L Duratec-16V (Sigma)/1.3L Duratec-8V (Rocam)/1.4L
Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma)................................................................ 310-02A-1
Acceleration Control - 2.0L Duratec-HE (MI4) ....................................................................... 310-02B-1
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303-00-1
Engine System - General Information
303-00-1
Page 1 of 2
SECTION 303-00 Engine System - General

Information
CONTENTS
PAGE

Engine ..............................................................................................................................
Engine/transmission combinations ...................................................................................
303-00-3
303-00-3

Engine ..............................................................................................................................
Engine - Oil Leaks............................................................................................................
Ultraviolet (UV) Testing ....................................................................................................
Measure the compression pressure .................................................................................
Measure the compression pressure (Engine - 1.4L Duratorq-TDCi (DV) Diesel) ..............
Measure the compression pressure (Engine - 1.6L Duratorq-TDCi (DV) Diesel) ..............
Measure the compression pressure (Engine - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma)) ..............................................................
Measure the compression pressure (Engine - 1.3L Duratec-8V (Rocam))........................
Measure the compression pressure (Engine - 2.0L Duratec-HE (MI4)) ............................
Measure the oil pressure (Engine - 1.4L Duratorq-TDCi (DV) Diesel)...............................
Measure the oil pressure (Engine - 1.6L Duratorq-TDCi (DV) Diesel)...............................
Measure the oil pressure (Engine - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V
(Sigma)/1.6L Duratec-16V (Sigma)) ..............................................................................
Measure the oil pressure (Engine - 1.3L Duratec-8V (Rocam)) ........................................
Measure the oil pressure (Engine - 2.0L Duratec-HE (MI4)) .............................................
Valve train analysis - static (engine off) ............................................................................
303-00-4
303-00-10
303-00-10
303-00-11
303-00-11
303-00-14
303-00-17
303-00-18
303-00-20
303-00-22
303-00-23
303-00-24
303-00-25
303-00-26
303-00-27
GENERAL PROCEDURES
Camshaft Bearing Journal Diameter .................................................................................
Camshaft Bearing Journal Clearance................................................................................
Camshaft End Play ...........................................................................................................
Camshaft Surface Inspection ............................................................................................
Camshaft Lobe Lift............................................................................................................
Crankshaft Main Bearing Journal Diameter.......................................................................
Crankshaft End Play .........................................................................................................
Cylinder Bore Taper ..........................................................................................................
Piston Inspection...............................................................................................................
Piston Pin to Bore Diameter ..............................................................................................
Piston Diameter ................................................................................................................
Piston Ring End Gap.........................................................................................................
Piston Ring-to-Groove Clearance......................................................................................
Piston Pin Diameter ..........................................................................................................
Connecting Rod Large End Bore ......................................................................................
Valve Stem Diameter ........................................................................................................
Flywheel Inspection ..........................................................................................................
Flywheel Inspection Vehicles With: Dual Mass Flywheel ..............................................
Cylinder Head Distortion ...................................................................................................
Cylinder Block Distortion ...................................................................................................
Exhaust Manifold Cleaning and Inspection........................................................................
303-00-29
303-00-30
303-00-31
303-00-32
303-00-33
303-00-34
303-00-35
303-00-36
303-00-37
303-00-38
303-00-39
303-00-40
303-00-41
303-00-42
303-00-43
303-00-44
303-00-45
303-00-46
303-00-47
303-00-48
303-00-49
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Page 2 of 2
Bearing Inspection.............................................................................................................
Valve Seat Inspection ........................................................................................................
303-00-50
303-00-51
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303-00-3
303-00-3

Engine
Engine/transmission combinations
Item
Part
Number
1.3L Duratec 8V engine
1.4/1.6L Duratec 16V engine
G186750 en
Description
Item
Part
Number
Description
1.4L Duratorq TDCi turbodiesel engine
iB5 manual transmission

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303-00-4

Engine

system.
Special Tool(s)
Socket, Spark Plug
303-499
Compression Test Adapter

303-1052

303-508
Name
Adhesive - Loctite 243
Specification
WSK-M2G349-A7

Mechanical
Electrical
Coolant leaks
Fuse(s)
Oil leaks
Loose or corroded
connector(s)
Fuel system leaks
Visibly damaged or Powertrain control
module
worn parts
Damaged or worn
Loose or missing
switch(es)
nuts or bolts
step.
Symptom Chart
Symptom
Loss of oil
Possible Sources
Action
Oil leaks on components that are CHECK for evidence of oil leaks
either coated in oil themselves or on components. Use an ultraon components local to them.
violet (UV) leak tester if an oil
leak is not evident. INSTALL new
gaskets or components as required.
Internal or external leak at the oil CHECK the coolant expansion
cooler.
tank for a film of oil on the coolant surface. INSTALL a new oil
cooler or oil cooler gasket.
Oil consumption
G152554 en
Leak at the crankshaft seal.
INSTALL a new crankshaft seal.
Leaks from oil carrying components or basic engine.
CHECK for cracks in oil carrying

components of the basic engine
by means of a UV leak test.
INSTALL new components or
seals as necessary.
Use of the wrong type of engine DETERMINE the last type of

oil.
engine oil used and compare
with the specification. Change
the engine oil to the specification.
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303-00-5

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303-00-5

Symptom
Possible Sources
Action
Faulty positive crankcase

ventilation (PCV) system.
Hoses or ventilation or breather
valves are blocked. This causes
excessive pressure in the
crankcase which causes more oil
to enter the combustion
chamber.
PCV oil separator is faulty and
engine oil can enter the combustion chamber through the
intake manifold.
CHECK if the PCV system is

operating correctly and repair as
303-08A.[Engine Emission Control - 1.25L Duratec-16V
(Sigma)/1.3L Duratec-8V (Rocam)/1.4L Duratec-16V
(Sigma), DIAGNOSIS AND
TESTING, Engine Emission
Control] REFER to Section
303-08B.[Engine Emission
Control - 2.0L Duratec-HE (MI4),
Engine Emission Control]
Turbocharger seals (diesel engine only).
INSTALL a new turbocharger.
Damaged gaskets or mating

surfaces.
Cylinder head gasket is
damaged or mating face are
warped.
Valve stem oil seals are worn
and engine oil can enter the
combustion chamber between
the valve stem and the valve
stem guide.
CHECK the gaskets and mating

surfaces for damage.
Remove the cylinder head.
CHECK the mating faces,
cylinder head gasket and the
evenness of the cylinder head
and engine block mating faces.
INSTALL new valve
seals.REFER to Section
303-01A.[Engine - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), IN-VEHICLE
REPAIR, Valve Seals]
REFER to Section
303-01B.[Engine - 2.0L Duratec-HE (MI4), IN-VEHICLE
REPAIR, Valve Seals]
Piston ring or cylinder liner wear. INSTALL new components as

necessary.
Damaged cylinder liners or
excessive clearance of engine
components.
Pistons
Piston rings (clearance in groove
and end gap)
Cylinder liners
G152554 en
CHECK the running surfaces

and clearances of the individual
engine components. INSTALL
new components as necessary.
INSTALL a new cylinder block if
necessary.
CHECK the pistons. REFER to
Piston Inspection in this section.
CHECK the piston rings.
REFER to Piston
Ring-to-Groove Clearance /
Piston Ring End Gap in this section.
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303-00-6

Symptom
Coolant consumption
Engine will not crank
Engine cranks but will not start
G152554 en
Possible Sources
Action
Cooling system components.
CHECK the coooling system.

REFER to Section
303-03A.[Engine Cooling - 1.25L
Duratec-16V (Sigma)/1.3L Duratec-8V (Rocam)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), DIAGNOSIS
AND TESTING, Engine Cooling]
REFER to Section
303-03B.[Engine Cooling - 2.0L
Duratec-HE (MI4), DIAGNOSIS
AND TESTING, Engine Cooling]
Oil cooler.
INSTALL a new oil cooler.
Damaged gaskets or warped

mating faces.
CHECK the cylinder head gasket

for damage. CHECK the cylinder
head for distortion.
Cracks or fractures in engine

components surrounded by
coolant, such as cylinder liners
and cylinder head combustion
chamber.
DETERMINE the damaged engine component(s) and install

new component(s) as necessary.
Battery or cables.
CHECK the battery, bracket and

cables. REFER to Section
414-01.[Battery, Mounting and
Cables, DIAGNOSIS AND
TESTING, Battery]
Starter motor or cables.
CHECK the starting system.

REFER to Section
303-06.[Starting System,
Starting System]
Fuel tank is empty.
CHECK the fuel level.
Water in fuel (diesel engine

only).
Drain the water from the fuel

system. Engine - 1.4L Duratorq-TDCi (DV) Diesel/Engine 1.6L Duratorq-TDCi (DV) Diesel.
Fuel filter blocked.
INSTALL a new fuel filter.
Engine intake air system.
CHECK the intake air system.

REFER to Section
303-12.[Intake Air Distribution
and Filtering, DIAGNOSIS AND
TESTING, Intake Air Distribution
and Filtering]
Glow plug faulty (diesel engine

only).
CHECK the glow plugs.

INSTALL new glow plugs as
necessary.
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303-00-7

Symptom
Possible Sources
Engine management system.
CHECK the engine management

system. REFER to Section
303-14.[Electronic Engine Controls, DIAGNOSIS AND
TESTING, Electronic Engine
Controls]
Ignition system (petrol engines

only).
CHECK the ignition system.

REFER to Section
303-07A.[Engine Ignition,
Engine Ignition]
REFER to Section
303-07B.[Engine Ignition - 2.0L
AND TESTING, Engine Ignition]
Incorrect valve timing.
CHECK and adjust the valve

timing. REFER to Section
REPAIR, Timing Belt]
REFER to Section
REPAIR, Crankshaft Pulley]
Broken or damaged timing

belt/timing chain or pulley/sprocket.
CHECK the timing belt/timing

chain and sprockets/pulleys.
REFER to Section
REPAIR, Timing Chain]
Very poor power output or fuel Fuel system.

consumption too high or engine
running rough
G152554 en
Action
CHECK the fuel system. REFER

to Section 303-04A.[Fuel
Charging and Controls - 1.25L
Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), DIAGNOSIS
AND TESTING, Fuel Charging
and Controls]
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Symptom
G152554 en
Possible Sources
Action
Engine intake air system.
CHECK the intake air system.

REFER to Section
303-12.[Intake Air Distribution
and Filtering, DIAGNOSIS AND
TESTING, Intake Air Distribution
and Filtering]
Exhaust system blocked.
CHECK the exhaust system.
Engine management system.
CHECK the engine management

system. REFER to Section
Controls]
Fault in ignition system (petrol

engines only).
CHECK the ignition system.

REFER to Section
303-07A.[Engine Ignition,
Engine Ignition]
REFER to Section
303-07B.[Engine Ignition - 2.0L
AND TESTING, Engine Ignition]
Turbocharger (diesel engine

only).
CHECK the turbocharger.
Incorrect valve timing. Timing

belt/timing sprocket or pulley/sprocket damaged.

REFER to Section
Ignition timing incorrect (petrol

engines only).
CHECK the electronic engine

controls. REFER to Section
Controls]
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303-00-9

Symptom
Possible Sources
Action
Noisy running
Engine auxiliary components

loose or damaged.
CHECK engine auxiliary components for damage or looseness. REFER to Section

REFER to Section
Noisy running, misfiring, backfiring or knocking
Incorrect fuel
DETERMINE which type of fuel

was last put in the tank (note the
country specific fuel specifications).
Water in fuel or fuel contaminated.
CHECK the fuel system for water

or other contamination.
Valve timing incorrect, timing

belt/chain or pulley/sprocket
damaged.

REFER to Section
Noisy running or valve train

noise
G152554 en
Valve clearance too large due to INSTALL new hydraulic lash

faulty valve tappets or worn
adjusters or adjust the valve
clearance. REFER to Section
valve train components.
303-01A.[Engine - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), GENERAL
PROCEDURES, Valve Clearance Adjustment]
REFER to Section
303-01B.[Engine - 2.0L Duratec-HE (MI4), GENERAL
PROCEDURES, Valve Clearance Adjustment]
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303-00-10

Symptom
Noisy running or engine noise
Possible Sources
Action
Timing belt or timing chain

damaged.
INSTALL a new timing belt or

timing chain. REFER to Section
REFER to Section
Timing belt or timing chain incorrectly tensioned.
CHECK the timing belt or timing

chain tension. INSTALL a new
timing belt or timing chain as
REFER to Section
Engine components
Pistons
Piston rings
Connecting rod big end, main
bearing or thrust bearing
journals
Connecting rods bent or
damaged.
CHECK the engine components

for wear or damage. Make sure
all components are within specification. INSTALL new components as necessary.
Engine - Oil Leaks

NOTE: Before installing new gaskets or seals,
make sure that the fault is clearly established.
If the oil leak cannot be identified clearly by a
visual inspection, carry out an ultraviolet (UV) test:
Ultraviolet (UV) Testing

1. Clean the engine and transmission with a
suitable cleaning fluid.
2. Pour the UV-test fluid in accordance with the
quantity specified by the manufacturer
through the oil filler neck into the engine and
install the oil filler cap.
WARNING: Vehicles with manual
transaxle, shift the transaxle into Neutral.
3. Start the engine and let it run for about five
minutes.
4. Switch off the engine.
NOTE: If no leak can be found, road test the
vehicle under various loads and check the engine
for leaks again.
G152554 en
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303-00-11

5. Check the engine for oil leaks using a suitable
UV lamp.
6. Rectify any leaks found and check the engine
for oil leaks.
2. Disconnect the fuel injector wiring harness

main connector.
Measure the compression pressure

NOTE: The powertrain control module (PCM)
receives an error message when the fuel pump
relay is removed or electrical components are
disconnected. This error message must be
deleted from the fault memory using WDS after
completing the compression test.
NOTE: Valve clearance must be set correctly
before performing a compression test. Make sure
the engine is at the normal operating temperature.
NOTE: The varying design of compression
checking devices and fluctuating starter motor
speeds normally only allows for a comparison to
be made of the compression pressures in all
cylinders.
3. Disconnect the glow plug relay electrical

connector.
Measure the compression pressure (Engine 1.4L Duratorq-TDCi (DV) Diesel)

4. Detach the exhaust gas recirculation (EGR)

tube from the cylinder block and from the EGR
valve (if equipped).
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303-00-12

5. Detach the EGR tube from the EGR cooler (if
equipped).
6. Remove the EGR tube from the intake

manifold assembly.
8. Remove the glow plugs.
9. Install a suitable compression pressure

recorder with a suitable adapter into the glow
plug bore.
NOTE: Operate the starter motor until the reading
on the compression tester stops rising.
10. Carry out the measurement in accordance
with the instructions supplied with the
measuring device on every cylinder using a
suitable compression pressure recorder with a
suitable adapter.
7. Disconnect the glow plug electrical

connectors.
11. Detach the compression tester and adapter.
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303-00-13

12. Install the glow plugs.
15. Attach the EGR tube to the cylinder block and

to the EGR valve (if equipped).
13. Connect the glow plug electrical connectors.

16. Attach the EGR tube to the EGR cooler (if
equipped).
NOTE: Check the EGR tube O-ring seal. Install a

new seal if necessary.
14. Install the EGR tube to the intake manifold
assembly.
G152554 en
17. Connect the glow plug relay electrical

connector.
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303-00-14

18. Connect the fuel injector wiring harness main
connector.
20. Using worldwide diagnostic system (WDS),
clear the fault codes from the PCM.
3. Remove the engine undershield.
Measure the compression pressure (Engine 1.6L Duratorq-TDCi (DV) Diesel)

WARNING: Do not smoke or carry lighted
tobacco or open flame of any type when
working on or near any fuel related
components. Highly flammable mixtures
are always present and can ignite. Failure
personal injury.
WARNING: Do not carry out any repairs to
the fuel injection system without
checking that the fuel pressure has
dropped to zero and that the fuel
temperature has either reached ambient
temperature or is below 30 C, whichever
is the greater. Failure to follow these
1. Using datalogger in world wide diagnostic
system (WDS), check that the fuel pressure
has dropped to zero and that the fuel
temperature has either reached ambient
temperature or is below 30C, whichever is
the greater.
G152554 en
4. Remove the radiator undershield.
5. Remove the glow plug relay.

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303-00-15

7. Remove the engine upper cover.
CAUTION: Do not disconnect the fuel

injection pump electrical connectors and
crank the engine.
8. Disconnect the fuel injector electrical
connectors.
9. Detach the exhaust gas recirculation (EGR)

cooler (if equipped) and position it to one side.
G152554 en
10. Remove the glow plug power supply.
11. Remove the glow plugs.
12. Install the special tool and a suitable

compression tester into the glow plug bore.
NOTE: Crank the engine with the starter motor
until the reading on the compression tester stops
rising.
13. Carry out the measurement on all cylinders,
following the measuring equipment
manufacturer's instructions.
14. Detach the compression tester and the special
tool.
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303-00-16

15. Install the glow plugs.
19. Install the engine upper cover.

16. Install the glow plug power supply.

21. Install the glow plug relay.
17. Attach the EGR cooler (if equipped).

22. Install the radiator undershield.
18. Connect the fuel injector electrical connectors.
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303-00-17

23. Install the engine undershield.
25. Reset the PCM fault memory.
4. Disconnect the electronic ignition (EI) coil

connector from the EI coil.
Measure the compression pressure (Engine 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V

(Sigma)/1.6L Duratec-16V (Sigma))
NOTE: Twist the spark plug connectors slightly

before disconnecting them. Pull on the connector
and not on the cable.
5. Disconnect the spark plug connectors.
1. Open the central junction box (CJB) and

remove the fuel pump relay.
NOTE: The engine will start, run for a few seconds
and then stop.
2. Start the engine.
3. Remove the air cleaner. REFER to Section
303-12.[Intake Air Distribution and Filtering,
REMOVAL AND INSTALLATION, Air Cleaner
Duratec-16V (Sigma)/1.6L Duratec-16V
(Sigma)]

plugs.
NOTE: Operate the starter motor with wide open

throttle until the reading on the compression tester
stops rising.
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303-00-18

suitable compression pressure recorder with
the suitable adapter.
8. Using the special tool, install the spark plugs.
10. Connect the EI coil electrical connector to the

EI coil.
11. Install the fuel pump relay.

12. Install the air cleaner. REFER to Section
(Sigma)]
Measure the compression pressure (Engine 1.3L Duratec-8V (Rocam))
9. Connect the spark plug connectors.

and then stop.
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303-00-19


electrical connector from the EI coil.
6. Remove the spark plugs.

throttle until the reading on the compression tester
stops rising.
suitable compression pressure recorder with
the suitable adapter.

5. Disconnect the spark plug connectors.
8. Install the spark plugs.
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303-00-20

9. Connect the spark plug connectors.

and then stop.
3. Remove the air cleaner. REFER to Section
- 2.0L Duratec-HE (MI4)]

EI coil.

electrical connector from the EI coil.

Measure the compression pressure (Engine 2.0L Duratec-HE (MI4))
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303-00-21

5. Using the special tool, remove the spark plug
connectors.
8. Using the special tool, install the spark plugs.
9. Install the spark plug connectors.

plugs.

EI coil.
throttle until the pointer on the measuring device
stops rising.
measuring device on every cylinder using
compression pressure recorder 623.000.101
with the suitable adapter.
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303-00-22

12. Install the air cleaner. REFER to Section
- 2.0L Duratec-HE (MI4)]
13. Reset the PCM fault memory.
3. Remove the oil pressure switch.

Discard the washer.
Measure the oil pressure (Engine - 1.4L

Duratorq-TDCi (DV) Diesel)
NOTE: The oil pressure depends on various
factors (engine speed, oil temperature, oil
viscosity, extent of oil filter contamination).
NOTE: Measure the oil pressure at the specified
engine speed.
4. Attach the oil pressure gauge with the oil

pressure gauge connector, and position it to
allow reading from above.
2. Disconnect the oil pressure switch electrical

connector from the oil pressure switch.
NOTE: Measure the oil pressure at an oil
temperature of 110C.
NOTE: Oil pressure at 2000 rpm: 2.3 to 3.7 bar.
6. Measure the oil pressure.
7. Raise and support the vehicle. Engine - 1.4L
Duratorq-TDCi (DV) Diesel
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303-00-23

8. Remove the oil pressure gauge and the oil
pressure gauge connector.


NOTE: Install a new oil pressure switch washer.
9. Install the oil pressure switch.
10. Connect the oil pressure switch electrical

connector to the oil pressure switch.
Duratorq-TDCi (DV) Diesel)
G152554 en

engine speed. Measure the oil pressure at an oil
temperature of 125C.
NOTE: Measure the oil pressure at idle speed and
at 2000 rpm.
4. Check the oil pressure.
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303-00-24

5. Detach the oil pressure gauge and the oil
6. Coat the oil pressure switch with .


(Sigma)/1.6L Duratec-16V (Sigma))

pressure gauge connector to the oil pressure
switch bore, and position it to allow reading
from above.

engine speed.

temperature of 80C.
NOTE: Oil pressure at 2000 rpm: 3.5 bar.
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303-00-25


Duratec-8V (Rocam))
engine speed.
8. Detach the oil pressure gauge and connector

from the oil pressure switch bore.

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pressure gauge connector to the oil pressure
switch bore, and position it to allow reading
from above.

temperature of 80C.
NOTE: Oil pressure at idle speed (750 rpm): 0.95
bar.
G152554 en

9. Coat the oil pressure switch with sealant .

Duratec-HE (MI4))
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303-00-27



4. Attach the oil pressure gauge (GV 2134) with

the oil pressure gauge connector to the oil
pressure switch bore, and position it to allow
reading from above.

Valve train analysis - static (engine off)
Remove the valve cover.
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Check all components of the valve train for
damage and wear. Make sure that only original
components are installed and that all nuts and
bolts are tightened to the specified torque.
G152554 en
11/2004 2005.25 Fiesta
303-00-29

TO MODEL INDEX
303-00-29
GENERAL PROCEDURES
Camshaft Bearing Journal Diameter
1. Determine the diameter of the camshaft
journals.
Using a micrometer measure the diameter
at 90 degrees intervals to determine if the
journals are out-of-round.
Measure at two different points on the
journal to determine if there is any tapering.
If the measurements are out of the specified
range, install a new camshaft.
G17620 en
11/2004 2005.25 Fiesta
303-00-30

TO MODEL INDEX
303-00-30
GENERAL PROCEDURES
Camshaft Bearing Journal Clearance
1. NOTE: Make sure that the following stages are
followed exactly. The tappets or followers must
be removed to carry out this measurement.
NOTE: Make sure that the camshaft is to
specification.
NOTE: The bearing caps and journals should be
free from engine oil and dirt.
4. Using the Plastigage, read off the

measurement.
Compare the width of plastigage with the
plastigage scale.
The value that is read off is the bearing
clearance.
Position on a width of plastigage on the

bearing cap.
Insert the camshaft, without lubrication, into
the cylinder head.
Position a plastigage strip, which should be
equal to the width of the bearing cap, on the
bearing journal.
2. Following the tightening specification,

install the camshaft bearing caps. Refer to
the corresponding Section 303-01.
3. NOTE: Do not strike the bearing caps.
Remove the camshaft bearing caps, refer
to the corresponding Section 303-01.
G17621 en
11/2004 2005.25 Fiesta
303-00-31

TO MODEL INDEX
303-00-31
GENERAL PROCEDURES
Camshaft End Play
1. NOTE: Make sure that the camshaft is to
specification.
Using a Dial Indicator Gauge, measure the
end play.
Slide the camshaft in both directions. Read
and note the maximum and minimum
values on the Dial Indicator Gauge.
End play = maximum value minus
minimum value
If the measurement is out of specification,
install new components.
G17622 en
11/2004 2005.25 Fiesta
303-00-32

TO MODEL INDEX
303-00-32
GENERAL PROCEDURES
Camshaft Surface Inspection
1. Inspect the camshaft lobes for pitting or
damage in the active area. Minor pitting is
acceptable outside the active area.
G17623 en
11/2004 2005.25 Fiesta
303-00-33

TO MODEL INDEX
303-00-33
GENERAL PROCEDURES
Camshaft Lobe Lift
1. Determine the cam lift.
Using a micrometer measure the cam in two
directions.
The difference between the two measurements is the cam lift.
G17624 en
11/2004 2005.25 Fiesta
303-00-34

TO MODEL INDEX
303-00-34
GENERAL PROCEDURES
Crankshaft Main Bearing Journal Diameter
General Equipment
Micrometer
1. Measure the diameter of the main bearing
journals and the big-end bearing journals.
Repeat the measurement with the
micrometer offset by 90, in order to
determine any eccentricity which may be
present.
Measure the journal at two different positions to determine any conicity which may
be present.
G21023 en
11/2004 2005.25 Fiesta
303-00-35

TO MODEL INDEX
303-00-35
GENERAL PROCEDURES
Crankshaft End Play
General Equipment
Dial indicator
Dial indicator fixture
1. NOTE: Operation for vehicles with Zetec-E
engines only. Dismantling the crank gear is not
permitted on Zetec-SE engines.
Determine the end float
Place on the dial indicator and bracket .
Determine the end float by raising the
crankshaft with the aid of a screwdriver.
If necessary, correct the end float by using
new thrust half washers.
G17627 en
11/2004 2005.25 Fiesta
303-00-36

TO MODEL INDEX
303-00-36
GENERAL PROCEDURES
Cylinder Bore Taper
1. NOTE: The main bearing caps or lower
crankcase must be in place and tightened to
the specified torque; however, the bearing
shells should not be installed.
Measure the cylinder bore with an internal
micrometer.
Carry out the measurements in different
directions and at different heights to
determine if there is any out-of-roundness
or tapering.
If the measurement is out of the specified
range, install a new block or hone out the
cylinder block (if aplicable/allowed).
G17628 en
11/2004 2005.25 Fiesta
303-00-37

TO MODEL INDEX
303-00-37
GENERAL PROCEDURES
Piston Inspection
1.
CAUTION: Do not use any aggressive

cleaning fluid or a wire brush to clean
the piston.
Carry out a visual inspection.
Clean the piston skirt, pin bush, ring
grooves and crown and check for wear or
cracks.
If there are signs of wear on the piston skirt,
check whether the connecting rod is twisted
or bent.
G17629 en
11/2004 2005.25 Fiesta
303-00-38

TO MODEL INDEX
303-00-38
GENERAL PROCEDURES
Piston Pin to Bore Diameter
1. NOTE: The piston and piston pin form a
matched pair. Do not mix up the components.
Measure the diameter of the piston pin
bore.
Measure the diameter in two directions.
If the values are not to specification, install
both a new piston and a new piston pin.
G17630 en
11/2004 2005.25 Fiesta
303-00-39

TO MODEL INDEX
303-00-39
GENERAL PROCEDURES
Piston Diameter
General Equipment
Micrometer
1. NOTE: Mark the piston to make sure the piston
is installed correctly.
Using a Micrometer measure the piston
diameter.
G17631 en
11/2004 2005.25 Fiesta
303-00-40

TO MODEL INDEX
303-00-40
GENERAL PROCEDURES
Piston Ring End Gap
1.
CAUTION: Do not mix up the piston

rings. Install the piston rings in the
same position and location.
Take the piston ring and use a piston
without rings to push the piston ring about
30 mm into the cylinder bore.
2. Using the Feeler Gauge, measure the piston ring gap.
G17632 en
11/2004 2005.25 Fiesta
303-00-41

TO MODEL INDEX
303-00-41
GENERAL PROCEDURES
Piston Ring-to-Groove Clearance
General Equipment
Feeler Gauge
1. NOTE: The piston ring must protrude from the
piston groove. To determine the piston ring
clearance, insert the Feeler Gauge right to the
back of the groove, behind the wear ridge.
Using the Feeler Gauge , measure the piston ring clearance.
G17633 en
11/2004 2005.25 Fiesta
303-00-42

TO MODEL INDEX
303-00-42
GENERAL PROCEDURES
Piston Pin Diameter
1. NOTE: The piston and piston pin are a matched
pair. Do not mix up the components.
Measure the piston pin diameter.
Measure the diameter in two directions.
If the values are not to specification, install a
new piston and a new piston pin.
G17634 en
11/2004 2005.25 Fiesta
303-00-43

TO MODEL INDEX
303-00-43
GENERAL PROCEDURES
Connecting Rod Large End Bore
1. Measure the bearing bore in two directions.
The difference is the connecting rod bore
out-of-round. Verify the out-of-round and
the bearing bore is within specification.
G17635 en
11/2004 2005.25 Fiesta
303-00-44

TO MODEL INDEX
303-00-44
GENERAL PROCEDURES
Valve Stem Diameter
1. Using a micrometer measure the diameter
of the valve stems.
If the measurements are not to specification,
install a new valve.
G17636 en
11/2004 2005.25 Fiesta
303-00-45

TO MODEL INDEX
303-00-45
GENERAL PROCEDURES
Flywheel Inspection
1. Inspect the flywheel for:
1. Any cracks.
2. Worn ring gear teeth.
3. Chipped or cracked ring gear teeth.
G17637 en
11/2004 2005.25 Fiesta
303-00-46

TO MODEL INDEX
303-00-46
GENERAL PROCEDURES
Flywheel Inspection Vehicles With: Dual Mass Flywheel
CAUTION: Do not rework the flywheel if it

is distorted.
CAUTION: Do not clean the dual mass
flywheel with any kind of fluid. Clean the
flywheel with a dry cloth only.
CAUTION: Do not clean the gap between
the primary and secondary mass. Only
clean the bolt connection surface and the
clutch surface.
1. Inspect the flywheel, if there is evidence of
the following install a new flywheel:
Cracks.
Worn ring gear teeth.
Chipped or cracked ring gear teeth.
2. Check the flywheel for lateral movement.
Rotation movement in either one or both
directions, or rock on its axis up to x = 1.5
mm measured at a radius of y = 125 mm in
relation to the primary mass is acceptable.
A small amount of lateral movement is
permissible.
G272661 en
3.
CAUTION: Make sure that the three

locating dowels are installed.
Check if the locating dowels are touching
the primary mass of the flywheel.
If the height of the locating dowels is less
than 11 mm, install a new flywheel.
4. Inspect for grease along the welding.

If more than 2 g or 2 cm grease is evident,
install a new flywheel.
11/2004 2005.25 Fiesta
303-00-47

TO MODEL INDEX
303-00-47
GENERAL PROCEDURES
Cylinder Head Distortion
General Equipment
Feeler gauge
Straight edge
1. Using a straight edge and feeler gauge,
measure the cylinder head distortion.
Measure the mating face distortion.
Refer to Specifications in the appropriate
engine section.
G17638 en
11/2004 2005.25 Fiesta
303-00-48

TO MODEL INDEX
303-00-48
GENERAL PROCEDURES
Cylinder Block Distortion
1. Using a Straight Edge and a Feeler Gauge,
measure the cylinder block/cylinder head
distortion.
Measure the mating face distortion.
If the value is not to specification rework the
mating face (if allowed).
G17639 en
11/2004 2005.25 Fiesta
303-00-49

TO MODEL INDEX
303-00-49
GENERAL PROCEDURES
Exhaust Manifold Cleaning and Inspection
1. Inspect the cylinder head joining flanges of
the exhaust manifold for evidence of
exhaust gas leaks.
2. Inspect the exhaust manifold for cracks,
damaged gasket surfaces, or other damage
that would make it unfit for further use.
G17640 en
11/2004 2005.25 Fiesta
303-00-50

TO MODEL INDEX
303-00-50
GENERAL PROCEDURES
Bearing Inspection
1. Inspect bearings for the following defects.
1. Cratering - fatigue failure
2. Spot polishing - incorrect seating.
3. Imbedded dirt engine oil.
4. Scratching - dirty engine oil.
5. Base exposed - poor lubrication.
6. Both edges worn - journal damaged.
7. One edge worn - journal tapered or bearing
not seated.
G17641 en
11/2004 2005.25 Fiesta
303-00-51

TO MODEL INDEX
303-00-51
GENERAL PROCEDURES
Valve Seat Inspection
General Equipment
Valve seat width scale
1. Measure the width of the valve seat.
Measure the valve seat width using the
Valve seat width scale.
If the value is not to specification rework the
valve seat.
G17642 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
303-01A-1
Engine 1.25L Duratec-16V (Sigma)/1.4L
303-01A-1
Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma)

Page 1 of 2
SECTION 303-01A Engine 1.25L Duratec-16V

(Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V
(Sigma)
CONTENTS
PAGE
SPECIFICATIONS
Specifications...................................................................................................................
Engine Data - 1.25L ........................................................................................................
Engine Data - 1.4L ..........................................................................................................
Engine Data - 1.6L ..........................................................................................................
Oil pressure.....................................................................................................................
Engine Oil Capacity - 1.25L/1.4L.....................................................................................
Engine Oil Capacity - 1.6L...............................................................................................
Valve Clearance - 1.25L/1.4L ..........................................................................................
Valve Clearance - 1.6L....................................................................................................
Cylinder block - 1.25L......................................................................................................
Cylinder block - 1.4L .......................................................................................................
Cylinder block - 1.6L .......................................................................................................
Cylinder head..................................................................................................................
Piston -1.25L...................................................................................................................
Piston -1.4L.....................................................................................................................
Piston - 1.6L....................................................................................................................
303-01A-3
303-01A-3
303-01A-3
303-01A-3
303-01A-3
303-01A-4
303-01A-4
303-01A-4
303-01A-4
303-01A-4
303-01A-4
303-01A-4
303-01A-4
303-01A-5
303-01A-5
303-01A-5

Engine .............................................................................................................................
1.4L/1.6L Duratec 16V engine.........................................................................................
303-01A-8
303-01A-8

Engine .............................................................................................................................
303-01A-11
GENERAL PROCEDURES
Valve Clearance Adjustment ............................................................................................
303-01A-12
IN-VEHICLE REPAIR
Crankshaft Front Seal ...................................................................................
Valves ...........................................................................................................
Intake Manifold..............................................................................................
Valve Cover ..................................................................................................
Valve Seals...................................................................................................
Camshafts.....................................................................................................
Camshaft Seal ..............................................................................................
Timing Belt....................................................................................................
Exhaust Manifold ..........................................................................................
Cylinder Head ...............................................................................................
Oil Pan..........................................................................................................
Oil Pump .......................................................................................................
Crankshaft Rear Seal....................................................................................
(21 467 0)
(21 215 4)
(21 183 0)
(21 141 0)
(21 238 0)
(21 284 0)
(21 288 0)
(21 304 0)
(21 187 0)
(21 163 0)
(21 154 0)
(21 714 0)
(21 468 4)
303-01A-13
303-01A-15
303-01A-18
303-01A-26
303-01A-28
303-01A-31
303-01A-33
303-01A-34
303-01A-43
303-01A-50
303-01A-60
303-01A-63
303-01A-65
11/2004 2005.25 Fiesta
303-01A-2

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303-01A-2
Page 2 of 2
Engine .............................................................................................................................
303-01A-68
DISASSEMBLY
Engine .......................................................................................................... (21 134 8)
303-01A-80
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES

Cylinder Head............................................................................................... (21 165 6)
303-01A-90
ASSEMBLY
Engine .......................................................................................................... (21 134 8)
303-01A-93
INSTALLATION
Engine .............................................................................................................................
303-01A-105
11/2004 2005.25 Fiesta
303-01A-3

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303-01A-3
SPECIFICATIONS
Engine Data - 1.25L
Description
Code - Stage III
Code - Stage IV
Firing order
Bore
Stroke
Displacement
Compression ratio
Power output at 5700 rpm (Engine codes M7JA/M7JB)
Power output at 5700 rpm (Engine codes FUJA/FUJB)
Torque at 3500 rpm
Maximum permissible engine speed continuous
Maximum permissible engine speed intermittent
Idle speed
Maximum oil consumption
FUJB/M7JA
FUJA/M7JB
1-3-4-2
71.9 mm
76.5 mm
1242 cc
10:1
51 kW (70 PS)
55 kW (75 PS)
110 Nm
5950 rpm
6175 rpm
750 rpm
0.5L/1000km
Engine Data - 1.4L

Description
Code
Firing order
Bore
Stroke
Displacement
Compression ratio
Power output at 5700 rpm
Torque at 3500 rpm
Idle speed
FXJA/FXJB
1-3-4-2
76.0 mm
76.5 mm
1388 cc
11:1
59 kW (80 PS)
124 Nm
6450 rpm
6800 rpm
750 rpm
0.5L/1000km
Engine Data - 1.6L

Description
Engine code
Firing order
Bore
Stroke
Displacement
Compression ratio
Power output at 6000 rpm
Torque at 4000 rpm
Idle speed
Oil pressure
Description
Oil pressure (minimum, oil temperature 80C) at 800 rpm
G154208 en
FYJA/FYJB
1-3-4-2
79.0 mm
81.4 mm
1595 cc
11:1
74 kW (100 PS)
146 Nm
6450 rpm
6800 rpm
750 rpm
0.5L/1000km
bar
1.0
11/2004 2005.25 Fiesta
303-01A-4

TO MODEL INDEX

303-01A-4
Description
Oil pressure (minimum, oil temperature 80C) at 2000 rpm
Pressure relief valve opening pressure
Engine Oil Capacity - 1.25L/1.4L
Description
Initial fill including oil filter
Service fill including oil filter (EFL500)
Service fill excluding oil filter
bar
2.5
4
Liters
4.25
3.75
3.80
3.50
Engine Oil Capacity - 1.6L

Description
Initial fill including oil filter (EFL600)
Initial fill including oil filter (EFL10)
Service fill excluding oil filter
Liters
4.50
4.30
4.25
4.10
3.75
Valve Clearance - 1.25L/1.4L

Description
Valve clearance (engine cold), intake
Valve clearance (engine cold), exhaust
mm
0.17 - 0.23
0.27 - 0.33
Valve Clearance - 1.6L

Description
mm
0.17 - 0.23
0.31- 0.37
Cylinder block - 1.25L

Description
Cylinder bore diameter, class 1
Crankshaft end float
mm
71.900 - 71.910
71.910 - 71.920
71.920 - 71.930
0.300 - 0.800

Description
mm
76.000 - 76.010
76.010 - 76.020
76.020 - 76.030
0.300 - 0.800

Description
mm
79.000 - 79.010
79.010 - 79.020
79.020 - 79.030
0.300 - 0.800
G154208 en
11/2004 2005.25 Fiesta
303-01A-5

TO MODEL INDEX

303-01A-5
Cylinder head
Description
Maximum distortion (mating face)
mm
0.05
Piston -1.25L
Description
Piston diameter, class 1 (uncoated)
Piston ring gaps, upper
Piston ring gaps, middle
Piston ring gaps, lower
Piston ring end float, upper
Piston ring end float, middle
mm
71.875 - 71.885
71.885 - 71.895
71.895 - 71.905
0.170 - 0.270
0.700 - 0.900
0.200 - 0.900
0.040 - 0.080
0.025 - 0.070
Piston -1.4L
Description
mm
75.960 - 75.970
75.970 - 75.980
75.980 - 75.990
0.170 - 0.270
0.700 - 0.900
0.200 - 0.900
0.040 - 0.080
0.025 - 0.070
Piston - 1.6L
Description
Piston diameter, class 1 (coated)
mm
78.975 - 79.005
78.985 - 79.015
78.995 - 79.025
0.180 - 0.280
0.700 - 0.900
0.200 - 0.900
0.040 - 0.080
0.025 - 0.070

Item
Ford Formula E SAE 5W-30 Engine Oil
Sealant, oil pan contact surface to oil seal carrier, oil pan to cylinder block, oil
pan to oil pump
Oil pressure switch sealer (Loctite 243)
Sealant, camshaft bearing cap to cylinder head
Silicone grease
Description
Exhaust flexible pipe to catalytic converter retaining
nuts
Lower arm to wheel knuckle pinch bolt
G154208 en
Specification
WSS-M2C913-B
WSE-M4G323-A4
WSK-M2G349-A7
WSK-M2G348-A2
ESE-M1C171-AA
Nm
44
lb-ft
33
lb-in
-
48
35
11/2004 2005.25 Fiesta
303-01A-6

TO MODEL INDEX

303-01A-6
Description
Intermediate shaft center bearing bracket to cylinder block retaining bolts
Starter motor cable retaining nut
Exhaust manifold heat shield retaining bolts
Ground cable to transaxle retaining bolt
Ground cable to automatic transaxle
Coolant expansion tank retaining bolts
Engine front mount bracket to cylinder block retaining bolts
Engine front mount retaining nuts and bolts
Engine rear mount center retaining nut
Engine rear mount outer retaining nuts
Power steering line support bracket retaining bolts
Power steering line to power steering pump
Air conditioning (A/C) compressor to cylinder block
retaining bolts
Generator to cylinder block top rear and lower retaining bolts
Water pump retaining bolts
Water pump pulley retaining bolts
Oil pump to cylinder block retaining bolts
Oil pan to cylinder block retaining bolts
Oil level indicator tube bracket retaining bolt
Engine oil drain plug
Oil pump pickup pipe to cylinder block retaining
bolts
Oil pressure switch
Cylinder head bolts
Valve cover retaining bolts
Intake manifold to cylinder head retaining bolts
Exhaust manifold to cylinder head
Exhaust manifold to cylinder block
Camshaft position (CMP) sensor
Timing belt rear cover retaining bolts
Spark plugs
Engine rear lifting eye retaining bolts
Coolant distribution housing retaining bolts
Ignition coil to coolant distribution housing
Camshaft bearing cap retaining bolts
Timing belt upper cover to cylinder block retaining
bolts
Timing belt lower cover to cylinder block retaining
bolts
Timing belt tensioner retaining bolts
Camshaft pulley retaining bolt
Crankshaft position (CKP) sensor bracket to cylinder block retaining bolts
Crankshaft rear oil seal carrier retaining bolts
Cylinder block blanking plug
Crankshaft pulley retaining bolt
G154208 en
Nm
24
lb-ft
18
lb-in
-
12
12
47
25
8
55
9
9
35
18
41
71
-
48
90
48
48
25
40
25
35
66
35
35
18
30
18
47
35
9
27
9
20
4
28
9
20
15
21
-
80
80
35
80
15
a)
a)
18
a)
47
9
9
15
20
20
6
a)
9
11
13
35
11
15
15
-
80
80
53
80
80
20
60
9
15
44
-
80
9
20
a)
15
-
80
11/2004 2005.25 Fiesta
303-01A-7

TO MODEL INDEX

303-01A-7
Description
Engine coolant temperature (ECT) sensor
Exhaust manifold studs
Fuel rail to intake manifold
Knock sensor (KS) retaining bolt
Positive crankcase ventilation (PCV) cover retaining bolts
Thermostat housing retaining bolts
Flywheel to crankshaft retaining bolts
Transaxle retaining bolts
Torque converter retaining nuts
Selector lever cable bracket to transaxle
Intermediate shaft center bearing cap retaining nuts
Ground cable to cylinder head retaining bolt
Suspension strut and spring assembly top mount
retaining nuts
Nm
18
10
15
20
9
lb-ft
13
11
15
-
lb-in
89
80
9
a)
47
35
20
25
18
25
35
26
15
18
13
18
80
-
a) Refer to procedure in this section.
G154208 en
11/2004 2005.25 Fiesta
303-01A-8

TO MODEL INDEX

303-01A-8

Engine
1.4L/1.6L Duratec 16V engine
Overview
The 1.4L and 1.6L Duratec 16V inline engines

have already been installed on Focus vehicles
under the name of the Zetec-SE engine.
Details of this engine have been modified. The
routing of the pipes in the intake manifold has
G179017 en
been revised, and for the first time the throttle

valve is electronically controlled.
The intake air routing and the air cleaner housing
have also been changed. The pistons and piston
rings have been modified. The cylinder head
cover is made of plastic.
11/2004 2005.25 Fiesta
303-01A-9

TO MODEL INDEX

303-01A-9

In addition, the auxiliary drive belt is an elastic
multi-groove belt without a separate tensioning
roller.
Engine
Cross-mounted 16-valve DOHC engines with 59

kW (80 PS) and 74 kW (100 PS) respectively.
Valve train with mechanical bucket tappets
Cylinder block and cylinder head made of an
aluminium alloy
Auxiliary drive via a self-tensioning belt without a
belt tensioner
Knock control
PCM with 84 pins and integrated passive anti-theft
system (PATS) immobiliser.
Engine emission control
European emissions level IV

European on-board diagnosis (EOBD) for the
monitoring of emissions-relevant components.
Diagnosis
WDS diagnosis CD B17.

Instrument cluster (engine indicator lamp)
Engine management
Sequential multi-port fuel injection (SFI)
Torque/power
temperature and manifold absolute pressure

(T-MAP) sensor in conjunction with a Siemens
powertrain control module (PCM).
The Duratec 16V engines are characterised by

their high level of running refinement, low
emission levels and balanced development of
power.
G179017 en
11/2004 2005.25 Fiesta
303-01A-10

TO MODEL INDEX

303-01A-10

Description
The basic procedure for installing the camshaft

timing belt pulleys remains the same.
Power curve for the

1.6L-Duratec 16V engine
Power curve for the

It should however be noted that plastic sleeves

are located above the stud on Special Tool
205-072 (15-030 A) in order to protect the
camshaft timing belt pulley against damage.
Torque curve for the

Torque curve for the

Item
Part
Number
Valve train
Item
Part
Number
Description
Camshaft timing belt pulleys,

1.4/1.6L Zetec SE engine
Camshaft timing belt pulleys,

1.4/1.6L Duratec 16V engine
As a significant modification of the valve train, the

camshaft timing belt pulleys are now made of
reinforced plastic. The design has also been
changed in the process.
G179017 en
11/2004 2005.25 Fiesta
303-01A-11

TO MODEL INDEX

303-01A-11

Engine
G17645 en
11/2004 2005.25 Fiesta
303-01A-12

TO MODEL INDEX

303-01A-12
GENERAL PROCEDURES
Valve Clearance Adjustment
General Equipment
Feeler gauges
1. Remove the valve cover.
2.
CAUTION: Only turn the engine in the

normal direction of rotation.
Turn the engine until piston No. 1 is at top

dead center (TDC).
3. NOTE: Note down each cylinder number and
the valve clearances measured.
Using a suitable set of feeler gauges,
measure the valve clearances.
6. NOTE: The number on the tappet indicates the

tappet thickness.
Determine the tappet thickness required:
1. Remove the tappet and read the thickness
from the underside.
2. Tappet thickness required = thickness of
currently installed tappet + the measured
valve clearance - the required valve
clearance. For additional information, refer
to Specifications in this section.
3. Install the correct tappet.
7. NOTE: Do not install the timing belt at this
stage.
Install the camshafts.
8. NOTE: Turn the camshafts to measure the
valve clearances.
Measure the valve clearances and repeat
this procedure as necessary until all valve
clearances are within the specified
tolerance.
9. Install the timing belt.
10. Install the valve cover.
4.
CAUTION: Only turn the engine in the

Turn the engine until each piston is at TDC

and measure the valve clearances.
5. NOTE: Only carry out the following steps when
the valve clearance(s) require adjustment. For
additional information, refer to Specifications in
this section.
Remove the camshafts.
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303-01A-13
IN-VEHICLE REPAIR
Crankshaft Front Seal (21 467 0)
3. Using the special tool, remove the crankshaft front oil seal.
Special Tool(s)
Remover, Crankshaft Oil Seal
303-293 (21-143)
Installer, Crankshaft Oil Seal

303-395 (21-171)
Name
Engine Oil
Specification
WSS-M2C912-A1
Removal
1. Remove the timing belt.
2. Remove the crankshaft timing pulley.
Installation
1. Coat the crankshaft front oil seal lip with
clean engine oil.
2. Using the special tool, install the crankshaft front oil seal.
3. Install the crankshaft timing pulley.
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TO MODEL INDEX
303-01A-14
IN-VEHICLE REPAIR (Continued)

4. Install the timing belt.
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303-01A-15

303-01A-15
IN-VEHICLE REPAIR
Valves (21 215 4)
Special Tool(s)
Compressor, Valve Spring
303-361 (21-155)
3. NOTE: Insert wooden wedges in the

combustion chamber recesses in the cylinder
head so that the valves are held in place for
removal.
Install the special tools.
Adaptor for 303-361

303-361-04 (21-155-04)
Adaptor for 303-361303-361-05 (21-155-05)
Installer, Valve Stem Collets

303-362 (21-156)
4. Remove the valve springs.

Compress the valve springs.
Remove the valve collets.
Remove the valve spring retainers and the
valve springs.
Pliers, Valve Stem Oil Seals

303-508 (21-211)
Name
Engine Oil
Specification
WSS-M2C912-A1
Removal
1. Remove the cylinder head. For additional
information, refer to Cylinder head in this
section.
2.
CAUTION: Keep the valve tappets in

order for reassembly.
Remove the valve tappets.
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303-01A-16

5. Using the special tool, remove the valve
seals.
Discard the valve seals.
4.
CAUTION: The valve seal for the intake

valve is green. The valve seal for the
exhaust valve is brown.
NOTE: Insert wooden wedges in the combustion
chamber recesses in the cylinder head so that the
valves are held in place for installation.
NOTE: Install new valves seals.
NOTE: Coat the valve seal lip and the valve stem
Using the special tool, install the valve
seals.
6. Remove the valves.
Installation
1. Coat the valve stem with clean engine oil.
2. Install the valves.
3. Install a valve stem mounting sleeve over
the valve collet groove (valve shown removed for clarity).
G21048 en
5. Using the special tool, install the valve

springs.
Install the valve spring retainers and the
valve springs.
Compress the valve springs.
Install the valve collets.
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303-01A-17

7.
CAUTION: The valve tappets must be

installed in their original locations.
Install the valve tappets.

8. Install the cylinder head. For additional
information, refer to Cylinder head in this
section.
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303-01A-18
IN-VEHICLE REPAIR
Intake Manifold (21 183 0)
Removal
are always present and may ignite.
Failure to follow these instructions may
1. Release the fuel system pressure. For
310-00.
2. Disconnect the battery ground cable. For
414-01.
3. Remove the air cleaner. For additional
4. Detach the power steering fluid reservoir
from the bracket and position it to one side.

303-05.
6. Remove the intake manifold lower retaining
bolt.
G183728 en
7. Disconnect the engine wiring harness

8. Disconnect the positive crankcase ventilation (PCV) hose from the PCV.
9. Disconnect the brake booster vacuum line

from the intake manifold.
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303-01A-19

10. Disconnect the evaporate emission
(EVAP) hose from the EVAP valve.
11. Disconnect the knock sensor (KS) electrical connector.
12. Detach the oil level indicator tube from

the intake manifold.
G183728 en
13. Disconnect the temperature and manifold

absolute pressure (T-MAP) sensor electrical connector.
14. Disconnect the throttle plate control motor (DC-ISC) electrical connector.
15. Disconnect the generator electrical connector.
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303-01A-20

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303-01A-20

16. Detach the generator from the engine.
1. Remove the bolts.
2. Remove the nut and the stud.

connectors and position it with the engine
wiring harness to one side.
18. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
19. Disconnect the fuel supply line quick release coupling. For additional information,
20. Disconnect the fuel return line quick release coupling. For additional information,
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303-01A-21

21. Detach the fuel line from the intake
manifold and position it to one side.
Remove the cable tie.
22. Remove the fuel supply manifold.

23. Detach the wiring harness and the coolant

hose from the intake manifold.
24. Detach the wiring harness from the intake

manifold.
25. Remove the intake manifold.

Discard the gaskets.
Installation
1. NOTE: Install new intake manifold gaskets.
Install the intake manifold.
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303-01A-22

2. Attach the wiring harness to the intake
manifold.
3. Attach the wiring harness and the coolant

hose to the intake manifold.
5. Connect the fuel return line quick release

coupling. For additional information, refer
to Section 310-00.
6. Connect the fuel supply line quick release

to Section 310-00.
4. NOTE: Install new injector O-ring seals.

NOTE: Coat the O-ring seals with clean engine oil.
Install the fuel supply manifold.
G183728 en
7. Attach the fuel line to the intake manifold.

Install the cable tie.
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303-01A-23

10. Attach the generator to the engine.

1. Install the stud and nut.
2. Install the bolts.
11. Connect the generator electrical connector.
9. Connect the engine coolant temperature

(ECT) sensor electrical connector.
12. Connect the throttle plate control motor
(DC-ISC) electrical connector.
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303-01A-24

13. Connect the temperature and manifold
14. Attach the oil level indicator tube to the

intake manifold.
15. Connect the knock sensor (KS) electrical

connector.
G183728 en
16. Connect the evaporate emission (EVAP)

hose to the EVAP valve.
17. Connect the brake booster vacuum line to

18. Connect the positive crankcase ventilation (PCV) hose to the PCV.
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303-01A-25

19. Connect the engine wiring harness electrical connector.
24. Connect the battery ground cable. For

414-01.
20. Install the intake manifold lower retaining

bolt and the generator bracket retaining
bolts.
21. Install the accessory drive belt. For

303-05.
22. Attach the power steering fluid reservoir
to the bracket.
23. Install the air cleaner. For additional

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303-01A-26
IN-VEHICLE REPAIR
Valve Cover (21 141 0)
Installation
Name
Silicone grease
Specification
ESE-M1C171-AA
Removal
1. NOTE: Check the valve cover gasket for

damage and install a new valve cover gasket if
necessary.
NOTE: Install the stud bolts to positions 5 and 6.
Install the valve cover.
Tighten the bolts in the sequence shown in
three stages.
Stage 1: Tighten bolt 1 by 3 to 4 turns.
Stage 2: Tigthen bolts 1 through 13 to 3 Nm.
Stage 3: Tigthen bolts 1 through 13 to 9 Nm.

414-01.
3. Disconnect the spark plug electrical connectors and detach the wires from the
valve cover.
2.
CAUTION: Use a suitable blunt object to

avoid damage to the spark plug
connector gasket. Coat the inside of
the spark plug connector with silicone
grease to depth of 5-10 mm.
Connect the spark plug electrical connectors and attach the wires to the valve cover.

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303-01A-27

414-01.
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303-01A-28

303-01A-28
IN-VEHICLE REPAIR
Valve Seals (21 238 0)
2. Remove the engine rear lifting eye.
Special Tool(s)
303-361 (21-155)
Adapter for 303-361

303-361-04 (21-155-04)
Adapter for 303-361

303-361-05 (21-155-05)
3.


4. Install the special tools.

303-362 (21-156)
Adapter, Air Supply (Cylinder

Head)
303-363 (21-157)
Pliers, Valve Stem Oil
303-508 (21-211)
5. Apply 7 to 10 bar of compressed air into the
cylinder.
Name
Engine oil
Specification
WSS-M2C912-A1
Removal
1. Remove the camshafts. For additional
information, refer to Camshafts in this
section.
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303-01A-29

springs.
Compress the valve spring.
Remove the valve spring retainer and the
valve springs.
Installation
1. Install a valve stem mounting sleeve over
the valve collet groove (valve shown removed for clarity).
2.

seals.
CAUTION: The intake valve seal are

colored green, and the exhaust valve
seals are colored brown.
NOTE: Install new valve seals.
NOTE: Coat the valve seal lip and the valve stem
seal.
3. Remove the mounting sleeve.
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303-01A-30

4. Using the special tool, install the valve
springs.
Install the valve spring retainer and the
valve springs.
8. Install the camshafts. For additional

section.
6.
CAUTION: The valve tappets must be

installed in their original locations.
Install the valve tappets.

7. Install the engine rear lifting eye.
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303-01A-31
IN-VEHICLE REPAIR
Camshafts (21 284 0)
3.
Special Tool(s)
Universal Flange Holding
Wrench
205-072
Installer, Crankshaft Seal
303-395
Name
CAUTION: Keep the camshaft bearing

caps in order for installation.
Slacken each camshaft bearing cap
retaining bolt in the sequence shown by one
turn until the camshaft is released.
Remove the camshaft bearing caps.
Remove and discard the camshaft seals.
Specification
Sealant
WSK-M2G348-A2
Engine Oil
WSS-M2C912-A1
Removal
1. Remove the timing belt. For additional
information, refer to Timing Belt in this
section.
2.
CAUTION: Install a hose (order no.

E890438S) to the special tool studs, to
prevent damage to the camshaft
pulleys.
Installation
1. Apply sealant to the points indicated on the
camshaft bearing cap no. 1 and to the
mating surface of the cylinder head.
Remove the camshaft pulleys.

Discard the retaining bolts.
2. Coat the camshafts and the camshaft

bearing caps with clean engine oil.
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303-01A-32

3.
CAUTION: Position the camshafts in

place so that none of the cams are at
full lift.
NOTE: The camshaft bearing cap numbering
starts at the timing belt end with E1 on the exhaust
side and with I1 on the intake side.
NOTE: The exhaust camshaft has an additional
cam for the camshaft position (CMP) sensor.
5. NOTE: Install new camshaft seals.

NOTE: Coat the camshaft journals and camshaft
seal lip with clean engine oil.
Using the special tool, install the camshaft
seals.
Install the camshafts and camshaft bearing

caps.
Tighten the camshaft bearing cap retaining
bolts in the sequence shown in three
stages.
Stage 1: One half turn on each bolt until all
of the camshaft bearing caps are in contact
with the cylinder head.
Stage 2: 7 Nm.
6. NOTE: Do not fully tighten the camshaft pulley
retaining bolts at this stage. Make sure the
camshaft pulleys turn on the camshafts.
Install the camshaft pulleys.
7. Install the timing belt. For additional
section.
4. Adjust the valve clearances. For additional

information, refer to Valve Clearance
Adjustment in this section.
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303-01A-33

303-01A-33
IN-VEHICLE REPAIR
Camshaft Seal (21 288 0)
Special Tool(s)
Wrench
205-072
3. Using the special tool, remove the

camshaft seal.
Discard the oil seal.
Remover, Crankshaft Seal

303-293

303-395
Installation
Name
Engine Oil
Specification
WSS-M2C912-A1
Removal
1. NOTE: Install a new camshaft seal.

NOTE: Coat the camshaft journals and camshaft
seal with clean engine oil.
Using the special tool, install the camshaft
oil seal.

section.
2.

pulleys.
2. NOTE: Do not fully tighten the camshaft pulleys

retaining bolts at this stage. Make sure the
camshaft pulleys turn on the camshafts.
NOTE: Install new camshaft pulley retaining bolts.
Install the camshaft timing pulleys.
section.
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303-01A-34

303-01A-34
IN-VEHICLE REPAIR
Timing Belt (21 304 0)
2. Loosen the coolant pump pulley retaining
bolts.
Special Tool(s)
Wrench
205-072
Gauge, Bolt Angle
303-174
Alignment Plate, Camshaft

303-376
Socket, Spark Plug

303-499

(Sigma), Vehicles With: Air Conditioning]
4. Remove the crankshaft pulley.
Timing Peg, Crankshaft TDC

303-507
Locking Tool, Crankshaft

303-748
General Equipment
Trolley jack
Name
Silicone grease
Specification
5. Remove the coolant pump pulley.
ESE-M1C171-AA
Removal
All vehicles
1. Remove the valve cover. For additional
information, refer to Valve Cover in this
section.
G183738 en
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303-01A-35

6. Remove the timing belt cover retaining
bolts.
1. Remove the timing belt upper cover
retaining bolts.
2. Remove the timing belt lower cover
retaining bolts.
Remove the lower cover.
11. Detach the generator from the engine.

1. Loosen the bolt.
2. Remove the bolt.
3. Remove the nut and the stud.
from the bracket and position it to one side.
12.

the bracket and position it to one side.
G183738 en
CAUTION: Do not support the engine

directly on the oil pan.
Place the trolley jack with a wooden block
under the engine and raise it slightly until
the engine front mount is free from strain.
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303-01A-36

13. Remove the engine front mount.
Discard the nuts.
14. Remove the timing belt upper cover.

plugs.
Engines with eccentric cam timing belt tensioner

17. Slacken the timing belt tensioner and
remove the timing belt.
Discard the timing belt.
15. Remove the engine front mount bracket.

18. Remove the timing belt tensioner.
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303-01A-37

Engines with slotted bracket timing belt tensioner
19. Remove the timing belt tensioner and the
timing belt.
2.

pulleys.
NOTE: Make sure the camshaft pulleys turn on
the camshafts.
Loosen the camshaft pulley retaining bolts.
Installation
All vehicles
1. Turn the camshafts to TDC on cylinder
number 1 and install the special tool.
3. NOTE: Install a new timing belt.

NOTE: Install the timing belt, beginning with the
crankshaft timing pulley and work
counterclockwise.
Install the timing belt.
4. Attach the timing belt lower cover.
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303-01A-38

5. Remove the blanking plug and install the
special tool.
Carefully turn the crankshaft against the
special tool.
6. NOTE: Install a new crankshaft pulley retaining

bolt.
8. Install the special tool.

special tool.

9. Install the timing belt tensioner.
Install the crankshaft pulley.

Tighten the crankshaft pulley retaining bolt
in two stages.
Stage 1: 40 Nm.
10. Tension the timing belt.

Tension the timing belt by turning the tensioner counterclockwise until the arrow
points at the mark and tighten the bolt.
7. Remove the special tool.
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303-01A-39

11. Install the timing belt tensioner and
tension the timing belt.
Screw in the bolts finger tight.
Tension the timing belt by turning the tensioner clockwise until the arrow points in
line with the center of the rectangular hole
and tighten the bolt.
13. Remove special tool.
All vehicles
12.

pulleys.
CAUTION: Do not tighten the camshaft

pulley bolts against the timing plate.
NOTE: The camshafts must remain at TDC.
Using the special tool, tighten the camshaft pulleys.
G183738 en
15. NOTE: Only turn the engine in its normal

direction of rotation.
Turn the engine two revolutions.
special tool.
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303-01A-40

17. Check the valve timing.
If necessary loosen the camshaft pulleys
and correct the camshaft alignment.
Remove the special tool.
21. Install the engine front mount bracket.
22. Install the timing belt upper cover.
18. Remove the special tool from the cylinder

block.
19. Install the blanking plug.
23. NOTE: Install new engine front mount

retaining nuts.
Install the engine front mount.

plugs.
24. Remove the trolley jack.
G183738 en
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303-01A-41

25. Attach the generator.
1. Install the stud and nut.
2. Install the bolt.
3. Tighten the bolt.
29. NOTE: Do not tighten the coolant pump pulley

Install the coolant pump pulley.

INSTALLATION, Accessory Drive Belt 1.4L Duratec-16V (Sigma)/1.6L
Conditioning]
31. Tighten the coolant pump pulley retaining
bolts.

28. Install the timing belt upper cover retaining bolts.
32. Install the valve cover. For additional

information, refer to Valve Cover in this
section.
G183738 en
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303-01A-42

to the bracket.
34. Attach the coolant expansion tank to the

bracket.
G183738 en
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303-01A-43

303-01A-43
IN-VEHICLE REPAIR
Exhaust Manifold (21 187 0)
Special Tool(s)
Support Bar, Engine
303-290A (21-140A)

(Sigma)/1.6L Duratec-16V (Sigma)]
4.

support wrap or suitable splint.
Adapter for 303-290A

303-290-01 (21-140-01)

303-290-02 (21-140-02)

303-290-03A (21-140-03A)

Discard the gasket and the nuts.

303-290A-14
General Equipment
Exhaust wrap
Removal
6. Detach the exhaust system insulators from

the exhaust brackets and position it to one
side.

GENERAL PROCEDURES, Battery
Disconnect]
information, refer to Section 303-12.[Intake
Air Distribution and Filtering, REMOVAL
AND INSTALLATION, Air Cleaner - 1.25L
G183739 en
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303-01A-44

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303-01A-44

7. Remove the engine support insulator retaining bolt.
11. Disconnect the heated oxygen (HO2S)

8. Remove the exhaust manifold lower heat

shield left-hand retaining bolts.
12. Disconnect the catalyst monitor sensor


shield right-hand retaining bolts.
Remove the lower heat shield.
13. Detach the power steering line support

bracket from the cylinder head.
G183739 en
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303-01A-45

from the bracket and position it to one
side.

G183739 en

Discard the nuts.
18. Using the special tools lower the engine.
19. Remove the exhaust manifold upper heat

shield.
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TO MODEL INDEX
303-01A-46

20. Remove the exhaust manifold retaining
bolts and the nuts.
Discard the nuts.

22. Remove the exhaust manifold.
Discard the gasket.
4. Tighten the exhaust manifold upper

retaining nuts and bolt in the sequence
shown in two stages.
Stage 1: 20 Nm.
Stage 2: 55 Nm.
5. Tighten the exhaust manifold lower retaining bolts.
Installation
1. NOTE: Install a new exhaust manifold gasket.
Attach the exhaust manifold to the cylinder
head.
3. NOTE: Install a new exhaust manifold gasket
and new exhaust manifold retaining nuts.
NOTE: Do not fully tighten the nuts and bolt at this
stage.
Install the exhaust manifold.
6. Install the exhaust manifold upper heat
shield.
G183739 en
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303-01A-47

7. Using the special tools, raise the engine.
8. NOTE: Install new engine front mount retaining

nuts.
G183739 en

bracket.

to the bracket.
12. Attach the power steering line bracket to

the cylinder head.
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TO MODEL INDEX
303-01A-48

13. Connect the catalyst monitor sensor
17. Install the exhaust manifold lower heat

14. Connect the heated oxygen (HO2S) sensor electrical connector.
18. Install the engine support insulator retaining bolt.

16. Position the exhaust manifold lower heat
shield and install the right-hand retaining
bolt.
19. Attach the exhaust system insulators to

the exhaust brackets.
and new nuts.
21. Remove the exhaust flexible pipe support

wrap or splint.
G183739 en
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303-01A-49

303-12.[Intake Air Distribution and
Filtering, REMOVAL AND INSTALLATION,
Air Cleaner - 1.25L Duratec-16V
Duratec-16V (Sigma)]
Disconnect]
G183739 en
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303-01A-50
IN-VEHICLE REPAIR
Cylinder Head (21 163 0)
Special Tool(s)
Socket, Cylinder Head Bolts
303-392 (21-167)

Discard the gasket and the nuts.
Clamp
303-397 (24-003)
Name
Engine oil
Specification
WSS-M2C912-A1
Removal
310-00.[Fuel System - General Information,
GENERAL PROCEDURES, Fuel System
Pressure Release]
2. Drain the cooling system. For additional
(Rocam)/1.4L Duratec-16V (Sigma)/1.6L
Duratec-16V (Sigma), GENERAL
PROCEDURES, Cooling System Draining,
Filling and Bleeding - 1.25L Duratec-16V
(Sigma)/1.3L Duratec-8V (Rocam)/1.4L
(Sigma)]
3. Remove the camshaft. For additional
section.
G183740 en

6. Using a suitable splint or wrap support the
exhaust flexible pipe.

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303-01A-51

Remove the lower heat shield.
9. Remove the intake manifold retaining bolt.

11. Disconnect the vacuum hose from the
fuel pressure regulator.
G183740 en
12. Disconnect the brake booster vacuum

line from the intake manifold.
13. Disconnect the positive crankcase ventilation (PCV) hose from the PCV.
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303-01A-52

15. Disconnect the evaporative emissions
(EVAP) hose from the EVAP valve.
refer to Section 310-00.[Fuel System General Information, GENERAL
PROCEDURES, Quick Release Coupling]

17. Disconnect the EVAP valve electrical

connector.

coolant hose from the coolant distribution
assembly.
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303-01A-53

assembly.
22. Using the special tool, detach the degas

hose from the cylinder head.
Using the special tool, detach the degas
hose from the cylinder head.
23. Disconnect the engine coolant temperature (ECT) electrical connector.
G183740 en


Detach the electrical connector from the
bracket.

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303-01A-54

shield
28. Detach the exhaust manifold and position

it to one side.
Discard the nuts and the exhaust manifold
gasket.
30. Detach the oil level indicator tube from

31.
CAUTION: The cylinder head must

have cooled to below 30C before
removal.
CAUTION: Position the cylinder head on a
soft surface.
CAUTION: Remove the cylinder head
bolts in the sequence shown.
cylinder head bolts.
Discard the cylinder head gasket.
29. Remove the timing belt rear cover (engine

G183740 en
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303-01A-55

Installation
2. Attach the oil level indicator tube to the

intake manifold.
1.
CAUTION: The thickness of the new

cylinder head gasket must be the same
as that of the old one (hole marked).
NOTE: Install a new cylinder head gasket.
NOTE: Position the cylinder head into the two
guide sleeves.
Using the special tool, install the cylinder
head.
Tighten the cylinder head bolts in the
sequence shown in three stages.
Stage 1: 15 Nm.
Stage 2: 30 Nm.
3. Install the timing belt rear cover (engine


stage.
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303-01A-56

Stage 1: 20 Nm.
Stage 2: 55 Nm.

shield.
G183740 en
8. Attach the power steering line bracket to

the cylinder head.
9. Connect the heated oxygen (HO2S) sensor

Attach the electrical connector to the
bracket.
10. Connect the electronic ignition (EI) coil

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303-01A-57

12. Using the special tool, connect the degas

hose to the cylinder head.
14. Using the special tool, connect the coolant hose to the coolant distribution assembly.

to Section 310-00.[Fuel System - General
Quick Release Coupling]
13. Using the special tool, connect the coolant hose to the coolant distribution assembly.
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303-01A-58

17. Connect the evaporate emission (EVAP)
valve electrical connector.
20. Connect the vacuum hose to the fuel

pressure regulator.
19. Connect the EVAP hose to the EVAP

valve.
22. Connect the positive crankcase ventilation (PCV) hose to the PCV.
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25. Install the intake manifold retaining bolt.

28. NOTE: Install a new flexible pipe gasket and

new nuts.
Attach the flexible pipe to the catalytic
converter
26. Position the exhaust manifold lower heat

shield and install the right-hand retaining
bolts.
29. Remove the exhaust flexible pipe support.

30. Install the camshaft. For additional
section.
31. NOTE: Install a new oil filter.
Change the engine oil.
32. Fill and bleed the cooling system. For
(Sigma)]
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303-01A-60

303-01A-60
IN-VEHICLE REPAIR
Oil Pan (21 154 0)
3.
Special Tool(s)
Slide Hammer
205-047 (15-011)
Adapter for 205-047

303-633 (21-227)
CAUTION: In order to prevent damage

to the sealing surfaces, only use the
designated special tool to remove the
oil pan. Do not use a chisel or a
screwdriver for removal.
NOTE: Tighten the lock nut against the oil pan and
use several taps to release the oil pan from the
cylinder block.
Using the special tool, remove the oil pan.
General Equipment
Five M8 x 20 mm studs
Name
Engine oil
Specification
WSS-M2C912-A1
Loctite 7070
Sealant
WSE-M4G323-A4
Removal
100-02.
2. Drain the engine and remove the oil pan
retaining bolts.
1. Remove the oil drain plug.
2. Remove the oil pan retaining bolts.
Installation
1.
CAUTION: The oil pump gasket projects

over the cylinder block sealing surface
and must not be damaged.
CAUTION: Do not damage the rubber
sealing surface of the crankshaft rear oil
seal carrier.
Using Loctite 7070, clean the engine
cylinder block and oil pan mating faces.
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2.
CAUTION: The crankcase may be

damaged if sealant enters the blind
holes.
Install five M8 x 20 mm studs into the blind
holes where shown.
4. NOTE: Align the oil pan flush with the cylinder

block at the transaxle end.
Install the oil pan.
Tighten the oil pan retaining bolts in the
sequence shown in two stages.
Stage 1: 10 Nm.
Stage 2: 20 Nm.
Remove the studs and install retaining
bolts.
3. NOTE: Install the oil pan within ten minutes of

applying sealant and tighten the bolts within a
further 5 minutes.
Apply a 3-4 mm diameter bead of sealant to
the oil pan flange.
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5. NOTE: Check the oil drain plug seal for damage
and install a new drain plug if necessary.
Install the oil drain plug.
6. Fill the engine with engine oil.
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303-01A-63
IN-VEHICLE REPAIR
Oil Pump (21 714 0)
Special Tool(s)
Installer, Crankshaft Oil Seal
303-395 (21-171)
5. Detach the oil pick-up tube from the oil

pump and remove the oil pump (engine
Remove and discard the crankshaft front oil
seal.
Removal
section.
2. Remove the crankshaft timing belt pulley.
Installation
1. NOTE: Install a new oil pump gasket.
Install the oil pump (engine shown removed for clarity).
3. Detach the air conditioning (A/C) compressor from the cylinder block and position it to one side.
4. Remove the oil pan. For additional

information, refer to Oil Pan in this section.
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2. NOTE: Install a new oil pump intake pipe
gasket.
6. Install the crankshaft timing belt pulley.
Attach the oil pick-up tube to the oil pump

(engine shown removed for clarity).

section.
3. NOTE: Install a new crankshaft front oil seal.
Using the special tool, install the crankshaft front oil seal.
4. Install the oil pan. For additional

5. Attach the air conditioning (A/C) compressor to the cylinder block.
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303-01A-65

303-01A-65
IN-VEHICLE REPAIR
Crankshaft Rear Seal (21 468 4)
Special Tool(s)
Locking Tool, Flywheel
303-393 (21-168)

flexplate.
Discard the bolts.
Gauge, Bolt Angle

303-174 (21-540)
Removal
1. Remove the clutch disc and pressure plate.
308-01.[Clutch, REMOVAL AND
INSTALLATION, Clutch Disc and Pressure
Plate]
2. Using the special tool, remove the flywheel.
Discard the bolts.
All vehicles
4. Remove the crankshaft rear oil seal carrier.
Discard the crankshaft rear oil seal carrier.
Installation
All vehicles
1. Clean the crankshaft journal.
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2. NOTE: Install a new crankshaft rear oil seal
carrier.
NOTE: A new crankshaft rear oil seal carrier is
supplied with an alignment sleeve which must be
removed following installation.
NOTE: Do not lubricate the oil seal or crankshaft
journal.
Install the crankshaft rear oil seal carrier.

3. NOTE: Position of location stud for the flywheel.
NOTE: Install new flywheel retaining bolts.
Using the special tool, install the flywheel.
two stages:
Stage 1: 30 Nm.
4. Install the clutch disc and pressure plate.

Plate]
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5. NOTE: Position of location stud for the
flexplate.
NOTE: Install new flexplate retaining bolts.
Using the special tool, install the flexplate.
two stages:
Stage 1: 30 Nm.
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REMOVAL
Engine
Special Tool(s)
Nut
211-269 (13-027)
Lifting Bracket, Engine

303-122 (21-068A)
Clamp
303-397 (24-003)
Remover, Halfshaft
308-256 (16-089)
General Equipment
Engine hoist
Securing straps
Workshop table
Removal

(Sigma)]
(Sigma)]
5. Disconnect the powertrain control module
(PCM) electrical connector. For additional
303-14.[Electronic Engine Controls,
REMOVAL AND INSTALLATION,
Powertrain Control Module (PCM) - 1.25L
mount nuts by three turns on both sides.
All vehicles
Pressure Release]
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REMOVAL (Continued)

from the bracket and position it to one
side.

degas hose from the cylinder head.

9. Detach the fuel line and the degas line from

Remove the cable tie.
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REMOVAL (Continued)
housing.

hose from the coolant distribution housing.



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REMOVAL (Continued)
19. Disconnect the EVAP electrical connector.
20. Disconnect the low pressure evaporate

emission (EVAP) hose from the EVAP
valve.
23. Disconnect the generator electrical connectors.
21. Detach the brake booster vacuum line

G113163 en
24. Remove the right-hand headlamp

assembly. For additional information,
refer to Section 417-01.[Exterior Lighting,
Headlamp Assembly]
25. Disconnect the air conditioning (A/C)
lower-pressure cut-off switch electrical
connector.
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303-01A-72
REMOVAL (Continued)
26. Remove the engine wiring harness support bracket.

bracket from the cylinder head.
27. Disconnect the engine coolant temperature (ECT) electrical connector.


31. Disconnect the engine ground cable.
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REMOVAL (Continued)
33. Disconnect the A/C compressor clutch

34. Disconnect the A/C high-pressure cut-off

switch electrical connector.
37. Disconnect the reversing lamp switch

35. Disconnect the oil pressure switch electrical connector.
38. Disconnect the ignition switch to starter

motor solenoid and battery to starter
motor solenoid cables.
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REMOVAL (Continued)
39.

42. Detach the A/C compressor from the cylinder block and position it to one side.

suitable support wrap or suitable splint.

bracket from the engine block.
Discard the nuts and the gasket.
44. Disconnect the power steering line from

the steering pump.
Conditioning]
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303-01A-75
REMOVAL (Continued)
45. Using the special tool, detach the power
steering line from the power steering
pump.

coolant hose from the radiator.

coolant hose from the distribution pipe
46. Disconnect the cooling fan motor and
cooling fan resistor electrical connectors.
47. Remove the cooling fan motor and

shroud.
1. Release the cooling fan motor and shroud
from the retaining brackets.
2. Push the cooling fan motor and shroud
upwards and then downwards to remove.
G113163 en
50. Detach the lower arm from the wheel

knuckle on both sides (right-hand side
shown).
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303-01A-76
REMOVAL (Continued)
51.

52.


seal.
ingress.

seal.
ingress.
Using the special tool, detach the

left-hand halfshaft from the transaxle and
secure it to one side.
container.
Detach the right-hand halfshaft and the

intermediate shaft from the transaxle and
Discard the center bearing cap and
locknuts.
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REMOVAL (Continued)
Vehicles with automated gearshift
54. Remove the gearshift actuator cover.
57.

water.
Disconnect the clutch slave cylinder
supply line.
Remove the spring clip.
55. Disconnect the gearshift actuator electrical connector (colored black).
Vehicles without automated gearshift

58.

water.
supply line.
56. Disconnect the gearshift actuator electrical connector (colored gey).
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REMOVAL (Continued)
59. Remove the gearshift cables cover.
All vehicles
61.
CAUTION: Do not support the engine

directly on the oil pan.
NOTE: Using suitable securing straps, secure the
engine and the transaxle on a workshop table.
Using suitable wooden blocks support
the engine and transaxle assembly.
60. Detach the gearshift cables from the

transaxle.
Detach the gearshift cables and the selector
cable from the selector levers.
Turn the abutment sleeve clockwise and
detach the cables from the bracket.
62. Remove the battery tray support bracket.
63. Remove the engine rear mount.

Discard the nuts.
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303-01A-79
REMOVAL (Continued)
Discard the nuts.
68. Remove the transaxle right-hand retaining bolt.
65. Raise the vehicle and remove the engine

and transaxle assembly.
66. Using the special tool, attach the engine
and transaxle assembly to the engine
hoist.
69. Remove the transaxle lower retaining

bolts.
70. Remove the transaxle from the engine.
67. Remove the starter motor and the transaxle left-hand retaining bolt.
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DISASSEMBLY
Engine (21 134 8)
General Equipment
Securing straps
Special Tool(s)
Engine hoist
Slide Hammer
205-047 (15-011)

Wrench
205-072 (15-030A)
Oil filter strap wrench

All vehicles
1. Remove the engine wiring harness.
Socket, Cylinder Head Bolt

303-392 (21-167)

303-393 (21-168)
Mounting Stand
303-435 (21-187)

Mounting Bracket for 303-435

303-435-06 (21-031B)
Mounting Plate for

303-435-06
303-435-14A (21-212A)
Socket, Spark Plug
303-499 (21-202)
Adapter for 205-047

303-633 (21-227)
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DISASSEMBLY (Continued)
shield.
7. Install the mounting bracket to the mounting plate.
5. Remove the catalytic converter.

Discard the gasket.
8. Install the engine to the mounting stand.
6. Install the mounting plate to the engine.
G154224 en
9. Drain the engine oil.

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10. Using a suitable oil filter strap wrench,
remove the oil filter.
Discard the oil filter.
14. Remove the engine front mount bracket.

12. Remove the generator.
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303-01A-83
15. Remove the timing belt upper cover.
17. Disconnect the spark plug electrical

connectors and detach the wires from the
valve cover.
16. Remove the fuel supply and return lines.

plugs.
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303-01A-84
20. Using the special tool, lock the crankshaft.

Discard the bolt.
22. Remove the timing belt lower cover.
G154224 en

23. Slacken the timing belt tensioner and
remove the timing belt.
24. Remove the timing belt tensioner.

25. Remove the timing belt tensioner and the
timing belt.
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All vehicles
26.

sprockets.
29.

caps and the camshafts in order for
installation.
Slacken each camshaft bearing cap
retaining bolt in the sequence shown by one
turn until the camshaft is released.
Remove and discard the camshaft seals.
27. Remove the crankshaft timing belt pulley.

30. Disconnect the positive crankcase ventilation (PCV) hose from the PCV cover.
28. Remove the timing belt rear cover.
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31. Detach the oil level indicator and tube
Detach the knock sensor (KS) electrical
connector from the oil level indicator tube.
33.
CAUTION: Place the cylinder head on

a suitable soft surface.
cylinder head.
Discard the gasket.
32. Remove the intake manifold lower bolts.
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34.
CAUTION: Do not damage the coolant

pump impeller.
37. Remove the the PCV cover.
Remove the coolant pump.

Discard the gasket.
35. Remove the thermostat housing.

Discard the gasket.
39.
36. Remove the KS.
CAUTION: In order to prevent damage

to the sealing surfaces, only use the
designated special tool to remove the
oil pan. Do not use a chisel or
screwdriver for removal.
NOTE: Tighten the lock nut against the oil pan and
use several taps to release the oil pan from the
cylinder block.
Using the special tool, remove the oil pan.
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40. Remove the oil pump pickup pipe.
Discard the gasket.
41. Remove the oil pump.

Discard the gasket.

42. Remove the clutch disc and pressure
Section 308-01.[Clutch, REMOVAL AND
Plate]
G154224 en

flywheel.
Discard the bolts.

flexplate.
Discard the bolts.
All vehicles
45. Remove the crankshaft position (CKP)
sensor.
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303-01A-89
46. Remove the CKP sensor bracket.
47. Remove the crankshaft rear seal carrier.

Discard the crankshaft rear seal carrier.
48. Detach the cylinder block (short block)

from the mounting stand.
Remove the special tools.
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303-01A-90

Disassembly
1. Disconnect the temperature and manifold
2. Disconnect the throttle plate control motor


connectors.
G202085 en
4. Remove the engine wiring harness.

5. Remove the fuel supply manifold.

7. Remove the engine rear lifting eye.
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303-01A-91
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

8. Remove the coolant distribution housing
and the ignition coil (EI).
Discard the gasket.
2. NOTE: Install a new camshaft position (CMP)

O-ring seal.
9. Remove the camshaft position (CMP)

sensor.
3. NOTE: Install a new coolant distribution

housing gasket.
Install the CMP sensor.
Install the coolant distribution housing and

the ignition coil (EI).
Assembly
4. Install the engine rear lifting eye.
1. NOTE: A new cylinder head is supplied without

exhaust manifold studs.
Install the exhaust manifold studs if necessary.
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303-01A-92

5. NOTE: Install new intake manifold gaskets.
Install the intake manifold.
6. NOTE: Install new fuel supply manifold O-ring

seals.
Install the fuel supply manifold.
9. Connect the throttle plate control motor

10. Connect the temperature and manifold

7. Install the engine wiring harness.

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303-01A-93

303-01A-93
ASSEMBLY
Engine (21 134 8)
Special Tool(s)
303-435-06 (21-031B)
Special Tool(s)
Wrench
205-072 (15-030A)
Mounting Plate for

303-435-06
303-435-14A (21-212A)

303-122 (21-068A)
Socket, Spark Plug

303-499 (21-202)
Gauge, Bolt Angle
303-174 (21-540)

303-393 (21-168)
Locking Tool, Crankshaft

303-748 (21-259)
General Equipment
Five M8 x 20 mm studs
Engine hoist

303-376 (21-162B)
Socket, Cylinder Head Bolt

303-392 (21-167)

303-395 (21-171)
Name
Specification
Engine Oil - 5W-30

WSS-M2C913-B
Silicone Sealant
WSE-M4G323-A4
Sealant
WDK-M2G349-A7
Sealant
WSK-M2G348-A2
All vehicles
1. Attach the cylinder block (short block) to
the mounting stand.
Install the special tools.
Mounting Stand
303-435 (21-187)
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303-01A-94
303-01A-94
ASSEMBLY (Continued)
2. NOTE: Install a new crankshaft rear seal
carrier.
NOTE: A new crankshaft rear seal carrier is
supplied with an alignment sleeve which must be
removed following installation.
NOTE: Do not lubricate the seal lip.
Install the crankshaft rear seal carrier.

5. NOTE: Install new flywheel retaining bolts.
Using the special tool, install the flywheel.
two stages.
Stage 1: 30 Nm.
3. Install the crankshaft position (CKP) sensor bracket.
4. Install the CKP sensor.
G154225 en

Plate]
7. Remove the special tool from the flywheel.
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303-01A-95
8. NOTE: Install new flexplate retaining bolts.
11. NOTE: Install a new pickup pipe gasket.

Install the oil pump pickup pipe.
Using the special tool, install the flexplate.

two stages.
Stage 1: 30 Nm.
12. Coat the crankshaft front seal lip with

clean engine oil.
13. Using the special tool, install the crankshaft front seal.
9. Remove the special tool from the flexplate.

All vehicles
10. NOTE: Install a new oil pump gasket.
Install the oil pump.
G154225 en
14.
CAUTION: The crankcase may be

damaged if sealant enters the blind
holes.
Install five M8 x 20 mm studs into the
blind holes as shown.
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303-01A-96
15. NOTE: Attach the oil pan within ten minutes of
applying sealant and tighten the bolts within a
further five minutes.
17. NOTE: Inspect the oil pan drain plug seal for
damage. Install a new drain plug and seal if
required.
Apply a 3 to 4 mm diameter thick bead of

sealant to the oil pan flange.
16. NOTE: Align the oil pan so that the cylinder

block is flush with the oil pan on the flywheel
side.
Install the drain plug.
18. Install the positive crankcase ventilation

(PCV) cover.
Install the oil pan, loosely install the

retaining bolts.
Remove the studs and install retaining
bolts.
Tighten the oil pan retaining bolts in the
sequence shown in two stages.
Stage 1: 10 Nm.
Stage 2: 20 Nm.
19.
CAUTION: The knock sensor (KS)

cable must not touch the cylinder head
or the PCV cover. Position the KS
cable at approximately the 10 o'clock
position.
Install the KS.
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303-01A-97
20. NOTE: Install a new thermostat housing
gasket.
Install the thermostat housing.
23. Turn the crankshaft to approximately 25

mm before top dead center (BTDC) on
cylinder number 1.
24.
CAUTION: The thickness of the new

cylinder head gasket must be the same
as that of the old one (hole marked).
NOTE: Install a new cylinder head gasket.
NOTE: Position the cylinder head onto the two
guide sleeves.

Apply sealant to the oil pressure switch
threads.
Using the special tool, install the cylinder

head.
sequence shown in three stages.
Stage 1: 15 Nm.
Stage 2: 30 Nm.
22.
CAUTION: Do not damage the coolant

pump impeller.
NOTE: Install a new coolant pump gasket.
Install the coolant pump.
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303-01A-98
25. Install the intake manifold lower retaining
bolts.
28. NOTE: Identification numbers are provided on

the outer face of the camshaft bearing caps.
Apply sealant to the points indicated on
the camshaft bearing cap no. 1 and to the
mating surface of the cylinder head.
26. Attach the oil level indicator tube.

Attach the KS electrical connector to the oil
level indicator tube.
29. Coat the camshafts and the camshaft
bearing caps with clean engine oil.
CAUTION: Position the camshafts in
place so that none of the cams are at
full lift.
NOTE: The camshaft bearing cap numbering
starts at the timing belt end with E1 on the exhaust
side and with I1 on the intake side.
NOTE: The exhaust camshaft has an additional
cam for the camshaft position (CMP) sensor.
30.
27. Connect the PCV hose to the PCV cover.
G154225 en
Install the camshafts and camshaft

bearing caps.
Tighten the camshaft bearing cap retaining
bolts in the sequence shown in three
stages.
Stage 1: One half turn on each bolt until all
of the camshaft bearing caps are in contact
with the cylinder head.
Stage 2: 7 Nm.
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303-01A-99
31. Coat the camshaft journals and seal lips
32. NOTE: Install new camshaft seals.
Using the special tool, install the camshaft seals.
33. Install the timing belt rear cover.
35. NOTE: Do not fully tighten the camshaft timing

pulley retaining bolts at this stage. Make sure
the camshaft pulleys turn on the camshafts.
Install the camshaft timing pulleys.
36. Install the crankshaft timing belt pulley.
37. NOTE: Install a new timing belt.

NOTE: Install the timing belt, beginning with the
crankshaft timing pulley working
counterclockwise.
Install the timing belt.
38. Install the timing belt lower cover.
34. Turn the camshafts to top dead center

(TDC) on cylinder number 1 and install the
special tool.
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303-01A-100
39. Remove the blanking plug and install the
special tool.
special tool.
40. NOTE: Install a new crankshaft pulley

retaining bolt.
Install the crankshaft pulley.
Tighten the crankshaft pulley retaining bolt
in two stages.
Stage 1: 40 Nm.
42. Tension the timing belt.

Tension the timing belt by turning the tensioner counterclockwise until the arrow
points at the mark and tighten the bolt.

43. Install the timing belt tensioner and
tension the timing belt.
Install the bolts finger tight.
Tension the timing belt by turning the tensioner clockwise until the arrow points in
line with the center of the rectangular hole
and tighten the bolts.

41. Install the timing belt tensioner.
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303-01A-101
All vehicles
44.

pulleys.
pulley bolts against the timing plate.
47. NOTE: Only turn the crankshaft in its normal

Turn the crankshaft two revolutions.
special tool.
Using the special tool, tighten the camshaft pulleys.
49. Check the valve timing.

If necessary loosen the camshaft pulleys
and correct the camshaft alignment.
G154225 en

51. Install the blanking plug.
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303-01A-102
52. Check the valve clearances, adjust if
refer to Valve Clearance Adjustment in
this section.
plugs.
54. NOTE: Install the stud bolts to positions 5 and

6.
three stages.
Stage 1: Tighten bolt 1 by 3 to 4 turns.
Stage 2: Tighten bolts 1 through 13 to 3 Nm.
Stage 3: Tighten bolts 1 through 13 to 9 Nm.
G154225 en
55.
CAUTION: Use a suitable blunt object

to avoid damage to the spark plug
connector gasket. Coat the inside of
the spark plug connector with silicone
grease to a depth of 5-10 mm.
Connect the spark plug electrical connectors and attach the wires to the valve
cover.
56. Install the timing belt upper cover.
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303-01A-103
57. Install the engine front mount bracket.
60. NOTE: Install a new oil filter.

Install the oil filter.
58. Install the coolant pump pulley.

61. Install the engine wiring harness.
62. Using the special tool attach the engine to
an engine hoist.
59. Install the generator.
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303-01A-104
stage.

shield.

Stage 1: 20 Nm.
Stage 2: 55 Nm.

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303-01A-105

303-01A-105
INSTALLATION
Engine
2. Install the transaxle lower retaining bolts.
Special Tool(s)
Nut
211-269 (13-027)

303-122 (21-068A)
3.
Clamp
303-397 (24-003)
WARNING: Support the engine and

transaxle assembly on wooden blocks
and secure it with suitable securing
straps.
Using the special tool and the engine hoist
position the engine and transaxle assembly on the workshop table.
General Equipment
Securing straps
Workshop table
Engine hoist
Installation
All vehicles
1.
4. Install the transaxle right-hand retaining

bolt.
CAUTION: Make sure that the two

locating dowels are installed.
Install the transaxle to the engine.
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303-01A-106
INSTALLATION (Continued)
5. Install the starter motor and the transaxle
left-hand retaining bolt.
9. NOTE: Install new engine rear mount retaining

nuts.
NOTE: Do not tighten the engine rear mount
center retaining nut at this stage.
Install the engine rear mount.

7. Position the engine and transaxle
assembly in the engine compartment.
Carefully lower the vehicle.
8. NOTE: Install new engine front mount retaining
nuts.
NOTE: Do not tighten the engine front mount
retaining bolts and nuts at this stage.
10. Install the battery tray support bracket.
11. Install the engine rear support insulator.
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303-01A-107
12.

14. Attach the lower arm to the wheel knuckle

on both sides (right-hand side shown).

seal.
NOTE: Install a new center bearing cap and
locknuts.
Attach the right-hand halfshaft and the
intermediate shaft to the transaxle.
15. Using the special tool, connect the coolant hose to the distribution pipe
13.

seal.

correctly seated.
16. Using the special tool, connect the coolant hose to the radiator.
Attach the left-hand halfshaft to the

transaxle.
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303-01A-108
17. Connect the A/C high-pressure cut-off
20. Using the special tool, attach the power

steering line to the power steering pump.
18. Install the cooling fan motor and shroud.

upwards and then downwards to install.
2. Install the cooling fan motor and shroud to
the retaining brackets.
21. Connect the power steering line to the

steering pump.
22. Attach the power steering line support

bracket to the engine block.
19. Connect the cooling fan motor and cooling fan resistor electrical connectors.
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303-01A-109
24. Connect the A/C compressor clutch electrical connector.

Conditioning]
26. Connect the starter motor electrical connectors.
G113164 en
27. Connect the reversing lamp switch electrical connector.
28. Connect the crankshaft position (CKP)


connector.
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303-01A-110
30. NOTE: Install new exhaust flange nuts and a
new exhaust flange gasket.

32.

water.
NOTE: Make sure the spring clip is correctly
seated.
Connect the clutch slave cylinder supply
line.
Install the spring clip.
31. Remove the exhaust flexible pipe support.
33. Attach the gearshift cables to the bracket

and turn the abutment sleeves counterclockwise.
34. NOTE: Do not install the air cleaner at this

stage.
Adjust the gearshift cable. For additional
308-00.[Manual Transmission/Transaxle
and Clutch - General Information,
GENERAL PROCEDURES, Gearshift
Cable Adjustment]
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303-01A-111
35. NOTE: Do not install the air cleaner at this
stage.
38. Install the gearshift actuator cover.
Bleed the hydraulic clutch system. For

GENERAL PROCEDURES, Clutch System
Bleeding]
36. Connect the gearshift actuator electrical
connector (colored grey).
39. Connect the clutch slave cylinder supply

line.

connector (colored black).
40. Bleed the hydraulic clutch system.

All vehicles
42. Tighten the engine front mount retaining
nuts and bolts.
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303-01A-112
43. NOTE: Install a new engine rear mount center
retaining nut.
Tighten the engine rear mount center retaining nut.
44. Attach the power steering line support

bracket to the cylinder head.
45. Attach the power steering line to the

G113164 en
46. Install the engine wiring harness support

brackets.
Connect the engine ground cable.
47. Connect the electronic ignition (EI) coil


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303-01A-113
49. Connect the generator electrical connectors.
53. Connect the evaporative emission (EVAP)

50. Connect the air conditioning (A/C)

lower-pressure cut-off switch electrical
connector.
51. Install the right-hand headlamp assembly.

Section 417-01.[Exterior Lighting,
Headlamp Assembly]
connector.
G113164 en
55. Connect the power steering pressure

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303-01A-114
57. Connect the heated oxygen sensor

(HO2S) electrical connector.
58. Using the special tool, connect the coolant hose to the coolant distribution
housing.
G113164 en
59. Using the special tool, connect the coolant hose to the coolant distribution
housing.
60. Attach the brake booster vacuum line to

61. Connect the low-pressure EVAP hose.
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303-01A-115

65. Using the special tool, connect the degas

hose to the cylinder head.
66. Attach the fuel line and the degas line to

Install the cable tie.

to the bracket.

bracket.
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303-01A-116
mount nuts on both sides.
69. Connect the powertrain control module

(PCM) electrical connector. For additional
303-14.[Electronic Engine Controls,
Powertrain Control Module (PCM) - 1.25L
71. Install the front wheels and tires. For
72. Fill the engine cooling system. For
(Sigma)]
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303-01B-1
Engine 2.0L Duratec-HE (MI4)
303-01B-1
Page 1 of 2
SECTION 303-01B Engine 2.0L Duratec-HE (MI4)

CONTENTS
PAGE
SPECIFICATIONS
Specifications.................................................................................................................
Engine Data ..................................................................................................................
Engine Oil .....................................................................................................................
Oil system .....................................................................................................................
Engine Oil Capacity.......................................................................................................
Valve Dimensions .........................................................................................................
Camshaft Dimensions ...................................................................................................
Crankshaft Dimensions .................................................................................................
Piston Dimensions ........................................................................................................
Cylinder Head ...............................................................................................................
Cylinder Block ...............................................................................................................
303-01B-3
303-01B-3
303-01B-3
303-01B-3
303-01B-3
303-01B-4
303-01B-4
303-01B-4
303-01B-4
303-01B-4
303-01B-4

Engine ...........................................................................................................................
303-01B-6

Engine ...........................................................................................................................
303-01B-13
GENERAL PROCEDURES
Valve Clearance Adjustment ..........................................................................................
303-01B-14
IN-VEHICLE REPAIR
Intake Manifold..............................................................................................(21 183 0)
Crankshaft Front Seal ...................................................................................(21 467 0)
Crankshaft Pulley..........................................................................................(21 572 0)
Valve Seals...................................................................................................(21 238 0)
Valves ...........................................................................................................(21 215 4)
Camshafts.....................................................................................................(21 284 0)
Oil Pan..........................................................................................................(21 154 0)
Oil Pump .......................................................................................................(21 714 0)
Crankshaft Rear Seal....................................................................................(21 468 4)
Engine Front Cover .......................................................................................(21 148 0)
Exhaust Manifold ...........................................................................................................
Timing Chain.................................................................................................(21 314 0)
Cylinder Head ...............................................................................................(21 163 0)
303-01B-18
303-01B-22
303-01B-23
303-01B-33
303-01B-35
303-01B-37
303-01B-48
303-01B-53
303-01B-55
303-01B-60
303-01B-64
303-01B-67
303-01B-69

Engine ...........................................................................................................................
303-01B-75
DISASSEMBLY
Engine ..........................................................................................................(21 134 8)
303-01B-84
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303-01B-2
Page 2 of 2
ASSEMBLY
Engine .......................................................................................................... (21 134 8)
303-01B-96
INSTALLATION
Engine ...........................................................................................................................
303-01B-113
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303-01B-3
303-01B-3
SPECIFICATIONS
Engine Data
Description
Engine code
Emission level
Firing order
Bore
Stroke
Cubic capacity
Compression ratio
Power output 6000 rpm
Maximum torque at 4500 rpm
Maximum engine speed (intermittent)
Maximum engine speed (continous)
Idle speed
Number of main bearings
Camshaft drive
Engine Oil
Viscosity / ambient
temperature
Recommended engine oil
SAE 5W-30 / below -20C to over
+40C
Alternative engine oils (for
top-up only)
SAE 10W-40 / -20C to over
+40C
SAE 5W-40 / below -20C to over
+40C
N4JA
Stage III
1-3-4-2
87.5 mm
83.1 mm
1998 cm
10.8 : 1
110 kW (150 PS)
190 Nm
7000 rpm
N4JB
Stage IV
1-3-4-2
87.5 mm
83.1 mm
1998 cm
10.8 : 1
110 kW (150 PS)
190 Nm
7000 rpm
6500 rpm
6500 rpm
700 rpm
5
Chain
0.5l/1000 km
700 rpm
5
Chain
0.5l/1000 km
Type
Specification
Ford Formula E
WSS-M2C913-B
Ford XR+ High-performance
ACEA A3/B3
Ford Formula S
ACEA A3/B3
If other types of engine oil are used, these must conform at least to the respective API SH/EC viscosity class.

Item
Silicone sealant, oil pan contact surface to crankshaft rear seal retainer, oil
pan to cylinder block, oil pan to engine front cover, engine front cover to cylinder block/ oil pan
Oil pressure switch and engine front cover blanking plug adhesive
Silicone grease
Specification
WSE-M4G323-A4
WSK-M2G349-A7
ESE-M1C171-AA
Oil system
Description
Pressure relief valve opening pressure
bar
5
Engine Oil Capacity

Description
Initial fill, including oil filter
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Liters
4.6
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303-01B-4
Description
Liters
4.3
3.9
Service fill including filter

Service fill excluding filter
Valve Dimensions
Description
Valve stem diameter, intake
Valve stem diameter, exhaust
mm
0.22 - 0.28
0.27 - 0.33
5.470 - 5.485
5.465 - 5.480
Camshaft Dimensions
Description
mm
24.97 0.01
0.035 - 0.080
0.09 - 0.24
8.8
7.7
Description
mm
0.335 0.115
Description
mm
87.465 - 87.475
87.475 - 87.485
87.485 - 87.495
Camshaft journal diameter

Camshaft journal clearance
Camshaft endplay
Camshaft lobe lift, intake
Camshaft lobe lift, exhaust
Crankshaft Dimensions
Crankshaft endplay
Piston Dimensions
Piston diameter - Class 1
Cylinder Head
CAUTION: The mating face of the cylinder head must not be reworked.
Description
Maximum distortion (mating face)
mm
0.1
Cylinder Block
Description
mm
87.500 + 0.030
0.1
Cylinder bore diameter

Cylinder block distortion (maximum)
Description
Cylinder head retaining bolts
Timing chain guide retaining bolts
Camshaft bearing caps retaining bolts
Camshaft sprocket retaining bolts
Camshaft position (CMP) sensor retaining bolt
Engine front cover retaining bolts
Crankshaft pulley retaining bolts
Coolant expansion tank retaining nut
G451278 en
Nm
a)
10
a)
65
6
a)
a)
10
lb-ft
48
-
lb-in
89
53
89
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303-01B-5
Description
Coolant plug to cylinder block
Coolant plugs (4) to cylinder head
Power steering pump retaining bolt
Power steering reservoir retaining bolts
Power steering reservoir retaining nut
Power steering pipe to the power steering
Power steering bracket retaining nut
Exhaust manifold bracket retaining bolts
Exhaust manifold upper heat shield retaining bolts
Exhaust manifold lower heat shield retaining bolts
Exhaust manifold to the cylinder head
Exhaust manifold studs to cylinder head
Exhaust gas recirculation (EGR) tube to cylinder
head
Coolant pump pulley retaining bolts
Coolant pump retaining bolts
Valve cover retaining bolts
Oil pressure switch
Oil pan retaining bolts
Oil cooler to oil filter adaptor retaining bolt
Crankshaft rear seal retaining bolts
Flywheel retaining bolts
Oil filter adaptor retaining bolts
Positive crankcase ventilation housing retaining
bolts
Knock sensor retaining bolt
Oil pump retaining bolts
Oil pump sprocket retaining bolt
Oil pump chain guide retaining bolts
Oil pump chain tensioner retaining bolt
Timing chain guide retaining bolts
Crankshaft position sensor retaining bolts
Accessory drive belt idler pulley retaining bolt
Intake manifold retaining bolts
Transaxle retaining bolts
Transaxle righthand retaining bolts
Halfshaft center bearing carrier retaining bolts
Intermediate shaft bearing cap retaining nuts
Starter motor retaining bolts
Wiring harness retaining bracket nuts
A/C compressor retaining bolts
Engine rear mount retaining nut
Engine front mount studs to front cover
Engine front mount retaining bolts
Top mount retaining nut
Piston cooling jets
Nm
43
75
23
25
10
65
15
25
10
10
51
17
55
lb-ft
32
55
17
18
48
11
18
41
13
41
lb-in
89
89
89
-
25
10
10
15
25
34
10
a)
25
10
18
11
18
25
18
-
89
89
89
89
20
10
a)
25
10
10
10
7
25
18
44
44
48
25
35
20
25
80
10
80
59
4
15
18
18
13
32
32
35
18
26
15
18
59
59
44
-
89
89
89
89
62
89
35
a) Refer to the procedure in this section.
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303-01B-6

Engine
Engine
For the Fiesta ST the engine is available with the

following specification:
2.0L Duratec-HE (MI4) engine
Engine code
N4JA (Stage III), N4JB (Stage IV)
Displacement
1998 cm
Maximum power output
110 kW (150 PS) at 6000 rpm
Maximum torque
190 Nm at 4000 rpm
Emission standard
European Emissions Standard Stage IV (Stage III, depending on
country)
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303-01B-7
303-01B-7

The complete engine is made of cast aluminum
which, when combined with the plastic intake
manifold, gives a very light unit.
Cylinder head
NOTE: 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.
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.
The engine management for the 2.0L Duratec-HE
(MI4) is provided by a Visteon system.
This engine management systems controls the
sequential multipoint fuel injection (SFI) and the
electronically controlled coolant-cooled exhaust
gas recirculation (EGR) valve.
Item
Part
Number
Description
Exhaust camshaft
Camshaft bearing cap
Cam to identify cylinder No. 1
Intake camshaft
Camshaft sprockets
The design and the valve arrangement in the

cylinder head is similar to the head of the
Zetec-SE engines.
Engine codes
Cylinder head gasket
Item
Part
Number
Description
Enngine code
Engine serial number
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.
Item
Part
Number
Description
Cylinder head gasket
Locating dowels
A four-layer laminated steel cylinder head gasket

is used.
The cylinder head gasket and cylinder head are
located with two locating dowels.
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303-01B-8

Valve tappets
Camshaft drive
Item
Part
Number
Description
Exhaust valve tappet
Intake valve tappet
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
available in the event of wear or repairs to the
valve gear.
Item
Part
Number
Description
Exhaust camshaft sprocket
Timing chain
Intake camshaft sprocket
Timing chain guide
Crankshaft sprocket
Hydraulic timing chain tensioner
Timing chain tensioner arm
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.
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303-01B-9
303-01B-9

The timing chain tensioner can be used again
after removal.
The camshaft drive requires no maintenance.
Engine front cover
Description
The camshaft drive is sealed with an aluminum

engine front cover.
Engine front cover
The crankshaft front seal is installed in the engine

front cover.
Crankshaft front seal
Silicone sealant for sealing at

bores
Silicone sealant for sealing

engine front cover
Item
Part
Number
G461395 en
The engine front cover is installed using silicone

sealant.
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303-01B-10
Crankshaft pulley
Item
Part
Number
Description
Crankshaft
Crankshaft front seal
Engine front cover
Friction washer
Crankshaft pulley
Crankshaft pulley retaining

bolt
M6 bolt
NOTE: The M6 bolt must never be used as

support when tightening the crankshaft pulley
retaining bolt as this could damage the engine
front cover.
The crankshaft pulley forms a unit with the rotor

for indicating the crankshaft position.
It is secured to the crankshaft by the contact
pressure of the retaining bolt (free to turn on the
seat on the crankshaft).
The crankshaft pulley retaining bolt must be
changed after removal.
The crankshaft pulley is positioned with the aid of
an M6 bolt.
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303-01B-11

Oil pump
Oil Pump Drive
Item
Part
Number
Description
Oil pump
Oil pump outer rotor
Oil pump inner rotor
Item
Part
Number
Description
Crankshaft sprocket
Oil pump chain tensioner
Oil pump sprocket
Oil pump chain
Oil pump chain guide
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.
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.
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303-01B-12

Oil filter adapter
Item
Part
Number
Engine oil cooler
Description
Item
Part
Number
Description
Oil cooler retaining bolt
Oil cooler retaining bolt
Oil cooler
Oil cooler
Oil filter
Oil cooler O-ring seal
Oil pressure switch
Oil filter adapter retaining

bolts
Oil filter adapter gasket
Oil filter adapter
The oil filter adapter is mounted on the cylinder

block with a gasket.
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303-01B-13

Engine
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303-01B-14
303-01B-14
GENERAL PROCEDURES
Valve Clearance Adjustment
4. Remove the positive crankshaft ventilation
(PCV) hose.
Special Tool(s)
Socket, Spark Plug
303-499 (21-202)

303-508 (21-211)
General Equipment
Feeler gauges
Name
Specification
Silicone Sealant
WSE-M4G323-A4
Disconnect]
Duratec-HE (MI4)]
3. Detach the engine wiring harness from the
valve cover.
1. Unclip the power steering return line from
the engine wiring harness bracket.
2. Remove the air cleaner retaining bracket.
3. Unclip the engine wiring harness bracket
4. Unclip the engine wiring harness from the
intake manifold.
G451279 en
5. Disconnect the camshaft position (CMP)

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303-01B-15

7. Remove the evaporative emission (EVAP)
valve support bracket.

spark plug electrical connectors.
11.
CAUTION: Only rotate the crankshaft

in the normal direction of rotation.
Rotate the crankshaft until piston No. 1 is

at top dead center (TDC).
12. NOTE: Make a note of each cylinder number
and the valve clearances measured.
Using a suitable set of feeler gauges,
measure the valve clearances.

plugs.
13.

Rotate the crankshaft until each piston is

at TDC and measure the valve clearances.
14. NOTE: Only carry out the following steps
when the valve clearance(s) require
adjustment. For additional information, refer to
Remove the camshafts. For additional
section.
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303-01B-16

15. NOTE: The number on the valve tappet is the
valve tappet thickness, however only the
decimal places are marked (for example .650 =
3.650).
Determine the valve tappet thickness
required:
1. Remove the valve tappet and read the
thickness from the underside.
2. Valve tappet thickness required = thickness
of currently installed valve tappet + the
measured valve clearance - the required
valve clearance. For additional information,
3. Install the correct valve tappet.
16. NOTE: Do not install the valve cover at this
stage.
Install the camshafts. For additional
section.
17.
20. NOTE: Install a new valve cover gasket if

necessary.
Tighten the bolts in the sequence shown.

plugs.

Rotate the crankshaft until each piston is

at TDC and measure the valve clearances.
18. Repeat this procedure as necessary until
all valve clearances are within the
specified tolerance.
19. Apply a small bead of sealant to the areas
as shown.

plug electrical connectors.
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303-01B-17

23. Install the evaporative emission (EVAP)
26. Install the positive crankshaft ventilation

(PCV) hose.
24. Install the air cleaner retaining bracket.
27. Attach the engine wiring harness to the

valve cover.
1. Clip the engine wiring harness to the intake
manifold.
2. Clip the engine wiring harness bracket to
4. Clip the power steering return line to the
engine wiring harness bracket.
25. Connect the CMP sensor electrical connector.

Air Cleaner - 2.0L Duratec-HE (MI4)]
Disconnect]
G451279 en
11/2004 2005.25 Fiesta
303-01B-18

TO MODEL INDEX
303-01B-18
IN-VEHICLE REPAIR
Intake Manifold (21 183 0)
Removal
1. Disconnect the battery. For additional
Disconnect]
Duratec-HE (MI4)]
3. Remove the right-hand headlamp. For
417-01.[Exterior Lighting, REMOVAL AND
INSTALLATION, Headlamp Assembly]
6. Disconnect the generator electrical connectors.
G451284 en
7. Remove the intake manifold lower retaining

bolt.
8. Remove the oil level indicator tube lower

retaining bolt.
9. Detach the wiring harness from the intake

manifold.
11/2004 2005.25 Fiesta
303-01B-19

TO MODEL INDEX
303-01B-19

10. Detach the power steering supply line
14. Detach the starter motor electrical connector from the intake manifold.

12. Detach the engine wiring harness from
the valve cover.
1. Unlcip the power steering return line from
the wiring harness bracket.
intake manifold.
15. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
16. Detach the evaporative emission valve

(EVAP) hose from the intake manifold.
13. Remove the fuel rail. For additional

303-04B.[Fuel Charging and Controls 2.0L Duratec-HE (MI4), REMOVAL AND
INSTALLATION, Fuel Rail]
G451284 en
11/2004 2005.25 Fiesta
303-01B-20

TO MODEL INDEX
303-01B-20

17. Disconnect the intake manifold runner
control (IMRC) electrical connector.
20. Disconnect the hood latch electrical

connector.
18. Disconnect the throttle body electrical

connector.
21. Remove the hood latch lever retaining

bolt.
19. Disconnect the knock sensor (KS)

electrical connector (power steering fluid
reservoir shown removed for clarity).
Detach the KS electrical connector from the
intake manifold.
22. Detach the hood latch from the radiator

grille opening panel reinforcement.
G451284 en
11/2004 2005.25 Fiesta
303-01B-21

TO MODEL INDEX
303-01B-21

24. Remove the oil level indicator and oil level

indicator tube.
26. Disconnect the positive crankshaft ventilation (PCV) hose from the intake manifold.
Installation
1. NOTE: Install new gaskets if necessary.
25. Remove the intake manifold retaining

bolts (engine shown removed for clarity).
Detach the intake manifold from the cylinder
head.
G451284 en
11/2004 2005.25 Fiesta
303-01B-22

TO MODEL INDEX
303-01B-22
IN-VEHICLE REPAIR
Crankshaft Front Seal (21 467 0)
Installation
Special Tool(s)
Pad)
205-071-02 (15-026-51)
1. NOTE: Install a new crankshaft front seal.

Using the special tools, install the crankshaft front seal.
Remover, Crankshaft Seal

303-293 (21-143)

303-395 (21-171)
2. Install the crankshaft pulley.

Remover, Halfshaft Seal
308-208 (16-074)
Removal
crankshaft front seal.
Discard the seal.
G323906 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
303-01B-23
303-01B-23
IN-VEHICLE REPAIR
Crankshaft Pulley (21 572 0)
Special Tool(s)
Flange Holding Wrench,
Universal
205-072
Adapter for 205-072
205-072-02

Duratec-HE (MI4)]
cylinder head cover.
1. Unclip the power steering return line.
2. Remove the air cleaner mounting bracket.
3. Unclip the engine wiring harness bracket at
the intake pipe.
4. Unclip the engine wiring harness at the intake pipe.
Alignment Tool, Camshaft

Alignment
303-376
Socket, Spark Plug

303-499
Alignment pin, crankshaft

TDC setting
303-507
4. Detach the positive crankcase ventilation

(PCV) hose from the cylinder head cover.

303-508 (21-211)
General Equipment
Bolt M6 x 18 mm
Name
Silicone Sealant
Specification
WSE-M4G323-A4
Removal
Disconnect]
G451288 en
11/2004 2005.25 Fiesta
303-01B-24

TO MODEL INDEX
303-01B-24


6. Remove the bracket of the air cleaner assembly.
9. Remove the spark plugs using the special

tool.
7. Detach the EVAP valve bracket.
10. Remove the cylinder head cover.
11. Remove the drive belt. For additional

INSTALLATION, Accessory Drive Belt 2.0L Duratec-HE (MI4)]
G451288 en
11/2004 2005.25 Fiesta
303-01B-25

TO MODEL INDEX
303-01B-25

12. NOTE: Only turn the crankshaft in the normal
Turn the crankshaft until piston no. 1 is
approx. 45 degrees before TDC.
13. NOTE: Do not discard the crankshaft pulley

bolt.
Counterhold the crankshaft pulley using
the special tools and remove the pulley.
15. Remove the front friction washer (engine

Discard the friction washer.

Pull the inner CV joint boot off the
intermediate shaft.
14. Remove the crankshaft front oil seal. For

additional information, refer to Crankshaft
Front Seal in this section.
G451288 en
11/2004 2005.25 Fiesta
303-01B-26

TO MODEL INDEX
303-01B-26

Installation
1. NOTE: Install a new front friction washer.
7. Remove the cylinder block lower blanking

plug and attach the special tool.
Install the front friction washer (engine


2. Install the crankshaft front oil seal. For
Front Seal in this section.
4. NOTE: Only turn the camshafts in the normal
Turn the engine at the crankshaft pulley

bolt until the crankshaft contacts the special tool.
Carefully turn the camshafts using a

spanner until the cams, cylinder no. 4, are
positioned at the valve overlap.
5. Mount the special tool.
6. Raise the vehicle.
G451288 en
11/2004 2005.25 Fiesta
303-01B-27

TO MODEL INDEX
303-01B-27

9. Remove the crankshaft pulley bolt.
Discard the bolt.
10.
12. Remove the M6 x 18 bolt.
CAUTION: Tighten the M6 x 18 mm

bolt hand-tight only.
Install the crankshaft pulley and fasten to
the timing cover with an M6 x 18 mm bolt.

11. NOTE: Install a new crankshaft pulley bolt.

Counterhold the crankshaft pulley using
the special tools and tighten the
crankshaft pulley bolt.
Tighten the bolt in two stages.
Stage 1: 100 Nm.

G451288 en
11/2004 2005.25 Fiesta
303-01B-28

TO MODEL INDEX
303-01B-28

Turn the crankshaft one and three quarters of a turn until piston no. 1 is approx.
45 degrees before TDC.
20.
CAUTION: Tighten M6 x 18 mm bolt

hand-tight only.
NOTE: If the M6 x 18 mm bolt cannot be installed,
correct the valve timing.
Check the position of the crankshaft pulley with the M6 x 18 mm bolt.
18. Mount the special tool.

22. NOTE: If the special tool cannot be attached,
correct the valve timing.
Check the position of the camshafts using
the special tool.

Turn the crankshaft until no. 1 piston is at
TDC.
G451288 en
11/2004 2005.25 Fiesta
303-01B-29

TO MODEL INDEX
303-01B-29


25. Remove the M6 x 18 mm bolt.
27. Screw in the cylinder block lower blanking plug.

mating surface for the joint boot is clean.
Slide the inner CV joint boot on the
intermediate shaft.
Use a suitable screwdriver under the boot to
allow air to escape.
G451288 en
11/2004 2005.25 Fiesta
303-01B-30

TO MODEL INDEX
303-01B-30

29. NOTE: Install a new halfshaft boot clamp.
30. NOTE: When installing a new timing cover, the

crankshaft position sensor (CKP sensor) must
be aligned using the tool supplied.
Align the CKP sensor (engine shown
removed for clarity).
1. Loosen the CKP sensor bolts.
2. Insert the supplied tool so that it engages
with the teeth of the crankshaft pulley.
G451288 en
31. Install the CKP sensor (engine shown

1. Install the CKP sensor bolts.
2. Remove the tool.
32. Install the belt. For additional information,

refer to Section 303-05.[Accessory Drive,
Accessory Drive Belt - 2.0L Duratec-HE
(MI4)]
33. Apply sealer thinly onto the indicated areas.
11/2004 2005.25 Fiesta
303-01B-31

TO MODEL INDEX
303-01B-31

34. NOTE: If necessary, install a new cylinder
head cover gasket.
37. Install the EVAP valve bracket.
Install the cylinder head cover.

38. Install the air cleaner bracket.
35. Install the spark plugs using the special

tool.
39. Plug in the camshaft position (CMP)

sensor.

G451288 en
11/2004 2005.25 Fiesta
303-01B-32

TO MODEL INDEX
303-01B-32

40. Attach the positive crankcase ventilation
(PCV) hose to the cylinder head cover.
41. Install the engine wiring harness on the

1. Clip the engine wiring harness on the intake
pipe.
2. Clip the engine wiring harness bracket on
the intake pipe.
3. Install the air cleaner mount bracket.
4. Connect the steering gear return line to the
retaining clip.

Disconnect]
G451288 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
303-01B-33
303-01B-33
IN-VEHICLE REPAIR
Valve Seals (21 238 0)
Special Tool(s)
303-361A (21-155A)

303-361-02 (21-155-02A)
3. Remove the valve tappets and keep them in

4. Using the special tools, remove the valve
springs.
Release the valve spring.
valve spring.

303-362 (21-156)
Adapter, Air Supply (Cylinder

Head)
303-363 (21-157)
303-508 (21-165)

seals.
Removal
1. Remove the camshafts. For additional
section.
2. Using the special tool, apply 7 to 10 bar of
compressed air into the cylinder.
G37453 en
11/2004 2005.25 Fiesta
303-01B-34

TO MODEL INDEX
303-01B-34

Installation
1. NOTE: Install new valve seals.
NOTE: Cover the valve collet groove on the valve
stem with a protective sleeve.
seals.
Remove the protective sleeve.
2. Using the special tools, install the valve

springs.
valve spring.

4. Install the valve tappets.
5. Install the camshafts. For additional
section.
G37453 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
303-01B-35
303-01B-35
IN-VEHICLE REPAIR
Valves (21 215 4)
Special Tool(s)
303-361A (21-155A)

seals.

303-361-02 (21-155-02A)

303-362 (21-156)

303-508 (21-165)
Removal
1. Remove the cylinder head. For additional
information, refer to Cylinder Head in this
section.
2. Using the special tools, remove the valve
springs.
valve spring.
G37454 en
4. Remove the valves.
Installation
1. Install the valves.
2. NOTE: Install new valve seals.
NOTE: Cover the valve collet groove on the valve
stem with a protective sleeve.
seals.
Remove the protective sleeve.
11/2004 2005.25 Fiesta
303-01B-36

TO MODEL INDEX
303-01B-36

3. Using the special tools, install the valve
springs.
valve spring.
Compress the valve spring

5. Install the cylinder head. For additional
information, refer to Cylinder Head in this
section.
G37454 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
303-01B-37
303-01B-37
IN-VEHICLE REPAIR
Camshafts (21 284 0)
Special Tool(s)
Wrench
205-072
303-376A

valve cover.
1. Unclip the power steering return line from
the engine wiring harness bracket.
intake manifold.
Socket, Spark Plug

303-499

303-507

303-508
4. Remove the positive crankshaft ventilation

(PCV) hose.
General Equipment
M6 x 18 mm bolt
M6 x 25 mm bolt
Name
Hypoid Gear Oil
Silicone Sealant
Specification
SQM-2C9002-AA
WSE-M4G323-A4
Removal
Disconnect]
Duratec-HE (MI4)]
G451293 en
11/2004 2005.25 Fiesta
303-01B-38

TO MODEL INDEX
303-01B-38



plugs.


G451293 en
11/2004 2005.25 Fiesta
303-01B-39

TO MODEL INDEX
303-01B-39

16. NOTE: Only rotate the crankshaft in the

approximately 45 degrees before top dead
center (BTDC).
14. Disconnect the generator electrical

connectors.
Unclip the wiring harness.
17. Remove the engine front cover lower
blanking plug.

Detach the inner CV joint boot from the
intermediate shaft.

plug and install the special tool.
G451293 en
11/2004 2005.25 Fiesta
303-01B-40

TO MODEL INDEX
303-01B-40
20. Remove the engine front cover upper

blanking plug.
21.
CAUTION: To detension the timing

chain, make sure the timing chain
tensioner ratchet is in the released
position.
Detension the timing chain.
1. Using a suitable screwdriver, unlock the
timing chain tensioner ratchet.
2. Carefully turn the exhaust camshaft by the
hexagon in the normal direction of rotation,
to detension the timing chain tensioner.
3. Install a suitable M6 x 18 mm bolt through
the blanking plug to secure the timing chain
guide in the detensioned position.
G451293 en
11/2004 2005.25 Fiesta
303-01B-41

TO MODEL INDEX
303-01B-41
22.
CAUTION: Hold the camshaft by the

hexagon with an open-ended wrench
to stop it from turning.
NOTE: Using a suitable piece of wire, prevent the
timing chain and the sprocket from dropping into
the timing case.
Loosen the camshaft sprockets retaining
bolts.
Detach the exhaust camshaft sprocket together with the timing chain from the exhaust camshaft.
24. NOTE: Using a suitable piece of wire, prevent

the timing chain and the sprocket from
dropping into the timing case.
Detach the intake camshaft sprocket from
the intake camshaft.
25.

order for installation.
Installation
2. NOTE: Do not tighten the camshaft sprocket
retaining bolt at this stage.
Attach the intake camshaft sprocket
together with the timing chain to the intake
camshaft and insert the intake camshaft.
3.
CAUTION: Install the camshafts

approximately at valve overlap
position cylinder No. 4.
CAUTION: Install the camshafts and
bearing caps in their original location.
23.

caps, the camshafts and the camshaft
sprockets in order for installation.
NOTE: Working in several stages, release each
camshaft bearing cap retaining bolt two turns at a
time.
Remove the camshaft bearing caps in the
sequence shown.
G451293 en

Working in several stages, evenly tighten
the camshaft bearing cap bolts in the
sequence shown, one half turn at a time.
Coat the camshaft bearing caps with oil.
Tighten the bolts in two stages:
Stage 1: 7 Nm.
Stage 2: 16 Nm.
11/2004 2005.25 Fiesta
303-01B-42

TO MODEL INDEX
303-01B-42

4. NOTE: Only carry out the following step when a
new cylinder head or new valves are installed.
Check the valve clearance and adjust if
refer to Valve Clearance Adjustment in this
section.
5. NOTE: Do not tighten the camshaft sprocket
8. Tension the timing chain.

Remove the timing chain guide securing
bolt and install the engine front cover upper
blanking plug.
Attach the exhaust camshaft sprocket together with the timing chain to the exhaust
camshaft.
9. NOTE: Only rotate the crankshaft in the normal

at TDC.
10. NOTE: Hold the camshafts by the hexagon
with an open-ended wrench to stop them from
rotating.
Tighten the camshaft sprocket retaining

bolts.
7. Coat the engine front cover upper blanking

plug with sealant.
G451293 en
11/2004 2005.25 Fiesta
303-01B-43

TO MODEL INDEX
303-01B-43



at TDC.
17.
CAUTION: Only tighten the crankshaft

pulley securing bolt finger tight.
NOTE: If it is not possible to install the crankshaft
pulley securing bolt, correct the valve timing.
Using a M6 x 18 mm bolt, check the position of the crankshaft pulley.

Rotate the crankshaft approximately one
and three quarter revolutions until piston
No. 1 is 45 degrees before TDC.
G451293 en
11/2004 2005.25 Fiesta
303-01B-44

TO MODEL INDEX
303-01B-44

19. NOTE: If it is not possible to install the special
tool, correct the valve timing.
Using the special tool, check the position

of the camshafts.
24. Install the cylinder block lower blanking

plug.

22. Remove the crankshaft pulley securing
bolt.
G451293 en
25. Coat the engine front cover lower

blanking plug with sealant.
26. Install the engine front cover lower
blanking plug.
11/2004 2005.25 Fiesta
303-01B-45

TO MODEL INDEX
303-01B-45

mating surface for the CV joint boot is clean.

Attach the inner CV joint boot to the intermediate shaft.
28. NOTE: Install a new CV joint boot clamp.

29. Connect the generator electrical

connectors.
Clip the wiring harness.
G451293 en

as shown.

necessary.
11/2004 2005.25 Fiesta
303-01B-46

TO MODEL INDEX
303-01B-46

plugs.


G451293 en
38. Connect the camshaft position (CMP)

39. Install the positive crankshaft ventilation

(PCV) hose.
11/2004 2005.25 Fiesta
303-01B-47

TO MODEL INDEX
303-01B-47

40. Attach the engine wiring harness to the
valve cover.
1. Clip the engine wiring harness to the intake
manifold.
2. Clip the engine wiring harness bracket to
4. Clip the power steering return line to the
engine wiring harness bracket.

Disconnect]
G451293 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
303-01B-48
303-01B-48
IN-VEHICLE REPAIR
Oil Pan (21 154 0)
4. Loosen the transaxle upper retaining bolts
approximately 10 mm.
Special Tool(s)
Separator, Oil Pan
303-428 (21-179)
Name
Cleaner
Silicone Sealant
Specification
WSK-M2G342-A
WSE-M4G323-A4
Removal
Disconnect]
Duratec-HE (MI4)]
indicator tube upper retaining bolt.

retaining bolt.
G451306 en
11/2004 2005.25 Fiesta
303-01B-49

TO MODEL INDEX
303-01B-49

8. Drain the engine.
container.
required.
12. Remove the engine front cover lower retaining bolts.

bolts.
10. Loosen the transaxle right-hand retaining

bolts approximately 10 mm.
14. Slide back the transaxle approximately 8

mm.
11. Loosen the transaxle left-hand retaining

bolts approximately 10 mm.
G451306 en
11/2004 2005.25 Fiesta
303-01B-50

TO MODEL INDEX
303-01B-50

16. Using the special tool, remove the oil pan.
4. NOTE: Do not tighten the oil pan retaining bolts

at this stage.
Installation
1. Clean the mating faces of the cylinder
block, the oil pan and the engine front
cover with cleaner.
2. Apply a 3 mm bead of sealant to the oil pan.
5. NOTE: Do not tighten the transaxle lower

Install the transaxle lower retaining bolts.
6. Install the engine front cover lower retaining bolts.

3. NOTE: Install the oil pan within 10 minutes of
applying the silicone sealant and tighten the
retaining bolts within a further 5 minutes.
Apply a 3 mm bead of sealant to the oil pan.
G451306 en
11/2004 2005.25 Fiesta
303-01B-51

TO MODEL INDEX
303-01B-51

7. Tighten the oil pan retaining bolts in the
sequence shown.
10. Install the oil level indicator tube lower

retaining bolt.
8. Tighten the transaxle lower retaining bolts.
11. Tighten the transaxle left-hand retaining

bolts.

12. Tighten the transaxle right-hand retaining
bolts.
G451306 en
11/2004 2005.25 Fiesta
303-01B-52

TO MODEL INDEX
303-01B-52

14. Tighten the transaxle upper retaining
bolts.
15. Install the oil level indicator and oil level


17. Connect the battery. For additional
Disconnect]
18. Fill the engine with engine oil. For
G451306 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
303-01B-53
303-01B-53
IN-VEHICLE REPAIR
Oil Pump (21 714 0)
5. Using the special tools, loosen the oil
pump sprocket retaining bolt.
Special Tool(s)
Wrench
205-072 (15-030A)
Adapter for 205-072
205-072-02 (15-030 A01)
Removal
1. Remove the timing chain. For additional
information, refer to Timing Chain in this
section.
2. Remove the oil pan. For additional
3. Remove the oil pump chain guide.
4. Remove the oil pump chain tensioner.
G37459 en
6. Remove the oil pump chain.

1. Remove the oil pump sprocket retaining
bolt.
2. Remove the oil pump chain and the oil
pump sprocket.
11/2004 2005.25 Fiesta
303-01B-54

TO MODEL INDEX
303-01B-54

Installation
1. Install the oil pump.
two stages.
Stage 1: 10 Nm
Stage 2: 23 Nm
3. Using the special tools, tighten the oil

4. Install the oil pump chain tensioner.
2. NOTE: Do not tighten the oil pump sprocket

Install the oil pump chain.
1. Install the oil pump chain and the oil pump
sprocket.
2. Install the oil pump sprocket retaining bolt.
5. Install the oil pump chain guide.
6. Install the oil pan. For additional

7. Install the timing chain. For additional
section.
G37459 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
303-01B-55
303-01B-55
IN-VEHICLE REPAIR
Crankshaft Rear Seal (21 468 4)
Special Tool(s)
303-254 (21-135)

container.
required.
Separator, Oil Pan

303-428 (21-179)
Name
Cleaner
Silicone Sealant
Specification
WSK-M2G342-A
WSE-M4G323-A4
Removal

retaining bolt.
2. Remove the clutch disc and pressure plate.

Plate]
G451307 en
11/2004 2005.25 Fiesta
303-01B-56

TO MODEL INDEX
303-01B-56

6. Using the special tool, lock the flywheel in
position.
10. Using the special tool, remove the oil pan.

7. Remove the flywheel.
Discard the bolts.
8. Remove the engine front cover lower retaining bolts.
G451307 en

Discard the crankshaft rear seal carrier.
11/2004 2005.25 Fiesta
303-01B-57

TO MODEL INDEX
303-01B-57

Installation
1.
CAUTION: Do not remove the the

installation sleeve before installation.
supplied preassembled with an installation sleeve
that must be removed following installation.
NOTE: Install a new crankshaft rear seal carrier.

applying the silicone sealant and tighten the
retaining bolts within a further 5 minutes.

Tighten the retaining bolts in the sequence
shown.
Discard the installation sleeve.
5. NOTE: Do not tighten the retaining bolts at this

stage.

block, the oil pan and the engine front
cover with cleaner.
3. Apply a 3 mm bead of sealant to the oil pan.
6. Install the engine front cover lower retaining bolts.
G451307 en
11/2004 2005.25 Fiesta
303-01B-58

TO MODEL INDEX
303-01B-58

7. Tighten the oil pan retaining bolts in the
sequence shown.
10. Tighten the flywheel retaining bolts.

three stages.
Stage 1: 50 Nm.
Stage 2: 80 Nm.
Stage 3: 112 Nm.
8. NOTE: Install new flywheel retaining bolts.

NOTE: Do not tighten the flywheel retaining bolts
at this stage.
Install the flywheel.
12. Install the oil level indicator tube lower
retaining bolt.

position.
Plate]
G451307 en
11/2004 2005.25 Fiesta
303-01B-59

TO MODEL INDEX
303-01B-59

14. Install the oil level indicator and oil level

G451307 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
303-01B-60
303-01B-60
IN-VEHICLE REPAIR
Engine Front Cover (21 148 0)
6. Detach the coolant expansion tank and lay
it to one side.
General Equipment
Vehicle jack
Name
Silicone Sealant
Specification
WSE-M4G323-A4
Removal
1. Remove the crankshaft belt pulley. For
Pulley in this section.
2. Remove the timing cover lower bolts.
7. Support the engine with a vehicle jack.
8. Remove the front engine mount.
Discard the front engine mount nuts.


G451289 en
11/2004 2005.25 Fiesta
303-01B-61

TO MODEL INDEX
303-01B-61

10. Remove the drive belt idler pulley.
2. NOTE: Install the timing cover within 10

minutes of applying the silicon sealer.
Apply sealer to the timing cover (bead diameter: 3 mm).
11. Remove the timing cover upper bolts.

Remove the timing cover.
Installation
1. Clean the sealing surfaces of the timing
cover and the cylinder block.
G451289 en
11/2004 2005.25 Fiesta
303-01B-62

TO MODEL INDEX
303-01B-62

3. Install the timing cover (engine shown
Tighten bolts 1 to 8 to a torque of 10 Nm.
Tighten bolt 9 to 48 Nm.
6. NOTE: Install new front engine mount nuts.

Install the front engine mount.
7. Install the coolant expansion tank.
4. Install the multi-groove belt idler pulley.
G451289 en
11/2004 2005.25 Fiesta
303-01B-63

TO MODEL INDEX
303-01B-63

10. Install the crankshaft belt pulley. For

Pulley in this section.
G451289 en
11/2004 2005.25 Fiesta
303-01B-64

TO MODEL INDEX
303-01B-64
IN-VEHICLE REPAIR
Exhaust Manifold
Duratec-HE (MI4)]
G451285 en

table(s).
Item
Part
Number
Description
Exhaust manifold upper heat
shield
11/2004 2005.25 Fiesta

TO MODEL INDEX
303-01B-65
303-01B-65

Item
Part
Number
Description
Exhaust manifold lower heat

shield
Exhaust manifold support

bracket retaining bolts
Exhaust manifold retaining

nuts
See Removal Detail
Exhaust manifold
See Removal Detail
Exhaust manifold gasket
Removal Details
2. Remove the exhaust manifold inner

retaining nuts (engine shown removed for
clarity).
Discard the nuts.

4. Remove the engine support insulator center retaining bolt.
Item 4 : Exhaust manifold retaining nuts

1. NOTE: Do not remove the exhaust manifold
outer retaining nuts at this stage.
Loosen the exhaust manifold outer retaining nuts by two turns (engine shown removed for clarity).
5. Remove the exhaust flexible pipe. For

309-00.[Exhaust System, REMOVAL AND
INSTALLATION, Exhaust Flexible Pipe 2.0L Duratec-HE (MI4)]
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11/2004 2005.25 Fiesta
303-01B-66

TO MODEL INDEX
303-01B-66

Item 5 : Exhaust manifold
1. Remove the exhaust manifold outer
retaining nuts.
Discard the nuts.
2. Install the engine support insulator center

retaining bolt.
3. Lower the vehicle and fully tighten the

exhaust manifold retaining nuts.
Item 5 : Exhaust manifold
CAUTION: Never use jointing
compound forward of the exhaust
manifold.
NOTE: Coat the exhaust manifold studs with
anti-seize grease.
NOTE: Install a new gasket and new nuts.
NOTE: Do not fully tighten the exhaust manifold
outer retaining nuts at this stage.
1.
Loosely install the exhaust manifold outer

retaining nuts.
Item 4 : Exhaust manifold retaining nuts

1. Install the exhaust flexible pipe. For
G451285 en
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303-01B-67

TO MODEL INDEX
303-01B-67
IN-VEHICLE REPAIR
Timing Chain (21 314 0)
Removal
4. Remove the timing chain guides.
1. Remove the engine front cover.

2. Detension the timing chain.
1. Unlock the timing chain tensioner ratchet.
2. Apply pressure to the timing chain guide.
3. Fix the timing chain tensioner with a suitable
pin punch.
5. Remove the timing chain tensioner.
3. NOTE: Hold the camshafts by the hexagon with

an open-ended wrench to stop them from
rotating.
Loosen the camshaft sprocket retaining
bolts.
Installation
1. Install the timing chain tensioner.
G323910 en
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303-01B-68

TO MODEL INDEX
303-01B-68

2. Install the timing chain guides.
5. NOTE: Hold the camshafts by the hexagon with

an open ended wrench to stop them from
rotating.
Tighten the camshaft sprocket retaining
bolts.
3.

sprocket retaining bolts at this stage.
Make sure the camshaft sprockets
rotate on the camshafts.
Install the camshaft sprockets.
Install the timing chain.
6. Install the engine front cover.

Apply pressure to the timing chain and remove the securing pin.
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TO MODEL INDEX
303-01B-69
303-01B-69
IN-VEHICLE REPAIR
Special Tool(s)
Clamp
303-397
Name
Hypoid Gear Oil
6. Disconnect the exhaust gas recirculation

(EGR) valve electrical connector.
Specification
SQM-2C9002-AA
Removal
components. Highly flammable vapors
303-03B.[Engine Cooling - 2.0L Duratec-HE
(MI4), GENERAL PROCEDURES, Cooling
System Draining, Filling and Bleeding]
2. Remove the exhaust manifold support
bracket retaining bolts.

coolant hose from the EGR valve.

coolant hoses from the coolant outlet
connector.

4. Remove the intake manifold. For additional
information, refer to Intake Manifold in this
section.
5. Remove the timing chain. For additional
section.
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303-01B-70

TO MODEL INDEX
303-01B-70

9. Disconnect the engine coolant temperature

shield (engine shown removed for clarity).
10. Remove the power steering pump return

line support bracket.

11. Remove the generator upper retaining

bolt.
14. Remove the exhaust manifold retaining

nuts (engine shown removed for clarity).
Detach the exhaust manifold from the
cylinder head and position it to one side.
Discard the gasket and nuts.
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TO MODEL INDEX
303-01B-71
15.

caps and the camshafts in order for
installation.
CAUTION: Remove the camshaft bearing

caps in the sequence shown.
time.
Installation
1. Check the cylinder head for distortion. For
303-00.[Engine System - General
Cylinder Head Distortion]
2. NOTE: Install a new cylinder head gasket and
bolts.
Install the cylinder head.
sequence shown in five stages:
Stage 1: 5 Nm.
Stage 2: 15 Nm.
Stage 3: 45 Nm.
16.

17.

Discard the gasket.
Discard the bolts.
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TO MODEL INDEX
303-01B-72
4.
CAUTION: Working in several stages,

evenly tighten the camshaft bearing
cap bolts in the sequence shown, one
half turn at a time.
7. Using the special tool, connect the coolant

hoses to the coolant outlet connector.

two stages:
Stage 1: 7 Nm.
Stage 2: 16 Nm.
8. Connect the exhaust gas recirculation

5. NOTE: Only carry out the following step when a

new cylinder head or new valves are installed.
Check the valve clearance and adjust if
refer to Valve Clearance Adjustment in this
section.
G451308 en
9. Using the special tool, connect the coolant

hose to the EGR valve.
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303-01B-73

TO MODEL INDEX
303-01B-73

and nuts.
13. Install the generator upper retaining bolt.
Tighten the exhaust manifold retaining

nuts (engine shown removed for clarity).
14. Install the power steering pump return

line support bracket.

G451308 en
15. Install the timing chain. For additional

section.
16. Install the intake manifold. For additional
information, refer to Intake Manifold in
this section.
18. Install the exhaust manifold support
bracket retaining bolts.
11/2004 2005.25 Fiesta
303-01B-74

TO MODEL INDEX
303-01B-74

Duratec-HE (MI4), GENERAL
Filling and Bleeding]
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TO MODEL INDEX
303-01B-75
303-01B-75
REMOVAL
Engine

Tray - 2.0L Duratec-HE (MI4)]
Special Tool(s)
Remover, Power Steering
Pump Pulley
211-198
303-122
Clamp
303-397
Remover, Halfshaft
308-237
General Equipment
Workshop table
Engine hoist
Securing straps
Removal
Duratec-HE (MI4)]
G451290 en
4. Remove the right-hand headlamp assembly.

exhaust manifold. For additional
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303-01B-76

TO MODEL INDEX
303-01B-76
REMOVAL (Continued)
9. Remove the cooling fan motor and shroud.

coolant hose from the coolant outlet
connector.
12. Detach the evaporative emission (EVAP)

valve from EVAP valve support bracket.
1. Disconnect the EVAP valve electrical
connector.
2. Disconnect the low pressure line from the
EVAP valve.
3. Push the EVAP valve from the support
bracket.

G451290 en
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303-01B-77

TO MODEL INDEX
303-01B-77
REMOVAL (Continued)
15. Disconnect the power steering pump
18. Remove the engine wiring harness

bracket.

19. Detach the power steering high-pressure

line retaining bracket from the transaxle.

20. Remove the coolant expansion tank.
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303-01B-78

TO MODEL INDEX
303-01B-78
REMOVAL (Continued)
24. NOTE: Note the position of the steering gear

to power steering fluid reservoir return line
support bracket to aid installation.
Detach the steering gear to power steering fluid reservoir return line support
bracket from the generator.
22.

water.
supply line.

suitable container.
23. Disconnect the air conditioning low

pressure switch connector.
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303-01B-79

TO MODEL INDEX
303-01B-79
REMOVAL (Continued)
26. Remove the power steering fluid reservoir.
27.
CAUTION: Cap the power steering

fluid reservoir to prevent power
steering fluid loss or dirt ingress.
Remove and discard the power steering
fluid reservoir O-rings.
28. Using the special tool, remove the power

steering pump pulley.
Discard the power steering pump pulley.
29. Detach the power steering pump to

steering gear pressure line from the
30. Detach the power steering pump to

steering gear pressure line from the intake manifold.
31. Disconnect the fuel supply line. For additional information, refer to Section
GENERAL PROCEDURES, Quick Release
Coupling]

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TO MODEL INDEX
303-01B-80
REMOVAL (Continued)
33. Remove the air cleaner resonator support
bracket.
36. Remove the intermediate shaft center

bearing cap.
Discard the bearing cap and retaining nuts.
Remove the intermediate shaft center
bearing heat shield (if equipped).
34. Detach the powertrain control module

(PCM) support bracket from the side
member.
37.
CAUTION: The inner CV joint must not

be bent more than 23 degrees. The
outer CV joint must not be bent more
than 45 degrees.
CAUTION: Make sure the halfshaft seal is
not damaged.
CAUTION: Plug the transaxle to prevent
oil loss or dirt ingress.
35.

Remove the halfshaft and intermediate

shaft assembly.

wheel knuckle on both sides.
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303-01B-81

TO MODEL INDEX
303-01B-81
REMOVAL (Continued)
38.


seal.
ingress.

transaxle.
1. Detach the gearshift cables and the selector
2. Turn the abutment sleeve clockwise and
Remove the left-hand halfshaft.
41. Disconnect the A/C high pressure switch

42. Detach the A/C compressor from the cylinder block and position it to one side.
G451290 en
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303-01B-82

TO MODEL INDEX
303-01B-82
REMOVAL (Continued)
44. NOTE: Use securing straps to secure the

engine and the transaxle on the workshop
table.
Position the workshop table under the
vehicle and carefully lower the vehicle,
until the engine and transaxle assembly is
in the correct position to remove the engine mounts.

Discard the nuts.
G451290 en
46. Remove the engine rear mount retaining

nuts.
Discard the nuts.
47. Raise and support the vehicle and remove

the engine and transaxle assembly.
48. Using a suitable engine hoist support the
engine and transaxle assembly and remove the retaining straps.
49. Remove the wiring harness retaining

bracket.
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303-01B-83

TO MODEL INDEX
303-01B-83
REMOVAL (Continued)
50. Remove the starter motor.
Detach the wiring harness from the retaining bracket.

bolts.
53. Remove the transaxle left-hand retaining

bolts.
54. Remove the transaxle upper retaining

bolts.
55. Remove the transaxle.

52. Remove the transaxle right-hand retaining bolts.
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303-01B-84

TO MODEL INDEX
303-01B-84
DISASSEMBLY
Engine (21 134 8)
Special Tool(s)
Socket, Spark Plug
303-499 (21-202)
Special Tool(s)
Wrench
205-072 (15-030A)

303-508 (21-211)
Adapter for 205-072

205-072-02 (15-030A-02)
Disassembly
303-122 (21-068A)

303-254 (21-135)
Clamp
303-397 (24-003)

shield.
Mounting Stand
303-435 (21-187)

303-435-06 (21-031B)
Mounting Plate for

303-435-06
303-435-11A (21-146D)
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TO MODEL INDEX
303-01B-85
shield.
6. Using the special tools, mount the engine

to the mounting stand.

5. Remove the generator.

container.
9. NOTE: Inspect the oil drain plug seal for
necessary.
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TO MODEL INDEX
303-01B-86
10. Detach the engine wiring harness bracket

connectors.

12. Disconnect the oil pressure switch electrical connector.
15. Disconnect the exhaust gas recirculation

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TO MODEL INDEX
303-01B-87
16. Disconnect the electronic ignition (EI)
19. Disconnect the throttle body (TB) electrical connector.
17. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
20. Disconnect the intake manifold runner

control (IMRC) electrical connector.
18. Disconnect the heated oxygen (H2OS)

21. Detach the starter motor electrical connector from the intake manifold.
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303-01B-88

TO MODEL INDEX
303-01B-88
22. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.

indicator tube.
23. Remove the exhaust manifold lower retaining bolts.
24. Remove the exhaust manifold.

Discard the gasket.
G451309 en
27. Disconnect the positive crankcase ventilation (PCV) hose from the intake manifold.
11/2004 2005.25 Fiesta
303-01B-89

TO MODEL INDEX
303-01B-89


plugs.
G451309 en

coolant hoses.
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303-01B-90

TO MODEL INDEX
303-01B-90
34. Remove the accessory drive belt tensioner.
35. Remove the accessory drive belt idler

pulley.
37. Using the special tools, prevent the

crankshaft pulley from rotating and remove the crankshaft pulley.
38. Remove the engine front cover.
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TO MODEL INDEX
303-01B-91
39. Detension the timing chain.
1. Unlock the timing chain tensioner ratchet.
2. Apply pressure to the timing chain guide.
3. Lock the timing chain tensioner with a
suitable piece of wire.
42. Remove the timing chain tensioner.
43. Remove the oil pump chain guide.
40. NOTE: Hold each camshaft by the hexagon

with an open-ended wrench to stop it from
rotating.
Remove the camshaft sprockets and the
timing chain.
44. Remove the oil pump chain tensioner.
41. Remove the timing chain guides.
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TO MODEL INDEX
303-01B-92
45. Using the special tools, loosen the oil
46. Remove the oil pump chain.

1. Remove the oil pump sprocket retaining
bolt.
2. Remove the oil pump chain and the oil
pump sprocket.
48. Remove the crankshaft sprocket.
49. Remove the rear friction washer (if

equipped).
47. Remove the front friction washer (if

equipped).
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303-01B-93

TO MODEL INDEX
303-01B-93
50.

caps in order for installation.
53. Remove the knock sensor (KS).
CAUTION: Remove the camshaft bearing

caps in the sequence shown.
time.
54. Remove the coolant pump.

51.

52.

Discard the gasket.
G451309 en

Discard the gasket.
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TO MODEL INDEX
303-01B-94
56. Remove the crankcase vent oil separator.
57. Remove the oil filter adapter.

Discard the gasket.
58. Remove the clutch disc and pressure

Plate]
position.
G451309 en
60. Remove the flywheel.

Discard the bolts.

62. Remove the oil pan.

Discard the seal carrier.
11/2004 2005.25 Fiesta
303-01B-95

TO MODEL INDEX
303-01B-95
G451309 en
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303-01B-96

TO MODEL INDEX
303-01B-96
ASSEMBLY
Engine (21 134 8)
Name
Hypoid Gear Oil
Specification
SQM-2C9002-AA
Special Tool(s)
Wrench
205-072 (15-030A)
Adapter for 205-072
205-072-02 (15-030A-02)
Assembly
1. Install the oil pump.
two stages.
Stage 1: 10 Nm.
Stage 2: 23 Nm.

303-122 (21-068A)

303-376A (21-162B)
2.
Clamp
303-397 (24-003)

303-507 (21-210)
CAUTION: Do not remove the the

installation sleeve before installation.
supplied preassembled with an installation sleeve
that must be removed following installation.
NOTE: Install a new crankshaft rear seal carrier.

303-508 (21-211)
General Equipment
Engine hoist
M6 x 18 mm bolt
Straight edge
Name
Silicone Sealant
G451310 en
Specification
WSE-M4G323-A4

block and the oil pan with a suitable metal
surface cleaner.
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TO MODEL INDEX
303-01B-97
applying the sealant and tighten the retaining
bolts within a further 5 minutes.

position.
5. Using a suitable straight edge, align the oil

pan to the cylinder block mating face on
the timing chain side.
6. Tighten the oil pan retaining bolts.
7. NOTE: Install new flywheel bolts.

Install the flywheel.
G451310 en
9. Tighten the flywheel bolts.

three stages.
Stage 1: 50 Nm.
Stage 2: 80 Nm.
Stage 3: 112 Nm.

Plate]
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TO MODEL INDEX
303-01B-98
12. NOTE: Install a new oil filter adapter gasket.
Install the oil filter adapter.
15. NOTE: Install a new thermostat housing

gasket.
Install the thermostat housing.
13. Install the crankcase vent oil separator.

16. NOTE: Install a new coolant pump O-ring.
Install the coolant pump.
14. NOTE: Rotate the knock sensor (KS) as far

counter-clockwise as possible without it
touching the crankcase vent oil separator.
Install the KS.
G451310 en
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TO MODEL INDEX
303-01B-99
17. NOTE: Install new cylinder head bolts and

gasket.
Install the cylinder head.
Tighten the cylinder head bolts in five
stages.
Stage 1: 5 Nm.
Stage 2: 15 Nm.
Stage 3: 45 Nm.
18. NOTE: Only rotate the crankshaft in its normal

20.
CAUTION: Install the camshafts

approximately at valve overlap
position on cylinder No. 4.
Working in several stages, evenly tighten
the camshaft bearing cap bolts in the
sequence shown, one half turn at a time.
Tighten the bolts in two stages.
Stage 1: 7 Nm.
Stage 2: 16 Nm.

approximately 45 degrees before top dead
center (TDC).
G451310 en
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TO MODEL INDEX
303-01B-100
22. NOTE: Install a new rear friction washer.
Install the rear friction washer.
25. Install the oil pump chain.

1. Install the oil pump chain and the oil pump
sprocket.
2. Install the oil pump sprocket retaining bolt.
23. Install the crankshaft sprocket.

26. Using the special tools, tighten the oil
24. NOTE: Install a new front friction washer.

Install the front friction washer.
27. Install the oil pump chain tensioner.
G451310 en
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303-01B-101

TO MODEL INDEX
303-01B-101
28. Install the oil pump chain guide.
31.
CAUTION: Do not fully tighten the

camshaft sprocket retaining bolts at
this stage. Make sure the camshaft
sprockets turn on the camshafts.
Install the camshaft sprockets.
Install the timing chain.
29. Install the timing chain tensioner.

Apply pressure to the timing chain and remove the securing pin.
30. Install the timing chain guides.
G451310 en
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303-01B-102

TO MODEL INDEX
303-01B-102
33.
CAUTION: Hold each camshaft by the

hexagon with an open-ended wrench
to stop it from turning.
Tighten the camshaft sprockets retaining
bolts.
35. NOTE: Install the engine front cover within 10

minutes of applying the sealant.
Apply a 3 mm bead of sealant to the engine front cover.
34. Clean the mating face of the engine front

cover with a suitable metal surface
cleaner.
G451310 en
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303-01B-103

TO MODEL INDEX
303-01B-103
36. Install the engine front cover.
Tighten bolts 1 through 8 to 10 Nm.
Tighten bolt 9 to 48 Nm.

Using the crankshaft pulley retaining bolt,
rotate the crankshaft until piston No. 1 is
at TDC.
39. Remove the crankshaft pulley retaining

bolt.
Discard the bolt.
40.

Install the crankshaft pulley onto the
crankshaft and secure the crankshaft
pulley to the front cover using a M6 x 18
mm bolt.

plug from the cylinder block and install
the special tool.
G451310 en
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303-01B-104

TO MODEL INDEX
303-01B-104
41. NOTE: Install a new crankshaft pulley
retaining bolt.
Using the special tools, prevent the

crankshaft pulley from rotating and
tighten the crankshaft pulley retaining
bolt.
Tighten the bolt in two stages.
Stage 1: 100 Nm.

Rotate the crankshaft two revolutions.

bolt.

at TDC.
G451310 en
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303-01B-105

TO MODEL INDEX
303-01B-105
48.

NOTE: If it is not possible to install the crankshaft
pulley securing bolt, correct the engine timing.

bolt.
Using a M6 x 18 mm bolt, check the position of the crankshaft pulley.
49. NOTE: If it is not possible to install the special

tool, correct the engine timing.
Using the special tool, check the position
of the camshafts.
53. Install the cylinder block lower blanking

plug.
G451310 en
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303-01B-106

TO MODEL INDEX
303-01B-106
54. NOTE: When installing a new crankshaft
pulley or engine front cover, the crankshaft
position (CKP) sensor must be aligned using
the alignment tool supplied with the new
component.
NOTE: Do not tighten the bolts at this stage.
Align the CKP sensor.

1. Loosen the CKP sensor retaining bolts.
2. Insert the alignment tool supplied, so that it
is hooked in the crankshaft pulley teeth.
57. Install the accessory drive belt idler pulley.
55. Install the CKP sensor.

1. Tighten the CKP sensor retaining bolts.
2. Remove the alignment tool.
58. Install the accessory drive belt tensioner.
G451310 en
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TO MODEL INDEX
303-01B-107
as shown.

necessary.

plugs.


64. Install the power steering pump.

G451310 en
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303-01B-108

TO MODEL INDEX
303-01B-108
65. Using the special tool, install the coolant
hoses.
66. Connect the positive crankcase ventilation (PCV) hose to the intake manifold.
68. Install the oil level indicator tube and oil

level indicator.
69. NOTE: Install a new exhaust manifold gasket.

NOTE: Do not tighten the exhaust manifold
retaining nuts at this stage.
67. Install the intake manifold.

70. Install the exhaust manifold lower retaining bolts.
G451310 en
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303-01B-109

TO MODEL INDEX
303-01B-109
71. Connect the manifold absolute pressure
(MAP) sensor electrical connector.
74. Connect the throttle body (TB) electrical

connector.
72. Attach the starter motor electrical connector to the intake manifold.
75. Connect the heated oxygen (H2OS) sensor electrical connector.
73. Connect the intake manifold runner control (IMRC) electrical connector.

G451310 en
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303-01B-110

TO MODEL INDEX
303-01B-110
77. Connect the electronic ignition (EI) electrical connector.
78. Connect the exhaust gas recirculation


connector.
79. Connect the camshaft position (CMP)


connector.
G451310 en
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303-01B-111

TO MODEL INDEX
303-01B-111
83. Attach the engine wiring harness bracket
to the intake manifold.

85. Using the special tool and an engine hoist,
support the engine.
87. Install the generator.


shield.
G451310 en
11/2004 2005.25 Fiesta
303-01B-112

TO MODEL INDEX
303-01B-112
shield.
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TO MODEL INDEX
303-01B-113
303-01B-113
INSTALLATION
Engine
3. Install the transaxle upper retaining bolts.
Special Tool(s)
Protector, Halfshaft Seal
205-775

211-188
Clamp
303-397
4. Install the transaxle left-hand retaining

bolts.
Installer, Camshaft Pulley

303-458
General Equipment
Workshop table
Securing straps
Engine hoist

bolts.

1. NOTE: Using suitable retaining straps, secure
the engine on the workshop table.
Support the engine with wooden blocks.
2. Install the transaxle.
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TO MODEL INDEX
303-01B-114
9. Position the workshop table under the vehicle and carefully lower the vehicle until
the engine and transaxle assembly is in the
correct position to install the engine
mounts.
7. Install the starter motor.
10. NOTE: Do not tighten the engine rear mount

Install the engine rear mount retaining
nuts.
8. Install the wiring harness retaining bracket.

Attach the wiring harness to the retaining
bracket.
G451291 en
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303-01B-115

TO MODEL INDEX
303-01B-115
11. NOTE: Install new engine front mount
retaining nuts.
NOTE: Do not tighten the engine front mount
retaining nuts and bolts at this stage.
16. Connect the A/C high pressure switch

Install the engine front mount retaining

nuts and bolts.

12. Remove the securing straps.
18. Attach the gearshift cables to the selector

levers.
G451291 en
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TO MODEL INDEX
303-01B-116
19.

than 45 degrees.
CAUTION: Make sure that the halfshaft
seal is not damaged.

correctly seated.
Using the special tool, attach the left-hand
halfshaft to the transaxle.
Remove the special tool before fully installing the halfshaft.
20.

than 45 degrees.
CAUTION: Make sure the halfshaft seal is
not damaged.
Using the special tool, attach the
right-hand halfshaft and intermediate
shaft assembly to the transaxle.
Remove the special tool before fully installing the halfshaft.
21. NOTE: Install a new intermediate shaft center

bearing cap and retaining nuts.
center bearing is correctly positioned in the
intermediate shaft center bearing retaining
bracket.
bearing cap.
Position the center bearing cap.
Position the intermediate shaft center
bearing heat shield (if equipped).
Tighten the center bearing cap retaining
nuts.
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303-01B-117
22.
CAUTION: Make sure that the lower

arm ball joint heat shield is installed to
prevent damage to the ball joint.
25. Install the air cleaner resonator support

bracket.
Install the lower arm ball joint heat shield.
23.

wheel knuckle.

27. Tighten the engine rear mount outer retaining nuts.
Attach the lower arm ball joint to the

wheel knuckle.
28. Tighten the engine rear mount center retaining nut.
24. Attach the powertrain control module

(PCM) support bracket to the side member.
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303-01B-118
29. Tighten the engine front mount retaining
nuts and retaining bolts.
32.
CAUTION: Care must be taken to

prevent dirt ingress.
seal onto the power steering pump to
steering gear pressure line union.
2. Locate the special tool onto the power
steering pump to steering gear pressure line
union and install the O-ring seal.
30. Connect the fuel supply line. For additional information, refer to Section
GENERAL PROCEDURES, Quick Release
Coupling]
33. Attach the power steering pump to

steering gear pressure line from the
31. Attach the power steering pump to

steering gear pressure line to the intake
manifold.
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303-01B-119
34. NOTE: Install a new power steering pump
pulley.
Using the special tool, install the power
steering pump pulley.
35. Install new power steering fluid reservoir

O-ring seals.
36. Install the power steering fluid reservoir.
G451291 en
37. Using the special tool, connect the

steering gear to power steering fluid reservoir return line to the power steering
fluid reservoir.
38. Attach the steering gear to power steering

fluid reservoir return line support bracket
to the generator.
39. Connect the A/C low pressure switch

connector.
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303-01B-120
40.

water.
seated.
43. Install the coolant expansion tank.

line.
44. Attach the power steering high-pressure

line retaining bracket to the transaxle.
45. Install the engine wiring harness bracket.
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303-01B-121

48. Connect the power steering pump switch

G451291 en

51. Attach the evaporative emission (EVAP)

valve from EVAP valve support bracket.
1. Connect the EVAP valve electrical
connector.
2. Connect the low pressure line to the EVAP
valve.
3. Push the EVAP valve onto the support
bracket.
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303-01B-122
52. Using the special tool, connect the coolant hose to the coolant outlet connector.

mount nuts.
54. Install the right-hand headlamp assembly.

Section 417-01.[Exterior Lighting,
Headlamp Assembly]
55. Attach the exhaust flexible pipe to the
exhaust manifold. For additional
G451291 en
56. Install the cooling fan motor and shroud.
57. Connect the cooling fan motor and cooling fan resistor electrical connectors.

59. Adjust the gearshift cables. For additional
Cable Adjustment]
60. Bleed the hydraulic clutch system. For
Bleeding]
61. Install the battery tray. For additional
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303-01B-123
Duratec-HE (MI4), GENERAL
Filling and Bleeding]
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303-03A-1
Engine Cooling 1.25L Duratec-16V (Sigma)/1.3L
303-03A-1
Duratec-8V (Rocam)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma)
SECTION 303-03A Engine Cooling 1.25L

Duratec-16V (Sigma)/1.3L Duratec-8V (Rocam)/1.4L
CONTENTS
PAGE
SPECIFICATIONS
Specifications...................................................................................................................
303-03A-2

Engine Cooling 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) ........................
Overview .........................................................................................................................
Components....................................................................................................................
303-03A-3
303-03A-3
303-03A-4

Engine Cooling.................................................................................................................
Symptom Chart ...............................................................................................................
Component Tests............................................................................................................
303-03A-7
303-03A-7
303-03A-7
303-03A-10
GENERAL PROCEDURES
(24 122 0)
Cooling System Draining, Filling and Bleeding 1.25L Duratec-16V
(Sigma)/1.3L Duratec-8V (Rocam)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) ........................................................................................
Draining...........................................................................................................................
Filling and Bleeding.........................................................................................................
303-03A-12
303-03A-12
303-03A-12

Water Pump 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L (24 404 0)
Duratec-16V (Sigma)....................................................................................
Thermostat 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L (24 454 0)
Duratec-16V (Sigma)....................................................................................
Radiator ........................................................................................................ (24 254 0)
303-03A-13
303-03A-15
303-03A-17
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303-03A-2
SPECIFICATIONS
Description
Motorcraft Super Plus 2000 antifreeze
Specification
WSS-M97B44-D
Antifreeze - All vehicles used in climates where daytime ambient air temperature does not
regularly exceed +46C (+115F)
Specific gravity
(providing no other
Approximate
additive is in the
percentage of
coolant)
antifreeze (by volume)
Remains fluid to
Solidifies at
1.061 at +15C (+59F)
50%
-25C (-13F)
-30C (-22F)
Antifreeze - Vehicles with 1.25L/1.4L/1.6L engine used in climates where daytime ambient air
temperature regularly exceeds +46C (+115F)
Specific gravity (providing no other additive is
Approximate percentage of antifreeze (by
in the coolant)
volume)
1.0278 at +35C (+95F)
25%
Cooling System Refill Capacities
Description
Cooling system, including heater system and coolant expansion tank (all except vehicles with diesel engine)
Cooling System Pressure Specification
Description
Radiator pressure test
Coolant expansion tank cap release pressure
Liters
5.0
Pressure kpa (psi)

138 (20)
120 to 150 (17-21)
Torque Specifications - vehicles with 1.25L/1.4L/1.6L engine

Description
Nm
Radiator retaining nut
10
10
10
24
Generator retaining bolts
45
Generator electrical connector retaining nut
8
Timing belt lower cover retaining bolts
9
lb-ft
18
33
-
lb-in
89
89
89
71
80
Torque Specifications - vehicles with 1.3L engine

Description
lb-ft
9
-
lb-in
89
89
89
G146257 en
Nm
10
10
12
10
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303-03A-3

Engine Cooling 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma)
Overview
Item
Part
Number
Coolant pump
Engine
G179022 en
Description
Item
Part
Number
Description
Water outlet housing
Heater heat exchanger

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303-03A-4

Description
Components
Thermostat housing
Coolant pump
Coolant expansion tank
Radiator
Item
Part
Number
1
2
Item
Part
Number
Description
The coolant pump is secured to the engine block

at the timing gear end.
Coolant pump
It is driven through a pulley by the accessory drive

belt.
Coolant pump gasket
G179022 en
The gasket for the coolant pump must not be

reused.
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303-03A-5

Thermostat and thermostat housing
Item
Part
Number
Description
Thermostat housing
Thermostat
Venting pin
The thermostat and thermostat housing are

located on the side of the engine block.
When installing the thermostat, make sure that the
venting pin is at the top.
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303-03A-6

Item
Part
Number
Description
Gasket
Engine Coolant Temperature

(ECT) sensor
The water outlet housing is located on the cylinder

head nearest the transmission.
Among other things, it is used to mount the
Electronic Ignition (EI) coil.
In addition, the ECT sensor is located in the
housing.
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303-03A-7

Engine Cooling
Mechanical
Special Tool(s)
Pressure Tester, Cooling
System
303-396 (24-001 A)
Adapter for 303-396
303-396-01
3.

4.
Electrical
Coolant leak(s)
Fuse(s)
Coolant level
Relay(s)
Air in system
Wiring harness
Gaskets/seals
Electrical
connector(s)
Hose(s)/hose joints
Cooling fan motor
Coolant expansion
Engine coolant
tank pressure cap
and seal
temperature (ECT)
sensor
Coolant expansion
Cylinder head
tank
temperature (CHT)
Radiator
sensor
Water pump
Powertrain control
Thermostat
module (PCM)
Thermostat housing
step.
Symptom Chart
Symptom
Loss of coolant
G146258 en
Possible Sources
Action
Hose(s)/hose joint(s).
INSPECT the hoses and hose

joints. INSTALL a new hose(s)
as necessary.
Radiator.
INSPECT the radiator for leaks.

CARRY OUT the Pressure Test
INSTALL a new radiator as
necessary.
Water pump.
INSPECT the water pump for

leaks. CARRY OUT the Pressure Test Component Test in this
section. INSTALL a new water
pump or water pump gasket as
necessary.
Thermostat housing.
INSPECT the thermostat housing for leaks. CARRY OUT the

Pressure Test Component Test
in this section. INSTALL a new
thermostat housing or thermostat housing gasket as necessary.
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303-03A-8

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303-03A-8

Symptom
Possible Sources
Action
Coolant expansion tank pressure CHECK the coolant expansion

cap or seal.
tank pressure cap for tightness.
If OK, CARRY OUT the Coolant
Expansion Tank Pressure Cap
in this section.
The engine overheats (signs of

coolant boiling)
G146258 en
Coolant expansion tank.
INSPECT the seal face on the

coolant expansion tank for
damage. INSTALL a new coolant
expansion tank as necessary.
Heater core.
CHECK the heater core for

leaks. REFER to Section
412-02A.
Engine.
INSPECT the engine, cylinder

head, cylinder block and cylinder
head gasket. REFER to Section
303-00.
Cooling system does not hold

pressure.
CARRY OUT the Coolant

in this section.
INSPECT the coolant
expansion tank for damage.
INSTALL a new coolant
expansion tank as
necessary.
INSPECT the water pump or
water pump gasket for
damage. INSTALL a new
water pump or water pump
gasket as necessary.
INSPECT the engine, cylinder head, cylinder block and
cylinder head gasket.
Radiator.
INSPECT the radiator for

blockage or damage. CARRY
OUT the Pressure Test Component Test in this section.
necessary.
Air in system.
BLEED the cooling system.

REFER to Cooling System
Draining, Filling and Bleeding 1.25L Duratec-16V (Sigma)/1.3L
Duratec-8V (Rocam)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) in this section.
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303-03A-9

Symptom
Possible Sources
Action
Coolant expansion tank pressure CHECK the coolant expansion

cap or seal.
tank pressure cap for tightness.
If OK, CARRY OUT the Coolant
in this section.
G146258 en
INSPECT the seal face on the

coolant expansion tank for
expansion tank as necessary.
Coolant level/condition.
CHECK the coolant level.

REFILL the cooling system as
necessary. REFER to Cooling
System Draining, Filling and
Bleeding - 1.25L Duratec-16V
(Rocam)/1.4L Duratec-16V
(Sigma) in this section.
CHECK the coolant condition. If
the coolant is in poor condition
drain and refill with new coolant.
Draining, Filling and Bleeding 1.25L Duratec-16V (Sigma)/1.3L
Duratec-8V (Rocam)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) in this section.
Coolant concentration.

section.
Radiator grille.
INSPECT the radiator grille for

air restrictions or damage.
REPAIR or INSTALL new parts
as necessary.
Water pump.

INSPECT the water pump for
leaks. INSTALL a new water
pump or water pump gasket as
necessary.
Thermostat.
CARRY OUT the Thermostat

Test Component Test in this
section. INSTALL a new thermostat as necessary.
CHECK the accessory drive belt

for correct operation. REFER to
Section 303-05.
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TO MODEL INDEX
303-03A-10

Symptom
The engine does not reach

normal operating temperature.
Possible Sources
Action
Cooling fan motor.
CHECK the operation of the

cooling fan motor. REFER to
WDS.
Engine.

303-00.
Thermostat.

section. INSTALL a new thermostat as necessary.
Component Tests
Pressure Test
WARNING: When releasing the system

pressure, cover the expansion tank cap
with a thick cloth to prevent the
possibility of coolant scalding, Failure to
personal injury.
1. Remove the coolant expansion tank pressure

cap.
2. Install the special tools to the coolant
expansion tank.
3. Pressurize the system to the coolant
expansion tank cap release pressure.
REFER to Specifications in this section.
4. Observe the cooling system pressure tester
gauge reading for approximately two minutes.
The pressure should not drop during this time.
If the system holds pressure, proceed to step
6. If the system does not hold pressure, check
it thoroughly for coolant leaks.
5. Check the engine for coolant leaks REFER to
Section 303-00. Drain the cooling system,
repair any coolant leaks found and fill and
bleed the cooling system as necessary.
REFER to Cooling System Draining, Filling
and Bleeding - 1.25L Duratec-16V
(Sigma) in this section.
6. Recheck the system by repeating steps 3 and
4 at least twice.
Thermostat Test
Remove the thermostat and immerse it in water.

Heat the water until it reaches 88 C (190 F). At
this temperature the thermostat should begin to
open. If it does not begin to open, install a new
thermostat.
Radiator Leak Test, Removed From Vehicle
CAUTION: Radiator internal pressure

must not exceed 130 kpa (20 psi) or
damage may result.
Clean the radiator thoroughly before leak testing it,
to prevent contamination of the water in the test
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303-03A-11

tank. Leak test the radiator in clean water with 138
kpa (20 psi) air pressure. Check it thoroughly for
air leaks. Install a new radiator if necessary.
Coolant Expansion Tank Pressure Cap Pressure
Test
WARNING: When releasing the system

pressure, cover the expansion tank cap
with a thick cloth to prevent the
possibility of coolant scalding, Failure to
personal injury.
1. Remove the coolant expansion tank pressure
cap.
2. Use water to clean the area of the rubber seal
and pressure relief valve. Install the pressure
tester and adapter and immerse the coolant
expansion tank pressure cap in water .
NOTE: If the plunger of the pump is depressed too
quickly, an erroneous pressure reading will result.
3. Slowly depress the plunger of the pressure
test pump until the pressure gauge reading
stops increasing, and note the highest
pressure reading obtained.
4. Release pressure by turning the pressure
relief screw counterclockwise. Tighten the
pressure relief screw and repeat step 3 at
least twice to make sure the pressure test
reading is repeatable and within acceptable
gauge reading limits of the coolant expansion
tank pressure cap.
5. If the pressure test gauge readings are not
within the acceptable gauge reading limits,
install a new coolant expansion tank pressure
cap.
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303-03A-12
GENERAL PROCEDURES
Cooling System Draining, Filling and Bleeding 1.25L Duratec-16V (Sigma)/1.3L
Duratec-8V (Rocam)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) (24 122 0)
Draining
1.
WARNING: When releasing the cooling

system pressure, cover the coolant
expansion tank cap with a thick cloth
to prevent the possibility of scalding.
Filling and Bleeding

1. Remove the radiator bleed plug (if
equipped).
Release the cooling system pressure by

slowly turning the coolant expansion tank
cap a quarter of a turn.
2. Fill the coolant expansion tank until

coolant is expelled from the radiator bleed
point or stabilizes at the MAX mark
(whichever occurs first).
3. Install the radiator bleed plug (if equipped).
4. Fill the coolant expansion tank to the MAX
mark (if necessary).
2. Remove the coolant expansion tank cap.
4. Drain the cooling system.
Allow the coolant to drain into a suitable
container.
5. Install the radiator drain plug.

G146259 en
5. Start and run the engine at 3000

revolutions per minute (RPM) for two
minutes.
6. Fill the coolant expansion tank completely.
7. Install the coolant expansion tank cap.
8. Start and run the engine at 3000 RPM for
another two minutes.
9. Switch the engine off.
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303-03A-13

Water Pump 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L
Duratec-16V (Sigma) (24 404 0)
Removal
414-01.
information, refer to Cooling System
Draining, Filling and Bleeding - 1.25L
Duratec-16V (Sigma) in this section.
4. Remove the crankshaft pulley splash
shield.

7. Disconnect the degas hose from the coolant expansion tank.
8. Detach the coolant expansion tank and

5.
WARNING: Do not remove the water

pump pulley retaining bolts at this
stage as the pulley is under tension
from the accessory drive belt. Failure
personal injury.
Loosen the water pump pulley retaining
bolts.
G189080 en
9. Remove the generator. For additional

10. Remove the water pump pulley.
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303-03A-14

11. Remove the timing belt cover (cover
12.
CAUTION: Protect the timing belt and

lower cover from contamination by the
coolant.
Remove the water pump.
Discard the gasket.
Installation
1. NOTE: Install a new water pump gasket.
G189080 en
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303-03A-15

Thermostat 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L
4. Disconnect the heater hose from the
thermostat housing.
Special Tool(s)
Remover/Installer, Cooling
Hose Clamp
303397 (24003)
Removal
2. Remove the generator. For additional
3. Using the special tool, disconnect the radiator lower hose from the thermostat
housing.
6. NOTE: The thermostat is installed with the

jiggle pin at the top.
Remove the thermostat.
G210040 en
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303-03A-16

Installation
Make sure the rubber seal is located correctly.
G210040 en
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303-03A-17

Radiator (24 254 0)
Special Tool(s)
Hose Clamp
303397 (24003)

Removal
414-01.
5. Using the special tool, disconnect the radiator upper hose.
6. Using the special tool, disconnect the radiator lower hose.
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303-03A-18

7. Remove the radiator retainers.
1. Remove the radiator retainer locking
screws.
2. Remove the radiator retainers and grommets.
10. Remove the radiator.
Installation
8. Detach the radiator and the air conditioning

(A/C) condenser from the support panel.
9.
CAUTION: Support the condenser by

positioning it on the support panel.
Slide the A/C condenser to detach it from
the radiator
G210041 en
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303-03B-1
Engine Cooling 2.0L Duratec-HE (MI4)
303-03B-1
SECTION 303-03B Engine Cooling 2.0L Duratec-HE

(MI4)
CONTENTS
PAGE
SPECIFICATIONS
Specifications.................................................................................................................
303-03B-2

Engine Cooling...............................................................................................................
System Overview ..........................................................................................................
Components..................................................................................................................
Coolant .........................................................................................................................
Changing Coolant .........................................................................................................
Fail-Safe Cooling...........................................................................................................
303-03B-3
303-03B-3
303-03B-3
303-03B-7
303-03B-7
303-03B-8

Engine Cooling...............................................................................................................
Inspection and Verification ............................................................................................
Symptom Chart .............................................................................................................
Component Tests..........................................................................................................
303-03B-9
303-03B-9
303-03B-9
303-03B-12
GENERAL PROCEDURES
Cooling System Draining, Filling and Bleeding ..............................................(24 122 0)
Draining.........................................................................................................................
Filling and Bleeding.......................................................................................................
303-03B-14
303-03B-14
303-03B-14

Coolant Pump ................................................................................................................
Thermostat Housing.......................................................................................................
Coolant Outlet Connector...............................................................................................
Radiator ........................................................................................................(24 254 0)
303-03B-16
303-03B-18
303-03B-20
303-03B-22
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303-03B-2
SPECIFICATIONS

Description
Motorcraft Super Plus 2000 antifreeze
Antifreeze
Specific gravity
(providing no other
additive is in the
coolant)
1.061 at +15C
Approximate
percentage of
antifreeze (by volume)
50%
Specification
WSS-M97B44-D
Remains fluid to
-25C (-13F)
Solidifies at
-30C (-22F)
Cooling System Refill Capacities

Description
Cooling system, including heater system and coolant expansion tank
Liters
4.0
Cooling System Pressure Specification

Description
Radiator pressure test
Coolant expansion tank cap release pressure
Torques
Description
Coolant pump pulley retaining bolts
Coolant outlet connector retaining bolts
Ignition coil pack retaining bolts
G421218 en
Pressure kpa (psi)

138 (20)
120 to 150 (17-21)
Nm
10
10
10
20
10
6
lb-ft
15
-
lb-in
89
89
89
89
53
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303-03B-3
303-03B-3

Engine Cooling
System Overview
Item
Part
Number
Coolant outlet connector
Exhaust gas recirculation

(EGR) valve
Cooling fan motor
Radiator
Oil cooler
Thermostat housing
Coolant pump
Coolant expansion tank
G421219 en
Description
11/2004 2005.25 Fiesta
303-03B-4

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303-03B-4
Components
Coolant Pump
Item
Part
Number
Description
Coolant pump pulley
Coolant pump
Coolant pump gasket
The coolant pump is of a conventional design and

is driven by the water pump pulley and accessory
drive belt.
It is driven through a pulley by the accessory drive
belt.
The coolant pump gasket must not be reused.
G421219 en
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303-03B-5
303-03B-5
Thermostat Housing
Item
Part
Number
Description
Thermostat housing
Thermostat housing gasket
The thermostat and thermostat housing are

located on the side of the engine block.
The thermostat is built into the thermostat housing
and cannot be serviced as a separate component.
G421219 en
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303-03B-6

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303-03B-6
Coolant Outlet Connector
Item
Part
Number
Description
Engine coolant temperature

(ECT) sensor

gasket
The coolant outlet connector is located on the

cylinder head above the transmission.
The ECT sensor is located in the coolant outlet
connector.
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303-03B-7
303-03B-7

No manual bleed points are provided on the
system.
Oil Cooler
The coolant expansion tank serves as the location

for:
Service fill.
Coolant expansion during warm-up.
Air separation during operation.
System pressurization by the coolant pressure
cap.
Coolant
WARNING: Coolant contains
monoethylene glycol and other
constituents which are toxic if taken
internally and can be absorbed into the
skin after prolonged contact. Failure to
personal injury.
Item
Part
Number
Description
Oil cooler
Oil filter adaptor
Oil filter
The oil cooler is an oil to water type and is a full

flow system.
The oil cooler and oil filter are fitted to an adaptor
which is mounted on the cylinder block.
The coolant supply for the oil cooler is through the
thermostat by-pass hose.
Coolant Recovery System
A pressurized coolant expansion tank system is
used which continuously separates the air from
the cooling system and replenishes the system
through the coolant expansion tank outlet hose.
Coolant concentration should be checked through

the neck of the expansion tank with a hydrometer.
The acceptable range of specific gravity (sg) of
correctly balanced fluids is between 1.06 and
1.07kg/l, which represents a coolant concentration
between 40% and 55%. If the concentration falls
below 40% there is insufficient low temperature
protection and the corrosion resistance will be
inadequate. In such cases the concentration must
be brought back to specification.
The coolant used is the orange-colored Motorcraft
Super Plus 2000. Motorcraft Super Plus 2000 is a
non silicated organic acid technology (OAT)
coolant, and must not be mixed with other coolant
types. For cooling system top up, only use coolant
which meets the correct specification and is
compatible with the existing coolant.
Changing Coolant
expansion tank cap with a thick cloth to
prevent the possibility of coolant
scalding. Failure to follow this instruction
A continuous vent from the engine and radiator to

the coolant expansion tank prevents air locks from
forming in the cooling system.
G421219 en
11/2004 2005.25 Fiesta
303-03B-8

TO MODEL INDEX
303-03B-8
CAUTION: When draining the coolant or

changing any cooling system
components, it is imperative that no
coolant comes into contact with the
camshaft drive belt or accessory drive
belt. If necessary the belt should be
removed. Contamination of the belt may
result in premature belt failure.
NOTE: Providing the coolant has not been
contaminated with other fluids or foreign matter,
the robust corrosion resistance properties of this
coolant means that it can be re-used after
changing an aluminium cooling system
component, although the concentration should
always be checked and maintained within
specification.
This coolant should be changed after a period of
10 years or 150 000 miles, whichever occurs first.
Refill the cooling system with coolant which meets
the correct specification and is compatible with the
existing coolant.
NOTE: If the driver is using a high percentage of

throttle travel (for example, an overtaking
maneuver) when the PCM starts engine
deactivation (stage 2), the deactivation will be
delayed for 10 seconds.
NOTE: After 2-cylinder operation has begun, the
engine will not revert to 4-cylinder operation, even
if the temperature should fall, until the ignition is
switched off and then on again.
NOTE: The MIL can only be extinguished by using
WDS after the fault has been rectified and the
DTC cleared.
If the engine temperature still continues to rise,
stage 3 of the strategy will commence. This will
result in the engine being totally disabled before
major engine damage or seizure occurs. The MIL
will begin to flash, indicating to the driver that the
engine will be switched off after 30 seconds. This
allows the driver time to choose a suitable parking
place.
Fail-Safe Cooling
The vehicle has a strategy built into the powertrain
control module (PCM) that will control the engine if
the engine starts to overheat.
If the engine starts to overheat, stage 1 of the
strategy will commence. The ECT sensor
transmits a signal to the PCM which then moves
the temperature gauge pointer into the red zone.
If the engine is not switched off and the
temperature continues to rise, the malfunction
indicator lamp (MIL) is illuminated. This indicates
to the driver that the engine is approaching critical
limits and should stop. At this point DTC P1285 is
set in the PCM which can be retrieved using WDS.
If the MIL and temperature gauge are ignored by
the driver, stage 2 of the strategy will commence.
The PCM will start to control the engine by cutting
out two cylinders and restricting the RPM to below
3000 RPM. The MIL will remain illuminated. This
indicates that long term engine damage may
occur and vehicle emissions will be affected. At
this point DTC P1299 is set in the PCM which can
be retrieved using WDS.
Air is drawn into the deactivated cylinders which
helps to control the temperature of the engine
internal components. The deactivated cylinders
are alternated to allow even cooling of all the
cylinders.
G421219 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
303-03B-9
303-03B-9

Engine Cooling
Mechanical
Special Tool(s)
Pressure Tester, Cooling
System
303-396 (24-001 A)
Adaptor for 303-396

303-396-01

3.

4.
Electrical
Coolant leak(s)
Fuse(s)
Coolant level
Relay(s)
Gasket(s) or seal(s) Wiring harness
Core plug(s)
Electrical
connector(s)
Hose(s) or hose
Engine coolant
joints
temperature (ECT)
Coolant expansion
sensor
tank cap and seal
Cooling fan motor
Coolant expansion
Powertrain control
tank
module (PCM)
Radiator
Coolant pump
Thermostat housing
Heater core
(if possible) before proceeding to the next step
Symptom Chart
Symptom
Loss of coolant
G426582 en
Possible Sources
Action
Hose(s) or hose joint(s).
INSPECT the hoses and hose

joints. INSTALL a new hose(s)
as necessary.
Radiator.
INSPECT the radiator for leaks.

necessary.
Coolant pump.
INSPECT the coolant pump for

leaks. CARRY OUT the Pressure Test Component Test in this
section. INSTALL a new coolant
pump or coolant pump gasket as
necessary. REFER to Coolant
Pump in this section.
11/2004 2005.25 Fiesta
303-03B-10

TO MODEL INDEX
303-03B-10

Symptom
The engine overheats (signs of

coolant boiling)
G426582 en
Possible Sources
Action
Thermostat housing.
INSPECT the thermostat housing for leaks. CARRY OUT the

in this section. INSTALL a new
thermostat housing and thermostat housing gasket as necessary. REFER to Thermostat
Housing in this section.
Coolant expansion tank cap or

seal(s).
CHECK the coolant expansion

tank cap for tightness and
expansion cap as necessary.
INSPECT the coolant expansion

tank for damage. INSTALL a
new coolant expansion tank as
necessary.
Heater core.
CHECK the heater core for

leaks.
Engine.

REPAIR, Cylinder Head]
Cooling system does not hold

pressure.

necessary.
INSPECT the coolant pump or
coolant pump gasket for
Air in cooling system.
BLEED the cooling system.

Draining, Filling and Bleeding in
this section.
Coolant expansion tank cap or

seal(s).
CHECK the coolant expansion

tank cap for tightness and
expansion cap as necessary.
11/2004 2005.25 Fiesta
303-03B-11

TO MODEL INDEX
303-03B-11

Symptom
G426582 en
Possible Sources
Action

necessary.
Coolant level or condition.
CHECK the coolant level.

REFILL the cooling system as
necessary. REFER to Cooling
System Draining, Filling and
Bleeding in this section.
CHECK the coolant condition
and concentration REFER to
Specifications in this section. If
the coolant is contaminated or
the concentration is below
specifications, drain and refill
with new coolant. REFER to
Cooling System Draining, Filling
and Bleeding in this section.
Radiator grille.
INSPECT the radiator grille for

air restrictions or damage.
REPAIR or INSTALL new parts
as necessary.
Coolant pump.

INSPECT the coolant pump for
leaks. INSTALL a new coolant
Thermostat.

section. INSTALL a new thermostat housing and thermostat
housing gasket as necessary.
REFER to Thermostat Housing
in this section.
Accessory drive belt.
CHECK the condition of the accessory drive belt. REFER to

Section 303-05.[Accessory
Drive, DIAGNOSIS AND
TESTING, Accessory Drive]
Cooling fan.
CHECK the operation of the

cooling fan. REFER to WDS.
Engine.

11/2004 2005.25 Fiesta
303-03B-12

TO MODEL INDEX
303-03B-12

Symptom
The engine does not reach
Possible Sources
Action
ECT sensor.
CHECK the ECT sensor. REFER

to WDS.
Temperature gauge.
CHECK the instrument cluster

engine temperature gauge.
REFER to Section
413-01.[Instrument Cluster,
Instrument Cluster]
Thermostat.

section. INSTALL a new thermostat housing and thermostat
housing gasket as necessary.
REFER to Thermostat Housing
in this section.
Component Tests
Pressure Test

expansion tank cap with a thick cloth to
prevent the possibility of coolant
scalding. Failure to follow this instruction
NOTE: If the coolant expansion tank cap is rotated
counterclockwise by 1/2 a full turn, the
pressurized coolant will be vented to the
underside of the coolant expansion tank cap.

2. Install the special tools 303-396 and
303-396-01 to the coolant expansion tank.
3. Pressurize the system to the coolant
expansion tank cap release pressure.
REFER to Specifications in this section.
4. Observe the cooling system pressure tester
gauge reading for approximately two minutes.
The pressure should not drop during this time.
If the system holds pressure, proceed to Step
7. If the system does not hold pressure, check
it thoroughly for coolant leaks.
5. Check the engine for coolant leaks. Drain the
cooling system, repair any coolant leaks found
and fill and bleed the cooling system as
necessary. REFER to Cooling System
Draining, Filling and Bleeding in this section.
6. Recheck the system by repeating Steps 3 and
4 at least twice.
Thermostat Test
Remove the thermostat housing and immerse it in

water. Heat the water until it reaches 90C (194F).
At this temperature the thermostat should begin to
open. If it does not begin to open, INSTALL a new
thermostat housing and thermostat housing
gasket as necessary. REFER to Thermostat
Radiator Leak Test, Removed From Vehicle
CAUTION: Radiator internal pressure

must not exceed 130 kpa (20 psi) or
damage may result.
G426582 en
11/2004 2005.25 Fiesta
303-03B-13

TO MODEL INDEX
303-03B-13

Clean the radiator thoroughly before leak testing it,
to prevent contamination of the water in the test
tank. Leak test the radiator in clean water with 138
kpa (20 psi) air pressure. Check it thoroughly for
air leaks. Install a new radiator if necessary.
G426582 en
11/2004 2005.25 Fiesta
303-03B-14

TO MODEL INDEX
303-03B-14
GENERAL PROCEDURES
Cooling System Draining, Filling and Bleeding (24 122 0)
Special Tool(s)
Hose Clamp
303397 (24003)

radiator lower hose to drain the cooling
system.
Allow the coolant to drain into a suitable
container.
Draining
1.

expansion tank cap with a thick cloth
to prevent the possibility of scalding.
Release the cooling system pressure by
slowly turning the coolant expansion tank
cap a quarter of a turn.
5. Install the radiator lower hose.

Filling and Bleeding
mark.

2. NOTE: Do not allow the engine to reach normal
operating temperature.
Start the engine, run the engine briefly at
2500 revolutions per minute (RPM) for 10
seconds to prime the heater circuit.
4. Fill the coolant expansion tank 15 mm over
the MAX mark.
5. Install the coolant expansion tank cap.
6. Start the engine, maintain the engine speed
at 2500 RPM for eight minutes or until the
G421226 en
11/2004 2005.25 Fiesta
303-03B-15

TO MODEL INDEX
303-03B-15

engine reaches normal operating
temperature.
7. Maintain the engine speed at 2500 RPM for
three minutes after the engine has reached
8. Increase the engine speed to 4000 RPM for
five seconds.
9. Decrease the engine speed to 2500 RPM for
three minutes.
10. Increase the engine speed to 4000 RPM
for five seconds.
11. Decrease the engine speed to 2500 RPM
for three minutes.
13. Check the cooling system for leaks.
14. Allow the engine to cool.
mark.
G421226 en
11/2004 2005.25 Fiesta
303-03B-16

TO MODEL INDEX
303-03B-16

Coolant Pump
Draining, Filling and Bleeding in this
section.
shield.
3. Loosen the coolant pump pulley retaining

bolts.

table(s).
G421227 en
11/2004 2005.25 Fiesta
303-03B-17

TO MODEL INDEX
303-03B-17

Item
Part
Number
Description
Coolant pump pulley
Coolant pump
Coolant pump gasket
G421227 en
11/2004 2005.25 Fiesta
303-03B-18

TO MODEL INDEX
303-03B-18

Thermostat Housing
Special Tool(s)
Remover/Installer, Coolant
Hose Clamp
303-397

section.
table(s).

G426583 en
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TO MODEL INDEX
303-03B-19
303-03B-19

Item
Part
Number
Description
Thermostat housing to
coolant expansion tank and
heater core return coolant
hose
See Removal Detail
Radiator lower to thermostat

housing coolant hose
See Removal Detail
Thermostat housing
Item 2 : Radiator lower to thermostat housing

coolant hose
1. Using the special tool, disconnect the radiator lower to thermostat housing coolant
hose.
Removal Details
Item 1 : Thermostat housing to coolant
expansion tank and heater core return
coolant hose
thermostat housing to coolant expansion
tank and heater core return coolant hose.
G426583 en
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303-03B-20

TO MODEL INDEX
303-03B-20

Coolant Outlet Connector
Removal
4. Remove the ignition coil pack.

Duratec-HE (MI4)]
2. Disconnect the spark plug wires from the
ignition coil pack.

section.
3. Disconnect the ignition coil pack electrical
connector.
7. Disconnect the radiator hose and the

heater hose from the coolant outlet connector.
G421228 en
11/2004 2005.25 Fiesta
303-03B-21

TO MODEL INDEX
303-03B-21

8. Disconnect the coolant expansion tank
hose from the coolant outlet connector.
Installation
1. NOTE: Install a new coolant outlet connector
gasket.
9. Disconnect the thermostat housing coolant

hose from the coolant outlet connector.
10. Remove the coolant outlet connector.

Discard the gasket.
G421228 en
11/2004 2005.25 Fiesta
303-03B-22

TO MODEL INDEX
303-03B-22

Radiator (24 254 0)
Special Tool(s)
Hose Clamp
303397 (24003)

Removal
Disconnect]
section.
G457934 en
5. Disconnect the radiator degas hose from

the radiator.
11/2004 2005.25 Fiesta
303-03B-23

TO MODEL INDEX
303-03B-23

6. Disconnect the radiator upper coolant
hose.
1. Pull out the quick release spring clip.
2. Pull the radiator upper hose from the quick
release connector.
9. Detach the radiator and the air conditioning

(A/C) condenser from the support panel.
10.
7. Using the special tool, disconnect the radiator lower coolant hose.
8. Remove the radiator retainers.

1. Remove the radiator retainer locking
screws.
2. Remove the radiator retainers and grommets.
G457934 en
CAUTION: Support the A/C condenser

by positioning it on the support panel.
Slide the A/C condenser to detach it from
the radiator
11. Remove the radiator.
Installation
11/2004 2005.25 Fiesta

TO MODEL INDEX
303-04A-1
Fuel Charging and Controls 1.25L Duratec-16V
303-04A-1
(Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma)
SECTION 303-04A Fuel Charging and Controls

1.25L Duratec-16V (Sigma)/1.4L Duratec-16V
(Sigma)/1.6L Duratec-16V (Sigma)
CONTENTS
PAGE
SPECIFICATIONS
Specifications...................................................................................................................
303-04A-2

Fuel Charging and Controls .............................................................................................
Principles Of Operation ...................................................................................................
303-04A-3
303-04A-3
303-04A-3

Throttle Body ................................................................................................ (23 198 0)
Fuel Charging Wiring Harness ...................................................................... (36 437 0)
Fuel Injection Supply Manifold ...................................................................... (23 450 0)
303-04A-4
303-04A-5
303-04A-7
11/2004 2005.25 Fiesta
303-04A-2

TO MODEL INDEX

303-04A-2
SPECIFICATIONS
General Specifications
Condition
Regulated fuel pressure
Maximum idle increase for high generator load
Air conditioning idle upspeed at low ambient temperatures
Air conditioning idle upspeed at high ambient temperatures
Power steering idle speed upspeed
Description
Throttle body retaining bolts
Fuel pressure regulator retaining bolts
Fuel injection supply manifold retaining bolts
G146265 en
Nm
10
10
15
Specification
380 kpa (55 psi)
100 rpm
100 rpm
150 rpm
50 rpm
lb-ft
11
lb-in
89
89
-
11/2004 2005.25 Fiesta
303-04A-3

TO MODEL INDEX

303-04A-3

Fuel Charging and Controls
Principles Of Operation
REFER to Section 310-02A.[Acceleration Control
- 1.25L Duratec-16V (Sigma)/1.3L Duratec-8V
Duratec-16V (Sigma), DIAGNOSIS AND
TESTING, Acceleration Control]
Mechanical
Electrical
Fuel leak(s)
Wiring harness
Blocked or
Electrical
contaminated fuel
connector(s)
filter
Fuel injector(s)
Fuel rail
Throttle body
Vacuum line(s)
Throttle body
step.
symptom and refer to WDS.
G28679 en
11/2004 2005.25 Fiesta
303-04A-4

TO MODEL INDEX

303-04A-4

Throttle Body (23 198 0)
Removal
1. Disconnect the air cleaner outlet pipe from
the throttle body.
Installation
2. Turn the ignition key to position II for 5
seconds and return the ignition key to
position 0 to initialize the throttle body.
2. Remove the throttle body retaining bolts.
3. Disconnect the throttle body electrical

connector and remove the throttle body.
G146266 en
11/2004 2005.25 Fiesta
303-04A-5

TO MODEL INDEX

303-04A-5

Fuel Charging Wiring Harness (36 437 0)
Removal
2. Disconnect the spark plug wires from the
ignition coil.
5. NOTE: It is necessary to lift the red locking tab

before the electrical connector can be
disconnected.
Disconnect the throttle body electrical
connector.

6. Disconnect the fuel charging wiring harness electrical connector.

7. Remove the positive crankcase ventilation

(PCV) hose.
G189082 en
11/2004 2005.25 Fiesta
303-04A-6

TO MODEL INDEX

303-04A-6

connectors and remove the fuel charging
wiring harness.
Installation
G189082 en
11/2004 2005.25 Fiesta
303-04A-7

TO MODEL INDEX

303-04A-7

Fuel Injection Supply Manifold (23 450 0)
Removal
personal injury.
WARNING: This procedure involves fuel
handling. Be prepared for fuel spillage at
all times and always observe fuel
handling precautions. Failure to follow
these instructions may result in personal
injury.
310-00.
414-01.
4. Remove the positive crankcase ventilation
(PCV) hose.
G189083 en

connectors and position the wiring harness to one side.
6. Disconnect the vacuum line from the fuel

pressure regulator.
11/2004 2005.25 Fiesta
303-04A-8

TO MODEL INDEX

303-04A-8

7. NOTE: Fuel supply line connectors are white or
are identified by a white band. Fuel return line
connectors are red or are identified by a red
band.
9. Remove the fuel injection supply manifold.
Disconnect the fuel supply line from the

fuel injection supply manifold. For additional information, refer to Section 310-00.
10. Remove the fuel pressure regulator.

band.
Disconnect the fuel return line from the fuel
injection supply manifold. For additional
11. Remove and discard the O-ring seal.
G189083 en
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303-04A-9

TO MODEL INDEX

303-04A-9

12. NOTE: Discard the fuel injector O-ring seals.
Remove the fuel injectors from the fuel
injection supply manifold.
1. Lift the retaining clip.
2. Slide the retaining clip.
3. Pull the fuel injector.
1. NOTE: Install new fuel injector O-ring seals.

NOTE: Install a new fuel pressure regulator O-ring
seal.
NOTE: Lubricate the O-ring seals with clean
engine oil to aid installation.
13. Remove and discard the O-ring seals.
Installation
personal injury.
injury.
G189083 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
303-04B-1
Fuel Charging and Controls 2.0L Duratec-HE (MI4)
303-04B-1
SECTION 303-04B Fuel Charging and Controls

2.0L Duratec-HE (MI4)
CONTENTS
PAGE
SPECIFICATIONS
Specifications...................................................................................................................
303-04B-2

303-04B-3

303-04B-6
303-04B-6

Throttle Body ...................................................................................................................
Fuel Injectors ................................................................................................ (23 455 0)
Fuel Rail...........................................................................................................................
303-04B-7
303-04B-9
303-04B-10
11/2004 2005.25 Fiesta
303-04B-2

TO MODEL INDEX
303-04B-2
SPECIFICATIONS
Description
Throttle body retaining bolts
Fuel injection supply manifold retaining bolts
G37518 en
Nm
10
25
lb-ft
18
lb-in
89
11/2004 2005.25 Fiesta
303-04B-3

TO MODEL INDEX
303-04B-3

Fuel Injection Supply Manifold
Item
Part
Number
Fuel injection supply manifold
Fuel injector retaining clip
Fuel injector O-ring seals
Fuel injector
G385113 en
Description
The fuel injection supply manifold is retained to

the engine by two bolts. The fuel injection supply
manifold has pressed steel cups to house the fuel
injectors.
The fuel injectors are fitted directly into the fuel
injection supply manifold and are retained by the
fuel injector retaining clips. Sealing between the
fuel injector to fuel injection supply manifold and
the intake manifold is achieved by means of upper
and lower O-ring seals.
11/2004 2005.25 Fiesta
303-04B-4

TO MODEL INDEX
303-04B-4

The fuel injectors are activated sequentially by the
powertrain control module (PCM) which modifies
the fuel quantity by adjusting fuel injector opening
Item
1
Part
Number
Description
Throttle body
Throttle Body
The throttle butterfly position is controlled by a

signal from the PCM which receives an input from
G385113 en
times according to the engine operating

conditions.
the accelerator pedal position sensor. The system

is fully electronic and does not use any cables.
The signal from the PCM is used to control a DC
motor within the throttle body which is connected
to the throttle butterfly through gears.
The throttle body also gives inputs back to the
PCM. This information allows the PCM to
compensate for factors such as carbon build up
11/2004 2005.25 Fiesta
303-04B-5

TO MODEL INDEX
303-04B-5

within the throttle body and throttle body wear.
The throttle body also provides information to the
PCM to enable the flagging of a DTC.
G385113 en
11/2004 2005.25 Fiesta
303-04B-6

TO MODEL INDEX
303-04B-6

General Equipment

Mechanical
Electrical
Fuel leak(s)
Powertrain control
module (PCM)
Vacuum line(s)
Wiring harness
Gasket(s)
Electrical
Seal(s)
connector(s)
Fuel injector(s)
Throttle body
Throttle body
Fuel injector(s)
Fuel injection supply
manifold
Fuel supply line
step.
symptom and refer to WDS to diagnose the
system.
G165371 en
11/2004 2005.25 Fiesta
303-04B-7

TO MODEL INDEX
303-04B-7

Throttle Body
table(s).
Item
Part
Number
Description
Air cleaner intake pipe retaining clip
Air cleaner intake pipe

See Removal Detail
Air cleaner outlet pipe retaining clip
Air cleaner outlet pipe and

resonator
See Removal Detail
Throttle body electrical connector
Throttle body
G421320 en
Item
Part
Number
Description
Throttle body gasket

3. NOTE: Do not press the accelerator pedal
during the initialization period as this will
prevent the complete initialization of the throttle
body.
Turn the ignition key to position II and wait
for one minute to initialize the throttle
body.
4. Turn the ignition key to the OFF position.
Removal Details
Item 2 : Air cleaner intake pipe
1. Detach the air cleaner intake pipe from the
air cleaner intake pipe duct.
11/2004 2005.25 Fiesta
303-04B-8

TO MODEL INDEX
303-04B-8

Item 5 : Air cleaner outlet pipe and resonator
1. Detach the air cleaner outlet pipe resonator
from the air cleaner and remove the air
cleaner outlet pipe.
Item 7 : Throttle body
NOTE: Do not fully tighten the throttle body
1. Install each throttle body retaining bolt
three full turns by hand.
Item 7 : Throttle body
1. Tighten the throttle body retaining bolts in

the sequence shown.
G421320 en
11/2004 2005.25 Fiesta
303-04B-9

TO MODEL INDEX
303-04B-9

Fuel Injectors (23 455 0)
1. Remove the fuel injection supply manifold.
G307349 en
11/2004 2005.25 Fiesta
303-04B-10

TO MODEL INDEX
303-04B-10

Fuel Rail
Name
Engine Oil - 5W-30
Specification
WSS-M2C913-B

injury.
G421322 en

Pressure Release]
Disconnect]
3. Remove the air cleaner assembly. For
REMOVAL AND INSTALLATION, Air
Cleaner - 2.0L Duratec-HE (MI4)]
table(s).
11/2004 2005.25 Fiesta
303-04B-11

TO MODEL INDEX
303-04B-11

Item
Part
Number
Fuel charging wiring harness

retaining clip
See Removal Detail

electrical connector
Fuel injector electrical connector(s)
Item
Part
Number
Fuel rail retaining bolts
Fuel rail
Fuel rail spacers
10
Fuel injector retaining clips

See Removal Detail
11
Fuel injector O-ring seals

12
Fuel injectors
G421322 en
Description
Description
Item
Part
Number
Description
Camshaft position sensor

(CMP) electrical connector
Fuel rail fuel supply line

See Removal Detail

retaining clip
See Removal Detail

injury.
11/2004 2005.25 Fiesta
303-04B-12

TO MODEL INDEX
303-04B-12

Removal Details
Item 1 : Fuel charging wiring harness retaining
clip
1. Detach the fuel charging wiring harness
retaining clip from the intake manifold.
Item 5 : Fuel rail fuel supply line
1. Disconnect the fuel supply line from the
fuel rail. For additional information, refer to
Section 310-00.[Fuel System - General
Item 6 : Fuel charging wiring harness retaining
clip
1. Detach the fuel charging wiring harness
retaining clip from the fuel rail retaining
bolt.
Item 10 : Fuel injector retaining clips
1. Remove the fuel injector retaining clips.
Discard the fuel injector retaining clips.
Item 11 : Fuel injector O-ring seals
1. Lubricate the fuel injector O-ring seals with
clean engine oil.
G421322 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
303-05-1
Accessory Drive
303-05-1
SECTION 303-05 Accessory Drive

CONTENTS
PAGE
SPECIFICATIONS
Specifications....................................................................................................................
303-05-2

Accessory Drive 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma)........................
Accessory Drive 2.0L Duratec-HE (MI4) .......................................................................
2.0L Duratec HE (MI4) engine..........................................................................................
303-05-3
303-05-4
303-05-4

Accessory Drive ................................................................................................................
Accessory Drive Belt Concerns ........................................................................................
Symptom Chart ................................................................................................................
Component Tests.............................................................................................................
303-05-5
303-05-5
303-05-5
303-05-8
303-05-11

Accessory Drive Belt 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V
(Sigma), Vehicles With: Air Conditioning ......................................................
Accessory Drive Belt 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V
(Sigma), Vehicles Without: Air Conditioning .................................................
Power Steering Pump Belt 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V
(Sigma), Vehicles With: Air Conditioning ......................................................
Accessory Drive Belt 2.0L Duratec-HE (MI4) ............................................
(31 413 0)
303-05-13
(31 413 0)
303-05-17
(13 424 0)
(31 413 0)
303-05-20
303-05-22
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Accessory Drive
303-05-2
SPECIFICATIONS
Torque Specifications - vehicles with 1.3L Duratec-8V (Rocam) engine

Description
Nm
lb-ft
Accessory drive belt tensioner re25
18
taining bolt
Accessory drive belt idler pulley re25
18
taining bolt
Accessory drive bracket assembly
30
22
retaining bolts
lb-in
-
Torque Specifications - vehicles with 1.4L Duratorq-TDCi (DV)/1.6L Duratorq-TDCi (DV) Diesel
engine
Description
Nm
lb-ft
lb-in
18
taining bolts
Torque Specifications - vehicles with 2.0L Duratec-HE (MI4) engine
Description
Nm
lb-ft
18
taining bolts
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lb-in
-
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303-05-3
Accessory Drive
303-05-3

Accessory Drive 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma)
Overview
Item
Part
Number
Description
Vehicles without air conditioning
Vehicles with air conditioning
Crankshaft pulley
Coolant pump
Generator
Power steering pump
Air conditioning compressor
Both versions are elastic multi-ribbed belts and do

not need a tensioning pulley. Re-tensioning is not
required.
Vehicles without air conditioning have one drive

belt, which drives the generator, the coolant pump
and the power steering pump.
Vehicles with air conditioning have two drive belts,
the longer of which drives the generator, the
coolant pump and the air conditioning compressor.
The shorter drive belt drives only the power
steering pump.
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Accessory Drive
303-05-4

Accessory Drive 2.0L Duratec-HE (MI4)
2.0L Duratec HE (MI4) engine
Item
Part
Number
Power steering pump pulley
Coolant pump pulley
Air conditioning (A/C) compressor pulley
Crankshaft pulley
Accessory drive belt tensioner pulley
Generator pulley
Accessory drive belt idler

pulley
G421383 en
Description
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Accessory Drive
303-05-5

Accessory Drive
mechanical damage.
Mechanical
Damaged or contaminated accessory drive
belt
Damaged or contaminated pulley(s)
Incorrect accessory drive belt
Incorrect fitment of the accessory drive belt
Accessory drive belt tensioner
Accessory drive belt idler pulley
Generator
Power steering pump
Power steering pump leakage
Air conditioning (A/C) compressor
Pulley(s)
Loose hardware
step.
1. Check the accessory drive belt for cracks. If

the damage exceeds the acceptable limit,
install a new accessory drive belt.
REFER to Accessory Drive Belt - 1.4L
(Sigma), Vehicles With: Air Conditioning in this
section.
REFER to Power Steering Pump Belt - 1.4L
section.
(Sigma), Vehicles Without: Air Conditioning in
this section.
Duratec-HE (MI4) in this section.
Chunking
Chunking describes the condition where long

lengths of rubber become detached from the ribs
of the belt. This is considered to be a failure of the
belt.
Accessory Drive Belt Concerns

CAUTION: Do not lubricate the accessory
drive belt, accessory drive belt tensioner
or idler pulley(s) as potential damage to
the accessory drive belt material
construction, accessory drive belt
tensioner damping mechanism,
accessory drive belt tensioner pulley
bearing and idler pulley(s) bearing may
occur.
Cracking
Accessory drive belts are made from rubber which

hardens with time and can develop cracks. As the
belt runs on the back of some of the pulleys, the
cracks are opened up. Small cracks are not
considered to be a failure of the belt. Only if the
crack is deep enough to reach the bottom of the
groove to expose the cord or any chunks are
found to be missing from the belt, is the belt
condition considered to be unacceptable.
G346263 en
2. Check the accessory drive belt for damage. If

any chunks are found to be missing, install a
new accessory drive belt.
section.
REFER to Power Steering Pump Belt - 1.4L
section.
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Accessory Drive
303-05-6

(Sigma), Vehicles Without: Air Conditioning in
this section.
Pilling
Pilling is dust that forms in between the ribs of the

belt from rubber that is worn off the belt when it is
new. There may also be loose particles left on the
belt during the manufacturing process. These are
worn off and form into small balls of rubber that
then get trapped in the grooves of the belt. This
condition will usually clear itself within 4800 km 8000 km (3000 miles - 5000 miles) of normal
driving.
3. Check the accessory drive belt for pilling. The

condition of the belt should be compared
against the illustration.
1. Small scattered pills. Not considered a
concern. No action required.
2. Small scattered pills. Not considered a
3. Longer pills up to 50% of the rib height.
Possible noise concern. INSTALL a new
belt if noise is apparent. REFER to
Accessory Drive Belt - 1.4L Duratec-16V
(Sigma)/1.6L Duratec-16V (Sigma),
G346263 en
Vehicles With: Air Conditioning / Power

Steering Pump Belt - 1.4L Duratec-16V
Vehicles With: Air Conditioning / Accessory
Drive Belt - 1.4L Duratec-16V (Sigma)/1.6L
Duratec-16V (Sigma), Vehicles Without: Air
Conditioning / Accessory Drive Belt - 2.0L
4. Longer pills up to 50% of the rib height.
Possible noise concern. INSTALL a new
belt if noise is apparent. REFER to
Accessory Drive Belt - 1.4L Duratec-16V
Vehicles With: Air Conditioning / Power
Steering Pump Belt - 1.4L Duratec-16V
Vehicles With: Air Conditioning / Accessory
Drive Belt - 1.4L Duratec-16V (Sigma)/1.6L
Duratec-16V (Sigma), Vehicles Without: Air
Conditioning / Accessory Drive Belt - 2.0L
5. Heavy deposits in the grooves. Possible
noise and stability concern. INSTALL a new
belt. REFER to Accessory Drive Belt - 1.4L
(Sigma), Vehicles With: Air Conditioning
/ Power Steering Pump Belt - 1.4L
/ Accessory Drive Belt - 1.4L Duratec-16V
Vehicles Without: Air Conditioning
/ Accessory Drive Belt - 2.0L Duratec-HE
(MI4) in this section.
6. Heavy deposits in the grooves. Possible
noise and stability concern. INSTALL a new
belt. REFER to Accessory Drive Belt - 1.4L
Fraying - Vehicles without accessory drive belt
tensioner built up to 02/2003
Due to the manufacturing process, the belt edge

may appear frayed, but this frayed appearance
does not necessarily affect the durability or
performance of the belt. If a concern is raised
during a service or repair over the level of fraying,
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Accessory Drive
303-05-7

the condition of the belt should be compared
G346263 en
against the illustrations.
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Accessory Drive
303-05-8

4. Check the accessory drive belt for fraying.
1. No fraying (new belt). Not considered a
2. Fraying just starting. Not considered a
3. Slight fraying. Not considered a concern. No
action required.
4. High amount of fraying without cord cuts.
INSTALL a new accessory drive belt.
5. High amount of fraying with cord cuts.
INSTALL a new accessory drive belt.

Incorrect fitment
Belt noise can be generated by the belt being

incorrectly fitted on the pulley as shown in the
following illustration. Make sure that all the V
grooves on the belt contact correctly with the
pulley.

Symptom Chart
Symptom
Accessory drive belt noise
Possible Sources
Accessory drive system - Vehicles with accessory drive belt
tensioner
Action
CHECK the system with the engine running and the accessory
drive belt removed (only run the
engine for a very short period). If
a noise is apparent, the cause is
not the accessory drive system.
If a noise is not apparent, the
cause is the accessory drive
system. CHECK where the noise
is coming from. Use a stethoscope or other listening device to
determine the source of the
noise. INSTALL new components as necessary. TEST the
Accessory drive system - Vehi- Use a stethoscope or other liscles without accessory drive belt tening device to determine the
tensioner
source of the noise. INSTALL
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Accessory Drive
303-05-9

Symptom
Possible Sources
Action
Accessory drive belt incorrectly

installed.

is correctly installed in the pulley
grooves. INSTALL a new accessory drive belt as necessary.
REFER to Accessory Drive Belt 1.4L Duratec-16V (Sigma)/1.6L
Duratec-16V (Sigma), Vehicles
With: Air Conditioning
/ Power Steering Pump Belt 1.4L Duratec-16V (Sigma)/1.6L
/ Accessory Drive Belt - 1.4L
Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), Vehicles
Without: Air Conditioning
Pulley(s).
CHECK the pulley(s) for damage, freedom of rotation, stone

entrapment and alignment.
necessary. TEST the system for
normal operation.
Lubricant or other contamination. CHECK the accessory drive belt

for contamination or damage.
RECTIFY the source of the leak
and INSTALL a new accessory
drive belt.
REFER to Accessory Drive Belt 1.4L Duratec-16V (Sigma)/1.6L
/ Power Steering Pump Belt 1.4L Duratec-16V (Sigma)/1.6L
Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), Vehicles
Without: Air Conditioning
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Accessory Drive
303-05-10

Symptom
Possible Sources
Action
NOTE: Squeal is defined as a

continuous shriek, most
noticeable when the engine is
being accelerated or with
electrical load.
Accessory drive belt squeal

worn, damaged or contaminated tensioner for correct operation,
with oil.
damage or contamination.
REFER to the Accessory Drive
Belt Tensioner Component Test
in this procedure. INSTALL a
new accessory drive belt tensioner as necessary.
NOTE: Whine is defined as a

continuous noise at the same
frequency, generally associated
with plastic pulleys.
Accessory drive belt whine
Poor surface finish on accessory REMOVE the accessory drive

drive belt idler pulley flat surbelt.
face(s).
REFER to Accessory Drive Belt 2.0L Duratec-HE (MI4) in this
section. INSPECT the idler pulley(s) for surface finish. INSTALL
a new idler pulley(s) as necessary. TEST the system for normal operation.
Accessory drive belt idler pulley REMOVE the accessory drive
bearing failure.
belt.
REFER to Accessory Drive Belt 2.0L Duratec-HE (MI4) in this
section. INSPECT the idler pulley(s) for smooth rotation.
INSTALL a new idler pulley(s) as
normal operation.
NOTE: Chirp is defined as a

Pulley misalignment (usually
twittering noise, often intermittent evident at idle).
Accessory drive belt chirp
CHECK that the accessory drive

belt is running centrally on the
flat pulleys. TEST the system for
normal operation.
CHECK the pulleys for excessive
end float and bent flanges.
With the engine running at idle,
use a stethoscope to identify the
source of the noise. INSTALL
NOTE: Rattle is defined as a

metallic knocking noise
Accessory drive belt rattle

tensioner for correct operation or
damage. REFER to the Accessory Drive Belt Tensioner Component Test in this procedure.
INSTALL a new accessory drive
belt tensioner as necessary.
G346263 en

hitting the end stops.
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303-05-11
Accessory Drive
303-05-11

Possible Sources
Symptom
Action
Loose components or hardware. CHECK the components or

hardware for correct installation
and tighten as necessary. TEST
Accessory drive belt fraying
Accessory drive belt.
CHECK the extent of the fraying

by referring to the illustrations
shown in the Visual Inspection
section. Only INSTALL a new
accessory drive belt if the fraying
is within the criteria quoted in the
Visual Inspection section. TEST
Pulley(s).
CHECK the pulley(s) for damage, freedom of rotation and

alignment. INSTALL new components as necessary. TEST the
Component Tests
Accessory Drive Belt Tensioner - Static Check
The accessory drive belt tensioner may be

checked statically as follows:
1. Inspect the area surrounding the accessory
drive belt tensioner for lubricant or other
contamination. Rectify any leaks before
installing a new accessory drive belt tensioner.
If the accessory drive belt tensioner is
contaminated, do not attempt to clean it as the
damping mechanism inside may be damaged.
INSTALL a new accessory drive belt tensioner
as necessary.
2. Detach the accessory drive belt in the area of
the accessory drive belt tensioner.
NOTE: The accessory drive belt tensioner has a
damping feature, which is usually a friction device,
therefore some friction within the system is
normal.
G346263 en
3. Using the correct tool, move the accessory

drive belt tensioner from its relaxed position
through its full stroke and back to the relaxed
position to make sure there is no excessive
stick, grab or bind, and to make sure there is
tension on the accessory drive belt tensioner
spring.
4. Rotate the accessory drive belt tensioner
pulley and check for damage, freedom of
rotation and alignment. INSTALL a new
accessory drive belt tensioner as necessary.
5. If the accessory drive belt tensioner meets the
above criteria, proceed to test the accessory
drive belt tensioner dynamically. If the
accessory drive belt tensioner does not meet
the above criteria, INSTALL a new accessory
drive belt tensioner.
Accessory Drive Belt Tensioner - Dynamic Check
The accessory drive belt tensioner may be

checked dynamically as follows:
1. With the engine running, observe the
accessory drive belt tensioner movement. The
accessory drive belt tensioner should move
(respond) when the engine is accelerated
rapidly or when the A/C clutch cycles ON and
OFF (the degree of movement can be up to 4
mm). If the accessory drive belt tensioner
movement is not constant without engine
acceleration or A/C clutch cycling, a pulley or
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Accessory Drive
303-05-12

shaft is possibly bent, out of round, or the
damping mechanism inside the accessory
drive belt tensioner may be damaged.
INSTALL a new accessory drive belt tensioner
as necessary.
2. Excessive accessory drive belt rideout
(uneven depth of grooves in the accessory
drive belt) may cause excessive accessory
drive belt tensioner movement. Check the
condition by installing a new accessory drive
belt.
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Accessory Drive
303-05-13

Accessory Drive Belt 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma),
Vehicles With: Air Conditioning (31 413 0)
General Equipment
Knife
2. Using paint or typing correction fluid, mark

the crankshaft pulley at the 6 o'clock position.
Removal
CAUTION: The accessory drive belt must
not be reused as it is designed to be
stretched onto the pulleys only once.
Failure to follow this instruction may lead
to premature failure of the belt.
100-02.
2. Detach the power steering line and remove
the crankshaft pulley splash shield.
3. Install the installation tool (supplied in the

parts kit) to the crankshaft pulley at the 6
o'clock position.
3. Using a suitable knife, cut both accessory

drive belts and remove.
Installation
NOTE: Install a new accessory drive belt and
power steering pump belt.
1. Wipe clean all of the pulleys to make sure
that the accessory drive belt does not slip
during installation.
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Accessory Drive
303-05-14

4. Install the accessory drive belt.
1. Install the belt around the generator pulley.
2. Install the belt around the air conditioning
compressor pulley.
3. Install the belt around the water pump
pulley.
4. Install the belt around the installation tool.
5. Make sure that the accessory drive belt is

correctly positioned in the grooves of the
pulleys.
6. NOTE: Only turn the engine in the normal
NOTE: Guide the accessory drive belt onto the
pulleys as the engine is rotated.
7. NOTE: The curved end of the tool fits around

the belt and the cranked end of the tool fits
around the generator mounting bracket.
Install the belt guide tool (supplied in the
parts kit) to the accessory drive belt
(shown from above for clarity).
8. Install the belt guide tool to the generator

mounting bracket.
Turn the engine until the paint mark is at

the 8 o'clock position.
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Accessory Drive
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the 3 o'clock position
10. Remove the installation tool from the

crankshaft pulley.
Turn the engine through 360 degrees.
12. Check that the accessory drive belt is
pulleys.
Repeat the installation procedure if the
accessory drive belt is misaligned.
13. Remove the belt guide tool from the
accessory drive belt.
Discard the belt guide tool.
14. Install the installation tool to the crankshaft pulley at the 12 o'clock position.
15. Install the power steering pump belt.

1. Install the power steering pump belt around
the power steering pump pulley.
2. Install the power steering pump belt around
the installation tool.
16. Make sure that the power steering pump

belt is correctly positioned in the grooves
of the pulleys.
NOTE: Guide the power steering pump belt onto
the pulleys as the engine is rotated.
Turn the engine until the tool is at the 9
o'clock position.

crankshaft pulley.
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Accessory Drive
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20. Check that the power steering pump belt
is correctly positioned in the grooves of
the pulleys.
power steering pump belt is misaligned.
Discard the installation tool.
21. Install the crankshaft pulley splash shield.
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Accessory Drive
303-05-17

Accessory Drive Belt 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma),
Vehicles Without: Air Conditioning (31 413 0)
General Equipment
Knife
2. Using paint or typing correction fluid, mark

the crankshaft pulley at the 6 o'clock position.
Removal
CAUTION: The accessory drive belt must
not be reused as it is designed to be
100-02.

o'clock position.
3. Using a suitable knife, cut the accessory

drive belt and remove.
Installation
NOTE: Install a new accessory drive belt.
1. Wipe clean all of the pulleys to make sure
that the accessory drive belt does not slip
during installation.
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Accessory Drive
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4. Install the accessory drive belt.
1. Install the belt around the generator pulley.
2. Install the belt around the power steering
pump pulley.
3. Install the belt around the water pump
pulley.
5. Make sure that the accessory drive belt is

pulleys.
7. NOTE: The curved end of the tool fits around

the belt and the cranked end of the tool fits
around the generator mounting bracket.
Install the belt guide tool (supplied in the
parts kit) to the accessory drive belt
(shown from above for clarity).
8. Install the belt guide tool to the generator

mounting bracket.

the 8 o'clock position.
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Accessory Drive
303-05-19

the 3 o'clock position

crankshaft pulley.
12. Check that the accessory drive belt is
pulleys.
accessory drive belt is misaligned.
13. Remove the belt guide tool from the
accessory drive belt.
Discard the belt guide tool.
14. Install the crankshaft pulley splash shield
and attach the power steering line.

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Accessory Drive
303-05-20

Power Steering Pump Belt 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma),
Vehicles With: Air Conditioning (13 424 0)
General Equipment
Knife

o'clock position.
Removal
CAUTION: The power steering pump belt
must not be reused as it is designed to be
100-02.
3. Install the power steering pump belt.

1. Install the belt around the power steering
pump pulley.
3. Using a suitable knife, cut the power

steering pump belt and remove.
Installation
NOTE: Install a new power steering pump belt.
1. Wipe clean both of the pulleys to make sure
that the power steering pump belt does not
slip during installation.
G100708 en
4. Make sure that the power steering pump

belt is correctly positioned in the grooves
of the pulleys.
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Accessory Drive
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NOTE: Guide the power steering pump belt onto
the pulleys as the engine is rotated.
Turn the engine until the installation tool is
at the 9 o'clock position.

crankshaft pulley.
8. Check that the power steering pump belt is
pulleys.
power steering pump belt is misaligned.
9. Install the crankshaft pulley splash shield.
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Accessory Drive
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Accessory Drive Belt 2.0L Duratec-HE (MI4) (31 413 0)
Removal
Disconnect]
shield.
4. Remove the accessory drive belt.

1. Rotate the accessory drive belt tensioner
counterclockwise.
2. Remove the accessory drive belt.
Installation
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303-06-1
Starting System
303-06-1
SECTION 303-06 Starting System

CONTENTS
PAGE
SPECIFICATIONS
Specifications....................................................................................................................
Torque Specifications - vehicles with 1.25L Duratec-16V (Sigma)/1.3L Duratec-8V (Rocam)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) engines.............................
Torque Specifications - vehicles with 1.4L Duratorq-TDCi (DV)/1.6L Duratorq-TDCi (DV)
Diesel engines...............................................................................................................
Torque Specifications - vehicles with 2.0L Duratec-HE (MI4) engine................................
303-06-2
303-06-2
303-06-2
303-06-2

Starting System.................................................................................................................
Starting system ................................................................................................................
303-06-3
303-06-3

Starting System.................................................................................................................
Symptom Chart ................................................................................................................
Pinpoint Tests ..................................................................................................................
303-06-4
303-06-4
303-06-4
303-06-5

Starter Motor 1.25L Duratec-16V (Sigma)/1.3L Duratec-8V (Rocam)/1.4L (26 204 0)
Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma)..........................................
Starter Motor 2.0L Duratec-HE (MI4) ............................................................................
303-06-12
303-06-13
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Starting System
303-06-2
SPECIFICATIONS
Torque Specifications - vehicles with 1.25L Duratec-16V (Sigma)/1.3L Duratec-8V (Rocam)/1.4L

Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) engines
Description
Nm
lb-ft
lb-in
Ignition switch to starter motor cable
7
62
retaining nut
Starter motor positive cable retaining
12
9
nut
35
26
Torque Specifications - vehicles with 1.4L Duratorq-TDCi (DV)/1.6L Duratorq-TDCi (DV) Diesel
engines
Description
Nm
lb-ft
lb-in
6
53
retaining nut
12
9
nut
25
18
Description
Nm
lb-ft
6
retaining nut
12
9
nut
Starter motor wiring harness support
20
15
bracket retaining nuts
Starter motor retaining studs
25
18
G421389 en
lb-in
53
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303-06-3
Starting System
303-06-3

Starting System
Starting system
Ignition/starter switch in position III.

The starter relay is activated by the PCM .
The solenoid is supplied with voltage.
The solenoid engages the starter motor pinion
with the flywheel ring gear.
The solenoid applies battery current to the
starter.
The starter turns the crankshaft until the
engine starts. The key can then be released
and it automatically returns to position II.
The system incorporates the "Smart
Starting"strategy. This makes starting faster and
protects the starter.
If the driver fails to release the key immediately
after the engine starts, the PCM interrupts
activation of the starter relay and thus switches off
the electric starter motor.
The speed signal provided by the CKP sensor is
used for monitoring the starting procedure.
Item
Part
Number
Description
Ignition/starter switch
Starter relay
Electric starter motor
Powertrain control module

(PCM)
Sensor,- crankshaft position

( CKP)
The purpose of the starting system is to turn the

engine crankshaft at a speed which enables the
engine to start.
The engine is started as follows:
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303-06-4
Starting System
303-06-4

Starting System
Refer to Wiring Diagrams Section 303-06 for
General Equipment
(418-F224)

2. Visually inspect for obvious signs of electrical
damage.
Electrical
- Fuse(s)
- Wiring harness
- Electrical connector(s)
- Relay
- Central junction box (CJB)
- Switch(es)
- Battery
- Starter motor
- Powertrain Control Module (PCM)
step.
Symptom Chart
Symptom
The engine does not crank/the
relay does click
The engine does not crank/the

relay does not click
The engine cranks slowly
G151301 en
Possible Sources
Action
Battery.
Starter motor.
CARRY OUT the starter motor

Component Test using WDS.
Relay.
CARRY OUT the relay Component Test. REFER to the wiring

diagrams.
Circuit(s).
PCM.
REFER to WDS.
Battery.
Fuse.
INSTALL a new fuse as necessary. If the fuse fails again check

for short to ground.
Passive anti-theft system

(PATS).
REFER to Section 419-01A /

419-01B.
Starter motor.

Ignition switch.
Relay.
CARRY OUT the relay Component Test. REFER to the wiring

diagrams.
Circuit(s).
Battery.
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303-06-5
Starting System
303-06-5

Possible Sources
Symptom
Unusual starter noise
Starter motor.

Circuit(s).
Starter motor.
REMOVE the starter motor. Vehicles with 1.4L/1.6L engine,

REFER to Starter Motor - 1.25L
Duratec-16V (Sigma)/1.3L Duratec-8V (Rocam)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) in this section.Vehicles with 1.4L diesel
engine, INSPECT the starter
motor gear for damage.
INSTALL a new starter motor as
necessary.
Flywheel ring gear.
INSPECT the flywheel for damage. REFER to Section 303-00.
The starter spins but the engine Starter motor.

does not crank
The starter stops cranking the

engine before the engine starts
Action
REMOVE the starter motor. Vehicles with 1.4L/1.6L engine,

REFER to Starter Motor - 1.25L
Duratec-16V (Sigma)/1.3L Duratec-8V (Rocam)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) in this section.Vehicles with 1.4L diesel
engine, INSPECT the starter
motor gear for damage.
INSTALL a new starter motor as
necessary.
Flywheel ring gear.
INSPECT the flywheel for damage. REFER to Section 303-00.
PCM.
REFER to WDS.
Pinpoint Tests
NOTE: Use a digital multimeter for all electrical
measurements.
PINPOINT TEST A: THE ENGINE DOES NOT CRANK/THE RELAY DOES CLICK
TEST CONDITIONS
A1: CHECK VOLTAGE TO STARTER SOLENOID

G151301 en
11/2004 2005.25 Fiesta
303-06-6

TO MODEL INDEX
Starting System
303-06-6

TEST CONDITIONS
2 Measure the voltage between starter motor
terminal 50, harness side and ground.
Is the voltage greater than 10 volts?

Yes
GO to A2
No
GO to A3
A2: CHECK THE VOLTAGE DROP
1 Measure the voltage between starter motor
terminal 30, component side and the battery
positive terminal.
Is the voltage less than 0.5 volts?

Yes
GO to A4
No
CLEAN and TIGHTEN all battery positive
cable connections. TEST the system for
normal operation. If the concern persists,
INSTALL a new starter motor to battery cable. REFER to Section 414-01. TEST the
A3: CHECK CIRCUIT 29-BB17 (OG/BK) FOR OPEN
1 Ignition switch in position 0.
2 Disconnect Starter Relay C423.
G151301 en
11/2004 2005.25 Fiesta
303-06-7

TO MODEL INDEX
Starting System
303-06-7

TEST CONDITIONS
3 Measure the voltage between starter relay
C423 pin 3, circuit 29-BB17 (OG/BK), harness
side and ground.

Yes
REPAIR circuit 50-BB10 (GY/BK). TEST the
No
REPAIR circuit 29-BB17 (OG/BK). TEST the
A4: CHECK THE STARTER MOTOR GROUND CIRCUIT FOR OPEN
1 Measure the resistance between the starter
motor casing and battery ground terminal.
Is the resistance less than 0.5 ohms?

Yes
INSTALL a new starter motor. Vehicles with
1.4L/1.6L engine, REFER to Starter Motor 1.25L Duratec-16V (Sigma)/1.3L Duratec-8V
Duratec-16V (Sigma) in this section.Vehicles
with 1.4L diesel engine, INSPECT the starter
motor gear for damage. INSTALL a new
starter motor as necessary.
No
CLEAN and TIGHTEN all battery and engine
ground cable connections. TEST the system
G151301 en
11/2004 2005.25 Fiesta
303-06-8

TO MODEL INDEX
Starting System
303-06-8

PINPOINT TEST B: THE ENGINE DOES NOT CRANK/RELAY DOES NOT CLICK
TEST CONDITIONS
B1: CHECK THE SWITCHED POWER TO THE STARTER RELAY

1 Disconnect Starter Relay C423.
3 Measure the voltage between the starter motor
relay C423 pin 1, harness side and ground.

Yes
GO to B3
No
GO to B2
B2: CHECK CIRCUIT 50-BB16 (GY/BK) FOR OPEN
2 Disconnect Ignition Switch C329.
3 Measure the resistance between the ignition
switch C329 pin 7, circuit 50-BB16 (GY/BK),
harness side and the starter relay C423 pin 1,
circuit 50-BB16 (GY/BK), harness side.
Is the resistance less than 5 ohms?

Yes
INSTALL a new ignition switch. REFER to
Section 211-05. TEST the system for normal
operation.
No
REPAIR the circuit. TEST the system for
normal operation.
B3: CHECK CIRCUIT 91S-BB16 (BK/RD) FOR OPEN
G151301 en
11/2004 2005.25 Fiesta
303-06-9

TO MODEL INDEX
Starting System
303-06-9

TEST CONDITIONS
relay C423 pin 2, circuit 91S-BB16 (BK/RD),
harness side and ground.

Yes
INSTALL a new starter relay. TEST the
No
For vehicles with petrol engine, GO to B4
For vehicles with diesel engine, GO to B5
2 Disconnect PCM C343.
harness side and PCM C343 pin F30,
91S-BB16 (BK/RD), harness side.

Yes
CHECK the PATS system. REFER to WDS.
No
normal operation.
G151301 en
11/2004 2005.25 Fiesta
303-06-10

TO MODEL INDEX
Starting System
303-06-10

TEST CONDITIONS
harness side and the PCM C342 pin C3,
91S-BB16 (BK/RD), harness side.

Yes
CHECK the PATS system. REFER to WDS.
No
Repair the circuit. Test the system for normal
operation.
PINPOINT TEST C: THE ENGINE CRANKS SLOWLY
TEST CONDITIONS
C1: CHECK FOR VOLTAGE DROP

terminal 30, component side and the battery
positive terminal.

Yes
GO to C2
No
CLEAN and TIGHTEN all battery positive
cable connections. TEST the system for
normal operation. If the concern persists,
INSTALL a new battery to starter motor solenoid cable. REFER to Section 414-01. Test
C2: CHECK FOR GROUND CONNECTION
G151301 en
11/2004 2005.25 Fiesta
303-06-11

TO MODEL INDEX
Starting System
303-06-11

TEST CONDITIONS
case and the battery ground terminal.

Yes
CHECK the battery. REFER to Section
414-00. TEST the system for normal operation.
No
CLEAN and TIGHTEN all battery ground
cable connections, starter motor mounting
and body to ground straps. TEST the system
for normal operation. If the concern persists,
INSTALL a new battery ground cable. Test
G151301 en
11/2004 2005.25 Fiesta
303-06-12

TO MODEL INDEX
Starting System
303-06-12

Starter Motor 1.25L Duratec-16V (Sigma)/1.3L Duratec-8V (Rocam)/1.4L
Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) (26 204 0)
Removal
414-01.
100-02.
motor solenoid and battery to starter motor
solenoid cables (oil filter shown removed
for clarity).
4. Remove the starter motor retaining bolts

and remove the starter motor.
Installation
G210046 en
11/2004 2005.25 Fiesta
303-06-13

TO MODEL INDEX
Starting System
303-06-13

Starter Motor 2.0L Duratec-HE (MI4)
Disconnect]
G421390 en

table(s).
11/2004 2005.25 Fiesta
303-06-14

TO MODEL INDEX
Starting System
303-06-14

Item
Part
Number
Starter motor electrical

connectors
See Removal Detail
Starter motor wiring harness

support bracket
Description
Starter motor
See Removal Detail
Item 1 : Starter motor electrical connectors
1. NOTE: Clean the electrical connectors before
connecting the cables. Failure to follow this
instruction may cause a high resistance
between the electrical connectors and the
starter motor solenoid.
Connect the ignition switch and battery to
starter motor solenoid cables.
Removal Details
Item 1 : Starter motor electrical connectors
1. Disconnect the ignition switch and battery
to starter motor solenoid cables.
Item 3 : Starter motor

1. NOTE: Clean the mating surfaces before
installing the new starter motor gasket.
Install a new starter motor gasket into the
transaxle housing prior to installing the
starter motor.
Item 3 : Starter motor

1. Discard the starter motor gasket.
G421390 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
303-07A-1
Engine Ignition
303-07A-1
SECTION 303-07A Engine Ignition

CONTENTS
PAGE
SPECIFICATIONS
Specifications...................................................................................................................
303-07A-2

Engine Ignition .................................................................................................................
303-07A-3
303-07A-3
11/2004 2005.25 Fiesta
303-07A-2

TO MODEL INDEX
Engine Ignition
303-07A-2
SPECIFICATIONS
Description
Ignition coil retaining bolts
Spark plugs
G148218 en
Nm
6
15
lb-ft
11
lb-in
53
-
11/2004 2005.25 Fiesta

TO MODEL INDEX
303-07A-3
Engine Ignition
303-07A-3

Engine Ignition
Mechanical
Electrical
3.
Spark plug wire(s)

Wiring harness
Spark plug(s)
Electrical connector(s)
Ignition coil pack
step.
4. If the concern remains after visual inspection,
use WDS to diagnose the system.
G28729 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
303-07B-1
Engine Ignition 2.0L Duratec-HE (MI4)
303-07B-1
SECTION 303-07B Engine Ignition 2.0L Duratec-HE

(MI4)
CONTENTS
PAGE
SPECIFICATIONS
Specifications...................................................................................................................
303-07B-2

Engine Ignition .................................................................................................................
Symptom Chart ...............................................................................................................
303-07B-3
303-07B-3
303-07B-3
11/2004 2005.25 Fiesta
303-07B-2

TO MODEL INDEX
303-07B-2
SPECIFICATIONS
Description
Spark plug(s)
G421398 en
Nm
6
12
lb-ft
lb-in
53
11/2004 2005.25 Fiesta
303-07B-3

TO MODEL INDEX
303-07B-3

Engine Ignition

step.
General Equipment

damage.
Electrical
Wiring harness
Spark plug(s)
Spark plug wire(s)
Ignition coil pack
Powertrain control module (PCM)
Symptom Chart
Symptom
Engine misfire
Engine stumbling
Engine lacks power
G17859 en
Possible Sources
Action
Spark plug(s).
Spark plug wire(s).
CARRY OUT a KV test using

WDS.
Ignition coil pack.

PCM.
PCM calibration.
REFER to WDS.
Spark plug(s).
Spark plug wire(s).

WDS.
Ignition coil pack.

PCM.
PCM calibration.
REFER to WDS.
Spark plug(s).
Spark plug wire(s).

WDS.
Ignition coil pack.
REFER to WDS.
11/2004 2005.25 Fiesta

TO MODEL INDEX
303-08A-1
Engine Emission Control 1.25L Duratec-16V
303-08A-1
(Sigma)/1.3L Duratec-8V (Rocam)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma)
SECTION 303-08A Engine Emission Control 1.25L

CONTENTS
PAGE
SPECIFICATIONS
Specifications.................................................................................................................
303-08A-2

Engine Emission Control................................................................................................
Positive Crankcase Ventilation (PCV) - 1.3L Duratec 8V...............................................
PCV - 1.4L/1.6L Duratec 16V ........................................................................................
303-08A-3
303-08A-3
303-08A-4

Symptom Chart .............................................................................................................
303-08A-6
303-08A-6
303-08A-6

Crankcase Vent Oil Separator........................................................................................
303-08A-7
11/2004 2005.25 Fiesta

TO MODEL INDEX
303-08A-2
303-08A-2
SPECIFICATIONS
Description
Crankcase vent oil separator retaining bolts
G148219 en
Nm
10
lb-ft
-
lb-in
89
11/2004 2005.25 Fiesta

TO MODEL INDEX
303-08A-3
303-08A-3

Engine Emission Control
Positive Crankcase Ventilation (PCV) - 1.3L
Duratec 8V
Overview
G167099 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
303-08A-4
303-08A-4

Deflection panel
Side view
Item
Part
Number
Description
Cylinder head cover with integrated oil separator
From PCV valve
From Evaporative Emission

(EVAP) solenoid valve
To the intake manifold
PCV valve
Side view
Item
Part
Number
Description
Deflection plate
The deflection plate is integrated into the cylinder

head cover.
It prevents oil from being sucked in and burned in
the combustion process.
The oil drops condense on the deflection plate and
are then returned to the oil circuit.
Sectional view
Item
Part
Number
Description
Spring
Pistons
The PCV valve is located on the upper side of the

The crankcase gases are sucked by the PCV
valve into the intake manifold.
The PCV valve is opened by the vacuum in the
intake manifold.
The amount of crankcase gases depends on the
engine speed. The quantity sucked in is
determined by the spring and the shape of the
piston.
G167099 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
303-08A-5
303-08A-5

PCV - 1.4L/1.6L Duratec 16V
Item
Part
Number
Description
The crankcase gases are freed of oil in the valve

cover and in the PCV oil separator in order to
prevent the oil from being sucked in and burned.
Valve cover
The PCV valve is located in the PCV oil separator.
Hose from valve cover to air

cleaner housing
The crankcase gases are sucked by the PCV

valve into the intake manifold.
Hose from PCV oil separator

to intake manifold
The PCV valve is opened by the vacuum in the

intake manifold.
PCV oil separator with integral PCV valve
The amount of crankcase gases depends on the

engine speed.
G167099 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
303-08A-6
303-08A-6

mechanical damage.
Mechanical
- Positive crankcase ventilation (PCV) valve
- PCV separator
- Hose(s)/hose joints
- Gasket(s)

step.
Symptom Chart
Symptom
Possible Sources
Action
Excessive crankcase pressure
Blocked PCV valve.

Blocked PCV separator.
Blocked PCV hose.
CLEAN or INSTALL new PCV

TEST the system for normal operation. If the concern persists,
Oil in the air intake system
Restriction in PCV separator.
CLEAN or INSTALL a new PCV

separator. TEST the system for
normal operation.
PCV valve permanently open.
INSTALL a new PCV valve.

G148220 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
303-08A-7
303-08A-7

Crankcase Vent Oil Separator
Removal
303-01B.
3. Remove the crankcase vent oil separater.
Discard the gasket.
Installation
1. NOTE: Install a new crankcase vent oil
separator gasket.
G210048 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
303-08B-1
Engine Emission Control 2.0L Duratec-HE (MI4)
303-08B-1
SECTION 303-08B Engine Emission Control 2.0L

Duratec-HE (MI4)
CONTENTS
PAGE
SPECIFICATIONS
Specifications.................................................................................................................
303-08B-2

303-08B-3

Symptom Chart .............................................................................................................
303-08B-6
303-08B-6
303-08B-6

Exhaust Gas Recirculation (EGR) Valve ........................................................................
Crankcase Vent Oil Separator........................................................................................
303-08B-7
303-08B-9
11/2004 2005.25 Fiesta
303-08B-2

TO MODEL INDEX
303-08B-2
SPECIFICATIONS
Description
Exhaust gas recirculation (EGR) valve bolts
EGR valve outlet tube union
Crankcase vent oil separator retaining bolts
G37567 en
Nm
25
55
10
lb-ft
18
41
lb-in
89
11/2004 2005.25 Fiesta
303-08B-3

TO MODEL INDEX
303-08B-3

Item
Part
Number
Description

(EGR) valve
EGR valve gasket
EGR outlet
The exhaust gas recirculation (EGR) system

allows a measured quantity of exhaust gas to be
directed back to the intake manifold. The exhaust
gas is introduced to the incoming charge in the
intake manifold, where it dilutes the air fuel
mixture and lowers the peak gas temperature,
reducing nitrogen oxide exhaust emissions.
The exhaust gas is drawn through a passage
within the cylinder head from the exhaust manifold
to the intake manifold by the EGR valve.
The EGR valve is controlled by an input from the
powertrain control module (PCM).
G37563 en
11/2004 2005.25 Fiesta
303-08B-4

TO MODEL INDEX
303-08B-4
Item
Part
Number
Description
Positive crankcase ventilation (PCV) valve
PCV hose
Crankcase vent oil separator
Crankcase vent oil separator

retaining bolt
The positive crankcase ventilation (PCV) system

consists of a valve mounted in the crankcase vent
oil separator (attached to the cylinder block) and
two hoses. One PCV hose connects the PCV
valve to the intake manifold, the other PCV hose
connects the valve cover to the air cleaner.
Under idle and part throttle conditions, the
crankcase vapor flows through the intake manifold
into the combustion chambers where the vapor is
burnt during combustion.
G37563 en
11/2004 2005.25 Fiesta
303-08B-5

TO MODEL INDEX
303-08B-5
Item
Part
Number
Description
PCV hose to valve cover

connector
PCV hose
PCV hose to air cleaner

connector
Under full throttle conditions, the crankcase vapor

flows from the valve cover into the air cleaner
through the PCV hose.
G37563 en
11/2004 2005.25 Fiesta
303-08B-6

TO MODEL INDEX
303-08B-6


step.
General Equipment

Mechanical
Hose(s)/hose joints
Gasket(s)
Positive crankcase
ventilation (PCV)
valve
PCV separator
Exhaust gas recirculation (EGR) valve
Electrical
Electrical
connector(s)
Wiring harness
Fuse(s)
Relay
EGR valve
Powertain control
module (PCM)
Symptom Chart
Symptom
Possible Sources
Action
Poor engine performance
EGR valve.
Using WDS, CHECK the EGR

Valve Duty Cycle input signal to
the EGR vacuum regulator
valve. If the result is 0%,
REMOVE the EGR valve.
INSPECT the EGR valve and
valve seat for damage. Make
sure that the EGR valve is in the
closed position. If the EGR valve
is not closed. INSTALL a new
EGR valve. TEST the system for
normal operation. If the result is
not 0% continue the engine diagnostic using WDS.
Excessive crankcase pressure
Blocked or damaged PCV

hose(s).
Blocked crankcase vent oil
separator.
CHECK the PCV system components for blockages, CLEAN

or INSTALL new components as
necessary.
Worn or damaged engine components.
REFER to Section 303-01A /

303-01B.
G334290 en
11/2004 2005.25 Fiesta
303-08B-7

TO MODEL INDEX
303-08B-7

Exhaust Gas Recirculation (EGR) Valve
Special Tool(s)
Remover/Installer, Coolant
Hose Clamp
303-397
4. Using the special tool, disconnect the radiator upper coolant hose from the coolant
outlet connector.

2. Remove the air cleaner outlet pipe.

table(s).
3. Remove the air cleaner intake tube.
G421887 en
11/2004 2005.25 Fiesta
303-08B-8

TO MODEL INDEX
303-08B-8
Item
Part
Number
Description
EGR valve electrical connector
EGR valve coolant hose

See Removal Detail
EGR valve
G421887 en
11/2004 2005.25 Fiesta
303-08B-9

TO MODEL INDEX
303-08B-9

Crankcase Vent Oil Separator
Removal
303-01B.
2. Disconnect the positive crankcase ventilation (PCV) hose from the PCV valve.
4. Remove the crankcase vent oil separator.

Discard the gasket.
Installation
3. Remove the PCV valve from the crankcase
vent oil separator.
1. Push in the locking tangs.
2. Twist the PCV valve to remove.
G37566 en
1. NOTE: Install a new crankcase vent oil

separator gasket.
11/2004 2005.25 Fiesta

TO MODEL INDEX
303-12-1
Intake Air Distribution and Filtering
303-12-1
SECTION 303-12 Intake Air Distribution and Filtering

CONTENTS
PAGE
SPECIFICATIONS
Specifications....................................................................................................................
303-12-2

Intake Air Distribution and Filtering 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V
(Sigma) ............................................................................................................................
Intake manifold................................................................................................................
Intake Air Distribution and Filtering 2.0L Duratec-HE (MI4)...........................................
2.0L Duratec HE (MI4) engine..........................................................................................
303-12-3
303-12-3
303-12-4
303-12-4

Intake Air Distribution and Filtering....................................................................................
Symptom Chart ................................................................................................................
303-12-7
303-12-7
303-12-7

Air Cleaner 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L (23 174 0)
Duratec-16V (Sigma)....................................................................................
Air Cleaner 2.0L Duratec-HE (MI4)...............................................................................
303-12-10
303-12-11
11/2004 2005.25 Fiesta
303-12-2

TO MODEL INDEX
303-12-2
SPECIFICATIONS
Description
Air cleaner intake pipe retaining bolt - vehicles with
1.4L Duratorq-TDCi (DV) diesel engine
Air cleaner retaining screws - vehicles with 1.4L
Duratorq-TDCi (DV) diesel engine
Air cleaner outlet hose retaining clip - vehicles with
1.6L Duratorq-TDCi (DV) diesel engine
Air cleaner intake pipe duct retaining bolts - vehicles with 1.6L Duratorq-TDCi (DV) diesel engine
Charge air cooler hose retaining clamps - 1.6L
Charge air cooler retaining bolts - 1.6L Duratorq-TDCi (DV) diesel engine
Radiator support bracket retaining bolts - 1.6L
G148224 en
Nm
4
lb-ft
-
lb-in
35
44
35
44
44
10
89
25
18
11/2004 2005.25 Fiesta

TO MODEL INDEX
303-12-3
303-12-3

Intake Air Distribution and Filtering 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V
(Sigma)
Intake manifold
The 1.4l and 1.6l versions feature a revised intake

manifold. The overall length of the intake pipes
has been increased, but the pipes are of equal
length on all cylinders. This has resulted in
increased torque in the lower engine speed range
and a reduction in noise levels.
Item
Part
Number
Description
Mounting for the throttle

valve unit
T-MAP sensor
The mounting for the electronic throttle valve is

located inside the intake manifold between the
intake pipes of cylinders 1 and 2. The T-MAP
sensor, which is used on both the 1.4l and 1.6l
versions, is situated next to the throttle valve unit.
G179057 en
11/2004 2005.25 Fiesta
303-12-4

TO MODEL INDEX
303-12-4

Intake Air Distribution and Filtering 2.0L Duratec-HE (MI4)
2.0L Duratec HE (MI4) engine
Intake manifold and ancillary components
Item
Part
Number
Intake manifold
Intake manifold tuning valve

solenoid

solenoid to intake manifold
vacuum pipe

solenoid to intake manifold
tuning valve vacuum pipe

actuator

flaps
G421936 en
Description
11/2004 2005.25 Fiesta
303-12-5

TO MODEL INDEX
303-12-5
Air intake system
G421936 en
11/2004 2005.25 Fiesta
303-12-6

TO MODEL INDEX
303-12-6

Item
Part
Number
Air cleaner housing cover

retaining bolts
Air cleaner housing outlet

pipe resonator
Air cleaner housing outlet

pipe resonator grommet
Air cleaner housing
Air cleaner pipe retaining

clamps

resonator isolators

resonator retaining bracket

resonator
10
Air cleaner intake pipe duct
11
Air cleaner intake pipe duct

retaining bolts
12
Air cleaner outlet pipe
13
Air cleaner housing resonator
14
Positive crankcase ventilation (PCV) hose
15
PCV hose foam filter
16
Air cleaner element
17
Air cleaner housing cover
G421936 en
Description
11/2004 2005.25 Fiesta

TO MODEL INDEX
303-12-7
303-12-7

Mechanical
Air cleaner element
Air cleaner intake
pipe
Air cleaner outlet
pipe
Charge air cooler
(Vehicles with 1.6L
Duratorq-TDCi (DV)
Diesel engine)
Charge air cooler
intake hose
(Vehicles with 1.6L
Duratorq-TDCi (DV)
Diesel engine)
Charge air cooler
outlet hose (Vehicles with 1.6L Duratorq-TDCi (DV)
Diesel engine)

step.
Electrical
Mass air flow (MAF)
sensor
Manifold absolute
pressure (MAP)
sensor (Vehicles
with 1.6L
Duratorq-TDCi (DV)
Diesel engine)
Symptom Chart
Symptom
Excessive intake air noise
G421937 en
Possible Sources
Action
Detached air cleaner pipe(s).

Detached turbocharger pipe(s)
(Vehicles with Duratorq-TDCi
(DV) Diesel engine or 1.6L
engine).
Detached charge air cooler
hose(s) (Vehicles with 1.6L Duratorq-TDCi (DV) Diesel engine).
CHECK the pipe(s) for security

and leaks to atmosphere.
INSTALL new intake air components as necessary. TEST the
11/2004 2005.25 Fiesta
303-12-8

TO MODEL INDEX
303-12-8

Symptom
Oil in the air intake system
Possible Sources
Blocked or damaged positive

Vehicles with 1.25L Duratec-16V
crankcase ventilation (PCV)
valve.
(Rocam)/1.4L Duratec-16V
Blocked or damaged PCV
pipe(s)/hose(s).
(Sigma) engine. REFER to
Blocked or damaged crankcase Section 303-08A.[Engine
vent oil separator.
Emission Control - 1.25L
Duratec-16V (Sigma)/1.3L
Duratec-8V (Rocam)/1.4L
Duratec-16V (Sigma),
REMOVAL AND
INSTALLATION, Crankcase
Vent Oil Separator]
Vehicles with 2.0L Duratec-HE
(MI4) engine.
Turbocharger (Vehicles with
Duratorq-TDCi (DV) Diesel engine or 1.6L Duratorq-TDCi (DV)
Diesel engine).
Water in the air cleaner
Engine lacks power
Action
Vehicles with 1.4L

engine.
Vehicles with 1.6L Duratorq-TDCi (DV) Diesel engine.
Detached air cleaner intake pipe. CHECK the air cleaner intake
pipe for security. INSTALL new
intake air system components as
normal operation.
Blocked air cleaner drain.
CLEAN the air cleaner drain.

Air cleaner element blocked.
INSPECT the air cleaner for

signs of blockage. INSTALL a
new air cleaner element as
necessary.
Charge air cooler pipe(s) (Vehi- INSPECT the charge air cooler
cles with 1.6L Duratorq-TDCi
pipes for damage. INSTALL a
(DV) Diesel engine).
new charge air cooler pipe(s) as
necessary.
Charge air cooler blocked (Vehicles with 1.6L Duratorq-TDCi
(DV) Diesel engine).
G421937 en
INSPECT the charge air cooler

for blockage. INSTALL a new
charge air cooler as necessary.
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303-12-9

Symptom
G421937 en
Possible Sources
Action
Fuel charging and controls

(Rocam) engine.
(Sigma) engine. REFER to
Section 303-04A.[Fuel Charging
and Controls - 1.25L
Duratec-16V (Sigma),
Fuel Charging and Controls]
Vehicles with 1.4L
engine.
Vehicles with 2.0L Duratec-HE
(MI4) engine. REFER to Section
303-04B.[Fuel Charging and
Controls - 2.0L Duratec-HE
(MI4), DIAGNOSIS AND
TESTING, Fuel Charging and
Controls]
Turbocharger (Vehicles with

Duratorq-TDCi (DV) Diesel engine or 1.6L Duratorq-TDCi (DV)
Diesel engine).
Vehicles with 1.4L

engine.
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Air Cleaner 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L
Removal
1. Disconnect the air cleaner outlet pipe and
the positive crankcase ventilation (PCV)
hose from the air cleaner.
2. Disconnect the air intake hose from the air

cleaner.

Remove the retaining bolts and lift the air
cleaner up at the rear to remove.
Installation
1. NOTE: Locate the rear isolators onto the rear
mounting pegs and push down.
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303-12-11
303-12-11

Air Cleaner 2.0L Duratec-HE (MI4)
table(s).
Item
Part
Number
Air cleaner outlet pipe

See Removal Detail
Air cleaner intake pipe retaining clip

See Removal Detail
Positive crankcase
ventilation (PCV) hose
See Removal Detail
PCV hose connector
Air cleaner
See Removal Detail
G421938 en
Description
Removal Details
Item 2 : Air cleaner outlet pipe
1. Detach the air cleaner outlet pipe from the
throttle body.
Item 4 : Air cleaner intake pipe
1. Detach the air cleaner intake pipe from the
air cleaner.
Item 5 : Positive crankcase ventilation (PCV)
hose
1. Detach the PCV hose from the air cleaner.
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Item 7 : Air cleaner
1.
CAUTION: Make sure the air cleaner is

removed from the air cleaner
mountings in a vertical direction.
cause damage to the air cleaner and
air cleaner mountings.
Detach the air cleaner from the air cleaner
mountings and remove the air cleaner.
G421938 en
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303-13-1
Evaporative Emissions
303-13-1
SECTION 303-13 Evaporative Emissions

CONTENTS
PAGE

Evaporative Emissions......................................................................................................
Overview ..........................................................................................................................
303-13-2
303-13-2

Evaporative Emissions......................................................................................................
303-13-3
303-13-3

Evaporative Emission Canister 1.25L Duratec-16V (Sigma)/1.3L Du(29 250 0)
ratec-8V (Rocam)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) .....
303-13-4
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Overview
Item
Part
Number
Description
From activated charcoal

canister
From fuel tank
Non-return valve
Carbon canister
Evaporative Emission
To the intake manifold
The EVAP collection system prevents fuel

vapours from reaching the atmosphere.
To achieve this, the fuel vapours are led from the
fuel tank into the activated charcoal canister, and
temporarily stored there.
Under part load the Powertrain Control Module
(PCM) activates the EVAP solenoid valve. This
causes the fuel vapours to be passed on to the
intake system of the engine.
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303-13-3

Mechanical
Electrical
Vacuum line(s)
Fuse(s)
Evaporative
Wiring harness
emission (EVAP)
Electrical connecsystem canister
tor(s)
EVAP system
hose(s)
EVAP system canister purge valve
step.
system.
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Evaporative Emission Canister 1.25L Duratec-16V (Sigma)/1.3L Duratec-8V
(Rocam)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) (29 250 0)
General Equipment
3. Detach the exhaust system from the center

exhaust hanger insulator.
Transmission jack
Removal
working on or near fuel related
injury.
100-02.
2. Remove the floor panel crossmember.
4. NOTE: When detaching the exhaust system

allow the system to be supported by the rear
suspension assembly.
Detach the exhaust system from the rear
5. Remove the exhaust system heat shield.
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303-13-5
6.
CAUTION: Use a suitable packing

material to prevent damage to the
underside of the fuel tank.
Using a suitable transmission jack , support the fuel tank.
7. Remove the fuel tank support strap rear

retaining bolts.
8. NOTE: Make note of the positions of the

support straps to make sure they are
positioned in exactly the same positions when
installing (left-hand over right-hand).
Remove the fuel tank support straps.
9.
CAUTION: When lowering the fuel tank,

make sure that excessive strain is not
placed on the fuel lines and electrical
connectors.
Partially lower the fuel tank.
G210050 en
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10. Disconnect the fuel tank vent pipe from
the evaporative emission canister. For
310-00.
11. Disconnect the back pressure valve from

the evaporative emission canister.
Hold the cap against the canister and pull
the back pressure valve.
Installation
1.
WARNING: Do not smoke or carry

lighted tobacco or open flame of any
type when working on or near fuel
related components. Highly flammable
vapors are always present and may
ignite. Failure to follow these
instructions may result in personal
injury.

injury.
NOTE: When installing the fuel tank make sure
the fuel lines do not get kinked or trapped.
12. Remove the evaporative emissions canister from the fuel tank.
G210050 en
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303-14-1
Electronic Engine Controls
303-14-1
SECTION 303-14 Electronic Engine Controls

CONTENTS
PAGE
SPECIFICATIONS
Specifications....................................................................................................................
303-14-2

Electronic Engine Controls 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L
Duratec-16V (Sigma)........................................................................................................
Overview ..........................................................................................................................
Throttle Control Unit (TCU)...............................................................................................
CPP switch .......................................................................................................................
(Brake Pedal Position) BPP switch....................................................................................
APP sensor.......................................................................................................................
Electronic Engine Controls 2.0L Duratec-HE (MI4) .......................................................
System Overview, 2.0L Duratec HE (MI4) Engine ............................................................
Components.....................................................................................................................
303-14-4
303-14-4
303-14-5
303-14-6
303-14-7
303-14-7
303-14-9
303-14-9
303-14-10

Electronic Engine Controls ................................................................................................
Principles of Operation .....................................................................................................
MIL Code List ...................................................................................................................
303-14-13
303-14-13
303-14-16
303-14-19

Powertrain Control Module (PCM) 1.25L Duratec-16V (Sigma)/1.4L Du- (29 200 0)
ratec-16V (Sigma)/1.6L Duratec-16V (Sigma) ..............................................
Powertrain Control Module (PCM) 2.0L Duratec-HE (MI4), Vehicles With: PCM Security
Shield...............................................................................................................................
Powertrain Control Module (PCM) 2.0L Duratec-HE (MI4), Vehicles Without: PCM
Security Shield .................................................................................................................
Heated Oxygen Sensor (HO2S).................................................................... (29 220 0)
Crankshaft Position (CKP) Sensor ....................................................................................
Knock Sensor (KS) ...........................................................................................................
303-14-20
303-14-22
303-14-25
303-14-28
303-14-30
303-14-33
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SPECIFICATIONS
Torque Specifications - vehicles with 1.3L Duratec-8V (Rocam) engine

Description
Nm
Powertrain control module (PCM) retaining bolts
3
20
Crankshaft position (CKP) sensor retaining bolt
10
6
Throttle position (TP) sensor screws
5
Idle air control (IAC) valve retaining bolts
10
6
Exhaust manifold heatshield retaining bolts
10
Heated oxygen sensor (HO2S)
47
Catalyst monitor sensor (CMS)
47
lb-ft
15
35
35
lb-in
27
89
53
44
89
53
89
-
Torque Specifications - vehicles with 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L

Duratec-16V (Sigma) engine
Description
Nm
lb-ft
lb-in
3
27
20
15
Cylinder head temperature (CHT) sensor
25
18
10
89
10
89
Engine coolant temperature (ECT) sensor
20
15
Idle air control (IAC) valve
10
89
47
35
47
35
Torque Specifications - vehicles with 1.4L Duratorq-TDCi (DV) Diesel engine
Description
Nm
lb-ft
Powertrain control module (PCM) retaining nuts
10
and retaining bolts
Timing belt upper cover retaining bolts
4
6
5
8
a
-
lb-in
89
35
53
44
71
-
a)

Description
Nm
lb-ft
Powertrain control module (PCM) retaining nuts
10
and retaining bolts
Timing belt upper cover retaining bolts
4
6
5
8
a
-
lb-in
89
35
53
44
71
-
a)
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Description
Nm
10
PCM mounting bracket retaining bolts
25
20
7
6
6
Exhaust manifold heatshield retaining bolts
10
47
47
G148226 en
lb-ft
18
15
35
35
lb-in
89
62
53
53
89
-
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Electronic Engine Controls 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V
(Sigma)/1.6L Duratec-16V (Sigma)
Overview
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303-14-5
303-14-5

Item
Part
Number
Description
Temperature and Manifold
Absolute Pressure (T-MAP)
sensor
Throttle Position (TP) sensor
Knock Sensor (KS)
Sensor - Engine Coolant

Temperature (ECT)
Crankshaft Position (CKP)

sensor
Camshaft Position (CMP)

sensor
Heated Oxygen Sensor

(HO2S)
Power Steering Pressure

(PSP) sensor
Vehicle Speed Sensor (VSS)

(only on vehicles without
Anti-lock Braking System
(ABS))
10
Brake Pedal Position (BPP)

switch
11
Accelerator Pedal Position

(APP) sensor
12
Clutch Pedal Position (CPP)

switch
13
Generator
14
Current supply relay
15
Ignition key
16
Battery
17
Powertrain Control Module

(PCM)
18
19
Fuel Pump (FP) relay
20
Inertia fuel shut-off switch
21
Fuel Pump Driver Module

(FPDM)
22
Fuel injectors
23
Evaporative emissions
24
Idle Air Control (IAC) valve
G204204 en
Item
Part
Number
Description
25
Throttle Control Unit (TCU)
26
Air Conditioning (A/C) compressor clutch / blower switch
27
Injector Driver Module (IDM)
28
Start inhibit relay
29
Instrument cluster
Throttle Control Unit (TCU)

Components
Item
Part
Number
Description
TP sensor
2
Electric motor
The electronically controlled throttle control unit
(TCU) consists of the following components:
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303-14-6
Housing
Throttle flap
Throttle flap spindle
Gear set
Electric motor with pinion
TP sensor
Stop screw
Throttle flap return spring
Function
CAUTION: The throttle control unit (TCU)

must not be dismantled. No adjustments
or repairs can be made to the TCU.
The APP sensor sends the data containing the

driver's acceleration requirement to the PCM. This
information depends directly on the movement of
the accelerator pedal.
The PCM processes this information and converts
it into an output signal for the throttle control unit
(TCU). This output signal is the control for the
electric motor.
The electric motor moves the throttle flap spindle
by means of the gear set.
The throttle flap position is adjusted and
monitored in a closed control loop. The TP sensor
provides the PCM with the information on the
actual position of the throttle flap.
Standby function
If a fault develops in the throttle control unit (TCU),

a standby function is carried out. This standby
function allows a slight opening of the throttle flap,
so that enough air passes through to allow limited
engine operation.
For this purpose, there is an throttle flap
adjustment screw on the throttle housing. The
return spring closes the throttle flap until the stop
of the toothed segment touches the stop screw. In
this way a defined throttle flap gap is formed for
limp home mode.
The stop screw has a spring loaded pin, which
holds the throttle flap open for limp home mode. In
normal operating mode, this spring loaded pin is
pushed in by the force of the electric motor when
the throttle flap must be closed past the limp home
position (e.g. for idle speed control or overrun
shutoff).
CPP switch
Item
Part
Number
Description
Stop screw
Toothed segment
Throttle flap spindle
Throttle flap return spring
Intermediate shaft with gear
Electric motor with pinion
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The CPP switch is located directly on the pedal
box.
APP sensor
The engine management recognises gearshifts

through the CPP switch and thus improves engine
running characteristics.
The CPP switch passes a ground signal to the
PCM when the clutch pedal is depressed
(disengaged).
(Brake Pedal Position) BPP switch
There are two brake pedal switches at the pedal

box: the brake lamp switch and the BPP switch.
The brake lamp switch only serves to switch on
the brake lamps. The BPP switch is used for
engine management purposes.
The BPP switch provides the PCM with the
information that the vehicle will be decelerated.
The BPP switch is closed in the rest state (brake
pedal not depressed) and sends a ground signal
to the PCM.
If when the APP sensor has failed, the BPP is
operated, the engine will be controlled to run at
idle speed by the PCM.
G204204 en
In order that the engine power output can be

matched to that required by the driver, the PCM
needs to know the position of the APP sensor.
The APP sensor is a variable resistor whose
resistance varies with the accelerator position. It is
a sliding contact potentiometer (2 potentiometers
in total).
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If a fault occurs in the APP sensor or the throttle
control unit (TCU) during vehicle operation, then
this will be briefly indicated by a digital display in
the instrument cluster after the ignition is switched
on, and a trouble code will be stored in the PCM.
If one potentiometer fails, the engine will run with
reduced power (maximum torque 80 Nm), if both
potentiometers fail, the engine will run with
reduced power (maximum torque 55 Nm).
This warning may also be indicated if the engine
does not start. The cause may be a poor state of
charge of the battery.
The warning indication normally disappears once
the battery is re-charged.
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303-14-9

Electronic Engine Controls 2.0L Duratec-HE (MI4)
System Overview, 2.0L Duratec HE (MI4)
Engine
G422229 en
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303-14-10

Description
Components
Manifold absolute pressure

and temperature (MAPT)
sensor
MAPT sensor
Camshaft position (CMP)

sensor
Knock sensor (KS)
Ambient air temperature

sensor
Instrument cluster
Battery
Spark plug wires

(EGR) valve
Fuel pump module
10
Fuel rail and fuel injectors
The MAPT sensor is attached to the housing of

the intake manifold valve behind the throttle body.
The signal from the MAPT sensor is used to
modify the ignition and fuel delivery.
11

solenoid
CMP sensor
12
Accelerator pedal position

(APP) sensor
13
Clutch pedal position (CPP)

switch
14
Brake pedal position (BPP)

switch
15
Stoplamp switch
16
Power steering pressure

(PSP) switch
17
Catalyst monitor sensor
18
Heated oxygen sensor

(HO2S)
19
Generator (input signal)
20
Crankshaft position (CKP)

sensor
21
Engine coolant temperature

(ECT) sensor
22
Throttle position (TP) sensor

(part of throttle body)
23

(PCM)
Item
Part
Number
G422229 en
The CMP sensor is located on the right-hand side

of the valve cover above the intake camshaft. The
CMP sensors send signals to the PCM which are
then used by the PCM to calculate the position of
the camshaft.
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303-14-11

Powertrain control module (PCM)
The knock sensor is located on the cylinder block

between cylinders 2 and 3.
The KS detects engine vibrations caused by
knock and produces an output voltage signal in
proportion to the knock. The PCM uses the
voltage signal to control knock by retarding the
ignition timing.
Intake manifold tuning valve solenoid
The powertrain control module is located within

the engine compartment below the battery and is
secured to the left-hand chassis rail by means of a
mounting bracket. On right-hand drive vehicles
the PCM is protected by a security shield which is
secured to the retaining bracket by a shear-head
bolt. In order to disconnect the PCM electrical
connectors it is necessary to remove the security
shield.
The PCM monitors and processes the signals
from the sensors and compares these with stored
parameters. The PCM uses this information to
calculate the output signals to the actuators.
Communications between the PCM and other
control units (for example, the stability assist and
the instrument cluster) including the DLC for
diagnosis of the system, take place on the
controller area network (CAN).
Diagnosis can be carried out through the DLC
using the Worldwide Diagnostic System (WDS)
diagnostic equipment.
The solenoid for the intake manifold tuning system

is located on the transmission side of the cylinder
head.
Vacuum is supplied by a central vacuum
connection from the intake manifold.
The solenoid for the intake manifold tuning system
is supplied with either the maximum voltage or
zero voltage, i.e. the valves are either fully open or
fully closed.
Actuation depends on the engine speed and the
engine load.
BPP switch
Knock sensor (KS)
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The BPP switch and the stoplamp switch are
located on the pedal box and provide the PCM
with the information that the brake pedal has been
pressed and that the vehicle is therefore being
decelerated.
The BPP switch is connected to the instrument
cluster via a CAN bus. In its rest state the switch is
closed and sends a ground signal to the PCM.
The signal from the BPP switch is used in the
event of failure of the APP sensor for the
emergency operating mode.
Accelerator pedal position (APP) sensor
of the engine according to the driver request for

power.
The APP sensor is a double contact-less inductive
sensor.
If a concern occurs with the APP sensor while
driving, a diagnostic trouble code (DTC) is stored
in the PCM.
If both sensors of the APP sensor fail, the engine
is regulated to a maximum engine speed of up to
4000 rev/min after a single operation of the BPP
switch and the stop lamp switch and a subsequent
comparative plausibility test. The vehicle can only
be accelerated to a maximum speed of 56 km/h.
When the brake pedal is pressed again the engine
speed drops to idle speed. When the brake pedal
returns to its rest position the engine speed is
increased again.
The PCM requires the pedal position from the

APP sensor in order to regulate the power output
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303-14-13

Warm-up Cycle
General Equipment
The warm-up cycle is an operation that consists of

key on, engine start and a coolant temperature
increase of 22C, exceeding 71C on completion.
Drive Cycle
For Principles of Operation on the electronic
accelerator control system REFER to Section
310-02A.[Acceleration Control - 1.25L
Duratec-16V (Sigma), DIAGNOSIS AND
TESTING, Acceleration Control]
European On-Board Diagnostics (EOBD)
EOBD is a diagnostic system integrated into the

powertrain control module (PCM). This system
continuously monitors vehicle emission
components. The system includes a malfunction
indicator lamp (MIL) which indicates when there is
a concern that can affect emissions or the system
malfunctions. Data stored within the module DTC
memory can be accessed using a generic scan
tool or WDS.
EOBD is mandated within European Union
regulations from the year 2000 for passenger
vehicles with petrol engines and from 2003
onwards for passenger vehicles with diesel
engines.
EOBD Functions:
Establishes when and how emissions control
faults must be indicated.
Actuates emission control malfunction
indicator lamp (MIL) and fault memory.
Indicates operating conditions in which the
concern occurred (freeze frame data).
Standardized output of operating data such as
engine speed, engine coolant temperature etc.
Standardized names and abbreviations for
components and systems.
Standardized DTCs for all manufacturers.
Standardized communication with the
diagnostic equipment.
Standardized 16-pin data link connector (DLC)
in area of the instrument panel.
Concern display must be possible using a
generic scan tool.
A drive cycle commences when the engine is

started (cold or warm) and ends when the engine
is switched off.
Trip
A trip begins when the engine is started and is

complete when all the EOBD monitors have
completed a self-test. This may take place over a
number of drive cycles. On diesel variants, the
information gathered from one drive cycle is not
carried over to a subsequent cycle or cycles.
When a concern has been rectified, particularly
after electronic engine control components have
been changed, the DTC memory, which is part of
the EEPROM must be cleared of all trouble codes.
When the DTC memory has been cleared, the
code P1000 (known as the readiness code) is set
in the PCM memory, which indicates that since the
EEPROM has been cleared, not all of the
monitoring systems have completed their tests.
P1000 can only be cleared by carrying out a trip,
which includes driving the vehicle under variable
conditions of speed, load and time so that all of the
monitors are completed. As P1000 will not
illuminate the MIL it is not necessary to carry out
the trip before returning the vehicle to the
customer.
Freeze Frame Data
When a concern is detected, various data is

stored depending on application including:
EOBD consists of the following elements:

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303-14-14
Diagnostic trouble code.

Vehicle speed.
Engine coolant temperature.
Engine speed.
Engine load.
Mixture formation trim value (trim value for
engine wear) (All except vehicles with diesel
engine).
State of oxygen sensor control (open and
closed loop) (All except vehicles with diesel
engine).
Distance covered since the concern was first
registered.
Monitors
The purpose of the monitors is to continuously

check the operation of the emission related
sensors and actuators. It then establishes if they
are operating within specified tolerances. All
monitors carry out their functions in such a way as
to be unnoticeable by the driver of the vehicle.
Each one is carried out under specific conditions
of load, speed and engine temperature. The
Comprehensive Component Monitor, Combustion
Misfire Monitor and Air/Fuel Ratio Monitor operate
continuously. The remaining monitors are only
invoked under certain operating conditions. On
diesel variants, all of the monitors operate under
normal driving conditions: There are no monitors
which intervene and cause special operating
modes to enable the monitors to work. Some
diesel monitors are non-continuous. This means
that in a drive cycle, monitoring is done as and
when suitable driving conditions exist and
potential faults are accumulated and compared
with acceptance criteria. Examples of this type
are the turbocharger boost pressure and exhaust
gas recirculation (EGR) monitors on vehicles with
common rail fuel injection.
Comprehensive Component Monitor (CCM)
When the CCM detects a component operating

out of tolerance, it sets a Diagnostic Trouble Code
(DTC), which is stored in the EEPROM. If the
same concern is confirmed during the next trip the
MIL will be switched on. The CCM monitors many
components, sub-systems and signals. The
following is a list of those that can effect emissions
depending on application:
Electronic Ignition (EI) System.

Crankshaft Position (CKP) Sensor.
Ignition Coil.
Electronic Throttle Control Unit.
Camshaft Position (CMP) Sensor.
Air Conditioning (A/C) Clutch.
Idle Air Control (IAC) Valve.
Mass Air Flow (MAF) Sensor.
Manifold Absolute Pressure (MAP) Sensor.
Intake Air Temperature (IAT) Sensor.
Engine Coolant Temperature (ECT) Sensor.
Cylinder Head Temperature (CHT) Sensor.
Heated Oxygen Sensor (HO2S).
Catalyst Monitor Sensor.
Charge Air Temperature Sensor.
Knock Sensor (KS).
Throttle Position (TP) Sensor.
Vehicle Speed Sensor (VSS).
Boost Pressure Sensor.
Cam-Crank Phasing Sensor.
EEPROM.
High Pressure Fuel Injection Pump.
Exhaust Gas Recirculation (EGR) Valve
Monitor.
Fuel Injectors.
Turbocharger.
Combustion Noise Monitor.
Barometric Pressure (BARO) Sensor.
Combustion Misfire Monitor (All except vehicles

with diesel engine)
The combustion misfire monitor operates

independently of the others, and can detect
misfires caused by the ignition system, fuel
system or mechanical engine components. As
each cylinder fires, a characteristic crankshaft
acceleration is produced. The monitor detects
irregularities in the acceleration pattern using the
crankshaft position (CKP) sensor, thus detecting
the misfire. It can also detect which cylinder has
misfired. Combustion misfires can be categorized
as follows:
Type A: These can cause catalytic converter
damage due to excessive internal temperatures. If
a certain number of misfires occur over a
pre-determined number of engine revolutions, the
MIL will be switched on to alert the driver of the
concern.
Type B: These can lead to an increase in
emissions to a point above the EOBD threshold. If
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the misfire is detected during a second trip, over a
pre-determined number of engine revolutions, the
MIL will be switched on. If the misfire does not
occur over the next three trips, the MIL will be
extinguished
Air/Fuel Ratio (AFR) Monitor (All except vehicles
with diesel engine)
The HO2S fitted before the catalytic converter

(upstream) measures the oxygen content of the
exhaust gas and the variations in it. This then
enables the PCM to adjust the opening times of
the fuel injectors to maintain the correct AFR. This
is known as Short Term Fuel Trim (STFT). If the
same variation is registered a pre-determined
number of times, a permanent correction factor is
applied. This is known as Long Term Fuel Trim
(LTFT), which is stored in the EEPROM. When the
correction factors exceed pre-determined limits a
DTC will be set in the EEPROM. If a concern is
detected in either the STFT or LTFT, and it is still
present on a second trip, the MIL will be switched
on.
Heated Oxygen Sensor (HO2S) Monitor (All except
vehicles with diesel engine)
This monitors the operation of the pre (upstream)

and post (downstream) catalytic converter HO2S
sensors. It will detect deviations in air/fuel ratios
(AFR) and sensor faults.
The HO2S will cause emission increase when its
response time increases too much. To diagnose a
sensor a period is measured and the number of
lean/rich transitions are counted. The sum of valid
periods is then calculated. To avoid
non-representative measurements, the period is
valid only if the HO2S has been below a low
threshold and above a high threshold between 2
consecutive lean/rich transitions. A failure is
declared when the sum of the measured periods
exceeds the sum of the corresponding limit (held
within the PCM) and the MIL is illuminated.
Catalytic Converter Efficiency Monitor (All except
vehicles with diesel engine)
The efficiency of a catalytic converter is measured

by its ability to store and later release oxygen to
convert harmful gases. The efficiency is reduced if
the converter becomes contaminated as it ages,
and at high gas flow rates, because the exhaust
gas does not remain in the converter long enough
to complete the conversion process.
This monitor checks for the oxygen storage
capacity (OSC) of the catalytic converter. During a
controlled period, the catalyst monitor sensor
G384566 en
signal is analyzed to evaluate the OSC of the

catalyst. It represents the quantity of oxygen that
is really used for the oxidation-reduction reaction
by the catalytic converter If a fault has occurred
with the catalyst monitor sensor during the
catalyst diagnosis, a sensor diagnosis is carried
out. During the controlled diagnosis phase, the
catalyst monitor sensor activity is measured and is
compared to the OSC of the catalyst. If this activity
is high (low OSC) the MIL will be illuminated. If
throughout the controlled phase, repeated several
times, the downstream sensor output has not
moved, the closed loop mode is delayed in order
to test the sensor. If the catalyst monitor sensor is
set to rich, the injection time is forced to lean and
conversely if the downstream sensor is set to lean,
the injection time is forced to rich until the sensor
switches over or until the end of a delay. If this
delay expires or the sensor does not switch, the
sensor is treated as failed.
Combustion Noise Monitor (Vehicles with common
rail fuel injection)
In diesel variants, the Combustion Noise Monitor

is used to trim the fuel injection pulse lengths.
Each fuel injector has an associated set of
correction data that is determined during a
production end of line test. The Combustion Noise
Monitor is used to determine how the fuel injector
characteristic changes from this initial calibration
over the life of the fuel injector.
EGR Monitor (Vehicles with diesel engine)
The functionality of the EGR system is checked by

comparing either the MAP sensor output or EGR
valve lift potentiometer output (depending upon
application) with expected values.
Diagnostic Requirements
Vehicles equipped with EOBD, can be diagnosed

using the WDS. In order for the EOBD system to
be invoked, a number of criteria must be met. After
any repair, which could affect emissions, a trip
must be carried out on the vehicle, to make sure
that engine management system operates
correctly.
Malfunction Indicator Lamp (MIL)
The MIL is located in the instrument cluster and is

fitted to alert the driver to the fact that an abnormal
condition has developed in the engine
management system, that is having an adverse
effect on emissions. In cases of misfires which are
likely to cause catalytic converter damage, it is
switched on immediately. With all other faults it will
illuminate continuously from the second trip after
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the condition occurred. Under normal operation it
should illuminate at key-on and go out almost as
soon as the engine is started.
Diagnostic Trouble Codes (DTCs)
The DTCs given by the PCM are standardized,

which means that generic scan tools can read
results from all vehicles.
The DTC is always a 5 digit alphanumerical
code, for example P0100".
The first digit of a code (letter) identifies the
system which has set the code. Provision has
been made for a total of four systems to be
identified although only the 'P' code is required
for EOBD.
- 'B' for the body
- 'C' for the chassis
- 'P' for the powertrain
- 'U' for the network communications systems
All of the x0xxx" codes are standardized
codes. However, any manufacturer can use
additional codes over and above the
standardized codes. These will be

labelled x1xxx"
The third digit of a code (numeric) identifies
the sub-system which has set the code.
- 'Px1xx' for metering of fuel and air supply
- 'Px2xx' for metering of fuel and air supply
- 'Px3xx' for ignition system combustion
misfires
- 'Px4xx' for auxiliary emission control
equipment
- 'Px5xx' for vehicle speed, idle setting and
other related inputs
- 'Px6xx' for trip computer and other related
outputs
- 'Px7xx' for transmission.
- 'Px8xx' for transmission.
- 'Px9xx' category to be determined
- 'Px0xx' category to be determined
When a concern occurs, the actions taken
include storage of the relevant information and
actuation of the MIL occurs in line with the
relevant legislation.
MIL Code List

MIL Code
P0030
P0031
P0032
P0036
P0037
P0038
P0053
P0054
P0106
P0107
P0108
P0109
P0112
P0113
P0114
P0116
P0117
P0118
P0119
P0122
P0123
P0130
P0131
P0132
P0133
P0134
G384566 en
Description
Heated oxygen sensor (HO2S) heater open circuit
HO2S heater low voltage
HO2S heater high voltage
Catalyst monitor sensor heater open circuit
Catalyst monitor sensor heater low voltage
Catalyst monitor sensor heater high voltage
HO2S heater resistance out of limits
Catalyst monitor sensor heater resistance out of limits
Manifold absolute pressure (MAP) sensor plausibility malfunction
MAP sensor circuit low input
MAP sensor circuit high input
MAP sensor temporary malfunction
Intake air temperature (IAT) circuit low input
IAT circuit high input
IAT intermittent failure
Engine coolant temperature (ECT) signal stuck at low level
ECT circuit low input
ECT circuit high input
ECT intermittent failure
Throttle position (TP) sensor circuit 1 low input
TP sensor circuit 1 high input
HO2S circuit open circuit
HO2S circuit low voltage
HO2S circuit high voltage
HO2S circuit slow response
HO2S low amplitude
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MIL Code
P0136
P0137
P0138
P0139
P0171
P0171
P0172
P0172
P0201
P0202
P0203
P0204
P0222
P0223
P0231
P0232
P0261
P0262
P0264
P0265
P0267
P0268
P0270
P0271
P0300
P0301
P0302
P0303
P0304
P0315
P0324
P0325
P0335
P0336
P0336
P0336
P0340
P0341
P0351
P0352
P0420
P0444
P0458
P0459
P0460
P0500
P0500
P0503
P0511
P0560
P0562
G384566 en
Description
Catalyst monitor sensor circuit open circuit
Catalyst monitor sensor circuit low voltage
Catalyst monitor sensor circuit high voltage
Catalyst monitor sensor circuit slow response
Fuel system error, lean limit
Fuel system error , NOx emissions
Fuel system error , rich limit
Fuel system error, HC/CO emissions
Cylinder No. 1 - injector circuit open circuit
TP sensor circuit 2 low input
TP sensor circuit 2 high input
Fuel pump input low voltage
Fuel pump input high voltage
Cylinder No. 1 - injector circuit low voltage
Cylinder No. 1 - injector circuit high voltage
Random misfire detected
Cylinder No. 1 misfire detected
Flywheel segment adaptation at the Limit
Knock sensor (KS) communication error or implausible signal
KS implausible signal
Crankshaft position (CKP) sensor implausible signal
CKP sensor missing teeth
CKP sensor loss of synchronization
CKP sensor no signal
Camshaft position (CMP) sensor no signal
CMP sensor implausible signal
Ignition coil A primary malfunction
Ignition coil B primary malfunction
Catalyst system efficiency below threshold
Evaporative mission canister purge valve open circuit
Evaporative mission canister purge valve low voltage
Evaporative mission canister purge valve high voltage
Fuel tank level malfunction from instrument cluster
Vehicle speed sensor (VSS) signal malfunction
Vehicle speed via CAN (VS CAN) implausible signal
VSS signal too high
Idle air control (IAC) valve circuit malfunction
Battery system voltage malfunction high voltage
Battery system voltage malfunction open circuit
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MIL Code
P0571
P0603
P0604
P0605
P0610
P0617
P0620
P0625
P0626
P0628
P0629
P0641
P0642
P0643
P0646
P0647
P0651
P0652
P0653
P0654
P0686
P0687
P0691
P0692
P0693
P0694
P0704
P1000
P1500
P1632
P1794
P2100
P2107
P2108
P2119
P2122
P2123
P2127
P2128
P2128
P2135
P2176
P2280
P2282
U0001
U0101
U0121
U0122
U0155
B1213
B1600
G384566 en
Description
Brake switch plausibility error
Powertrain control module (PCM) error NVMY or EEPROM error
PCM error RAM error
PCM error checksum error
VID block checksum not correct or not programmed
Starter relay malfunction
Generator circuit malfunction
Generator low voltage
Generator high voltage
Fuel pump primary circuit low voltage
Fuel pump primary circuit high voltage
Transmission sensor power supply 1 noisy signal
Transmission sensor power supply 1 low voltage
Transmission sensor power supply 1 high voltage
Air conditioning (A/C) clutch relay circuit low voltage
A/C clutch relay circuit high voltage
Transmission sensor power supply 2 noisy signal
Transmission sensor power supply 2 low voltage
Transmission sensor power supply 2 high voltage
Engine run output circuit malfunction
Main relay malfunction low voltage
Main relay malfunction high voltage
Cooling fan 1 control circuit low voltage
Cooling fan 1 control circuit high voltage
Cooling fan 2 control circuit low voltage
Cooling fan 2 control circuit high voltage
Clutch switch implausible signal
EOBD system readiness test not complete
Vehicle speed sensor (VSS) output circuit malfunction
Generator command malfunction
Battery voltage malfunction too high or too low
Engine throttle body H-bridge malfunction
Safety failure level 3
Safety failure level 2 error
Engine throttle body throttle flap malfunction
Accelerator pedal position (APP) sensor circuit 1 low input
APP sensor circuit 1 high input
APP sensor circuit 2 low input
APP sensor circuit 2 high input
APP sensor circuits 1 and 2 plausibility error
TP sensor circuits 1 and 2 plausibility error
Engine throttle body adaptive algorithm failed
Air cleaner obstruction or leakage
Air leakage between throttle and inlet valves
Control Area Network (CAN) bus-off or mute
CAN missing frame from TCU
CAN missing frame from ABS
CAN missing frame from ESP
CAN missing frame from HEC
Number of Passive Anti-Theft System (PATS) programmed keys is below minimum
PATS ignition key transponder signal is not received
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MIL Code
B1601
B1602
B1681
B2103
B2139
B2141
B2431
U2510
Description
PATS received incorrect key-code from ignition key transponder
PATS received invalid format of key-code from ignition key transponder
PATS transceiver module signal is not received
PATS immobilizer antenna not connected
PATS immobilizer challenge response doesn't match
PATS immobilizer no PCM-ID transferred
PATS immobilizer transponder programming failure
PATS immobilizer problem with messages on data link

system.
Mechanical
Electrical
Sensors
Actuators
Fuse(s)
Wiring harness
Electrical
connector(s)
Powertrain control
module (PCM)
step.
symptom and refer to or equivalent scan tool
for further diagnostics.
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Powertrain Control Module (PCM) 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V
(Sigma)/1.6L Duratec-16V (Sigma) (29 200 0)
3. Insert the special tool into the PCM electrical connector.
Special Tool(s)
Drill Bush, Powertrain Control
Module
418-537 (29-016)
Removal
NOTE: If a new PCM is being installed connect
WDS. Upload the PCM configuration information
using the programmable modules installation
routine prior to commencing the removal of the
PCM.
Tray]
2. Position the PCM on the battery tray support panel.
G100753 en
4.
CAUTION: Make sure the special tool is

used to guide the drill bit. Failure to
damage to the electrical connector.
Using the special tool as a guide, drill into

the shear bolt using a 6mm drill bit, until
the head is removed.
5. Remove the special tool from the PCM
electrical connector and clean all foreign
material from the electrical connector.
6. Disconnect the PCM electrical connector
and remove the PCM.
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7. Remove the remains of the shear bolt from
the PCM using grips.
Installation
1. Install a new shear bolt and securing clip,
using the special tool to push the clip onto
the shank of the bolt.
2. Install the PCM electrical connector to the

PCM.
Tighten the bolt until the head shears off.

Tray]
4. If a new PCM is being installed connect
WDS. Download the PCM configuration
information using the programmable
modules installation routine.
5. NOTE: Do not press the accelerator pedal
during the initialization period as this will
prevent the complete initialization of the throttle
body.
Turn the ignition key to position II and wait
for one minute to initialize the throttle
body.
6. Turn the ignition key to the OFF position.
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Powertrain Control Module (PCM) 2.0L Duratec-HE (MI4), Vehicles With: PCM
Security Shield
the Worldwide Diagnostic System (WDS). Upload
the PCM configuration information using the
programmable modules installation routine prior to
commencing the removal of the PCM.
Tray]
3. Disconnect the ambient air temperature
sensor electrical connector and detach the
wiring harness from the retaining clip.
4. Remove the PCM mounting bracket lower

retaining bolt.

6. Remove the PCM mounting bracket upper
retaining bolt.
7. Position the PCM, PCM retaining bracket

and PCM mounting bracket on the battery
tray support panel.
table(s).
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303-14-23
Item
Part
Number
Description
PCM security shield shear
bolts
See Removal Detail
PCM security shield

See Removal Detail
PCM electrical connectors
G422234 en
Item
Part
Number
Description
PCM retaining bolts

See Removal Detail
PCM retaining bracket
PCM mounting bracket
PCM
See Removal Detail
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information using the programmable modules
installation routine after the installation of the
PCM.
Removal Details
Item 4 : PCM retaining bolts

1. Support the PCM, PCM retaining bracket
and PCM mounting bracket while removing
the PCM retaining bolts.
Item 7 : PCM
1. Remove the PCM from the PCM retaining
bracket.
Item 1 : PCM security shield shear bolts

1. Remove the PCM security shield shear
bolts.
Drill a 3 mm pilot hole in the center of the
PCM security shield shear bolts.
Drill a 8 mm hole in the PCM security shield
shear bolts and remove the PCM security
shield.
Item 2 : PCM security shield

1. Remove the PCM security shield.
1. Swing the PCM security shied away from
the PCM retaining bracket.
2. Slide the PCM security shield from the PCM
retaining bracket.
Item 1 : PCM security shield shear bolts
1. Tighten the PCM security shield shear
bolts until the head of the bolt shears off.
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Powertrain Control Module (PCM) 2.0L Duratec-HE (MI4), Vehicles Without:
PCM Security Shield
WDS. Upload the PCM configuration information
routine prior to commencing the removal of the
PCM.
Disconnect]
2. Disconnect the ambient air temperature
sensor electrical connector and detach the
wiring harness from the retaining clip.
G422233 en

table(s).
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Item
Part
Number
PCM electrical connectors
PCM retaining bolts

See Removal Detail
PCM retaining bracket
PCM mounting bracket
PCM
See Removal Detail
G422233 en
Description

information using the programmable modules
installation routine after the installation of the
PCM.
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Removal Details
Item 2 : PCM retaining bolts
1. Support the PCM and PCM retaining
bracket while removing the PCM retaining
bolts.
Item 5 : PCM
1. Remove the PCM from the PCM retaining
bracket.
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Heated Oxygen Sensor (HO2S) (29 220 0)
4. Disconnect the HO2S electrical connector.
Special Tool(s)
Socket, Fuel Injector (22mm)
310-063 (23-050)
Removal
2. Disconnect the ignition coil pack electrical
connector.
3. Detach the ignition coil pack and position it

to one side
G210054 en
5. Remove the exhaust manifold heat shield.
6. Using the special tool, remove the HO2S.
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Installation
CAUTION: When installing a new HO2S, it
is possible that the new component will
be supplied with a longer cable than the
one removed. It is important that the
cable is routed and secured in such a way
that it cannot be damaged by heat or
moving components and will not cause a
noise, vibration or harshness (NVH)
issue.
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Crankshaft Position (CKP) Sensor
General Equipment
Bolt, M6 x 18 mm
CKP alignment tool
2. Remove the splash shield
3.

table(s).
CAUTION: Only turn the crankshaft

pulley in the normal direction of
rotation.
CAUTION: Tighten the M6 x 18 mm bolt
finger-tight only.
Rotate the crankshaft pulley clockwise until the crankshaft pulley timing bolt, M6 x 18
mm can be installed through the crankshaft
pulley timing hole into the engine front
cover.
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Item
Part
Number
CKP sensor electrical connector
CKP sensor retaining bolts

CKP sensor
G423211 en
Description
Item 3 : CKP sensor
1. Install the CKP sensor alignment tool to the
CKP sensor.
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2. Align the CKP sensor with the crankshaft
pulley sensor ring.
Item 2 : CKP sensor retaining bolts

1. Install the CKP sensor retaining bolts.
2. Remove the CKP sensor alignment tool.
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Knock Sensor (KS)
1. Detach the KS electrical connector from
Item
Part
Number
KS electrical connector
Coolant hose
See Removal Detail
G426587 en
Description

303-01B.[Engine - 2.0L Duratec-HE (MI4),
IN-VEHICLE REPAIR, Intake Manifold]
table(s).
Item
Part
Number
Description
KS
See Removal Detail
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Removal Details
Item 2 : Coolant hose
1. Detach the coolant hose from the coolant
hose retaining clip and position it to one
side.
Item 3 : KS
NOTE: Make a note of the position of the KS and
make sure it is positioned in the same position
when installed.
Item 3 : KS
NOTE: Prior to installing the KS, clean the engine
block and KS mating surfaces.
NOTE: Make sure the KS is installed in the same
position as removed.
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308-00-1
Manual Transmission/Transaxle and Clutch - General
308-00-1
Information
SECTION 308-00 Manual Transmission/Transaxle and

Clutch - General Information
CONTENTS
PAGE
SPECIFICATIONS
Specifications....................................................................................................................
Clutch Dimensions ...........................................................................................................
308-00-2
308-00-2

Manual Transaxle and Clutch............................................................................................
Gear shifting concerns .....................................................................................................
Transaxle noise concerns ................................................................................................
Oil leakage concerns........................................................................................................
308-00-3
308-00-3
308-00-3
308-00-3
308-00-3
GENERAL PROCEDURES
Gearshift Cable Adjustment .......................................................................... (16 513 0)
Clutch System Bleeding ................................................................................ (16 843 0)
308-00-11
308-00-13
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Information
308-00-2
SPECIFICATIONS
Description
High melting point grease
Specifications
WSD-M2C200-C
ESD-M1C220-A
ESD-M6C57-A
Capacities
Description
Manual transmission fluid: 10 - 15 mm below the lower edge of the fluid filler plug
Litres
2.3
Clutch Dimensions
Description
Pedal travel
Worn clutch disc discard thickness*
Clutch disc diameter: 1.25L/1.4L Duratec-16V (Sigma)
Clutch disc diameter: 1.6L Duratec-16V (Sigma)
Clutch disc diameter: 2.0L Duratec-HE (MI4)
Clutch disc diameter: 1.4L/1.6L Duratorq-TDCi (DV)
Diesel
Clutch disc diameter: 1.3L Duratec-8V (Rocam)
mm
135 5
7
190
210
220
210
190
* When the discard thickness has been reached, install a new clutch disc.
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Information
308-00-3

Manual Transaxle and Clutch
far as the stop. If first or second gear can be

selected with the engine running and the
parking brake applied, without any concerns,
the clutch is OK.
2. If the gear(s) cannot be selected, REFER to
Symptom Chart.
General Equipment
Ultraviolet fluid leak detection equipment
Transaxle noise concerns

mechanical damage.
Mechanical
3.
Oil leaks.
Visibly damaged or worn components.
Loose or missing nuts or bolts.
step.
4. If the cause is not evident, verify the symptom
and REFER to Symptom Chart.
The following checks should be carried out before
repairing or installing a new transaxle.
The inspection and verification of manual
transaxle concerns can be considered in three
main areas.
Gear shifting concerns
1. Check the operation of the clutch: Lay a block
of wood approximately 25 mm thick under the
clutch pedal and depress the clutch pedal as
1. Check the engine and transaxle support for

insufficient gap between the transaxle and the
body.
2. Road test the vehicle. REFER to Section
100-00.[General Information, DESCRIPTION
AND OPERATION, Road/Roller Testing]
3. If a noise occurs in various gears at the same
engine speed, check if the noise also occurs
in the neutral position. If it does, the noise is
not caused by the transaxle.
4. REFER to Symptom Chart.
Oil leakage concerns
1. Check the transaxle fluid level. If necessary,
drain off any excess fluid.
2. Clean the transaxle and the adjacent areas
carefully and road test the vehicle. REFER to
DESCRIPTION AND OPERATION,
Road/Roller Testing]
3. Using suitable ultraviolet fluid leak detection
equipment, locate the leak and check whether
the leaking fluid is transaxle fluid, brake fluid
(from the hydraulically operated clutch) or
engine oil.
4. REFER to Symptom Chart.
Symptom Chart
Symptom
Possible Sources
Action
Clutch slippage
Clutch master cylinder.

Clutch slave cylinder.
Clutch pressure plate.
Clutch disc.
Engine or transaxle housing oil
or fluid leak(s).
Clutch chatter or shudder
Engine and transaxle mounts.
REFER to Section
100-04.[Noise, Vibration and
Harshness, DIAGNOSIS AND
TESTING, Noise, Vibration and
Harshness (NVH)]
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Information
308-00-4

Symptom
Clutch drag
Clutch pedal pulsation
Hard shifting
G25629 en
Possible Sources
Action

Clutch disc.
Flywheel.
Insufficient brake fluid.
FILL the brake master cylinder

reservoir to the MAX mark.
INSPECT the brake and clutch
hydraulic systems for leaks.
REPAIR as necessary.
Air in the clutch hydraulic system.
BLEED the system. REFER to

Clutch System Bleeding in this
section.
Clutch pedal free travel.

Clutch disc.
Crankshaft end play.

Clutch disc.
INSTALL a new clutch disc and

pressure plate. REFER to Section 308-01.[Clutch, REMOVAL
AND INSTALLATION, Clutch
Disc and Pressure Plate]
Crankshaft end play.
CHECK the crankshaft end play.

REFER to Section
303-00.[Engine System - General Information, GENERAL
PROCEDURES, Crankshaft End
Play]
Clutch drag.
Gearshift cable adjustment
CHECK the gearshift cable adjustment. REFER to Gearshift

Cable Adjustment in this section.
External controls.
CHECK the external controls for

wear or damage. INSTALL new
Gear wheels.
DISASSEMBLE the transaxle.

REFER to Section
308-03.[Manual Transmission/Transaxle, DISASSEMBLY,
Transaxle] INSTALL new components as necessary.
Selector mechanism.

REFER to Section
11/2004 2005.25 Fiesta
308-00-5

TO MODEL INDEX

Information
308-00-5

Symptom
Excessive noise
Possible Sources
Action
Synchronizer(s).

REFER to Section
Engine vibrations inadequately

damped.
REFER to Section
Harshness, DIAGNOSIS AND
TESTING, Noise, Vibration and
Harshness (NVH)]
Transaxle fluid level low.
CHECK the transaxle for leaks.

TOP UP the transmission fluid.
Engine or transaxle is in contact REFER to Section

with the chassis or body.
Harshness, GENERAL
PROCEDURES, Powertrain/Drivetrain Mount Neutralizing]
Fluid leakage
G25629 en
Engine and transaxle out of

alignment.
REFER to Section
Harshness, GENERAL
PROCEDURES, Powertrain/Drivetrain Mount Neutralizing]
External controls.
CHECK the external controls for

wear or damage. INSTALL new
Gear wheels and bearings.

REFER to Section
Clutch pedal.
Clutch release bearing.
Clutch master cylinder.

Clutch slave cylinder.
Clutch hydraulic lines.
INSPECT the brake and clutch

hydraulic systems for leaks.
REPAIR as necessary.
Halfshaft seal.
INSTALL a new halfshaft seal.

REFER to Section
308-03.[Manual Transmission/Transaxle, IN-VEHICLE
REPAIR, Halfshaft Seal LH]
REFER to Section
308-03.[Manual Transmission/Transaxle, IN-VEHICLE
REPAIR, Halfshaft Seal RH]
11/2004 2005.25 Fiesta
308-00-6

TO MODEL INDEX

Information
308-00-6

Possible Sources
Symptom
Action
Fluid leak between the transaxle DISASSEMBLE the transaxle

housing sections.
and clean the mating faces.
CHECK the mating faces for
damage. SEAL the transaxle
with sealant. REFER to Section
308-03.[Manual Transmission/Transaxle, ASSEMBLY,
Transaxle]
PINPOINT TEST A: CLUTCH SLIPPAGE
TEST CONDITIONS
A1: TEST CLUTCH SLIPPAGE

1
2
3
4
Lock the wheels and apply the parking brake.

Start the engine and engage fourth gear.
Run the engine at approximately 2000 rpm.
Release the clutch pedal slowly.
Does the engine stall when the clutch pedal is

fully released?
Yes
Clutch OK.
No
Go to A2
A2: CHECK THE CLUTCH PEDAL OPERATION
1 Depress clutch pedal and allow it to return.
Does the pedal return to the initial position?
Yes
Go to A3
No
Go to A4
A3: CHECK THE CLUTCH DISC AND PRESSURE PLATE
1 Remove the clutch disc and pressure plate.
REFER to Section 308-01.[Clutch, REMOVAL
AND INSTALLATION, Clutch Disc and Pressure Plate]
Is the clutch disc or pressure plate contaminated with oil or hydraulic fluid?
Yes
CHECK the engine and transaxle for leaks.
No
INSTALL a new clutch disc and pressure
plate. REFER to Section 308-01.[Clutch,
REMOVAL AND INSTALLATION, Clutch
Disc and Pressure Plate] TEST the system
A4: CHECK THE CLUTCH HYDRAULIC SYSTEM
1 Release the clutch slave cylinder bleed nipple.
G25629 en
11/2004 2005.25 Fiesta
308-00-7

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Information
308-00-7

TEST CONDITIONS
Does the pedal return to the initial position?

Yes
INSTALL a new clutch slave cylinder.
REFER to Section 308-02.[Clutch Controls,
Slave Cylinder] TEST the system for normal
operation.
No
INSTALL a new clutch master cylinder.
Master Cylinder] TEST the system for normal
operation.
PINPOINT TEST B: CLUTCH CHATTER OR SHUDDER
TEST CONDITIONS
B1: TEST FOR CLUTCH SHUDDER
1
2
3
4
Start the engine.

Engage the clutch and select fourth gear.
Run the engine at approximately 2000 rpm.
Release the clutch pedal slowly.
Does the clutch take up the drive smoothly?

Yes
Clutch is OK.
No
Go to B2
B2: CHECK THE CLUTCH DISC AND PRESSURE PLATE FOR OIL OR HYDRAULIC FLUID
CONTAMINATION
Is the clutch disc and pressure plate contaminated with oil or hydraulic fluid?
Yes
No
Go to B3
B3: CHECK THE CLUTCH DISC AND PRESSURE PLATE
1 Visually check the clutch disc and pressure
plate.
Is the clutch disc and pressure plate worn or
damaged?
Yes
G25629 en
11/2004 2005.25 Fiesta
308-00-8

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Information
308-00-8

TEST CONDITIONS
No
CARRY OUT the flywheel clutch surface
inspection. REFER to Section
303-00.[Engine System - General Information, GENERAL PROCEDURES, Flywheel
Inspection] TEST the system for normal operation.
PINPOINT TEST C: CLUTCH DRAG

TEST CONDITIONS
C1: CHECK THE OPERATION OF THE CLUTCH PEDAL
1 Depress and release the clutch pedal.

Is excessive force required to depress the clutch
pedal?
Yes
Go to C2
No
Go to C3
C2: CHECK THE CLUTCH HYDRAULIC SYSTEM
1 Release the clutch slave cylinder bleed nipple
and depress the clutch pedal.
Does the clutch pedal operate freely?
Yes
INSTALL a new clutch slave cylinder.
Slave Cylinder] TEST the system for normal
operation.
No
INSTALL a new clutch master cylinder.
Master Cylinder] TEST the system for normal
operation.
C3: CHECK THE CLUTCH DISC AND PRESSURE PLATE FOR OIL OR HYDRAULIC FLUID
CONTAMINATION
Is the clutch disc and pressure plate contaminated with oil or hydraulic fluid?
Yes
G25629 en
11/2004 2005.25 Fiesta
308-00-9

TO MODEL INDEX

Information
308-00-9

TEST CONDITIONS
No
Go to C4
C4: CHECK THE CLUTCH DISC AND PRESSURE PLATE
1 Visually check the clutch disc and pressure
plate.
Is the clutch disc and pressure plate worn or
damaged?
Yes
No
Go to C5
C5: CHECK THE INPUT SHAFT SPLINES
1 Check that the clutch disc slides freely on the
input shaft splines.
Does the clutch disc stick on the input shaft?
Yes
CHECK the clutch disc and input shaft
splines for damage. INSTALL new components as necessary. TEST the system for
normal operation.
No
MEASURE the crankshaft end play. REFER
to Section 303-00.[Engine System - General
Crankshaft End Play]
PINPOINT TEST D: EXCESSIVE NOISE
TEST CONDITIONS
D1: STATIC CHECK
1 Depress and release the clutch pedal.
Is the noise apparent when the clutch is operated?
Yes
LUBRICATE the clutch and brake pedal
shaft. TEST the system for normal operation.
No
Go to D2
D2: DYNAMIC CHECK

1 Start the engine.
2 Depress the clutch pedal.
Is the noise apparent when the clutch pedal is
depressed?
Yes
G25629 en
11/2004 2005.25 Fiesta
308-00-10

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Information
308-00-10

TEST CONDITIONS
G25629 en
REFER to Section 303-00.[Engine System General Information, DIAGNOSIS AND
TESTING, Engine]
No
INSTALL a new clutch slave cylinder and
release bearing assembly. REFER to Section 308-01.[Clutch, REMOVAL AND
Plate] REFER to Section 308-02.[Clutch
Controls, REMOVAL AND INSTALLATION,
Clutch Slave Cylinder] TEST the system for
normal operation.
11/2004 2005.25 Fiesta
308-00-11

TO MODEL INDEX

Information
308-00-11
GENERAL PROCEDURES
Gearshift Cable Adjustment (16 513 0)
4. NOTE: Measure the selector cable between the

two positions shown.
Adjust the length of the selector cable.
XX mm = 138 2.0 mm.
3. Release the selector cable adjuster locking

insert (gearshift cable box shown removed
for clarity).
Press the orange colored insert into the
adjuster body.
5. Shift the transaxle into third or fourth gear.

Move the gearshift lever to its right-hand or
left-hand stop position.
G152562 en
11/2004 2005.25 Fiesta
308-00-12

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Information
308-00-12

6. NOTE: Make sure that the orange colored
insert returns to the locked position.
Lock the selector cable adjuster.
Press down the clip on the adjuster.
7. Install the gearshift cables cover.
G152562 en
11/2004 2005.25 Fiesta

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308-00-13

Information
308-00-13
GENERAL PROCEDURES
Clutch System Bleeding (16 843 0)
Special Tool(s)
Hand Vacuum
Pump/Pressure Pump
416-D001 (23-036A)
Name
Super DOT 4 Brake
Fluid
Install the special tool.
Specification
ESD-M6C57-A

water.
NOTE: If proprietary brake bleeding equipment is
available, this can be used to bleed the clutch
system, following the method below. The
maximum pressure must not exceed 1.5 bar.
NOTE: The clutch control system is self-venting.
The components are arranged in such a way that
small amounts of air trapped in the system are
removed automatically during clutch operation.
1. Remove the air cleaner, if necessary.For
303-12.
2. Remove the battery, if necessary. For
414-01.
3. Remove the battery tray, if necessary.
4. Drain the brake fluid reservoir.
5. Raise and support the vehicle, if necessary.
100-02.
G183752 en
6. Fill the reservoir of the special tool with

approximately 100 ml of new brake fluid.
7. NOTE: Make sure that the special tool reservoir
is positioned lower than the bleed nipple.
8. Using the special tool, bleed the clutch

system.
Pump approximately 80 ml of brake fluid
into the clutch system.
9. Close the bleed nipple.
11. Lower the vehicle, if necessary.
12. In order to remove any small amounts of
trapped air remaining in the system,
operate the clutch pedal several times
(maximum five times), using the full
clutch pedal travel.
reservoir and top up to the MAX mark with
brake fluid if necessary.
14. Install the battery tray, if necessary.
15. Install the battery, if necessary. For
414-01.
16. Install the air cleaner, if necessary. For
303-12.
11/2004 2005.25 Fiesta
308-00-14

TO MODEL INDEX
308-00-14
Information
17. Test the clutch control system for normal

operation.
Start the engine, depress the clutch pedal,
wait two seconds, then carefully engage
reverse gear. If there are any abnormal
noises, or reverse gear is difficult to engage,
repeat the clutch system bleeding
procedure.
18. Initialize the door window motors, if
G183752 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
308-01-1
Clutch
308-01-1
SECTION 308-01 Clutch

CONTENTS
PAGE
SPECIFICATIONS
Specifications....................................................................................................................
308-01-2

Clutch ...............................................................................................................................
Self-adjusting clutch .........................................................................................................
308-01-3
308-01-3

Clutch ...............................................................................................................................
308-01-6

Clutch Disc and Pressure Plate..................................................................... (16 724 4)
308-01-7
11/2004 2005.25 Fiesta
308-01-2

TO MODEL INDEX
Clutch
308-01-2
SPECIFICATIONS
Item
Clutch pressure plate retaining bolts
G113195 en
Nm
29
lb-ft
21
lb-in
-
11/2004 2005.25 Fiesta

TO MODEL INDEX
308-01-3
Clutch
308-01-3

Clutch
Self-adjusting clutch
Advantages of the self-adjusting clutch
Item
Part
Number
G251010 en
Item
Part
Number
Description
Release travel in mm
Conventional clutch - condition when new
Conventional clutch - after

wear
Description
3
Self-adjusting clutch
The self-adjusting clutch has the following
advantages over conventionally designed
clutches:
lower release forces, which remain constant
over the service life and thus ensure high
driving comfort throughout the entire service
life
increased wear reserve and therefore greater
service life due to the automatic wear
adjustment
Release force in kN
Function
11/2004 2005.25 Fiesta
308-01-4

TO MODEL INDEX
Clutch
308-01-4

Item
Part
Number
Description
Cover
Adjusting ring (ramp ring)
Spring
Sensing Belleville washer
Main Belleville washer
A conventional clutch responds to clutch wear with

an increase in the release force, which ultimately
has to be delivered by the driver to press down the
clutch pedal.
The main distinction to a conventional clutch is

that the main Belleville washer is not riveted in a
fixed manner to the cover, but instead is
supported by a so-called sensing Belleville
washer. In addition an adjusting ring (ramp ring) is
used to compensate the wear of the clutch lining.
The sensing Belleville washer is hooked into the
clutch cover at the outside and, with the inner
tongues, forms the bearing for the main Belleville
washer.
The sensing Belleville washer is designed to
deliver a slightly greater opposing force under
normal conditions than the maximum required
release force.
This increase in the release force after clutch wear

is used on the self-adjusting clutch as the key
indicator for adjusting the clutch.
Item
Part
Number
Description
Air gap
If when the clutch is operated the release force is

less than the opposing force of the sensing
Belleville washer, then the pivot bearing point of
the main Belleville washer remains in the same
position.
If however the release force increases due to
lining wear, then the opposing force of the sensing
Belleville washer is exceeded.
G251010 en
If the opposing force of the sensing Belleville

washer is exceeded, the sensing Belleville washer
and therefore also the main Belleville washer are
displaced towards the flywheel.
This displacement towards the flywheel has the
effect that the release force is reduced again.
Once the release force has dropped to the level of
the opposing force of the sensing Belleville
washer again (equilibrium of forces), the
displacement of the components towards the
flywheel stops.
11/2004 2005.25 Fiesta
308-01-5

TO MODEL INDEX
Clutch
308-01-5

When the sensing Belleville washer is displaced
this results in an air gap between the main
Belleville washer and the clutch cover.
The adjusting ring (ramp ring) arranged around
the circumference immediately compensates for
the air gap. To do this, springs press the adjusting
ring and therefore the ramp against the main
Belleville washer.
This results in a balancing of the clutch actuation
mechanism, which keeps the forces required to
operate the clutch constant throughout the entire
service life of the clutch.
G251010 en
11/2004 2005.25 Fiesta
308-01-6

TO MODEL INDEX
Clutch
308-01-6

Clutch
G18068 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
308-01-7
Clutch
308-01-7

Clutch Disc and Pressure Plate (16 724 4)
Installation
Special Tool(s)
Aligner, Clutch Disk
308-204 (16-067)
1. Using the special tool, centralize the clutch

disc on the pressure plate.
Removal
1. Remove the transaxle.For additional
308-03.[Manual Transmission/Transaxle,
REMOVAL, Transaxle - 1.25L Duratec-16V
REMOVAL, Transaxle - 2.0L Duratec-HE
(MI4)]
2.
CAUTION: Loosen the clutch pressure

plate retaining bolts by two turns at a
time in the sequence shown.
Remove the clutch disc and pressure plate.
Discard the bolts.
G28811 en
11/2004 2005.25 Fiesta
308-01-8

TO MODEL INDEX
Clutch
308-01-8
2.
CAUTION: Tighten the clutch pressure

plate retaining bolts finger tight and
then evenly by two turns at a time in
the sequence shown to the specified
torque.
NOTE: Install new clutch pressure plate retaining
bolts.
Using the special tool, install the clutch
disc and pressure plate.

4. Install the transaxle. For additional
INSTALLATION, Transaxle - 1.25L
Duratec-HE (MI4)]
G28811 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
308-02-1
Clutch Controls
308-02-1
SECTION 308-02 Clutch Controls

CONTENTS
PAGE
SPECIFICATIONS
Specifications....................................................................................................................
308-02-2

Clutch Controls .................................................................................................................
Overview ..........................................................................................................................
Function ...........................................................................................................................
308-02-3
308-02-3
308-02-4

Clutch Controls .................................................................................................................
308-02-5

Clutch Slave Cylinder.................................................................................... (16 862 0)
Clutch Master Cylinder.................................................................................. (16 856 0)
308-02-6
308-02-7
11/2004 2005.25 Fiesta
308-02-2

TO MODEL INDEX
Clutch Controls
308-02-2
SPECIFICATIONS

Specifications
ESDM-1C220-A
High-temperature grease
Item
Clutch slave cylinder retaining bolts
Clutch master cylinder retaining bolts
Pedal pivot shaft retaining nut
G113286 en
Nm
10
8
25
lb-ft
18
lb-in
89
71
-
11/2004 2005.25 Fiesta

TO MODEL INDEX
308-02-3
Clutch Controls
308-02-3

Clutch Controls
Overview
Item
Part
Number
Brake fluid reservoir
Supply line
Clutch Pedal
Master cylinder
Pressure line
G281360 en
Description
Item
Part
Number
Description
Slave cylinder with choke
assembly
The hydraulic clutch is supplied from a separate

chamber in the brake fluid reservoir.
Because of this separate chamber, the braking
system remains operational if a leak occurs in the
hydraulic clutch system.
11/2004 2005.25 Fiesta
308-02-4

TO MODEL INDEX
Clutch Controls
308-02-4

Function
Pressure is created in the master cylinder when
the clutch pedal is operated.
The hydraulic fluid in the master cylinder is put
under pressure and fed through the pressure pipe
to the slave cylinder.
The displaced hydraulic fluid moves the piston in
the slave cylinder and this in turn slides the
release bearing axially.
The release bearing pushes the bearing inner ring
against the tongues of the diaphragm spring.
The spring induced grip between the clutch disc
and the flywheel is broken.
When the clutch pedal is released the diaphragm
spring presses the piston in the slave cylinder
back to its starting position. The spring induced
grip between the clutch disc and the flywheel is
created again.
A spring in the slave cylinder ensures preload on
the release bearing.
The release bearing is always touching the
pressure plate because of this preload. The extra
travel caused by clutch lining wear is
compensated for by the preload.
There is a choke assembly in the slave cylinder
which helps to increase smoothness when pulling
away.
Because of the choke assembly, the pressure
drop of the fluid leaving the slave cylinder and
returning to the reservoir is delayed.
Because of this, the clutch closing time is delayed
when the clutch pedal is released suddenly, and a
soft and comfortable clutch engagement is
achieved.
Choking does not occur during clutch
disengagement.
CAUTION: Vehicles with an automated
shift manual (ASM) transmission have a
slave cylinder without a choke assembly.
The slave cylinders must not be
exchanged for one another.
NOTE: The clutch pedal travel cannot be
adjusted.
The release bearing is an interference fit in the
slave cylinder and cannot be renewed separately.
G281360 en
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308-02-5

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Clutch Controls
308-02-5

Clutch Controls
G18080 en
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TO MODEL INDEX
308-02-6
Clutch Controls
308-02-6

Clutch Slave Cylinder (16 862 0)
Installation
Name
High-temperature
grease
Specification
ESDM-1C220-A
Removal
1. Remove the transaxle. For additional
REMOVAL, Transaxle - 1.25L Duratec-16V
Duratec-16V (Sigma)] For additional
REMOVAL, Transaxle - 2.0L Duratec-HE
(MI4)]
2. Clean any grease and foreign material from
the input shaft.
3.

water.
CAUTION: Using suitable adhesive tape,
cover the input shaft splines to prevent
damage to the input shaft oil seal.
Remove the clutch slave cylinder.
G113288 en
1.

water.
CAUTION: Do not apply grease on any
area of the clutch slave cylinder.
Install the clutch slave cylinder.
2. Remove the adhesive tape from the input

shaft splines.
3. Coat the input shaft splines with a thin
layer of high-temperature grease.
4. Install the transaxle. For additional
Duratec-HE (MI4)]
11/2004 2005.25 Fiesta
308-02-7

TO MODEL INDEX
Clutch Controls
308-02-7

Clutch Master Cylinder (16 856 0)
Removal
water.
All vehicles
1. Using a suitable syringe, remove brake
fluid from the brake fluid reservoir until the
brake fluid level is at the MIN mark.
3. Disconnect the two vacuum hoses.
Detach the vacuum hoses from the battery
clamp clip.
All vehicles
5. NOTE: Plug the brake fluid reservoir to prevent
Disconnect the clutch master cylinder
supply hose from the brake fluid reservoir.
Push the clip to release the clutch master
cylinder supply hose.
6. Remove the clutch master cylinder supply

hose.
Release the clutch master cylinder supply
hose retaining clip.

Tray] For additional information, refer to
Section 414-01.[Battery, Mounting and
Cables, REMOVAL AND INSTALLATION,
Battery Tray - 2.0L Duratec-HE (MI4)]
G152706 en
11/2004 2005.25 Fiesta
308-02-8

TO MODEL INDEX
Clutch Controls
308-02-8

7. NOTE: Plug the clutch slave cylinder supply line
to prevent fluid loss or dirt ingress.
9. NOTE: Remove the clutch master cylinder and

the clutch pedal as an assembly.

supply line from the clutch master cylinder
and position it to one side.
Release the clutch slave cylinder supply line
retaining clip.
Remove the clutch master cylinder and the

clutch pedal assembly.
Remove the pedal pivot shaft retaining nut
and remove the pivot shaft.
Rotate the clutch master cylinder and clutch
pedal assembly counterclockwise.
8. Remove the clutch master cylinder retaining bolts.
G152706 en
10. Remove the clutch master cylinder.

1. Remove the clutch pedal return spring.
2. Detach the clutch master cylinder actuating
rod from the clutch pedal.
11/2004 2005.25 Fiesta
308-02-9

TO MODEL INDEX
Clutch Controls
308-02-9

Installation
All vehicles
1. NOTE: Using suitable tape, secure the clutch
pedal return spring in position.
3. Install the clutch master cylinder retaining

bolts.
Install the clutch master cylinder.

1. Attach the clutch master cylinder actuating
rod to the clutch pedal.
2. Install the clutch pedal return spring.

line to the clutch master cylinder.
Install the clutch slave cylinder supply line
retaining clip.
2. NOTE: Install the clutch master cylinder and the

clutch pedal as an assembly.
Install the clutch master cylinder and the
clutch pedal assembly.
Rotate the clutch master cylinder and the
clutch pedal assembly clockwise.
Install the pedal pivot shaft.
5. Connect the clutch master cylinder supply

hose to the clutch master cylinder.
Install the clutch master cylinder supply
hose retaining clip.
G152706 en
11/2004 2005.25 Fiesta
308-02-10

TO MODEL INDEX
Clutch Controls
308-02-10

6. Connect the clutch master cylinder supply
hose to the brake fluid reservoir.

Section 303-12.[Intake Air Distribution
and Filtering, REMOVAL AND
INSTALLATION, Air Cleaner - 2.0L
Duratec-HE (MI4)]
7. Bleed the clutch system. For additional

Bleeding]
Tray] For additional information, refer to
Cables, REMOVAL AND INSTALLATION,
Battery Tray - 2.0L Duratec-HE (MI4)]
9. Connect the two vacuum hoses.
Attach the vacuum hoses to the battery
clamp clip.

G152706 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
308-03-1
Manual Transmission/Transaxle
308-03-1
Page 1 of 2
SECTION 308-03 Manual Transmission/Transaxle

CONTENTS
PAGE
SPECIFICATIONS
Specifications....................................................................................................................
Required shim thickness ..................................................................................................
308-03-3
308-03-3

Manual Transaxle .............................................................................................................
General ............................................................................................................................
Transmission construction................................................................................................
Internal shift mechanism ..................................................................................................
Power transmission in the individual gears.......................................................................
308-03-5
308-03-5
308-03-5
308-03-10
308-03-14

Manual Transaxle .............................................................................................................
308-03-17
GENERAL PROCEDURES
Bearing Check ..................................................................................................................
308-03-18
IN-VEHICLE REPAIR
Halfshaft Seal LH .......................................................................................... (14 303 0)
Halfshaft Seal RH ......................................................................................... (14 304 0)
Vehicle Speed Sensor (VSS) ........................................................................ (33 654 0)
308-03-20
308-03-21
308-03-22

Transaxle 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L
(16 114 0)
Duratec-16V (Sigma)....................................................................................
Transaxle 2.0L Duratec-HE (MI4) ............................................................. (16 114 0)
308-03-23
308-03-30
DISASSEMBLY
Transaxle ...................................................................................................... (16 118 8)
308-03-35

Output Shaft......................................................................................................................
Input Shaft ........................................................................................................................
Differential..................................................................................................... (16 118 6)
Selector Plate ............................................................................................... (16 284 8)
308-03-41
308-03-47
308-03-49
308-03-51
ASSEMBLY
Transaxle ...................................................................................................... (16 118 8)
308-03-53
INSTALLATION
(16 114 0)
Duratec-16V (Sigma)....................................................................................
308-03-63
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308-03-2

TO MODEL INDEX
308-03-2
Page 2 of 2
Transaxle 2.0L Duratec-HE (MI4)............................................................. (16 114 0)
308-03-70
11/2004 2005.25 Fiesta

TO MODEL INDEX
308-03-3
308-03-3
SPECIFICATIONS

Description
High-temperature grease
Sealer, transaxle housing to clutch housing
Sealer, fifth gear end cap
Specifications
ESDM-1C220-A
WSD-M2C200-C
ESD-M6C57-A
WSK-M2G348-A5
WSE-M4G323-A4
Capacities
Description
Manual transmission fluid (just below the bottom of the filler hole)
Transaxle ratios
1.25L
First gear
3.58
Second
1.93
gear
Third gear
1.28
Fourth gear
0.95
Fifth gear
0.76
Reverse
3.62
gear
Final drive
4.25
1.3L
3.58
1.93
1.4L
3.58
1.93
1.6L
3.15
1.93
1.28
0.95
0.76
3.62
1.28
0.95
0.76
3.62
1.28
0.95
0.76
3.62
1.28
0.95
0.76
3.62
1.28
0.95
0.76
3.62
1.41
1.11
0.88
3.62
3.82/4.06
4.06
4.25
3.37
3.37
3.82
Required shim thickness

Description
Measuring shim
Shim availability (in increments of 0.1 mm)
Item
Clutch slave cylinder retaining bolts
Selector gate retaining bolts
Transaxle housing retaining bolts
Fifth gear housing to transaxle housing retaining
bolts
Selector mechanism to transaxle retaining bolts
Reversing lamp switch
Transaxle housing final drive cover retaining bolts
Transaxle to engine retaining bolts
Engine support insulator to engine retaining bolt
Engine support insulator to subframe retaining bolts
Engine rear mount outer retaining nuts
Exhaust flexible pipe retaining nuts
Wiring harness retaining bracket retaining nut
1.4L Diesel 1.6L Diesel

3.58
3.58
1.93
1.93
2.0L
3.58
2.04
mm
3.8
0.1 - 0.7
Required snap ring thickness

Description
Snap ring fifth gear
G113289 en
Litres
2.3
mm
1.48
Nm
10
22
25
17
lb-ft
16
21
13
lb-in
89
-
22
12
12
47
48
48
48
44
22
16
9
9
35
35
35
35
32
16
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308-03-4
Item
Power steering high-pressure line retaining bracket
retaining bolt
Lower arm ball joint to the wheel knuckle retaining
nut
Engine rear mount center retaining nut
Intermediate shaft center bearing retaining nuts
Strut and spring assembly top mount retaining nuts
Transmission fluid filler plug
Starter motor wiring harness retaining bracket retaining nuts
G113289 en
Nm
25
lb-ft
21
lb-in
-
52
38
90
25
48
35
35
20
66
18
35
26
26
15
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308-03-5

Manual Transaxle
General
The iB5 manual transmission is a two shaft

transmission.
All gear wheels are helical toothed, synchronised
(except reverse gear) and run in plain bearings.
1st and 2nd gears are double synchronised.
There is no need to change the oil.
G281365 en
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308-03-6
Transmission construction
Item
Part
Number
5th gear housing
Transmission side housing

halves
G281365 en
Description
Item
Part
Number
Description
Breather
Hydraulic clutch connection
Clutch side housing halves

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308-03-7
308-03-7

Item
Part
Number
Slave cylinder with integral

release bearing
Input shaft
Output shaft
Item
Part
Number
Description
Ball bearing
Input shaft
Reverse gear idler
1st gear wheel
Reverse gear wheel
2nd gear wheel
3rd gear wheel
4th gear wheel
Snap ring
10
5th gear wheel
G281365 en
Description
Item
Part
Number
Description
Differential assembly
Input shaft
Item
Part
Number
11
Description
Snap ring
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Output shaft
Item
Part
Number
1st gear double synchronisation
Output shaft with differential

drive wheel
Synchroniser - 1st/2nd gear

with reverse gear wheel
1st gear wheel
2nd gear double synchronisation
Item
Part
Number
Open cylinder roller bearing
G281365 en
Description
Description
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308-03-9
308-03-9

Item
Part
Number
Description
Item
Part
Number
Description
2nd gear wheel
14
Snap ring
3rd gear wheel
15
5th gear wheel
3rd gear simple synchronisation
16
5th gear simple synchronisation
10
Synchroniser assembly 3rd/4th gear
17
5th gear synchroniser assembly
11
4th gear simple synchronisation
18
Retaining plate
19
Snap ring
12
4th gear wheel
13
Ball bearing (closed both

sides)
Item
Part
Number
Gearwheel
Inner synchroniser ring
Conical ring
Outer synchroniser ring
Synchroniser hub
Double synchronisation
Description
1st and 2nd gears are double synchronised.

The effective synchronisation surface for double
synchronisation is almost twice that of simple
synchronisation. Because of this, the speeds of
the gearwheels are equalised much faster, which
considerably improves gearshifting comfort.
G281365 en
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Item
Part
Number
Description
Bearing
Crown wheel
Sender wheel - Vehicle

Speed Sensor (VSS)
Crown wheel bolts
On vehicles without Anti-lock Brake System (ABS)

a VSS detects the speed of the differential
assembly at the VSS sender wheel.
On vehicles with ABS the VSS sender wheel is
also installed. The VSS is however not installed in
this case. A plug with an O-ring closes the
corresponding bore instead.
The differential assembly is built into the

transmission housing.
The drive torque is transmitted to the differential
by the crown wheel which is bolted to it.
The differential assembly contains differential
pinion gears mounted on a spindle and the axle
halfshaft pinion gears which connect to the front
wheel axle halfshafts through helical gearing.
The axle halfshaft pinion gears can revolve
around the differential pinion gears when the road
wheel speeds are different (e.g when cornering).
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308-03-11
Internal shift mechanism

Layout
Item
Part
Number
Description
The selector interlock maintains engagement of

the selected gear.
Selector gate
Both the shift and the select process is performed

through the selector shaft.
Shift locking bush
Return spring from reverse

gear position
Reverse gear selector shaft
Snap ring
Shift rod - 5th gear/reverse

gear
Selector interlock
Selector shaft
Guide sleeve
The shift locking bush prevents two gears from

being engaged at the same time.
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Select movement
Item
Part
Number
Description
Shift locking bush
Selector shaft
Selector boss
Selector gate
The axial movement of the selector cable is

transferred at the transmission to the selector
shaft which can turn in its bearing.
If the gearshift lever is moved to the left or right,
the selector shaft and the selector boss both turn
together in the corresponding direction.
As this happens, the selector shaft is guided by a
pin in the selector gate.
The selector boss selects the required selector
fork.
At the same time the shift locking bush prevents
access to other gear combinations.
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308-03-13
308-03-13
Shift movement
Item
Part
Number
Description
Shift locking bush
Selector shaft
Selector boss
Selector gate
After the gear pair to be shifted has been selected,

the shift movement takes place.
Here the axial movement of the shift cable at the
transmission produces an axial movement of the
selector shaft.
If the gearshift lever is moved forwards or
backwards, the selector shaft and the selector
boss both move vertically together.
As this happens, the selector shaft is guided by a
pin in the selector gate.
The selector boss shifts the required selector fork.
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Engage reverse gear
Description
During the select and shift process the selector

shaft is guided through the selector gate by a pin.
Shift locking bush
The reverse gear idler is slid by the reverse gear

selector shaft and reverse gear is engaged.
Reverse gear selector shaft
Shift rod - 5th gear/reverse

gear
Selector shaft
Selector boss
Selector gate
Item
Part
Number

In order to select reverse gear, the gearshift lever

must be moved to the right over and past the
reverse gear inhibit device. As this occurs the
axial movement of the selector cable is transferred
to the selector shaft which can turn in its bearing.
When shifting into reverse gear, the gearshift lever
is moved backwards. The selector boss engages
in the 5th gear/reverse gear shift rod, which in turn
engages through a pin in the reverse gear selector
shaft.
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Power transmission in the individual gears
G281365 en
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308-03-16

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308-03-16
G281365 en
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308-03-17

Manual Transaxle
G18097 en
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308-03-18
GENERAL PROCEDURES
Bearing Check
1. NOTE: Establish the cause of the damage and
resolve it.
Check whether the bearing cage is
damaged at the top, side or at the
openings is damaged because of the
unprofessional use of a special tool or of
the wrong tool.
Install a new bearing if necessary.
2. Check whether the ends of the taper rollers

are discoloured as a result of inadequate
lubrication or overheating, possibly
through excessive pre-load.
Install a new bearing and new seals if
necessary.
Check the bearing is correctly lubricated.
G21559 en
3. Check whether the ends of the taper rollers

are worn away due to incorrect installation,
excessive pre-load or faulty bearing
seating.
necessary.
4. Check whether the bearing surfaces are

grey or grey/black with deposits between
the rollers.
necessary.
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5. Check whether the bearing ring surfaces
are grooved caused by static impact.
Install a new bearing if its surface is rough,
or if it is noisy.
7. Check the surfaces for abrasion due to

metal fatigue.
Install a new bearing and clean all other
affected components as necessary.
6. NOTE: Overheating can cause loss of surface

hardness.
Check for a dark blue colour caused by
overheating (yellow or brown is normal)
due to excessive pre-load or inadequate
lubrication.
Install a new bearing, new seals and check
other components as necessary.
G21559 en
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308-03-20
IN-VEHICLE REPAIR
Halfshaft Seal LH (14 303 0)
Installation
Special Tool(s)
Installer, Drive Pinion Seal
205-115 (15-058)
1. Using the special tool, install the halfshaft

seal.
Remover, Halfshaft Seal

308-208 (16-074)
Name
Manual transmission
fluid
Specification
WSD-M2C200-C
Removal
205-04.[Front Drive Halfshafts, REMOVAL
AND INSTALLATION, Halfshaft LH]
2. Using the special tool, remove the halfshaft
seal.
Discard the seal.
G152565 en

fluid level is just below the bottom of the
filler hole.
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308-03-21
308-03-21
IN-VEHICLE REPAIR
Halfshaft Seal RH (14 304 0)
Installation
Special Tool(s)
Remover, Drive Pinion Seal
205-078 (15-048)
1. Using the special tool, install the halfshaft

seal.
Installer, Halfshaft Seal

308-039 (16-018)
Name
Manual transmission
fluid
Specification
WSD-M2C200-C
Removal
AND INSTALLATION, Halfshaft RH]
2. Using the special tool, remove the halfshaft
seal.
Discard the seal.
G152566 en

fluid level is just below the bottom of the
filler hole.
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IN-VEHICLE REPAIR
Vehicle Speed Sensor (VSS) (33 654 0)
Removal
2. Disconnect the vehicle speed sensor (VSS)
3. Remove the VSS.

1. Remove the retaining pin.
2. Remove the VSS.
Installation
1. Install VSS.
1. Insert the VSS.
2. Insert the retaining pin.
2. Install VSS connector.
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308-03-23
308-03-23
REMOVAL
Special Tool(s)
Support Bar, Engine
303-290A (21-140A)

Tray]
3. Disconnect the powertrain control module
(PCM) electrical connector.

303-290-01 (21-140-01)

303-290-02 (21-140-02)

303-290-03A (21-140-03A)

Remover, Halfshaft
308-256 (16-089)
General Equipment
Retaining strap
Transmission jack
Removal
All vehicles
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REMOVAL (Continued)
bolts.
Detach the engine wiring harness bracket
from the transaxle.


10. Remove the gearshift actuator cover.
Detach the starter motor electrical connector from the starter motor.
11. Disconnect the gearshift actuator electrical connector (colored black).
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REMOVAL (Continued)
12. Disconnect the gearshift actuator electrical connector (colored grey).
13.

transaxle.

water.
supply line.
All vehicles
16. Remove the accessory drive belt cover.

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REMOVAL (Continued)
18.

20. NOTE: Discard the intermediate shaft center

bearing cap and locknuts.
Remove the intermediate shaft center
bearing cap.
1. Remove the locknuts.
2. Detach the heat shield.
3. Remove the center bearing cap.
Detach the lower arm from the wheel

19.


seal.
ingress.
Using the special tool, detach the
left-hand halfshaft from the transaxle and
21.


seal.
ingress.
Detach the halfshaft and the intermediate
shaft from the transaxle and secure it to
one side.
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REMOVAL (Continued)
24.

water.

Discard the gasket.

supply line.
28. Remove the engine and transaxle rear

mount.
Discard the nuts.
25. Disconnect the vehicle speed sensor

(VSS) electrical connector (if equipped).
G113290 en
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REMOVAL (Continued)
29. Using the special tools, lower the engine
32. NOTE: Secure the transaxle with a retaining

strap on the transmission jack.
Using a suitable transmission jack, support the transaxle.

mount retaining bracket.

bolts.
bolt.
G113290 en
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308-03-29
REMOVAL (Continued)
35. Using a suitable transmission jack, remove the transaxle.
G113290 en
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308-03-30
REMOVAL
Transaxle 2.0L Duratec-HE (MI4) (16 114 0)
Special Tool(s)
Support Bar, Engine
303-290A (21-140A)

303-290-01 (21-140-01)

303-290-03A (21-140-03A)
4. Remove the engine wiring harness bracket.

303-290-05A (21-140-05A)

303-290-06 (21-140-06)
bolts.
General Equipment
Retaining strap
Transmission jack
Removal
Duratec-HE (MI4)]
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308-03-31
REMOVAL (Continued)
6. Detach the power steering high-pressure
line retaining bracket from the transaxle.


8. Remove the wiring harness retaining
bracket.

Detach the wiring harness from the retaining bracket.
G453416 en

transaxle.
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308-03-32
REMOVAL (Continued)
13. Remove the accessory drive belt cover.
17.

suitable support wrap or suitable splint.

19.

water.
supply line.

G453416 en
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REMOVAL (Continued)
Discard the gasket.
23. Using the special tools, lower the engine


mount retaining bracket.

mount.
Discard the nuts.

bolts.
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REMOVAL (Continued)
27. NOTE: Secure the transaxle with a retaining
strap on the transmission jack.
30. Using a suitable transmission jack, remove the transaxle.
Using a suitable transmission jack, support the transaxle.

bolt.
G453416 en
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308-03-35
308-03-35
DISASSEMBLY
Transaxle (16 118 8)
General Equipment
Blanking plugs
Special Tool(s)
Drift
Remover, Drive Pinion Seal
205-078 (15-048)
CAUTION: Use vise protectors.
Remover, Differential Bearing

Cone
205-176 (15-074)
CAUTION: Use a copper or plastic mallet

to prevent damage.
1. Using the special tools, mount the transaxle on the mounting stand.
Mounting Bracket,
Engine/Differential
205-329 (15-105A)
Separator, Oil Pan

303-428 (21-179)
Mounting Stand
303-435 (21-187)
2. Clean any grease and foreign material from

the input shaft.
3. Remove the clutch slave cylinder.

303-435-06 (21-031B)

Bushing/Seal
308-045 (16-015)
Remover, Input Shaft Fifth
Gear
308-082 (16-035)
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4. Remove the vehicle speed sensor (VSS) (if
equipped).
1. Remove the retaining pin.
2. Pull out the VSS.
7. Remove the gearshift cable bracket.
8. Remove the selector lever.

Remove the bellows.
5. Remove the selector mechanism cover.
9. Remove the selector interlock mechanism.

6. Remove the gearshift lever.
1. Remove the protective cap (if equipped).
2. Remove and discard the snap ring.
G23118 en
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308-03-37
10. Remove the fifth gear housing cover retaining bolts.
13. NOTE: To aid assembly mark the position of

the fifth gear synchroniser assembly.
Disassemble the fifth gear and
synchroniser assembly.
1. Snap ring.
2. Retaining plate.
3. Synchroniser assembly.
4. Synchroniser ring.
5. Fifth gear.
11. Using the special tool, remove the fifth

gear housing cover.
12. Remove the fifth gear synchroniser

assembly, the selector fork and the fifth
gear.
2. Remove and discard the retaining pin.
14. Remove the fifth gear snap ring.
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15. Using the special tool, remove the fifth
gear.
18. Using the special tool, remove both

halfshaft oil seals (left-hand side shown).
Only remove the reversing lamp switch if
there is evidence of leakage.
16. Remove the fifth gear housing.

Discard the bolts.
19. Separate the two halves of the transaxle
housing (14 bolts).
Carefully separate the transaxle housing.
17. Remove the fifth gear housing gasket, the

snap rings and the blanking plug.
1. Remove and discard the gasket.
2. Remove the output shaft snap ring.
3. Remove the input shaft snap ring.
4. Pull out the blanking plug.
G23118 en
20. Remove the selector shaft guide sleeve

upper snap ring.
1. Remove and discard the upper snap ring.
2. Slide the selector shaft guide sleeve
downwards.
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308-03-39
21. Remove the selector shaft guide sleeve.
1. Remove and discard the selector shaft
guide sleeve lower snap ring.
2. Remove the selector shaft guide sleeve.
24. Remove the differential assembly and the

permanent magnet.
25. Remove the reverse gear idler.

22. NOTE: Install a rubber band to the second
selector shaft to aid disassembly.
Remove the input shaft, the output shaft
and the selector forks as an assembly.
26. Remove the selector shaft and the shift

lock.
1. Remove the shift lock.
2. Remove the fifth and reverse gear selector
shaft.
23. Using a suitable drift remove and discard
the input shaft oil seal.
G23118 en
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308-03-40
27. Remove the output shaft roller bearing.
Remove the rollers and the roller cage from
the output shaft roller bearing.
28.
30. NOTE: Install the special tool in the transaxle

housing grooves.
Using the special tool, remove the differential bearing cup.
CAUTION: Only use the special tool as

shown, failure to do so may result in
the blanking plug being pressed out of
the housing.
Using the special tool, remove the output
shaft roller bearing outer race.
Remove the oil funnel.
29. Using the special tool, remove the differential bearing cup.
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308-03-41
308-03-41

Output Shaft
Disassembly
Special Tool(s)
Tool)
205-295 (15-050A)
Bushing Oil Seal
308-045 (16-015)
1. Remove the ball bearing and the fourth

gear.
1. Remove and discard the small snap ring.
2. Install the output shaft snap ring .
3. Using a suitable two-leg puller, remove the
ball bearing.
Discard the output shaft snap ring and the
ball bearing.
4. Remove the fourth gear and the synchronizer ring.
Collet for 205-295

307-217 (17-048)
General Equipment
Two-leg puller
Press
Name
Transmission Oil
G21539 en
Specification
WSD-M2C200-C
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308-03-42

2. Remove the third and fourth gear
synchronizer assembly.
2. Remove the gear synchronizer, third and
fourth gear synchronizer assembly and the
third gear as an assembly.
4. Remove the second gear synchronizer

assembly
1. Retaining ring.
2. Snap rings.
3. Second gear.
4. Inner synchronizer ring.
5. Synchronizer cone.
6. Outer synchronizer ring.
3. Third gear synchronizer assembly.

3. Third gear.
G21539 en
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308-03-43
5. NOTE: Remove the synchronizer assembly and

the first gear as an assembly.
Remove the first and reverse gear , the
gear synchronizer and synchronizer
assembly.
2. Remove the first and second gear
synchronizer clutch and the reverse gear .
6. First gear.
G21539 en
6.
CAUTION: To aid assembly mark the

position of the selector ring in relation
to the synchronizer hub.
Disassemble the synchronizer clutch.
1. Selector ring.
2. Synchronizer spring.
3. Synchronizer lock.
4. Synchronizer hub.
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308-03-44

7. Using the special tools, remove the output
shaft bearing cone.
1. Remove and discard the output shaft
bearing cone snap ring.
2. Install the special tools underneath the
bearing cone.
Discard the output shaft bearing cone.
3. NOTE: Install a new output shaft bearing cone

snap ring.
NOTE: Install a new output shaft bearing cone.
Install the output shaft bearing cone.
Evenly heat the bearing cone to
approximately 80C and install it onto the
output shaft.
Install the snap ring.
4. NOTE: Assemble the synchronizer clutch to the

marks.
Assemble the synchronizer clutch.
1. Synchronizer hub.
2. Selector ring.
3. Synchronizer lock.
4. Synchronizer spring.
Assembly
1. Coat the synchronizer assembly with clean
transmission oil before assembly.
2. Carefully clean and check all running
surfaces and coat them with clean
G21539 en
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308-03-45

5. NOTE: Use a new first and reverse gear snap
ring.
Install the first and reverse gear, the gear
synchronizer and synchronizer assembly.
1. First gear.
5. Install the first and second gear
synchronizer clutch and the reverse gear.
6. Install the snap ring.
G21539 en
6. NOTE: Assemble the synchronizer assembly

before installation on the output shaft.
Install the second gear synchronizer
assembly.
4. Second gear.
5. Snap rings.
6. Retaining ring.
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308-03-46

7. Third gear synchronizer assembly.
1. Third gear.
9. NOTE: Install a new snap ring.

NOTE: Install a new ball bearing.
NOTE: Install the ball bearing with the annular
groove facing outwards.
Using the special tool and a suitable press,
install the fourth gear and the ball bearing.
1. Install the synchronizer ring and the fourth
gear.
2. Using a suitable press , install the ball
bearing.
8. NOTE: Install a new third and fourth gear

synchronizer assembly snap ring.
NOTE: Install the selector ring with the annular
groove facing downwards and the small hub collar
facing upwards.
Install the third and fourth gear
synchronizer assembly.
1. Install the gear synchronizer, third and
fourth gear synchronizer assembly and the
third gear.
G21539 en
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308-03-47
308-03-47

Input Shaft
Special Tool(s)
Bushing/Oil Seal
308-045 (16-015)
2. Using a suitable two-leg puller remove the

ball bearing.
Discard the ball bearing.
General Equipment
Two-leg puller
Press
Name
Transmission Oil
Specification
WSD-M2C200-C
Disassembly
1. Using a suitable two-leg puller, remove the
ball bearing.
1. Install the input shaft snap ring.
2. Remove the ball bearing.
Discard the input shaft snap ring and the
ball bearing.
G21537 en
Assembly
1. Coat all components with clean
2. NOTE: Install a new ball bearing.
Using the special tool and a suitable press ,
install the ball bearing.
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308-03-48

3. NOTE: Install a new ball bearing.
NOTE: The ball bearing groove must face
outwards.
Using the special tool and a suitable press ,
install the ball bearing.
G21537 en
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TO MODEL INDEX
308-03-49
308-03-49

Differential (16 118 6)
Disassembly
Special Tool(s)
Pad)
204-158-01 (14-038-01)
Installer, Differential Bearing

205-062 (15-025A)
1. Using the special tools, remove the

differential taper roller bearings.
2. Remove the differential taper roller
bearings.
3. Remove the vehicle speed sensor (VSS)
sensor ring.

Tool)
205-295 (15-050A)
Collet for 205-295
308-197 (16-062)
General Equipment
Press
Drift
Name
Transmission Oil
G21541 en
Specification
WSD-M2C200-C
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308-03-50

2. Remove the differential pinions and the
ring gear.
1. Rotate the differential pinions approximately
90 degrees in the differential case and
remove them.
2. Remove and discard the snap ring and
using a suitable drift, drive out the pin.
Remove the two differential pinions and
plastic thrust elements.
3. Remove the ring gear retaining bolts.
2. NOTE: Install a new differential pinion snap

ring.
Install the ring gear and the differential
pinions.
1. Using the old bolts, carefully attach the ring
gear to the differential case.
Discard the ring gear bolts.
2. Install the two differential pinions, plastic
thrust elements and using a suitable drift,
install the pin and snap ring.
3. Install the differential pinions and rotate
them 90 degrees in the differential case.
Assembly
1. NOTE: Do not lubricate the differential
bearings.
Carefully clean and check all components
and coat them with clean transmission oil
before assembly.
G21541 en
3. NOTE: Install new ring gear retaining bolts.

NOTE: Do not rest the differential on the lower
differential taper roller bearing.
Using the special tool, install the
differential taper roller bearings and
tighten the ring gear retaining bolts.
1. Install new ring gear retaining bolts and
tighten the bolts working diagonally.
2. Install the vehicle speed sensor (VSS)
sensor ring.
3. Using the special tool, install the differential
taper roller bearings.
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308-03-51

Selector Plate (16 284 8)
Overview, selector mechanism
Item
Part
Number
Fifth and reverse gear selector shaft guide sleeve
Selector plate
Shift lock
Selector shaft interlock

mechanism
Selector shaft
Reverse gear selector lever

return spring
Reverse gear selector lever
Snap-ring
Fifth and reverse gear selector shaft
G18111 en
Description
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Disassembly
1. Remove the selector mechanism.
1. Fifth and reverse gear selector shaft.
2. Selector shaft.
3. Reverse gear selector lever .
4. Selector plate.
5. Fifth and reverse gear selector shaft guide
sleeve.
Assembly
1. Install the selector mechanism.
1. Selector shaft.
2. Reverse gear selector lever.
3. Fifth and reverse gear selector shaft guide
sleeve.
4. Selector plate.
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308-03-53
308-03-53
ASSEMBLY
Transaxle (16 118 8)
General Equipment
Press
Special Tool(s)
Dial indicator gauge

Installer, Wheel Hub Bearing
Cone/Seal
205-296 (15-085)
Magnetic stand for dial indicator gauge

Blanking plugs
M8 x 50 mm bolt

303-060 (21-024)
Thread die
Name
Sealant
Adapter for 303-060

303-060-02 (21-024-02)
Adapter for 303-060

303-060-07 (21-024-07)
Mounting Stand
303-435 (21-187)
Installer, Halfshaft Seal

308-039 (16-018)
Specification
ESEE-M4G1008-A
Transmission Oil
WSD-M2C200-C
Oil Pan Sealer
WSK-M2G348-A5
Silicon Sealer
WSE-M4G323-A4
High Temperature
ESDM-1C220-A
Grease
1. Clean and check all parts carefully before
reassembly.
Apply clean transmission oil to all running
surfaces.
2.
CAUTION: Make sure the output shaft

roller bearing is installed with the
scribed text uppermost.
Using the special tool, install the output
shaft roller bearing and the output shaft
bearing cup.
1. Install the oil funnel.
2. Install the output shaft roller bearing.
Installer, Input Shaft Bearing

Cone
308-041 (16-020)
Bushing/Seal
308-045 (16-015)
Installer, Input Shaft Snap
Ring
308-076 (16-031)
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3. Using the special tool, install the differential bearing cup.
6. Install the differential assembly and the

permanent magnet.
4. Install the fifth and reverse gear selector

shaft, and the shift lock.
1. Install the shift lock.
2. Install the fifth and reverse gear selector
shaft.
7. Prepare the input and output shaft for

installation.
1. Engage the input shaft and output shaft.
2. Move the first and second gear shift forks to
the installation position.
3. Move the third and fourth gear shift forks to
the installation position.
5. Install the reverse gear idler.
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8. NOTE: Install a rubber band to the second
selector shaft to aid assembly.
Install the input shaft, the output shaft and
the selector forks.
Insert the input shaft to a depth of
approximately 50 mm and move it slightly to
one side.
Insert the output shaft to the level of the
input shaft and engage the gear wheels.
Install the input shaft and the output shaft.

Install the selector shaft guide sleeve
upper snap ring.
1. Lift the guide sleeve.
11. Move the inner gearshift linkage to the

fifth gear.
Before pressing it downwards, turn the selector shaft clockwise until it reaches the
reverse and fifth gear passage.
Install the selector shaft guide sleeve lower
snap ring.
1. Install the guide sleeve.
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12. Install the 3.8 mm thick measuring shim
and secure it with a punch mark.
1. Transaxle housing.
2. Measuring shim.
3. Bearing cup.
13. NOTE: Make sure that the transaxle housing

mating surfaces are clean.
Assemble the transaxle housing.
Using a M8 x 50 mm bolt install the special
tool.
Install the blanking plugs.
Install the bolts.
Turn the transaxle 180 degrees.

Remove the blanking plugs.
15. Prepare the differential for measuring.

Turn the differential assembly
approximately ten times to settle the
bearings.
Position the dial indicator gauge and
magnetic stand and set the dial indicator
gauge to zero.
Pre-tension the dial indicator gauge by a
minimum of 1 mm.
16. NOTE: Carry out the measuring procedure

three times and calculate the average value.
NOTE: The adjusting shims are available from 0.1
mm to 1.1 mm in steps of 0.1 mm.
Measure the differential end float.
1. Using the special tool, lift the differential
assembly.
2. Note the resulting measurement.
Example: 0.73 mm + 0.74 mm + 0.72 mm
divided by three = 0.73 mm.
The value of the thickness of the shim
should be rounded down to the nearest
tenth of a millimeter below if the value
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ends in 0.05 mm and below, and rounded
up to the nearest tenth of a millimeter if
the value ends in 0.06 mm and above.
17. Calculate the required adjusting shim

thickness.
Thickness of adjusting shim = measuring
shim (3.80 mm) + average value (0.73 mm)
+ bearing pre-load (0.14 mm) thickness of
the Belleville washers (4.42 mm)
Example: Adjusting shim = 3.80 mm +
0.73 mm + 0.14 mm 4.42 mm = 0.25
mm.
The thickness of the adjusting shim
becomes 0.2 mm (rounded down from 0.25
mm).
18. Separate the transaxle housing.
Install the blanking plugs.
Turn the transmission approximately 180
degrees.
Remove the dial indicator gauge, the
magnetic stand and the special tools.
19. Using the special tool, remove the differential bearing cup and the measuring
shim.
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20.
CAUTION: The Belleville washers

must be installed with the inner
diameter of both washers touching.
22. Assemble the transaxle housing and

tighten the bolts.
Install the measured adjusting shim.

1. Install the Belleville washers.
2. Install the measured adjusting shim.
3. Install the bearing cone.
Using a suitable center punch, secure the
bearing cone.
23. NOTE: Install new input and output shaft snap

rings.
Raise the input and output shafts slightly
and install the snap rings.
21. Apply sealer on the inside edge of the

transaxle housing mating face.
24. Using a suitable thread die, clean all the

hole threads in the fifth gear housing.
25. NOTE: Install a new fifth gear housing gasket.
Install the fifth gear housing gasket.
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26.
CAUTION: Make sure the snap rings

are in the correct position. Failure to
follow this instruction may cause
damage to the fifth gear housing.
Turn the snap rings to the position
shown.
27. NOTE: Install new fifth gear housing retaining

bolts.
Install the fifth gear housing.
29. NOTE: The transaxle housing must not

contact the press table. Support the input shaft
splines.
Using the special tool and a suitable
press, install the fifth gear.
30. Mount the transaxle on the mounting

stand.
31. NOTE: Install a new fifth gear snap ring.
Install the fifth gear snap ring.
1. Install the snap ring onto the special tool.
2. Install the special tool and push on the snap
ring.
28. Remove the transaxle from the mounting

stand.
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32. Make sure that the selector shaft is in the
neutral position.
Correct installation position for the selector
shaft interlock mechanism.
34. NOTE: Align the gear synchronizer to the

marks.
Assemble the fifth gear synchronizer.
1. Fifth gear.
2. Synchronizer ring.
3. Synchronizer assembly.
4. Retaining plate.
33. Install the selector shaft interlock

mechanism.
Apply sealant to the thread.
35. NOTE: Install a new fifth gear synchronizer
assembly snap ring.
NOTE: Use a new selector fork retaining pin.
Install the fifth gear synchronizer
assembly and the selector fork.
Install the retaining pin.
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36. Apply sealer evenly to the inside edge of
the fifth gear housing mating face.
39. Engage the fifth gear.

Turn the selector shaft clockwise as far as
possible and push the shaft in.
37. Install the fifth gear housing cover.

40. NOTE: Install new halfshaft oil seals.
Using the special tools, install both halfshaft oil seals (left-hand side shown).
38. Install the selector lever.

Install the bellows.
41. Install the gearshift cable bracket.
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45.
Install the gearshift lever.

2. Install the protective cap (if equipped).
CAUTION: Using suitable adhesive

tape, cover the input shaft splines to
prevent damage to the input shaft oil
seal.
Position the input shaft oil seal.
43. Install the selector mechanism cover.

46.
CAUTION: Do not apply grease on any

parts of the clutch slave cylinder.
Install the clutch slave cylinder.
Tighten the bolts evenly. In doing so, press
the input shaft oil seal into the transmission
housing.
44. Install the vehicle speed sensor (VSS) (if

equipped).
1. Push in the VSS.
2. Install the retaining pin.
47. Remove the adhesive tape from the input

shaft splines.
48. Coat the input shaft splines with a thin
layer of grease.
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308-03-63
INSTALLATION
Installation
Special Tool(s)
Support Bar, Engine
303-290A (21-140A)

303-290-01 (21-140-01)
All vehicles
1.
CAUTION: Use suitable retaining straps

to secure the transaxle on the
transmission jack.
CAUTION: Make sure that the two locating
dowels are installed.
Using a suitable transmission jack, install
the transaxle.

303-290-02 (21-140-02)

303-290-03A (21-140-03A)
bolts.
General Equipment
Retaining strap
Transmission jack
Name
Manual transmission
fluid
G113293 en
Specification
WSD-M2C200-C
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bolt.
9. Using the special tools, raise the engine


NOTE: Install new engine rear mount retaining
nuts.
5. Remove the retaining strap.

6. Remove the transmission jack.
7. Install the engine and transaxle rear mount
retaining bracket.
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14.

water.
seated.
line.
13. Connect the vehicle speed sensor (VSS)

electrical connector (if equipped).

bracket.

100-02.
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17.

19.

seal.
Attach the right-hand halfshaft and the
intermediate shaft to the transaxle.

seal.

correctly seated.
Attach the left-hand halfshaft to the
transaxle.
18. NOTE: Install a new center bearing cap and

locknuts.
bearing cap.
1. Install the center bearing cap.
2. Attach the heat shield.
3. Install the locknuts.
20.

to the ball joint.
NOTE: The lower arm pinch bolt must be installed
from the rear of the wheel knuckle.
Attach the lower arm to the wheel knuckle
on both sides.
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levers.
22. Install the accessory drive belt cover.

connector (colored grey).

G113293 en

connector (colored black).
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27. Install the gearshift actuator cover.

line.
Install the clip.
All vehicles
G113293 en

Attach the starter motor electrical connector
to the starter motor.

32. Tighten the strut spring assembly top
mount nuts on both sides.

Attach the engine wiring harness bracket to
the transaxle.
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37. Connect the powertrain control module

(PCM) electrical connector to the PCM.

204-04.
All vehicles
transaxle until the oil level is just below
the bottom of the filler hole.
43.
CAUTION: The worldwide diagnostic

system (WDS) gearshift actuator bleed
option must be carried out if any part
of the clutch hydraulic system is
opened or any new components are
installed.
NOTE: When the WDS gearshift actuator bleed
option is selected, the learn transmission and
learn clutch parameter options will automatically
be completed.
Bleed the clutch system. For additional
G113293 en
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308-03-70
INSTALLATION
Transaxle 2.0L Duratec-HE (MI4) (16 114 0)
Installation
Special Tool(s)
Support Bar, Engine
303-290A (21-140A)
1.
CAUTION: Use suitable retaining straps

to secure the transaxle on the
transmission jack.
CAUTION: Make sure that the two locating
dowels are installed.

303-290-01 (21-140-01)
Using a suitable transmission jack, install

the transaxle.

303-290-03A (21-140-03A)

303-290-05A (21-140-05A)

bolts.

303-290-06 (21-140-06)
General Equipment
Retaining strap
Transmission jack
Name
Manual transmission
fluid
G453417 en
Specification
WSD-M2C200-C
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308-03-71

bolt.
9. Using the special tools, raise the engine


NOTE: Install new engine rear mount retaining
nuts.
5. Remove the retaining strap.

6. Remove the transmission jack.
8. Install the engine and transaxle rear mount
retaining bracket.
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15. Remove the support wrap or suitable

splint from the exhaust flexible pipe.

13.

water.
seated.
line.

19. Install the accessory drive belt cover.

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levers.
22. Install the gearshift cables cover.
25. Install the wiring harness retaining

bracket.
Attach the wiring harness to the retaining
bracket.
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27. Attach the power steering high-pressure
line retaining bracket to the transaxle.
29. Install the engine wiring harness bracket.


G453417 en
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Cable Adjustment]
Bleeding]
transaxle until the fluid level is just below
the bottom of the filler hole.
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308-06-1
Manual Transmission/Transaxle External Controls
308-06-1
SECTION 308-06 Manual Transmission/Transaxle

External Controls
CONTENTS
PAGE
SPECIFICATIONS
Specifications....................................................................................................................
308-06-2

External Controls ..............................................................................................................
308-06-3

External Controls ..............................................................................................................
Symptom Chart ................................................................................................................
Pinpoint Tests ..................................................................................................................
308-06-5
308-06-5
308-06-5
308-06-5

Gearshift Lever ............................................................................................. (16 524 0)
Gearshift Cables ........................................................................................... (16 575 0)
308-06-6
308-06-7
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308-06-2
SPECIFICATIONS
Description
Shift and selector cable bushing.
Gearshift mechanism to floor assembly
Exhaust flange bolts
Gearshift lever
G18149 en
Nm
9
9
47
5
lb-ft
lb-in
80
80
35
44
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308-06-3

External Controls
G163328 en
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308-06-4

Item
Part
Number
Description
Shift cable
Selector cable
Body duct
The selector cable is moved in an axial direction

when a gear is selected with the gear lever. In the
internal gearshift mechanism, this axial movement
translates into the selection of the shift slot.
The shift cable is also moved in an axial direction
when a gear is selected with the gear lever. In the
internal gearshift mechanism, this axial movement
is used to engage the corresponding gear.
The selector cable is marked black and the shift
cable is marked white.
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External Controls
mechanical damage.
3. Make sure that the gearshift cables are
correctly routed and not under any tension
from other components.

step.
Symptom Chart
Symptom
Possible Sources
Action
External controls do not operate Gearshift cables incorrectly adfreely.

justed.
Gearshift lever damaged.
Selector mechanism damaged.
Gearshift cables damaged.
ADJUST the gearshift cables.

Pinpoint Tests
PINPOINT TEST A: STIFF GEARSHIFT
TEST CONDITIONS
A1: CHECK THE GEARSHIFT LEVER

1 Detach the gearshift cables from the gearshift
lever.
Is the gearshift lever difficult to operate?
Yes
Install a new gearshift lever. REFER to
Gearshift Lever in this section.
No
GO to A2
A2: CHECK THE GEARSHIFT CABLES
1 Attach the gearshift cables to the gearshift
lever.
2 Detach the gearshift cables from the transaxle.
Is the gearshift lever difficult to operate?
Yes
Install new gearshift cables. REFER to
Gearshift Cables in this section.
No
Install a new selector mechanism. REFER to
Section 308-03.[Manual Transmission/Transaxle, DISASSEMBLY, Transaxle]
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Gearshift Lever (16 524 0)
Removal
1. Remove the gearshift lever trim panel.
Disconnect the cigar lighter electrical connector.

gearshift lever.

retaining bracket.
Turn the abutment sleeves clockwise.
G186744 en
4. Remove the gearshift lever front retaining

bolts.
5. Remove the gearshift lever.

Remove the bolts.
Installation
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308-06-7

Gearshift Cables (16 575 0)
Removal
1. Remove the gearshift lever. For additional

information, refer to Gearshift Lever in this
section.
100-02.
4. Remove the exhaust front hanger insulator.

transaxle.
1. Detach the gearshift cable and the selector
2. Turn the abutment sleeves clockwise and
5. Detach the exhaust heat shield from the

floor panel.
Slide the heat shield backwards.
8. Detach the gearshift cables from the retaining clip.
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308-06-8

9. Detach the selector cable from the retaining clip.
13. Detach the gearshift cables bushing from

the floor panel and pull the cables
through to the vehicle interior.

11. Remove the air distribution channel.
Installation
1. NOTE: Do not bend or kink the gearshift cables.
Feed the gearshift cables through the floor
panel and attach the gearshift cables
bushing.
12. Cut the floor covering and the sound

deadening material to gain access to the
gearshift cable bushing.
2. Install the air distribution channel.
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308-06-9

100-02.
7. Install the exhaust front hanger insulator.
8. Attach the gearshift cables to the retaining

clip.

levers.
9. Attach the selector cable to the retaining

clip.
6. Attach the exhaust heat shield to the floor

panel.
Slide the heat shield forwards.
10. Install the gearshift lever. For additional

information, refer to Gearshift Lever in
this section.
G186745 en
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309-00-1
Exhaust System
309-00-1
SECTION 309-00 Exhaust System

CONTENTS
PAGE
SPECIFICATIONS
Specifications....................................................................................................................
309-00-2

Exhaust System ................................................................................................................
Exhaust system - 1.3l, 1.4l and 1.6l petrol engines and 1.4l diesel engines......................
309-00-3
309-00-3

Catalytic Converter 2.0L Duratec-HE (MI4)...................................................................
Exhaust Flexible Pipe 2.0L Duratec-HE (MI4)...............................................................
309-00-5
309-00-7
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Exhaust System
309-00-2
SPECIFICATIONS

Specification
ESE-M99B144-B
SA-M1C9107-A
Lubricant
Anti-seize grease
Description
Catalytic converter to exhaust flexible pipe retaining
nuts - All except vehicles with diesel engine
Catalytic converter to turbocharger retaining nuts Vehicles with 1.4L diesel engine
Catalytic converter to turbocharger retaining clamp
- Vehicles with 1.6L diesel engine
Catalytic converter to muffler and tailpipe assembly
clamp retaining nut - Vehicles with 2.0L engine
Exhaust flexible pipe to catalytic converter clamp
retaining nut - Vehicles with diesel engine
Exhaust flexible pipe to exhaust manifold retaining
nuts
Turbocharger heat shield upper retaining screws Vehicles with 1.4L diesel engine
Turbocharger heat shield lower retaining bolts Vehicles with 1.4L diesel engine
Catalytic converter heat shield retaining screws Vehicles with 1.6L diesel engine
Exhaust flexible pipe to muffler and tailpipe assembly retaining nuts - Vehicles with diesel engine
Catalytic converter support bracket to engine block
retaining nuts - Vehicles with 1.4L or 1.6L engine
retaining nuts - Vehicles with 1.3L or 1.4L diesel
engine
retaining bolts - Vehicles with 1.6L diesel engine
Catalytic converter to support bracket retaining nuts
Catalytic converter to catalytic converter support
bracket retaining bolts - Vehicles with 1.6L diesel
engine
Catalytic converter to muffler and tailpipe assembly
retaining nuts - Vehicles with 1.6L diesel engine
Catalytic monitor sensor
Exhaust flexible pipe to front muffler pipe heat
shield retaining bolts Vehicles with 1.6L engine
Exhaust flexible pipe clamp retaining nut Vehicles
with diesel engine
Rear muffler clamp retaining nuts All except vehicles with diesel engine
G149908 en
Nm
47
lb-ft
35
lb-in
-
25
18
25
18
40
30
40
30
47
35
27
12
35
47
35
47
35
25
18
25
18
25
25
18
18
48
35
47
47
8
35
35
-
71
47
35
47
35
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TO MODEL INDEX
309-00-3
Exhaust System
309-00-3

Exhaust System
Exhaust system - 1.3l, 1.4l and 1.6l petrol
engines and 1.4l diesel engines
Item
Part
Number
1.3l Duratec 8V SOHC
1.4l Duratec 16V DOHC
G167275 en
Description
Item
Part
Number
Description
1.6l Duratec 16V DOHC
1.4l DuraTorq TDCi

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Exhaust System
309-00-4

Item
Part
Number
Description
Flexible pipe
Servicing clamp
Front muffler
All exhaust systems are single-part systems. The

final muffler can be renewed separately in service.
In this case the pipe needs to be cut through, and
the new final muffler needs to be secured with a
servicing clamp.
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309-00-5
Exhaust System
309-00-5

Catalytic Converter 2.0L Duratec-HE (MI4)
Name
Specification
Grease
SA-M1C9107-A
NOTE: If installing a new catalytic converter to the
original exhaust system, a new muffler and
tailpipe assembly must also be installed.
2.


table(s).
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Exhaust System
309-00-6

Item
Part
Number
Description
Catalytic converter monitor

sensor electrical connector
Catalytic converter monitor

sensor
Exhaust hanger insulator

See Removal Detail
Catalytic converter to exhaust flexible pipe retaining

nuts
Catalytic converter to muffler

and tailpipe assembly
retaining clamp
See Removal Detail
Catalytic converter.
See Removal Detail
Item 5 : Catalytic converter to muffler and

tailpipe assembly retaining clamp
NOTE: Install a new catalytic converter to muffler
and tailpipe assembly clamp retaining nut.
Item 3 : Exhaust hanger insulator
CAUTION: Take care when installing the
exhaust hanger insulator to prevent
damage.
NOTE: Check the exhaust hanger insulator for
damage. Install a new exhaust hanger insulator if
required.
Removal Details
Item 3 : Exhaust hanger insulator
CAUTION: Take care when removing the
exhaust hanger insulator to prevent
damage.
Item 5 : Catalytic converter to muffler and
tailpipe assembly retaining clamp
NOTE: Discard the catalytic converter to muffler
and tailpipe assembly clamp retaining nut.
Item 6 : Catalytic converter.
CAUTION: Using cable ties, support the
muffler and tailpipe assembly to prevent
damage to the exhaust hanger insulators.
NOTE: Discard the catalytic converter to exhaust
flexible pipe gasket.
Item 6 : Catalytic converter.
NOTE: Remove the cable ties.
NOTE: Install a new catalytic converter to exhaust
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309-00-7
Exhaust System
309-00-7

Exhaust Flexible Pipe 2.0L Duratec-HE (MI4)
Name
Grease
G458157 en
Specification
SA-M1C9107-A

table(s).
Item
Part
Number
Description
Heated oxygen sensor
(HO2S) electrical connector
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Exhaust System
309-00-8

Description
Item 4 : Exhaust flexible pipe to muffler and

tailpipe assembly retaining nuts
HO2S
1.
Exhaust flexible pipe to

exhaust manifold retaining
nuts
See Removal Detail
Exhaust flexible pipe to

muffler and tailpipe assembly
retaining nuts
See Removal Detail
Exhaust flexible pipe
Exhaust flexible pipe gaskets
Item
Part
Number

pipe more than 2 degrees may cause
retaining nuts.
Remove the exhaust flexible pipe to catalytic converter retaining nuts.

CAUTION: Never use jointing compound
forward of the catalytic converter.
Removal Details
Item 3 : Exhaust flexible pipe to exhaust
manifold retaining nuts
1.

Item 4 : Exhaust flexible pipe to muffler and
tailpipe assembly retaining nuts
pipe more than 2 degrees may cause
retaining nuts.
1.
Install the exhaust flexible pipe to catalytic

converter retaining nuts.
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Exhaust System
309-00-9

Item 3 : Exhaust flexible pipe to exhaust
manifold retaining nuts
1.

wrap or splint.
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310-00-1
Fuel System - General Information
310-00-1
SECTION 310-00 Fuel System - General Information

CONTENTS
PAGE

Fuel System 1.25L Duratec-16V (Sigma)/1.3L Duratec-8V (Rocam)/1.4L Duratec-16V
(Sigma)/1.6L Duratec-16V (Sigma)/2.0L Duratec-HE (MI4) ..............................................
310-00-2
310-00-2
GENERAL PROCEDURES
Fuel System Pressure Release..................................................................... (23 420 0)
Fuel Tank Draining........................................................................................ (23 551 0)
Quick Release Coupling....................................................................................................
Fuel System Pressure Check 2.0L Duratec-HE (MI4)...................................................
310-00-3
310-00-4
310-00-5
310-00-11
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310-00-2

Fuel System 1.25L Duratec-16V (Sigma)/1.3L Duratec-8V (Rocam)/1.4L
Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma)/2.0L Duratec-HE (MI4)
Mechanical
3.
4.
Electrical
Fuel level
Electrical
connector(s)
Fuel leak(s)
Wiring harness
Fuel line(s)
Inertia fuel shutoff
Fuel filter (if
(IFS) switch
equipped)
Fuel pump module
Fuel tank
Fuel tank filler pipe
Fuel filler cap
(if possible) before proceeding to the next step
symptom and refer to WDS.
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310-00-3
GENERAL PROCEDURES
Fuel System Pressure Release (23 420 0)
Release
1.

type when working on or near any fuel
injury.
WARNING: The fuel system remains
pressurized for a long time after the
ignition is switched off. The fuel pressure
must be released before attempting any
repairs. Failure to follow this instruction
Remove the fuel pump fuse.

2. Start the engine and allow to idle until the
engine stalls.
3. Crank the engine for approximately five
seconds to make sure the fuel injection
supply manifold pressure has been
released.
4. Install the fuel pump fuse.
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310-00-4
GENERAL PROCEDURES
Fuel Tank Draining (23 551 0)
General Equipment
Fuel tank draining equipment
Draining
WARNING: The fuel system remains
pressurized for a long time after the
ignition is switched off. The fuel pressure
must be relieved before attempting any
repairs. Failure to follow these
414-01.
2. Remove the fuel tank filler cap.
3. Using fuel tank draining equipment, drain
the fuel from the fuel tank using a 12.5mm
nylon drain tube.
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310-00-5
GENERAL PROCEDURES
Quick Release Coupling
General Equipment
Flat-bladed screwdriver
2. Disconnect the fuel line quick release

coupling.
1. Press the fuel line quick release coupling
locking tangs.
2. Disconnect the fuel line quick release coupling.
Disconnection
WARNING: Do not carry lighted tobacco
or open flame of any type when working
on or near any fuel related components.
Highly flammable vapors are always
present and can ignite. Failure to follow
injury.
injury.
CAUTION: Fuel injection equipment is
manufactured to very precise tolerances
and fine clearances. It is therefore
essential that absolute cleanliness is
observed when working with these
components. Always install blanking
plugs to any open orifices or lines.
NOTE: Fuel supply line connectors are white or
connectors are red or are identified by a red band.
additional information, refer to Fuel System
Pressure Release in this section.
G18192 en

coupling.
1. Pull the fuel line quick release coupling
locking tang.
2. Push the clip through the fuel line quick
release coupling to release the fuel line.
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310-00-6

coupling.
locking tangs.
6. Release the fuel tank vent line quick

release coupling.
Press the fuel tank vent line quick release
coupling locking release collar.
7. Disconnect the fuel tank vent line quick

release coupling.
coupling.
Press the fuel line quick release coupling
buttons and pull the fuel line to disconnect.
8. Release the fuel line quick release

coupling.
Press the fuel line quick release coupling
locking release collar.
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310-00-7

12. Disconnect the fuel line from the fuel line

10. Using a suitable Flat-bladed screwdriver

release the fuel line quick release coupling secondary locking tang.
13. Disconnect the fuel line from the fuel

filter.
1. Press the collar into the connector body.
2. Disconnect the fuel line from the fuel filter.
11. Operate the fuel line quick release

coupling primary locking tang.
Push the fuel line quick release coupling
primary locking tang into from the fuel line
Connect
WARNING: Do not carry lighted tobacco
or open flame of any type when working
on or near any fuel related components.
Highly flammable vapors are always
present and can ignite. Failure to follow
injury.
injury.
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310-00-8
CAUTION: Fuel injection equipment is

manufactured to very precise tolerances
and fine clearances. It is therefore
essential that absolute cleanliness is
observed when working with these
components. Always install blanking
plugs to any open orifices or lines.
NOTE: Fuel supply line connectors are white or
connectors are red or are identified by a red band.
1. Push the connector on to the fuel filter.
3.
Insert the fuel line quick release coupling

secondary locking tang into the fuel line
4.
2. Install the fuel line to the fuel line quick

release coupling.
G18192 en
CAUTION: Make sure the quick release

coupling primary locking tang clicks
into place when installing.
CAUTION: After installation, to make

sure that the fuel line is fully seated,
pull on the line.
Install the fuel line quick release coupling.
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310-00-9
5.
CAUTION: After installation , to make

sure that the vent line is fully seated,
pull on the line.
Install the fuel tank vent line quick release
coupling.
6.
CAUTION: Make sure the fuel line clicks

into place when installing the line. To
make sure that the fuel line is fully
seated, pull on the line.
G18192 en
7. NOTE: Make sure the collar on the fuel line is

inserted fully into the fuel line quick release
coupling.

coupling before the locking tang is locked.
1. Install the fuel line quick release coupling
locking tang.
2. Rotate the fuel line quick release coupling
locking tang into position.
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310-00-10

coupling before the locking tang is locked.
1. Install the fuel line quick release coupling.
locking tang into position.
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310-00-11
310-00-11
GENERAL PROCEDURES
Fuel System Pressure Check 2.0L Duratec-HE (MI4)
Special Tool(s)
Test Hose for 310-025
310-025-18 (23-024-10)

band.
Disconnect the fuel supply line from the
fuel rail. For additional information, refer to
Quick Release Coupling in this section.
Test Hose for 310-025

310-025-19A (23-024-11A)
General Equipment
(418-F224)
4. Connect the special tool to the fuel rail.
1.

type when working on or near any fuel
injury.
This procedure involves fuel handling.
Be prepared for fuel spillage at all
times and always observe fuel
these instructions may result in
personal injury.
Release the fuel system pressure. For

2. Remove the air cleaner assembly. For
G461172 en
5. Connect the special tool to the fuel rail fuel

supply line.
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310-00-12

6. Connect the WDS pressure/vacuum
transducer adapter to the special tools.
7. Connect the WDS pressure/vacuum

transducer to the WDS pressure/vacuum
transducer adapter.
8. NOTE: The fuel system pressure should be 3.8
0.2 bar after key on and it should maintain this
pressure when the engine is running.
Using the digital multimeter function in
WDS, start the engine and measure the fuel
system pressure.
10. Disconnect the WDS pressure/vacuum
transducer from the WDS
pressure/vacuum transducer adapter.
11. Disconnect the WDS pressure/vacuum
transducer adapter from the special tools.
12. Disconnect the special tool from the fuel

rail fuel supply line.
13. Disconnect the special tool from the fuel

rail.
14. NOTE: Fuel supply line connectors are white

or are identified by a white band. Fuel return
line connectors are red or are identified by a
red band.
Connect the fuel supply line to the fuel rail.
For additional information, refer to Quick
Release Coupling in this section.
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310-00-13

15. Install the air cleaner assembly. For
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310-01-1
Fuel Tank and Lines
310-01-1
SECTION 310-01 Fuel Tank and Lines

CONTENTS
PAGE
SPECIFICATIONS
Specifications....................................................................................................................
310-01-2

Fuel Tank and Lines 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) ............................................................................................................
Overview ..........................................................................................................................
310-01-3
310-01-3

Fuel Tank and Lines .........................................................................................................
310-01-5

Fuel Tank...................................................................................................... (23 554 0)
Fuel Pump Module........................................................................................ (23 534 0)
Fuel Tank Filler Pipe ..................................................................................... (23 572 0)
Fuel Level Sensor .............................................................................................................
310-01-6
310-01-12
310-01-13
310-01-15
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Fuel Tank and Lines
310-01-2
SPECIFICATIONS
Description
Fuel tank support strap retaining bolts
Fuel tank filler pipe retaining bolts
Fuel pump module locking ring - All except vehicles
with diesel engine
Fuel level sensor locking ring - Vehicles with diesel
engine
Floor panel crossmember
G148228 en
Nm
25
9
85
lb-ft
18
63
lb-in
80
-
85
63
35
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310-01-3
Fuel Tank and Lines
310-01-3

Fuel Tank and Lines 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L
Duratec-16V (Sigma)
Overview
Item
Part
Number
Description
Fuel return line
Non-return valve, Evaporative Emission (EVAP) system
Fuel pump unit
Tank breather pipe
Tank filler neck
Activated charcoal canister
Fuel filter
Fuel feed line
In the event of an accident, the fuel cut-off safety

switch interrupts the power supply so that no more
fuel can be supplied.
It is located behind a cover on the right-hand
A-pillar in the footwell next to the central junction
box.
The fuel tank holds 45 litres.

The fuel pump unit is located in the fuel tank. It
consists of the fuel pump and the sender for the
fuel gauge.
The fuel pump is electrically controlled through the
fuel cut-off safety switch.
G207055 en
The fuel tank must be removed before the fuel

pump unit can be removed.
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Fuel Tank and Lines
310-01-4

Care must be taken on installation, that the arrows
on the fuel tank and the fuel pump unit point at
each other.
If the alignment is wrong, then the fuel level shown
may be incorrect.
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Fuel Tank and Lines
310-01-5

Fuel Tank and Lines
All except vehicles with diesel engine, REFER to
Section 310-00.[Fuel System - General
Information, DIAGNOSIS AND TESTING, Fuel
System - 1.25L Duratec-16V (Sigma)/1.3L
Duratec-8V (Rocam)/1.4L Duratec-16V
Duratec-HE (MI4)]
Vehicles with diesel engine,
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Fuel Tank and Lines
310-01-6

Fuel Tank (23 554 0)
5. Detach the exhaust system from the center
Special Tool(s)
Wrench, Sender Unit, Fuel
Tank
310-069 (23-055)
General Equipment
Transmission jack
Removal
All vehicles
injury.
310-00.
2. Drain the fuel tank. For additional
100-02.
4. Remove the floor panel crossmember.
G189084 en
6. NOTE: When detaching the exhaust system

allow the system to be supported by the rear
suspension assembly.
Detach the exhaust system from the rear
7. Remove the exhaust system heat shield.
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Fuel Tank and Lines
310-01-7
8.
CAUTION: When removing the fuel tank

vent and filler pipes, do not use any
sharp edge tools to lever off the pipes.
cause damage to the pipes.
NOTE: Make note of the positions of the retaining
clamps to make sure they are positioned in exactly
the same positions when installing.
10. Remove the fuel tank support strap rear

retaining bolts.
Disconnect the fuel tank filler pipe and the

fuel tank vent pipe from the fuel tank.
Discard the retaining clamps.
11. NOTE: Make note of the positions of the

support straps to make sure they are
positioned in exactly the same positions when
installing (left-hand over right-hand).
Remove the fuel tank support straps.
9.
CAUTION: Use a suitable packing

material to prevent damage to the
underside of the fuel tank.
Using a suitable transmission jack, support
the fuel tank.
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Fuel Tank and Lines
310-01-8

All except vehicles with diesel engine
12. Disconnect the fuel tank vent pipe from
the evaporative emission canister. For
310-00.
All vehicles
13.

14. Disconnect the fuel pump module electrical connector.

15. Disconnect the fuel level sensor electrical
connector.
CAUTION: When lowering the fuel tank,

make sure that excessive strain is not
placed on the fuel lines and electrical
connectors.
Partially lower the fuel tank.
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Fuel Tank and Lines
310-01-9

All vehicles
16. NOTE: Make note of the color of the fuel lines
to make sure they are connected in exactly the
same positions when installing. Fuel supply line
connectors are white or are identified by a
white band. Fuel return line connectors are red
or are identified by a red band.
18. Remove the evaporative emissions canister from the fuel tank.
Disconnect the fuel supply and fuel return

lines from the fuel tank. For additional
All vehicles
19. Remove the fuel tank assembly.
All except vehicle with diesel engine
20. Using the special tool, loosen the fuel
pump module locking ring.

17. Disconnect the evaporative emissions
canister pipe.
Squeeze the clip to release the pipe.
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Fuel Tank and Lines
310-01-10
21.
CAUTION: Make sure that the float or

arm are not damaged while removing
or installing the fuel pump module.
Remove the fuel pump module.
1. Remove the locking ring.
2. Remove the O-ring seal.
3. Lift the module from the fuel tank.

22. Using the special tool, loosen the fuel
level sensor locking ring.
23.
CAUTION: Make sure that the float or

arm are not damaged while removing
or installing the fuel level sensor.
Remove the fuel level sensor.
1. Remove the locking ring.
2. Remove the O-ring seal.
3. Lift the sensor from the fuel tank.
Installation
injury.
CAUTION: Make sure the fuel lines are
connected in the correct fuel-flow
direction. Fuel supply line connectors are
white or are identified by a white band.
Fuel return line connectors are red or are
identified by a red band.
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Fuel Tank and Lines
310-01-11
CAUTION: Make sure that the fuel supply

and fuel return lines click into place when
installing the lines. To make sure that the
fuel lines are fully seated, pull on the
lines.
NOTE: Install a new O-ring seal.
NOTE: When installing the fuel tank make sure
the fuel lines do not get kinked or trapped.
NOTE: Install new fuel filler and vent pipe
retaining clamps.
NOTE: The fuel filler and vent pipe retaining
clamps must be installed in the same position as
removed.
1. NOTE: Make sure that the arrows on the fuel
tank and the fuel pump module or fuel level
sensor are aligned correctly.
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Fuel Tank and Lines
310-01-12

Fuel Pump Module (23 534 0)
Removal
1. Remove the fuel pump module. For
additional information, refer to Fuel Tank in
this section.
Installation
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Fuel Tank and Lines
310-01-13

Fuel Tank Filler Pipe (23 572 0)
Removal
components. Highly flammable vapours
personal injury.
injury.
414-01.
2. Drain the fuel tank. For additional
100-02.
4. Remove the left-hand rear fender splash
shield (road wheel shown removed for
clarity).
G210057 en
5. Remove the fuel tank filler pipe upper retaining bolt.
6.
CAUTION: When disconnecting the fuel

tank vent and fuel tank filler pipes, do
not use any sharp edge tools to lever
off the pipes. Failure to follow this
instructions may cause damage to the
pipes.
NOTE: Make note of the positions of the retaining
clamps to make sure they are positioned in exactly
the same positions when installing.
Disconnect the fuel tank filler pipe and the
fuel tank vent pipe from the fuel tank.
Discard the retaining clamps.
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Fuel Tank and Lines
310-01-14

7. Remove the fuel tank filler pipe lower retaining bolt and remove the fuel tank filler
pipe.
Installation
components. Highly flammable vapours
personal injury.
injury.
NOTE: Install new fuel tank filler pipe and vent
pipe retaining clamps.
NOTE: The fuel tank filler pipe and vent pipe
retaining clamps must be installed in the same
position as removed.
G210057 en
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310-01-15
Fuel Tank and Lines
310-01-15

Fuel Level Sensor
Removal
1. Remove the fuel level sensor. For
additional information, refer to Fuel Tank in
this section.
Installation
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310-02A-1
Acceleration Control 1.25L Duratec-16V
310-02A-1
SECTION 310-02A Acceleration Control 1.25L

CONTENTS
PAGE

Acceleration Control.......................................................................................................
1.3L Duratec 8V ............................................................................................................
1.4L/1.6L Duratec 16V ..................................................................................................
310-02A-2
310-02A-2
310-02A-2

Acceleration Control.......................................................................................................
Principles of Operation ..................................................................................................
Diagnostic Trouble Codes .............................................................................................
Symptom Chart .............................................................................................................
310-02A-3
310-02A-3
310-02A-4
310-02A-6
310-02A-6
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310-02A-2
310-02A-2

Acceleration Control
1.3L Duratec 8V
Item
Part
Number
Description
Accelerator cable
Throttle body
The throttle is cable operated on the 1.3L Duratec

8V engine.
There are two different throttle bodies, depending
on the power of the variant.
Because the throttle flap opening angle is different,
the way in which the cable is controlled at the
throttle flap varies slightly between the two
different variants.
1.4L/1.6L Duratec 16V
The 1.4L/1.6L Duratec 16V engines have an
electronically controlled throttle flap control unit.
For information on the electronically controlled
throttle flap control unit, please refer to Section
303-14.
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310-02A-3
310-02A-3

System Overview
Electronic Accelerator Control System Overview
Item
Part
Number
Area "A"- accelerator pedal

to powertrain control (PCM)
module circuit
Area "B"- electronic throttle

body to PCM circuit
Accelerator pedal
42-way electrical connector
PCM
16-way inline electrical connector
Electronic throttle body
G356253 en
Description
Description
The system consists primarily of two circuits

connected to the PCM. The two circuits are the
accelerator pedal to PCM and the electronic
throttle body to PCM.
Accelerator Pedal
The accelerator pedal contains two sensors that

measure the movement of the pedal and output a
voltage corresponding to the pedal position.
Electronic Throttle Body
The electronic throttle body is similar to a

mechanical throttle body used on a cable
accelerator system. Instead of the cable moving
the throttle plate open and closed, it uses an
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310-02A-4

internal electrical motor that is driven by the PCM.
The electronic throttle body has two sensors that
measure the throttle plate position. The sensors
output a voltage to the PCM corresponding to the
plate position.
When the electronic throttle body motor is not in
use, the throttle plate sits slightly open in a default
position (not idle position). This position is
maintained by two internal springs. One acts
upwards and one downwards. Screws on the
electronic throttle body will not adjust the idle
speed, the idle speed is controlled by the PCM.
PCM
The PCM reads the voltage from the pedal and

converts this signal into a driver request. The
driver request is realized by opening or closing the
throttle body. To do this, the PCM increases or
decreases power to the electronic throttle body
motor. The PCM then checks the signal from the
electronic throttle body throttle position (TP)
sensor, to make sure that the requested position
has been achieved. The PCM also monitors all the
sensors to make sure that the system is
functioning as expected. All electronic accelerator
control system faults will be detected by the PCM
and set a diagnostic trouble code (DTC) which
triggers the electronic accelerator control fail
message accordingly. For safety reasons, some
faults will also reduce the vehicle performance.
Diagnostic Trouble Codes
Description
When a component electrical error is set it means

that the PCM is not receiving the expected signal.
This means that the concern may lie between the
component and the PCM. All wiring and electrical
connectors should be checked before a new
component is installed. Also note that general
vehicle electrical issues can have an effect on
other systems. Battery voltage and relay concerns
should be rectified first.
Accelerator Pedal Codes
These are the DTCs relating to the pedal circuit.

They do not imply necessarily that the accelerator
pedal is at fault, but it will in any case relate to area
"A" (see system overview).
G356253 en
P2120 Accelerator pedal sensor 1 electrical

error
error short to ground or open circuit
error short to battery
error
error short to ground or open circuit
error short to battery
P2138 Accelerator pedal sensor 1 & 2 ratio
error
Electronic Throttle Body Circuit Codes
These are the DTCs relating to the electronic

throttle body circuit. They do not imply necessarily
that the electronic throttle body is the concern, but
it will in any case relate to area "B" (see system
overview).
P0120 Throttle position (TP) sensor 1
electrical error
P0122 (TP) sensor 1 electrical error short to
ground
battery or line break
P0220 (TP) sensor 2 electrical error
ground or open circuit
battery
P2135 (TP) sensor ratio error
P2119 Throttle plate convergence error
- This is when the throttle plate has not moved
to the requested position in the required time.
This could be caused by the following:
- The electronic throttle body motor is not
receiving the necessary voltage. Check the
electronic throttle body motor wiring. The
PCM is not receiving the correct throttle
plate position signal from the electronic
throttle body. Check the TP sensor wiring
from the PCM to the electronic throttle body
including the electrical connectors in area
"B" (see system overview).
- There is an obstruction inside the throttle
body bore. Remove the air cleaner outlet
pipe and check for obstructions.
- There is an obstruction inside the electronic
throttle body. Remove the air cleaner outlet
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310-02A-5
310-02A-5

pipe and check that the plate moves freely
against the springs and returns to a slightly
open position. If it does not, install a new
electronic throttle body.
P2176 Throttle plate adaptation error
- When the ignition is turned off, the throttle
body carries out an adaptation cycle and
spring check. This can be audible after a
short delay (up to 30 seconds) following the
ignition key being turned to position 0 and
can be visually observed with the air cleaner
outlet pipe removed. The throttle plate is
moved through a series of positions to check
the TP sensor value and relearn the
electronic throttle body characteristics. If a
concern is detected during this test, P2176
DTC will be set. If there are already any of
the other DTCs, the adaptation test could
potentially fail. Therefore the other DTCs
should be resolved first (e.g. low battery
voltage) and a retest can be carried out by
clearing the DTCs and keying on and off
again. Check the whole area "B" (see
system overview) for any concerns and if no
concern is found, install a new electronic
throttle body.
P2100 H bridge error
- A fault has been detected on the circuit
connecting the electronic throttle body motor
and the PCM. Check for any other
non-electronic accelerator control related
DTCs and rectify them first. Check area "B"
(see system overview) and if no failure is
found, install a new PCM.
PCM Related Codes
The PCM continuously monitors all the sensors. It

also checks that the monitor is functioning as
expected. If there is a fault with the monitor, the
following DTCs will be set.
P2107 Processor monitoring on the main
controller fault.
P2108 -Analogue to digital converter
- Inferred intake mass air flow lower than
expected
- Engine speed monitor ratio error
- Pedal ratio monitor error
- TP sensor ratio monitor error
- Fault in torque generation
- Fault present in engine speed limitation
Multiple sensor faults can make the PCM assume
that there is a monitor fault. If other DTCs exist,
G356253 en
rectify these first. These DTCs indicate a failure in

area "A" or "B" and they are also related to the
manifold absolute pressure and temperature
(MAPT) sensor and the crankshaft position (CKP)
sensor. If no other failures are found, install a new
PCM.
Indirect Codes
There are two brake pedal switches located under

the brake pedal. Check that both of these are
connected and functioning correctly. A brake
pedal switch concern will only cause the "EAC
FAIL" message to be displayed, it will not lead to a
limited performance mode. Follow WDS
instructions.
P0571 Brake switch error
If the voltage to the accelerator pedal and the
electronic throttle body cannot be regulated
correctly, the components may not operate as
expected. Therefore it is important to detect if
there is a concern in the supply voltage
P0641 Sensor voltage supply circuit 1 noisy
signal
P0642 Sensor voltage supply circuit 1 short
to ground or open circuit
to battery
P0651 Sensor voltage supply circuit 2 noisy
signal
to ground or open circuit
to battery
- Check the power supply to the PCM (battery
voltage, relays, wiring harness and electrical
connectors as well as fuses). If no concern is
found, install a new PCM.
P1712 Electronic gear shift torque demand
is not a plausible signal (ASM only)
- Follow WDS instructions.
NOTE: If the vehicle is in a limited performance
mode, a system related DTC and the electronic
accelerator control fail light message will
illuminate. If there is a performance issue without
these items the electronic accelerator control
system is running correctly but another issue may
exist elsewhere on the vehicle.
Be aware that installing new system related
components without these DTCs will not improve
the vehicle behavior for general issues such as:
11/2004 2005.25 Fiesta
310-02A-6

TO MODEL INDEX
310-02A-6

high fuel consumption
poor idle quality
poor or no engine start
Mechanical
Fuse(s)
Relay(s)
Wiring harness
Electrical
connector(s)
Accelerator pedal
Throttle body
Powertrain control
module (PCM)
step.
symptom and refer to Symptom Chart.

Accelerator pedal
Linkage
Accelerator cable
Throttle body
Electrical
Symptom Chart - Vehicles With 1.3L Engine

Symptom
Possible Sources
Accelerator pedal is hard to de- Damaged accelerator cable.

press or has a rough/raspy or
sticky feel
Accelerator cable incorrectly
installed.
Action
INSTALL a new accelerator cable.
CHECK the accelerator cable for
correct installation.
Worn or damaged throttle body. INSTALL a new throttle body.

Accelerator pedal does not return freely
Weak or broken throttle body

return spring.
INSTALL a new throttle body.
Worn or damaged throttle body. INSTALL a new throttle body.

High engine idle speed
Damaged accelerator cable.
INSTALL a new accelerator cable.
Accelerator cable incorrectly

installed.
CHECK the accelerator cable for

Symptom Chart - Vehicles With 1.25L, 1.4L or 1.6L Engine

Symptom
Possible Sources
Accelerator pedal is hard to de- Accelerator pedal incorrectly

installed.
sticky feel
G356253 en
Action
CHECK the accelerator pedal for
Worn or damaged accelerator

pedal.
INSTALL a new accelerator

pedal.
Accelerator pedal incorrectly

installed.
CHECK the accelerator pedal for


pedal.

pedal.
Damaged accelerator pedal.
REFER to WDS to diagnose the

system.
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310-02A-7
310-02A-7

Symptom
Poor idling
G356253 en
Possible Sources
Action
Throttle body.

system.
PCM calibration.

system.
Throttle body.

system.
PCM calibration.

system.
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310-02B-1
Acceleration Control 2.0L Duratec-HE (MI4)
310-02B-1
SECTION 310-02B Acceleration Control 2.0L

Duratec-HE (MI4)
CONTENTS
PAGE

Acceleration Control..........................................................................................................
310-02B-2

Acceleration Control..........................................................................................................
Symptom Chart ................................................................................................................
310-02B-4
310-02B-4
310-02B-4
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310-02B-2

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310-02B-2

Item
Part
Number
Description
Throttle body

(PCM)
Accelerator pedal
The accelerator pedal incorporates two sensors,

accelerator pedal position (APP) sensor 1, and
APP sensor 2. Movement of the accelerator pedal
G422706 en
generates a percentage of reference voltage

(0-5V) on APP sensor 1 and a percentage of
duty-cycle output on APP sensor 2 corresponding
to that accelerator pedal position.
The PCM reads the output from both the APP
sensors and converts the signals into a driver
requested torque. To achieve the driver requested
torque, the PCM controls the position of the
throttle plate, ignition timing and fuel injection
timing to produce the appropriate demanded
engine torque output. The PCM monitors the
actual throttle plate position from the throttle
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310-02B-3

position (TP) sensors to make sure that the
requested position has been achieved.
NOTE: Do not install a new accelerator pedal
unless a relevant accelerator pedal DTC has been
stored in the PCM. For additional information refer
to WDS.
The accelerator pedal is a non-serviceable
component which cannot be adjusted and
therefore must not be disassembled or tampered
with.
The throttle body is directly controlled by the PCM
and has two TP sensors, TP 1 and TP 2. The TP
sensors output a voltage to the PCM that
corresponds to the actual throttle plate position.
When the throttle body motor is not being powered
up, the throttle plate sits open at approximately 8
degrees from the closed in-bore position. This
position (also referred to as the default position), is
maintained within the throttle body by two internal
compression return springs acting in opposing
directions, these springs are a non-serviceable
item.
The PCM continuously monitors both APP
sensors and both TP sensors to make sure that
the system is functioning as expected. All
acceleration control system concerns will be
detected by the PCM and the appropriate
diagnostic trouble code (DTC) set. The
malfunction indicator lamp (MIL), located in the
instrument cluster will also be illuminated if a
concern is apparent. As the acceleration control
system is of a safety-critical nature, it is possible
that a system concern will result in a reduced
vehicle performance and a DTC stored in the PCM.
For additional information refer to WDS.
G422706 en
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310-02B-4

Mechanical
Accelerator pedal
Electronic throttle
body

step.
symptom and refer to Symptom Chart.
Electrical
Fuse(s)
Wiring harness(s)
Electrical
connector(s)
Accelerator pedal
Electronic throttle
body
Powertrain control
module (PCM)
Symptom Chart
Symptom
Possible Sources
Action
Accelerator pedal is hard to de- Adjacent hardware, wiring har- CHECK the accelerator pedal
ness(s), trim(s), carpet or mat(s) and adjacent parts for correct
sticky feel
incorrectly installed.
installation.
pedal.
Poor idling
G426591 en

pedal.
Adjacent hardware, wiring har- CHECK the accelerator pedal

ness(s), trim(s), carpet or mat(s) and adjacent parts for correct
incorrectly installed.
installation.
pedal.

pedal.
Damaged accelerator pedal.

system.
Electronic throttle body.

system.
PCM calibration.

system.
Electronic throttle body.

system.
PCM calibration.

system.
11/2004 2005.25 Fiesta
BACK TO MAIN INDEX

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Group
Electrical
SECTION TITLE
4
PAGE
Climate Control System

Climate Control System - General Information ...................................................................... 412-00-1
Air Distribution and Filtering .................................................................................................. 412-01-1
Heating and Ventilation ......................................................................................................... 412-02-1
Air Conditioning..................................................................................................................... 412-03-1
Control Components ............................................................................................................. 412-04-1
Instrumentation and Warning Systems
Instrument Cluster and Panel Illumination ............................................................................. 413-00-1
Instrument Cluster................................................................................................................. 413-01-1
Horn ...................................................................................................................................... 413-06-1
Warning Devices ................................................................................................................... 413-09-1
Parking Aid............................................................................................................................ 413-13-1
Battery and Charging System
Charging System - General Information ................................................................................ 414-00-1
Battery, Mounting and Cables ............................................................................................... 414-01-1
Generator and Regulator....................................................................................................... 414-02-1
Entertainment Systems
Entertainment System - General Information......................................................................... 415-00-1
Audio Unit ............................................................................................................................. 415-01-1
Antenna................................................................................................................................. 415-02-1
Lighting
Exterior Lighting .................................................................................................................... 417-01-1
Interior Lighting ..................................................................................................................... 417-02-1
Electrical Distribution
Module Communications Network ......................................................................................... 418-00-1
Module Configuration ............................................................................................................ 418-01-1
Electronic Feature Group
Anti-Theft - Active.................................................................................................................. 419-01A-1
Anti-Theft - Passive............................................................................................................... 419-01B-1
Cellular Phone.......................................................................................................................
Multifunction Electronic Modules ...........................................................................................
419-08-1
419-10-1

TO MODEL INDEX
412-00-1
Climate Control System - General Information
412-00-1
SECTION 412-00 Climate Control System - General

Information
CONTENTS
PAGE
SPECIFICATIONS
Specifications....................................................................................................................
412-00-2

Climate Control System ....................................................................................................
Inspection and Checking ..................................................................................................
Refrigerant Circuit - Quick Check ......................................................................................
Symptom Chart .................................................................................................................
System Checks .................................................................................................................
Component Tests..............................................................................................................
412-00-3
412-00-3
412-00-3
412-00-4
412-00-5
412-00-36
GENERAL PROCEDURES
Air Conditioning (A/C) Clutch Air Gap Adjustment......................................... (34 628 6)
Air Conditioning (A/C) System Recovery, Evacuation and Charging ............. (34 620 2)
Refrigerant Oil Adding................................................................................... (34 621 1)
Air Distribution System Cleaning .......................................................................................
Contaminated Refrigerant Handling .............................................................. (34 620 9)
Spring Lock Coupling ........................................................................................................
Electronic Leak Detection ............................................................................. (34 620 7)
Fluorescent Dye Leak Detection .......................................................................................
Vacuum Leak Detection ................................................................................ (34 620 3)
412-00-37
412-00-38
412-00-41
412-00-42
412-00-44
412-00-45
412-00-47
412-00-48
412-00-49
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412-00-2
SPECIFICATIONS
Lubricants, sealants and adhesives

Material
Refrigerant R134a
Refrigerant oil
Specification
WSH-M17B19-A
WSH-M1C231-B
Refrigerant fill quantities

Grams
650 13
520 13
Air conditioning
Air conditioning (vehicles with 1.6L Duratorq-TDCi (DV) diesel engine)
Refrigerant oil fill quantities
millilitres
207
200
Air conditioning
Air conditioning (vehicles with 1.6L Duratorq-TDCi (DV) diesel engine)
Addition of refrigerant oil when new components are installed
Air conditioning compressor (if the amount of refrigerant oil taken from the
compressor is less than 90 ml)
Air conditioning compressor (vehicles with 1.6L Duratorq-TDCi (DV) diesel
engine) (if the amount of refrigerant oil taken from the compressor is less than
50 ml)
compressor is between 90 ml and 150 ml))
Air conditioning compressor (vehicles with 1.6L Duratorq-TDCi (DV) diesel
engine) (if the amount of refrigerant oil taken from the compressor is between
50 ml and 150 ml))
compressor is more than 150 ml)
Air conditioning condenser
Air conditioning evaporator
Air conditioning evaporator (vehicles with 1.6L Duratorq-TDCi (DV) diesel
engine)
Renewal of all lines
Renewal of all lines and components
Always, if refrigerant was drained.
Accumulator/dehydrator
Accumulator/dehydrator (vehicles with 1.6L Duratorq-TDCi (DV) diesel engine)
millilitres
add 90.
add 50.
Add same quantity + 30.
Add same quantity + 30.
Add the same quantity.
add 30.
add 90.
add 50.
Add same quantity +2.
add 0.
Add the same quantity.
Air conditioning clutch

mm
0,35 - 0,75
Clutch gap, A/C compressor

Tightening torques
Description
Bolt, A/C compressor drive plate
G105769 en
Nm
13
lb/ft
10
lb/in
-
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412-00-3
412-00-3

Climate Control System
Special Tool(s)
Terminal Probe Kit
29-011A
General Equipment
Digital Multimeter (compatible with K-type thermocouple)
Refrigerant center
Thermometer - Fluke 80 PK-8 (FSE number 260
4102 001 07)
Refrigerant Circuit - Quick Check
Inspection and Checking

1. VERIFY customer concern.
2. Visually CHECK for any obvious mechanical
or electrical damage.
Visual Inspection
Mechanical
Coolant level
Refrigerant lines
Drive belt
Condenser
Refrigerant compressor
G115900 en
3. RECTIFY any obvious causes for a concern

found during the visual inspection before
performing any further tests.
CHECK the operation of the system.
4. If the concern persists after the visual
inspection, PERFORM a fault diagnosis on
the electronic engine management with WDS
and RECTIFY any displayed faults in
accordance with the displayed fault
description. CHECK the operation of the
system.
5. For vehicles with no stored fault(s),
PROCEED in accordance with the symptom
chart according to the fault symptom.
6. Following checking or elimination of the fault
and after completion of operations, the fault
memories of all vehicle modules must be
READ OUT and any stored faults must be
DELETED. READ OUT all fault memories
again following a road test.
Electrical
Fuses
Wiring harness
Connectors
WARNING: The air conditioning system is

filled with refrigerant R134a.
Observe "Health and Safety Precautions".
For further information REFER to Section
100-00.[General Information,
Refrigerant circuit check
WARNING: Under certain circumstances,

refrigerant lines and A/C components
may be extremely hot or cold.
Exercising care, touch the refrigerant
lines or A/C components in order to
check this. Failure to observe this
instruction can lead to injury.
The high pressure line from the A/C
compressor to the A/C condenser should be
hot.
The high pressure line from the refrigerant
condenser to the fixed orifice tube should be
warm, but cooler than the previously
mentioned high pressure line.
Determine the difference in temperature
upstream and downstream of the A/C
condenser by measuring the temperatures.
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412-00-4

The temperature difference should be more
than 20, depending on the ambient
temperature. If the temperature difference is
less, check the condenser for contamination or
damage to the fins as well as operation of the
radiator fan.
The low pressure line between the fixed orifice
tube and the evaporator must be cold from the
installation position of the fixed orifice tube.
Depending on the weather, the line may also
be iced up on the outside.
The low pressure line between the evaporator
and the A/C compressor should be cold,
including the dehydrator.
Evaporator outlet temperature test
In order to check the A/C output, the temperature

of the evaporator outlet line must be measured.
The following preparations must be taken for this
purpose:
Open all windows.
Set the air distribution to the
defrost/dashboard position and open all the
ventilation nozzles.
DO NOT switch on recirculated air.
Select lowest blower switch setting.
Select lowest temperature setting.
NOTE: Temperature measurements cannot be
performed using a non-contact thermometer.
Incorrect measurements result owing to surface
reflection.
Connect temperature sensor (Fluke 80 PK-8) to
the refrigerant line from the evaporator to the
dehydrator in the area of the dehydrator (metal
line). Connect the temperature sensor to the
multimeter.
Start the engine and allow it to run at idle speed for
several minutes.
Switch on the air-conditioning system.
After three minutes, measure the surface
temperature of the evaporator outlet line.
If the temperature measured is 2 C or lower

(vehicles with automatic transmission: 5 C or
lower) the A/C system is OK. If the temperature is
higher, the A/C system may be under-filled.
For further information, refer to Air Conditioning
(A/C) System Recovery, Evacuation
and Charging in this section.
Frequent faults and their causes
Should a customer express concern about poor

cooling performance of the A/C system it must be
ensured that the temperature control valve
actuation is OK.
No or poor cooling performance:
- Blockage or restriction in one of the
refrigerant lines or in the dehydrator: By
comparing temperatures at the refrigerant
lines or at the dehydrator, the location of the
blockage or restriction can easily be
identified. The blockage or restriction is
located at the point where the temperature
difference is identified. Note: A
temperature difference in the area of the
fixed orifice tube is normal.Once the
location of the blockage or restriction has
been detected, check the relevant
component and renew if necessary.
Sudden poor cooling performance.
After the compressor has been switched off for
approx. 5 minutes, the cooling performance
returns to normal:
- Fixed orifice tube iced up.
The cause for an iced-up fixed orifice tube is
moisture in the system. In order to ensure
that moisture is completely removed from
the refrigerant circuit, evacuation time must
be extended to 2-3 hours and the dehydrator
must be renewed. For further information,
REFER to Air Conditioning (A/C) System
Recovery, Evacuation and Charging in this
section.
Symptom Chart
Symptom
Possible Sources
Blower motor faulty / inoperative Fuse(s)

Circuit(s)
Blower motor
Blower switch
Blower resistor assembly
G115900 en
Action
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412-00-5

Symptom
Possible Sources
Action
Blower motor running continuously
Circuit(s)
Blower switch
Blower resistor assembly
Air conditioning inoperative

(blower motor function OK)
Fuse(s)
Circuit(s)
A/C clutch diode
Air conditioning clutch relay
Refrigerant low-pressure switch
Refrigerant high-pressure switch
Air conditioning control panel
(PCM)
Refrigerant circuit
Refrigerant quantity
Air conditioning operating continuously
Circuit(s)
(PCM)
Refrigerant low-pressure switch
Refrigerant high-pressure switch
Recirculated air flaps inoperative Circuit(s)

GO to Pinpoint Test E
(air conditioning function OK)
Recirculated air flaps
Operating cables for recirculated
air flaps
Recirculated air flap actuator
Condensation water from the air Outlet line
conditioning system in the foot- Rubber grommet
well
CHECK condition of the outlet

line and the rubber grommet and
REPAIR if necessary.
System Checks
PINPOINT TEST A: BLOWER MOTOR FAULTY / INOPERATIVE
TEST CONDITIONS
A1: CHECK ALL SPEED SETTINGS OF THE BLOWER MOTOR
2 Switch the blower switch through all speed settings.
Is the blower motor inoperative in all the switch
positions?
Yes
GO to A2
No
- The blower motor is inoperative in switch
positions 1, 2 and/or 3:
GO to A9
G115900 en
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TEST CONDITIONS
- The blower motor is only inoperative in
switch position 4:
GO to A8
A2: CHECK FUSE F49

2 CHECK fuse F49 (CJB).
Is the fuse OK?
Yes
GO to A3
No
INSTALL A NEW fuse F49 (30 A).
If the fuse blows again, LOCATE and
REPAIR the short using the Wiring Diagrams.
A3: CHECK THE VOLTAGE AT FUSE F49
1 Connect fuse F49 (CJB).
3 Measure the voltage between fuse F49 (30 A)
and ground.
Does the meter display battery voltage?
Yes
GO to A4
No
REPAIR the voltage supply to fuse F49 using
the Wiring Diagrams.
A4: CHECK VOLTAGE AT THE BLOWER MOTOR
1
2
3
4
Ignition switch in position 0.

Disconnect connector C322 from blower motor.
Ignition switch in position II.
Measure the voltage between the blower motor,
connector C322, pin 1, circuit 15-FA18
(GN/OG), wiring harness side and ground.

Yes
GO to A5
No
G115900 en
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TEST CONDITIONS
LOCATE and REPAIR break in circuit
15-FA18 (GN/OG), between blower motor
and fuse F49 using the Wiring Diagrams.
A5: CHECK GROUND CONNECTION OF BLOWER MOTOR
2 Set the blower switch to position 4.
3 Measure the resistance between the blower
motor, connector C322, pin 2, circuit 31S-FA18
(BK/RD), wiring harness side and ground.
Is a resistance of less than 2 Ohm registered?

Yes
RENEW the blower motor.
No
GO to A6
A6: CHECK CIRCUIT BETWEEN THE BLOWER MOTOR AND THE BLOWER SWITCH FOR OPEN
CIRCUIT
1 Disconnect connector C324 from blower switch.
(BK/RD), wiring harness side and the blower
switch, connector C324, pin 1, circuit 31S-FA33
(BK/OG), wiring harness side.

Yes
GO to A7
No
G115900 en
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TEST CONDITIONS
LOCATE and REPAIR the break in circuit
31S-FA18 (BK/RD) between the blower
motor and soldered connection S269 using
A7: CHECK THE GROUND CONNECTION OF THE BLOWER SWITCH
switch, connector C324, pin 3, circuit 31-FA25
(BK), wiring harness side and ground.

Yes
INSTALL A NEW blower switch.
No
LOCATE and RECTIFY the break in circuit
31-FA25 (BK) between the blower switch and
ground connection G30 using the Wiring
Diagrams. CHECK the operation of the system.
A8: CHECK CIRCUIT BETWEEN THE BLOWER MOTOR AND THE BLOWER SWITCH FOR OPEN
CIRCUIT
1
2
3
4

Disconnect connector C324 from blower switch.
Disconnect connector C322 from blower motor.
Measure the resistance between the blower
(BK/RD), wiring harness side and the blower
switch, connector C324, pin 1, circuit 31S-FA33

Yes
G115900 en
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TEST CONDITIONS
No
31S-FA33 (BK/OG) between soldered connection S269 and the blower switch using the
Wiring Diagrams. CHECK the operation of
the system.
A9: CHECK VOLTAGE AT BLOWER RESISTOR ASSEMBLY
2 Disconnect connector C323 from blower resistor assembly.
5 Measure the voltage between the blower resistor, connector C323, pin 4, circuit 31S-FA1
(BK/BU), wiring harness side and ground.

Yes
GO to A10
No
31S-FA1 (BK/BU) between soldered connection S269 and the blower resistor assembly using the Wiring Diagrams.
A10: CHECK THE GROUND CONNECTION OF BLOWER RESISTOR ASSEMBLY - STAGE 1
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TEST CONDITIONS
resistor, connector C323, pin 2, circuit
31S-FA30 (BK/WH) and ground.

Yes
GO to A12
No
GO to A11
A11: CHECK CIRCUIT BETWEEN THE BLOWER RESISTOR ASSEMBLY AND THE BLOWER
SWITCH FOR OPEN CIRCUIT
resistor assembly, connector C323, pin 2, circuit
31S-FA30 (BK/WH), wiring harness side and
the blower switch, connector C324, pin 4, circuit
31S-FA30 (BK/WH), wiring harness side.

Yes
No
31S-FA30 (BK/WH) between the blower resistor assembly and the blower switch using
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412-00-11

TEST CONDITIONS
31S-FA31 (BK/YE) and ground.

Yes
GO to A14
No
GO to A13
31S-FA31 (BK/YE), wiring harness side and the
blower switch, connector C324, pin 2, circuit
31S-FA31 (BK/YE), wiring harness side.

Yes
No
31S-FA31 (BK/YE) between the blower resistor assembly and the blower switch using
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TEST CONDITIONS
31S-FA32 (BK/BU) and ground.

Yes
RENEW the blower resistor assembly.
No
GO to A15
31S-FA32 (BK/BU), wiring harness side and the
blower switch, connector C324, pin 6, circuit
31S-FA32 (BK/BU), wiring harness side.

Yes
No
31S-FA32 (BK/BU) between the blower resistor assembly and the blower switch using
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PINPOINT TEST B: BLOWER MOTOR RUNNING CONTINUOUSLY
TEST CONDITIONS
B1: CHECK BLOWER SWITCH

1
2
3
4

Disconnect connector C324 from blower switch.
Check function of blower motor.
Does the blower motor run continuously?

Yes
GO to B2
No
B2: CHECK CIRCUITS AT BLOWER RESISTOR ASSEMBLY
2 Disconnect connector C323 from blower resistor assembly.
4 Check function of blower motor.
Does the blower motor run continuously?
Yes
CHECK all circuits that are connected to
soldered connection S269 for a short to
ground using the Wiring Diagrams and
RECTIFY any short circuit(s) found.
No
CHECK all circuits between the blower resistor and the blower switch for a short to
ground using the Wiring Diagrams and
RECTIFY any short circuit(s) found.
PINPOINT TEST C: AIR CONDITIONING INOPERATIVE (BLOWER MOTOR FUNCTION OK)
TEST CONDITIONS
C1:CHECK FUSE F4
Is the fuse OK?
Yes
GO to C2
No
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TEST CONDITIONS
REPAIR the short using the Wiring
Diagrams.
- All except vehicles with diesel engines:
In addition, CHECK and if necessary
RENEW the air conditioning clutch diode.
C2: CHECK THE VOLTAGE AT FUSE F4

and ground.
Yes
GO to C3
No
C3: CHECK FUSE F12
Is the fuse OK?
Yes
GO to C4
No
and ground.
Yes
GO to C5
No
C5: CHECK FUSE F38
Is the fuse OK?
Yes
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TEST CONDITIONS
GO to C6
No
INSTALL A NEW fuse F38 (7.5 A).

3 Measure the voltage between fuse F38 (7.5 A)
and ground.
Yes
GO to C7
No
C7: CHECK THE VOLTAGE AT THE AIR CONDITIONING CLUTCH RELAY
2 Disconnect air conditioning clutch relay from
socket C403 (relay box, engine compartment).
3 Measure the voltage between the air conditioning clutch relay, socket C403, pin 3, circuit
29-FA12 (OG/BU), wiring harness side and
ground.

Yes
GO to C8
No
29-FA12 (OG/BU) between the air conditioning clutch relay and fuse F4 using the
the system.
C8: CHECK THE CONTROL VOLTAGE AT THE AIR CONDITIONING CLUTCH RELAY
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TEST CONDITIONS
15S-FA11 (GN/YE), wiring harness side and
ground.

Yes
GO to C9
No
15S-FA11 (GN/YE) between the air conditioning clutch relay and soldered connection
S110 using the Wiring Diagrams.
C9: CHECK THE AIR CONDITIONING CLUTCH CIRCUIT
2 Use a fused test cable (10 A) to bridge the air
conditioning clutch relay, socket C403, pin 3
and pin 5, wiring harness side.
Does the air conditioning clutch work?

Yes
GO to C12
No
GO to C10
C10: CHECK FOR OPEN CIRCUIT BETWEEN AIR CONDITIONING CLUTCH RELAY AND AIR
CONDITIONING CLUTCH
1 Disconnect connector C401 from air conditioning clutch.
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TEST CONDITIONS
2 Measure the resistance between the air conditioning clutch relay, socket C403, pin 5, circuit
15S-FA1 (GN/BU) (vehicles with diesel engine:
15S-FA6 (GN/YE)), wiring harness side and air
conditioning clutch, connector C401, pin 1, circuit 15S-FA6 (GN/YE), wiring harness side.

Yes
GO to C11
No
LOCATE and REPAIR the open circuit between the air conditioning clutch relay and air
conditioning clutch using the Wiring Diagrams. CHECK the operation of the system.
C11: CHECK GROUND CONNECTION OF THE AIR CONDITIONING CLUTCH
1 Measure the resistance between the air conditioning clutch, connector C401, pin 2, circuit
31-FA6 (BK), wiring harness side and ground.

Yes
INSTALL A NEW air conditioning clutch.
No
LOCATE and REPAIR the open circuit between the air conditioning clutch and ground
connection G22 (vehicles with diesel engine:
ground connection G24) using the Wiring
C12: CHECK THE GROUND CONNECTION OF THE AIR CONDITIONING CLUTCH RELAY
2 Run the engine at idle speed.
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TEST CONDITIONS
3 Switch on the blower.
4 Switch on the air-conditioning system.
CAUTION: It is imperative that a test lamp
with a nominal voltage of 12 V and a
nominal power rating of 1.2 W is used
during the following test.
Otherwise the powertrain control module
(PCM) could be damaged, or the test could
deliver incorrect results.
5 Use a test lamp (12 V, 1.2 W) to check the
voltage at the air conditioning clutch relay,
socket C403, between pin 1 and pin 2, wiring
harness side.
Does the test lamp illuminate?

Yes
RENEW the air conditioning clutch relay.
No
GO to C13
- Vehicles with diesel engine:
GO to C15
C13: CHECK THE A/C REQUEST SIGNAL AT THE PCM
1
2
3
4
5

Disconnect connector C343 from the PCM.
Switch on the blower.
CAUTION: In order to avoid damaging the

vehicle, the measuring device should be
operated in a measuring range up to a
maximum of 200 mA.
6 Measure the current between the PCM, connector C343, pin F22, circuit 31S-FA87
(BK/GN), wiring harness side and battery voltage.
Is a current of more than 8 mA measured?

Yes
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TEST CONDITIONS
GO to C14
No
GO to C17
C14: CHECK FOR OPEN CIRCUIT BETWEEN AIR CONDITIONING CLUTCH RELAY AND PCM
PCM, connector C343, pin M26, circuit
91S-FA11 (BK/YE), wiring harness side.

Yes
CHECK PCM with WDS.
RENEW PCM if necessary.
No
91S-FA11 (BK/YE) between the air conditioning clutch relay and the PCM using the
the system.
C15: CHECK THE A/C REQUEST SIGNAL AT THE PCM
1
2
3
4
5


maximum of 200 mA.
6 Measure the current between the PCM, connector C370, pin A2, circuit 31S-FA87 (BK/GN),
wiring harness side and battery voltage.

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TEST CONDITIONS
Yes
GO to C16
No
GO to C17
C16: CHECK FOR OPEN CIRCUIT BETWEEN AIR CONDITIONING CLUTCH RELAY AND PCM
2 Disconnect connector C372 from the PCM.
PCM, connector C372, pin F4, circuit 91S-FA11
(BK/YE), wiring harness side.

Yes
CHECK PCM with WDS.
No
91S-FA11 (BK/YE) between the air conditioning clutch relay and the PCM using the
the system.
C17: CHECK THE QUANTITY OF REFRIGERANT IN THE SYSTEM
2 Check the quantity of refrigerant in the system.
REFER to Air Conditioning (A/C) System Recovery, Evacuation and Charging in this section.
Is the quantity of refrigerant in the system in
accordance with the manufacturer's specifications?
Yes
GO to C18
No
FILL the system with the correct quantity of
refrigerant. REFER to Air Conditioning (A/C)
System Recovery, Evacuation and Charging
in this section. CHECK the system function.
C18: CHECK THE A/C REQUEST SIGNAL AT THE REFRIGERANT HIGH-PRESSURE SWITCH
1 Disconnect connector C405 from refrigerant
high-pressure switch.
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TEST CONDITIONS
maximum of 200 mA.
5 Measure the current between the refrigerant
high-pressure switch, connector C405, pin 4,
circuit 31S-FA17A (BK/RD), wiring harness side
and battery voltage.

Yes
GO to C19
No
GO to C20
C19: CHECK REFRIGERANT HIGH-PRESSURE SWITCH
2 Measure the resistance at the refrigerant
high-pressure switch, connector C405, between
pin 1 and pin 4, component side.

Yes
31S-FA87 (BK/GN) between the PCM and
the refrigerant high-pressure switch using the
the system.
No
RENEW the refrigerant high-pressure switch.
C20: CHECK THE A/C REQUEST SIGNAL AT THE REFRIGERANT LOW-PRESSURE SWITCH
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TEST CONDITIONS
low-pressure switch.
maximum of 200 mA.
6 Measure the current between the refrigerant
low-pressure switch, connector C402, pin 1,
circuit 31S-FA17 (BK/RD), wiring harness side
and battery voltage.

Yes
GO to C21
No
GO to C22
C21: CHECK REFRIGERANT LOW-PRESSURE SWITCH
2 Measure the resistance at the refrigerant
low-pressure switch, connector C402, between
pin 1 and pin 4, component side.

Yes
31S-FA17A (BK/RD) between the refrigerant
high-pressure switch and the refrigerant
low-pressure switch using the Wiring Diagrams.CHECK the operation of the system.
No
RENEW the refrigerant low-pressure switch.
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TEST CONDITIONS
C22: CHECK CIRCUIT BETWEEN AIR CONDITIONING CONTROL PANEL AND REFRIGERANT
LOW-PRESSURE SWITCH FOR OPEN CIRCUIT
2 Disconnect connector C302 from the air conditioning control pane.
3 Measure the resistance between the air conditioning control panel, connector C302, pin 2,
and the refrigerant low-pressure switch, connector C402, pin 1, circuit 31S-FA17 (BK/RD),
wiring harness side.

Yes
GO to C23
No
31S-FA17 (BK/RD) between the air conditioning control panel and the refrigerant
low-pressure switch using the Wiring Diagrams.CHECK the operation of the system.
C23: CHECK THE VOLTAGE AT THE AIR CONDITIONING CONTROL PANEL
1 Measure the voltage between the air conditioning control panel, connector C302, pin 7,
circuit 29-FA10 (OG/GN), wiring harness side
and ground.

Yes
GO to C24
No
LOCATE and RECTIFY the open circuit
between the air conditioning control panel
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TEST CONDITIONS
C24: CHECK THE VOLTAGE AT THE AIR CONDITIONING CONTROL PANEL

circuit 15-FA90 (GN/BK), wiring harness side
and ground.

Yes
GO to C25
No
LOCATE and RECTIFY the open circuit
between the air conditioning control panel
and soldered connection S266 using the
the system.
C25: CHECK FOR OPEN CIRCUIT BETWEEN THE AIR CONDITIONING CONTROL PANEL AND
THE BLOWER SWITCH
circuit 31S-FA13 (BK/OG), wiring harness side
and ground.

Yes
GO to C26
No
31S-FA13 (BK/OG) between the air conditioning control panel and the blower switch
using the Wiring Diagrams.
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TEST CONDITIONS
C26: CHECK THE GROUND CONNECTION OF THE AIR CONDITIONING CONTROL PANEL
circuit 31-LH27 (BK), wiring harness side and
ground.

Yes
CHECK and if necessary RENEW the air
conditioning control panel.
No
LOCATE and REPAIR the open circuit between the air conditioning control panel and
PINPOINT TEST D: AIR CONDITIONING OPERATING CONTINUOUSLY
TEST CONDITIONS
D1: CHECK AIR CONDITIONING CLUTCH RELAY

2 Disconnect air conditioning clutch relay from
socket C403 (relay box, engine compartment).
4 Run the engine at idle speed.
5 Check operation of air conditioning clutch.
Does the air conditioning clutch work?
Yes
GO to D2
No
GO to D3
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TEST CONDITIONS
D2: CHECK CIRCUIT BETWEEN AIR CONDITIONING CLUTCH RELAY AND AIR CONDITIONING
CLUTCH FOR SHORT TO VOLTAGE
15S-FA1 (GN/BU) (vehicles with diesel engine:
15S-FA6 (GN/YE)), wiring harness side and
ground.
Is a voltage measured?
Yes
LOCATE and REPAIR the short to battery
voltage in the circuit between the air conditioning clutch relay and air conditioning
clutch using the Wiring Diagrams.
No
INSTALL A NEW air conditioning clutch.
D3: CHECK OPERATION OF AIR CONDITIONING CLUTCH RELAY
2 Check the air conditioning clutch relay according to the component check at the end of this
section.
Is the air conditioning clutch relay OK?
Yes
GO to D4
GO to D6
No
RENEW the air conditioning clutch relay.
D4: CHECK THE A/C REQUEST SIGNAL AT THE POWERTRAIN CONTROL MODULE (PCM)
1
2
3
4
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TEST CONDITIONS
maximum of 200 mA.
5 Measure the current between the PCM, connector C343, pin F22, circuit 31S-FA87
(BK/GN), wiring harness side and battery voltage.

Yes
GO to D8
No
GO to D5
D5: CHECK CIRCUIT BETWEEN AIR CONDITIONING CLUTCH RELAY AND PCM FOR SHORT TO
GROUND
91S-FA11 (BK/YE), wiring harness side and
ground.
Is a resistance of more than 10,000 Ohm

measured?
Yes
CHECK PCM with WDS.
No
LOCATE and RECTIFY the short to ground
in circuit 91S-FA11 (BK/YE) between the air
conditioning clutch relay and the PCM using
D6: CHECK THE A/C REQUEST SIGNAL AT THE POWERTRAIN CONTROL MODULE (PCM)
1 Disconnect connector C370 from the PCM
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TEST CONDITIONS
4 Switch off the air conditioning system.
maximum of 200 mA.
5 Measure the current between the PCM, connector C370, pin A2, circuit 31S-FA87 (BK/GN),
wiring harness side and battery voltage.

Yes
GO to D8
No
GO to D7
D7: CHECK CIRCUIT BETWEEN AIR CONDITIONING CLUTCH RELAY AND PCM FOR SHORT TO
GROUND
91S-FA11 (BK/YE), wiring harness side and
ground.

measured?
Yes
CHECK PCM with WDS.
No
in circuit 91S-FA11 (BK/YE) between the air
conditioning clutch relay and the PCM using
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TEST CONDITIONS
D8: CHECK CIRCUIT BETWEEN AIR CONDITIONING CONTROL PANEL AND PCM FOR SHORT
TO GROUND
2 Disconnect connector C302 from the air conditioning control panel.
and ground.

measured?
Yes
No
GO to D9
D9: CHECK CIRCUIT BETWEEN AIR CONDITIONING CONTROL PANEL AND REFRIGERANT
LOW-PRESSURE SWITCH FOR SHORT TO GROUND
low-pressure switch.
and ground.

measured?
Yes
GO to D10
No
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TEST CONDITIONS
LOCATE and REPAIR short to ground in
circuit 31S-FA17 (BK/RD) between the air
conditioning control panel and the refrigerant
low-pressure switch using the Wiring Diagrams. CHECK the operation of the system.
D10: CHECK REFRIGERANT LOW-PRESSURE SWITCH
1 Measure the resistance between the refrigerant
low-pressure switch, C402, pin 1, component
side and ground.

measured?
Yes
GO to D11
No
RENEW the refrigerant low-pressure switch.
D11: CHECK CIRCUIT BETWEEN REFRIGERANT HIGH-PRESSURE SWITCH AND
REFRIGERANT LOW-PRESSURE SWITCH FOR SHORT TO GROUND
high-pressure switch.
2 Measure the resistance between refrigerant
circuit 31S-FA17A (BK/RD), wiring harness side
and ground.

measured?
Yes
GO to D12
No
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TEST CONDITIONS
LOCATE and REPAIR short to ground in
circuit 31S-FA17A (BK/RD) between the refrigerant high-pressure switch and the refrigerant low-pressure switch using the Wiring Diagrams. CHECK the operation of the
system.
D12: CHECK CIRCUIT BETWEEN REFRIGERANT HIGH-PRESSURE SWITCH AND
REFRIGERANT LOW-PRESSURE SWITCH FOR SHORT TO GROUND
1 Measure the resistance between refrigerant
circuit 31S-FA87 (BK/GN), wiring harness side
and ground.

measured?
Yes
RENEW the refrigerant high-pressure switch.
No
in circuit 31S-FA87 (BK/GN) between the
refrigerant high-pressure switch and the
PCM using the Wiring Diagrams.
PINPOINT TEST E: RECIRCULATED AIR FLAPS INOPERATIVE (AIR CONDITIONING FUNCTION
OK)
TEST CONDITIONS
E1: CHECK VOLTAGE AT RECIRCULATED AIR FLAP ACTUATOR

2 Disconnect connector C611 from recirculated
air flap actuator.
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TEST CONDITIONS
4 Measure the voltage at the recirculated air flap
actuator, connector C611, between pin 4, circuit
15S-FA76 (GN/RD) and pin 2, circuit 31S-FA76
5 Actuate the recirculated air switch several times

during the measurement.
Is a voltage of more than 10 V measured with
alternating polarity?
Yes
CHECK the mountings and the operation of
the recirculated air flaps and recirculated air
flap actuation cables. If the recirculated air
flaps and the recirculated air flap actuation
cables are OK, RENEW the recirculated air
flap actuator. CHECK the operation of the
system.
No
GO to E2
E2: CHECK FOR OPEN CIRCUIT BETWEEN RECIRCULATED AIR FLAP ACTUATOR AND AIR
CONDITIONING CONTROL PANEL
2 Disconnect connector C302 from the air conditioning control panel.
and the recirculated air flap actuator, connector
C611, pin 2, circuit 31S-FA76 (BK/OG), wiring
harness side.

Yes
GO to E3
No
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TEST CONDITIONS
31S-FA76 (BK/OG) between the air conditioning control panel and the recirculated air
flap actuator using the Wiring Diagrams.
E3: CHECK FOR OPEN CIRCUIT BETWEEN RECIRCULATED AIR FLAP ACTUATOR AND AIR
CONDITIONING CONTROL PANEL
circuit 15S-FA76 (GN/RD), wiring harness side
and the recirculated air flap actuator, connector
C611, pin 4, circuit 15S-FA76 (GN/RD), wiring
harness side.

Yes
GO to E4
No
15S-FA76 (GN/RD) between the air conditioning control panel and the recirculated air
E4: CHECK CIRCUIT BETWEEN RECIRCULATED AIR FLAP ACTUATOR AND AIR
CONDITIONING CONTROL PANEL FOR SHORT TO VOLTAGE
and ground.
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TEST CONDITIONS
and ground.
Is a voltage measured during any of these

measurements?
Yes
LOCATE and RECTIFY the short to voltage
supply in the relevant circuit between the air
conditioning control panel and the recirculated air flap actuator using the Wiring Diagrams. CHECK the operation of the system.
No
GO to E5
E5: CHECK CIRCUITS BETWEEN RECIRCULATED AIR FLAP ACTUATOR AND AIR
CONDITIONING CONTROL PANEL FOR SHORT TO GROUND
and ground.
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TEST CONDITIONS
and ground.
Is a resistance greater than 10,000 Ohms

measured in both cases?
Yes
No
in the relevant circuit between the air conditioning control panel and the recirculated air
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Component Tests
1. Check the normally open contact in the

unswitched state:
Measure the resistance at the air
conditioning clutch relay, between pin 3 and
pin 5, component side.
measured?
If yes, go to 2.
If no, RENEW the air conditioning clutch
relay.
G115900 en

switched state:
Use a fused test cable (1 A) to connect pin 1
of the air conditioning clutch relay,
component side, to the battery positive
terminal.
Use a test cable to connect pin 2 of the air
conditioning clutch relay, component side,
to the battery negative terminal.
Measure the resistance at the air
conditioning clutch relay, between pin 3 and
Is a resistance of less than 2 Ohm
registered?
If yes, then the air conditioning clutch
relay is OK.
If no, RENEW the air conditioning clutch
relay.
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GENERAL PROCEDURES
Air Conditioning (A/C) Clutch Air Gap Adjustment (34 628 6)
Name
Specification
Spacer washer set

1. Measurement for recessed pulley
Check the air gap A between the drive plate
and the pulley at 60 degree intervals
around the circumferance of the pulley,
while operating the A/C clutch several
times by means of a 5A fused jumper wire
connected between the battery positive
terminal, A/C clutch and battery ground.
1. Belt pulley
2. Drive plate
Air gap A (the difference measured between
the A/C clutch engaged and disengaged)
2. Measurement for non recessed pulley

Check the air gap A between the drive plate
and the pulley at 60 degrees intervals
around the circumference. For additional
section.
1. Belt pulley
2. Spacer washer
3. Drive plate
Air gap A
3. Remove the drive plate.
4. Correct air gap A as necessary using

spacer washers.
5. Install the drive plate. For additional
section.
6. Check air gap A as described in step 1 or
step 2. Repeat steps 3-5 if necessary.
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GENERAL PROCEDURES
Air Conditioning (A/C) System Recovery, Evacuation and Charging (34 620 2)
General Equipment
Refrigerant centre
Refrigerant analyzer
1. NOTE: This step is not necessary for vehicles
equipped with the 1.6L Duratorq-TDCi (DV)
diesel engine.
Remove the right-hand headlamp. For
2.
CAUTION: The refrigerant analyzer

must be used before recovery,
otherwise the refrigerant centre may
become contaminated. Contaminated
refrigerant must be disposed of as
hazardous waste. Always follow the
manufacturer's instructions when
using the refrigerant centre and the
refrigerant analyzer.
NOTE: All vehicles except those with the 1.6L
CAUTION: The refrigerant analyzer

must be used before recovery,
otherwise the refrigerant center may
hazardous waste. Always follow the
manufacturer's instructions when
using the refrigerant center and the
refrigerant analyzer.
NOTE: Vehicles with the 1.6L Duratorq-TDCi (DV)
diesel engine
3.
Unscrew and remove the protective caps

from the A/C charging connections.
1. Low-pressure connection
2. High-pressure connection
Unscrew and remove the protective caps

from the A/C charging connections.
1. Low-pressure connection
2. High-pressure connection
4. Pull back the catches of the quick-fit unions on the refrigerant centre lines.
5. NOTE: Larger inner diameter for high-pressure

side. Smaller inner diameter for low-pressure
side.
Connect the refrigerant centre lines to the
A/C charging connections.
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6.
WARNING: When recovering the

refrigerant do not allow it to enter the
atmosphere under any circumstances.
Failure to follow these instructions
NOTE: When removing components of the air
conditioning system, calculate the residual
quantity of refrigerant oil. For additional
information, refer to Refrigerant Oil Adding in this
section.
CAUTION: The air conditioning system

must always be evacuated before
charging. Failure to observe this
instruction can cause damage to the A/C
system.
Recover the refrigerant from the A/C

system via the low-pressure connection in
accordance with the refrigerant centre
7.
CAUTION: The A/C system must be

evacuated for about 30 minutes before
recharging, to ensure that it operates
correctly.
CAUTION: If moisture was able to enter an
open system over an extended period
(several hours), install a new
accumulator/dehydrator and increase the
evacuation time to 2-3 hours.
Evacuate the A/C system according to the

refrigerant centre manufacturer's
instructions.
8. NOTE: If an air conditioning system that was
filled with refrigerant is being evacuated, some
refrigerant will still be in the refrigerant oil in the
compressor. This remaining refrigerant may
evaporate, causing a slight increase in
pressure during the leak test. The system is
leak-free provided, that this pressure increase
does not exceed 20 mbar (2 kPa, 0.29 psi).
Perform the leak test.
1. For the leak test, close the hand valves on
the pressure gauge set, switch off the
refrigerant centre vacuum pump and
observe the low pressure gauge.
2. Locate any leaks in the A/C refrigerant
circuit using a leak tester. For additional
information, refer to Fluorescent Dye Leak
Detection/ Electronic Leak Detection in this
section.
9. Top up with refrigerant oil. For additional
information, refer to Refrigerant Oil Adding
in this section.
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10. NOTE: Depending on the type of refrigerant
centre and the equipment (with or without
heated filling cylinder), the air conditioning
system is either charged with liquid via the
high-pressure connection or with gas through
the low-pressure connection.
NOTE: Charge quantity on sticker in engine
compartment.
Install the right-hand headlamp. For

Charging the A/C system (with liquid) via

the high-pressure connection.
1. Open the shut-off valve on the
high-pressure side.
2. Switch the refrigerant centre to "Fill" mode
and fill with the prescribed quantity of liquid
refrigerant (R134a).
11.
CAUTION: Only gaseous charging of

the air conditioning system is
performed via the low-pressure
connection. Failure to follow these
instructions may cause damage to the
compressor.
Charging the A/C system via the
low-pressure connection.
1. Open the shut-off valve on the low-pressure
side.
2. Switch the refrigerant centre to "Fill" mode
and charge with gaseous refrigerant.
3. Top up with the remaining amount of
refrigerant whilst the air conditioning is
switched on. For this purpose, run the
engine at approx. 1200-1500 rpm. Switch
the air conditioning to maximum cooling
power and fresh air mode. Set the blower to
maximum speed. Fill with the remainder of
the prescribed fill capacity.
12.
WARNING: Do not detach the

high-pressure hose when the air
conditioning is switched on. Failure to
personal injury.
Disconnecting the refrigerant centre.

1. Close the shut-off valves.
2. Switch off the refrigerant centre.
3. Disconnect the service unit line from the
A/C charging connection.
4. Attach the protective caps to the filling
valves.
13. NOTE: This step is not necessary for vehicles
equipped with the 1.6L Duratorq-TDCi (DV)
diesel engine.
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GENERAL PROCEDURES
Refrigerant Oil Adding (34 621 1)
CAUTION: Store the refrigerant oil in a

closed, sealed container to prevent the
ingress of moisture.
NOTE: Collect the refrigerant oil in a clean
measuring cylinder when replacing the A/C
compressor, the suction accumulator or
refrigerant lines.
1. NOTE: This step only needs to be carried out
when removing the A/C compressor.
Drain the refrigerant oil from the A/C
compressor.
Rotate the compressor shaft at least 6 to 8
turns when draining the refrigerant oil.
when removing the suction accumulator.
Drain the refrigerant oil from the suction
accumulator.
when removing refrigerant lines.
Drain the refrigerant oil from the refrigerant
lines.
4. NOTE: If more than one air conditioning system
component is being renewed, the oil quantity to
be added is the sum of each individual quantity.
NOTE: In addition, add the same quantity of new
refrigerant oil as was collected in the oil separator
of the servicing unit when the air conditioning was
drained.
Add the calculated quantity of new
refrigerant oil. For additional information,
see Specifications in this subsection.
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GENERAL PROCEDURES
Air Distribution System Cleaning
General Equipment
Spray gun with hose
Name
Specification
Odour eliminating
agent (240 ml) (TOX
Number 142040)
All vehicles
WARNING: Avoid contact with eyes and
skin; wear gloves and respiratory
protection. Ensure that you perform
this operation in a well ventilated room.
Keep all vehicle doors and windows
open for the duration of the operation.
Do not inhale vapors under any
circumstances. Do not smoke and
avoid open fire and unprotected light
sources. Avoid contact with eyes and
skin; wear gloves and respiratory
protection. Ensure that you perform
this operation in a well ventilated room.
Keep all vehicle doors and windows
open for the duration of the operation.
Do not inhale vapors under any
circumstances. Do not smoke and
avoid open fire and unprotected light
sources. Failure to observe this
instruction can lead to injuries.
NOTE: The odour eliminating agent can remove
deposits in the heater housing but cannot prevent
odours that are distributed by the ventilation
system, for example those caused by damp
carpets.
1.
Precisely locate the musty or damp odour.

2. Disconnect the low pressure switch
connector.
3. Turn on the ignition.
4. Open all ventilation nozzles.
5. Set the temperature control to maximum
heating power.
6. Set the blower motor control switch to the
highest setting.
7. Set the air distribution control to the fresh
air position.
8. Start the engine and let it warm up to
operating temperature.
G21704 en
9. To dry out the system, switch off the air

conditioning system and ventilate the
vehicle for approx. 15 minutes.
Only Focus to MY 2004.75 and Galaxy
11. Remove the blower motor.
Only Ka, Fiesta 96 to MY 2002.25 and Puma
12. Remove the blower motor resistor
Only Fiesta from MY 2002.25, Focus C-Max and
Focus from MY 2004.75 with pollen filter
13. Remove the pollen filter.
Only Fiesta from MY 2002.25, Focus C-Max and
Focus from MY 2004.75 without pollen filter
14. Remove the pollen filter housing cover.
All vehicles
15. Fill the spray gun with the odour
eliminating agent (240 ml).
16.
WARNING: The maximum pressure of

13.5 bar must not be exceeded. Failure
to observe this instruction can lead to
injuries.
Use the tyre inflator to apply pressure of

5.5 to 10 bar (operating pressure) to the
spray gun.
17. Insert the hose of the spray gun as far as
possible into the opening created by
removal of the above component and
point it in the direction of the evaporator.
18. By moving the hose, spray the odour
eliminating agent over the entire surface
of the evaporator.
19. Spray all of the odour eliminating agent
into the opening.
Allow the odour eliminating agent to take
effect for 10 minutes.
20. Install the components in reverse order.
21. Start the engine, switch off the air
conditioning system and ventilate the
vehicle for approx. 15 minutes.
22. Open all ventilation nozzles.
23. Set the temperature control to maximum
heating power.
24. Set the blower motor control switch to the
highest setting.
25. Set the air distribution control to the fresh
air position.
11/2004 2005.25 Fiesta
412-00-43

TO MODEL INDEX
412-00-43

27. Connect the low pressure switch
connector.
28. Ventilate the vehicle with the doors open
for another 30 minutes.
G21704 en
11/2004 2005.25 Fiesta
412-00-44

TO MODEL INDEX
412-00-44
GENERAL PROCEDURES
Contaminated Refrigerant Handling (34 620 9)
CAUTION: Any R134a or R12 refrigerant

which is contaminated with unsuitable
refrigerant should be extracted only by
means of a suitable servicing unit
designed for the purpose of collecting
and storing contaminated refrigerant, so
that the spread to other vehicles can be
prevented.
1. Use refrigerant identification equipment to
check that there is contaminated
refrigerant in the air conditioning system.
2. Inform the customer about the additional
cost to repairing the system caused by the
contamination.
3. Extract the contaminated refrigerant.
G18273 en
11/2004 2005.25 Fiesta
412-00-45

TO MODEL INDEX
412-00-45
GENERAL PROCEDURES
Spring Lock Coupling
1. NOTE: Select special tool to suit the line
diameter.
Fit the special tool.
Fit the special tool so that the inner collar
can be guided into the clamping spring.
2. Press the special tool into the clamping

spring.
4. Connect the refrigerant line.

Check the clamping spring for damage.
Carefully pull out any damaged clamping
springs using a thin piece of wire and install
new one.
5. NOTE: Clean the connections using refrigerant

oil and a lint-free cloth.
Press the indicator ring into the clamping
spring.
3. Disconnect the refrigerant line.

G18266 en
11/2004 2005.25 Fiesta
412-00-46

TO MODEL INDEX
412-00-46

6. NOTE: Install new refrigerant line O-ring seals.
NOTE: Coat the refrigerant line O-ring seals in
clean refrigerant oil prior to installation.
Connect the refrigerant lines.
Check that the clamping spring engages
correctly.
G18266 en
11/2004 2005.25 Fiesta
412-00-47

TO MODEL INDEX
412-00-47
GENERAL PROCEDURES
Electronic Leak Detection (34 620 7)
General Equipment
Automatic Calibration Halogen Leak Detector
Manifold Gauge Set
Refrigerant Identifier
WARNING: Good ventilation before leak

detection is necessary in the area where
it is to be performed. If the surrounding
air is contaminated with refrigerant gas,
the leak detector will indicate this gas all
the time. Odors from other chemicals
such as antifreeze, diesel fuel, disc brake
cleaner, or other cleaning solvents can
cause the same problem. While leak
detection air movement must be
prevented.
1.
CAUTION: The refrigerant identification

equipment must be used before the
manifold gauge set is installed,
otherwise the manifold gauge may
special waste. The manufacturer's
instructions must be followed when
working with the service unit.
NOTE: Both manifold gauges should indicate
4,1-5,5 bar at 24C with the engine off.
Attach the manifold gauge set to the
service gauge port valves.
1. For the leak test, close the manual valves
on the gauge set.
2. If little or no pressure is indicated, charge
the system with approx. 300g of refrigerant.
2. Use R-134a Automatic Calibration Halogen
Leak Detector to leak test the refrigerant
system. Follow the instructions included
with leak detector for handling and
operation techniques.
3. If a leak is found, recover the A/C system.
G18270 en
11/2004 2005.25 Fiesta
412-00-48

TO MODEL INDEX
412-00-48
GENERAL PROCEDURES
Fluorescent Dye Leak Detection
General Equipment
UV Spot Lamp
Manifold Gauge Set
Fluorescent Dye Injector
NOTE: Vehicles built 07/1999 onwards have a
fluorescent tracer dye tablet inserted into the air
conditioning (A/C) system. If tracer dye is present,
there is a green cross on the suction accumulator.
NOTE: On vehicles built up to 07/1999 tracer dye
must be added.
1. Using the dye injector, add 7.4 ml of
Fluorescent Tracer Dye.
NOTE: Some vehicles may have signs of
refrigerant oil at the spring lock couplers. This may
be caused from the assembly process which
applies to the fittings before installation to aid in
assembly. When a spring lock coupler is
suspected of leaking, always wipe the fitting clean
and verify the leak with R-134a Automatic
Calibration Halogen Leak Detector.
NOTE: The exact location of leaks can be
pinpointed by the bright yellow - green glow of the
tracer dye. Since more than one leak may exist,
always inspect each component.
2. Check for leaks using a 120 Watt UV Spot
Lamp. Always scan all components,
fittings and lines of the A/C system.
3. After the leak is found and repaired,
remove any traces of dye with a general
purpose oil solvent.
4. Verify the repair by operating the system
for some minutes and inspecting with the
UV lamp again.
G18269 en
11/2004 2005.25 Fiesta
412-00-49

TO MODEL INDEX
412-00-49
GENERAL PROCEDURES
Vacuum Leak Detection (34 620 3)
1. Drain the air conditioning (A/C) system. For
additional information, refer to Air Conditioning
(A/C) System Recovery, Evacuation and
Charging in this section.
G18275 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
412-01-1
Air Distribution and Filtering
412-01-1
SECTION 412-01 Air Distribution and Filtering

CONTENTS
PAGE

Air Distribution...................................................................................................................
Pollen filter .......................................................................................................................
412-01-2
412-01-2

Air Distribution and Filtering ..............................................................................................
412-01-3

Pollen Filter................................................................................................... (34 350 0)
412-01-4
11/2004 2005.25 Fiesta
412-01-2

TO MODEL INDEX
412-01-2

Air Distribution
Pollen filter
The purpose of the pollen filter is to remove

particles which are 0,003 mm or larger from the air
taken in.
If installed, it is located in the heat
exchanger/evaporator housing.
It is accessible from the left-hand footwell.
The pollen filter must be renewed in accordance
with the service intervals.
G179066 en
11/2004 2005.25 Fiesta
412-01-3

TO MODEL INDEX
412-01-3

G21711 en
11/2004 2005.25 Fiesta
412-01-4

TO MODEL INDEX
412-01-4

Pollen Filter (34 350 0)
Removal
All vehicles
1. Detach the centre console side trim on the
left-hand side.

2. Detach the accelerator pedal with its
bracket from the bulkhead and lay it to one
side (vehicle with petrol engine shown).
4. Remove the pollen filter.
Installation
1. Reinstall the components in reverse order.
All vehicles
G98893 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
412-02-1
Heating and Ventilation
412-02-1
SECTION 412-02 Heating and Ventilation

CONTENTS
PAGE
SPECIFICATIONS
Specifications....................................................................................................................
412-02-2

Heating and Ventilation .....................................................................................................
Heater core / evaporator housing .....................................................................................
412-02-3
412-02-3

Heating and Ventilation .....................................................................................................
412-02-6

Blower Motor................................................................................................. (34 374 0)
Heater Core .................................................................................................. (34 364 0)
Heater Core and Evaporator Core Housing.......................................................................
412-02-7
412-02-9
412-02-10

Heater Core and Evaporator Core Housing.......................................................................
412-02-22
11/2004 2005.25 Fiesta
412-02-2

TO MODEL INDEX
412-02-2
SPECIFICATIONS
Description
Bolts, reinforcing element
Bolts, heater core / evaporator housing to reinforcing element
Nut, heater core / evaporator housing
G105771 en
Nm
20
5
lb/ft
15
-
lb/in
44
11/2004 2005.25 Fiesta

TO MODEL INDEX
412-02-3
412-02-3

Heater core / evaporator housing
Overview
Item
Part
Number
G207061 en
Description
Air distribution flap
11/2004 2005.25 Fiesta
412-02-4

TO MODEL INDEX
412-02-4

Item
Part
Number
Description
Blower motor
Pollen filter (optional)
Evaporator (only vehicles

with Air Conditioning (A/C))
Heat exchanger
Electric additional heater

(only for vehicles with a diesel engine)
Temperature control flap
Cold air distribution
Item
Part
Number
Cold air to the nozzles
Cold air to the footwell
Air sucked in
Air flow
G207061 en
Description
11/2004 2005.25 Fiesta

TO MODEL INDEX
412-02-5
412-02-5
Warm air distribution
Item
Part
Number
Warm air to the nozzles
Warm air to the footwell
Air sucked in
Air flow
G207061 en
Description
11/2004 2005.25 Fiesta
412-02-6

TO MODEL INDEX
412-02-6

G21715 en
11/2004 2005.25 Fiesta
412-02-7

TO MODEL INDEX
412-02-7

Blower Motor (34 374 0)
Removal
1. Remove the glove box.
2. Detach the central junction box from the

bulkhead and lay it to one side (shown
without the crash padding for clarity).
4. Remove the defrost air duct (shown without the crash padding for clarity).
5. Disconnect the blower motor connector

(LHD vehicle shown).
6. Detach the air intake flap actuation cable.

3. Unscrew and remove the bolt from the defrost air duct (shown without the crash
padding for clarity).
G105773 en
11/2004 2005.25 Fiesta
412-02-8

TO MODEL INDEX
412-02-8

7. Remove the air intake flap (shown with the
heater housing removed for clarity).
Installation
G105773 en
11/2004 2005.25 Fiesta
412-02-9

TO MODEL INDEX
412-02-9

Heater Core (34 364 0)
Removal
5. Remove the heater core.
1. Remove the heater core / evaporator

housing. For additional information, refer
to Heater Core and Evaporator Core
2. Remove the bracket for the coolant pipes.
Installation
housing gasket.
4. Remove the heater core cover.
G105774 en
11/2004 2005.25 Fiesta
412-02-10

TO MODEL INDEX
412-02-10

Heater Core and Evaporator Core Housing
Special Tool(s)
Remover, quick-release
coupling 1/2" (blue)
412-027 (34-001)
7. Remove the retaining clips of the

quick-release couplings on the refrigerant
lines.
coupling 5/8" (black)
412-081 (34-003)
Removal
303-03B.
417-01.
3. Drain the air conditioning system. For
412-00.
4. Remove the crash padding. For additional
6. Detach the coolant hoses from the heater
core.
8. Detach the left-hand refrigerant line from

the evaporator using the special tool.
Discard the O-rings.
9. Detach the right-hand refrigerant line from

the evaporator using the special tool.
G98900 en
11/2004 2005.25 Fiesta
412-02-11

TO MODEL INDEX
412-02-11

10. Unscrew and remove the nut from the
heater core / evaporator housing.
13. Remove the ground strap bolt in the

left-hand footwell.
11. Unclip part of the left-hand footwell trim.
14. Disconnect the connector of the generic

electronic module (GEM).
12. Disconnect the left-hand connector of the

fascia/crash padding wiring harness (the
footwell trim is shown removed for clarity).
G98900 en
15. Detach the GEM from the reinforcing

element and lay it to one side.
11/2004 2005.25 Fiesta
412-02-12

TO MODEL INDEX
412-02-12

16. Unclip part of the right-hand footwell trim.
19. Detach the antenna cable from the

right-hand lower clips on the reinforcing
element.
17. Disconnect the right-hand connector of

the fascia/crash padding wiring harness
(the footwell trim is shown removed for
clarity).
20. Detach the antenna cable from the central

clips on the reinforcing element.
18. Detach the antenna cable from the

right-hand upper clip on the reinforcing
element.
21. Disconnect the electrical connectors for

the blower motor, blower motor resistor
and air inlet flap actuator.
G98900 en
11/2004 2005.25 Fiesta
412-02-13

TO MODEL INDEX
412-02-13

22. Disconnect the connector from the airbag
module.
Unclip the wiring harness.
23. Unscrew and remove the ground cable

bolt from the airbag module.
24. Disconnect the electrical connector of the

handbrake warning lamp switch.
G98900 en
25. Remove the bolts of the windshield air

duct (left-hand side shown).
26. Remove the windshield air ducts

27. Mark the position of the reinforcing element relative to the A-pillars (left-hand
side shown).
11/2004 2005.25 Fiesta
412-02-14

TO MODEL INDEX
412-02-14

28. Remove the A-pillar outer trims (left-hand
side shown).
31. Remove the upper bolts of the heater core

/ evaporator housing.
29. Remove the caps (left side shown).
32. Remove the side bolts from the heater

core / evaporator housing (left side
shown).
30. Remove the reinforcing element side

bolts.
33. Remove the reinforcing element lower
bolts.
G98900 en
11/2004 2005.25 Fiesta
412-02-15

TO MODEL INDEX
412-02-15
34. Remove the reinforcing element upper

bolts.
36.
WARNING: Before performing any

work on the electrical booster heater,
make certain that the surface of its
heating element has cooled to ambient
temperature. Failure to observe this
instruction can lead to injury.
Detach the electrical booster heater from
the heater core / evaporator housing and
lay it to one side.
35. Remove the reinforcing element.

1. Lift the reinforcing element.
2. Pull the reinforcing element rearwards.
37.
CAUTION: Make sure that the water

drain tube is not damaged when laying
down the housing.
Remove the heater core / evaporator
housing.
Installation
1.
CAUTION: Ensure that the adjustment

nut for the heater core / evaporator
housing is freely accessible.
Screw on the adjustment nut for the heater
core / evaporator housing (the heater core /
G98900 en
11/2004 2005.25 Fiesta
412-02-16

TO MODEL INDEX
412-02-16

evaporator housing seal is shown removed
for clarity).
1. Tighten the adjustment nut to the stop.
2. Undo the adjustment nut one turn.
3.
CAUTION: Ensure that the rubber

grommet for the wiring harness of the
electrical additional heater is correctly
located in the bulkhead.
Attach the electrical additional heater to
the heater core / evaporator housing.
2.
CAUTION: Make certain that the rubber

grommet of the heater core evaporator
housing water drain tube is correctly
located in the vehicle floor.
Install the heater core / evaporator housing.
4. Install the reinforcing element.

1. Slide the reinforcing element forwards.
2. Lower the reinforcing element.
5. Align the reinforcing element to the

A-pillars (left-hand side shown).
G98900 en
11/2004 2005.25 Fiesta
412-02-17

TO MODEL INDEX
412-02-17

6. Install the upper bolts on the reinforcing
element.
7. Install the lower bolts on the reinforcing

element.
8. Install the side bolts on the heater core /

evaporator housing (left-hand side shown).
G98900 en
9. Install the upper bolts on the heater core /

evaporator housing.
10. Install the side bolts on the reinforcing

element.
11. Install the caps (left-hand side shown).
11/2004 2005.25 Fiesta
412-02-18

TO MODEL INDEX
412-02-18

12. Install the outer A-pillar trims (left-hand
side shown).
15. Connect the electrical connector of the

handbrake warning lamp switch.
13. Install the windshield air ducts (left-hand

side shown).
16. Install the ground cable bolt for the airbag

module.
14. Install the bolts of the windshield air

ducts (left-hand side shown).
17. Connect the airbag module connector.

Clip the wiring harness in place.
G98900 en
11/2004 2005.25 Fiesta
412-02-19

TO MODEL INDEX
412-02-19

18. Connect the electrical connectors for the
blower motor, the blower motor resistor
and the air inlet flap actuator.
19. Attach the antenna cable to the middle

clips on the reinforcing element.
20. Attach the antenna cable to the right-hand

lower clips on the reinforcing element.
G98900 en
21. Attach the antenna cable to the right-hand

upper clip on the reinforcing element.
22. Connect the right-hand connector of the

23. Clip the right-hand footwell trim in place.
11/2004 2005.25 Fiesta
412-02-20

TO MODEL INDEX
412-02-20

24. Attach the GEM to the reinforcing element.
27. Connect the left-hand connector of the

25. Connect the GEM connector.

28. Clip the left-hand footwell trim in place.
26. Install the left-hand footwell ground cable

bolt.
29. Install the nut on the heater core /
evaporator housing.
G98900 en
11/2004 2005.25 Fiesta
412-02-21

TO MODEL INDEX
412-02-21

30. NOTE: Coat the refrigerant line O-rings with
clean refrigerant oil before installation.
Connect the right-hand refrigerant line to
the evaporator.
Install new O-rings on the refrigerant lines.
31. NOTE: Coat the refrigerant line O-rings with

Connect the left-hand refrigerant line to
the evaporator.
Install new O-rings on the refrigerant lines.
33. Attach the coolant hoses to the heater

core.

35. Install the fascia/crash padding. For
501-12.
36. Fill the air conditioning system. For
412-00.
37. Install the right-hand headlamp. For
417-01.
303-03A / 303-03B.
32. Install the retaining clips on the

quick-release couplings on the refrigerant
lines.
G98900 en
11/2004 2005.25 Fiesta
412-02-22

TO MODEL INDEX
412-02-22

Heater Core and Evaporator Core Housing
Disassembly
to Heater Core and Evaporator Core
5. Remove the heater core.
6. Detach the air inlet flap operating cables

(right-hand side shown).

housing gasket.
7. Remove the air inlet flaps with the fresh air

ducting (right-hand side shown).
4. Remove the heater core cover.
G98901 en
11/2004 2005.25 Fiesta
412-02-23

TO MODEL INDEX
412-02-23

9. Remove the blower motor resistor
12. Remove the bolts of the heater core /

evaporator lower housing.
10. Remove the air inlet flap actuator motor.

Unclip the operating cables.
G98901 en

lower housing.
11/2004 2005.25 Fiesta
412-02-24

TO MODEL INDEX
412-02-24

17. Separate the heater core / evaporator

housing.
15. Remove the front bolts of the heater core /

evaporator housing.
18. Remove the evaporator.
16. Remove the rear bolts of the heater core /

evaporator housing.
19. Remove the temperature flap and the air

distribution flap.
Assembly
1. Assemble the components in the reverse
order.
G98901 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
412-03-1
Air Conditioning
412-03-1
SECTION 412-03 Air Conditioning

CONTENTS
PAGE
SPECIFICATIONS
Specifications....................................................................................................................
412-03-2

Air Conditioning.................................................................................................................
Overview ..........................................................................................................................
412-03-3
412-03-3

Air Conditioning.................................................................................................................
412-03-5

Clutch and Clutch Field Coil ..........................................................................
Evaporator Core............................................................................................
Evaporator Core Orifice ................................................................................
Low-Pressure Cutoff Switch ..........................................................................
High-Pressure Cutoff Switch .........................................................................
Condenser Core............................................................................................
Suction Accumulator .....................................................................................
Air Conditioning (A/C) Compressor 1.25L Duratec-16V (Sigma)/1.3L
Duratec-8V (Rocam)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V
(Sigma)/2.0L Duratec-HE (MI4)....................................................................
(34 628 0)
(34 622 0)
(34 624 0)
(34 629 0)
(34 631 0)
(34 632 0)
(34 630 0)
(34 626 0)
412-03-6
412-03-8
412-03-11
412-03-14
412-03-15
412-03-16
412-03-18
412-03-20
11/2004 2005.25 Fiesta
412-03-2

TO MODEL INDEX
Air Conditioning
412-03-2
SPECIFICATIONS
A/C compressor
A/C compressor (vehicles with 1.4L Duratorq-TDCi (DV) diesel engine)
A/C compressor (vehicles with 1.6L Duratorq-TDCi (DV) diesel engine)
A/C compressor (vehicles with1.25L Duratec-16V (Sigma)/1.3L Duratec-8V
(Rocam)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) petrol engine)
A/C compressor (vehicles with 2.0L Duratec-HE (MI4) petrol engine)
Type
SD6V12 (Sanden)
SD7V16 (Sanden)
FVS 090
FS 10
Evaporator core orifice

Evaporator core orifice
Evaporator core orifice (vehicles with 1.6L Duratorq-TDCi (DV) diesel engine)
Evaporator core orifice (vehicles with automatic transmission)
Tightening torques
Description
Bolt, refrigerant line to A/C compressor
Bolt, A/C compressor
Bolt, A/C compressor drive plate
High-pressure cutoff switch
Low-pressure cutoff switch
Nut, refrigerant line to condenser
Bolt, accumulator/dehydrator
Nut, accumulator refrigerant line to A/C compressor
G115901 en
Nm
20
20
13
8
2.5
8
8
8
lb.ft
15
15
10
-
Colour/Type
Red/fixed
Blue/fixed
brown/variable
lb.in
71
23
71
71
71
11/2004 2005.25 Fiesta

TO MODEL INDEX
412-03-3
Air Conditioning
412-03-3

Air Conditioning
Overview
1.4L/1.6L Duratec 16V
Part
Number
Description
Compressor
Item
Part
Number
Heat exchanger housing
High pressure connection
Condenser
Dual pressure switch
Accumulator
G207063 en
Description
Item
11/2004 2005.25 Fiesta
412-03-4

TO MODEL INDEX
Air Conditioning
412-03-4

Item
Part
Number
Description
Low pressure connection
Evaporator outlet
Condenser outlet
The location of the components varies slightly

depending on the engine variant.
Vehicles with a petrol engine are equipped with a
performance regulated scroll compressor.
Vehicles with a diesel engine are equipped with a
wobble plate compressor.
G207063 en
11/2004 2005.25 Fiesta
412-03-5

TO MODEL INDEX
Air Conditioning
412-03-5

Air Conditioning
G21730 en
11/2004 2005.25 Fiesta
412-03-6

TO MODEL INDEX
Air Conditioning
412-03-6

Clutch and Clutch Field Coil (34 628 0)
Removal
All vehicles
1. Remove the auxiliary drive belt. For
INSTALLATION, Power Steering Pump Belt
Conditioning] For additional information,
refer to Section 303-05.[Accessory Drive,
Accessory Drive Belt - 2.0L Duratec-HE
(MI4)]
2. Detach the A/C compressor clutch connector.

3. Disconnect the pressure cutoff switch
Unclip the pressure cutoff switch wiring
harness and lay it to the side.
4. Detach the A/C compressor from the engine block, lower it and secure it at the
side.
All vehicles
NOTE: Mark the installation position of the A/C
compressor clutch connector in relation to the
compressor housing.
G105784 en
11/2004 2005.25 Fiesta
412-03-7

TO MODEL INDEX
Air Conditioning
412-03-7

5. Remove the A/C compressor driveplate
(A/C compressor shown removed for clarity).
8. NOTE: Mark the installation position of the A/C

compressor clutch connector in relation to the
compressor housing.
Remove the solenoid coil.
6. NOTE: If necessary, remove a seized A/C

compressor pulley using a suitable remover.
Remove the A/C compressor pulley.
Remove the spacer washers.
Discard the pulley snap ring.
Installation
CAUTION: Do not skew the solenoid coil
when installing in the A/C compressor.
NOTE: Installation position of the A/C compressor
clutch connector in relation to the compressor
housing.
NOTE: Install new snap rings on the A/C
compressor pulley and the solenoid coil.
procedure.
2. Check the A/C clutch air gap. For additional
412-00.[Climate Control System - General
Information, GENERAL PROCEDURES, Air
Conditioning (A/C) Clutch Air Gap
Adjustment]
7. Remove the solenoid coil snap ring.

Discard the solenoid coil snap ring.
G105784 en
11/2004 2005.25 Fiesta
412-03-8

TO MODEL INDEX
Air Conditioning
412-03-8

Evaporator Core (34 622 0)
Removal
to Section 412-02A.

housing gasket.
5. Unclip the operating cable of the left-hand

air inlet flap from the heater core / evaporator housing.
6. Detach the left-hand air inlet flap from the

fresh air duct and lay it to one side.
Remove the fresh air duct.

4. Remove the right-hand bolts of the fresh air
duct.
G105785 en
11/2004 2005.25 Fiesta
412-03-9

TO MODEL INDEX
Air Conditioning
412-03-9

8. Remove the bolts of the heater core /
evaporator lower housing.
11. Remove the front bolts of the heater core /

evaporator housing.
9. Remove the heater core / evaporator lower

housing.
12. Remove the rear bolts of the heater core /

evaporator housing.

13. Separate the heater core / evaporator

housing.
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Air Conditioning
412-03-10

14. Remove the evaporator.
Installation
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412-03-11
Air Conditioning
412-03-11

Evaporator Core Orifice (34 624 0)
Special Tool(s)
coupling 1/2" (blue)
412-027 (34-001)

3. Evacuate the air conditioning (A/C) system.
Conditioning (A/C) System Recovery,
Evacuation and Charging]
4. Remove the retaining clip of the refrigerant
line quick-release coupling.
Remover/Installer, Fixed
Orifice
412-034 (34-004)
Remover, Broken Orifice
412-035 (34-005)
Adapter for 412-034

412-034-01
5.
Removal
RHD vehicles
1. Unclip the condenser to evaporator line
from the side member.
CAUTION: Close off the refrigerant line

and the evaporator to prevent dirt
ingress.
Detach the refrigerant line from the
evaporator.
All vehicles
2. Remove the air cleaner housing. For
Cleaner - 1.25L Duratec-16V (Sigma)/1.4L
(Sigma)] For additional information, refer to
Section 303-12.[Intake Air Distribution and
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Air Conditioning
412-03-12
6.
CAUTION: Close off the refrigerant line

to prevent dirt ingress.
Remove the refrigerant line with the fixed
orifice tube.
Vehicles with manual transmission

7. Using the special tool, remove the fixed
orifice tube.
Hook the special tool into the fixed orifice
tube, turn it clockwise and remove the fixed
orifice tube.
G105786 en
Vehicles with automatic transmission

8. Hook the special tool into the fixed orifice
tube.
1. Insert the special tool with adapter into the
fixed orifice tube.
2. By turning the adapter a quarter turn, hook it
into the fixed orifice tube.
9. Remove the fixed orifice tube.

Turn the special tool, holding the adapter at
the same time.
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Air Conditioning
412-03-13

All vehicles
10. NOTE: This step is only necessary if the fixed
orifice tube is faulty.
Using the special tools, remove the broken fixed orifice tube.
Installation
1. NOTE: Install new refrigerant line O-rings.
NOTE: Coat the refrigerant line O-rings with clean
refrigerant oil before installation.
Install the components in the reverse
order.
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Air Conditioning
412-03-14

Low-Pressure Cutoff Switch (34 629 0)
Removal
2. Disconnect the low pressure switch connector.
Installation
1. NOTE: Install new O-rings on the low pressure
switch.
NOTE: Coat the low pressure switch O-rings with
Reinstall the components in reverse order.
3.
WARNING: Make certain that the valve

of the low pressure switch is
completely closed after removal of the
low pressure switch, to prevent
refrigerant from escaping. Failure to
observe this instruction can lead to
injury.
Remove the low pressure switch.
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Air Conditioning
412-03-15

High-Pressure Cutoff Switch (34 631 0)
Removal
1. Raise the vehicle. For additional
2. Disconnect the high-pressure switch electrical connector.
Installation
1. NOTE: Install new O-rings on the high pressure
switch.
NOTE: Coat the high pressure switch O-rings with
3.
WARNING: Make certain that the valve

of the high pressure switch is
completely closed after removal of the
high pressure switch, to prevent
refrigerant from escaping. Failure to
observe this instruction can lead to
injury.
Remove the high pressure switch.
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Air Conditioning
412-03-16

Condenser Core (34 632 0)
Removal
412-00.
3. Disconnect the radiator fan resistor connector.
4. Disconnect the radiator fan connector.
G105790 en
5. Unclip the radiator fan from the left-hand

clip.
1. Pull back the clip.
2. Press the radiator fan out of the clip.
6. Remove the radiator fan.

1. Pull back the clip.
2. Press the radiator fan out of the clip and
remove it.
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Air Conditioning
412-03-17

7. Remove the radiator bracket bolts
(right-hand side shown).
1. Remove the security bolts.
2. Unscrew the bolts.
8.
CAUTION: Close off the refrigerant

lines and the A/C condenser to prevent
dirt from entering.
Detach the refrigerant lines from the
condenser.
10.
CAUTION: Do not damage the foam

seals of the condenser.
Remove the condenser.
Installation
1.
CAUTION: Do not damage the foam

seals of the condenser.
NOTE: Install new O-rings on the refrigerant lines.
NOTE: Coat the refrigerant line O-rings with clean
refrigerant oil before installation.
9. Detach the radiator and condenser from

the front panel.
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Air Conditioning
412-03-18

Suction Accumulator (34 630 0)
4. Remove the refrigerant line quick release
coupling securing clips.
Special Tool(s)
coupling 3/4" (white)
412-069 (34-002)
Removal
3. Disconnect the low-pressure cutoff switch
G115903 en
5.

lines and the suction accumulator to
prevent contamination.
upper refrigerant line from the suction
accumulator.
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Air Conditioning
412-03-19
6.

lines and the suction accumulator to
lower refrigerant line from the suction
accumulator.
Unclip the refrigerant line.

8. Remove the suction accumulator.
Installation
NOTE: Lubricate the refrigerant line O-ring seals
with clean refrigerant oil before installation.
To install reverse the removal procedure.
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Air Conditioning
412-03-20

Air Conditioning (A/C) Compressor 1.25L Duratec-16V (Sigma)/1.3L Duratec-8V
(Rocam)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma)/2.0L Duratec-HE
(MI4) (34 626 0)
Removal
All vehicles
1. Drain the A/C system. For additional
3. Disconnect the A/C clutch connector (1.3l
engine shown).
4.

lines and the A/C compressor to
NOTE: On vehicles with a 2.0L engine, this step
should only be carried out once the A/C
compressor has been detached.
Disconnect the refrigerant lines from the
A/C compressor (1.3l engine shown).

5. Disconnect the high-pressure cutoff switch
Unclip the high-pressure cutoff switch wiring
harness and position it to one side.
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Air Conditioning
412-03-21

6. Detach the A/C compressor from the engine, lower it and secure it to one side.
Vehicles with 1.3l engine

8.
CAUTION: Support the A/C compressor

before removing the retaining bolts
and secure it to one side to prevent
load being placed on the refrigerant
lines.
Remove the A/C compressor.
Vehicles with 1.25l,1.4l or 1.6l engine

7.
CAUTION: Support the A/C compressor

before removing the retaining bolts
and secure it to one side to prevent
load being placed on the refrigerant
lines.
Remove the A/C compressor.
Installation
NOTE: Lubricate the refrigerant line O-ring seals
with clean refrigerant oil before installation.
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412-04-1
Control Components
412-04-1
SECTION 412-04 Control Components

CONTENTS
PAGE

Control Components .........................................................................................................
Heating, ventilation and air conditioning controls..............................................................
412-04-2
412-04-2

Control Components .........................................................................................................
412-04-4

Climate Control Assembly ............................................................................. (34 300 0)
Blower Motor Switch ..................................................................................... (33 574 0)
412-04-5
412-04-9
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Control Components
412-04-2

Control Components
Heating, ventilation and air conditioning
controls
Item
Part
Number
Description
Blower motor switch
Temperature control
Air distribution control
Air conditioning switch
Recirculated air switch
Temperature control
NOTE: The heating power depends on the

temperature of the coolant.
The temperature control operates the temperature
control flap in the heat exchanger housing through
a Bowden cable and correspondingly more or less
warm air is mixed with the air of the surroundings.
Air distribution control
Blower switch
The speed of the air flow is adjusted using the

blower switch.
The blower switch is connected to a three speed
blower resistor and can switch through four
speeds.
The blower is switched off in position 0.
G251066 en
The air distribution control operates the air

distribution flap in the heat exchanger housing via
a Bowden cable and air is guided accordingly to
the air nozzles.
Air conditioning switch
NOTE: A cover is installed instead of the air

conditioning switch on vehicles without air
conditioning.
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Control Components
412-04-3

Vehicles with air conditioning have a heating
control module which is integrated in the control.
Among other things, this heating control module
passes on the information to the Powertrain
Control Module (PCM) when the air conditioning
switch is operated.
The air conditioning system is switched on
through the air conditioning switch.
This pre-supposes that the blower switch is not in
position 0.
The heating control module sends a request
signal to the PCM, which then switches on the A/C
compressor.
An orange coloured LED in the A/C switch shows
that the air conditioning system is switched on.
If the switch is operated when the blower switch is
in position 0, the request signal is initially not sent
to the PCM.
As soon as the blower switch is moved from
position 0 however, the request signal is sent and
the PCM switches the A/C compressor on.
When the ignition is switched off, the status of the
A/C system is stored ready for the next engine
start.
Recirculated air switch
NOTE: A cover is installed instead of the

recirculated air switch on vehicles without air
conditioning.
The purpose of the recirculated air switch is to
switch between recirculated air and fresh air.
Recirculated air flaps are integrated in the heat
exchanger housing in order to switch the
recirculated air.
These recirculated air flaps are operated by an
electric motor in the heat exchanger housing.
When the recirculated air switch is operated, the
servo motor in the heat exchanger housing is
actuated by the heating control module and opens
or closes the recirculated air flaps.
An orange coloured LED in the recirculated air
switch shows that recirculated air is in operation.
The state is not stored when the ignition is
switched off while recirculated air is in operation.
Fresh air operation is started when the ignition is
switched on again.
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Control Components
412-04-4

Control Components
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Control Components
412-04-5

Climate Control Assembly (34 300 0)
Removal
All vehicles
1. Open the stowage compartment and unscrew and remove the bolts from the lower
fascia/crash padding trim.
RHD vehicles
to the clips on the upper steering column trim.
Detach the upper steering column trim
from the lower steering column trim
1. Use a narrow screwdriver to release the
clips.
2. Detach the trim.
2. Remove the lower fascia/crash padding

trim.
5. Remove the lower steering column trim

(steering wheel shown removed for
clarity).
3. Unscrew and remove the left-hand bolts

from the fascia/crash padding console.
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Control Components
412-04-6

All vehicles
6. Unscrew and remove the lower bolts from
the fascia/crash padding console.
7. Fully open the glove compartment.

Press the sides towards the centre to release the glove compartment from the
stops.
8. Detach the shaft of the air distribution flap

from the adjusting mechanism on the
Release the catch and pull out the shaft.
G105792 en
9. Unscrew and remove the right-hand bolts

10.
CAUTION: Support the screwdriver on

suitable padding to avoid damaging
Detach the switches from the fascia/crash
padding console.
11. Unplug the connector and remove the

switches.
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Control Components
412-04-7

12. Unscrew and remove the upper bolts from
13.
CAUTION: Use adhesive tape on the

three segments of the audio unit to
ensure that the audio unit is not
damaged during removal of the
fascia/crash padding console.

from the heater/air conditioning control
unit.
Turn the air distribution rotary control while
detaching the shaft.
16. Unscrew and remove the bolt for the

temperature flap adjusting mechanism.
Cover the front of the three segments of

the audio unit with adhesive tape.
14. Pull the fascia/crash padding console

forwards to gain access to the heater/air
conditioning control unit.
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Control Components
412-04-8
17.
CAUTION: Do not kink the actuation

cable for the temperature flap
adjusting mechanism.
19. Remove the heater/air conditioning control unit.
Detach the temperature flap adjusting

mechanism from the heater/air
conditioning control unit (heater/air
conditioning control unit shown from the
rear for clarity).
1. Rotate the adjusting mechanism clockwise.
2. Pull out the adjusting mechanism.
Installation
1.
18. Unplug the connector from the heater/air

conditioning control unit and remove the
G105792 en
CAUTION: Ensure that the shaft of the

air distribution flap engages properly
in the adjusting mechanism on the
CAUTION: Do not kink the actuation cable
for the temperature flap adjusting
mechanism.
Refit the components in reverse order.
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Control Components
412-04-9

Blower Motor Switch (33 574 0)
Removal
All vehicles
1. Open the stowage compartment and unscrew and remove the bolts from the lower
fascia/crash padding trim.
RHD vehicles
to the clips on the upper steering column trim.
Detach the upper steering column trim
from the lower steering column trim
1. Use a narrow screwdriver to release the
clips.
2. Detach the trim.
2. Remove the lower fascia/crash padding

trim.
5. Remove the lower steering column trim

clarity).
3. Unscrew and remove the left-hand bolts

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Control Components
412-04-10

All vehicles
6. Unscrew and remove the lower bolts from

Press the sides towards the centre to release the glove compartment from the
stops.

from the adjusting mechanism on the
Release the catch and pull out the shaft.
G105794 en
9. Unscrew and remove the right-hand bolts

10.
CAUTION: Support the screwdriver on

suitable padding to avoid damaging
Detach the switches from the fascia/crash
padding console.
11. Unplug the connector and remove the

switches.
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TO MODEL INDEX
Control Components
412-04-11

12. Unscrew and remove the upper bolts from
13.
CAUTION: Use adhesive tape on the

three segments of the audio unit to
ensure that the audio unit is not
damaged during removal of the

from the heater/air conditioning control
unit.
Turn the air distribution rotary control while
detaching the shaft.
16. Unscrew and remove the bolt for the

temperature flap adjusting mechanism.
Cover the front of the three segments of

the audio unit with adhesive tape.
14. Pull the fascia/crash padding console

forwards to gain access to the heater/air
conditioning control unit.
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Control Components
412-04-12
17.
CAUTION: Do not kink the actuation

cable for the temperature flap
adjusting mechanism.
19. Unscrew and remove the bolt from the

blower motor switch.
Detach the temperature flap adjusting

mechanism from the heater/air
conditioning control unit (heater/air
conditioning control unit shown from the
rear for clarity).
1. Rotate the adjusting mechanism clockwise.
2. Pull out the adjusting mechanism.
20. Remove the blower motor switch.

1. Rotate the switch clockwise.
2. Pull out the switch.
18. Unplug the connector from the heater/air

conditioning control unit and remove the
Installation
1.
CAUTION: Ensure that the shaft of the

air distribution flap engages properly
in the adjusting mechanism on the
CAUTION: Do not kink the actuation cable
for the temperature flap adjusting
mechanism.
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413-00-1
Instrument Cluster and Panel Illumination
413-00-1
SECTION 413-00 Instrument Cluster and Panel

Illumination
CONTENTS
PAGE

Instrument Cluster and Panel Illumination .........................................................................
Symptom Chart ................................................................................................................
Pinpoint Tests ..................................................................................................................
413-00-2
413-00-2
413-00-2
413-00-3
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413-00-2

damage.

step.

Electrical
- Fuse(s)
- Wiring harness
- Light emitting diode(s) LED(s)
- Instrument cluster
- Audio unit
- Climate control assembly
- Switch(es)
Symptom Chart
Symptom
The control illumination is inoperative
Possible Sources
Headlamp switch.
Circuit.
Action
If one illumination is not working
(control knob or backlight),
INSTALL a new headlamp
switch. REFER to Section
417-01. TEST the system for
normal operation. If both illuminations are not working (control
knob and backlight),
The Instrument cluster illumina- Circuit(s).

tion is inoperative
Instrument cluster.
The climate control/integrated

control panel illumination is inoperative (vehicles without air
conditioning)
Climate control assembly.

Circuit(s).
GO to Pinpoint Test C.
The climate control/integrated

Climate control assembly.
control panel illumination is in- Circuit(s).
operative (vehicles with air conditioning)
GO to Pinpoint Test D.
The audio unit illumination is

inoperative
Audio unit.
Circuit(s).
GO to Pinpoint Test E.
The hazard lamp switch illumination is inoperative
Hazard lamp switch.

Circuit(s).
GO to Pinpoint Test F.
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413-00-3

Symptom
Possible Sources
Action
The multifunction switch assem- Multifunction switch assembly.

bly illumination is inoperative (air Circuit(s).
bag deactivation warning, stability assist, front window defrost or
rear window defrost)
GO to Pinpoint Test G.
Pinpoint Tests
PINPOINT TEST A: THE CONTROL ILLUMINATION IS INOPERATIVE
TEST CONDITIONS
A1: CHECK CIRCUIT 31-LE29 (BK) FOR OPEN
1 Disconnect Headlamp Switch C338.
2 Measure the resistance between the headlamp
switch C338 pin 10, 31-LE29 (BK), harness side
and ground.

Yes
INSTALL a new headlamp switch. REFER
to Section 417-01.TEST the system for
normal operation.
No
normal operation.
PINPOINT TEST B: THE INSTRUMENT CLUSTER ILLUMINATION IS INOPERATIVE
TEST CONDITIONS
B1: CHECK THE INSTRUMENT CLUSTER FOR POWER
1 Disconnect Instrument Cluster C332.

2 Turn the headlamp switch to the ON position.
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413-00-4

TEST CONDITIONS
3 Measure the voltage between the instrument
cluster C332 pin 15, circuit 29S-LK19 (OG/BU),

Yes
GO to B2.
No
REPAIR circuit 29S-LK19 (OG/BU). TEST
B2: CHECK THE INSTRUMENT CLUSTER FOR GROUND
1 Measure the resistance between instrument the
instrument cluster C332 pin 18, circuit 31-GG11
(BK), harness side and ground.
Is the resistance less than 5 ohms

Yes
INSTALL a new instrument cluster. REFER
to Section 413-01. TEST the system for
normal operation.
No
REPAIR circuit 31-GG11 (BK). TEST the
PINPOINT TEST C: THE CLIMATE CONTROL/INTEGRATED CONTROL PANEL ILLUMINATION IS
INOPERATIVE (VEHICLES WITHOUT AIR CONDITIONING)
TEST CONDITIONS
C1: CHECK CLIMATE CONTROL ASSEMBLY ILLUMINATION FOR POWER
1 Disconnect Climate Control Assembly Illumination C620.
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413-00-5

TEST CONDITIONS
3 Measure the voltage between the climate control assembly illumination C620 pin 1, circuit
29S-LH27 (OG/GN), harness side and ground.

Yes
GO to C2.
No
REPAIR circuit 29S-LH27 (OG/GN). TEST
C2: CHECK CLIMATE CONTROL ASSEMBLY ILLUMINATION FOR GROUND
1 Measure the resistance between climate control
assembly illumination C620 pin 2, circuit
31-LH27 (BK), harness side and ground.

Yes
INSTALL a new climate control assembly.
REFER to Section 412-04. TEST the system
No
REPAIR circuit 31-LH27 (BK). TEST the
PINPOINT TEST D: THE CLIMATE CONTROL/INTEGRATED CONTROL PANEL ILLUMINATION IS
INOPERATIVE (VEHICLES WITH AIR CONDITIONING)
TEST CONDITIONS
D1: CHECK CLIMATE CONTROL ASSEMBLY ILLUMINATION FOR POWER
1 Disconnect Climate Control Assembly C302.
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413-00-6

TEST CONDITIONS
3 Measure the voltage between the climate control assembly C302 pin 8, circuit 29S-LH27
(OG/GN), harness side and ground.

Yes
GO to D2.
No
D2: CHECK CLIMATE CONTROL ASSEMBLY ILLUMINATION FOR GROUND
1 Measure the resistance between climate control
assembly C302 pin 10, circuit 31-LH27 (BK),

Yes
INSTALL a new climate control assembly.
REFER to Section 412-04. TEST the system
No
REPAIR circuit 31-LH27 (BK). TEST the
PINPOINT TEST E: THE AUDIO UNIT ILLUMINATION IS INOPERATIVE
TEST CONDITIONS
E1: CHECK AUDIO UNIT ILLUMINATION FOR POWER

1 Disconnect Audio Unit C344.
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413-00-7

TEST CONDITIONS
3 Measure the voltage between the audio unit
C344 pin 3, circuit 29S-LK34 (OG/BK), harness
side and ground.

Yes
GO to E2.
No
REPAIR circuit 29S-LK34 (OG/BK). TEST
E2: CHECK AUDIO UNIT ILLUMINATION FOR GROUND
1 Measure the resistance between the audio unit
C344 pin 4, circuit 31-LK34 (BK), harness side
and ground.

Yes
INSTALL a new audio unit. REFER to Section 415-01. TEST the system for normal
operation.
No
REPAIR circuit 31-LK34 (BK). TEST the
PINPOINT TEST F: THE HAZARD LAMP SWITCH ILLUMINATION IS INOPERATIVE
TEST CONDITIONS
F1: CHECK HAZARD LAMP SWITCH ILLUMINATION FOR POWER

1 Disconnect Hazard Lamp Switch C321.
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413-00-8

TEST CONDITIONS
3 Measure the voltage between the hazard lamp
switch C321 pin 6, circuit 29S-LH54 (OG/GN),

Yes
GO to F2.
No
F2: CHECK HAZARD LAMP SWITCH ILLUMINATION FOR GROUND
1 Measure the resistance between the hazard
lamp switch C321 pin 5, circuit 31-LG8 (BK),

Yes
INSTALL a new hazard lamp switch. TEST
No
REPAIR circuit 31-LG8 (BK). TEST the
PINPOINT TEST G: THE MULTIFUNCTION SWITCH ASSEMBLY ILLUMINATION IS INOPERATIVE
(AIR BAG DEACTIVATION WARNING, STABILITY ASSIST, FRONT WINDOW DEFROST OR REAR
WINDOW DEFROST)
TEST CONDITIONS
G1: CHECK MULTIFUNCTION SWITCH ASSEMBLY ILLUMINATION FOR POWER
1 Disconnect Multifunction Switch Assembly
C714.
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413-00-9

TEST CONDITIONS
3 Measure the voltage between the multifunction
switch assembly C714 pin 12, circuit 29S-DK1
(OG/YE), harness side and ground.

Yes
GO to G2.
No
REPAIR circuit 29S-DK1 (OG/YE). TEST the
G2: CHECK MULTIFUNCTION SWITCH ASSEMBLY ILLUMINATION FOR GROUND
1 Measure the resistance between the multifunction switch assembly C714 pin 9, circuit 31-DK1

Yes
INSTALL a new multifunction switch assembly. TEST the system for normal operation.
No
REPAIR circuit 31-DK1 (BK). TEST the
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413-01-1
Instrument Cluster
413-01-1
SECTION 413-01 Instrument Cluster

CONTENTS
PAGE

Instrument Cluster.............................................................................................................
Self-Diagnostic Mode .......................................................................................................
Configuration of Instrument Cluster ..................................................................................
413-01-2
413-01-2
413-01-2
413-01-4

Instrument Cluster......................................................................................... (33 214 0)
413-01-5
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413-01-2
Instrument Cluster
413-01-2

Instrument Cluster
Mechanical
Electrical
4. Verify the following warning indicators are

working correctly:
Charging.
Turn signals.
Headlamps.
symptom and enter the instrument cluster
Self-Diagnostic Mode.
Self-Diagnostic Mode
Engine oil filter

Fuse(s)
Engine oil level
Wiring harness
Engine coolant
Electrical
temperature (ECT)
connector(s)
sensor
Instrument cluster
Engine coolant level Light emitting di Thermostat
ode(s) (LED)(s)
Collapsed or
damaged fuel tank
Door adjustment
step.
NOTE: If none of the following warning indicators
are operating correctly this may indicate a concern
with the generic electronic module (GEM). If only
one or two of the following warning indicators are
not operating correctly this may indicate an
instrument cluster concern.
NOTE: The instrument cluster tripmeter reset

button is located on the right-hand side of the
instrument cluster lens.
1. To enter the instrument cluster
Self-Diagnostic Mode simultaneously press
and hold the tripmeter reset button and turn
the ignition switch to position II.
2. When TEST is displayed in the LCD, release
the tripmeter reset button.
3. To navigate through or skip any of the
instrument cluster self-diagnostic mode tests
press the tripmeter RESET button. If the reset
button is depressed for more than 3 seconds
between tests, the instrument cluster will exit
the self-diagnostic mode.
4. The self-diagnostic mode is deactivated when
the ignition switch is turned to the OFF
position.
5. If the self-diagnostic mode cannot be
accessed, use WDS to diagnose the
instrument cluster.
NOTE: Additional tests are available after the
following self-diagnostic mode tests, but are not
applicable for this diagnostic.
Test
1. Gauge drive and
displays
G148233 en
Odometer
Display
GAGE
Gauge/Indicator/Display
Tested
Tachometer, speedometer,
temperature and fuel
Description
Both pointers move from the
rest position (zero) to below the
rest position and then back to
the rest position (the pointers
will not carry out a full sweep
as in previous vehicles). All
segments of the engine temperature and fuel level liquid
crystal displays (LCD) are illuminated.
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TO MODEL INDEX
413-01-3
Instrument Cluster
413-01-3
3. Indicator LED(s)
Odometer
Display
All segments
illuminated
bulb
4. ROM level
r XXXXFAIL
Test
2. Fill in all LCD
5. Non-volatile memory level
nrXXXX
6. Not required
7. Not required
8. Not required
9. Not required
10. Diagnostic trouble
code (DTC)
EE XXFAIL
CF1 XX
CF2 XX
CF3 XX
dtc then
XXXXNONE
11. Vehicle speed

m.p.h.
E XXXX
12. Vehicle speed

km/h
XXXX
13. Not required
SGXXXX
14. Engine speed
t XXXX
15. Not required
tGXXXX
16. Fuel volume
F1 XXX
17. Not required

18. Not required
19. Fuel level
FP1 XXX
FPt XXX
FGXXXX
20. Engine coolant

temperature
21. Engine temperature
G148233 en
XXX C
CGXXXX
Tested
Odometer LCD
Description
Fills in LCD of odometer.
Indicators and warning indica- Illuminates all the warning intors

dicators that are controlled by
the instrument cluster.
Instrument cluster read only Displays the instrument cluster
memory (ROM)
ROM level and type.
Instrument cluster non-volatile Displays the instrument cluster
memory
ROM level and type as stored
in the non-volatile memory.
Checksum fault
Not required.
Configuration
Not required.
Configuration
Not required.
Configuration
Not required.
DTCs
If any DTCs are displayed.
REFER to WDS to diagnose
the instrument cluster. A new
DTC code will be displayed
with each press of the reset
button.
Speedometer
Displays the speed signal input
in m.p.h. Dashes in odometer
display if no signal received.
Speedometer
Displays the speed signal input
in km/h. Dashes in odometer
display if no signal received.
Speedometer driver gauge
Not required.
count
Tachometer
Displays the tachometer input
signal (RPM). Dashes in
odometer display if no signal
received.
Tachometer driver gauge
Not required.
count
Fuel sender system
Displays the fuel volume signal
input. 000 - 009 Short circuit.
010 - 254 Normal range. 255
open circuit
Input
Not required.
Input
Not required.
Fuel LCD
Displays the number of segments illuminated in the Fuel
LCD.
Engine coolant temperature Displays the last engine coolant temperature signal input in
1/10 degree C.
Temperature LCD
Displays the number of segments illuminated in the temperature LCD.
11/2004 2005.25 Fiesta

TO MODEL INDEX
413-01-4
Instrument Cluster
413-01-4

Odometer
Display
odoXXX
Tested
Odometer display
23. Not required

24. Not required
25. Battery voltage
26. Brake fluid switch
trn -X
IUd XX
bAtXXX
bf -X
Input
Input
Battery Voltage
Brake fluid level input
27. Handbrake switch
hb -X
Handbrake input
28. Illumination
SLP -X
Parking light input
29. Not required

30. Crank sense
LCXXXX
Cr -X
LCD duty cycle

Crank sense circuit
Test
22. Odometer input
Description
Displays the odometer input
received. 0 - 254 valid
odometer input. 255 invalid
odometer input.
Not required.
Not required.
Displays battery voltage input.
-O Good fluid level. -G Low
fluid level.
-O Handbrake off. -G Handbrake on.
-b Parking lights on. -O Parking
lights off.
Not required.
Displays the crankshaft sensor
input to the instrument cluster.
-b Input high. -O Input low.
6. REFER to WDS to continue diagnostics.

Configuration of Instrument Cluster
The instrument cluster is a programmable module,
which must be configured by selecting the
Programmable Module Installation Routine on
WDS.
NOTE: When the new instrument cluster has been
configured with the odometer value, its
configuration cannot be decreased or matched. A
new configuration will result in an increase in the
value by a minimum of two units.
NOTE: The odometer value must be recorded
from the original instrument cluster before
removal.
If the odometer value cannot be obtained from the
instrument cluster (display failure) the customer
should supply the approximate value.
The following features will need to be configured
when a new instrument cluster is installed:
Malfunction Indicator Lamp (MIL)
Anti-lock Brake System (ABS) warning
indicator
Anti-Lock Control - Stability Assist indicator
Odometer display
Automated Gearshift System indicator
Passive Anti-Theft System (PATS) indicator
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413-01-5
Instrument Cluster
413-01-5

Instrument Cluster (33 214 0)
2. Detach the instrument cluster from the instrument panel.
Special Tool(s)
Worldwide Diagnostic System
(WDS)
418-F224
Removal
1. NOTE: If a new instrument cluster is to be
installed, connect WDS and upload the
instrument cluster configuration information
routine, prior to commencing the removal of the
instrument cluster.
NOTE: If a new instrument cluster is to be
installed, the odometer value must be recorded
from the original instrument cluster before removal
as this will be required when configuring the new
instrument cluster. If the odometer value cannot
be obtained from the instrument cluster (display
failure). The customer should supply the
approximate value.
3. Disconnect the electrical connector and

remove the instrument cluster.
Remove the instrument cluster finish panel.

(Steering wheel shown removed for clarity).
Installation
1. NOTE: If a new instrument cluster is being
installed, connect WDS and configure the new
instrument cluster to the PATS system after the
installation of the instrument cluster.
NOTE: If a new instrument cluster is being
installed connect WDS and download the
instrument cluster configuration information using
the programmable modules installation routine
after the installation of the instrument cluster.
G148234 en
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413-06-1
Horn
413-06-1
SECTION 413-06 Horn

CONTENTS
PAGE
SPECIFICATIONS
Specifications....................................................................................................................
413-06-2

Horn..................................................................................................................................
Symptom Chart ................................................................................................................
Pinpoint Tests ..................................................................................................................
413-06-3
413-06-3
413-06-3
413-06-3
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413-06-2

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Horn
413-06-2
SPECIFICATIONS
Description
Horn retaining nut
G28929 en
Nm
26
lb-ft
19
lb-in
-
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TO MODEL INDEX
413-06-3
Horn
413-06-3

Horn
damage.

step.

Electrical
- Fuse(s)
- Wiring harness
- Horn switch
- Horn
- Clockspring
- Generic Electronic Module (GEM)
Symptom Chart
Symptom
Possible Sources
Action
The horn is inoperative
Fuse(s).
Circuit(s).
Horn switch.
Horn.
Clockspring.
GEM.
The horn is always on
Clockspring.
Horn switch.
Circuit(s).
GEM.
Pinpoint Tests
PINPOINT TEST A: THE HORN IS INOPERATIVE
TEST CONDITIONS
A1: CHECK HORN FOR POWER

1 Disconnect Horn C413.
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413-06-4

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Horn
413-06-4

TEST CONDITIONS
2 Measure the voltage between the horn C413
pin 1, circuit 29S-GJ6 (OG/YE), harness side
and ground while pressing the horn switch.

Yes
INSTALL a new horn. TEST the system for
normal operation.
No
GO to A2.
A2: CHECK GEM FOR POWER
1 Disconnect GEM C319.
2 Measure the voltage between the GEM C319
pin 5, circuit 29-GJ8 (OG), harness side and
ground.

Yes
GO to A3.
No
REPAIR circuit 29-GJ8 (OG). TEST the
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413-06-5

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Horn
413-06-5

TEST CONDITIONS
A3: CHECK CIRCUIT 29S-GJ6 (OG/YE) FOR OPEN

1 Measure the resistance between the GEM
C319 pin 7, circuit 29S-GJ6 (OG/YE), harness
side and the horn C413 pin 1, circuit 29S-GJ6
(OG/YE), harness side.

Yes
GO to A4.
No
normal operation.
A4: CHECK HORN SWITCH CIRCUIT FOR OPEN
C320 pin 22, circuit 31S-GJ7 (BK/BU), harness
side and ground while pressing the horn switch.

Yes
INSTALL a new GEM. REFER to Section
No
GO to A5.
A5: CHECK THE HORN SWITCH GROUND CIRCUIT
1 Disconnect Clockspring C763 - Vehicles Without Stability Assist.
2 Disconnect Clockspring C353 - Vehicles With
Stability Assist.
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413-06-6

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Horn
413-06-6

TEST CONDITIONS
3 Measure the resistance between the clockspring C763 pin 7, circuit 31-GJ9 (BK) (vehicles
without stability assist) or C353 pin 14, circuit
31-GJ9 (BK) (vehicles with stability assist),

Yes
GO to A6.
No
REPAIR circuit 31-GJ9 (BK). TEST the system for normal operation.
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Horn
413-06-7

TEST CONDITIONS
A6: CHECK CIRCUIT 31S-GJ7 (BK/BU) FOR OPEN

1 Measure the resistance between the clockspring C763 pin 6, circuit 31S-GJ7 (BK/BU)
(vehicles without stability assist) or C353 pin 13,
circuit 31S-GJ7 (BK/BU) (vehicles with stability
assist), harness side and the GEM C320 pin 22,
circuit 31S-GJ7 (BK/BU), harness side.

Yes
GO to A7.
No
normal operation.
A7: CHECK CLOCKSPRING CIRCUIT FOR OPEN
WARNING: To deactivate the driver air bag, refer to the procedure in section 501-20B for the
correct air bag deactivation procedure. Failure to follow this instruction, may result in
personal injury.
1 Remove the driver air bag module REFER to
Section 501-20A / 501-20B.
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Horn
413-06-8

TEST CONDITIONS
2 Measure the resistance between the driver air
bag connector, clockspring side and the clockspring C763 pin 6, circuit 31S-GJ7 (BK/BU)
assist) component side.

Yes
GO to A8.
No
INSTALL a new clockspring. REFER to
Section 501-20A / 501-20B. TEST the system for normal operation.
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Horn
413-06-9

TEST CONDITIONS
A8: CHECK CLOCKSPRING CIRCUIT FOR OPEN

1 Measure the resistance between the driver air
bag connector, clockspring side and clockspring
C763 pin 7, circuit 31-GJ9 (BK) (vehicles without stability assist) or C353 pin 14, circuit
31-GJ9 (BK) (vehicles with stability assist)
component side.

Yes
INSTALL a new driver air bag module
REFER to Section 501-20A / 501-20B.
No
PINPOINT TEST B: THE HORN IS ALWAYS ON
TEST CONDITIONS
B1: CHECK HORN SWITCH CIRCUIT FOR SHORT TO GROUND
Does the horn stop sounding with C320 disconnected?
Yes
GO to B2.
No
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413-06-10

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Horn
413-06-10

TEST CONDITIONS
B2: CHECK CIRCUIT 31S-GJ7 (BK/BU) FOR SHORT TO GROUND

1 Disconnect Clockspring C763 - Vehicles Without Stability Assist.
2 Disconnect Clockspring C353 - Vehicles With
Stability Assist.
C320 pin 22, circuit 31S-GJ7 (BK/BU), harness
side and ground.
Is the resistance greater than 10,000 ohms?

Yes
GO to B3.
No
normal operation.
B3: CHECK CLOCKSPRING FOR SHORT TO GROUND
WARNING: To deactivate the driver air bag, refer to the procedure in section 501-20B for the
correct air bag deactivation procedure. Failure to follow this instruction, may result in
personal injury.
1 Remove the driver air bag module REFER to
Section 501-20A / 501-20B.
2 Disconnect Horn Switch N54.
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413-06-11

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Horn
413-06-11

TEST CONDITIONS
3 Measure the resistance between the clockspring C763 pin 6, circuit 31S-GJ7 (BK/BU)
assist) component side and ground.

Yes
INSTALL a new driver air bag module
REFER to Section 501-20A / 501-20B.
No
G148235 en
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TO MODEL INDEX
413-09-1
Warning Devices
413-09-1
SECTION 413-09 Warning Devices

CONTENTS
PAGE

Warning Devices...............................................................................................................
413-09-2
413-09-2
GENERAL PROCEDURES
Safety Belt Minder Deactivating/Activating ........................................................................
Preparation ......................................................................................................................
Deactivating/Activating .....................................................................................................
413-09-3
413-09-3
413-09-3

Low Washer Fluid Warning Indicator Switch ................................................. (33 607 0)
413-09-4
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TO MODEL INDEX
413-09-2
Warning Devices
413-09-2

Warning Devices
Mechanical
Door ajar switch(es)
Electrical
Fuse(s)
Wiring harness
Electrical
connector(s)
Switch(es)
Generic electronic
module (GEM)
Instrument cluster

step.
system.
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Warning Devices
413-09-3
GENERAL PROCEDURES
Safety Belt Minder Deactivating/Activating
Preparation
1. Apply the parking brake.
2. Place gearshift in P (Park) - vehicles with
automatic transmission or the neutral
position - vehicles with manual
transmission.
3. Turn the ignition switch to the 0 position.
4. Close all the vehicle doors.
5. Unbuckle the drivers safety belt.
6. Place the parking lamps/headlamps switch
in the OFF position.
Deactivating/Activating
1. Turn the ignition switch to position II. (Do
not start the engine).
2. NOTE: The air bag warning indicator will turn off
after 5 seconds.
Wait until the safety belt warning indicator
and air bag warning indicator turns off.
(this will take up to a maximum of two
minutes).
3. NOTE: Steps 3 through 5 must be completed
within 60 seconds or the procedure must be
repeated. Each operation should be
approximately at 1 second intervals.
Buckle then unbuckle the safety belt three
times, ending with the safety belt
unbuckled.
4. Turn the headlamps ON then OFF.
5. Buckle then unbuckle the safety belt three
times ending with the safety belt unbuckled.
After this step the safety belt warning
indicator will flash for three seconds. This
will enable the belt minder if disabled or
disable belt minder if enabled.
6. After confirmation, the
deactivation/activation procedure is
complete.
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TO MODEL INDEX
Warning Devices
413-09-4

Low Washer Fluid Warning Indicator Switch (33 607 0)
Removal
1. Loosen the right-hand side front wheel
nuts.
100-02.
3. Remove the right-hand side wheel.
4. Remove the fender splash shield.
6. NOTE: Drain the windshield washer fluid into a

suitable container.
Remove the switch.
Installation
5. Disconnect the low washer fluid level
G28932 en
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413-13-1
Parking Aid
413-13-1
SECTION 413-13 Parking Aid

CONTENTS
PAGE

Parking Aid .......................................................................................................................
Parking Aid Module Reset Procedure...............................................................................
Symptom Chart ................................................................................................................
Pinpoint Test ....................................................................................................................
Component Tests.............................................................................................................
413-13-2
413-13-2
413-13-2
413-13-2
413-13-3
413-13-3
413-13-7
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413-13-2

TO MODEL INDEX
Parking Aid
413-13-2

Parking Aid
damage.
Electrical
Fuse(s)
Relay(s)
Wiring harness
Parking aid sensor(s)
Parking aid display and speaker
Parking aid module
Parking aid resistance plug

step.
symptom and refer to the Parking Aid Module
Reset Procedure.
Parking Aid Module Reset Procedure
1.
2.
3.
4.
Turn the ignition key to position 0.

Disconnect the parking aid resistance plug.
Turn the ignition key to position II.
Select the reverse gear and then deselect the
reverse gear.
5. Turn the ignition key to position 0.
6. Connect the parking aid resistance plug.
7. TEST the system for normal operation. If the
cause persists, refer to the Self-Diagnostic
Mode.
1. To enter the parking aid module
Self-Diagnostic Mode, turn the ignition key to
position 0, remove the parking aid resistance
plug and make sure the vehicle is in neutral
gear.
2. Make sure that no obstacle is within 2 meters
of the rear of the vehicle.
3. Turn the ignition key to position II and select
reverse gear.
4. Self-Diagnostic Mode will be indicated by an
audible tone for three seconds from the
parking aid speaker, and is paused for one
second.
5. If a concern is detected with a parking aid
sensor, the parking aid module will indicate
this by emitting an audible tone sequence
from the parking aid speaker.
6. If there is a concern with more than one
parking aid sensor, a second sequence will be
emitted after the first.
7. To exit the Self-Diagnostic Mode, select
neutral, turn the ignition key to position 0 and
install the parking aid resistance plug.
Audible Tone Sequence
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413-13-3

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Parking Aid
413-13-3

Audible Tone Sequence
Description
ON for three seconds, pause for Opening sequence for concern
one second
diagnostics
ON and OFF once, pause for one Right-hand outer sensor concern
second
ON and OFF twice, pause for one Right-hand inner sensor concern
second
ON and OFF three times, pause Left-hand inner sensor concern
for one second
ON and OFF four times, pause for Left-hand outer sensor concern
one second
Module concern. Low battery
ON for seventy five milliseconds,
voltage. Short in parking aid repause for seventy five millisecsistance plug circuit.
onds
8. If the concern remains after the
Self-Diagnostic Mode, refer to the Symptom
Chart.
Action
REFER to the Component Test in
this procedure.
this procedure.
this procedure.
this procedure.
Symptom Chart
Symptom
Possible Sources
Action
A continuous audible tone is

emitted
Parking aid sensor(s).

Parking aid module.
Parking aid resistance plug.
REFER to the Self-Diagnostic

Mode.
The parking aid speaker has a

continuous or intermittent tone
when the reverse gear is selected
Parking aid sensor(s) dirty or

CLEAN the rear parking aid
iced over.
sensor(s).
Parking aid sensor(s) incorrectly INSTALL the rear parking aid
installed.
sensor(s) correctly.
Parking aid is inoperative/does

not operate correctly
Parking aid module.

Reversing lamp switch.
Circuit(s).
Parking aid speaker.
Parking aid resistance plug.
Pinpoint Test
PINPOINT TEST A: PARKING AID IS INOPERATIVE/DOES NOT OPERATE CORRECTLY
TEST CONDITIONS
A1: CHECK THE REVERSING LAMP SWITCH
2 Select reverse gear.
Is the reversing lamp working?

Yes
GO to A2.
No
A2: CHECK THE PARKING AID MODULE POWER SUPPLY
1
2
3
4
G189086 en

Disconnect Parking Aid Module C1015.
Select reverse gear.
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413-13-4

TO MODEL INDEX
Parking Aid
413-13-4

TEST CONDITIONS
5 Measure the voltage between the parking aid
module C1015 pin 18, (RD), harness side and
ground.

Yes
GO to A3.
No
CHECK and REPAIR the circuit between the
parking aid module C1015 pin 18, (RD),
harness side and C800 pin 27, (GN/YE),
harness side. IF the circuit is OK, INSTALL a
new parking aid module. TEST the system
A3: CHECK THE PARKING AID MODULE GROUND CIRCUIT
2 Measure the resistance between the parking
aid module C1015 pin 10, (BN), harness side
and ground.

Yes
GO to A4.
No
parking aid module C1015 pin 10, (BN)
harness side and ground. IF the circuit is OK,
INSTALL a new parking aid module. TEST
A4: CHECK THE PARKING AID SPEAKER CIRCUIT
1 Disconnect Parking Aid Speaker C1016.
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413-13-5

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Parking Aid
413-13-5

TEST CONDITIONS
2
3
4
5
Connect Parking Aid Module C1015.

Select reverse gear.
Place an obstacle within one meter of the
parking aid sensor. Measure the voltage between the parking aid speaker C1016 pin 1,
(BN), harness side and parking aid speaker
C1016 pin 2, (BN/RD), harness side.

Yes
INSTALL a new parking aid speaker. TEST
No
GO to A5.
A5: CHECK THE PARKING AID SPEAKER CIRCUIT FOR OPEN
2 Disconnect Parking Aid Module C1015.
aid module C1015 pin 1, (BN), harness side and
the parking aid speaker C1016 pin 1, (BN),
harness side.

Yes
GO to A6.
No
REPAIR the circuit between the parking aid
module C1015 pin 1, (BN), harness side and
the parking aid speaker C1016 pin 1, (BN),
harness side. TEST the system for normal
operation.
G189086 en
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413-13-6

TO MODEL INDEX
Parking Aid
413-13-6

TEST CONDITIONS
A6: CHECK THE PARKING AID SPEAKER CIRCUIT FOR OPEN

aid module C1015 pin 2, (BN/RD), harness side
and the parking aid speaker C1016 pin 2,
(BN/RD), harness side.

Yes
GO to A7.
No
REPAIR the circuit between the parking aid
module C1015 pin 2, (BN/RD), harness side
and the parking aid speaker C1016 pin 2,
(BN/RD), harness side. TEST the system for
normal operation.
A7: CHECK THE PARKING AID RESISTANCE PLUG CIRCUIT FOR SHORT TO GROUND
1 Disconnect Parking Aid Resistance Plug.
aid module C1015 pin 24, (PK), harness side
and ground.

Yes
GO to A8.
No
parking aid module C1015 pin 24, (PK),
harness side and ground. If the circuit is OK,
INSTALL a new parking aid resistance plug.
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TO MODEL INDEX
413-13-7
Parking Aid
413-13-7

TEST CONDITIONS
A8: CHECK THE PARKING AID RESISTANCE PLUG CIRCUIT FOR SHORT TO GROUND
aid module C1015 pin 25, (PK), harness and
ground.
Component Tests
Parking Aid Sensor Wiring Harness

Yes
INSTALL a new parking aid module. TEST
No
parking aid module C1015 pin 25, (PK),
harness and ground. If the circuit is OK,
INSTALL a new parking aid resistance plug.
NOTE: Check the parking aid wiring harness for
short to ground, short to battery or damage.
1. Test the parking aid sensor wiring harness
using the following table as a guide to meter
lead placement as well as expected values.
NOTE: Refer to the Wiring Diagram, Section

413-13 for Schematic and Connector information.
Parking Aid
Parking Aid
Sensor C1019 Module C1014
Expected Value
Pin 1
Pin 4
Less than 5 ohms
Pin 2
Pin 10
Less than 5 ohms
Pin 3
Pin 11
Less than 5 ohms
G189086 en
Action
If the resistance is greater than 5 ohms,
CHECK and REPAIR the circuit. If the
circuit is OK, INSTALL a new parking aid
sensor. TEST the system for normal
operation
operation
operation
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413-13-8

TO MODEL INDEX
Parking Aid
413-13-8
Expected Value
Less than 5 ohms
Action
If the resistance is greater than 5
ohms, CHECK and REPAIR the circuit.
If the circuit is OK, INSTALL a new
parking aid sensor. TEST the system
for normal operation

Parking Aid
Parking Aid
Pin 1
Pin 3
Pin 2
Pin 10
Less than 5 ohms
Pin 3
Pin 11
Less than 5 ohms
Parking Aid
Parking Aid
Pin 1
Pin 2
Expected Value
Less than 5 ohms
Pin 2
Pin 10
Less than 5 ohms
Pin 3
Pin 11
Less than 5 ohms
Parking Aid
Parking Aid
Pin 1
Pin 1
Expected Value
Less than 5 ohms
Pin 2
Pin 10
Less than 5 ohms
Pin 3
Pin 11
Less than 5 ohms
G189086 en
Action
Action
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TO MODEL INDEX
414-00-1
Charging System - General Information
414-00-1
SECTION 414-00 Charging System - General

Information
CONTENTS
PAGE

Charging System ..............................................................................................................
414-00-2
414-00-2
GENERAL PROCEDURES
Battery Charging ........................................................................................... (31 003 0)
414-00-3
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414-00-2

TO MODEL INDEX
414-00-2

Charging System
WARNING: Batteries contain sulphuric
acid. Avoid contact with skin, eyes, or
clothing. Also, shield your eyes when
working near batteries to protect against
possible splashing of the acid solution. In
case of acid contact with skin or eyes,
flush immediately with water for a
minimum of 15 minutes and get prompt
medical attention. If acid is swallowed,
call a physician immediately. Failure to
personal injury.
WARNING: Batteries normally produce
explosive gases which can cause
personal injury. Therefore, do not allow
flames, sparks or lighted substances to
come near the battery. When charging or
working near a battery, always shield
your face and protect your eyes. Always
provide ventilation. Failure to follow
injury.
Mechanical
Electrical
Accessory drive belt Fuse(s)

Generator
Wiring harness
Generator decou Electrical
pler (if equipped)
connector(s)
Battery junction box
(BJB)
Battery
Battery cables
Charging system
warning indicator
step.
system.
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414-00-3

TO MODEL INDEX
414-00-3
GENERAL PROCEDURES
Battery Charging (31 003 0)
G18345 en
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414-00-4

TO MODEL INDEX
414-00-4
GENERAL PROCEDURES
1.
WARNING: Keep batteries out of reach

of children. Batteries contain sulphuric
acid, avoid contact with skin, eyes or
clothing. Shield your eyes when
working near the battery to protect
against possible splashing of the acid
solution. In case of acid contact with
the skin or the eyes, flush immediately
with water for a minimum of 15
minutes and seek prompt medical
attention. If acid is swallowed, call a
physician immediately. Failure to
personal injury.
personal injury, therefore do not allow
working near the battery always shield
provide adequate ventilation. Failure to
personal injury.
WARNING: Always observe all
manufacturers instructions when using
any charging equipment. Failure to follow
this instruction may result in personal
injury.
WARNING: Connect the charger to the
battery before switching the charger on.
WARNING: Switch the charger off before
disconnecting the charger from the
battery. Failure to follow this instruction
CAUTION: Batteries should not be
charged in the vehicle.
CAUTION: Do not rely on the generator to

recharge a discharged battery as it would
take in excess of eight hours of
continuous driving with no additional
loads placed on the charging system.
NOTE: The maximum level mark is approximately
40mm below the top of the battery.
Place the battery on a level surface and
check the electrolyte level through the
casing, reaches the indicated maximum
mark.
G18345 en
WARNING: It is important not to overfill a

battery, as this can cause acid leakage
and corrosion damage to the vehicle.
2. If the level is below the maximum mark,
remove the vent covers and top up the
cell(s) to the correct level.
3. Cold batteries will not readily accept a
charge. Therefore batteries should be
allowed to warm up to approximately 5C.
(41F.) before charging. This may require
four to eight hours at room temperature
depending on the initial temperature and
the battery size.
4. A battery which has been completely
discharged may be slow to accept a charge
initially, and in some cases may not accept
a charge at the normal charger setting.
When batteries are in this condition,
charging can be started by use of the dead
battery switch on chargers that have this
facility equipped.
5. To determine whether a battery is
accepting a charge, follow the
manufacturer's instructions for the charger,
for use of the dead battery switch. If the
switch is the spring-loaded type, it should
be held in the ON position for up to three
minutes.
6. After releasing the dead battery switch and
with the charger still on, measure the
battery voltage. If it shows 12 volts or
higher, the battery is accepting a charge
and is capable of being recharged.
However, it may require up to two hour of
charging with batteries colder than 5C
(41F) before the charge rate is high
enough to show a charge on an ammeter. It
has been found that all non-damaged
11/2004 2005.25 Fiesta
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414-00-5

batteries can be charged by this procedure.
If a battery cannot be charged by this
procedure, a new one should be installed.
7. A rapid recharger procedure has been
developed for recharging batteries that
have passed the Load Test and only need a
recharge. This can be due to in-service
no-start battery failures (vehicle will not
crank due to low battery state of charge) or
battery discharged in vehicle due to key-off
loads.
8. With the cables then disconnected, the
battery can be rapidly recharged by using
either of the following methods:
Carry out a two hour charge using 20A
constant current (manual setting on
charger).
Carry out a two hour charge using a
constant potential (automatic setting on
charger).
G18345 en
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414-01-1
Battery, Mounting and Cables
414-01-1
SECTION 414-01 Battery, Mounting and Cables

CONTENTS
PAGE
SPECIFICATIONS
Specifications....................................................................................................................
414-01-2

Battery ..............................................................................................................................
Symptom Chart ................................................................................................................
414-01-3
414-01-3
414-01-3
GENERAL PROCEDURES
Battery Disconnect............................................................................................................
414-01-4

Battery Tray .................................................................................................. (44 271 4)
Battery to Starter Motor Solenoid Cable 1.25L Duratec-16V (Sigma)/1.4L (36 206 0)
Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma)..........................................
Battery Tray 2.0L Duratec-HE (MI4) ......................................................... (44 271 4)
Battery Cables 2.0L Duratec-HE (MI4) .........................................................................
414-01-5
414-01-7
414-01-9
414-01-11
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414-01-2
SPECIFICATIONS
Description
Battery clamp retaining nuts
Battery positive terminal retaining nut
Battery positive terminal cable retaining nut
Battery ground terminal retaining nut
Battery ground terminal cable retaining nut
Battery tray retaining bolts
Generator positive cable retaining nut - vehicles
with 1.25L Duratec-16V (Sigma)/1.3L Duratec-8V
(Rocam)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) engines
Generator positive cable retaining nut - vehicles
with 1.4L Duratorq-TDCi (DV) Diesel/1.6L Duratorq-TDCi (DV) Diesel/2.0L Duratec-HE (MI4) engines
Starter motor positive cable retaining nut - all vehicles
Ignition switch to starter motor cable retaining nut vehicles with 1.4L Duratorq-TDCi (DV) Diesel//1.6L
Duratorq-TDCi (DV) Diesel/2.0L Duratec-HE (MI4)
engines
Ignition switch to starter motor cable retaining nut vehicles with 1.25L Duratec-16V (Sigma)/1.3L
Duratec-8V (Rocam)/1.4L Duratec-16V
(Sigma)/1.6L Duratec-16V (Sigma) engines
G148237 en
Nm
8
5
12
5
8
12
8
lb-ft
9
9
-
lb-in
71
44
44
71
71
15
11
12
53
62
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414-01-3

Battery
General Equipment
Battery Tester

acid. Avoid contact with skin, eyes, or
clothing. Also, shield your eyes when
working near batteries to protect against
case of acid contact with skin or eyes,
flush immediately with water for a
minimum of 15 minutes and get prompt
medical attention. If acid is swallowed,
call a physician immediately. Failure to
personal injury.

personal injury. Therefore, do not allow
working near a battery, always shield
personal injury.
damage.
Electrical
3.
Battery terminal clamps
Battery cable(s)
Battery
step.
Symptom Chart
Symptom
Possible Sources
Action
Vehicle electrical systems inop- Battery.

erative
CARRY OUT a battery condition

test, using the battery tester.
The engine cranks slowly
Battery.
CARRY OUT a battery condition

test, using the battery tester.
Battery cable(s).
Starter motor.
G167284 en
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414-01-4
GENERAL PROCEDURES
Battery Disconnect
Disconnect
Connect

explosive gases which may cause
personal injury.

explosive gases which may cause
personal injury.

acid, avoid contact with skin eyes or
clothing. Shield your eyes when working
near the battery to protect against
case of acid contact with the skin or eyes,
flush immediately for a minimum of 15
attention. If swallowed, call a physician

acid, avoid contact with skin eyes or
clothing. Shield your eyes when working
near the battery to protect against
case of acid contact with the skin or eyes,
flush immediately for a minimum of 15
attention. If swallowed, call a physician
WARNING: Audio unit key code saving

devices must not be used when working
on supplemental restraint or fuel systems.
When using these devices the vehicle
electrical system is still live but with a
reduced current flow. Failure to follow
injury.
CAUTION: Make sure the engine is not
running before disconnecting the battery
ground cable to avoid damage to the
vehicle electrical system.
NOTE: This procedure should be used to
disconnect the battery while carrying out repairs
that refer to the battery being disconnected.
1. Obtain and record the audio unit keycode
and preset radio frequencies.
G371115 en
CAUTION: Make sure all electrical

systems are switched OFF before
connecting the battery ground cable to
avoid damage to the vehicle electrical
system.
1. Connect the battery ground cable.
2. Enter the audio unit keycode and preset
radio frequencies.
3. Reset the clock to the correct time.
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414-01-5

Battery Tray (44 271 4)
Removal
5. Detach the left-hand headlamp assembly.
All vehicles
2. Open the battery positive terminal cover.

remove the headlamp assembly.
3. Disconnect the battery positive cable and
position it to one side.
7. Remove the powertrain control module

(PCM) retaining screws.
4. Remove the radiator grill.
G189087 en
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414-01-6

8. Detach the PCM from the retaining bracket.
All vehicles
9. Detach the battery clamp from the battery
tray and position it to one side.
1. Remove the battery clamp front retaining
nut.
2. Remove the battery clamp rear retaining
nut.
3. Unhook the battery clamp.
11. Detach the battery junction box (BJB)

from the battery tray and position it to one
side.
12. Remove the battery tray.
Installation
1.
10. Remove the battery.
CAUTION: When installing the battery

clamp, make sure that the rear
retaining nut is tightened first. Failure
damage to the battery.
G189087 en
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414-01-7

Battery to Starter Motor Solenoid Cable 1.25L Duratec-16V (Sigma)/1.4L
Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) (36 206 0)
Removal
3. Disconnect the battery positive cables.
4. Detach the battery to starter motor solenoid cable from the retaining clip on the
wiring harness cover.
G210059 en
5. Remove the protective cap and disconnect

the generator electrical connector.

100-02.
7. Detach the battery to starter motor solenoid cable from the retaining clip.
8. Disconnect the starter motor solenoid cable electrical connector.
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414-01-8

motor solenoid and battery to starter motor
solenoid cables (oil filter shown removed
for clarity).
10. Detach the battery to starter motor solenoid cable from the retaining clip on the
intake manifold.
11. Remove the battery to starter motor

solenoid cable.
Installation
G210059 en
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414-01-9

Battery Tray 2.0L Duratec-HE (MI4) (44 271 4)
Removal
additional information, refer to Battery
Disconnect in this section.
3. Disconnect the battery positive cable and

4. Detach the battery clamp from the battery

tray and position it to one side.
1. Remove the battery clamp front retaining
nut.
2. Remove the battery clamp rear retaining
nut.
3. Unhook the battery clamp.
5. Remove the battery.
6. Detach the battery junction box (BJB) from

the battery tray and position it to one side.
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7. Remove the battery tray.
Installation
1.
CAUTION: When installing the battery

clamp, make sure that the rear
retaining nut is tightened first. Failure
damage to the battery.
G426594 en
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414-01-11
414-01-11

Battery Cables 2.0L Duratec-HE (MI4)
additional information, refer to Battery
Disconnect in this section.
Item
Part
Number
Battery positive terminal

clamp cover
Battery junction box (BJB)

cable electrical connector to
battery cable retaining nut
G453324 en
Description

Duratec-HE (MI4)]
table(s).
Item
Part
Number
Description
Battery positive terminal

clamp
Wiring harness support

See Removal Detail
Battery cable retaining clip
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414-01-12
Item
Part
Number
Starter motor solenoid inline

Starter motor solenoid cable

electrical connector retaining
nut
Starter motor battery positive

cable electrical connector
retaining nut
10
Starter motor solenoid electrical connector
11
12
G453324 en
Description
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414-01-13
414-01-13
Item
Part
Number
13
Engine wiring harness

retaining clip
See Removal Detail
14
15
Engine wiring harness electrical connector
16
Power steering line retaining

clip
See Removal Detail
17
Battery cable inline fuse

holder
See Removal Detail
G453324 en
Description
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414-01-14
Item
Part
Number
Description
18

sensor electrical connector
19
CKP wiring harness retaining

clip
20
21
Generator electrical connector
22
Battery cable to generator

23
Battery cable
Item 13 : Engine wiring harness retaining clip

battery cable retaining clip
Item 16 : Power steering line retaining clip
battery cable inline fuse holder
Removal Details
Item 4 : Wiring harness support
1. Detach the battery cable from the wiring
harness support.
G453324 en
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414-01-15

Item 17 : Battery cable inline fuse holder
1. Detach the battery cable inline fuse holder
from the valve cover and intake manifold.
Item 22 : Battery cable to generator electrical
connector
NOTE: The battery cable to generator electrical
connector must follow the profile of the generator
as closely as possible.
G453324 en
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414-02-1
Generator and Regulator
414-02-1
SECTION 414-02 Generator and Regulator

CONTENTS
PAGE
SPECIFICATIONS
Specifications....................................................................................................................
Torque Specifications - vehicles with 1.25L Duratec-16V (Sigma)/1.3L Duratec-8V (Rocam)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) engines.............................
Torque Specifications - vehicles with - 1.4L Duratorq-TDCi (DV) Diesel engine ...............
Torque Specifications - vehicles with 1.6L Duratorq-TDCi (DV) Diesel engine .................
Torque Specifications - vehicles with 2.0L Duratec-HE (MI4) engine................................
414-02-2
414-02-2
414-02-2
414-02-2
414-02-2

Generator..........................................................................................................................
414-02-3

Generator 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L
(31 414 0)
Duratec-16V (Sigma)....................................................................................
Generator 2.0L Duratec-HE (MI4).................................................................................
414-02-4
414-02-8
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414-02-2
SPECIFICATIONS
Torque Specifications - vehicles with 1.25L Duratec-16V (Sigma)/1.3L Duratec-8V (Rocam)/1.4L

Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) engines
Description
Nm
lb-ft
lb-in
45
33
Generator electrical connector re8
71
taining nut
Torque Specifications - vehicles with - 1.4L Duratorq-TDCi (DV) Diesel engine
Description
Nm
lb-ft
45
33
11
taining nut
25
18
retaining bolts
Accessory drive belt idler pulley re45
33
taining bolt
Description
Nm
lb-ft
45
33
11
taining nut
25
18
retaining bolts
18
taining bolts
Turbocharger heatshield retaining
3
bolts
Description
Nm
lb-ft
48
35
11
taining nut
G148238 en
lb-in
-
lb-in
27
lb-in
-
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414-02-3

Generator
G18359 en
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414-02-4

Generator 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L
Removal
414-01.
303-05.
4. Remove the radiator grille.

remove the headlamp.
7. Remove the protective cap and disconnect

the generator electrical connectors.
5. Detach the right-hand headlamp.
8. Detach the power steering reservoir and

G148239 en
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414-02-5

9. NOTE: It is not possible to fully remove the
retaining bolt from the generator at this stage.
Remove the generator upper retaining nut,
bolt and stud.
Installation
1. NOTE: Install the generator upper retaining bolt
into the generator prior to installing the
generator.
Install the generator through the headlamp
aperture.
10. Remove the generator lower retaining

bolt.
2. NOTE: Do not tighten the generator lower
Install the generator lower retaining bolt.
11. Remove the generator through the headlamp aperture.
G148239 en
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414-02-6

3. NOTE: Do not tighten the generator upper
retaining nut and bolt at this stage.
6. Install the power steering reservoir.
Install the generator upper retaining nut,

bolt and stud.
7. Connect the generator electrical connectors and install the protective cap.
4. Tighten the generator lower retaining bolt.
8. Connect the electrical connector and install the headlamp.

5. Tighten the generator upper retaining nut
and bolt.
G148239 en
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9. Install the right-hand headlamp.
10. Install the radiator grille.

12. Install a new accessory drive belt. For
303-05.
414-01.
G148239 en
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414-02-8

Generator 2.0L Duratec-HE (MI4)
Name
Grease
Specification
SA-M1C9107-A

Disconnect]
Duratec-HE (MI4)]
4.

5. Disconnect the catalytic converter from the

exhaust flexible pipe.
Discard the gasket.
6. Remove the engine support insulator retaining bolt.


table(s).
G426595 en
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414-02-9
G426595 en
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414-02-10

Item
Part
Number
Description
Generator wiring harness

retaining clip
See Removal Detail
Generator electrical
connector
See Removal Detail
Battery cable to generator


sensor wiring harness
retaining clip
See Removal Detail
CKP sensor electrical connector
Intermediate shaft center

bearing cap

bearing cap retaining bracket
retaining bolts

bearing cap retaining bracket
Generator
See Removal Detail
10
Generator cooling duct

See Removal Detail
NOTE: Install a new catalytic converter to exhaust

Removal Details
Item 2 : Generator electrical connector

1. Disconnect the generator electrical
connector (generator cooling duct shown
Release the locking tang.
Item 4 : Crankshaft position (CKP) sensor

wiring harness retaining clip
1. Detach the CKP sensor wiring harness
retaining clip from the generator.
Item 9 : Generator
1. With the aid of another technician, push the
engine towards the radiator and remove
the generator and generator cooling duct.
Item 10 : Generator cooling duct
1. Remove the generator cooling duct from
the generator.
Item 3 : Battery cable to generator electrical
connector
NOTE: The battery cable to generator electrical
connector must follow the profile of the generator
as closely as possible.
Item 1 : Generator wiring harness retaining

clip
1. Detach the generator wiring harness from
the retaining clip.
G426595 en
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415-00-1
Entertainment System - General Information
415-00-1
SECTION 415-00 Entertainment System - General

Information
CONTENTS
PAGE

Audio System....................................................................................................................
Symptom Chart ................................................................................................................
Pinpoint Tests ..................................................................................................................
415-00-2
415-00-2
415-00-5
415-00-6
415-00-7
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415-00-2
415-00-2

Audio System
Mechanical
Audio unit
Cassette player
Compact disc (CD)
player
Digital Versatile Disc
(DVD) Player
Antenna mast or
base
Electrical
Fuse(s)
Wiring harness
Electrical
connector(s)
Speaker(s)
Audio unit
Cassette player
Compact disc (CD)
player
Digital Versatile Disc
(DVD) Player
Antenna cable
Remote audio control

step.
4. If an obvious cause is not found, codes may
be shown in the audio unit display. Check the
audio unit display for the following Error
Codes:
for vehicles with 6006E or 9006 audio unit
refer to the CD Error Codes - vehicles with
Vehicles with 6006E or 9006 Audio Unit
for vehicles with 4500 audio unit refer to the
CD Error Codes - vehicles with 4500 Audio
Unit
5. If no error codes are displayed on the audio
unit refer to the Self-Diagnostic Mode.
CD Error Codes Vehicles with 6006E Audio Unit

Error Codes
Error Code
E1
E2
G149876 en
Error Description
Communications Error
Overtemp Error
Error Rectification
Install a new audio unit. REFER to Section
415-01.[Audio Unit, REMOVAL AND
INSTALLATION, Audio Unit] TEST the system for
normal operation.
The Audio unit is too hot, it will not work until it has
cooled down. Check the heater duct(s) are not
bleeding hot air on to the audio unit. REFER to
Section 415-01.[Audio Unit, REMOVAL AND
INSTALLATION, Audio Unit] If the concern persists,
INSTALL a new audio unit. TEST the system for
normal operation.
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415-00-3

E3
Mechanical Error
E4
Focus Error
E5
Overcurrent Error
PRESS and HOLD the LOAD and EJECT buttons

simutaneously. WAIT until the audio unit has
checked through the CDs currently in the unit. TEST
the system for normal operation. If the concern persists, DISCONNECT the audio unit power connector. WAIT 20 seconds and then CONNECT the audio
unit power connector. WAIT until the audio unit has
the system for normal operation. If the error code is
still displayed, INSTALL a new audio unit. REFER to
normal operation.
CD is upside down or dirty. Clean the CD and try it
again, if the error code is still displayed, INSERT a
different CD. If the error code is still displayed.
INSTALL a new audio unit. REFER to Section
normal operation.
Install a new audio unit. REFER to Section
normal operation.
CD Error Codes - vehicles with 4500 Audio Unit

Error Codes
Error Code
E-2B
E-2C
G149876 en
Error Description
CD Read Error
Jump Error
Error Rectification
again, if the error code is still displayed.
DISCONNECT the audio unit power connector.
WAIT 30 seconds and then CONNECT the audio
unit power connector. If the error code is still displayed. INSTALL a new audio unit. REFER to Section 415-01.[Audio Unit, REMOVAL AND
normal operation.
normal operation.
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415-00-4

E-2D
HF Detector Error
E-2E
CD Decoder Hardware Error
E-8x
Load/Eject Error
E-23
Sledge Error
E-24
Focus Error
E-25
Spindle Motor Error
G149876 en

normal operation.
normal operation.
normal operation.
normal operation.
normal operation.
normal operation.
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415-00-5
415-00-5

E-26
Radial Error
E-27
PLL Lock Error
E-28
Subcode Timeout Error
E-29
Subcode Not Found Error

normal operation.
normal operation.
normal operation.
normal operation.
1. To enter the audio unit Self-Diagnostic Mode,
switch the audio unit ON. Press the preset
buttons 3 and 6 together for at least 2
seconds.
2. Release the preset buttons 3 and 6 and the
audio unit will enter the Self-Diagnostic Mode.
On entering the Self-Diagnostic Mode, the
audio unit will automatically search the FM
band to carry out the waveband check,
starting at the lowest frequency until it finds a
signal.
3. To exit the audio unit Self-Diagnostic Mode,
press the preset button 6.
Self-Diagnostic Mode - Model 2500
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415-00-6

Test
1. FM waveband check.
2. Volume.
3. Test speaker circuit.
End of the audio unit
Syntax Displayed
Description
Numeric value (of station found) Tests the signal from the antenna
or Er2 if no signal received.
cable.
No display shown. Audio unit
Tests the traffic announcement
volume preset at 15.
preset volume and volume control.
RF.
Tests the right-hand front speaker
circuit.
LF.
Tests the left-hand front speaker
circuit.
END.
Displayed until the audio unit
preset button 6 is pressed or
Self-Diagnostic Mode times out.
Self-Diagnostic Mode - Models 3500, 4500 and 6006

Test
Syntax Displayed
Description
1. FM waveband check.
Numeric value (of station found) Tests the signal from the antenna
or NOT FOUND if no signal recable.
ceived.
2. Volume.
No display shown. Audio unit
Tests the traffic announcement
volume preset at 15.
preset volume and volume control.
4CH RF for four channel system Tests the right-hand front speaker
2CH RF for two channel system.
circuit.
4CH LF for four channel system Tests the left-hand front speaker
2CH LF for two channel system.
circuit.
4CH RR.
Tests the right-hand rear speaker
circuit.
4CH LR.
Test the left-hand rear speaker
circuit.
Tests the compact disc
7. Test compact disc
CDDJ OK if communications are
auto-changer circuit.
auto-changer circuit (if equipped). achieved.NO CDDJ if no communications are achieved.
End of the audio unit
END.
Displayed until the audio unit
preset button 6 is pressed or
Self-Diagnostic Mode times out.
4. If the concern is still evident after the
self-diagnostic mode, refer to the Symptom
Chart.
Symptom Chart
Symptom
Possible Sources
Action
The audio unit is inoperative/does not operate correctly
Fuse(s).
Circuit(s).
Audio unit.
The display is blank - radio and

cassette player or CD player
operate
Audio unit.
INSTALL a new audio unit.

REFER to Section 415-01.[Audio
Unit, REMOVAL AND
INSTALLATION, Audio Unit]
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415-00-7

Possible Sources
Symptom
Poor reception
Antenna.
Antenna cable.
Audio unit.
Action
Poor quality/distorted sound

Speaker(s).
from one or more speakers (not Circuit(s).
all speakers)
Audio unit.
No sound from all speakers
Audio unit.
Circuit(s).
Speaker(s).
The CD player is inoperative/does not operate correctly
Audio unit.
INSTALL a new audio unit.

REFER to Section 415-01.[Audio
Unit, REMOVAL AND
INSTALLATION, Audio Unit]
No sound from one or more of

the speakers (not all speakers)
Circuit(s).
Speaker(s).
Audio unit.
The audio remote control is in- Circuit(s).

operative/does not operate cor- Audio remote control.
rectly
Audio unit.
GO to Pinpoint Test F
The digital versatile disc (DVD)

player is inoperative/does not
operate correctly
GO to Pinpoint Test G
DVD player
Circuit(s)
Fuse(s)
Pinpoint Tests
measurements.
PINPOINT TEST A: THE AUDIO UNIT IS INOPERATIVE/DOES NOT OPERATE CORRECTLY
TEST CONDITIONS
A1: CHECK AUDIO UNIT FOR POWER

3 Measure the voltage between the audio unit
C344 pin 1, circuit 29-MD15 (OG/BK), harness
side and ground; and between the audio unit
C344 pin 2, circuit 75-MD15 (YE/GN), harness
side and ground.
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TEST CONDITIONS
Are the voltages greater than 10 volts?
Yes
GO to A2
No
REPAIR circuit 29-MD15 (OG/BK) or circuit
75-MD15 (YE/GN). TEST the system for
normal operation.
A2: CHECK AUDIO UNIT FOR GROUND

C344 pin 13, circuit 91-MD15 (BK/GN), harness
C344 pin 17, circuit 91-MD34 (BK/YE), harness
C344 pin 24, circuit 91-MD15A (BK/GN), harness and ground.
Are the resistances less than 1 ohm?

Yes
INSTALL a new audio unit. REFER to Section 415-01.[Audio Unit, REMOVAL AND
INSTALLATION, Audio Unit] TEST the system for normal operation.
No
REPAIR circuit 91-MD15 (BK/GN) or
91-MD34 (BK/YE) or 91-MD15A (BK/GN).
PINPOINT TEST B: POOR RECEPTION
TEST CONDITIONS
B1: CHECK THE ANTENNA CABLE SHIELD
2 Disconnect Audio Unit Antenna Connector.
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TEST CONDITIONS
3 Measure the resistance between the antenna
cable ground connector (shield) and ground.
Is the resistance less than 1 ohm?

Yes
GO to B2
No
CLEAN and TIGHTEN the antenna mast
base connection to the body. If the concern
persists, INSTALL a new antenna cable.
REFER to Section 415-02.[Antenna,
REMOVAL AND INSTALLATION, Antenna
Cable] TEST the system for normal operation.
B2: CHECK THE ANTENNA CENTER CONDUCTOR FOR OPEN
1 Remove the antenna mast.
2 Measure the resistance of the center conductor,
between the ends of the antenna cable.

Yes
GO to B3
No
INSTALL a new antenna cable. REFER to
Section 415-02.[Antenna, REMOVAL AND
INSTALLATION, Antenna Cable] TEST the
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415-00-10

TEST CONDITIONS
B3: CHECK ANTENNA CABLE FOR SHORT

1 Measure the resistance between the antenna
center conductor and the antenna ground
(shield).
Is the resistance greater than 10,000 ohms

(open circuit)?
Yes
CLEAN and TIGHTEN the ground connections at the base of the antenna and battery
ground cable to body. If the concern persists,
No
INSTALL a new antenna cable. REFER to
Section 415-02.[Antenna, REMOVAL AND
INSTALLATION, Antenna Cable] TEST the
PINPOINT TEST C: POOR QUALITY/DISTORTED SOUND FROM ONE OR MORE SPEAKERS (NOT
ALL SPEAKERS)
TEST CONDITIONS
C1: CHECK THE SPEAKER RESISTANCE
1 Disconnect Inoperative Speaker.
2 Measure the resistance between the inoperative speaker pin 1 and pin 2, component side.
Is the resistance approximately 4 ohms?

Yes
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TEST CONDITIONS
GO to C2
No
INSTALL a new speaker. TEST the system
C2: CHECK SPEAKER INPUT FOR SHORT TO GROUND
2 Measure the resistance between the inoperative speaker connector pin 1, harness side and
ground.

(open circuit)?
Yes
GO to C3
No
REPAIR the inoperative speaker input circuit.
C3: CHECK SPEAKER RETURN FOR SHORT TO GROUND
ground.

(open circuit)?
Yes
GO to C4
No
REPAIR the inoperative speaker input circuit.
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415-00-12

TEST CONDITIONS
C4: CHECK SPEAKER CIRCUIT FOR SHORT

pin 2, harness side.

(open circuit)?
Yes
No
REPAIR the circuit(s). TEST the system for
normal operation.
PINPOINT TEST D: NO SOUND FROM ALL SPEAKERS
TEST CONDITIONS
D1: CHECK SPEAKER INPUT CIRCUIT FOR SHORT TO GROUND

3 Measure the resistance between the following
audio unit connector pins and ground:
- (Front left speaker) C344 pin 8, circuit 8-MD10
(WH/BK), harness side and ground.
- (Rear left speaker) C344 pin 9, circuit 8-MD11
(WH/VT), harness side and ground.
- (Front right speaker) C344 pin 11, circuit
8-MD17 (WH/RD), harness side and ground.
- (Rear right speaker) C344 pin 10, circuit
8-MD18 (WH), harness side and ground.
Are the resistances greater than 10,000 ohms

(open circuit)?
Yes
GO to D2
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TEST CONDITIONS
No
normal operation.
D2: CHECK SPEAKER RETURN CIRCUIT FOR SHORT TO GROUND
1 Measure the resistance between the following
audio connector pins and ground.
- (Front left speaker) C344 pin 21, circuit
10-MD10 (GY/BK), harness side and ground.
- (Rear left speaker) C344 pin 22, circuit
10-MD11 (GY/VT), harness side and ground.
10-MD17 (GY/RD), harness side and ground.
10-MD18 (GY), harness side and ground.
Are the resistances greater than 10,000 ohms

(open circuit)?
Yes
No
normal operation.
PINPOINT TEST E: NO SOUND FROM ONE OR MORE OF THE SPEAKERS
TEST CONDITIONS
E1: CHECK THE SPEAKER RESISTANCE

1 Disconnect Inoperative Speaker.
2 Measure the resistance between the inoperative speaker pin 1 and pin 2, component side.
Is the resistance approximately 4 ohms?

Yes
GO to E2
No
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TEST CONDITIONS
INSTALL a new speaker(s). TEST the system for normal operation.
E2: CHECK SPEAKER CIRCUIT RESISTANCE

C344 and the inoperative speaker(s) connector
pins.
- (Front left speaker) C344 pin 8, circuit 8-MD10
(WH/BK), harness side and C527 pin 1, circuit
8-MD28 (WH), harness side.
- (Front left speaker) C344 pin 21, circuit
10-MD10 (GY/BK), harness side and C527 pin
2, circuit 10-MD28 (GY), harness side.
8-MD17 (WH/RD), harness side and C528 pin
1, circuit 8-MD28 (WH), harness side.
10-MD17 (GY/RD), harness side and C528 pin
2, circuit 10-MD28 (GY), harness side.
- (Rear left speaker) C344 pin 9, circuit 8-MD11
(WH/VT), harness side and C533 pin 1, circuit
8-MD29 (WH/VT), harness side.
- (Rear left speaker) C344 pin 22, circuit
10-MD11 (GY/VT), harness side and C533 pin
2, circuit 10-MD29 (GY/WH), harness side.
8-MD18 (WH), harness side and C534 pin 1,
circuit 8-MD29 (WH/VT), harness side.
10-MD18 (GY), harness side and C534 pin 2,
circuit 10-MD29 (GY/WH), harness side.
Yes
INSTALLATION, Audio Unit] Test the system
No
REPAIR the relevant circuit. TEST the system for normal operation.
PINPOINT TEST F: THE AUDIO REMOTE CONTROL IS INOPERATIVE/DOES NOT OPERATE
CORRECTLY
TEST CONDITIONS
F1: CHECK THE CIRCUIT 8-MD26 FOR OPEN
2 Disconnect Audio Remote Control C681.
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TEST CONDITIONS
C344 pin 18, circuit 8-MD26 (WH/BK), harness
side and the audio remote control C681 pin 1,
circuit 8-MD26 (WH/BK), harness side.

Yes
GO to F2
No
normal operation.
F2: CHECK CIRCUIT 9-MD26 (BN/YE) FOR OPEN
C344 pin 19, circuit 9-MD26 (BN/YE), harness
side and the audio remote control C681 pin 2,
circuit 9-MD26 (BN/YE), harness side.

Yes
INSTALL a new audio remote control. If the
concern persists, INSTALL a new audio unit.
REFER to Section 415-01.[Audio Unit,
REMOVAL AND INSTALLATION, Audio
Unit] TEST the system for normal operation.
No
normal operation.
PINPOINT TEST G: THE DVD PLAYER IS INOPERATIVE/DOES NOT OPERATE CORRECTLY
TEST CONDITIONS
G1: CHECK THE DVD PLAYER FOR POWER
1 Disconnect DVD Player C437.
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TEST CONDITIONS
2 Measure the voltage between the DVD player
C437 pin 1, circuit 29-MD8 (OG), harness side
and ground.

Yes
GO to G2
No
REPAIR circuit 29-MD8 (OG). TEST the
system for normal operation. If the concern
persists, intall a new CJB. Test the system
G2: CHECK THE DVD PLAYER FOR SWITCHED POWER

C437 pin 2, circuit 75-MD8 (YE/BU), harness
side and ground.
Yes
GO to G3
No
REPAIR circuit 75-MD8 (YE/BU). Test the
G3: CHECK THE DVD PLAYER FOR GROUND
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TEST CONDITIONS
2 Measure the resistance between the DVD

player C437 pin 3, circuit 31-MD8 (BK), harness
side and ground.
Yes
GO to G4
No
REPAIR circuit 31-MD8 (BK). Test the system for normal operation.
G4: CHECK THE DVD PLAYER ILLUMINATION CIRCUIT FOR POWER
1 Turn the multi-function swtich to the on position.

C437 pin 15, circuit 29S-LK17(OG-BK), harness
side and ground.
Yes
GO to G5
No
REPAIR circuit 29S-LK17 (OG-BK). Test the
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TEST CONDITIONS
G5: CHECK THE DVD PLAYER ILLUMINATION CIRCUIT FOR GROUND

player C437 pin 16, 31-LK17 (BK), harness side
and ground.
Yes
Right-hand drive vehicles: GO to G6
Left-hand drive vehicles: Install a new DVD
player. Test the system for normal operation.
No
Repair the circuit(s) 31-LK17 (BK), or
31-MD8. Test the system for normal operation.
G6: CHECK FROM THE DVD PLAYER TO HOOD SWITCH FOR OPEN

player C437 PIN 5, 31S-GL7A (BK-YE) and the
hood switch C604 pin 1, 31S-GL7A (BK-YE).
Is the voltage greater than 1 ohm?
Yes
REFER to Section 419-01A.[Anti-Theft - Active, DIAGNOSIS AND TESTING, Anti-Theft
- Active]
No
Repair circuit 31S-GL7A (BK-YE),
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415-01-1
Audio Unit
415-01-1
SECTION 415-01 Audio Unit

CONTENTS
PAGE

Audio System....................................................................................................................
415-01-2

Audio Unit ..................................................................................................... (38 222 0)
415-01-3
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Audio Unit
415-01-2

Audio System
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Audio Unit
415-01-3

Audio Unit (38 222 0)
Removal
4. Remove the audio unit rear support.
NOTE: It is not necessary to remove the audio unit

in order to obtain the serial number. To obtain the
serial number, simultaneously PRESS buttons 2
and 6. The serial number will be shown in the
audio unit display.
1. Remove the climate control assembly. For
412-04.
2. Detach the audio unit from the instrument
panel.
Installation
1.
3. Disconnect the electrical connectors and

remove the audio unit.
2. Disconnect the antenna cable connector.

new audio unit while installing the
climate control and audio unit trim
panel, apply masking tape to the three
sections of the audio unit.
CAUTION: To prevent possible damage to
the audio unit while connecting the
electrical connector, make sure that the
antenna cable connector is connected
first.
CAUTION: The audio unit wiring harness

must not become trapped when installing
the audio unit.
NOTE: The audio unit rear support must engage
with the audio unit support bracket.
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415-02-1
Antenna
415-02-1
SECTION 415-02 Antenna

CONTENTS
PAGE

Antenna ............................................................................................................................
415-02-2

Antenna Cable ..................................................................................................................
415-02-3
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Antenna
415-02-2

Antenna
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Antenna
415-02-3

Antenna Cable
Vehicles without roof opening panel
3. Detach the interior lamp.
General Equipment
Two suitable draw cords, each with a minimum
length of one meter
Removal
All vehicles
1. Detach the front door opening weatherstrips.

remove the interior lamp.
2. Remove the A-pillar trim panels (A-pillar

trim shown removed to show location of
retaining clips).
Vehicles with manual roof opening panel

5. Remove the roof opening panel regulator
handle.
Vehicles with overhead console

6. Remove the overhead console. For
501-12.
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Antenna
415-02-4

7. Detach the headliner at the rear of the
overhead console opening.
All vehicles
8. Remove the sun visors.
Vehicles without navigation system

11. Disconnect the antenna cable from the
antenna base.
Vehicles with navigation system

12. Disconnect the antenna cable from the
antenna base.
9. Remove the sun visor retaining clips.

All vehicles
13. Detach the antenna cable from the roof
panel (headliner shown removed for clarity).
10. Carefully detach the front edge of the

headliner to allow access to the antenna
cable.
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Antenna
415-02-5

Vehicles with heated windshield
14. Disconnect the heated windshield ground
connector.

All vehicles
15. Detach the antenna cable from the A-pillar

clarity).

16. Open the stowage compartment and remove the instrument panel lower panel
retaining screws.
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Antenna
415-02-6

19. Remove the steering column lower
shroud (steering wheel shown removed
for clarity).

Press the sides towards the center to release the glove compartment from the
stops.
G210061 en
All vehicles
21. NOTE: Do not remove the antenna cable
retaining clip from the cross-vehicle beam.
Detach the antenna cable from the retaining clip (instrument panel shown removed for clarity).
22. NOTE: Do not remove the antenna cable

retaining clips cross-vehicle beam.
Detach the antenna cable from the retaining clips at the back of the
cross-vehicle beam.
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Antenna
415-02-7

23. Detach the antenna cable from the clips
behind the cross-vehicle beam support
bracket.
27. Attach the second suitable draw cord to

the audio unit end of the antenna cable
and pull the cable from behind the
instrument panel to expose the connector
and the draw cord.
28. Detach the suitable draw cords and
remove the antenna cable.
Installation
1. NOTE: When installing a new antenna cable,
some of the retaining clips are not required.
Remove and discard the retaining clips
from the antenna cable.
24. Detach the antenna cable from the clip
and disconnect the antenna cable from
the audio unit.
25. Attach a suitable draw cord to the antenna base end of the antenna cable.
26. Pull the antenna cable along the roof

panel towards the A-pillar to expose the
suitable draw cord .
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417-01-1
Exterior Lighting
417-01-1
Page 1 of 2
SECTION 417-01 Exterior Lighting

CONTENTS
PAGE
SPECIFICATIONS
Specifications....................................................................................................................
417-01-3

Exterior Lighting ................................................................................................................
Front lighting ....................................................................................................................
Rear lighting.....................................................................................................................
417-01-4
417-01-4
417-01-4

Headlamps........................................................................................................................
Symptom Chart ................................................................................................................
System Checks ................................................................................................................
Stoplamps.........................................................................................................................
Symptom Chart ................................................................................................................
System Checks ................................................................................................................
Turn Signal and Hazard Lamps.........................................................................................
Symptom Chart ................................................................................................................
System Check ..................................................................................................................
Parking, Rear and License Lamps ....................................................................................
Symptom Chart ................................................................................................................
System Checks ................................................................................................................
Reversing Lamps ..............................................................................................................
Symptom Chart ................................................................................................................
System Checks ................................................................................................................
Fog Lamps........................................................................................................................
Symptom Chart ................................................................................................................
System Checks ................................................................................................................
Headlamp Leveling ...........................................................................................................
Symptom Chart ................................................................................................................
System Checks ................................................................................................................
417-01-7
417-01-7
417-01-7
417-01-8
417-01-31
417-01-31
417-01-31
417-01-31
417-01-42
417-01-42
417-01-42
417-01-43
417-01-72
417-01-72
417-01-72
417-01-72
417-01-89
417-01-89
417-01-89
417-01-89
417-01-104
417-01-104
417-01-104
417-01-104
417-01-124
417-01-124
417-01-124
417-01-124
GENERAL PROCEDURES
Headlamp Adjustment................................................................................... (32 113 0)
Headlamp Masking ...........................................................................................................
Front Fog Lamp Adjustment..............................................................................................
417-01-133
417-01-134
417-01-140

Front Fog Lamp Vehicles Built Up To: 11/2004 ........................................ (32 281 0)
417-01-141
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Exterior Lighting
417-01-2
Page 2 of 2
Front Fog Lamp Vehicles Built From: 11/2004 .........................................
Headlamp Switch..........................................................................................
Headlamp Assembly.....................................................................................
Rear Lamp Assembly ...................................................................................
(32 281 0)
(35 514 0)
(32 115 0)
(32 305 0)
417-01-142
417-01-143
417-01-144
417-01-146
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Exterior Lighting
417-01-3
SPECIFICATIONS
Exterior Lighting
Component
Headlamps
Fog lamps
Headlamps - Align (both sides)
Component
Headlamps
Fog lamps
G115905 en
Design
Complex reflector system, aligned by positioning the reflector
Reflector system, aligned by positioning the reflector
X value
X = 10 cm/10 m = 0 34' = 1,0 %
X = 22 cm/10 m = 1 16' = 2,2 %
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Exterior Lighting
417-01-4

Exterior Lighting
The reflectors are free shape reflectors. The free
shape technology allows the full reflector to be
utilised.
Front lighting
In this technology, every point of the freely

calculated reflector is allocated to illuminating a
certain part of the road in front of the vehicle. As a
result it is possible to optimise the light distribution
through the form of the reflector alone.
Front headlamps
The plastic cover is only there for protection.

Conventional H4 bulbs are used in the main
headlamps.
The turn signal lamps are equipped with PY21W
bulbs. These are coloured yellow and feature
special bases to avoid confusion.
5W glass base bulbs are used for the side lights.
Fog lights
Item
Part
Number
Description
The fog lights are mounted in the lower part of the

front bumper.
H11 bulbs with a power rating of 55W are used.
Turn signal lamp
Side light
Main headlamp
The headlamps form a unit with the front turn

signal lamps and the side lights. They are made
entirely of plastic and can only be replaced as a
whole unit.
The motors for the electric headlamp levelling

system are integrated in the headlamp unit.
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417-01-5
Exterior Lighting
417-01-5
Rear lighting
Description
The rear lamp cluster should be detached from the

vehicle before replacing any bulbs.
Stoplamp/side light
Side light
Turn signal lamp
Rear fog lamp
Bulb carrier
Securing bolts
Item
Part
Number
As well as the rear lamps, the rear lamp clusters

incorporate all rearward facing lights with
exception of the license plate lamp and the
additional high-mounted stoplamp.
The side light is a combined 21/5 W bulb, which

also contains the stoplamp.
Stoplamp
The additional high-mounted stoplamp is mounted

in the middle of the tailgate above the rear window
and also incorporates the washer nozzle for the
rear window. A 16W glass base bulb is used.
The rear lamps can only be replaced as a

complete unit.
The stoplamps (21/5W bulb) are switched on by

the stoplamp switch on the brake pedal as soon as
the brake pedal is depressed.
They incorporate a bulb carrier with the bulb

sockets.
Turn signal lamps
The bulb carrier is connected to the wiring harness

via a compact connector.
G179068 en
The turn signal lamps are used to indicate a turn

signal and for the hazard warning lights. They use
a PY21W bulb coloured yellow.
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Exterior Lighting
417-01-6

The function of the turn signal lamps is controlled
by the GEM, as a result of which the conventional
turn signal/hazard warning relay is no longer
required.
The sound generator for the acoustic turn signal
check is integrated in the multifunction switch.
Backup lamp
The backup lamp (21W bulb) is used to illuminate

the road when reversing, and is switched on by
the reversing switch on the transmission when
reverse gear is engaged.
There is only a backup lamp on the passenger
side of the vehicle, i.e. on the right-hand side for a
LHD vehicle and on the left-hand side for a RHD
vehicle.
Rear fog lamp
The rear fog lamp (21W bulb) is used to make the

vehicle more readily visible for vehicles behind
and can only be switched on if at least the side
lights are switched on.
This is achieved via the mechanical design of the
light switch, which will only allow the lever to be
pulled if it was moved to at least "P" beforehand.
The rear fog lamp is always installed on the
driver's side, i.e. on the opposite side to the
backup lamp
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417-01-7
Exterior Lighting
417-01-7

Headlamps
Special Tool(s)
Terminal Probe Kit
29-011A
Electrical system
3.
Fuse(s)
Lamp(s)
Connector(s)
Switches
Wiring harness
Resolve any obvious causes or concerns
carrying out any further tests.
4. If the concern is not visually evident, refer to
the Symptom Chart.

damage.
Symptom Chart
Symptom
Dipped beam and main beam
are inoperative
Possible Sources
Action
Fuse
Circuit(s)
Headlight switch
Turn signal switch
Central junction box (CJB)
The dipped beam is inoperative Circuit(s)

Dipped beam relay
Turn signal switch
The main beam is inoperative
Circuit(s)
Main beam relay
Turn signal switch
One dipped beam is inoperative Fuse

Circuit(s)
Left/right-hand headlamp
One main beam is inoperative
G105797 en
Fuse
Circuit(s)
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417-01-8
Exterior Lighting
417-01-8

Possible Sources
Symptom
Action
The headlamps illuminate continuously
Circuit(s)
Dipped beam relay
Main beam relay
Turn signal switch
Headlight switch
Instrument cluster
The headlamp flasher is inoperative
Circuit(s)
Turn signal switch
The main beam warning lamp is Circuit(s)

inoperative
Instrument cluster
REFER to Section
Instrument Cluster]
System Checks
NOTE:Use a digital multimeter for all electrical
measurements.
PINPOINT TEST A: DIPPED BEAM AND MAIN BEAM INOPERATIVE
TEST CONDITIONS
A1: CHECK FUSE F40 (CJB)
1Ignition switch in position 0.
2CHECK fuse F40 (10 A) (CJB).
Is the fuse OK?
Yes
GO to A2
No
INSTALL A NEW fuse F40 (10 A) and check
the operation of the system. If the fuse blows
again, LOCATE and RECTIFY the short to
ground using the Wiring Diagrams. CHECK
the operation of the system.
A2: CHECK THE VOLTAGE AT FUSE F40 (CJB)

1 Connect fuse F40 (10 A) (CJB).
and ground.
Yes
GO to A3
No
LOCATE and RECTIFY the break in the
voltage supply to fuse F40 (CJB) using the
Wiring Diagrams, if necessary CHECK and
INSTALL A NEW CJB. CHECK the operation
of the system.
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Exterior Lighting
417-01-9

TEST CONDITIONS
A3: CHECK THE VOLTAGE AT THE DIPPED BEAM RELAY

2 Disconnect dipped beam relay from socket
C417.
4 SWITCH ON dipped beam
5 Measure the voltage between the dipped beam
relay, socket C417, pin 1, circuit 15S-LE19
(GN/BU), CJB side and ground.

Yes
GO to A4
No
GO to A5
A4: CHECK THE GROUND CONNECTION OF THE DIPPED BEAM RELAY AND THE MAIN BEAM
RELAY
2 Measure the resistance between the dipped
beam relay, socket C417, pin 2, circuit 31-LE19
(BK), CJB side and ground.
Is less than 2 Ohm measured?

Yes
circuit 30-DB1 (RD), between fuse FE (BJB)
and the CJB using the wiring diagrams,
CHECK and INSTALL A NEW CJB if necessary. CHECK the operation of the system.
No
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Exterior Lighting
417-01-10

TEST CONDITIONS
LOCATE and RECTIFY break in circuit
31-DA12 (BK), between solder point S15 and
ground G13 using the wiring diagrams.
A5: CHECK THE VOLTAGE AT THE HEADLIGHT SWITCH
2 Disconnect headlight switch from connector
C338.
3 Measure the voltage between the headlight
switch, connector C338, pin 8, circuit 15-LE29
(GN/BK), wiring harness side and ground.

Yes
GO to A6
No
circuit between fuse F40 (CJB) and the
headlight switch using the wiring diagrams.
A6: CHECK THE HEADLIGHT SWITCH
2 Connect dipped beam relay to socket C417.
3 Using a fused test cable (10 A) at the headlight
switch, bridge between connector C338, pin 8,
circuit 15-LE29 (GN/BK) and pin 6, circuit
15S-LE14 (GN/RD), wiring harness side.

5 Check the operation of the dipped beam.
Does the dipped beam illuminate?
Yes
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Exterior Lighting
417-01-11

TEST CONDITIONS
INSTALL A NEW headlight switch. CHECK
No
GO to A7
A7: CHECK THE VOLTAGE AT THE TURN SIGNAL SWITCH
2 Connect headlight switch with connector C338.
3 Disconnect turn signal switch from connector
C357.
6 Measure the voltage between turn signal
switch, connector C357, pin 8, circuit 15S-LE14
(GN/RD), wiring harness side and ground.

Yes
INSTALL A NEW turn signal switch. CHECK
No
circuit between the headlight switch and turn
signal switch using the wiring diagrams.
PINPOINT TEST B: THE DIPPED BEAM IS INOPERATIVE
TEST CONDITIONS
B1: TEST THE VOLTAGE AT THE DIPPED BEAM RELAY (POWER CIRCUIT)
C417.
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TEST CONDITIONS
relay, socket C417, pin 3, circuit 30-LE20 (RD),
CJB side and ground.

Yes
GO to B2
No
circuit between the CJB and the dipped
beam relay using the wiring diagrams,
INSTALL A NEW CJB if necessary. CHECK
B2: CHECK THE VOLTAGE AT THE DIPPED BEAM RELAY (CONTROL CIRCUIT)
1 SWITCH ON dipped beam.

Yes
GO to B3
No
GO to B5
B3: CHECK THE POWER CIRCUIT OF THE DIPPED BEAM RELAY FOR OPEN CIRCUIT
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TEST CONDITIONS
2 Connect a fused jumper wire (20 A) at the
dipped beam relay, socket C417, between pin 3
circuit 30-LE20 (RD) and pin 5, circuit 15S-DB7
(GN/YE), CJB side.

4 Check the dipped beam.
Yes
GO to B4
No
circuit between the dipped beam relay and
the bridge (CJB) using the wiring diagrams,
B4: CHECK THE GROUND CONNECTION OF THE DIPPED BEAM RELAY
2 Measure the resistance between the dipped

Yes
INSTALL A NEW dipped beam relay.
No
circuit between the dipped beam relay and
soldered connection S15 using the wiring
diagrams. CHECK the operation of the system.
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TEST CONDITIONS
B5: CHECK TURN SIGNAL SWITCH

C357.
4 Connect a fused jumper wire (10 A) at the turn
indicator switch, connector C357, between pin
8, circuit 15S-LE14 (GN/RD) and pin 9, circuit
15S-LE19 (GN/BU), wiring harness side.

Yes
No
circuit between the turn signal switch and the
dipped beam relay using the wiring diagrams. CHECK the operation of the system.
PINPOINT TEST C: THE MAIN BEAM IS INOPERATIVE
TEST CONDITIONS
C1: CHECK THE MAIN BEAM WARNING LAMP
2 SWITCH ON main beam.
3 Check the main beam warning lamp.
Does the main beam warning lamp illuminate?
Yes
GO to C3
No
GO to C2
C2: CHECK TURN SIGNAL SWITCH

C357.
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TEST CONDITIONS
3 Connect a fused jumper wire (10 A) at the turn
indicator switch, connector C357, between pin
6, circuit 15-LE14 (GN/RD) and pin 7, circuit
15S-LE12A (GN/YE), wiring harness side.

5 Check main beam.
Does the main beam illuminate?
Yes
No
circuit between the turn signal switch and
C3: CHECK THE VOLTAGE AT THE MAIN BEAM RELAY (CONTROL CIRCUIT)
1
2
3
4
5

Disconnect main beam relay from socket C411.
SWITCH ON main beam.
Measure the voltage between the main beam
(GN/YE), CJB side and ground.

Yes
GO to C4
No
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TEST CONDITIONS
circuit between the soldered connection
S274 and the main beam relay using the
wiring diagrams, INSTALL A NEW CJB if
necessary. CHECK the operation of the
system.
C4: TEST THE VOLTAGE AT THE MAIN BEAM RELAY (POWER CIRCUIT)
1 Measure the voltage between the main beam
relay, socket C411, pin 3, circuit 30-LE13 (RD),
CJB side and ground.

Yes
GO to C5
No
circuit between the CJB (bridge) and the
main beam relay using the wiring diagrams,
C5: CHECK THE GROUND CONNECTION OF THE MAIN BEAM RELAY
2 Measure the resistance between the main

Yes
GO to C6
No
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Exterior Lighting
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TEST CONDITIONS
circuit between the main beam relay and
C6: CHECK THE POWER CIRCUIT OF THE MAIN BEAM RELAY FOR OPEN CIRCUIT
2 Connect a fused bridging cable (20 A) at the
main beam relay, socket C411, between pin 3
circuit 30-LE13 (RD) and pin 5, circuit 15S-DB6
(GN/WH), CJB side.

4 Check main beam.
Yes
INSTALL A NEW main beam relay. CHECK
No
circuit between the main beam relay and the
CJB (bridge) using the wiring diagrams,
PINPOINT TEST D: ONE DIPPED BEAM IS INOPERATIVE
TEST CONDITIONS
D1: DETERMINE THE FAULT CONDITION

3 Determine the fault condition.
Is the left-hand dipped beam inoperative?
Yes
GO to D2
No
The right-hand dipped beam is inoperative:
GO to D6
D2: CHECK FUSE F9 (CJB)
2 CHECK fuse F9 (10 A) (CJB).
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TEST CONDITIONS
Is the fuse OK?
Yes
GO to D3
No
INSTALL A NEW fuse F9 (10 A). If the fuse
blows again, LOCATE and RECTIFY the
short to ground using the Wiring Diagrams.
D3: CHECK THE VOLTAGE AT FUSE F9 (CJB)

1
2
3
4
Connect fuse F9 (10 A) (CJB).

SWITCH ON dipped beam
Measure the voltage between fuse F9 (10 A)
and ground.

Yes
GO to D4
No
of the system.
D4: CHECK VOLTAGE AT THE LEFT-HAND HEADLAMP
2 Disconnect left-hand headlamp from connector
C416.
5 Measure the voltage between left-hand headlamp, connector C416, pin 2, circuit 15S-LE16

Yes
GO to D5
No
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TEST CONDITIONS
headlamp using the wiring diagrams.
D5: CHECK GROUND CONNECTION OF THE LEFT-HAND HEADLAMP
2 Measure the resistance between left-hand
headlamp, connector C416, pin 6, circuit
31-LE31 (BK), wiring harness side and ground.

Yes
CHECK and if necessary INSTALL A NEW
left-hand headlamp. CHECK the operation of
the system.
No
circuit between the headlamp and soldered
connection S10 using the wiring diagrams.
D6: CHECK FUSE F10 (CJB)
Is the fuse OK?
Yes
GO to D7
No
D7: CHECK THE VOLTAGE AT FUSE F10 (CJB)
1
2
3
4

SWITCH ON dipped beam
and ground.

Yes
GO to D8
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TEST CONDITIONS
No
voltage supply to the fuse using the wiring
diagrams, if necessary CHECK and
of the system.
D8: CHECK VOLTAGE AT THE RIGHT-HAND HEADLAMP
2 Disconnect right-hand headlamp from connector C422.
5 Measure the voltage between right-hand
15S-LE23 (GN/WH), wiring harness side and
ground.

Yes
GO to D9
No
D9: CHECK GROUND CONNECTION OF THE RIGHT-HAND HEADLAMP
2 Measure the resistance between right-hand

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TEST CONDITIONS
Yes
right-hand headlamp. CHECK the operation
of the system.
No
PINPOINT TEST E: ONE MAIN BEAM IS INOPERATIVE

TEST CONDITIONS
E1: DETERMINE THE FAULT CONDITION
Is the left-hand main beam inoperative?
Yes
GO to E2
No
The right-hand main beam is inoperative:
GO to E6
E2: CHECK FUSE F52 (CJB)

Is the fuse OK?
Yes
GO to E3
No
E3: CHECK THE VOLTAGE AT FUSE F52 (CJB)
1
2
3
4

and ground.

Yes
GO to E4
No
of the system.
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TEST CONDITIONS
E4: CHECK VOLTAGE AT THE LEFT-HAND HEADLAMP

C416.
(GN/BK), wiring harness side and ground.

Yes
GO to E5
No
circuit between fuse F52 (CJB) and the left
E5: CHECK GROUND CONNECTION OF THE LEFT-HAND HEADLAMP

Yes
headlamp. CHECK the operation of the
system.
No
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TEST CONDITIONS
E6: CHECK FUSE F53 (CJB)

Is the fuse OK?
Yes
GO to E7
No
E7: CHECK THE VOLTAGE AT FUSE F53 (CJB)
1
2
3
4

and ground.

Yes
GO to E8
No
of the system.
E8: CHECK VOLTAGE AT THE RIGHT-HAND HEADLAMP
2 Disconnect right-hand headlamp from connector C422.
15S-LE22 (GN/OG), wiring harness side and
ground.
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TEST CONDITIONS

Yes
GO to E9
No
circuit between fuse F53 (CJB) and the right
E9: CHECK GROUND CONNECTION OF THE RIGHT-HAND HEADLAMP

Yes
system.
No
PINPOINT TEST F: THE HEADLAMPS ILLUMINATE CONTINUOUSLY
TEST CONDITIONS
F1: DETERMINE THE FAULT CONDITION
Is the main beam permanently switched on?

Yes
GO to F7
No
Dipped beam permanently switched on: GO
to F2
F2: NARROW DOWN THE CAUSE OF THE SHORT TO BATTERY VOLTAGE
NOTE:Switch off dipped beam.
C417.
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TEST CONDITIONS

Yes
GO to F3
No
GO to F4
1
2
3
4
5

Disconnect fuse F9 (10 A) (CJB).
Check the dipped beam.
Does the dipped beam illuminate on one side?

Yes
- Left-hand dipped beam illuminates:
LOCATE and RECTIFY the short to battery
voltage in circuit 15S-LE16 (GN/OG), which
is connected to the output of fuse F9 (10 A)
(CJB), using the wiring diagrams. CHECK
- Right-hand dipped beam illuminates:
voltage in circuit 15S-LE23 (GN/WH), which
No
voltage in circuit 15S-DB7 (GN/YE), between
dipped beam relay and CJB, using the wiring
diagrams, if necessary INSTALL A NEW
CJB. CHECK the operation of the system.
F4: CHECK THE VOLTAGE AT THE DIPPED BEAM RELAY (CONTROL CIRCUIT)

Yes
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TEST CONDITIONS
GO to F5
No
INSTALL A NEW dipped beam relay.
F5:CHECK CONTROL CIRCUIT 15S-LE19 (GN/BU) FOR SHORT TO BATTERY VOLTAGE
C357.
4 Measure voltage between turn signal switch,
connector C357, pin 9, circuit 15S-LE19
(GN/BU), wiring harness side and ground.

Yes
voltage in the circuit between the turn signal
switch and the dipped beam relay using the
wiring diagrams. CHECK the operation of the
system.
No
GO to F6
F6: CHECK THE HEADLIGHT SWITCH
C338.
3 Connect turn signal switch with connector
C357.
Yes
LOCATE and RECTIFY short to battery
voltage in circuit 15S-LE14 (GN/RD) between headlight switch and turn signal switch
using the wiring diagrams. CHECK the operation of the system.
No
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TEST CONDITIONS
NOTE: Main beam is switched off.
1
2
3
4

Disconnect main beam relay from socket C411.
Check the main beam.

Yes
GO to F8
No
GO to F9
1
2
3
4
5

Check the main beam.
Does main beam illuminate on one side?

Yes
- Left-hand main beam illuminates: LOCATE
and RECTIFY the short to battery voltage in
circuit 15S-LE15 (GN/BK), which is connected to the output of fuse F52 (10 A) (CJB),
- Right-hand main beam illuminates:
voltage in circuit 15S-LE22 (GN/OG), which
No
voltage in circuit 15S-DB6 (GN/WH), between main beam relay and CJB, using the
wiring diagrams, if necessary INSTALL A
NEW CJB. CHECK the operation of the
system.
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TEST CONDITIONS
F9: CHECK THE VOLTAGE AT THE MAIN BEAM RELAY (CONTROL CIRCUIT)
1 Measure the voltage between the main beam
(GN/YE), CJB side and ground.

Yes
GO to F10
No
INSTALL A NEW main beam relay. CHECK
F10: CHECK CONTROL CIRCUIT 15S-LE12 (GN/YE) FOR SHORT TO BATTERY VOLTAGE
C357.
switch, connector C357, pin 7, circuit
15S-LE12A (GN/YE), wiring harness side and
ground.

Yes
GO to F11
No
F11: CHECK THE INSTRUMENT CLUSTER
2 Disconnect instrument cluster from connector
C332.
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TEST CONDITIONS
switch, connector C357, pin 7, circuit
15S-LE12A (GN/YE), wiring harness side and
ground.

Yes
voltage in the circuit(s) connected to soldered connection S274 using the wiring
No
CHECK the instrument cluster using WDS,
INSTALL A NEW ONE if necessary. CHECK
PINPOINT TEST G: THE HEADLAMP FLASHER IS INOPERATIVE
TEST CONDITIONS
G1:DETERMINE THE FAULT CONDITION
Is the main beam permanently switched on?
Yes
GO to G2
No
G2: LOCATE THE FAULT

C357.
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TEST CONDITIONS
(GN/RD), wiring harness side and ground.

Yes
No
circuit between the headlight switch and turn
signal switch using the wiring diagrams.
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Exterior Lighting
417-01-31

Stoplamps
Special Tool(s)
Terminal Probe Kit
29-011A
Mechanical
Electrical
Stop lamp switch

adjustment
Fuse(s)
Lamp(s)
Connector(s)
Switches
Wiring harness
3. Resolve any obvious causes or concerns
the Symptom Chart.

2. Visually inspect for the following mechanical
and electrical causes of the concern.
Visual Inspection
Symptom Chart
Symptom
Possible Sources
Action
Stop lamps are inoperative
Fuse
Circuit(s)
Stop lamp switch
GO to Pinpoint Test H
One or more stop lamps are inoperative
Circuit(s)
Left/right-hand rear lamp
assembly
Additional high-mounted stop
lamp
GO to Pinpoint Test I
Stop lamps illuminate continuously
Circuit(s)
GO to Pinpoint Test J
Stop lamp switch
ABS control module
Electronic stability program
(ESP) module
Transmission control unit (TCU)
(with automatic clutch and
gearshift actuation)
Transmission selector lever
assembly
Trailer control unit
(PCM)
System Checks
NOTE:Use a digital multimeter for all electrical
measurements.
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PINPOINT TEST H: STOP LAMPS ARE INOPERATIVE
TEST CONDITIONS
H1: CHECK FUSE F45 (CJB)

2 Disconnect fuse F45 (15 A) (CJB.
3 CHECK fuse F45 (15 A).
Is the fuse OK?
Yes
GO to H2
No
H2: CHECK THE VOLTAGE AT FUSE F45 (CJB)
and ground.
Yes
GO to H3
No
of the system.
H3: CHECK VOLTAGE AT STOP LAMP SWITCH
2 Disconnect stop lamp switch from connector
C355.
4 Measure the voltage between the stop lamp
switch, connector C355, pin 1, circuit 15-LG23
(GN/WH), wiring harness side and ground.

Yes
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TEST CONDITIONS
GO to H4
No
15-LG23 (GN/WH) between fuse F45 (CJB)
and the stop lamp switch using the wiring
H4: CHECK THE STOP LAMP SWITCH

2 Connect a fused jumper wire (15 A) at the stop
lamp switch, connector C355, between pin 1,
circuit 15-LG23 (GN/WH) and pin 3, circuit
15S-DA12 (GN/WH), wiring harness side.

4 Check the operation of the stop lamps.
Do the stop lamps illuminate?
Yes
INSTALL A NEW stop lamp switch. CHECK
No
15S-DA12 (GN/WH) between the stop lamp
switch and soldered connection S12 using
the wiring diagrams. CHECK the operation of
the system.
PINPOINT TEST I: ONE OR MORE STOP LAMPS ARE INOPERATIVE
TEST CONDITIONS
I1:DETERMINE THE FAULT CONDITION

C355.
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TEST CONDITIONS
3 Connect a fused jumper wire (15 A) at the stop
lamp switch, connector C355, between pin 1,
circuit 15-LG23 (GN/WH) and pin 3, circuit
15S-DA12 (GN/WH), wiring harness side.

6 Check the stop lamps.
Is the additional high-mounted stop lamp inoperative?
Yes
GO to I8
No
- Left-hand stop lamp is inoperative: GO to I2
- Right-hand stop lamp is inoperative: GO to
I5
I2: DETERMINE THE FAULT CONDITION
2 SWITCH ON the side lights.
3 Check the left-hand rear side light.
Does the left-hand rear side light illuminate?
Yes
GO to I3
No
GO to I4
I3: CHECK THE VOLTAGE SUPPLY TO THE LEFT-HAND STOP LAMP
NOTE: The jumper wire used in the first step is still connected.
2 Disconnect left-hand rear lamp assembly from.
- Vehicles without trailer socket: connector
C333
- Vehicles with trailer socket: connector C333a
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TEST CONDITIONS
4 Measure the voltage between:
- Without trailer socket: left-hand rear lamp
assembly, connector C333, pin 2, circuit
15S-LG14 (GN/RD), wiring harness side and
ground.
- With trailer socket: left-hand rear lamp assembly, connector C333a, pin 2, circuit

Yes
left-hand rear lamp assembly. CHECK the
operation of the system.
No
circuit between soldered connection S12 and
left-hand rear lamp assembly using the wiring diagrams. CHECK the operation of the
system.
I4: CHECK GROUND CONNECTION OF LEFT-HAND REAR LAMP ASSEMBLY
2 Disconnect left-hand rear lamp assembly from.
C333
3 Measure the resistance between the left-hand
rear lamp assembly:
- Without trailer socket: connector C333, pin 4,
circuit 31-LF23 (BK), wiring harness side and
ground.
- With trailer socket: connector C333a, pin 4,
circuit (GN), wiring harness side and ground.

Yes
No
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TEST CONDITIONS
circuit between the left-hand rear lamp assembly and soldered connection S24 using
the system.
I5:DETERMINE THE FAULT CONDITION

2 Check the rear right-hand side light.
Does the rear right-hand side light illuminate?
Yes
GO to I6
No
GO to I7
I6: CHECK THE VOLTAGE SUPPLY TO THE RIGHT-HAND STOP LAMP
2 Disconnect right-hand rear lamp assembly
from.
C348
- Without trailer socket: right-hand rear lamp
assembly, connector C348, pin 2, circuit
15S-LG21 (GN/BK), wiring harness side and
ground.
- With trailer socket: right-hand rear lamp assembly, connector C348a, pin 2, circuit (GN),
wiring harness side and ground.

Yes
right-hand rear lamp assembly. CHECK the
No
right-hand rear lamp assembly using the
system.
I7: CHECK GROUND CONNECTION OF THE RIGHT-HAND REAR LAMP ASSEMBLY
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TEST CONDITIONS
from.
C348
3 Measure the resistance between the right-hand
rear lamp assembly:
- Without trailer socket: connector C348, pin 4,
ground.
- With trailer socket: connector C348a, pin 4,
circuit (BK), wiring harness side and ground.

Yes
No
circuit between the right-hand rear lamp
assembly and ground G18 using the wiring
I8: CHECK VOLTAGE AT THE ADDITIONAL HIGH-MOUNTED STOP LAMP
2 Disconnect additional high-mounted stop lamp
from connector C550.
4 Measure the voltage between the additional
high-mounted stop lamp, connector C550, pin 1,
circuit 15S-LG6 (GN/YE) or 31-LG6S (BK) (vehicles with anti-theft warning system), wiring

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TEST CONDITIONS
Yes
GO to I9
No
the additional high-mounted stop lamp using
the system.
I9: CHECK GROUND CONNECTION OF ADDITIONAL HIGH-MOUNTED STOP LAMP
2 Measure the resistance between the additional
high-mounted stop lamp, connector C550, pin 2,
circuit 31-LG6 (BK), wiring harness side and
ground.

Yes
additional high-mounted stop lamp. CHECK
No
circuit between the additional high-mounted
stop lamp and soldered connection S201
PINPOINT TEST J: STOP LAMPS ILLUMINATE CONTINUOUSLY
TEST CONDITIONS
J1: CHECK THE STOP LAMP SWITCH

C355.
4 CHECK the stop lamps.
Do the stop lamps illuminate continuously?
Yes
- Vehicles with manual transmission: GO to
J4
- Vehicles with 4-speed automatic transmission (AW81-40): GO to J2
- Vehicles with Durashift EST: GO to J3
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TEST CONDITIONS
No
INSTALL A NEW stop lamp switch. CHECK
J2: RULE OUT TRANSMISSION SELECTOR LEVER ASSEMBLY AS POSSIBLE CAUSE FOR A
SHORT TO BATTERY VOLTAGE
1
2
3
4

Disconnect fuse F33 (7.5 A) (CJB).
CHECK the stop lamps.

Yes
GO to J4
No
INSTALL A NEW transmission selector lever
assembly.CHECK the operation of the system.
J3: RULE OUT THE TRANSMISSION CONTROL MODULE (TCU) AS POSSIBLE CAUSE FOR A
1
2
3
4
5

Disconnect fuse F41 (7.5 A) (CJB).
Disconnect fuse FB (60 A) (BJB).

Yes
GO to J4
No
CHECK the transmission control unit (TCU)
using WDS and INSTALL A NEW ONE if
system.
J4: DETERMINE MODEL VERSION
2 Connect following components.
- Vehicles with 4-speed automatic transmission
(AW81-40): fuse F33 (7.5 A) (CJB)
- Vehicles with Durashift EST: fuse F41 (7.5 A)
(CJB)
- Vehicles with Durashift EST: fuse FB (60 A)
(BJB)
3 Determine the model version.
Is the vehicle equipped with ABS or ESP?
Yes
GO to J5
No
GO to J6
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TEST CONDITIONS
J5: RULE OUT ABS CONTROL MODULE OR ELECTRONIC STABILITY PROGRAM (ESP)
MODULE AS POSSIBLE CAUSE FOR A SHORT TO BATTERY VOLTAGE
1
2
3
4
5


Yes
GO to J6
No
CHECK the ABS control module or electronic
stability program (ESP) module using WDS,
J6: DETERMINE MODEL VERSION
1
2
3
4
5

Determine the model version.
Is the vehicle equipped with a trailer socket?

Yes
GO to J7
No
GO to J8
J7: RULE OUT TRAILER CONTROL UNIT AS CAUSE FOR A SHORT TO BATTERY VOLTAGE
1 Disconnect following components.
- Vehicles built before 09/2002: fuse F31 (20 A)
(CJB)
- Vehicles built after 09/2002: fuse F56 (20 A)
(CJB)
Yes
GO to J8
No
INSTALL A NEW trailer control unit. CHECK
J8: RULE OUT THE POWERTRAIN CONTROL MODULE (PCM) AS POSSIBLE CAUSE FOR A
2 Connect following components.
(CJB)
(CJB)
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TEST CONDITIONS
3 Disconnect powertrain control module from.
- 1.25/ 1.4/ 1.6L Duratec-16V (Sigma):
connector C343
- 1.4L Duratorq-TDCI (DV): connectors C370,
C371 and C372
Yes
voltage in the circuits connected to soldered
No
CHECK the PCM module using WDS,
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Exterior Lighting
417-01-42

Turn Signal and Hazard Lamps
Special Tool(s)
Terminal Probe Kit
29-011A
Electrical
3.
Fuse(s)
Lamp(s)
Connector(s).
Switches
Wiring harness
the Symptom Chart.

damage.
Visual Inspection
Symptom Chart
Symptom
Possible Sources
Action
All turn signal lamps inopera Fuse(s)

tive/flash continuously/illuminate Circuit(s)
continuously
Turn signal switch
Generic electronic module
(GEM)
GO to Pinpoint Test K
One/several turn signal lamps

are inoperative
Circuit(s)
Headlamp
Turn signal side lamp
assembly
GO to Pinpoint Test L
One or more turn signal lamps

flash continuously:
Circuit(s)
Headlamp
assembly
GO to Pinpoint Test M
One/several turn signal lamps

illuminate continuously
Circuit(s)
Headlamp
assembly
GO to Pinpoint Test N
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Symptom
Possible Sources
Action
Hazard lamps inoperative / con- Fuse(s)

tinuously switched on
Circuit(s)
Hazard warning light switch
(GEM)
GO to Pinpoint Test O
System Check
measurements.
PINPOINT TEST K: ALL TURN SIGNAL LAMPS INOPERATIVE/FLASH
CONTINUOUSLY/ILLUMINATE CONTINUOUSLY
TEST CONDITIONS
K1: READ OUT THE FAULT MEMORY

1 Connect the diagnostic tool.
2 Check the system using WDS.
Are trouble codes (DTCs) shown?
Yes
RECTIFY the faults according to the WDS
instructions. CLEAR the fault memory and
No
GO to K2
K2: CHECK FUSE F38 (CJB)
2 Disconnect fuse F38 (7.5 A) (CJB).
3 CHECK fuse F38 (7.5 A) (CJB).
Is the fuse OK.?
Yes
GO to K3
No
RENEW fuse F38 (7.5 A) and check the operation of the system. If the fuse blows again,
using the Wiring Diagrams. CHECK the operation of the system.
K3: CHECK THE VOLTAGE AT FUSE F38 (CJB)
1 Connect fuse F38 (7.5 A) (CJB).
and ground.
Yes
GO to K4
No
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TEST CONDITIONS
RECTIFY the break in the voltage supply to
fuse F38 (CJB) using the wiring diagrams.
CHECK and RENEW the CJB if necessary.
K4: CHECK FUSE F25 (CJB)

2 Disconnect fuse F25 (15 A) (CJB).
Is the fuse OK.?
Yes
GO to K5
No
RENEW fuse F25 (15 A) and check the operation of the system. If the fuse blows again,
K5: CHECK THE VOLTAGE AT FUSE F25 (CJB)
and ground.
Yes
GO to K6
No
RECTIFY the break in the voltage supply to
fuse F25 (CJB) using the wiring diagrams.
CHECK and INSTALL A NEW CJB if necessary. CHECK the operation of the system.
K6: CHECK THE VOLTAGE SUPPLY TO THE GENERIC ELECTRONIC MODULE (GEM)
2 Disconnect generic electronic module (GEM)
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TEST CONDITIONS
5 Measure the voltage between the generic
electronic module (GEM), connector C319, pin
10, circuit 15-DK20 (GN/OG), wiring harness
side and ground.

4, circuit 29-LG26 (OG), wiring harness side
and ground.
Is battery voltage registered following both

measurements?
Yes
GO to K7
No
RECTIFY the break in the corresponding
circuit between fuse F38 (CJB) and the generic electronic module (GEM) or between
fuse F25 (CJB) and generic electronic module (GEM) using the wiring diagrams.
K7: CHECK THE GROUND CONNECTION FROM THE GENERIC ELECTRONIC MODULE (GEM)
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TEST CONDITIONS
3 Measure the resistance between the generic
2, circuit 91-DK20 (BK/RD), wiring harness side
and ground.

Yes
GO to K8
No
RECTIFY the break in the circuit between the
generic electronic module (GEM) and ground
G14 using the wiring diagrams. CHECK the
K8: DETERMINE THE FAULT CONDITION
1 Connect generic electronic module (GEM) with
connectors C318, C319 and C320.
3 Switch off the turn signals.
4 Check the turn signal lamps.
Do all turn signal lamps on the left and
right-hand side illuminate continuously?
Yes
generic electronic module (GEM). CHECK
No
- All turn signal lamps are inoperative GO to
K9
- All turn signal lamps flash continuously: GO
to K11
K9: DETERMINE THE FAULT CONDITION
1
2
3
4

Switch on LEFT-HAND TURN SIGNAL.
Switch on RIGHT-HAND TURN SIGNAL.
Check the left/right-hand turn signal lamps.
Are all of the turn signal lamps inoperative?

Yes
GO to K10
No
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TEST CONDITIONS
K10: CHECK THE GROUND CONNECTION OF THE TURN SIGNAL SWITCH

C357.
3 Measure the resistance between the turn signal
switch, connector C357, pin 2, circuit 31-LG27

Yes
RENEW the turn signal switch. CHECK the
No
circuit between the turn signal switch and
K11: CHECK HAZARD WARNING LIGHT SWITCH
2 Disconnect hazard warning light switch from
connector C321.
Do all turn signal lamps flash continuously?
Yes
GO to K12
No
INSTALL A NEW hazard warning light
switch. CHECK the operation of the system.
K12: CHECK CIRCUIT 31S-LG8 (BK/OG) FOR SHORT TO GROUND
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TEST CONDITIONS
16, circuit 31S-LG8 (BK/OG), wiring harness
side and ground.
Are more than 10 kOhm measured?

Yes
CHECK generic electronic module (GEM)
using WDS, and INSTALL a new one if
system.
No
in the circuit between the hazard warning
light switch and generic electronic module
(GEM) using the wiring diagrams. CHECK
PINPOINT TEST L: ONE/SEVERAL TURN SIGNAL LAMPS ARE INOPERATIVE
TEST CONDITIONS
L1: READ OUT THE FAULT MEMORY

Yes
No
GO to L2
L2: DETERMINE THE FAULT CONDITION
1
2
3
4

Switch on LEFT-HAND TURN SIGNAL.
Switch on RIGHT-HAND TURN SIGNAL.
Determine which turn signal lamp is inoperative.
Is one left-hand turn signal lamp inoperative?

Yes
- Left-hand turn signal side lamp and
left-hand front turn signal lamp are inoperative: GO to L3
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TEST CONDITIONS
- Left-hand rear turn signal lamp is inoperative: GO to L4
- Left-hand front turn signal lamp is inoperative: GO to L12
- Left-hand turn signal side lamp is inoperative: GO to L13
No
- Right-hand turn signal side lamp and
right-hand front turn signal lamp are inoperative: GO to L14
- Right-hand rear turn signal lamp is inoperative: GO to L15
- Right-hand front turn signal lamp is inoperative: GO to L23
- Right-hand turn signal side lamp is inoperative: GO to L24
L3: CHECK THE GROUND CONNECTION OF THE LEFT-HAND HEADLAMP
2 Switch on PARKING LIGHTS.
3 Check the front left-hand parking lamp.
Does parking lamp illuminate?
Yes
No
ground connection G4 using the Wiring Diagrams. CHECK the operation of the system.
L4: CHECK THE GROUND CONNECTION OF THE LEFT-HAND REAR LAMP ASSEMBLY
3 Check the rear parking lamp.
Yes
GO to L5
No
31-LF23 (BK) or (GN) between the rear lamp
diagrams. CHECK and INSTALL A NEW rear
lamp assembly if necessary. CHECK the
L5: CHECK THE VOLTAGE AT THE LEFT-HAND REAR LAMP ASSEMBLY
2 Disconnect rear lamp assembly from .
C333
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TEST CONDITIONS
4 Switch on LEFT-HAND TURN SIGNAL.
5 Measure voltage between left-hand rear lamp
assembly:
C333, pin 3, circuit 49-LG12 (BU), wiring
- Vehicles with trailer socket: connector C333a,
pin 3, circuit (GY/WH), wiring harness side and
ground.
Does the meter display fluctuating battery

voltage?
Yes
rear lamp assembly. CHECK the operation of
the system.
No
- Vehicles without trailer socket: LOCATE
and RECTIFY the break in the circuit
49-LG12 (BU) between generic electronic
module (GEM) and the rear lamp assembly
using the wiring diagrams. CHECK and
INSTALL A NEW generic electronic module
(GEM) if necessary. CHECK the operation of
the system.
- Vehicles with trailer socket: GO to L6
L6: CHECK FUSE
2 Disconnect following components .
(CJB)
(CJB)
3 CHECK fuse F31 or F56 (20 A) (CJB) .
Is the fuse OK.?
Yes
GO to L7
No
INSTALL A NEW fuse F31 (20 A) or F56 (20
A) and check the operation of the system. If
the fuse blows again, LOCATE and
RECTIFY the short to ground using the
the system.
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TEST CONDITIONS
L7: CHECK VOLTAGE AT FUSE

1 Connect Fuse .
- Vehicles built before 09/2002: F31 (20 A)
(CJB)
- Vehicles built after 09/2002: F56 (20 A) (CJB)
- Vehicles built before 09/2002: fuse F31, CJB
and ground.
- Vehicles built after 09/2002: fuse F56, CJB
and ground.
Yes
GO to L8
No
- Vehicles built before 09/2002: RECTIFY the
break in the voltage supply to fuse F31 (CJB)
- Vehicles built after 09/2002: RECTIFY the
L8: CHECK THE VOLTAGE SUPPLY OF THE TRAILER CONTROL UNIT
2 Disconnect trailer control unit from connector
C1041 .
4 Measure the voltage between the trailer control
unit, connector C1041, pin 8, circuit (RD), wiring
harness side and pin 10, circuit (RD), wiring

measurements?
Yes
GO to L9
No
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TEST CONDITIONS
- Vehicles built before 09/2002: LOCATE and
RECTIFY the break in the circuit between
fuse F31 (CJB) and the trailer control unit
- Vehicles built after 09/2002: LOCATE and
L9: CHECK THE GROUND CONNECTION OF THE TRAILER CONTROL UNIT
2 Measure the resistance between the trailer
control unit, connector C1041, pin 1, circuit
(BN), wiring harness side and ground.

Yes
GO to L10
No
relevant circuit (BN) between the trailer control unit and ground connection G18 using
the Wiring Diagrams. CHECK the operation
of the system.
L10: CHECK THE CONTROL CIRCUIT 49-LG12 (BU) OR (WH) AT THE TRAILER CONTROL UNIT
FOR OPEN CIRCUIT
C1030 .
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TEST CONDITIONS
unit, connector C1030, pin 1, circuit (WH), wiring harness side and ground.

voltage?
Yes
GO to L11
No
circuit 49-LG12 (BU) or (WH) between generic electronic module (GEM) and the trailer
control unit using the wiring diagrams.
CHECK and INSTALL A NEW generic electronic module (GEM) if necessary. CHECK
L11: CHECK THE TRAILER CONTROL UNIT
2 Connect a fused jumper lead (20 A) at the trailer
control unit, connector C1030, between pin 1,
circuit (WH) and pin 3, circuit (GY/WH), wiring
harness side.

5 Check the operation of the left-hand rear turn
signal lamp.
Does the turn signal lamp operate correctly?
Yes
RENEW the trailer control unit. CHECK the
No
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TEST CONDITIONS
circuit (GY/WH) between the trailer control
unit and rear lamp assembly using the wiring
L12: CHECK THE LEFT-HAND FRONT TURN SIGNAL LAMP
C416 .
5 Measure the voltage between the left-hand
49-LG11 (BU/OG), wiring harness side and
ground.

voltage?
Yes
31-LE31 (BK), between the headlamp and
diagrams. CHECK and INSTALL NEW
headlamps if necessary. CHECK the operation of the system.
No
circuit between generic electronic module
(GEM) and the headlamp using the wiring
L13: CHECK THE VOLTAGE AT THE LEFT-HAND TURN SIGNAL SIDE LAMP
2 Disconnect left-hand turn signal side lamp from
connector C337 .
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TEST CONDITIONS
5 Measure the voltage between the left-hand turn
signal side lamp, connector C337, pin 1, circuit
49-LG13 (BU/RD), wiring harness side and
ground.

voltage?
Yes
31-LG13 (BK) between the turn signal side
lamp and soldered connection S10 using the
wiring diagrams. CHECK and INSTALL A
NEW turn signal side lamp if necessary.
No
(GEM) and the turn signal side lamp using
the wiring diagrams. CHECK and INSTALL A
L14: CHECK THE GROUND CONNECTION OF THE RIGHT-HAND HEADLAMP
3 Check the front right parking lamp.
Yes
No
L15: CHECK THE GROUND CONNECTION OF THE RIGHT-HAND REAR LAMP ASSEMBLY
Yes
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TEST CONDITIONS
GO to L16
No
31-LF24 (BK) or (BK) between the rear lamp
diagrams. CHECK and INSTALL A NEW rear
L16: CHECK THE VOLTAGE AT THE RIGHT-HAND REAR LAMP ASSEMBLY
2 Disconnect rear lamp assembly from .
C348
4 Switch on RIGHT-HAND TURN SIGNAL.
5 Measure voltage between the right-hand rear
lamp assembly:
C348, pin 3, circuit 49-LG19 (BU/RD), wiring
pin 3, circuit (GN/YE), wiring harness side and
ground.

voltage?
Yes
rear lamp assembly. CHECK the operation of
the system.
No
and RECTIFY the break in the circuit between the generic electronic module (GEM)
and the rear lamp assembly using the wiring
diagrams. CHECK and INSTALL A NEW
generic electronic module (GEM) if necessary. CHECK the operation of the system.
- Vehicles with trailer socket: GO to L17
L17: CHECK FUSE
(CJB)
(CJB)
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TEST CONDITIONS
3 CHECK fuse F31 or F56 (20 A) (CJB) .
Is the fuse OK.?
Yes
GO to L18
No
the system.
L18: CHECK VOLTAGE AT FUSE

1 Connect Fuse .
(CJB)
and ground.
- Vehicles built after 09/2002: fuse F56, CJB
and ground.
Yes
GO to L19
No
L19: CHECK THE VOLTAGE SUPPLY OF THE TRAILER CONTROL UNIT
C1041 .
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TEST CONDITIONS

measurements?
Yes
GO to L20
No
L20: CHECK THE GROUND CONNECTION OF THE TRAILER CONTROL UNIT

Yes
GO to L21
No
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TEST CONDITIONS
of the system.
L21: CHECK THE CONTROL CIRCUIT 49-LG19 (BU/RD) OR (GN/RD) AT THE TRAILER CONTROL
UNIT FOR OPEN CIRCUIT
C1035 .
unit, connector C1035, pin 1, circuit (GN/RD),

voltage?
Yes
GO to L22
No
circuit 49-LG19 (BU/RD) or (GN/RD) between generic electronic module (GEM) and
the trailer control unit using the wiring diagrams. CHECK and INSTALL A NEW generic electronic module (GEM) if necessary.
L22: CHECK THE TRAILER CONTROL UNIT
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TEST CONDITIONS
circuit (GN/RD) and pin 3, circuit (GN/YE), wiring harness side.

5 Check the operation of the right-hand rear turn
signal lamp.
Does the turn signal lamp operate correctly?
Yes
No
circuit (GY/YE) between the trailer control
unit and rear lamp assembly using the wiring
L23: CHECK THE RIGHT-HAND FRONT TURN SIGNAL LAMP
2 Disconnect right-hand headlamp from connector C422 .
5 Measure the voltage between the right-hand
49-LG18 (BU), wiring harness side and ground.

voltage?
Yes
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TEST CONDITIONS
31-LE30 (BK), between the headlamp and
No
(GEM) and the headlamp using the wiring
L24: CHECK THE VOLTAGE AT THE RIGHT-HAND TURN SIGNAL SIDE LAMP
2 Disconnect right-hand turn signal side lamp
from connector C352 .
5 Measure the voltage between the right-hand
turn signal side lamp, connector C352, pin 1,
circuit 49-LG20 (BU/WH), wiring harness side
and ground.

voltage?
Yes
31-LG20 (BK) between the turn signal side
lamp and soldered connection S11 using the
No
circuit between the generic electronic module
(GEM) and the turn signal side lamp using
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PINPOINT TEST M: ONE OR MORE TURN SIGNAL LAMPS FLASH CONTINUOUSLY:
TEST CONDITIONS
M1: READ OUT THE FAULT MEMORY

Yes
No
GO to M2
M2: DETERMINE THE FAULT CONDITION
Does one or more turn signal lamp on the
left-hand side flash continuously?
Yes
- All left-hand turn signal lamps flash continuously: GO to M3
left-hand front turn signal lamp flash continuously: INSTALL A NEW generic electronic module (GEM). CHECK the operation
of the system.
- Left-hand rear turn signal lamp flashes
continuously: INSTALL A NEW generic
electronic module (GEM). CHECK the operation of the system.
No
- All right-hand turn signal lamps flash continuously: GO to M5
right-hand front turn signal lamp flash continuously: INSTALL A NEW generic electronic module (GEM). CHECK the operation
of the system.
- Right-hand rear turn signal lamp flashes
continuously. INSTALL A NEW generic
M3: CHECK THE TURN SIGNAL SWITCH
C357 .
4 Check the left-hand turn signal lamps.
Do the turn signal lamps flash?
Yes
GO to M4
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TEST CONDITIONS
No
M4: CHECK CIRCUIT 31S-LG1 (BK/YE) FOR SHORT TO GROUND
switch, connector C357, pin 1, circuit 31S-LG1
(BK/YE), wiring harness side and ground.

Yes
No
in the circuit between the turn signal switch
and generic electronic module (GEM) using
the system.
M5: CHECK THE TURN SIGNAL SWITCH
C357 .
4 Check the right-hand turn signal lamps.
Do the turn signal lamps flash?
Yes
GO to M6
No
M6: CHECK CIRCUIT 31S-LG2 (BK/BU) FOR SHORT TO GROUND
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TEST CONDITIONS
switch, connector C357, pin 3, circuit 31S-LG2

Yes
No
in the circuit between the turn signal switch
the system.
PINPOINT TEST N: ONE/SEVERAL TURN SIGNAL LAMPS ILLUMINATE CONTINUOUSLY
TEST CONDITIONS
N1: READ OUT THE FAULT MEMORY
Yes
No
GO to N2
N2: DETERMINE THE FAULT CONDITION

Do one or more turn signal lamps on the
left-hand side illuminate continuously?
Yes
- All left-hand turn signal lamps illuminate
left-hand front turn signal lamp illuminate
continuously: GO to N3
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TEST CONDITIONS
- Left-hand rear turn signal lamp illuminates
No
- All right-hand turn signal lamps illuminate
right-hand front turn signal lamp illuminate
- Right-hand rear turn signal lamp illuminates
continuously. GO to N8
N3: CHECK CIRCUIT 49-LG13 (BU/RD) OR 49-LG11 (BU/OG) FOR SHORT TO BATTERY
VOLTAGE
4 Check the left-hand turn signal lamps.
Do the front left turn signal lamps illuminate?
Yes
voltage in circuit 49-LG13 (BU/RD) or
49-LG11 (BU/OG) using the wiring diagrams.
No
N4: CHECK CIRCUIT 49-LG12 FOR SHORT TO BATTERY VOLTAGE
4 Check the left-hand rear turn signal lamp.
Does the left-hand rear turn signal illuminate?
Yes
the circuit 49-LG12 (BU) between generic
electronic module (GEM) and the rear lamp
assembly using the wiring diagrams. CHECK
- Vehicles with trailer socket: GO to N5
No
N5: CHECK CIRCUIT (GY/WH) FOR SHORT TO BATTERY VOLTAGE
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TEST CONDITIONS
C1030 .
4 Check the left-hand rear turn signal lamps.
Does the left-hand rear turn signal lamp illuminate continuously?

Yes
voltage in circuit (GY/WH) between the trailer
control unit and rear lamp assembly using
the system.
No
GO to N6
N6: CHECK CIRCUIT 49-LG12 (BU) OR (WH) FOR SHORT TO BATTERY VOLTAGE
unit, connector C1030, pin 1, circuit (WH), wiring harness side and ground.

Yes
voltage in the circuit 49-LG12 (BU) or (WH)
between the generic electronic module
(GEM) and the trailer control unit using the
system.
No
trailer control unit. CHECK the operation of
the system.
N7: CHECK CIRCUIT 49-LG18 (BU) OR 49-LG20 (BU/WH) FOR SHORT TO BATTERY VOLTAGE
4 Check the right-hand turn signal lamps.
Do the right-hand turn signal lamps illuminate?
Yes
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TEST CONDITIONS
voltage in circuit 49-LG18 (BU) or 49-LG20
(BU/WH) between the generic electronic
module (GEM) and the turn signal side lamp
or headlamp using the wiring diagrams.
No
N8: CHECK CIRCUIT 49-LG19 (BU/RD) FOR SHORT TO BATTERY VOLTAGE
4 Check the right-hand rear turn signal lamp.
Does the right-hand rear turn signal illuminate
continuously?
Yes
the circuit 49-LG19 (BU/RD) between the
generic electronic module (GEM) and the
rear lamp assembly using the wiring diagrams. CHECK the operation of the system.
- Vehicles with trailer socket: GO to N9
No
N9: CHECK CIRCUIT (GN/YE) FOR SHORT TO BATTERY VOLTAGE
C1035 .
4 Check the right-hand rear turn signal lamp.
Does the right-hand rear turn signal illuminate
continuously?
Yes
voltage in circuit (GN/YE) between the trailer
control unit and rear lamp assembly using
the system.
No
GO to N10
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TEST CONDITIONS
N10: CHECK CIRCUIT 49-LG19 (BU/RD) OR (GN/RD) FOR SHORT TO BATTERY VOLTAGE
unit, connector C1035, pin 1, circuit (GN/RD),

Yes
voltage in the circuit 49-LG19 (BU/RD) or
(GN/RD) between the generic electronic
module (GEM) and the trailer control unit
No
trailer control unit. CHECK the operation of
the system.
PINPOINT TEST O: HAZARD LAMPS INOPERATIVE / CONTINUOUSLY SWITCHED ON
TEST CONDITIONS
O1: READ OUT THE FAULT MEMORY

Yes
No
GO to O2
O2: DETERMINE THE FAULT CONDITION
2 Switch off the HAZARD WARNING LIGHTS.
Do the turn signal lamps illuminate continuously?
Yes
(GEM). CHECK the operation of the system.
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TEST CONDITIONS
No
- Turn signal lamps flash continuously: GO
to O4
- Turn signal lamps do not flash: GO to O3
O3: DETERMINE THE FAULT CONDITION

3 Check the left/right-hand turn signal lamps.
Do the left and right-hand turn signal lamps
work correctly?
Yes
GO to O6
No
O4: CHECK HAZARD WARNING LIGHT SWITCH
connector C321 .
Do the turn signal lamps flash continuously?
Yes
GO to O5
No
O5: CHECK CIRCUIT 31S-LG8 (BK/OG) FOR SHORT TO GROUND
warning light switch, connector C321, pin 3,
circuit 31S-LG8 (BK/OG), wiring harness side
and ground.

Yes
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TEST CONDITIONS
No
in the circuit between the hazard warning
light switch and generic electronic module
(GEM) using the wiring diagrams. CHECK
O6: CHECK THE GROUND CONNECTION OF THE HAZARD WARNING LIGHT SWITCH
connector C321 .
circuit 31-LG8 (BK), wiring harness side and
ground.

Yes
GO to O7
No
circuit between the hazard warning light
switch and soldered connection S265 using
the system.
O7: CHECK HAZARD WARNING LIGHT SWITCH
hazard warning light switch, connector C321,
between pin 3, circuit 31S-LG8 (BK/OG) and pin
5, circuit 31-LG8 (BK), wiring harness side.

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TEST CONDITIONS
Do the turn signal lamps operate correctly?

Yes
No
GO to O8
O8: CHECK CIRCUIT 31S-LG8 (BK/OG) FOR OPEN CIRCUIT
circuit 31S-LG8 (BK/OG), wiring harness side
and the generic electronic module (GEM),
connector C320, pin 16, circuit 31S-LG8

Yes
No
circuit between the hazard warning light
switch and generic electronic module (GEM)
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Exterior Lighting
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Parking, Rear and License Lamps
Special Tool(s)
Terminal Probe Kit
29-011A
Electrical
3.
Fuse(s)
Lamp(s)
Connector(s)
Switches
Wiring harness
the Symptom Chart.

damage.
Symptom Chart
Symptom
Parking lamps, rear lamps and
license lamps are inoperative
Possible Sources
Action
Fuse(s)
Circuit(s)
Headlight switch
Gasket for license plate lamp
GO to Pinpoint Test P
One or more parking lamps, rear Fuse(s)

lamps or license plate lamps are Circuit(s)
inoperative
Left-/right-hand rear lamp
assembly
Left/right-hand license plate
lamp
Gasket for license plate lamp
GO to Pinpoint Test Q
Parking lamps, rear lamps and

license plate lamps illuminate
continuously
GO to Pinpoint Test R
Circuit(s)
Headlight switch
(GEM)
System Checks
measurements.
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PINPOINT TEST P: PARKING LAMPS, REAR LAMPS AND LICENSE LAMPS ARE INOPERATIVE
TEST CONDITIONS
P1: DETERMINE THE FAULT CONDITION

1 A failure of the license plate lamps is not necessarily caused by an electrical defect. Due to a
high level of heat emitted from the bulb in the
license plate lamp, the gasket for the license
plate lamp may become deformed or melt. If
there is a problem, a comprehensive visual inspection of the license plate lamp or the tailgate
handle should first be performed, looking in
particular for any traces of corrosion caused by
the penetration of water.
Can traces of corrosion be seen in the area of
the license plate lamp?
Yes
Install modified gaskets for the license plate
lamps. Check the operation of the system.
No
GO to P2
P2: CHECK FUSE F17 (CJB)
2 Disconnect fuse F17 (15 A) (CJB) .
3 CHECK fuse F17 (15 A) (CJB) .
Is the fuse OK?
Yes
GO to P3
No
P3: CHECK THE VOLTAGE AT FUSE F17 (CJB)
1 Connect fuse F17 (15 A) (CJB) .
and ground.
Yes
GO to P4
No
REPAIR the voltage supply to fuse F17
(CJB) using the Wiring Diagrams, CHECK
the CJB and INSTALL A NEW ONE if necessary. CHECK the operation of the system.
P4: CHECK VOLTAGE AT HEADLIGHT SWITCH
C338 .
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TEST CONDITIONS
(OG/BK), wiring harness side and ground.

Yes
GO to P5
No
P5: CHECK HEADLIGHT SWITCH
headlight switch, connector C338, between pin
11, circuit 29-LE29 (OG/BK) and pin 13, circuit
29S-DB8 (OG/BU), wiring harness side.

4 Check the parking lamps.
Do the parking lamps illuminate?
Yes
No
29S-DB8 (OG/BU), between headlight switch
and CJB (bridge) using the wiring diagrams,
and if necessary INSTALL A NEW CJB.
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PINPOINT TEST Q: ONE OR MORE PARKING LAMPS, REAR LAMPS OR LICENSE PLATE LAMPS
ARE INOPERATIVE
TEST CONDITIONS
Q1: DETERMINE THE FAULT CONDITION

1 A failure of the license plate lamps is not necessarily caused by an electrical defect. Due to a
high level of heat emitted from the bulb in the
license plate lamp, the gasket for the license
plate lamp may become deformed or melt. If
there is a problem, a comprehensive visual inspection of the license plate lamp or the tailgate
handle should first be performed, looking in
particular for any traces of corrosion caused by
the penetration of water.
Can traces of corrosion be seen in the area of
the license plate lamp?
Yes
Install modified gaskets for the license plate
lamps. Check the operation of the system.
No
GO to Q2
Is one left-hand parking lamp and/or the license
plate lamp(s) inoperative?
Yes
- Front left-hand parking lamp (all other
lamps OK): GO to Q5
- Front left-hand parking lamp and left-hand
rear lamp: GO to Q3
- Left-hand rear lamp (all other lamps OK):
GO to Q11
- Licence plate lamp(s) (all other lamps OK):
GO to Q17
No
- Front right-hand parking lamp (all other
lamps OK): GO to Q8
- Front right-hand parking lamp and rear
right-hand lamp: GO to Q4
- Right-hand rear lamp (all other lamps OK):
GO to Q14
Q3: CHECK FUSE F22 (CJB)
2 Disconnect fuse F22 (7.5 A) (CJB) .
3 CHECK fuse F22 (7.5 A) (CJB) .
Is the fuse OK?
Yes
No
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TEST CONDITIONS
INSTALL A NEW fuse F22 (CJB). If the fuse

Is the fuse OK?
Yes
No
INSTALL A NEW fuse F23 (CJB). If the fuse
Q5: CHECK LEFT-HAND HEADLAMP
2 SWITCH ON the left-hand turn signal.
3 Check left-hand turn signal.
Does left-hand turn signal operate?
Yes
GO to Q6
No
GO to Q7
Q6: CHECK VOLTAGE AT THE FRONT LEFT-HAND PARKING LAMP
C416 .
4 Measure the voltage at left-hand headlamp,
connector C416, pin 4, circuit 29S-LF7
(OG/BU), wiring harness side and ground.

Yes
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TEST CONDITIONS
system.
No
circuit between fuse F22 (CJB) and the left
Q7: CHECK GROUND CONNECTION AT THE LEFT-HAND HEADLAMP
C416 .

Yes
system.
No
circuit between the left-hand headlamp and
Q8: CHECK THE RIGHT-HAND HEADLAMP
2 SWITCH ON the right-hand turn signal.
3 Check right-hand turn signal.
Does right-hand turn signal work?
Yes
GO to Q9
No
GO to Q10
Q9: CHECK VOLTAGE AT THE FRONT RIGHT-HAND PARKING LAMP
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TEST CONDITIONS
29S-LF16 (OG/GN), wiring harness side and
ground.

Yes
system.
No
circuit between fuse F23 (CJB) and the right
Q10: CHECK GROUND CONNECTION AT THE RIGHT-HAND HEADLAMP

Yes
system.
No
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TEST CONDITIONS
circuit between the right-hand headlamp and
Q11: CHECK THE LEFT-HAND REAR LAMP ASSEMBLY
2 SWITCH ON the left-hand turn signal.
3 Check left-hand turn signal.
Is the left-hand rear turn signal operative?
Yes
GO to Q12
No
GO to Q13
Q12: CHECK THE VOLTAGE AT THE LEFT-HAND REAR LAMP ASSEMBLY
2 Disconnect left-hand rear lamp assembly from .
C333
4 Measure the voltage at the left-hand rear lamp
assembly:
C333, between pin 1, circuit 29S-LF11
(OG/WH), wiring harness side and ground.
between pin 1, circuit (GY/BK), wiring harness
side and ground.

Yes
No
left-hand rear lamp assembly using the wiring diagrams. CHECK the operation of the
system.
Q13: CHECK GROUND CONNECTION OF LEFT-HAND REAR LAMP ASSEMBLY
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TEST CONDITIONS
2 Disconnect left-hand rear lamp assembly from .
C333
rear lamp assembly:
C333, pin 4, circuit 31-LF23 (BK), wiring
pin 4, circuit (GN), wiring harness side and
ground.

Yes
No
circuit between the left-hand rear lamp assembly and soldered connection S24 using
the system.
Q14: CHECK THE RIGHT-HAND REAR LAMP ASSEMBLY
2 SWITCH ON the right-hand turn signal.
3 Check right-hand turn signal.
Does right-hand turn signal work?
Yes
GO to Q15
No
GO to Q16
Q15: CHECK THE VOLTAGE AT THE RIGHT-HAND REAR LAMP ASSEMBLY
from .
C348
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TEST CONDITIONS
4 Measure the voltage at the right-hand rear lamp
assembly:
C348, between pin 1, circuit 29S-LF20 (OG),
between pin 1, circuit (GY/RD), wiring harness
side and ground.

Yes
No
right-hand rear lamp assembly using the
system.
Q16: CHECK GROUND CONNECTION OF THE RIGHT-HAND REAR LAMP ASSEMBLY
from .
C348
rear lamp assembly:
C348, between pin 4, circuit 31-LF24 (BK),
between pin 4, circuit (BK), wiring harness
side and ground.

Yes
No
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TEST CONDITIONS
circuit between the right-hand rear lamp

Are both license plate lamps inoperative?
Yes
GO to Q18
No
- Left-hand license plate lamp is inoperative:
GO to Q21
- Right-hand license plate lamp is inoperative: GO to Q22
Is the fuse OK?
Yes
GO to Q19
No
INSTALL A NEW fuse F33 (7.5 A). If the fuse
Q19: CHECK VOLTAGE AT FUSE F33 (CJB)
1 Connect fuse F33 (7.5 A) (CJB) .
and ground.
Yes
GO to Q20
No
wiring diagrams, if necessary CHECK and
of the system.
Q20: TEST THE VOLTAGE SUPPLY OF THE LICENSE PLATE LAMPS
2 Disconnect right-hand license plate lamp from
connector C760 .
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TEST CONDITIONS
4 Measure the voltage between right-hand license plate lamp, connector C760, pin 1, circuit
29S-LF22 (OG/BK), wiring harness side and
ground.

Yes
circuit(s) 31-DA25 (BK) between soldered
connection S201 and soldered connection
S24 using the wiring diagrams. CHECK the
No
LOCATE and RECTIFY the break in circuit(s)
between fuse F33 (CJB) and left-hand license plate lamp using the wiring diagrams.
Q21: CHECK GROUND CONNECTION OF LEFT-HAND LICENSE PLATE LAMP
1 Disconnect left-hand license plate lamp from
connector C759 .
license plate lamp, connector C759, pin 1, circuit 31-LF21 (BK) wiring harness side and
ground.

Yes
license plate lamp. CHECK the operation of
the system.
No
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TEST CONDITIONS
circuit between the license plate lamp and
diagrams. Check the operation of the system.
Q22: CHECK VOLTAGE SUPPLY TO RIGHT-HAND LICENSE PLATE LAMP
connector C760 .
5 Measure the voltage between right-hand license plate lamp, connector C760, pin 1, circuit
29S-LF22 (OG/BK), wiring harness side and
ground.

Yes
GO to Q23
No
circuit between the left-hand license plate
lamp and the right-hand license plate lamp
using the wiring diagrams. Check the operation of the system.
Q23: CHECK GROUND CONNECTION OF RIGHT-HAND LICENSE PLATE LAMP
connector C761 .
license plate lamp, connector C761, pin 1, circuit 31-LF22 (BK), wiring harness side and
ground.
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TEST CONDITIONS
Is the resistance less than 2 Ohm?
Yes
CHECK and INSTALL A NEW license plate
lamp. CHECK the operation of the system.
No
circuit between the right-hand license plate
lamp and soldered connection S201 using
the wiring diagrams. Check the operation of
the system.
PINPOINT TEST R: PARKING LAMPS, REAR LAMPS AND LICENSE PLATE LAMPS ILLUMINATE
CONTINUOUSLY
TEST CONDITIONS
R1: READ OUT THE FAULT MEMORY

Are any trouble codes (DTCs) displayed?
Yes
No
GO to R2
R2: DETERMINE THE FAULT CONDITION
1
2
3
4
5

Disconnect fuse F22 (7.5 A) (CJB) .
Check the parking lamps.
Are the left-hand parking lamps illuminated

continuously?
Yes
the circuits connected to fuse F22 (CJB),
output side, using the wiring diagrams.
- Vehicles with trailer socket: LOCATE and
RECTIFY the short to battery voltage in the
circuits connected to fuse F22 (CJB), output
side, using the wiring diagrams. CHECK the
operation of the system. If the concern persists, CHECK and if necessary INSTALL A
NEW trailer control unit. CHECK the operation of the system.
No
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TEST CONDITIONS
- Vehicles without trailer socket: Right-hand
parking lamps illuminate continuously:
voltage in the circuits connected to fuse F23
(CJB), output side, using the wiring diagrams. CHECK the operation of the system.
- Vehicles with trailer socket: Right-hand
parking lamps illuminate continuously:
(CJB), output side, using the wiring diagrams. CHECK the operation of the system.
If the concern persists, CHECK and if necessary INSTALL A NEW trailer control unit.
- Licence plate lamps illuminate continuously: GO to R3
- No malfunction detected: GO to R4
R3: CHECK GENERIC ELECTRONIC MODULE (GEM)

Do the license plate lamps illuminate continuously?
Yes
No
CHECK the GEM module using WDS,
C338 .
5 Check the parking lamps.
Are the left-hand parking lamps illuminated
continuously?
Yes
LOCATE AND RECTIFY short to battery
voltage in circuits 29S-DB8 (OG/BU) or
29S-DD33 (OG), which are connected to the
corresponding bridge in the CJB, using the
system.
No
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TEST CONDITIONS
- Vehicles without daytime running lights:
- Vehicles with daytime running lights: GO to
R5
R5: CHECK HEADLIGHT SWITCH


Yes
GO to R6
No

Yes
(CJB), output side, using the Wiring Diagrams. CHECK the operation of the system.
No
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TEST CONDITIONS
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Reversing Lamps
Special Tool(s)
Terminal Probe Kit
29-011A
Electrical
3.
Fuse(s)
Lamp(s)
Connector(s)
Switches
Wiring harness
4. If the concern persists, check the symptoms
and continue with the symptom chart.

2. Visually check the following electrical causes
for the concern:
Visual Inspection
Symptom Chart
Symptom
The reversing lamp is inoperative
Possible Sources
Fuse
Circuit(s)
Rear lamp assembly
Reversing lamp relay
Transmission range sensor
Action
GO to Pinpoint Test S
Reversing lamp illuminates con- Circuit(s)

GO to Pinpoint Test T
tinuously
Reversing lamp relay
(PCM)
Audio/navigation control panel
(GEM)
Transmission range sensor
Automatic transmission module
System Checks
measurements.
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PINPOINT TEST S: THE REVERSING LAMP IS INOPERATIVE
TEST CONDITIONS
S1: CHECK FUSE F48 (CJB)

3 CHECK fuse F48 (7.5 A) .
Is the fuse OK.?
Yes
GO to S2
No
RENEW fuse F48 (7.5 A) and check the operation of the system. If the fuse blows again,
S2: CHECK THE VOLTAGE AT FUSE F48 (CJB)
(CJB) and ground.
Yes
- Vehicles with manual transmission and with
Durashift EST: GO to S3
- Vehicles with 4-speed automatic transmission (AW81-40): GO to S6
No
Wiring Diagrams. If necessary RENEW the
S3: CHECK THE VOLTAGE AT THE REVERSING LAMP SWITCH
2 Disconnect reversing lamp switch from connector C425 .
4 Measure the voltage between the reversing
lamp switch, connector C425, pin 1, circuit
15-LG28 (GN/WH), wiring harness side and
ground.
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TEST CONDITIONS
Yes
GO to S4
No
circuit between fuse F48 (CJB) and the reversing lamp switch using the wiring diagrams. CHECK the operation of the system.
S4: CHECK REVERSING LAMP SWITCH

2 Connect a fused jumper wire (7.5 A) at the reversing lamp switch, connector C425, between
pin 1, circuit 15-LG28 (GN/WH) and pin 2, circuit
15S-LG5 (GN/RD) (diesel engine) or 15S-LG1
(GN/YE) (petrol engine), wiring harness side.

4 Check operation of reversing lamp.
Does the reversing lamp illuminate?
Yes
INSTALL A NEW reversing lamp switch.
No
- Vehicles without trailer socket: GO to S5
- Vehicles with trailer socket: GO to S12
S5: CHECK THE GROUND CONNECTION OF THE REAR LAMP ASSEMBLY
2 SWITCH ON the parking lamps.
Does the parking lamp illuminate?
Yes
LOCATE and RECTIFY the break in circuits
15S-LG5 (GN/RD), 15S-LG1 (GN/YE) and
15S-LG39 (GN/OG), between the reversing
lamp switch and the rear lamp assembly
INSTALL A NEW rear lamp assembly if
system.
No
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TEST CONDITIONS
- LHD: LOCATE and RECTIFY the break in
circuit 31-LF24 (BK), between the right-hand
rear lamp assembly and ground G18 using
NEW rear lamp assembly if necessary.
- RHD: LOCATE and RECTIFY the break in
circuit 31-LF23 (BK) between the left-hand
rear lamp assembly and soldered connection
S24 using the wiring diagrams. CHECK and
system.
S6: CHECK THE VOLTAGE AT THE REVERSING LAMP RELAY
2 Disconnect reversing lamp relay from socket
C434 .
lamp relay, socket C434, pin 3, circuit 15-LG28

Yes
GO to S7
No
circuit between fuse F48 (CJB) and the reversing lamp relay using the Wiring Diagrams. CHECK the operation of the system.
S7: CHECK CIRCUIT 15S-LG1 (GN/YE) AND 15S-LD39 (GN/OG)
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TEST CONDITIONS
2 Connect a fused jumper lead (7.5 A) at reversing lamp relay, socket C434, between pin 3,
circuit 15-LG28 (GN/WH), wiring harness side
and pin 5, circuit 15S-LG1 (GN/YE), wiring
harness side.

Yes
GO to S9
No
- Vehicles without trailer socket: GO to S8
- Vehicles with trailer socket: GO to S12
2 SWITCH ON the parking lamps.
Yes
15S-LG1 (GN/YE) or 15S-LG39 (GN/OG)
between the reversing lamp switch and the
rear lamp assembly using the wiring diagrams. CHECK and INSTALL A NEW rear
No
circuit 31-LF24 (BK), between the right-hand
rear lamp assembly and ground G18 using
circuit 31-LF23 (BK) between the left-hand
system.
S9: CHECK CIRCUIT 15S-TC6 (GN/YE)
NOTE: Ignition key in ON position.
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TEST CONDITIONS
lamp relay, socket C434, pin 1, circuit 15S-TC6
(GN/YE), wiring harness side and ground.

Yes
GO to S10
No
circuit between pin 1 and pin 3 on the reversing lamp relay using the Wiring Diagrams. If necessary RENEW the engine
compartment relay box. CHECK the operation of the system.
S10: CHECK REVERSING LAMP RELAY
NOTE: Ignition key in ON position.
1 ENGAGE reverse gear
(GN/YE), wiring harness side and pin 2, circuit
91S-TC6 (BK/YE), wiring harness side.

Yes
RENEW the reversing lamp relay. CHECK
No
GO to S11
S11: CHECK CONTROL WIRES 91S-TC6 (BK/YE) AND 91S-TA1 (BK/BU) OF REVERSING LAMP
RELAY
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TEST CONDITIONS
2 Disconnect transmission range sensor from
connector C431 .
3 Measure the resistance between the reversing
lamp relay, socket C434, pin 2, circuit 91-TC6
(BK/YE), wiring harness side and the transmission range sensor, connector C431, pin 2, circuit 91S-TA1 (BK/BU), wiring harness side.

Yes
RENEW the transmission range sensor.
No
circuit between the reversing lamp relay and
transmission range sensor using the Wiring
S12: CHECK THE TRAILER CONTROL UNIT
2 Connect following components .
Durashift EST: reversing lamp switch with
connector C425
(AW81-40): reversing lamp relay to socket
C434
C1035 .
5 Engage reverse gear.
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TEST CONDITIONS
unit C1035, pin 2, circuit (VT/OG), wiring harness side and ground.

Yes
GO to S13
No
Durashift EST: LOCATE and RECTIFY the
break in the circuits between the reversing
lamp switch and the trailer control unit using
the system.
- Vehicles with 4-speed automatic transmission (AW81-40): LOCATE and RECTIFY the
break in the circuits between the reversing
lamp relay and the trailer control unit using
of the system.
S13: CHECK THE TRAILER CONTROL UNIT
2 Connect a fused jumper wire (7.5 A), at the
trailer control unit, connector C1035, between
pin 2, circuit (VT/OG) and pin 6, circuit (BK/BU),

Yes
- Vehicles built before 09/2002: GO to S14
- Vehicles built after 09/2002: GO to S16
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TEST CONDITIONS
No
GO to S20

3 CHECK fuse F31 (20 A) .
Is the fuse OK.?
Yes
GO to S15
No
(CJB) and ground.
Yes
GO to S18
No
3 CHECK fuse F56 (20 A) .
Is the fuse OK.?
Yes
GO to S17
No
(CJB) and ground.
Yes
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TEST CONDITIONS
GO to S18
No
S18: CHECK THE VOLTAGE SUPPLY OF THE TRAILER CONTROL UNIT
C1041 .
Is battery voltage measured in both cases?

Yes
GO to S19
No
relevant circuit 29-ND16 (OG/BU) or (RD),
between fuse F31 (CJB) before 09/2002 or
F56 (CJB) from 09/2002 and the trailer control unit using the Wiring Diagrams. If necessary CHECK and RENEW the central
junction box (CJB). CHECK the operation of
the system.
S19: CHECK THE GROUND CONNECTION OF THE TRAILER CONTROL UNIT
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TEST CONDITIONS

Yes
No
of the system.
1
2
3
4

Connect trailer control unit to connector C1035 .
SWITCH ON the parking lamps.
Check the rear parking lamp.

Yes
(BK/BU) (LHD) or (BK/BU) and (VT/YE)
(RHD) between the trailer control unit and the
No
circuit (BK) or 31-LF24 (BK) between the rear
lamp assembly and ground connection G18
system.
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TEST CONDITIONS
circuit (GN) or 31-LF23 (BK) between the
system.
PINPOINT TEST T: REVERSING LAMP ILLUMINATES CONTINUOUSLY

TEST CONDITIONS
T1: CHECK REVERSING LAMP SWITCH

Durashift EST: reversing lamp switch from
connector C425
(AW81-40): reversing lamp relay from socket
C434
4 Check reversing lamp.
Does reversing lamp illuminate continuously?
Yes
- Vehicles without trailer socket: GO to T4
- Vehicles with trailer socket: GO to T2
No
Durashift EST: INSTALL A NEW reversing
lamp switch. CHECK the operation of the
system.
- Vehicles with 4-speed automatic transmission (AW81-40): GO to T7
T2: RULE OUT TRAILER CONTROL UNIT AS CAUSE FOR A SHORT TO BATTERY VOLTAGE
- Vehicles built before 09/2002: fuse F31 (CJB)
- Vehicles built after 09/2002: fuse F56 (CJB)
Yes
GO to T3
No
T3: NARROW DOWN THE FAULT CONDITION
C1035 .
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TEST CONDITIONS

Yes
voltage in circuits (BK/BU) or (VT/YE) between the trailer control unit and the rear
lamp assembly using the wiring diagrams.
No
GO to T4
T4: RULE OUT GENERIC ELECTRONIC MODULE (GEM) AS POSSIBLE CAUSE FOR A SHORT
TO BATTERY VOLTAGE
2 Disconnect fuse F20 (CJB) .
12 CHECK the reversing lamps.
Do the reversing lamps illuminate continuously?
Yes
GO to T5
No
CHECK generic electronic module (GEM)
using WDS, and INSTALL a new one if
system.
T5: RULE OUT AUDIO/NAVIGATION CONTROL UNIT AS POSSIBLE CAUSE FOR A SHORT TO
BATTERY VOLTAGE
2 Connect fuse F20 (CJB) .
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TEST CONDITIONS

Yes
- Vehicles with diesel engines: GO to T6
- Vehicles with petrol engines: LOCATE and
RECTIFY the short to battery voltage in the
circuits connected to soldered connection
S32 using the Wiring Diagrams. CHECK the
No
CHECK and if necessary RENEW the audio/navigation control panel. CHECK the
T6: RULE OUT THE POWERTRAIN CONTROL MODULE (PCM) AS POSSIBLE CAUSE FOR A
1
2
3
4
5

Connect fuse F18 (CJB) .
Disconnect powertrain control module from
connectors C370, C371 and C372 .
Yes
connection S32 using the Wiring Diagrams.
No
CHECK the powertrain control module
(PCM) using WDS and RENEW if necessary.
T7: RULE OUT TRANSMISSION RANGE SENSOR AS POSSIBLE CAUSE FOR A SHORT TO
GROUND
2 Connect reversing lamp relay to socket C434 .
3 Disconnect transmission range sensor from
connector C431 .
Yes
GO to T8
No
RENEW the transmission range sensor.
T8: RULE OUT AUTOMATIC TRANSMISSION MODULE AS POSSIBLE CAUSE FOR A SHORT TO
GROUND
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TEST CONDITIONS
2 Disconnect automatic transmission module
Yes
GO to T9
No
CHECK the automatic transmission module
using WDS and RENEW if necessary.
T9: CHECK REVERSING LAMP RELAY

2 Disconnect reversing lamp relay from socket
C434 .
4 Measure the resistance between the reversing
Is the resistance greater than 10,000 Ohms?

Yes
RENEW the reversing lamp relay. CHECK
No
in the circuits connected to soldered connection S134 using the Wiring Diagrams.
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Exterior Lighting
417-01-104

Fog Lamps
Special Tool(s)
Terminal Probe Kit
29-011A
Electrical
3.
Fuse(s)
Lamp(s)
Connector(s).
Switches
Wiring harness
the Symptom Chart.

damage.
Visual Inspection
Symptom Chart
Symptom
Possible Sources
Action
Fog lamps are inoperative
Fuse
Circuit(s)
Headlight switch
GO to Pinpoint Test U
Rear fog lamps or front fog

lamps are inoperative
Circuit(s)
Headlight switch
GO to Pinpoint Test V
Individual fog lamps inoperative Circuit(s)

Right/left-hand front fog lamp.
Rear lamp assembly
GO to Pinpoint Test W
Rear fog lamps or front fog

lamps illuminate continuously
GO to Pinpoint Test X
Circuit(s)
Headlight switch
System Checks
measurements.
PINPOINT TEST U: FOG LAMPS ARE INOPERATIVE
TEST CONDITIONS
U1: CHECK FUSE F50 (CJB)

2 CHECK fuse F50 (20 A) (CJB) .
Is the fuse OK.?
Yes
GO to U2
No
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TEST CONDITIONS
U2: CHECK THE VOLTAGE AT FUSE F50 (CJB)

and ground.
Yes
GO to U3
No
the system.
U3: CHECK THE VOLTAGE AT THE HEADLIGHT SWITCH
C338 .
switch, connector C338, pin 7, circuit 15-LD10

Yes
headlight switch. CHECK the operation of the
system.
No
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PINPOINT TEST V: REAR FOG LAMPS OR FRONT FOG LAMPS ARE INOPERATIVE
TEST CONDITIONS
V1: DETERMINE THE FAULT CONDITION

NOTE: A mechanical interlock in the headlight switch allows the fog lamps to be turned on only when the
headlight switch is in the "Dipped beam ON" position.
2 Switch on the FRONT and REAR FOG LAMPS.
3 Check operation of the front fog lamps.
Does the rear fog lamp illuminate?
Yes
GO to V19
No
GO to V2
V2: CHECK THE HEADLIGHT SWITCH
C338 .
7, circuit 15-LD10 (GN/OG) and pin 2, circuit
15S-LD6A (GN/YE), wiring harness side.

5 Check the rear fog lamp.
Yes
No
- LHD, vehicles without trailer socket: GO to
V3
- RHD, vehicles without trailer socket: GO to
V4
- LHD, vehicles with trailer socket: GO to V5
- RHD, vehicles with trailer socket: GO to
V12
V3: CHECK GROUND CONNECTION OF REAR FOG LAMP (LHD)
2 Disconnect left-hand rear lamp assembly from
connector C333 .
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TEST CONDITIONS
rear lamp assembly, connector C333, pin 4,
ground.

Yes
15S-LD6A (GN/YE) or 15S-LD6 (GN/YE)
between the headlight switch and the rear
CHECK and INSTALL A NEW rear lamp
assembly if necessary. CHECK the operation
of the system.
No
31-LF23 (BK) between the rear lamp assembly and soldered connection S24 using
V4: CHECK GROUND CONNECTION OF REAR FOG LAMP (RHD)
2 Disconnect right-hand rear lamp assembly from
connector C348 .
rear lamp assembly, connector C348, pin 4,
ground.

Yes
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TEST CONDITIONS
15S-LD6A (GN/YE) or 15S-LD6 (GN/YE)
between the headlight switch and the rear
CHECK and INSTALL A NEW rear lamp
assembly if necessary. CHECK the operation
of the system.
No
31-LF24 (BK), between the rear lamp assembly and ground connection G18 using
the Wiring Diagrams. CHECK and INSTALL
A NEW rear lamp assembly if necessary.
V5: CHECK GROUND CONNECTION OF REAR FOG LAMP (LHD)
2 Disconnect left-hand rear lamp assembly from
connector C333a .
rear lamp assembly, connector C333a, pin 4,
circuit (GN), wiring harness side and ground.

Yes
GO to V6
No
(GN) or 31-LF23 (BK) between the rear lamp
assembly and soldered connection S24 using the wiring diagrams. CHECK and
system.
V6: CHECK CIRCUITS 15S-LD6(A) (GN/YE) OR (RD/WH) FOR OPEN CIRCUIT
2 Connect headlight switch with connector C338 .
C1030 .
5 Switch on the REAR FOG LIGHT.
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TEST CONDITIONS
unit, connector C1030, pin 4, circuit (RD/WH),

Yes
GO to V7
No
15S-LD6(A) (GN/YE) or (RD/WH) between
the headlight switch and the trailer control
unit using the wiring diagrams. CHECK the
V7: CHECK THE TRAILER CONTROL UNIT
2 Connect left-hand rear lamp assembly with
connector C333a .
circuit (RD/WH) and pin 6, circuit (VT/YE), wiring harness side.

Yes
GO to V8
No
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TEST CONDITIONS
(VT/YE) between the trailer control unit and
V8: CHECK FUSE

2 CHECK Fuse .
(CJB)
Is the fuse OK.?
Yes
GO to V9
No
the system.
V9: CHECK VOLTAGE AT FUSE
1 Connect Fuse .
(CJB)
and ground.
- Vehicles built after 09/2002: F56, CJB and
ground.
Yes
GO to V10
No
V10: CHECK THE VOLTAGE SUPPLY OF THE TRAILER CONTROL UNIT
C1041 .
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TEST CONDITIONS

measurements?
Yes
GO to V11
No
using the Wiring Diagrams. CHECK and
system.
system.
V11: CHECK THE GROUND CONNECTION OF THE TRAILER CONTROL UNIT

Yes
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TEST CONDITIONS
No
circuit (BN) between the trailer control unit
and ground connection G18 using the wiring
V12: CHECK GROUND CONNECTION OF REAR FOG LAMP (RHD)
2 Disconnect right-hand rear lamp assembly from
connector C348a .
rear lamp assembly, connector C348a, pin 4,
circuit (BK), wiring harness side and ground.

Yes
GO to V13
No
(BK) or 31-LF24 (BK) between the rear lamp
assembly and ground connection G18 using
V13: CHECK CIRCUITS 15S-LD6(A) (GN/YE), (VT/OG) AND (RD/WH) FOR OPEN CIRCUIT
2 Connect headlight switch with connector C338 .
C1030 .
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TEST CONDITIONS

Yes
GO to V14
No
15S-LD6(A) (GN/YE), (VT/OG) or (RD/WH)
between the headlight switch and the trailer
control unit using the wiring diagrams.
V14: CHECK THE TRAILER CONTROL UNIT
2 Connect right-hand rear lamp assembly with
connector C348a .
3 Using a fused test cable (20 A) at the trailer
control unit, connector C1030, bridge between
pin 4, circuit (RD/WH) and pin 6, circuit (VT/YE),

Yes
GO to V15
No
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TEST CONDITIONS
(VT/YE) or (BK/BU) between the trailer control unit and rear lamp assembly using the
V15: CHECK FUSE

2 CHECK Fuse .
(CJB)
Is the fuse OK.?
Yes
GO to V16
No
the system.
V16: CHECK VOLTAGE AT FUSE
1 Connect Fuse .
(CJB)
and ground.
ground.
Yes
GO to V17
No
V17: CHECK THE VOLTAGE SUPPLY OF THE TRAILER CONTROL UNIT
C1041 .
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TEST CONDITIONS

measurements?
Yes
GO to V18
No
system.
system.
V18: CHECK THE GROUND CONNECTION OF THE TRAILER CONTROL UNIT

Yes
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TEST CONDITIONS
No
of the system.
V19: CHECK THE HEADLIGHT SWITCH

C338 .
7, circuit 15-LD10 (GN/OG) and pin 3, circuit
15S-LD5A (GN/BU) wiring harness side.

5 Check the operation of the front fog lamps.
Do the front fog lamps illuminate?
Yes
No
GO to V20
V20: CHECK THE GROUND CONNECTION OF THE FRONT FOG LAMPS
2 Disconnect right-hand front fog lamp from
connector C421 .
front fog lamp, connector C421, pin B, circuit
31-LD17 (BK), wiring harness side and ground.
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TEST CONDITIONS
Yes
15S-LD5A (GN/BU) or 15S-LD5 (GN/BU),
between the headlight switch and soldered
No
circuit between soldered connection S242
and ground connection G4 using the wiring
PINPOINT TEST W: INDIVIDUAL FOG LAMPS INOPERATIVE

TEST CONDITIONS
W1: DETERMINE THE FAULT CONDITION
2 SWITCH ON all fog lamps.
Is one of the rear fog lamps inoperative?

Yes
No
- Left-hand front fog lamp not working: GO to
W2
- Right-hand front fog lamp not working: GO
to W3
W2: CHECK THE GROUND CONNECTION OF THE LEFT-HAND FRONT FOG LAMP
2 Disconnect left-hand front fog lamp from connector C415 .
3 Measure the resistance between left-hand front
fog lamp, connector C415, pin B, circuit

Yes
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TEST CONDITIONS
15S-LD11 (GN/WH) between soldered
connection S241 and the front fog lamp using
the wiring diagrams. If necessary CHECK
and INSTALL A NEW front fog lamp. CHECK
No
31-LD11 (BK) between the front fog lamp
wiring diagrams. If necessary CHECK and
INSTALL A NEW front fog lamp. CHECK the
W3: CHECK THE GROUND CONNECTION OF THE RIGHT-HAND FRONT FOG LAMP
2 Disconnect right-hand front fog lamp from
connector C421 .
front fog lamp, connector C421, pin B, circuit

Yes
15S-LD17 (GN/WH) between soldered
connection S241 and the front fog lamp using
the wiring diagrams. If necessary CHECK
and INSTALL A NEW front fog lamp. CHECK
No
31-LD17 (BK) between the front fog lamp
wiring diagrams. If necessary CHECK and
INSTALL A NEW front fog lamp. CHECK the
PINPOINT TEST X: REAR FOG LAMPS OR FRONT FOG LAMPS ILLUMINATE CONTINUOUSLY
TEST CONDITIONS
X1: DETERMINE THE FAULT CONDITION

2 Switch on DIPPED BEAM.
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TEST CONDITIONS
3 Switch off the FRONT and REAR FOG LAMPS.
4 Check the fog lamps.
Do the rear fog lamps illuminate?
Yes
GO to X2
No
Front fog lamps illuminate continuously: GO
to X10
X2: CHECK THE HEADLIGHT SWITCH

C338 .
Does the rear fog lamp illuminate continuously?
Yes
GO to X3
No
X3: CHECK THE INSTRUMENT CLUSTER
C332 .
Yes
the circuits connected to soldered connection
S281 using the wiring diagrams. CHECK the
- Vehicles with trailer socket: GO to X4
No
X4: NARROW DOWN THE FAULT CONDITION
C1030 .
Yes
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TEST CONDITIONS
voltage in circuits (VT/YE) or (BK/BU) between the trailer control unit and the rear
No
GO to X5
X5: CHECK THE TRAILER CONTROL UNIT


Yes
No
GO to X6
X6: CHECK FUSE
2 CHECK Fuse .
(CJB)
Is the fuse OK.?
Yes
GO to X7
No
the system.
X7: CHECK VOLTAGE AT FUSE
1 Connect Fuse .
(CJB)
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TEST CONDITIONS
and ground.
ground.

Yes
GO to X8
No
X8: CHECK THE VOLTAGE SUPPLY OF THE TRAILER CONTROL UNIT
C1041 .

measurements?
Yes
GO to X9
No
system.
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TEST CONDITIONS
system.
X9: CHECK THE GROUND CONNECTION OF THE TRAILER CONTROL UNIT

Yes
No
of the system.
X10: CHECK THE HEADLIGHT SWITCH
C338 .
4 Check the front fog lamps.
Yes
GO to X11
No
X11: CHECK THE INSTRUMENT CLUSTER
C332 .
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TEST CONDITIONS
4 Check the front fog lamps.
Yes
No
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Exterior Lighting
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Headlamp Leveling
Special Tool(s)
Terminal Probe Kit
29-011A
Electrical
3.
Fuse(s)
Connector(s)
Switches
Wiring harness
the Symptom Chart.

damage.
Visual Inspection
Symptom Chart
Symptom
Headlamp leveling system is
inoperative/malfunctioning
Possible Sources
Circuit(s)
Headlight switch
Action
GO to Pinpoint Test Y
System Checks
measurements.
PINPOINT TEST Y: HEADLAMP LEVELING SYSTEM IS INOPERATIVE/MALFUNCTIONING
TEST CONDITIONS
Y1: DETERMINE THE FAULT CONDITION
Is the headlamp leveling system inoperative for
both headlamps?
Yes
- Inoperative: GO to Y3
- Malfunctioning: GO to Y2
No
- Left-hand side inoperative: GO to Y12
- Right-hand side inoperative: GO to Y14
- Left or right-hand side malfunctioning:
CHECK headlamp range adjustment unit and
if necessary INSTALL A NEW headlamp.
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TEST CONDITIONS
Y2: CHECK THE HEADLAMP ADJUST VARIABLE RESISTOR

NOTE: Switch off the lights.
C416 .
3 CHANGE the SETTING of the headlamp leveling system during the measurement
(UP/DOWN).
64S-LE45 (BU), wiring harness side and
ground.
Does the registered resistance vary with change

to the variable resistor?
Yes
GO to Y3
No
Y3: CHECK THE VOLTAGE SUPPLY OF THE HEADLIGHT SWITCH
2 Operate the headlamp flasher and check that it
works correctly.
Is the headlamp flasher operating correctly?
Yes
GO to Y4
No
RECTIFY the break in the voltage supply of
the headlight switch using the wiring diagrams. CHECK the operation of the system.
REFER to Headlamps in this section.
Y4: CHECK THE GROUND CONNECTION OF THE HEADLIGHT SWITCH
C338 .
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TEST CONDITIONS
3 Measure the resistance between the headlight

Yes
GO to Y5
No
circuit between the headlight switch and
Y5: CHECK THE HEADLIGHT SWITCH
1 Check the headlight switch (variable resistor,
headlamp leveling system) according to the
component checks in the wiring diagrams.
- Check headlight switch connector C338 at
pins 1, 8 and 10.
Is the headlight switch OK?
Yes
GO to Y6
No
Y6: CHECK CONTROL CIRCUIT OF HEADLAMP LEVELLING SYSTEM FOR SHORT TO BATTERY
VOLTAGE
NOTE: Keep the testing rig for use during further voltage measurements.
2 Connect left-hand headlamp to connector
C416 .
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TEST CONDITIONS
(BU/RD), wiring harness side and ground.

Yes
GO to Y7
No
GO to Y9
Y7: CHECK LEFT-HAND HEADLAMP ASSEMBLY FOR SHORT TO BATTERY VOLTAGE
C416 .

Yes
GO to Y8
No
the system.
Y8: CHECK RIGHT-HAND HEADLAMP ASSEMBLY FOR SHORT TO BATTERY VOLTAGE
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TEST CONDITIONS

Yes
LOCATE and RECTIFY short to battery
voltage in circuit(s) 64S-LE5 (BU/RD),
64S-LE45 (BU) or 64S-LE46 (BU/RD), between the headlight switch and the left-hand
or right-hand headlamp using the wiring
No
of the system.
Y9: CHECK CONTROL CIRCUIT OF HEADLAMP LEVELLING SYSTEM FOR SHORT TO GROUND
NOTE: Keep the testing rig for use during further resistance measurements.

Yes
LOCATE and RECTIFY short to ground in
circuit(s) 64S-LE5 (BU/RD), 64S-LE45 (BU)
or 64S-LE46 (BU/RD), between the headlight
switch and the left-hand or right-hand headlamp using the wiring diagrams. CHECK the
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TEST CONDITIONS
No
GO to Y10
Y10: CHECK LEFT-HAND HEADLAMP ASSEMBLY FOR SHORT TO GROUND
C416 .

Yes
the system.
No
GO to Y11
Y11: CHECK RIGHT-HAND HEADLAMP ASSEMBLY FOR SHORT TO GROUND

Yes
of the system.
No
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TEST CONDITIONS
LOCATE and RECTIFY short to ground in
circuit(s) 64S-LE5 (BU/RD), 64S-LE45 (BU)
or 64S-LE46 (BU/RD), between the headlight
switch and the left-hand or right-hand headlamp using the wiring diagrams. CHECK the
Y12: CHECK CONTROL VOLTAGE AT THE LEFT-HAND HEADLAMP
C416 .
(UP/DOWN).
(BU), wiring harness side and ground.
Does the voltage measured change in accordance with the position set?
Yes
GO to Y13
No
circuit between the headlamp and intermediate connector C810 using the wiring diagrams. CHECK the operation of the system.
Y13: CHECK GROUND CONNECTION OF THE LEFT-HAND HEADLAMP
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TEST CONDITIONS

Yes
headlamp and adjustment unit. CHECK the
No
Y14: CHECK VOLTAGE AT THE RIGHT-HAND HEADLAMP
(UP/DOWN).
64S-LE46 (BU/RD), wiring harness side and
ground.
Does the voltage measured change in accordance with the position set?
Yes
GO to Y15
No
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TEST CONDITIONS
circuit between the headlamp and intermediate connector C810 using the wiring diagrams. CHECK the operation of the system.
Y15: CHECK GROUND CONNECTION OF THE RIGHT-HAND HEADLAMP

Yes
headlamp and adjustment unit. CHECK the
No
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GENERAL PROCEDURES
Headlamp Adjustment (32 113 0)
intersection point of the horizontal line and

the 15 line (LHD variant shown).
General Equipment
Beam setting equipment
1. Place the vehicle on a level surface.
2. Check that the tyre pressures meet the
specifications and that the vehicle is not
excessively laden.
3. Switch on the dipped beam.
4. Repeatedly operate the headlamp levelling
switch and then set it to "0".
5. Set up the measuring screen of the beam
setting device to the correct headlamp
setting value.
6. Adjust the dipped beam so that the
light/dark boundary touches the horizontal
line.
7. NOTE: A diffused part of the dipped beam may

lie above the 15 line.
Adjust the dipped beam so that the rising
line of the light/dark boundary lies in the
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GENERAL PROCEDURES
Headlamp Masking
All vehicles
NOTE: The templates are different for LHD and
RHD vehicles. The templates are different for the
left and right-hand headlamps.
1. Print out the corresponding templates at
the end of this operation.
2. Measure dimension X on the printout of the
template.
3. Calculate the enlargement/reduction factor
Y for the photocopier using the following
formula: Y=ZX100.
X = measurement on the printout of the
template in mm
Y = enlargement/reduction factor in %
Z = original dimension in mm = 25
4. Enlarge/reduce the printout with a
photocopier by the calculated percentage.
Compare dimension X on the photocopy
with the original dimension.
5. Cut out the prepared template for the
headlamp.
6. Cut out the shaded areas.
LHD vehicles
7. NOTE: Right-hand headlamp only.
Align the template on the lens of the
headlamp.
1. Template
2. Area to be masked
3. Alignment edges on the headlamp lens
G115915 en
8. NOTE: Left-hand headlamp only.

headlamp.
1. Template
RHD vehicles
9. NOTE: Right-hand headlamp only.
headlamp.
1. Template
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10. NOTE: Left-hand headlamp only.
headlamp.
1. Template
12. Remove the template.

13. NOTE: Make sure that the marked area is not
exceeded.
Mask the marked area with opaque black
adhesive tape.
14. Repeat steps 11 to 13 for the headlamp on
the other side.
15. Template for LHD vehicles, right-hand
headlamp
Alignment edges
All vehicles
11.
CAUTION: Do not damage the surface

of the headlamp.
Copy the outline of the template with a
suitable pen onto the headlamp lens.
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16. Template for LHD vehicles, left-hand

headlamp
Alignment edges
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17. Template for RHD vehicles, right-hand

headlamp
Alignment edges
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18. Template for RHD vehicles, left-hand

headlamp
Alignment edges
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GENERAL PROCEDURES
Front Fog Lamp Adjustment
General Equipment
Beam setting equipment
1. Place the vehicle on a level surface.
2. Check that the tyre pressures meet the
specifications and that the vehicle is not
excessively laden.
3. Switch on the front fog lamps.
4. Set up the measuring screen of the beam
setting device to the correct setting value
for the front fog lamps.
5. Adjust the front fog lamps so that the
light/dark boundary touches the horizontal
line.
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Front Fog Lamp Vehicles Built Up To: 11/2004 (32 281 0)
Removal
1. Raise the vehicle.For additional
2. Disconnect the fog lamp electrical connector.
3. Remove the fog lamp assembly.
Installation
2. Adjust the fog lamps. For additional
information, refer to Front Fog Lamp
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Front Fog Lamp Vehicles Built From: 11/2004 (32 281 0)
Removal
1. Remove the fog lamp bezel.
Installation
procedure.
2. Adjust the fog lamp beam alignment. For
additional information, refer to Headlamp
2. Detach the fog lamp from the fog lamp

bracket.
3. Remove the fog lamp assembly.

Pull off the fog lamp connector.
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Headlamp Switch (35 514 0)
Removal
4. Remove the headlamp switch.
1. Open the stowage space and remove the

screws for the facia crash padding lower
trim.
Installation
2. Detach the lower fascia/crash padding
cover.
1. Install the components in the reverse

order.
3. Disconnect the headlamp switch electrical

connector.
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Headlamp Assembly (32 115 0)
Removal
4. Disconnect the headlamp connector.
2. Unscrew and remove the headlamp bolts.
Installation
1. Connect the headlamp connector.
3.
CAUTION: Do not damage the fixing

points of the headlamps during
removal.
Detach the headlamp from the hood lock
panel.
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2. NOTE: Clean the lens with a damp cloth to
prevent the build-up of electrostatic charge,
which could cause dust to stick to the plastic
lens.
NOTE: Check that the headlamp is engaged at
the fixing points.
5. Adjust the headlamps. For additional

information, refer to Headlamp Adjustment
in this section.
Install the headlamp.
3. Screw in the headlamp bolts.
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Rear Lamp Assembly (32 305 0)
Removal
1. Partially release the inner wheel arch trim
panel and press it to one side.
2. Unscrew the nut for the rear lamp assembly.
3. Disconnect the connector from the rear

lamp assembly.
4. Unscrew the bolts from the rear lamp assembly.
5. Remove the rear lamp assembly.

Pull out the rear lamp assembly from the
mounting.
Installation
order.
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Interior Lighting
417-02-1
SECTION 417-02 Interior Lighting

CONTENTS
PAGE

Interior Lighting .................................................................................................................
Symptom Chart ................................................................................................................
Pinpoint Tests ..................................................................................................................
417-02-2
417-02-2
417-02-2
417-02-2
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Interior Lighting
417-02-2

Interior Lighting
damage.

step.

Electrical
- Fuse(s)
- Transportation fuse pack
- Wiring harness
- Lamp(s)
- Switch(es)
- Generic Electronic Module (GEM)
Symptom Chart
Symptom
The front interior lamp is inoperative
Possible Sources
Fuse.
Bulb.
Circuit(s).
Interior lamp switch.
Front interior lamp.
GEM.
Action
The luggage compartment lamp Fuse.

is inoperative
Bulb.
Circuit(s).
Luggage compartment lamp
switch.
Luggage compartment lamp.
GEM.
The interior lamp does not

GEM.
automatically turn off after 10
Circuit.
minutes when the lamp is in the
ILLUMINATED ENTRY position
CHECK circuit 31S-LC7 (BK/BU)

for short to ground. If the circuit is
OK, INSTALL a new GEM.
REFER to Section 419-10. TEST
The interior lamp does not

GEM.
automatically turn off after 30
minutes when the lamp is in the
ON position
INSTALL a new GEM. REFER

to Section 419-10. TEST the
Pinpoint Tests
measurements.
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Interior Lighting
417-02-3
PINPOINT TEST A: THE FRONT INTERIOR LAMP IS INOPERATIVE

TEST CONDITIONS
A1: CHECK THE OPERATION OF THE INTERIOR LAMP

1 Check the operation of the interior lamp in both
ON and ILLUMINATED ENTRY positions.
Is the interior lamp inoperative in both positions?
Yes
GO to A2.
No
If inoperative in the ON position, GO to A3.
If inoperative in the ILLUMINATED ENTRY
position, GO to A4.
A2: CHECK THE INTERIOR LAMP FOR POWER
1
2
3
4
Disconnect Lamp C750.

Measure the voltage between the interior lamp
C750 pin 1, circuit 29-LC7 (OG/BU), harness
side and ground.

Yes
INSTALL a new interior lamp. TEST the
No
REPAIR circuit 29-LC7 (OG/BU). TEST the
A3: CHECK THE INTERIOR LAMP FOR GROUND
1 Disconnect Lamp C751.
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Interior Lighting
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TEST CONDITIONS
2 Measure the resistance between the interior
lamp C751 pin 2, 31-LC7 (BK), harness side
and ground.

Yes
No
REPAIR circuit 31-LC7 (BK). TEST the system for normal operation.
A4: CHECK THE INTERIOR LAMP FOR GROUND WITH THE DRIVER DOOR OPEN
1 Disconnect Lamp C751.
2 Open the driver door.
lamp C751 pin 1, 31-LC7 (BK/BU), harness side
and ground.

Yes
No
GO to A5.
A5: CHECK CIRCUIT 31S-LC7 FOR OPEN
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TEST CONDITIONS
lamp C751 pin 1, 31-LC7 (BK/BU), harness side
and the GEM C316 pin 3, circuit 31-LC7
(BK/BU), harness side.

Yes
No
REPAIR circuit 31-LC7 (BK/BU). TEST the
PINPOINT TEST B: THE LUGGAGE COMPARTMENT LAMP IS INOPERATIVE
TEST CONDITIONS
B1: CHECK THE LUGGAGE COMPARTMENT LAMP FOR POWER
1 Disconnect Luggage Compartment Lamp
C576.
4 Measure the voltage between the luggage
compartment lamp C576 pin 1, circuit 29-LB25
(OG/BU), harness side and ground.

Yes
GO to B2.
No
REPAIR circuit 29-LB25 (OG/BU). TEST the
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TEST CONDITIONS
B2: CHECK THE LUGGAGE COMPARTMENT LAMP FOR GROUND

1 Open the liftgate.
2 Measure the resistance between the luggage
compartment lamp C576 pin 2, circuit 31S-LB25
(BK/BU), harness side and ground.

Yes
INSTALL a new luggage compartment lamp.
No
GO to B3.
B3: CHECK CIRCUIT 31S-LB25 (BK/BU) FOR OPEN
1 Disconnect Liftgate Switch C565.
2 Measure the resistance between the luggage
compartment lamp C576 pin 2, circuit 31S-LB25
(BK/BU), harness side and the liftgate switch
C565 pin 2, circuit 31S-LB25 (BK/BU), harness
side.

Yes
INSTALL a new liftgate switch. TEST the
No
REPAIR circuit 31S-LB25 (BK/BU). TEST
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418-00-1
Module Communications Network
418-00-1
SECTION 418-00 Module Communications Network

CONTENTS
PAGE

Communications Network .................................................................................................
Databus systems..............................................................................................................
418-00-2
418-00-2

Communications Network .................................................................................................
Symptom Chart ................................................................................................................
System Checks ................................................................................................................
Component Tests.............................................................................................................
418-00-3
418-00-3
418-00-3
418-00-4
418-00-74
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Communications Network
Databus systems
Overview
Item
Part
Number
Transmission control unit

(integrated into the clutch
actuator) (only on vehicles
with an automated manual
transmission)
Airbag module
ISO 9141 databus
CAN databus
Generic Electronic Module

(GEM)
Instrument cluster
Anti-lock Brake System

(ABS) module
Powertrain Control Module

(PCM)
Item
Part
Number
Electronic selector lever

(only on vehicles with an
automated manual transmission)
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418-00-3

Communications Network
Electrical
3.
Special Tool(s)
Terminal Probe Kit
29-011A
General Equipment
Digital Multimeter

1. CHECK the concern.
Visual Inspection
Fuses
Wiring harness
Connectors
RECTIFY any obvious causes for a concern
performing any further tests. CHECK the
inspection, PERFORM a fault diagnosis with
WDS and RECTIFY any displayed faults in
accordance with the displayed fault
description. CHECK the operation of the
system.
5. For vehicles with no stored fault(s),
PROCEED in accordance with the symptom
chart according to the fault symptom.
6. Following checking or elimination of the fault
and after completion of operations, the fault
memories of all vehicle modules must be
READ OUT and any stored faults must be
DELETED. READ OUT all fault memories
again following a road test.
Symptom Chart
Symptom
Possible Sources
Action
Safety restraint control module

(RCM) not communicating with
the diagnostic unit
Fuse(s)
Circuit(s)
(RCM)
Anti-lock braking system (ABS)

module or electronic stability
program (ESP) module not
communicating with the diagnostic unit
Fuse(s)
Circuit(s)
ABS module or ESP module

(GEM) not communicating with
the diagnostic tester
Fuse(s)
Circuit(s)
(GEM)

(PCM) not communicating with
the diagnostic tester
Fuse(s)
Circuit(s)
PCM
Instrument cluster not communicating with the diagnostic unit
Fuse(s)
Circuit(s)
Instrument cluster
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Possible Sources
Symptom
Action
Transmission control module

(TCM) not communicating with
diagnostic tester - vehicles with
automatic clutch and gearshift
actuation
Fuse(s)
Circuit(s)
TCM

not communicating with diagnostic unit - vehicles with automatic transmission
Fuse(s)
Circuit(s)
Faulty communication between

the modules (ISO bus)
Circuit(s)
(GEM)
(RCM)
Faulty communication between

the modules (CAN bus)
Circuit(s)
Instrument cluster
Transmission control module
(TCM) - vehicles with automatic
clutch and gearshift actuation
Transmission selector unit vehicles with automatic clutch
and gearshift actuation
Automatic transmission module vehicles with automatic
transmission
(PCM)
System Checks
PINPOINT TEST A: SAFETY RESTRAINT CONTROL MODULE (RCM) NOT COMMUNICATING
WITH THE DIAGNOSTIC UNIT
TEST CONDITIONS
WARNING: The backup power supply must be depleted to prevent the risk of accidental
airbag deployment. After disconnecting the battery, wait at least 1 minute before starting
work on the safety restraint system. Failure to observe this instruction can lead to injury.
WARNING: Do not program any keycodes while working on the safety restraint system in
order to prevent the risk of accidental deployment of safety restraint system components.
Failure to observe this instruction can lead to injury.
WARNING: Only test the connectors of airbags or other safety restraint systems using the
correct test probe adapter. Failure to observe this instruction can lead to injury.
A1: DETERMINE THE CONDITIONS UNDER WHICH THE FAULT OCCURS
3 Select the generic electronic module (GEM)
with the diagnostic tester.
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TEST CONDITIONS
Is it possible to establish communication with
the GEM?
Yes
GO to A2
No
A2: CHECK FUSE F39

Is the fuse OK?
Yes
GO to A3
No
INSTALL A NEW fuse F39 (7.5 A). CHECK
again, LOCATE and REPAIR the short using
and ground.
Yes
GO to A4
No
of the system.
A4: CHECK THE VOLTAGE AT THE SAFETY RESTRAINT CONTROL MODULE (RCM)
2 Disconnect the ground cable from the battery.
3 Disconnect connector C500 from safety restraint control module (RCM).
4 Connect the ground cable to the battery.
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TEST CONDITIONS
6 Measure the voltage between the safety restraint control module (RCM), connector C500,
pin 1, circuit 15-JA10 (GN/OG), wiring harness
side and ground.

Yes
GO to A5
No
15-JA10 (GN/OG) between the safety restraint control module (RCM) and fuse F39
A5: CHECK THE GROUND CONNECTION OF THE SAFETY RESTRAINT CONTROL MODULE
(RCM)
2 Measure the resistance between the safety
restraint control module (RCM), connector
C500, pin 20, circuit 91-JA10 (BK/RD), wiring

Yes
- Vehicles built for Japan:
GO to A6
- All, except vehicles built for Japan:
GO to A7
No
91-JA10 (BK/RD) between the safety restraint control module (RCM) and ground
connection G21 using the Wiring Diagrams.
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TEST CONDITIONS
A6: CHECK THE GROUND CONNECTION OF THE SAFETY RESTRAINT CONTROL MODULE
(RCM)
C500, pin 21, circuit 91-JA47A (BK/OG), wiring

Yes
GO to A7
No
LOCATE and REPAIR the break in the circuit
between the safety restraint control module
(RCM) and ground connection G21 using the
the system.
A7: CHECK FOR OPEN CIRCUIT BETWEEN THE SAFETY RESTRAINT CONTROL MODULE
(RCM) AND THE DATA LINK CONNECTOR (DLC)
C500, pin 17, circuit 4-EE7 (GY/RD), wiring
harness side and the DLC, C308, pin 7, circuit
4-EE10 (GY/BK), wiring harness side.

Yes
CHECK and if necessary RENEW the safety
restraint control module (RCM). CHECK the
No
4-EE7 (GY/RD) between the safety restraint
control module (RCM) and soldered connection S270 using the Wiring Diagrams.
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PINPOINT TEST B: ABS MODULE OR ESP MODULE NOT COMMUNICATING WITH THE
DIAGNOSTIC UNIT
TEST CONDITIONS
B1: DETERMINE THE CONDITIONS UNDER WHICH THE FAULT OCCURS

3 Select the generic electronic module (GEM)
the GEM?
Yes
GO to B2
No
B2: CHECK FUSE F5
Is the fuse OK?
Yes
GO to B3
No
INSTALL A NEW fuse F5 (20 A). CHECK the
operation of the system. If the fuse blows
B3: CHECK THE VOLTAGE AT FUSE F5
and ground.
Yes
GO to B7
No
GO to B4
B4: CHECK FUSE FH
2 CHECK fuse FH (BJB).
Is the fuse OK?
Yes
GO to B5
No
RENEW fuse FH (60 A). CHECK the operation of the system. If the fuse blows again,
LOCATE and REPAIR the short using the
Wiring Diagrams.
B5: CHECK THE VOLTAGE AT FUSE FH
1 Connect fuse FH (BJB).
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TEST CONDITIONS
2 Measure the voltage between fuse FH (60 A)
and ground.

Yes
GO to B6
No
REPAIR the voltage supply to fuse FH using
of the system.
B6: CHECK FOR OPEN CIRCUIT BETWEEN FUSE FH AND FUSE F5
1 Disconnect connector C1001 from BJB.
2 Measure resistance between BJB, connector
C1001, circuit 30S-DB5 (RD), wiring harness
side and fuse F5 (CJB), wiring harness side.

Yes
CHECK the BJB and INSTALL a new one as
system.
No
30-DB8 (RD) between fuse FH and fuse F5
B7: CHECK FUSE F37
Is the fuse OK?
Yes
GO to B8
No
B8: CHECK THE VOLTAGE AT FUSE F37
and ground.
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TEST CONDITIONS

Yes
- Vehicles with ABS - vehicles built up to
03/2004 / or with electronic stability program
(ESP)
GO to B15
- Vehicles with ABS - vehicles built after
04/2004
GO to B20
No
GO to B9
B9: CHECK THE VOLTAGE AT THE IGNITION RELAY
2 Disconnect ignition relay from socket C328.
3 Measure the voltage between the ignition relay,
socket C328, pin 3, circuit 30-BB8 (RD), wiring

Yes
GO to B12
No
GO to B10
B10: CHECK FUSE FF
2 CHECK fuse FF (BJB).
Is the fuse OK?
Yes
GO to B11
No
RENEW fuse FF (60 A). CHECK the operation of the system. If the fuse blows again,
Wiring Diagrams.
B11: CHECK THE VOLTAGE AT FUSE FF
1 Connect fuse FF (BJB).
2 Measure the voltage between fuse FF (60 A)
and ground.
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TEST CONDITIONS
Yes
30-BB8 (RD) between the ignition relay and
fuse FF using the Wiring Diagrams. CHECK
No
REPAIR the voltage supply to fuse FF using
of the system.
B12: CHECK THE VOLTAGE AT THE IGNITION RELAY
2 Measure the voltage between the ignition relay,
socket C328, pin 1, circuit 15-BB7 (GN/BU),

Yes
GO to B13
No
circuit between the ignition relay and the ignition switch using the Wiring Diagrams.
B13: CHECK GROUND CONNECTION AT IGNITION RELAY
relay, socket C328, pin 2, circuit 91S-RH9

Yes
GO to B14
No
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TEST CONDITIONS
circuit between the ignition relay and soldered connection S109 using the Wiring
B14: CHECK CIRCUIT BETWEEN THE IGNITION RELAY AND FUSE F37 FOR OPEN CIRCUIT
relay, socket C328, pin 5, circuit 15-DB2
(GN/BU), wiring harness side and fuse F37
(CJB).

Yes
CHECK and if necessary RENEW the ignition relay. CHECK the operation of the system.
No
LOCATE and REPAIR the open circuit between the ignition relay and fuse F37 using
of the system.
B15: CHECK THE VOLTAGE AT THE ABS MODULE OR ESP MODULE
2 Disconnect connector C303 from ABS module
or ESP module.
3 Measure the voltage between the ABS module
or ESP module, connector C303, pin 32, circuit
29-CF6 (OG/YE), wiring harness side and
ground.

Yes
GO to B16
No
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TEST CONDITIONS
29-CF6 (OG/YE) between the ABS module
or ESP module and fuse F5 using the Wiring
B16: CHECK THE VOLTAGE AT THE ABS MODULE OR ESP MODULE
2 Measure the voltage between the ABS module
or ESP module, connector C303, pin 4, circuit
15-CF6 (GN/YE), wiring harness side and
ground.

Yes
GO to B17
No
15-CF6 (GN/YE) between the ABS module
or ESP module and fuse F37 using the Wiring Diagrams. CHECK the operation of the
system.
B17: CHECK THE GROUND CONNECTION OF THE ABS MODULE OR ESP MODULE
2 Measure the resistance between the ABS
module or ESP module, connector C303, pin
16, circuit 31-CF6 (BK), wiring harness side and
ground.

Yes
GO to B18
No
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TEST CONDITIONS
between the ABS module or ESP module
and ground connection G23 using the Wiring
B18: CHECK FOR OPEN CIRCUIT BETWEEN THE ABS MODULE OR ESP MODULE AND THE
DLC
1 Measure the resistance between the DLC,
connector C308, pin 6, circuit 4-EC1 (GY/RD),
wiring harness side and the ABS module or ESP
module, connector C303, pin 11, circuit 4-EC9
(GY), wiring harness side.

connector C308, pin 14, circuit 5-EC1 (BU/RD),
wiring harness side and the ABS module or ESP
(BU), wiring harness side.
Is a resistance of less than 2 Ohms measured in

both cases?
Yes
GO to B19
No
LOCATE and REPAIR the break in the
relevant circuit between the ABS module or
ESP module and DLC using the Wiring Diagrams. CHECK the operation of the system.
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TEST CONDITIONS
B19: CHECK FOR OPEN CIRCUIT BETWEEN THE ABS MODULE OR ESP MODULE AND THE
DATA LINK CONNECTOR (DLC)
module or ESP module, connector C303, pin 2,
circuit 4-EE6 (GY), wiring harness side and
DLC, C308, pin 7, circuit 4-EE10 (GY/BK), wiring harness side.

Yes
CHECK and if necessary RENEW the ABS
module or ESP module. CHECK the operation of the system.
No
between the ABS module or ESP module
the system.
B20: CHECK VOLTAGE AT THE ABS MODULE
2 Disconnect connector C304 from ABS module.
3 Measure the voltage between the ABS module,
connector C304, pin 1, circuit 29-CF6 (OG/YE),

Yes
GO to B21
No
29-CF6 (OG/YE) between the ABS module
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TEST CONDITIONS
B21: CHECK VOLTAGE AT THE ABS MODULE

2 Measure the voltage between the ABS module,
connector C304, pin 20, circuit 15-CF6
(GN/YE), wiring harness side and ground.

Yes
GO to B22
No
15-CF6 (GN/YE) between the ABS module
B22: CHECK THE GROUND CONNECTION OF THE ABS MODULE
module, connector C304, pin 26, circuit 31-CF6

Yes
GO to B23
No
circuit between the ABS module and ground
connection G23 using the Wiring Diagrams.
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TEST CONDITIONS
B23: CHECK FOR OPEN CIRCUIT BETWEEN THE ABS MODULE AND THE DLC
wiring harness side and ABS module, connector
C304, pin 23, circuit 4-EC9 (GY), wiring harness
side.
wiring harness side and ABS module, connector
C304, pin 21, circuit 5-EC9 (BU), wiring harness
side.
both cases?
Yes
GO to B24
No
relevant circuit between the ABS module and
the DLC using the Wiring Diagrams. CHECK
B24: CHECK FOR OPEN CIRCUIT BETWEEN THE ABS MODULE AND THE DATA LINK
CONNECTOR (DLC)
module, connector C304, pin 18, circuit 4-EE6
(GY), wiring harness side and DLC, connector
C308, pin 7, circuit 4-EE10 (GY/BK), wiring
harness side.

Yes
module. CHECK the operation of the system.
No
4-EE6 (GY) or 4-EE1 (GY/RD) between the
ABS module and soldered connection S270
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PINPOINT TEST C: GENERIC ELECTRONIC MODULE (GEM) NOT COMMUNICATING WITH THE
DIAGNOSTIC TESTER
TEST CONDITIONS
C1: DETERMINE THE CONDITIONS UNDER WHICH THE FAULT OCCURS

3 Select the safety restraint control module
(RCM) with the diagnostic tester.
the safety restraint control module (RCM)?
Yes
GO to C2
No
C2: CHECK FUSE F38
Is the fuse OK?
Yes
GO to C3
No
and ground.
Yes
GO to C4
No
of the system.
C4: CHECK THE VOLTAGE AT THE GEM
2 Disconnect connector C319 (white) from GEM.
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TEST CONDITIONS
4 Measure the voltage between the GEM, connector C319 (white), pin 10, circuit 15-DK20

Yes
GO to C5
No
15-DK20 (GN/OG) between the GEM and
soldered connection S3 using the Wiring
C5: TEST THE GEM GROUND CONNECTION
2 Disconnect connector C316 (black) from GEM.
3 Measure the resistance between the GEM,
connector C316 (black), pin 2, circuit 31-DK20

Yes
GO to C6
No
31-DK20 (BK) between the GEM and soldered connection S15 using the Wiring Diagrams. CHECK the operation of the system.
C6: TEST THE GEM GROUND CONNECTION
1 Disconnect connector C320 (brown) from GEM.
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TEST CONDITIONS
connector C320 (brown), pin 2, circuit 91-DK20

Yes
GO to C7
No
91-DK20 (BK/RD) between the GEM and
C7: CHECK FOR OPEN CIRCUIT BETWEEN THE GEM AND THE DLC.
1 Measure the resistance between GEM, connector C320 (brown), pin 10, circuit 4-EE11
(GY/WH), wiring harness side and DLC, C308,
pin 7, circuit 4-EE10 (GY/BK), wiring harness
side.

Yes
TEST the GEM and RENEW as necessary.
No
between the GEM and the DLC using the
the system.
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PINPOINT TEST D: POWERTRAIN CONTROL MODULE (PCM) NOT COMMUNICATING WITH THE
DIAGNOSTIC TESTER
TEST CONDITIONS
D1: DETERMINE THE CONDITIONS UNDER WHICH THE FAULT OCCURS

3 Select the instrument cluster with the diagnostic
tester.
the instrument cluster?
Yes
GO to D2
GO to D12
No
D2: CHECK FUSE F16
Is the fuse OK?
Yes
GO to D3
No
D3: CHECK THE VOLTAGE AT FUSE F16
and ground.
Yes
GO to D4
No
of the system.
D4: CHECK FUSE F12
Is the fuse OK?
Yes
GO to D5
No
INSTALL A NEW fuse F12 (15 A). CHECK
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TEST CONDITIONS

and ground.
Yes
GO to D8
No
GO to D14
D6: CHECK FOR OPEN CIRCUIT BETWEEN THE PCM MODULE RELAY AND THE PCM
2 Measure the resistance between the PCM
module relay, socket C420, pin 2, circuit
91S-RH9 (BK/BU), wiring harness side and
PCM, connector C343, pin M8, circuit 91S-RH9
(BK/BU), wiring harness side.

Yes
GO to D7
No
between the PCM module relay and the PCM
D7: CHECK FOR OPEN CIRCUIT BETWEEN THE PCM MODULE RELAY AND FUSE F12
module relay, socket C470, Pin 5, circuit
15S-RE9 (GN/YE), wiring harness side and fuse
F12 (CJB), wiring harness side.
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TEST CONDITIONS
Yes
GO to D18
No
LOCATE and REPAIR the open circuit between the PCM module relay and fuse F12
D8: CHECK THE VOLTAGE AT THE PCM

3 Measure the voltage between the PCM, connector C343, pin F9, circuit 29-RE8 (OG/YE),

Yes
GO to D9
No
29-RE8 (OG/YE) between PCM and fuse
F16 using the Wiring Diagrams. CHECK the
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TEST CONDITIONS

1 Use a fused test lead (1 A) at the PCM, connector C343, pin M8, to bridge circuit 91S-RH9
2 Measure the voltage between the PCM, connector C343, pin F8, circuit 15S-RE8 (GN/YE),

Yes
GO to D10
No
LOCATE and REPAIR the open circuit between the PCM and fuse F12 using the
the system.
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TEST CONDITIONS
2 Measure the voltage between the PCM, connector C343, pin F21, circuit 15-RE8 (GN/YE),

Yes
GO to D11
No
between the PCM and the ignition switch
D11: CHECK THE GROUND CONNECTION OF THE PCM
2 Measure the resistance between the PCM,
connector C343, pin F40, circuit 91-RE8A

connector C343, pin F7, circuit 91-RE8B
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TEST CONDITIONS
connector C343, pin M5, circuit 91-RE8C

connector C343, pin M42, circuit 91-RE8D

all of the cases?
Yes
CHECK the PCM and RENEW if necessary.
No
- If a resistance of more than 2 Ohms is
measured in one of the measurements:
relevant circuit between the PCM and soldered connection S109 using the Wiring
measured in all of the measurements:
between soldered connection S109 and
D12: CHECK FUSE F13
Is the fuse OK?
Yes
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TEST CONDITIONS
GO to D13
No

and ground.
Yes
GO to D19
No
GO to D14
D14: CHECK THE VOLTAGE AT THE PCM MODULE RELAY
2 Disconnect PCM module relay from socket
C420.
3 Measure the voltage between the PCM module
relay, socket C420, pin 1, circuit 29S-RH9
(OG/BU), wiring harness side and ground.

Yes
GO to D15
No
LOCATE and REPAIR the open circuit between the PCM module relay and fuse F16
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TEST CONDITIONS
D15: CHECK THE VOLTAGE AT THE PCM MODULE RELAY

1 Measure the voltage between the PCM module
relay, socket C420, pin 3, circuit 30-RH10 (RD),

Yes
GO to D16
GO to D6
No
LOCATE and REPAIR the open circuit between the PCM module relay and fuse FB
D16: CHECK FOR OPEN CIRCUIT BETWEEN THE PCM MODULE RELAY AND THE PCM
module relay, socket C420, pin 2, circuit
91S-RH9 (BK/BU), wiring harness side and
PCM, connector C372, pin D2, circuit 91S-RH9
(BK/BU), wiring harness side.

Yes
GO to D17
No
between the PCM module relay and the PCM
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TEST CONDITIONS
D17: CHECK FOR OPEN CIRCUIT BETWEEN THE PCM MODULE RELAY AND FUSE F13
module relay, socket C420, Pin 5, circuit
15S-DB9 (GN/RD), wiring harness side and
fuse F13 (CJB), wiring harness side.

Yes
GO to D18
No
CHECK CJB and RENEW as necessary.
D18: CHECK THE PCM MODULE RELAY
1 Check the PCM module relay according to the
component test at the end of this section.
Is the PCM module relay OK?
Yes
No
RENEW the PCM module relay. CHECK the
3 Measure the voltage between the PCM, connector C371, pin G4, circuit 29-RE8 (OG/YE),

Yes
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TO MODEL INDEX
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TEST CONDITIONS
GO to D20
No
29-RE8 (OG/YE) between PCM and fuse

2 Use a fused test lead (1 A) at the PCM, connector C372, pin D2, to bridge circuit 91S-RH9
3 Measure the voltage between the PCM, connector C372, pin E3, circuit 15S-RE8A (GN/YE),
4 Measure the voltage between the PCM, connector C372, pin F3, circuit 15S-RE8B (GN/YE),
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TEST CONDITIONS
5 Measure the voltage between the PCM, connector C372, pin F2, circuit 15S-RE8C (GN/YE),
Is battery voltage measured in all cases?

Yes
GO to D21
No
- If battery voltage is not measured during a
measurement:
- If battery voltage is not measured during all
measurements:
15S-RN3 (GN/BU) between soldered connection S108 and fuse F13 using the Wiring
3 Measure the voltage between the PCM, connector C370, pin C3, circuit 15-RE8 (GN/YE),

Yes
GO to D22
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TO MODEL INDEX
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TEST CONDITIONS
No
between the PCM and the ignition switch
D22: CHECK THE GROUND CONNECTION OF THE PCM
connector C370, pin H4, circuit 91-RE8A

connector C370, pin G4, circuit 91-RE8B

connector C371, pin K2, circuit 91-RE8C
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TEST CONDITIONS
connector C372, pin C4, circuit 91-RE8D

all of the cases?
Yes
No
measured in all of the measurements:
LOCATE and REPAIR the break in the affected circuit between soldered connection
S109 and ground connection G1 using the
system.
PINPOINT TEST E: INSTRUMENT CLUSTER NOT COMMUNICATING WITH THE DIAGNOSTIC
UNIT
TEST CONDITIONS
E1: DETERMINE THE CONDITIONS UNDER WHICH THE FAULT OCCURS
3 Select the powertrain control module (PCM)
the PCM?
Yes
GO to E2
No
E2: CHECK FUSE F20
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TEST CONDITIONS
Is the fuse OK?
Yes
GO to E3
No
E3: CHECK THE VOLTAGE AT FUSE F20

and ground.
Yes
GO to E4
No
of the system.
E4: CHECK FUSE F44
Is the fuse OK?
Yes
GO to E5
No
and ground.
Yes
GO to E6
No
of the system.
E6: CHECK FUSE F38
Is the fuse OK?
Yes
GO to E7
No
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TEST CONDITIONS

and ground.
Yes
GO to E8
No
of the system.
E8: CHECK THE VOLTAGE AT THE INSTRUMENT CLUSTER
2 Disconnect connector C332 from instrument
cluster.
cluster, connector C332, pin 17, circuit
29-GG11 (OG/BU), wiring harness side and
ground.

Yes
GO to E9
No
29-GG11 (OG/BU) between the instrument
cluster and fuse F20 using the Wiring Diagrams. CHECK the operation of the system.
1 Ignition switch in position I.
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TO MODEL INDEX
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TEST CONDITIONS
cluster, connector C332, pin 3, circuit 75-GG11
(YE/RD), wiring harness side and ground.

Yes
GO to E10
No
75-GG11 (YE/RD) between the instrument
cluster and fuse F44 using the Wiring Diagrams. CHECK the operation of the system.
15-GG11 (GN/BU), wiring harness side and
ground.

Yes
GO to E11
No
circuit between the instrument cluster and
fuse F38 using the Wiring Diagrams. CHECK
E11: CHECK THE GROUND CONNECTION OF THE INSTRUMENT CLUSTER
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TO MODEL INDEX
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TEST CONDITIONS
2 Measure the resistance between the instrument
31-GG11 (BK), wiring harness side and ground.

Yes
CHECK and if necessary RENEW the instrument cluster. CHECK the operation of the
system.
No
LOCATE and REPAIR the open circuit between the instrument cluster and ground
connection G25 (vehicles built from 01/2004:
G14) using the Wiring Diagrams. CHECK the
PINPOINT TEST F: TRANSMISSION CONTROL MODULE (TCM) NOT COMMUNICATING WITH
DIAGNOSTIC TESTER - VEHICLES WITH AUTOMATIC CLUTCH AND GEARSHIFT ACTUATION
TEST CONDITIONS
F1: DETERMINE THE CONDITIONS UNDER WHICH THE FAULT OCCURS

the PCM?
Yes
GO to F2
No
F2: CHECK FUSE FB
2 CHECK fuse FB (BJB).
Is the fuse OK?
Yes
GO to F3
No
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TEST CONDITIONS
RENEW fuse FB (60 A). CHECK the operation of the system. If the fuse blows again,
Wiring Diagrams.
F3: CHECK THE VOLTAGE AT FUSE FB

1 Connect fuse FB (BJB).
2 Measure the voltage between fuse FB (60 A)
and ground.
Yes
GO to F4
No
REPAIR the voltage supply to fuse FB using
of the system.
F4: CHECK FUSE F41
Is the fuse OK?
Yes
GO to F5
No
F5: CHECK THE VOLTAGE AT FUSE F41
and ground.
Yes
GO to F6
No
of the system.
F6: CHECK VOLTAGE AT TCM
2 Disconnect connector C676 from TCM.
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TEST CONDITIONS
3 Measure the voltage between the TCM, connector C676, pin 49, circuit 30-TA55A (RD),

Yes
GO to F7
No
between the TCM and fuse FB using the
the system.
F7: CHECK VOLTAGE AT TCM
2 Measure the voltage between the TCM, connector C676, pin 47, circuit 15-TA55 (GN/BK),

Yes
GO to F8
No
15-TA55 (GN/BK) between TCM and fuse
F8: CHECK GROUND CONNECTION OF TCM
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TO MODEL INDEX
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TEST CONDITIONS
2 Measure the resistance between the TCM,
connector C676, pin 48, circuit 91-TA55
(BK/GN), wiring harness side and ground.

Yes
CHECK the TCM and RENEW if necessary.
No
91-TA55 (BK/GN) between TCM and battery
negative using the Wiring Diagrams. CHECK
PINPOINT TEST G: AUTOMATIC TRANSMISSION MODULE NOT COMMUNICATING WITH
DIAGNOSTIC UNIT - VEHICLES WITH AUTOMATIC TRANSMISSION
TEST CONDITIONS
G1: DETERMINE THE CONDITIONS UNDER WHICH THE FAULT OCCURS
the PCM?
Yes
GO to G2
No
G2: CHECK FUSE F7
Is the fuse OK?
Yes
GO to G3
No
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TO MODEL INDEX
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TEST CONDITIONS
G3: CHECK THE VOLTAGE AT FUSE F7

and ground.
Yes
GO to G4
No
of the system.
G4: CHECK FUSE F41
Is the fuse OK?
Yes
GO to G5
No
G5: CHECK THE VOLTAGE AT FUSE F41
and ground.
Yes
GO to G6
No
of the system.
G6: CHECK THE VOLTAGE AT THE AUTOMATIC TRANSMISSION MODULE
2 Disconnect connector C428 from automatic
transmission module.
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TEST CONDITIONS
3 Measure the voltage between the automatic
transmission module, connector C428, pin 22,
circuit 29-TA55A (OG/BK), wiring harness side
and ground.

circuit 29-TA55B (OG/BK), wiring harness side
and ground.
Is battery voltage measured in both cases?
Yes
GO to G7
No
- If battery voltage is not measured during a
measurement:
relevant circuit between the automatic
transmission module and soldered connection S128 using the Wiring Diagrams.
- If battery voltage is not measured during
both measurements:
between soldered connection S128 and fuse
G7: CHECK THE VOLTAGE AT THE AUTOMATIC TRANSMISSION MODULE
circuit 15-TA55A (GN/BK), wiring harness side
and ground.

Yes
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TO MODEL INDEX
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TEST CONDITIONS
GO to G8
No
between the automatic transmission module
G8: CHECK THE GROUND CONNECTION OF THE AUTOMATIC TRANSMISSION MODULE
2 Measure the resistance between the automatic
circuit 91-TA55A (BK/GN), wiring harness side
and ground.
3 Measure the resistance between the automatic

circuit 91-TA55B (BK/GN), wiring harness side
and ground.
both cases?
Yes
GO to G9
No
transmission module and soldered connection S132 using the Wiring Diagrams.
measured in both of the measurements:
relevant circuit between soldered connection
S132 and battery negative using the Wiring
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TO MODEL INDEX
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TEST CONDITIONS
G9: CHECK THE CIRCUIT BETWEEN THE AUTOMATIC TRANSMISSION MODULE AND DLC FOR
CONTINUITY.
1 Vehicles with automatic transmission: Measure
the resistance between the DLC, connector
C308, pin 6, circuit 4-EC1 (GY/RD), wiring
harness side and the automatic transmission
(GY/WH), wiring harness side.
2 Vehicles with automatic transmission: Measure

the resistance between the DLC, connector
C308, pin 14, circuit 5-EC1 (BU/RD), wiring
harness side and the automatic transmission
(BU/OG), wiring harness side.

both cases?
Yes
CHECK automatic transmission module and
RENEW as necessary. CHECK the operation of the system.
No
transmission module and the DLC using the
the system.
PINPOINT TEST H: FAULTY COMMUNICATION BETWEEN THE MODULES (ISO BUS)
TEST CONDITIONS
H1: CHECK FUSE F18
Is the fuse OK?
Yes
GO to H2
No
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TO MODEL INDEX
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TEST CONDITIONS
H2: CHECK THE VOLTAGE AT FUSE F18

and ground.
Yes
GO to H3
No
of the system.
H3: CHECK THE VOLTAGE AT THE DATA LINK CONNECTOR (DLC)
1 Measure the voltage between the DLC, connector C308, pin 16, circuit 29-RA1 (OG), wiring

Yes
GO to H4
No
LOCATE and REPAIR the open circuit between the DLC and fuse F18 using the Wiring
H4: CHECK THE VOLTAGE AT THE DLC
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TO MODEL INDEX
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TEST CONDITIONS
2 Measure the voltage between the DLC, connector C308, pin 9, circuit 15-RA1 (GN/RD),

Yes
GO to H5
No
15-RA1 (GN/RD) between the DLC and the
ignition switch using the Wiring Diagrams.
H5: CHECK THE GROUND CONNECTION OF THE DLC
connector C308, pin 4, circuit 31-RA1 (BK),

Yes
GO to H6
No
LOCATE and REPAIR the open circuit between the DLC and ground connection G25
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TEST CONDITIONS
H6: CHECK THE GROUND CONNECTION OF THE DLC

connector C308, pin 5, circuit 91-RA1 (BK/OG),

Yes
GO to H7
No
91-RA1 (BK/OG) between the DLC and
H7: PERFORM NETWORK TEST
1 Disconnect Connector C303 from ABS module vehicles built up to 03/2004 / or ESP module.
2 Disconnect Vehicles with ABS - vehicles built
after 04/2004: connector C304 from ABS module.
4 Select the vehicle with the diagnostic tester.
Is it possible to establish a connection between
the vehicle and the generic electronic module
(GEM)?
Yes
module or electronic stability program module (ESP). CHECK the operation of the system.
No
GO to H8
H8: PERFORM NETWORK TEST (SAFETY RESTRAINT CONTROL MODULE (RCM))
WARNING: After disconnecting the battery, wait for at least one minute before working on
the supplementary restraint system to prevent the risk of accidental airbag deployment.
WARNING: Do not program any keycodes while working on the safety restraint system in
order to prevent the risk of accidental deployment of safety restraint system components.
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TO MODEL INDEX
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TEST CONDITIONS
WARNING: Always use adapters for terminal probe kit when testing any connectors of the
airbag systems or of any other safety restraint systems. Failure to observe this instruction
can lead to injury.
1 Disconnect ground cable from battery.
2 Disconnect connector C500 from safety restraint control module (RCM).
3 Connect ground cable from battery.
Is it possible to establish a connection between
the vehicle and the generic electronic module
(GEM)?
Yes
CHECK and if necessary RENEW the safety
restraint control module (RCM). CHECK the
No
GO to H9
H9: CHECK THE ISO 9141 BUS FOR A SHORT TO VOLTAGE SUPPLY
1
2
3
4

Disconnect connector C320 (brown) from GEM.
Measure the voltage between the DLC, connector C308, pin 7, circuit 4-EE10 (GY/BK),
Yes
LOCATE and REPAIR the short to voltage in
No
GO to H10
H10: CHECK THE ISO 9141 BUS FOR A SHORT TO GROUND
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TO MODEL INDEX
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TEST CONDITIONS
connector C308, pin 7, circuit 4-EE10 (GY/BK),

measured?
Yes
GO to H11
No
LOCATE and REPAIR the short to ground in
H11: CHECK FOR OPEN CIRCUIT BETWEEN THE GEM AND THE DLC.
1 Measure the resistance between GEM, connector C320 (brown), pin 10, circuit 4-EE11
(GY/WH), wiring harness side and DLC, C308,
pin 7, circuit 4-EE10 (GY/BK), wiring harness
side.

Yes
No
4-EE10 (GY/BK) between the DLC and soldered connection S270 using the Wiring
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PINPOINT TEST I: FAULTY COMMUNICATION BETWEEN THE MODULES - CAN BUS
TEST CONDITIONS
NOTE: The number of modules connected to the CAN bus depends on the equipment levels of the vehicle. Therefore not every vehicle will have all the modules mentioned below.
I1: CHECK FUSE F18
Is the fuse OK?
Yes
GO to I2
No
I2: CHECK THE VOLTAGE AT FUSE F18
and ground.
Yes
GO to I3
No
of the system.
I3: CHECK THE VOLTAGE AT THE DATA LINK CONNECTOR (DLC)
1 Measure the voltage between the DLC, connector C308, pin 16, circuit 29-RA1 (OG), wiring

Yes
GO to I4
No
LOCATE and REPAIR the open circuit between the DLC and fuse F18 using the Wiring
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TO MODEL INDEX
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TEST CONDITIONS
I4: CHECK THE VOLTAGE AT THE DLC

2 Measure the voltage between the DLC, connector C308, pin 9, circuit 15-RA1 (GN/RD),

Yes
GO to I5
No
15-RA1 (GN/RD) between the DLC and the
ignition switch using the Wiring Diagrams.
I5: CHECK THE GROUND CONNECTION OF THE DLC
connector C308, pin 4, circuit 31-RA1 (BK),

Yes
GO to I6
No
LOCATE and REPAIR the open circuit between the DLC and ground connection G25
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TO MODEL INDEX
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TEST CONDITIONS
I6: CHECK THE GROUND CONNECTION OF THE DLC

connector C308, pin 5, circuit 91-RA1 (BK/OG),

Yes
GO to I7
No
91-RA1 (BK/OG) between the DLC and
I7: CHECK THE CAN BUS FOR SHORT CIRCUIT
1 Disconnect the ground cable from the battery.
connector C308, between pin 6, circuit 4-EC1
(GY/RD), wiring harness side and pin 14, circuit
5-EC1 (BU/RD), wiring harness side.
Is a resistance of between 55 and 65 Ohms

measured?
Yes
- Vehicles without automatic clutch and
gearshift actuation:
GO to I14
- Vehicles with automatic clutch and gearshift
actuation:
GO to I8
No
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TO MODEL INDEX
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TEST CONDITIONS
- A resistance of between 115 and 125 Ohms
is measured:
GO to I17
- A resistance of between 115 and 125 Ohms
is not measured:
GO to I28
I8: PERFORM NETWORK TEST

3 Disconnect a listed component, then perform
the following test step:
- connector C303 from ABS module - vehicles
built up to 03/2004 / or ESP module
04/2004: connector C304 from ABS module
- connector C679 from von transmission
selector unit
- connector C332 from instrument cluster
the PCM?
Yes
The component disconnected last is the
cause of the concern, CHECK component
and if necessary RENEW. CHECK the operation of the system.
No
- If not all the listed components are
disconnected:
Key in the OFF position. DISCONNECT the
next component (go to test step 3).
- If all the listed components are
disconnected:
GO to I9
I9: CHECK THE CAN BUS FOR A SHORT TO VOLTAGE SUPPLY
2 Disconnect connector C676 from transmission
control module (TCM).
3 Disconnect Vehicles with diesel engines: connector C370 from the PCM.
4 Disconnect All except vehicles with diesel engines: connector C343 from the PCM.
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TO MODEL INDEX
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TEST CONDITIONS
6 Measure the voltage between the DLC, connector C308, pin 6, circuit 4-EC1 (GY/RD),
7 Measure the voltage between the DLC, connector C308, pin 14, circuit 5-EC1 (BU/RD),
Yes
the affected circuit using the Wiring Diagrams. CHECK the operation of the system.
No
GO to I10
I10: CHECK THE CAN BUS FOR A SHORT TO GROUND

Yes
GO to I11
No
in the affected circuit using the Wiring Diagrams. CHECK the operation of the system.
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TO MODEL INDEX
418-00-55

TEST CONDITIONS
I11: CHECK THE CAN BUS BETWEEN TCM AND PCM FOR SHORT TO VOLTAGE
1 Measure the voltage between the TCM, connector C676, pin 61, circuit 4-EC7 (GY/RD) and
ground.
2 Measure the voltage between the TCM, connector C676, pin 63, circuit 5-EC7 (BU/RD) and
ground.
Yes
No
GO to I12
I12: CHECK THE TCM FOR BREAKS
1 Measure the resistance at TCM, connector
C676, between pin 54 and pin 61, component
side.
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TO MODEL INDEX
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TEST CONDITIONS
side.

both cases?
Yes
GO to I13
No
CHECK the TCM and RENEW as necessary.
I13: CHECK THE CAN BUS BETWEEN TCM AND PCM FOR SHORT TO GROUND
connector C676, pin 61, circuit 4-EC7 (GY/RD)
and ground.

connector C676, pin 63, circuit 5-EC7 (BU/RD)
and ground.

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TO MODEL INDEX
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TEST CONDITIONS
Yes
CHECK the operation of the system. If the
system is still inoperative, CHECK the PCM
and RENEW if necessary. CHECK the operation of the system.
No

- Vehicles with automatic transmission:
connector C428 from automatic transmission
module
the PCM?
Yes
No
disconnected:
disconnected:
GO to I15
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TO MODEL INDEX
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TEST CONDITIONS
Yes
No
GO to I16

Yes
No
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TO MODEL INDEX
418-00-59

TEST CONDITIONS
I17: CHECK INSTRUMENT CLUSTER

cluster.
Is a resistance of between 115 and 125 Ohms

measured?
Yes
GO to I18
No
actuation:
GO to I20
- All, except vehicles with diesel engine,
without Durashift automatic transmission:
GO to I26
- Vehicles with diesel engine, without
Durashift automatic transmission:
GO to I24
I18: CHECK THE CIRCUIT BETWEEN THE INSTRUMENT CLUSTER AND THE DLC FOR
CONTINUITY
cluster, connector C332, pin 31, circuit 5-EC8A
(BU/WH), wiring harness side and the DLC,

Yes
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TO MODEL INDEX
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TEST CONDITIONS
GO to I19
No
between the instrument cluster and the DLC
CONTINUITY
(GY/VT), wiring harness side and the DLC,

Yes
CHECK and if necessary RENEW the instrument cluster. CHECK the operation of the
system.
No
I20: CHECK THE CIRCUIT BETWEEN THE TCM AND THE DLC FOR CONTINUITY.
wiring harness side and the TCM, connector
C676, pin 54, circuit 4-EC8 (GY/VT), wiring
harness side.
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TO MODEL INDEX
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TEST CONDITIONS
wiring harness side and the TCM, connector
C676, pin 56, circuit 5-EC8 (BU/WH), wiring
harness side.

all of the cases?
Yes
GO to I21
GO to I22
No
relevant circuit using the Wiring Diagrams.
I21: CHECK CIRCUIT BETWEEN THE TCM AND PCM FOR OPEN CIRCUIT - VEHICLES WITH
DIESEL ENGINE
wiring harness side and the PCM, connector
C370, pin A4, circuit 4-EC7 (GY/RD), wiring
harness side.
G105811 en
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TO MODEL INDEX
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TEST CONDITIONS
C370, pin A3, circuit 5-EC7 (BU/RD), wiring
harness side.

all of the cases?
Yes
GO to I23
No
I22: CHECK CIRCUIT BETWEEN THE TCM AND PCM FOR OPEN CIRCUIT - VEHICLES WITH
PETROL ENGINE
C343, pin F31, circuit 4-EC7 (GY/RD), wiring
harness side.

C343, pin F19, circuit 5-EC7 (BU/RD), wiring
harness side.
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TO MODEL INDEX
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TEST CONDITIONS
all of the cases?
Yes
GO to I23
No

side.

side.

both cases?
Yes
No
I24: CHECK CIRCUIT BETWEEN THE PCM AND THE DLC FOR OPEN CIRCUIT
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TO MODEL INDEX
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TEST CONDITIONS
connector C370, pin A4, circuit 4-EC7 (GY/RD),
wiring harness side and the DLC, connector
C308, pin 6, circuit 4-EC1 (GY/RD), wiring
harness side.

Yes
GO to I25
No
between the PCM and the DLC using the
the system.
connector C370, pin A3, circuit 5-EC7 (BU/RD),
wiring harness side and the DLC, connector
C308, pin 14, circuit 5-EC1 (BU/RD), wiring
harness side.

Yes
No
the system.
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TO MODEL INDEX
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TEST CONDITIONS
connector C343, pin F31, circuit 4-EC7
(GY/RD), wiring harness side and the DLC,

Yes
GO to I27
No
the system.
connector C343, pin F19, circuit 5-EC7
(BU/RD), wiring harness side and the DLC,

Yes
No
the system.
CONTINUITY
cluster.
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TEST CONDITIONS
(BU/WH), wiring harness side and the DLC,

Yes
GO to I29
No
CONTINUITY
(GY/VT), wiring harness side and the DLC,

Yes
- Vehicles without automatic clutch and
gearshift actuation:
GO to I30
actuation:
GO to I34
No
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TO MODEL INDEX
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TEST CONDITIONS

NOTE: The number of modules connected to the CAN bus depends on the equipment levels of the vehicle. Therefore not every vehicle will have all the modules mentioned below.
- Vehicles with automatic transmission:
connector C428 from automatic transmission
module
the PCM?
Yes
No
disconnected:
disconnected:
GO to I31
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TEST CONDITIONS
Yes
No
GO to I32

Yes
GO to I33
No
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TEST CONDITIONS


Yes
No
LOCATE and REPAIR the short in the CAN
Bus using the Wiring Diagrams. CHECK the
actuation: connector C679 from transmission
selector unit
the PCM?
Yes
No
disconnected:
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TEST CONDITIONS
disconnected:
GO to I35
2 Disconnect connector C676 from transmission
control module (TCM).
Yes
No
GO to I36
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TEST CONDITIONS

Yes
GO to I37
No
side.
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TEST CONDITIONS
side.

both cases?
Yes
GO to I38
No
I38: CHECK THE CAN BUS BETWEEN TCM AND PCM FOR SHORT TO VOLTAGE
1 Measure the voltage between the TCM, connector C676, pin 61, circuit 4-EC7 (GY/RD) and
ground.
2 Measure the voltage between the TCM, connector C676, pin 63, circuit 5-EC7 (BU/RD) and
ground.
Yes
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TEST CONDITIONS
No
GO to I39
I39: CHECK THE CAN BUS BETWEEN TCM AND PCM FOR SHORT TO GROUND
connector C676, pin 61, circuit 4-EC7 (GY/RD)
and ground.

connector C676, pin 63, circuit 5-EC7 (BU/RD)
and ground.

Yes
GO to I40
No
G105811 en
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418-00-74

TEST CONDITIONS


Yes
No
LOCATE and REPAIR the short in the CAN
Bus using the Wiring Diagrams. CHECK the
Component Tests
PCM module relay
G105811 en

unswitched state:
1. Measure the resistance at the PCM module
relay, between pin 3, component side and
2. Is a resistance of more than 10,000 Ohm
measured?
3. If yes, go to 2.
4. If no, RENEW the PCM module relay.
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418-00-75

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418-00-75

switched state:
1. Use a fused test cable (1 A) to connect pin 1
of the PCM module relay, component side,
to the battery positive terminal.
2. Use a test cable to connect pin 2 of the PCM
module relay, component side, to the
battery negative terminal.
3. Measure the resistance at the PCM module
relay, between pin 3, component side and
4. Is a resistance of less than 2 Ohm
registered?
5. If yes, then the PCM module relay is OK.
6. If no, RENEW the PCM module relay.
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418-01-1
Module Configuration
418-01-1
SECTION 418-01 Module Configuration

CONTENTS
PAGE

Module Configuration ........................................................................................................
Description of operation ...................................................................................................
418-01-2
418-01-2
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418-01-2

Description of operation
Configuration of a new module is performed using
WDS. In doing so, the same system
requirements must apply as for the diagnosis of
the respective module:
The BUS connection between the module and
WDS must be in order.
The voltage supply to the module and to WDS
must be guaranteed.
For this reason, if there are communication
problems which cannot be attributed to the
incorrect software version in WDS, the system test
for module communication of the particular
module must be performed. For further
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419-01A-1
Anti-Theft - Active
419-01A-1
SECTION 419-01A Anti-Theft - Active

CONTENTS
PAGE

Anti-Theft - Active ............................................................................................................
419-01A-2
419-01A-2
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419-01A-2
Anti-Theft - Active
419-01A-2

Anti-Theft - Active
Mechanical
Electrical
Misaligned door(s),
hood or liftgate
Latch(es)
Cable(s)
Switch(es)
Lock cylinder(s)
Linkage(s)
Fuse(s)
Wiring harness
Electrical
connector(s)
Relay(s)
Generic electronic
module (GEM)
Anti-theft alarm horn
Anti-theft alarm horn
with integral battery
step.
system.
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419-01B-1
Anti-Theft - Passive
419-01B-1
SECTION 419-01B Anti-Theft - Passive

CONTENTS
PAGE

Anti-Theft - Passive..........................................................................................................
Function ..........................................................................................................................
Key programming............................................................................................................
Expanded passive anti-theft system (PATS ) functionality..............................................
419-01B-2
419-01B-3
419-01B-3
419-01B-4
419-01B-4

419-01B-5
419-01B-5
GENERAL PROCEDURES
Key Programming Using Two Programmed Keys ......................................... (33 005 0)
Key Programming Using Diagnostic Equipment ............................................ (33 005 0)
Key Programming Switch State Control ...........................................................................
Erasing All Key Codes Using Diagnostic Equipment ........................................................
Anti-Theft Security Access ............................................................................ (33 004 0)
419-01B-7
419-01B-8
419-01B-9
419-01B-10
419-01B-11
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419-01B-2

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419-01B-2

Item
Part
Number
Transponder in the key
Transceiver in the ignition

lock

( PCM )
G195498 en
Description
Item
Part
Number
Description
Instrument Cluster
Starter motor
Electronic ignition ( EI )
Injectors
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419-01B-3
419-01B-3

Item
Part
Number
Description
Passive anti-theft system

( PATS ) warning lamp
Data link connector (DLC)
Flash code for PATS (example: code 21)

Item
Part
Number
Warning lamp OFF
Warning lamp ON
Two flashing signals (1st

digit)
One flashing signal (2nd

digit)
Approx. 3-second pause
Repetition of the flash code
Function
PATS is a passive system designed to increase
the anti-theft security of a vehicle. It does not need
to be activated or deactivated by the driver.
The PATS system uses specially encoded keys.
Every encoded ignition key contains a
transponder which is permanently fitted to the key.
This transponder contains an identification code
randomly selected from millions of possible
combinations (crypto-transponder with
automatically changing code).
The transmitter/receiver (transceiver) is located
on the ignition lock. The transceiver incorporates
an antenna which is connected to an integrated
electronics module.
When the ignition key is turned to position II,
communications take place initially between the
transceiver and the PCM.
If these communications are free of errors, then
the transponder is actuated by the PCM via the
transceiver.
The transponder returns the identification code to
the PCM for processing.
Description
As an optical signal, the (PATS ) system sends an

actuation signal to the PATS warning lamp
approx. every 2 seconds when the ignition lock is
in position "0" .
In the event of a system fault, the PATS outputs a
corresponding flash code.
Key programming
Every encoded key must be programmed into the
(PCM ) before it can be used to start the engine.
Keys can be programmed either by authorised
Ford dealers with WDS and access to OASIS, or
directly by the customer if two keys which have
already been programmed are available.
Up to eight keys can be programmed.
PATS warning lamp
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419-01B-4

Expanded passive anti-theft system (PATS )
functionality
The PATS functionality has been expanded to
increase anti-theft security. The new system also
uses new keys.
NOTE: Only keys with a blue insert and the
labelling "W1" can be used.
After completion of the usual PATS
communications between the transponder,
transceiver and the powertrain control module
(PCM ), the PCM also requests a code from the
instrument cluster module via the CAN databus in
order to increase the passive anti-theft security.
As a result, a further component which is not
easily removable is required to enable an engine
start.
All of the code requests must be completed
successfully before the PCM will start the engine.
NOTE: When renewing the instrument cluster or
the PCM an initialisation with WDS is required.
In order to ensure that the engine can be started
as quickly as possible, the initial starting
procedure is initiated provided the correct key has
been detected and no communications errors to
the instrument cluster have arisen.
However, if the PCM determines within a
maximum of three seconds that not all of the
PATS conditions have been satisfied, then the
engine is switched back off and cannot be
restarted (no starter signal, no fuel injection signal,
no ignition signal).
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419-01B-5
419-01B-5

Refer to Wiring Diagrams Section 419-01B for
General Equipment

Diagnostic Trouble Code (DTC) Index

Indicator
Flash Description/Conditio
Code
n
DTC
0000
No DTCs, vehicle OK
B1681
11
PATS transceiver
signal is not received
B1232
and
B2103
B1600
13
B2431
13
G422761 en
12
PATS transceiver
antenna coil fault, vehicle does not start
Non-PATS key or
damaged encoded
ignition key, or no key
code received, vehicle
does not start
PATS transponder
programming failed
crypto transponder
only, vehicle does not
start
Mechanical
Electrical
Ignition lock cylinder Fuse(s)

Passive anti-theft
Wiring harness(s)
system (PATS)
Electrical
ignition key (blue
connector(s)
dot)
Relay(s)
Non-PATS ignition
PATS transceiver
key
Ignition switch
Use of a
Powertrain control
non-progammed
module (PCM)
PATS ignition key
Instrument cluster
Use of a
non-encoded PATS
ignition key
More than one
PATS key in close
proximity of the
PATS transceiver
step.
4. If the cause is not visually evident, use to
retrieve any DTCs and refer to the Diagnostic
Trouble Code (DTC) Index.
Possible Source
PATS transceiver
wiring, PATS transceiver connector,
PATS transceiver,
PCM or instrument
cluster
PATS transceiver,
PATS transceiver
mounting
PATS encoded ignition key
Ignition key
Action
REFER to WDS.
Make sure the PATS transceiver

is connected correctly, if OK, install a new PATS transceiver.
REFER to WDS. PATS test.
Follow the instructions.

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TO MODEL INDEX
419-01B-6
DTC
B1602
B1601
U2510
B1213
B2141
B2139
P1260
G422761 en
Indicator
Flash Description/Conditio
Code
n
Possible Source
PATS encoded igni14
Partial key read of
tion key, PATS
PATS key, vehicle
transceiver
does not start
PATS encoded igni15
Incorrect key code,
tion key
Unprogrammed PATS
key (keycode format
OK), vehicle does not
start (20 second
anti-scan invoked)
Circuit, PCM or
16
CAN communication
link between the PCM instrument cluster
and instrument cluster, vehicle does not
start
Incorrect number of
21
Number of programmed PATS en- keys programmed or
PATS encoded ignicoded keys below
tion key
minimum, vehicle
does not start
PCM or instrument
22
NVM Configuration
cluster
failure. No security ID
exchange between
PCM and instrument
cluster, vehicle does
not start
PCM or instrument
23
Data mismatch (recluster
ceived data does not
match what was expected). Security
messages do not
match between PCM
and instrument cluster, vehicle does not
start
PCM disabled
PCM or instrument
cluster
Action




Follow the instructions. If the
concern persists. INSTALL a
new PCM. REFER to Section
303-14.[Electronic Engine Controls, REMOVAL AND
INSTALLATION, Powertrain
Control Module (PCM) - 1.25L
Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma)]
REFER to Section
Duratec-HE (MI4), Vehicles
Without: PCM Security Shield]
REFER to Section
Duratec-HE (MI4), Vehicles With:
PCM Security Shield]
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TO MODEL INDEX
419-01B-7
GENERAL PROCEDURES
Key Programming Using Two Programmed Keys (33 005 0)
NOTE: This procedure only works if two or more
programmed ignition keys are available. For
additional information, refer to Key Programming
Using Diagnostic Equipment in this section.
NOTE: If the programming procedure is
successful, the new key(s) will start the vehicle
and the anti-theft indicator will illuminate for
approximately three seconds.
NOTE: If the programming procedure is not
successful, the new key(s) will not start the engine.
If the programming procedure was not successful,
repeat the Key Programming procedure from Step
1. If the failure repeats, refer to Diagnostic and
Testing to review DTCs.
NOTE: A maximum of eight ignition keys can be
programmed to a passive anti-theft system
(PATS) equipped vehicle.
NOTE: If the steps are not carried out as outlined,
the programming procedure will end.
NOTE: Ignition keys must have correct
mechanical key cut for the vehicle and must be a
PATS encoded key.
NOTE: If this procedure does not program new
ignition key(s) using two programmed ignition
keys, check that the Key Programming Switch
State Control is in the DISABLE position. For
additional information, refer to Key Programming
Switch State Control in this section.
1. Insert the first programmed ignition key
into the ignition lock cylinder and turn the
ignition key from the 0 position to the II
Position (maintain the ignition key in the II
position for one second).
2. Turn the ignition key to the 0 position and
remove the first ignition key from the
ignition lock cylinder.
3. Within five seconds of turning the first
ignition key to the 0 position, insert the
second programmed ignition key into the
ignition lock cylinder and turn the ignition
key from the 0 position to the II position
(maintain the ignition key in the II position
for one second).
4. Turn the ignition key to the 0 position and
remove the second ignition key from the
ignition lock cylinder.
5. Within ten seconds of turning the second
ignition key to the 0 position, insert the
unprogrammed ignition key (new key) into
the ignition lock cylinder and turn the
G296006 en
ignition key from the 0 position to the II

position (maintain the ignition key in the II
position for one second).
6. If it is desired to program additional key(s),
repeat the applicable ignition key
programming procedure from Step 1.
7. Verify that the engine starts using the new
programmed key(s).
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419-01B-8
GENERAL PROCEDURES
Key Programming Using Diagnostic Equipment (33 005 0)
General Equipment
(418-F224)
NOTE: This procedure is used when a customer
needs keys programmed into the system or after
keys have been erased using diagnostic
equipment.
NOTE: During this procedure it will be necessary
to utilize the Anti-Theft System (PATS) Security
Access Procedure. PATS security access must be
granted to erase or program ignition keys. The
anti-theft security access procedure requires
access to the GSEVIN database in order to obtain
the coded security access.
NOTE: This procedure will not erase programmed
ignition keys from the passive anti-theft alarm
system (PATS) memory.
NOTE: A maximum of eight ignition keys can be
programmed to a passive anti-theft system
(PATS) equipped vehicle.
1. Insert an ignition key into the ignition lock
cylinder and turn the ignition key from the 0
position to the II position.
2. From the diagnostic tool menu Select:
Body/Security/PATS Functions. Follow the
instructions on the screen.
Ignition Key Programming. Follow the
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419-01B-9
GENERAL PROCEDURES
Key Programming Switch State Control
General Equipment
(418-F224)
NOTE: The spare key programming switch is a
programmable switch which provides the
capability to enable or disable the normal
customer spare key programming procedure
detailed in the Owner's Manual. This
programmable switch is provided as a
convenience for rental company fleets or other
fleet purchasers who may not want the spare key
programming procedure available to the vehicle
driver.
granted to erase or program ignition keys or to
enable or disable the ignition key programming
switch state control. The anti-theft security access
procedure requires access to the GSEVIN
database in order to obtain the coded security
access.
1. Insert a programmed ignition key into the
ignition lock cylinder and turn the ignition
key from the 0 position to the II position.
Body/Security/PATS Functions Follow the
Enable Fleet or Hire vehicle mode or
Disable Fleet or Hire vehicle mode. Follow
the instructions on the screen.
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419-01B-10
GENERAL PROCEDURES
Erasing All Key Codes Using Diagnostic Equipment
General Equipment
(418-F224)
NOTE: This procedure is used when a customer
needs ignition keys programmed into the system.
This procedure is also useful when programmed
ignition key(s) have been lost or when the ignition
lock cylinder has been replaced or when it is
necessary to erase a key(s) from the passive
anti-theft alarm system (PATS) memory.
granted to erase or program ignition keys. The
anti-theft security access procedure requires
access to the GSEVIN database in order to obtain
the coded security access.
NOTE: This procedure will erase all programmed
ignition keys from the passive anti-theft alarm
system (PATS) memory and the engine will not
start until two keys have been reprogrammed to
the system. For additional information, refer to
Key Programming Using Diagnostic Equipment in
this section.
NOTE: Two PATS encoded keys with the correct
mechanical cut must be available to carry out this
procedure. One or both of them may be the
original keys.
NOTE: If the remaining keys are with the
customer and are not available with the vehicle,
instruct the customer that the remaining keys are
no longer valid to start the vehicle. If the customer
wants to have these keys to be valid for the
vehicle, the keys must be programmed using
WDS. For additional information, refer to Key
Programming Using Diagnostic Equipment in this
section.
1. Turn the ignition lock cylinder from the 0
Body/Security/PATS Functions from the
menu. Follow the instructions on the
screen.
Ignition Key Erase. Follow the instructions
on the screen.
Ignition Key Programming. Follow the
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419-01B-11
GENERAL PROCEDURES
Anti-Theft Security Access (33 004 0)
General Equipment
(418-F224)
NOTE: Anti-Theft System (PATS) security access
must be granted to erase or program ignition keys
or to enable or disable the ignition key
programming switch state control. The anti-theft
security access procedure requires access to the
GSEVIN database in order to obtain the coded
security access.
NOTE: When installing a new powertrain control
module (PCM), the following sequence must be
completed:
1. Ignition Key Programming.
2. Module Initialization.
NOTE: When installing a new instrument cluster,
the following must be completed:
1. Module Initialization.
1. Insert an ignition key into the ignition lock
cylinder and turn the ignition key from the 0
Body/Security/PATS Functions. Follow the
G334170 en
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419-08-1
Cellular Phone
419-08-1
SECTION 419-08 Cellular Phone

CONTENTS
PAGE

Cellular Phone ..................................................................................................................
Symptom Chart ................................................................................................................
Pinpoint Test ....................................................................................................................
419-08-2
419-08-2
419-08-2
419-08-3
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419-08-2

TO MODEL INDEX
Cellular Phone
419-08-2

Cellular Phone
1. Verify the customers concern.
damage.
Electrical
- Fuse(s)
- Wiring Harness
- Microphone
- Cellular phone antenna
- Cellular phone speaker
- Handset holder
- Cellular phone
- Portable Support Electronics (PSE) Module
3. Verify that the cellular phone operates

correctly out of the vehicle before proceeding
to the next step.
4. Verify the audio unit or navigation system
display module is working correctly before
proceeding to the next step.
step.
Symptom Chart
Symptom
Possible Sources
Action
The handset battery does not

charge
Circuit(s).
Handset holder.
Cellular phone.
PSE Module.
Interference from the cellular

phone speaker - vehicles with
Traffic Pro navigation system
Incorrect settings of the naviga- MAKE sure that MUTE is setion system display module.
lected in the navigation system
display module RADIO MODE.
Reduced sound or no sound

through the speaker
Circuit(s).
Cellular phone speaker.
Handset holder.
PSE Module.
No SVC display stays on
Cellular phone antenna.

Handset holder.
GO to Pinpoint Test C.
The hands-free system is inoperative
Cellular phone and handset

holder electrical contacts.
CHECK the cellular phone is

correctly installed into the
handset holder. TEST the system for normal operation.
Microphone sensitivity too low

(user is difficult to hear when
making calls)
Microphone incorrectly adjusted. INCREASE the microphone

sensitivity on the PSE module
during a conversation.
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419-08-3

TO MODEL INDEX
Cellular Phone
419-08-3

Symptom
Possible Sources
Microphone location incorrect.
Action
CHECK the location of the microphone. INSTALL the microphone in the correct location if
necessary.
Microphone sensitivity too high Microphone incorrectly adjusted. DECREASE the microphone
(user hears their own voice when
making calls)
Whistling noise when the cellular Microphone incorrectly adjusted. DECREASE the microphone
phone is in use
The cellular phone speaker op- PSE module wiring harness.
erates but the audio unit speak- Electrical connection to the audio
ers do not mute.
unit or navigation system display
module.
Threshold voltage to the audio
unit or navigation system display
module is not achieved.
INSTALL a new PSE module

wiring harness. TEST the system
for normal operation. If the concern persists, INSTALL a new
PSE module. TEST the system
Audio unit or navigation system INSTALL a new audio unit.

display module.
INSTALL a new navigation system display module. Vehicles
with Travel Pilot, Vehicles with
Traffic Pro,
Pinpoint Test
PINPOINT TEST A: THE HANDSET BATTERY DOES NOT POWER UP
TEST CONDITIONS
A1: CHECK THE POWER SUPPLY TO THE PSE MODULE
1 Disconnect PSE Module C1026.
2 Ignition switch in position I.
3 Measure the voltage between the PSE module
C1026 pin 4, (PK), harness side and ground;
and the PSE module C1026 pin 5, (GY), harness side and ground.

Yes
GO to A3.
No
GO to A2.
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Cellular Phone
419-08-4

TEST CONDITIONS
A2: CHECK THE PSE MODULE POWER WIRING HARNESS FOR OPEN
1 Disconnect PSE Harness C1025.
2 Measure the resistance between the PSE
module C1026 pin 4, (PK), harness side and
PSE harness C1025 pin 1, (YE), harness side;
and the PSE module C1026 pin 5, (GY), harness side and PSE harness C1025 pin 1, (YE),
harness side.
Is the resistances less than 5 ohms?

Yes
For audio unit, GO to A5.
For navigation display module, GO to A6.
No
normal operation.
A3: CHECK THE PSE MODULE FOR GROUND
1 Connect PSE Harness C1025.
ground; and the PSE module C1026 pin 6, (YE),

Yes
CLEAN the handset holder and cellular
phone electrical connectors. TEST the system for normal operation. If the concern
persists, INSTALL a new handset holder.
TEST the system for normal operation. If the
concern persists, INSTALL a new PSE
module.
No
GO to A4.
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Cellular Phone
419-08-5

TEST CONDITIONS
A4: CHECK THE PSE MODULE GROUND WIRING HARNESS FOR OPEN
1 Disconnect PSE Harness C1025.
PSE harness C1025 pin 3, (YE), harness side;
and the PSE module C1026 pin 6, (YE), harness side and PSE harness C1025 pin 3, (YE),
harness side.

Yes
For audio unit, GO to A7.
For navigation display module, GO to A8.
No
INSTALL a new PSE module wiring harness.
A5: CHECK THE PSE MODULE POWER WIRING HARNESS TO AUDIO UNIT WIRING HARNESS
FOR OPEN
module C1025 pin 1, (YE), harness side and
audio unit C344 pin 2, circuit 75-MD15 (YE/GN),
harness side.

Yes
For additional information. REFER to Section
415-00.
No
normal operation.
A6: CHECK THE PSE MODULE POWER WIRING HARNESS TO NAVIGATION SYSTEM DISPLAY
MODULE WIRING HARNESS FOR OPEN
1 Disconnect Navigation System Display Module
C717.
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419-08-6

TO MODEL INDEX
Cellular Phone
419-08-6

TEST CONDITIONS
module C1025 pin 1, (YE), harness side and
navigation system display module C717 pin 7,
circuit 75-MD15 (YE/GN), harness side.

Yes
For additional information. for vehicles with
Travel Pilot or for vehicles with Traffic Pro.
No
normal operation.
A7: CHECK THE PSE MODULE GROUND WIRING HARNESS TO AUDIO UNIT WIRING HARNESS
FOR OPEN
audio unit C344 pin 13, circuit 91-MD15
(BK/GN), harness side.

Yes
For additional information. REFER to Section
415-00.
No
normal operation.
A8: CHECK THE PSE MODULE GROUND WIRING HARNESS TO NAVIGATION SYSTEM DISPLAY
MODULE WIRING HARNESS FOR OPEN
1 Disconnect Navigation System Display Module
C717.
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Cellular Phone
419-08-7

TEST CONDITIONS
navigation system display module C717 pin 8,
circuit 91-MD15 (BK/GN), harness side.

Yes
For additional information. for vehicles with
Travel Pilot or for vehicles with Traffic Pro.
No
normal operation.
PINPOINT TEST B: REDUCED SOUND OR NO SOUND THROUGH THE SPEAKER
TEST CONDITIONS
B1: CHECK THE CELLULAR PHONE SPEAKER
1 Disconnect Cellular Phone Speaker.
2 Measure the resistance between the speaker
terminals (component side).
Is the resistance between 3 and 5 ohms?

Yes
REPAIR if necessary the circuit between the
cellular phone speaker and the PSE module.
TEST the system for normal operation. If the
concern persists, CLEAN the handset holder
and cellular phone electrical connectors.
INSTALL a new handset holder. TEST the
system for normal operation. If the concern
persists, INSTALL a new PSE module. TEST
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419-08-8

TO MODEL INDEX
Cellular Phone
419-08-8

TEST CONDITIONS
No
INSTALL a new cellular phone speaker.
PINPOINT TEST C: NO SVC DISPLAY STAYS ON

TEST CONDITIONS
C1: CHECK THE HANDSET HOLDER ANTENNA CABLE FOR OPEN
1 Disconnect Handset Holder Antenna Cable.
2 Measure the resistance between the center pin
of the cellular phone handset holder antenna
connection and the center pin of the antenna
cable connector.

Yes
No
INSTALL a new handset holder. TEST the
G189090 en
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419-10-1
Multifunction Electronic Modules
419-10-1
SECTION 419-10 Multifunction Electronic Modules

CONTENTS
PAGE

Module Controlled Functions.............................................................................................
Generic Electronic Module (GEM) .......................................................................
419-10-2
419-10-2

Generic Electronic Module (GEM).....................................................................................
Description of operation ...................................................................................................
Defect Identification Table................................................................................................
System Check ..................................................................................................................
419-10-8
419-10-8
419-10-9
419-10-9
419-10-9

Generic Electronic Module (GEM).....................................................................................
419-10-16
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419-10-2

Module Controlled Functions
Four different variants are available depending on
the equipment level of the vehicle:
A - vehicles with manual unlocking
B - vehicles with central locking
C - vehicles with central locking and remote
control
D - vehicles with central/double locking,
anti-theft warning system and remote control
Generic Electronic Module (GEM)

The GEM is an independent control module which
controls a series of functions of the body electrics.
It replaces various previously used components,
such as the turn signal relay, the Central Timer
Module (CTM) and the central locking module.
Overview of operation
Functions
Turn signals
Turn signals and hazard warning lights
Interior lighting
On/off
Dimmer function
Window heating
Windshield
Rear window
Wipers
Windshield wash/wipe function
Windshield post wipe
Rear window wipe during reversing
Rear window wash/wipe function
Information/warning functions
Door open warning lamp
Lights on warning lamp
Locking/unlocking
Manual locking/unlocking with a key
Central locking/unlocking
Remote control
Locking/unlocking with remote control
Double locking
Learning of remote control operations
Alarm
Anti-theft alarm system
Tailgate release
Release via switch in the passenger compartment
Release via remote control
Other functions
Battery protection function
Diagnosis
Diagnosis
Service mode
B- GEM Ax
B- GEM Bx
B- GEM Cx
B- GEM Dx
X
--
X
--
-X
-X
-X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
-X
X
X
X
X
X
X
X
--
X
X
X
X
X
X
----
----
X
-X
X
X
X
--
--
--
--
--
--
Turn signals
The GEM actuates the turn signal lamps to

indicate a turn signal and for the hazard warning
G163332 en
X
X
X
X
X
X
X
X
lights. It therefore replaces the conventional turn
signal relay.
For the turn signal, the turn signal lamps at the
front, rear and on the side of the vehicle and the
telltale in the instrument cluster are actuated
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according to the position of the turn signal switch
with approx. 80 impulses per minute.
An audible sound is generated with the same
rhythm by a sound generator in the instrument
cluster as an audible check for the driver.
If one of the turn signal lamp bulbs fails then the
flashing frequency is increased to around 160
impulses per minute.
The turn signal lamps are also used for the
following signals:
Confirmation of locking and alarm activation
(central locking/anti-theft alarm system)
Alarm triggered (anti-theft alarm system)
Confirmation of reprogramming (remote
control)
As these signals could overlap in certain situations,
a priority level has been assigned to each one.
Priority 1: hazard warning signal
Priority 2: alarm triggered
Priority 3: turn signal
Priority 4: confirmation of locking/activation of
alarm
Priority 5: confirmation of reprogramming
Interior lighting
Depending on the model and the equipment level

of the vehicle, the interior lighting controlled by the
GEM includes the overhead light at the front and
rear and the luggage compartment light.
The overhead lights are only switched by the GEM
if the corresponding light has been set to "Door
operation" (not if the light is in the "Continuous" or
"Off" settings).
The lights are switched on as soon as one of the
following conditions is satisfied:
A door or the tailgate has been opened (switch
in the door/tailgate lock).
The ignition lock is in position "0" or "I" and the
vehicle is unlocked centrally.
The ignition lock is turned from position "II" to
position "I" or "0"
NOTE: On vehicles with GEM Ax there are no
switches in the locks of the rear doors. As a result
the overhead lights are not switched on when the
rear doors are opened.
The lights are switched off when all of the doors
and the tailgate are closed and one of the
following conditions is satisfied:
G163332 en
25 seconds after the lights are switched on or

after closing the last door on non centrally
locked vehicles
On closing the last door on centrally locked
vehicles
The ignition lock is turned from position "0" or
"I" to position "II"
Ignition lock in position "0" or "I" while the
vehicle is being locked
The lights are dimmed on and off with the GEM
variants Cx and Dx.
When the lights are switched on, their operating
voltage is brought from 0V to operating voltage
within a period of 0.7 seconds.
When the lights are switched off, the operating
voltage is continuously reduced to 0V within a
period of 1.7 seconds.
The dimmer function is not utilised if the lights are
switched off by the battery protection function.
Heated windshield
The heated windshield can only be switched on if

the engine is running.
The GEM switches on the relay for the heated
windshield in response to a request from the
switch in the dash panel.
The LED in the corresponding switch lights up all
the time the windshield is being heated.
The GEM switches the relay off if
four minutes have passed since switching on
the switch in the dash panel is pressed again
the engine is switched off
Rear window heating
The rear window heating can only be switched on

with the ignition key in position "II".
The GEM switches on the relay for the rear
window heating in response to a request from the
switch in the dash panel.
The LED in the switch lights up all the time the rear
window is being heated.
NOTE: If the vehicle is equipped with heated
exterior mirrors, then these are operated together
with the rear window heating.
The GEM switches the relay off if
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14 minutes have passed since switching on
the switch in the dash panel is pressed again
the ignition key is turned to position "I" or "0"
Windshield wash/wipe functions
NOTE: All of the wash/wipe functions are only

available if the ignition key is in position "II".
The windshield wiper switch has four settings: Off,
Intermittent, Level 1 and Level 2.
In levels 1 and 2 the wipers run continuously at
normal or high speed.
In the intermittent setting a wipe is performed
every 7 seconds when the basic setting is
selected.
The intermittent wipe delay time can be adjusted.
To do this, the wiper switch is set to the
intermittent wipe position and then switched back
off after the first wipe. After the desired wipe
interval has elapsed the switch is again moved to
the intermittent wipe position. The intermittent
wipe delay time is then stored in the GEM .
The time delay can be adjusted to between 1 and
25 seconds.
When the ignition is switched off the time delay is
reset to the basic setting.
Windshield wash/wipe function
If the washer switch is activated with the wiper

switch in the "Off" position, then the washer pump
is switched on first to protect the wiper blades, and
then after a short delay the wipers. The wipers
then perform 2 or 3 wipes.
The post wipe function on the windshield ensures
that any water remaining on the windshield after
washing is wiped away. It is only required if the
wipers are switched off or set to intermittent mode.
If the wiper switch is in the "Off" position then a
post wipe operation is performed 4 seconds after
the washing process is finished.
When the wipers are in intermittent mode the post
wipe is performed after 6 seconds, but only if the
wiper delay time is set to more than 6 seconds.
Afterwards the wipers continue in intermittent
mode.
If the wipers are in operation at normal or high
speed when the washer is activated then they
continue to run at this speed.
G163332 en
The rear window wiper changes the wiper delay

interval according to the setting of the windshield
wiper switch.
If the windshield wiper switch is set to Level 2 and
the rear window wiper is switched on, then the
wiper delay interval is 6 seconds.
If the windshield wiper switch is in the Off,
Intermittent or Level 1 setting and the rear window
wiper is switched on, then the wiper delay interval
is 10 seconds.
If reverse gear is engaged while the windshield
wiper is switched on and the rear window wiper is
switched off, then the GEM automatically switches
on the rear wiper with the wiper delay interval as
described above. This function remains activated
until reverse gear is no longer engaged or the
windshield wiper is switched off.
When the switch for the rear window washer is

activated the wipers perform wipe operations
(while the switch is being activated).
When the switch is released the wipers perform
2-3 more wipes.
Information/warning functions
A warning lamp in the instrument cluster is

actuated if at least one door or the tailgate is not
fully closed with the ignition lock in position "II".
An acoustic signal is generated by the GEM if:
the system changes over to the learning mode
for the remote control (once).
in diagnostic mode as entry confirmation
(once), as confirmation of input signals (once
each) and as exit confirmation when leaving
the diagnostic mode (3 times).
the ignition lock is in position "I" or "0" and the
light switch is in position "1" or "2" and the
driver's door is opened (continuous "Lights on"
warning sound).
Locking/unlocking - central locking
The central locking system locks all doors and the

tailgate so that they can no longer be opened from
the outside.
The central locking system is activated by turning
a key in one of the door lock cylinders to the
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locking position. All of the turn signal lamps flash
once as confirmation.
If the vehicle was double locked beforehand, then

all the other doors switch over to central locking.
The central locking can also be activated by

pressing the internal door openers into the locking
position.
If the unlocking button on the remote control is

pressed twice within 3 seconds then the vehicle is
centrally unlocked.
If during the central locking process one of the

front doors is not fully closed then all of the doors
are unlocked again.
The driver's door unlocking system can be

programmed and cancelled with the aid of the
remote control.
If during the central locking process one of the

rear doors is not fully closed then all of the doors
are still centrally locked.
However, this is only possible if the ignition lock is

not in position "II".
Locking/unlocking - double locking
The double locking system locks all doors in such

a way that they can neither be opened from the
outside nor the inside of the vehicle.
The double locking mechanism is only available if
the ignition lock is in the position "0" or "I" and the
front doors are fully closed.
To activate the double locking, press the locking
button on the remote control twice within 3
seconds, or insert the key into one of the door
locks and turn it first to the unlocking position and
then within 3 seconds to the locking position.
All of the turn signal lamps flash twice to confirm
activation of the double locking.
If the ignition lock is in the position "II" or one of the
rear doors is not fully closed then the vehicle is
centrally locked but not double locked.
If within 45 seconds of double locking the vehicle
the ignition lock is moved to a different position
then the system reverts back from double locking
to central locking.
If the engine is started after the 45 seconds have
elapsed then the double locking remains in force
provided the speed of the vehicle does not reach 7
km/h. Once this speed is reached the system
reverts from double locking back to central
locking.
Locking/unlocking - driver's door unlocking
system
NOTE: The following description only applies if

the driver's door unlocking system has been
programmed.
If the unlocking button on the remote control is
only pressed once within 3 seconds, then only the
driver's door is unlocked.
G163332 en
Reprogramming is performed by simultaneously

pressing the unlocking and locking buttons on the
remote control for at least 4 seconds. The turn
signal lamps flash twice to confirm the
reprogramming.
Locking/unlocking - central unlocking
The vehicle is centrally unlocked if:

one of the door locks is turned with a key to the
unlocking position (also applies to double
locking)
the unlocking button on the remote control is
pressed (also applies to double locking)
the internal door openers are pulled to the
unlocking position (does not apply to double
locking)
Locking/unlocking - automatic central locking
The vehicle is centrally locked again automatically

after unlocking with the remote control if within 45
seconds neither a door or the tailgate are opened
or the remote control is operated.
Learning of remote control operations
NOTE: Up to a maximum of four remote control

operations can be learned per vehicle.
During the learning process the memory for the
known remote control operations in the GEM is
deleted and the existing and new operations are
relearned.
To enter the learning mode for remote control
operations, turn the ignition lock four times in the
space of 6 seconds from the position "0" to the
position "II".
The learning mode is confirmed with an acoustic
signal. Afterwards the corresponding remote
control operations can be learned within 10
seconds.
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To start the learning process, press one of the
buttons on the remote control.
The GEM confirms each learning process with a
signal tone.
Anti-theft alarm system
The anti-theft alarm system provides a visual and

acoustic signal that an unauthorised person is
attempting to gain access to the vehicle or that an
attempt is being made to turn the ignition key while
the anti-theft alarm system is activated.
The system monitors:
Hood
Doors
Tailgate
Ignition lock
In the event of an alarm, the system actuates a
separate signal horn (acoustic alarm) for 30
seconds and the hazard warning lights (visual
alarm) for 5 minutes.
The anti-theft alarm system is activated with a
delay of 20 seconds by centrally locking or double
locking the vehicle. To do this the ignition lock
must be in the position "0".
After the time delay of 20 seconds the hood, all
doors and the tailgate are alarmed, provided they
are fully closed.
If the hood, one of the doors or the tailgate are not
fully closed then they can be opened without
triggering an alarm. If they are then closed, the
same time delay of 20 seconds applies before
they are alarmed.
The anti-theft alarm system can be switched off by
centrally unlocking the vehicle either at the lock on
one of the doors or with the remote control.
If the tailgate is opened manually with a key or
with the remote control then only the anti-theft
alarm for the tailgate is deactivated.
Tailgate release
The tailgate can be unlocked manually

with the key
with the remote release button in the
passenger compartment
with the remote control
The remote release button will not unlock the
tailgate if the vehicle is centrally locked or if the
vehicle is travelling in excess of 6 km/h.
The remote control can be used to unlock the
tailgate by pressing the corresponding button
twice within 3 seconds.
Battery protection function
The battery protection function prevents the

battery from discharging as a result of the interior
lighting or the warning sound generator when the
engine is switched off.
As soon as the ignition lock is turned to position "I"
or "0", a time counter is started in the GEM.
If a door is open the interior lights are switched off
after 10 minutes.
If the doors are closed the interior lights, reading
lights, luggage compartment lights and the
warning sound generator are switched off after 30
minutes.
The battery protection function and the time
counter are stopped after the following actions
and then if necessary restarted:
Ignition lock in position "II"
Opening of a door or the tailgate
Unlocking of a door or the tailgate (with a key
or the remote control)
The battery protection function is also in operation
if the GEM is in service mode or diagnostic mode.
Diagnosis
If the tailgate is then closed again the anti-theft

alarm is reactivated for the tailgate after 20
seconds.
The GEM can be diagnosed with the aid of WDS.
The current status of the anti-theft alarm system is

stored if the power supply to the GEM is
interrupted. This means that as soon as the power
supply to the GEM is restored it reverts to the
stored status (if for example the vehicle was
alarmed beforehand, it is then re-alarmed).
This service mode allows testing of various input

and output signals.
G163332 en
There is also an additional service mode.
Service mode is activated by:
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Pressing and holding the switch for the heated
rear window
Turning the ignition key to position "II"
Releasing the switch for the heated rear
window
Pressing the switch for the heated rear window
8 times in 6 seconds
A signal sounds and the turn signal lamps come
on to indicate that service mode has been
successfully activated.
It is however also possible to manually exit the

service mode by:
Pressing and holding the switch for the heated
rear window
Turning the ignition key out of position "II"
Releasing the switch for the heated rear
window
3 acoustic signals sound and the turn signal lamps
come on to confirm that the service mode has
been exited.
NOTE: If the alarm has been triggered (in vehicles

equipped with an anti-theft alarm system), service
mode cannot be activated.
The wiper switch must be in the "Off" position for
testing of the input signals.
The relevant input signals are indicated with an
acoustic signal and by the flashing of the turn
signal lamps.
The following signals can be tested in any order:
Turn signals (right, left, hazard warning signal)
"Lights on" warning signal
Interior lighting
Windshield wipe function
Windshield wash function
Rear window wipe function
Rear window wash function
Doors/tailgate
Central locking
Hood (only on vehicles with an anti-theft alarm
system)
Heated rear window
Heated windshield
The wiper switch must be in the "Intermittent"
position for testing of the output signals.
Each operation of the heated rear window switch
activates and deactivates the following output
signals in this order:
Front wipers (a signal sounds and the direction
indicator lamps flash when the "Park" position
is reached)
Heated rear window
Interior light(s) (the switch for the interior lights
must be in the "Door operation" setting)
Rear window wiper
Heated windshield (only activated if the engine
is running)
The GEM automatically exits the service mode 20
seconds after the last input.
G163332 en
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Description of operation
A diagnosis of the generic electronic module
(GEM) can be performed with WDS. Furthermore,
an integrated service mode enables testing of the
input and output signals without the need for
further tools. To enable activation of service
mode:
Switch off the ignition

Switch off all other electrical consumers
Apply the handbrake
Shift to neutral
Close the doors.
Activate service mode
Proceed as follows to activate service mode:

OPERATE the switch of the heated rear
window and HOLD IT THERE
Turn on the ignition.
RELEASE the switch of the heated rear
window
PRESS the heated rear window switch 8 times
within 6 seconds
A signal sounds and the direction indicator lamps
come on to indicate that service mode has been
successfully activated.
NOTE: If the alarm sounds (in vehicles fitted with
an anti-theft alarm system), service mode cannot
be activated.
Input signals
SWITCH the wiper switch to the "Off" position to

test the input signals. The following is a list of the
signals to be tested, in no particular order:
Direction indicators (right, left, hazard warning

lights)
"Lights on" warning (terminal 58)
windshield wiper (intermittent wipe)
windshield washer system
rear window wiper
rear window washer system
Doors open/closed
Central locking (if fitted)
Bonnet up/down (in vehicles fitted with
anti-theft alarm system)
Heated rear window
Heated windscreen (if fitted)
An acoustic signal sounds and the turn signal
lamps flash to indicate receipt of each input signal
by the generic electronic module.
Output signals
SWITCH the wiper switch to the "Intermittent"

position to test the output signals. PRESSING the
heated rear window switch activates or
deactivates the output signals in the following
order:
a Windshield wipers (a signal sounds and the
direction indicator lamps flash when the "Park"
position is reached)
b Heated rear window
c Interior light(s) (the interior light switch must be
in the "ON" position)
d rear window wiper
e heated windshield (if equipped, is only
activated when engine is running)
If the heated rear window switch is operated again,
the sequence restarts with point 'a' and the
functions are activated again in this order.
End service mode
The GEM automatically ends service mode 20

seconds after the final input. However, service
mode can be manually ended at any time by
proceeding as follows:
G98965 en
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419-10-9

OPERATE the switch of the heated rear
window and HOLD IT THERE
Switch off the ignition.
RELEASE the switch of the heated rear
window
3 signals sound and the direction indicator lamps
come on to indicate that service mode has ended.
1. CHECK the concern.
Visual Inspection
3. RESOLVE any obvious causes for a concern

carrying out any further tests. CHECK
operation of system.
inspection, PERFORM a fault diagnosis using
WDS and RESOLVE the fault(s) displayed
according to the fault description. CHECK
operation of system.
5. On a vehicle without stored fault(s), continue
according to the Symptom Chart and the
corresponding symptom.
6. After testing and resolving the fault, the fault
memory of all vehicles should be READ OUT
and any stored faults CLEARED. READ OUT
the all fault memory again after a road test.
Electrical
Fuses
Wiring harness
Connectors
Defect Identification Table
Symptom
Possible Sources
Action
Service mode cannot be activated
Fuse(s).
Circuit(s).
Integrated control assembly
(GEM)

(GEM) not communicating with
the diagnostic unit
Fuse(s).
Circuit(s).
(GEM)
System Check
PINPOINT TEST A: SERVICE MODE CANNOT BE ACTIVATED
TEST CONDITIONS
A1: CHECK FUSE F24
2 CHECK Fuse F24 (CJB).
Is the fuse OK?
Yes
GO to A2
No
RENEW fuse F24 (20 A). CHECK the operation of the system. If the fuse blows again,
with the aid of the Wiring Diagrams.
A2: TEST VOLTAGE AT FUSE F24

1 Connect Fuse F24 (CJB).
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TEST CONDITIONS
and ground.
Yes
GO to A3
No
REPAIR the voltage supply to fuse F24 with
the aid of the Wiring Diagrams. CHECK operation of system.
A3: CHECK FUSE F38

1 CHECK Fuse F38 (CJB).
Is the fuse OK?
Yes
GO to A4
No
RENEW fuse F38 (7.5 A). CHECK operation
of system. If the fuse blows again, LOCATE
and RECTIFY the short to ground with the
aid of the Wiring Diagrams.
1 Connect Fuse F38 (CJB).
and ground.
Yes
GO to A5
No
REPAIR the voltage supply to fuse F38 with
A5: CHECK THE VOLTAGE AT THE GENERIC ELECTRONIC MODULE (GEM)
2 Disconnect GEM C318 (blue).
3 Measure the voltage between the GEM, connector C318, pin 2, circuit 29-AA80 (OG/WH),

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TEST CONDITIONS
Yes
GO to A6
No
29-AA80 (OG/WH) between GEM and fuse
F24 with the aid of the Wiring Diagrams.
CHECK operation of system.
A6: CHECK THE VOLTAGE AT THE GEM

1 Disconnect GEM C319 (white).
3 Measure the voltage between the GEM, connector C319, pin 10, circuit 15-DK20 (GN/OG),

Yes
GO to A7
No
15-DK20 (GN/OG) between the GEM and
solder point S3 with the aid of the Wiring
Diagrams. CHECK operation of system.
A7: TEST THE GEM GROUND CONNECTION
2 Disconnect GEM C316 (black).
connector C316, pin 2, circuit 31-DK20 (BK),

Yes
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TEST CONDITIONS
GO to A8
No
between the GEM and ground point G13 with
A8: TEST THE GEM GROUND CONNECTION

1 Disconnect GEM C320 (brown).
connector C320, pin 2, circuit 91-DK20

Yes
GO to A9
No
91-DK20 (BK/RD) between the GEM and
ground connection G14 with the aid of the
the system.
A9: CHECK THE CONTROL IMPULSE OF THE HEATED REAR WINDOW SWITCH
1 Operate the heated rear window switch and
keep it operated.
connector C320, pin 11, circuit 31S-HB22

Yes
GO to A10
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TEST CONDITIONS
No
GO to A12
A10: CHECK THE SWITCH OF THE HEATED REAR WINDOW
1 Release the switch of the heated rear window.
Is a resistance of more than 10 kOhms measured?

Yes
No
GO to A11
A11: CHECK THE CIRCUIT BETWEEN THE GEM AND THE INTEGRATED CONTROL ASSEMBLY
FOR A SHORT TO GROUND
1 Disconnect Integrated control assembly C714.
Is a resistance of more than 10 kOhms measured?

Yes
RENEW the integrated control assembly.
No
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TEST CONDITIONS
in circuit 31S-HB22 (BK/GN) with the aid of
the Wiring Diagrams. CHECK operation of
system.
A12: TEST THE CIRCUIT BETWEEN THE GEM AND THE INTEGRATED CONTROL ASSEMBLY
FOR OPEN CIRCUIT
1 Disconnect Integrated control assembly C714.
(BK/GN), wiring harness side and the integrated
control assembly, connector C714, pin 1, circuit
31S-HB22 (BK/GN), wiring harness side.

Yes
GO to A13
No
31S-HB22 (BK/GN) between the GEM and
the integrated control assembly with the aid
of the Wiring Diagrams. CHECK the operation of the system.
A13: TEST THE GROUND CONNECTION OF THE INTEGRATED CONTROL ASSEMBLY
1 Measure the resistance between the integrated
control assembly, connector C714, pin 9, circuit
31-DK1 (BK), wiring harness side and ground.

Yes
RENEW the integrated control assembly.
No
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TEST CONDITIONS
G98965 en
31-DK1 (BK) between the integrated control
assembly and soldered connection S265
with the aid of the Wiring Diagrams. CHECK
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Removal
4. Remove the GEM.
1. Unscrew and remove the bolts for the lower

fascia/crash padding cover.
Installation
2. Detach the lower fascia/crash padding
cover.
1. NOTE: Initialise the GEM with WDS after

installation.
3. Disconnect the GEM connector.
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BACK TO MAIN INDEX

TO MODEL INDEX
Group
Body and Paint

SECTION TITLE
5
PAGE
Body and Paint

Body System - General Information.......................................................................................
Front End Body Panels .........................................................................................................
Body Closures.......................................................................................................................
Interior Trim and Ornamentation ...........................................................................................
Exterior Trim and Ornamentation ..........................................................................................
Rear View Mirrors .................................................................................................................
Seating..................................................................................................................................
Glass, Frames and Mechanisms ...........................................................................................
Instrument Panel and Console ..............................................................................................
Handles, Locks, Latches and Entry Systems.........................................................................
Wipers and Washers.............................................................................................................
Bumpers................................................................................................................................
Safety Belt System................................................................................................................
Supplemental Restraint System ............................................................................................
Body Repairs - General Information ......................................................................................
Body Repairs - Corrosion Protection .....................................................................................
Body Repairs - Plastic Repairs..............................................................................................
Body Repairs - Water Leaks..................................................................................................
Body Repairs - Wind Noise ...................................................................................................
Body Repairs - Paintless Dent Removal................................................................................
Body Repairs - Noise, Vibration and Harshness....................................................................
Body Repairs - Vehicle Specific Information and Tolerance Checks......................................
Front End Sheet Metal Repairs .............................................................................................
Roof Sheet Metal Repairs .....................................................................................................
Side Panel Sheet Metal Repairs............................................................................................
Rear End Sheet Metal Repairs..............................................................................................
Frame and Mounting
Uni-Body, Subframe and Mounting System...........................................................................
501-00-1
501-02-1
501-03-1
501-05-1
501-08-1
501-09-1
501-10-1
501-11-1
501-12-1
501-14-1
501-16-1
501-19-1
501-20A-1
501-20B-1
501-25A-1
501-25B-1
501-25C-1
501-25D-1
501-25E-1
501-25F-1
501-25G-1
501-26-1
501-27-1
501-28-1
501-29-1
501-30-1
502-00-1
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501-00-1
Body System - General Information
501-00-1
SECTION 501-00 Body System - General Information

CONTENTS
PAGE

Body .................................................................................................................................
Front end design features ................................................................................................
Rear end design features .................................................................................................
NVH elements..................................................................................................................
Attached parts..................................................................................................................
501-00-2
501-00-2
501-00-3
501-00-4
501-00-5
11/2004 2005.25 Fiesta
501-00-2

TO MODEL INDEX
501-00-2

Body
Front end design features
The newly designed front end structure of the
Fiesta consists mainly of the plastic front end
module and the sheet steel crash element.
Item
Part
Number
Description
module can be detached together with the

flanged-on assemblies.
In areas subjected to more severe loads the
plastic front end module is additionally reinforced
with high-resistance foam.
Reinforcement with
high-resistance foam
Plastic front end module
Sheet steel crash element

(crossmember)
Plastic front end module
The plastic front end module acts among other

things as a mounting for various components like
the radiator, radiator fan and hood lock.
This design allows repairs to be performed easily
and economically, as the complete front end
G195513 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
501-00-3
501-00-3

Sheet steel crash element
Item
Part
Number
Description
Laser weld seam
As well as the sheet steel crash element, the front

longitudinal members also contribute to the
passive safety of the Fiesta.
Two additional designated yield points in the front
part of the longitudinal members absorb further
crash energy (above 15 km/h).
2-part frame construction in the deformation area increased ease of repair.
Laser butt weld seam directly behind the crash
area - optional sectional replacement.
Item
Part
Number
Description
Securing bolts
Designated yield points
Towing eye mounting
The sheet steel crash element consists of a

crossmember to which two crash boxes are
welded.
The crash element absorbs the majority of the
impact energy in a crash up to 15 km/h.
In the front area of the longitudinal members

(deformation area) there are no inward
reinforcements - increased ease of repair.
Front bumper
The plastic bumper is positioned relative to the

fenders with two plastic lugs on each side of the
vehicle and bolted in place.
The fog lamps are integrated in the bumper, and
the ventilation grille and the front apron are
clipped onto the bumper.
The plastic material can be welded.
Flange plates on the longitudinal members allow

the bolted crash element to be easily replaced.
Towing eye mounting
Front longitudinal member
Item
Part
Number
G195513 en
Description
11/2004 2005.25 Fiesta
501-00-4

TO MODEL INDEX
501-00-4
Rear end design features
Item
Part
Number
Description
Studs
addition to the crossmember. Designated yield

points in this area allow the residual energy to be
dissipated in a controlled manner and prevent
follow-on damage on the body structure. Sectional
replacements are possible in the area of the
designated yield points.
Rear crossmember
NVH elements
The rear crossmember makes the connection

between the two ends of the longitudinal members
and therefore contributes to increased passive
safety in the event of rear end damage. Due to the
slightly curved basic shape of the bolted
crossmember, any impact energy can more easily
be converted into deformation energy. In lesser
impacts this prevents deformation of the
longitudinal members and therefore of the body
structure.
As already featured on the Ford Focus and Ford

Mondeo (as of model year 2001.25), the Fiesta
now also features three elements on each side of
the vehicle to reduce the transmission of airborne
noise to the body.
If any body repairs are carried out in these areas
then the NVH elements must also be reinstalled or
renewed. Information on repair techniques will be
published in the Student Information "Accident
damage repairs" and in the Body Repair Manual
(TIS).
Rear longitudinal member
In more serious rear impacts the ends of the rear

longitudinal members are also deformed in
G195513 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
501-00-5
501-00-5
Description
Divides up the resonant space of the sill panel and

the C-pillar.
NVH element - C-pillar/inner

wheel arch
Attached parts
NVH element - C-pillar/outer

wheel arch
Doors
Item
Part
Number
1
2
3
Clip connections
NVH element - A-pillar with

leadthrough for the sun roof
water drain hose
A-pillar area
Separation of wet and dry areas.

Leadthrough for the sun roof water drain hose.
The dividable door hinges are attached with two

bolts each to the body and the door. Adjustment
options are provided via the oversized bores in the
halves of the hinge, allowing adjustments to be
performed without removing trim panels.
The central electrical power supply to the doors is
provided on the front doors via a round bayonet
connector and on the rear doors via a rectangular
clip connector.
2-part element.
The doors are only hung by the hinge halves on

pivot pins and can be simply unhinged when open.
The doors are locked in the closed position via a
mechanical locking mechanism which is
integrated into the hinge half on the body side.
Mounting provided by a clip connection in the

intermediate panel of the wheel arch.
Sealing for the doors is provided in the form of a

surrounding rubber seal on the body side.
C-pillar/wheel arch area
G195513 en
11/2004 2005.25 Fiesta
501-00-6

TO MODEL INDEX
501-00-6
Item
Part
Number
Hinge half, body side
Mechanical locking mechanism
Stop
Hinge half, door side
Mechanical locking mechanism with the door closed
Front door reinforcement
Door hinge mounting plate
Door hinge retaining bolts
Rear door reinforcement
G195513 en
Description
11/2004 2005.25 Fiesta
501-00-7

TO MODEL INDEX
501-00-7

Hood
Forced ventilation
Item
Part
Number
Description
Plastic mounting element
Moving plates
In the rear part of the Fiesta there are three

clipped-in elements for forced ventilation of the
passenger compartment and luggage
compartment.
Due to the reinforcement of the panel areas (grey

areas), there are limited options for performing
dent removal techniques without damaging the
paintwork.
Surrounding seals and sealing bead in the
clinched flange area.
Windshield washer nozzles (1) integrated into the
hood.
Two elements in the lower part of the

left/right-hand side panel.
One central element in the area of the rear
panel.
Fascia/crash padding
The fascia/crash padding in the Fiesta is secured

to a cross-car beam bolted between the two
A-pillars. Components like the passenger airbag,
steering column etc. are directly attached to this
component.
Mechanical hood prop (2) on the right-hand side of

the vehicle.
Hinge on the body side (4) and hood side (3), each
secured with 2 bolts. Adjustment options are
provided via oversized bores,
The hood lock can be released via a cable from
the passenger compartment.
Diesel vehicles are equipped with a hood
insulation.
G195513 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
501-02-1
Front End Body Panels
501-02-1
SECTION 501-02 Front End Body Panels

CONTENTS
PAGE
SPECIFICATIONS
Specifications....................................................................................................................
501-02-2

Fender .......................................................................................................... (44 252 0)
Radiator Grille Opening Panel...........................................................................................
501-02-3
501-02-5
11/2004 2005.25 Fiesta
501-02-2

TO MODEL INDEX
501-02-2
SPECIFICATIONS
Item
Hood hinge to hood retaining bolts
Hood hinge to fender retaining bolts
Windshield wiper arm retaining nuts
Cowl panel grille retaining bolts
Fender splash shield retaining bolts
Fender retaining bolts
Washer reservoir to radiator grille opening panel
retaining bolt
Power steering fluid cooler to radiator grille opening
panel retaining bolts
Radiator lower retaining bolts
Front bumper retaining bolts
Radiator grille opening panel retaining bolts
G152578 en
Nm
23
23
20
10
5
7
3
lb-ft
17
17
15
-
lb-in
44
62
27
27
3
25
25
18
18
27
-
11/2004 2005.25 Fiesta
501-02-3

TO MODEL INDEX
501-02-3

Fender (44 252 0)
Removal
1. Remove the front bumper cover. For
501-19.
2. Remove the headlamp assembly. For
417-01.
3. Remove the front wheel and tire. For
204-04.
4. NOTE: Mark the position of the hood hinge in
relation to the hood on both sides to aid
installation.
6. Remove the cowl panel grille.

Remove the windshield wipers.
Remove the bolts.
Remove the hood.

Remove the bolts on both sides.
7. Remove the fender splash shield.
5. NOTE: Mark the position of the hood hinge in

relation to the fender on both sides to aid
installation.
Remove the hood hinge.
G152579 en
8. Remove the fender inner retaining bolt and

disconnect the turn signal electrical connector.
11/2004 2005.25 Fiesta
501-02-4

TO MODEL INDEX
501-02-4

9. Remove the fender lower retaining bolts.
10. Remove the fender front retaining bolts.
11. Remove the fender.
Installation
1. NOTE: Align the hood and hood hinge bolts to
the previously marked positions.
G152579 en
11/2004 2005.25 Fiesta
501-02-5

TO MODEL INDEX
501-02-5

Radiator Grille Opening Panel
General Equipment
3. Detach the windshield washer reservoir

from the radiator grille opening panel.
Transmission jack
Wooden block
Removal
WARNING: To avoid accidental
deployment, the air bag control module
backup power supply must be depleted.
Wait at least one minute after
disconnecting the battery ground
cable(s) before commencing any repair or
adjustment to the supplemental restraint
system (SRS), or any component(s)
adjacent to the SRS sensors. Failure to
personal injury.
4. Release the hood latch release cable.
WARNING: To minimize the possibility of

premature deployment, do not use radio
key code savers when working on the
supplemental restraint system. Failure to
personal injury.
WARNING: Never probe the electrical
connectors of air bag modules or any
other supplemental restraint system
component. Failure to follow this
414-01.
501-19.
G152580 en
5. Detach the air intake hose from the radiator

grille opening panel.
11/2004 2005.25 Fiesta
501-02-6

TO MODEL INDEX
501-02-6

6. Detach the power steering pump (PSP)
reservoir from the radiator grille opening
panel.
9. Detach the power steering fluid cooler from

the radiator grille opening panel and position it to one side.
7. Disconnect the crash sensor electrical

connector.
10. Remove the radiator lower retaining bolts.
8. Remove the air deflectors.
G152580 en
11. Remove the radiator lower retaining clips.

Turn the retaining clips counterclockwise.
11/2004 2005.25 Fiesta
501-02-7

TO MODEL INDEX
501-02-7

12. Detach the radiator from the radiator grille
opening panel.
Using suitable cable ties, secure the radiator to the exhaust manifold.
Installation
1.
CAUTION: The radiator grille opening

panel must be installed centrally
between the fenders, the hood and
headlamps must engage freely to
prevent damage.
CAUTION: Make sure the crash sensor
electrical connector is fully connected.
2.
13. Remove the front bumper retaining bolts.
CAUTION: Make sure that the operation

of the air bag warning lamp is
observed during the first cycle of the
ignition following installation of the
radiator grille opening panel.
Prove out the supplemental restraint
system (SRS) by cycling the ignition and
observing the air bag warning lamp.
If the air bag warning light begins to flash,
re-check the crash sensor electrical
connector.
Note the flash code and repair the SRS. For
501-20A / 501-20B.
14. Remove the radiator grille opening panel.
G152580 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
501-03-1
Body Closures
501-03-1
SECTION 501-03 Body Closures

CONTENTS
PAGE
SPECIFICATIONS
Specifications....................................................................................................................
501-03-2
11/2004 2005.25 Fiesta
501-03-2

TO MODEL INDEX
Body Closures
501-03-2
SPECIFICATIONS
Item
Door check strap to door retaining bolts
Door check strap to door pillar retaining bolts
Door striker plate retaining bolts
Door hinge retaining bolts
Liftgate striker plate retaining bolts
Liftgate hinge retaining nuts
Liftgate hinge retaining bolts
Hood hinge retaining bolts
G149910 en
Nm
6
23
14
25
11
18
11
23
lb-ft
17
10
18
8
13
8
17
lb-in
53
-
11/2004 2005.25 Fiesta

TO MODEL INDEX
501-05-1
Interior Trim and Ornamentation
501-05-1
SECTION 501-05 Interior Trim and Ornamentation

CONTENTS
PAGE
SPECIFICATIONS
Specifications....................................................................................................................
501-05-2

Front Door Trim Panel...................................................................................
Rear Door Trim Panel ...................................................................................
Headliner 5-Door ......................................................................................
Headliner 3-Door ......................................................................................
Headliner Van...........................................................................................
B-Pillar Trim Panel 5-Door........................................................................
B-Pillar Trim Panel 3-Door........................................................................
C-Pillar Trim Panel 5-Door........................................................................
C-Pillar Trim Panel 3-Door........................................................................
Rear Quarter Trim Panel...............................................................................
(43 705 0)
(43 706 0)
(43 612 0)
(43 612 0)
(43 612 0)
(43 617 0)
(43 617 0)
(43 618 0)
(43 618 0)
(43 731 0)
501-05-3
501-05-5
501-05-7
501-05-12
501-05-16
501-05-21
501-05-22
501-05-24
501-05-26
501-05-28
11/2004 2005.25 Fiesta
501-05-2

TO MODEL INDEX
501-05-2
SPECIFICATIONS
Description
Safety belt lower anchor retaining bolts
G164710 en
Nm
40
lb-ft
30
lb-in
-
11/2004 2005.25 Fiesta
501-05-3

TO MODEL INDEX
501-05-3

Front Door Trim Panel (43 705 0)
Removal
1. Detach the interior door handle.
1. Remove the screw cover.
2. Remove the screw.
2. Detach the door pull handle cover.
3. Disconnect the power window electrical

connector and remove the door pull handle
cover.
G148243 en
4. Detach the exterior mirror trim panel.

1. Detach the panel at the front of the door.
2. Pull the panel towards the rear of the door.
5. Disconnect the exterior mirror control

switch electrical connector and remove the
exterior mirror trim panel.
6. Remove the door trim panel retaining bolts.
11/2004 2005.25 Fiesta
501-05-4

TO MODEL INDEX
501-05-4

7. Remove the door pull handle retaining
screws.
8. Detach the front door trim panel.

1. Pull the trim panel out at the bottom.
2. Lift up the trim panel to release from the
door.
10. Release the locking tangs and remove the

front door latch remote control handle
from the front door trim panel.
Installation
9. Disconnect the front door latch remote

control cable from the front door latch remote control handle and remove the front
door trim panel.
G148243 en
11/2004 2005.25 Fiesta
501-05-5

TO MODEL INDEX
501-05-5

Rear Door Trim Panel (43 706 0)
Removal
All vehicles
1. Detach the rear door latch remote control
handle bezel.
2. Detach the door pull handle.

G148244 en
Vehicles with manual windows

3. Remove the window regulator handle.
Use a suitable piece of hooked wire or
similar.
Vehicles with power windows

4. Remove the window control switch.
1. Detach the window control switch from the
rear door trim panel.
2. Disconnect the window control switch electrical connector.
11/2004 2005.25 Fiesta
501-05-6

TO MODEL INDEX
501-05-6

All vehicles
5. Detach the door trim panel
1. Pull the door trim panel out at the bottom to
detach the retaining clips.
2. Lift up the door trim panel to release from
the door.
6. Disconnect the door latch remote control

cable from the door handle and remove the
door trim panel.
Installation
G148244 en
11/2004 2005.25 Fiesta
501-05-7

TO MODEL INDEX
501-05-7

Headliner 5-Door (43 612 0)
General Equipment
6 mm flat-bladed screwdriver

connector.
Removal
All vehicles
All vehicles
4.
2. Remove the A-pillar trim panels.
CAUTION: In order to prevent water

ingress into the interior lighting wiring
harness electrical connector,
disconnect the interior lighting wiring
harness electrical connector and
position both parts to one side prior to
disconnecting the rear washer tube.
NOTE: When disconnecting the rear washer tube,
allow the washer fluid to drain into a suitable
container.
Disconnect the interior lighting wiring
harness electrical connector and the rear
washer tube.
G148245 en
11/2004 2005.25 Fiesta
501-05-8

TO MODEL INDEX
501-05-8

5. Detach the interior lighting wiring harness
and the rear washer tube from the A-pillar.

Vehicles with roof opening panel

8. Remove the roof opening panel weatherstrip.

501-12.[Instrument Panel and Console,
REMOVAL AND INSTALLATION, Overhead
Console]
Vehicles with power roof opening panel
10. Disconnect the roof opening panel motor

G148245 en
11/2004 2005.25 Fiesta
501-05-9

TO MODEL INDEX
501-05-9

All vehicles
14. Using a suitable 6 mm flat-bladed

screwdriver, remove the passenger assist
handle.
Rotate the screwdriver 90 degrees to release the retaining clips.
All vehicles
15. Detach the rear door opening weatherstrips.
Vehicles built 09/2004 onwards

13. Lever open the covers on the passenger
assist handle.
16. Detach the B-pillar upper trim panels and

position them to one side.
Unclip the upper trim panel.
G148245 en
11/2004 2005.25 Fiesta
501-05-10

TO MODEL INDEX
501-05-10

screwdriver, remove the coat hooks.
18. Detach the liftgate opening weatherstrip.
21. Remove the rear parcel shelf supports.

Disconnect the load space lamp electrical
connector to remove the right-hand rear
parcel shelf support.
22. Detach the C-pillar trim panels and

3. Unclip the C-pillar trim panel .
19. Remove the C-pillar trim panel retaining

clips.
23. Remove the interior lamp bezel.
20. Remove the rear parcel shelf.
G148245 en
11/2004 2005.25 Fiesta
501-05-11

TO MODEL INDEX
501-05-11

All vehicles
25. Remove the headliner rear retaining clips.
27. Remove the headliner through the liftgate

opening.
Installation
26. Disconnect the rear washer tube from the

headliner.
G148245 en
11/2004 2005.25 Fiesta
501-05-12

TO MODEL INDEX
501-05-12

Headliner 3-Door (43 612 0)
General Equipment
6 mm flat-bladed screwdriver

connector.
Removal
All vehicles
All vehicles
4.

ingress into the interior lighting wiring
harness electrical connector,
disconnect the interior lighting wiring
harness electrical connector and
position both parts to one side prior to
disconnecting the rear washer tube.
NOTE: When disconnecting the rear washer tube,
container.
Disconnect the interior lighting wiring
harness electrical connector and the rear
washer tube.
G275800 en
11/2004 2005.25 Fiesta
501-05-13

TO MODEL INDEX
501-05-13



8. Remove the roof opening panel weatherstrip.

501-12.[Instrument Panel and Console,
REMOVAL AND INSTALLATION, Overhead
Console]
10. Disconnect the roof opening panel motor

G275800 en
11/2004 2005.25 Fiesta
501-05-14

TO MODEL INDEX
501-05-14

All vehicles

screwdriver, remove the passenger assist
handle.
All vehicles
screwdriver, remove the coat hooks.

13. Lever open the covers on the passenger
assist handle.
G275800 en
11/2004 2005.25 Fiesta
501-05-15

TO MODEL INDEX
501-05-15

17. Remove the C-pillar trim panels. For
additional information, refer to C-Pillar
Trim Panel - 3-Door in this section.
3. Unclip the upper trim panel.
All vehicles

headliner.


opening.

Installation
G275800 en
11/2004 2005.25 Fiesta
501-05-16

TO MODEL INDEX
501-05-16

Headliner Van (43 612 0)
Removal
3.

ingress into the electrical connector,
disconnect the electrical connector
and position both parts to one side
prior to disconnecting the washer
tube.
NOTE: When disconnecting the washer tube,
container.
Disconnect the electrical connector and
the rear washer tube.

G371378 en
11/2004 2005.25 Fiesta
501-05-17

TO MODEL INDEX
501-05-17


G371378 en
10. Remove the load space upper trim panel

retaining screws and remove the load
space upper trim panels.
Disconnect the load space lamp electrical
connector to remove the right-hand load
space upper trim panel.
11/2004 2005.25 Fiesta
501-05-18

TO MODEL INDEX
501-05-18

11. Remove the bulkhead upper retaining
bolts.
16. NOTE: It is necessary to maneuver the

bulkhead into the rear of the vehicle first, by
tilting it backwards in order to clear the side
retaining brackets.
With the aid of another technician,
remove the bulkhead through a front door
opening.
17. Detach the C-pillar trim panels from the
headliner.
12. Position both front seats as far forward as

possible.
13. Tilt the front seat backrests as far forward
as possible.
14. Remove the bulkhead side retaining bolts.
18. Remove the safety belt upper anchor

blanking plugs.
15. Remove the bulkhead lower retaining

bolts.
G371378 en
11/2004 2005.25 Fiesta
501-05-19

TO MODEL INDEX
501-05-19

19. Remove the C-pillar trim panels.
22. Remove the bulkhead left-hand retaining

bracket to allow access to remove the
headliner.
20. Detach the B-pillar lower trim panels from

the B-pillar.
23. Remove the left-hand rear lower trim

panel to allow access to remove the
headliner.

3. Unclip the upper trim panel.
G371378 en
11/2004 2005.25 Fiesta
501-05-20

TO MODEL INDEX
501-05-20


headliner.

opening.
Installation
G371378 en
11/2004 2005.25 Fiesta
501-05-21

TO MODEL INDEX
501-05-21

B-Pillar Trim Panel 5-Door (43 617 0)
1. Detach the door opening weatherstrips
from the B-pillar.
4. Remove the B-pillar upper trim panel.

3. Detach the retaining clips.
Feed the safety belt webbing through the
B-pillar upper trim panel.
2. NOTE: Hold the safety belt webbing when

detaching the safety belt lower anchor from the
floor panel.
Detach the safety belt lower anchor from
the floor panel.
Remove the retaining bolt and spacer from
the anchor plate.
3. Move the safety belt shoulder height

adjuster to its lowest position.
5. Remove the B-pillar lower trim panel.

Detach the retaining clips.
Installation
G148246 en
11/2004 2005.25 Fiesta
501-05-22

TO MODEL INDEX
501-05-22

B-Pillar Trim Panel 3-Door (43 617 0)
Removal
1. Detach the door opening weatherstrip from
the B-pillar.
2.
CAUTION: The bolt securing the safety

belt lower anchor rail is held captive by
a fibre washer. The bolt, three spacers
and fibre washer must remain on the
safety belt lower anchor rail at all times
when the safety belt lower anchor rail
is detached or removed. Failure to
follow this instruction may cause the
safety belt to jam on the anchor rail.
3. Detach the C-pillar trim panel from the

headliner.
1. Remove the screw covers.
4. Detach the rear quarter trim panel from the

B-pillar.
Remove the safety belt lower anchor rail

from the rear quarter trim panel.
1. Remove the safety belt lower anchor rail
retaining bolt.
2. Rotate the safety belt lower anchor rail 90
degrees.
3. Pull the safety belt lower anchor rail from
the rear quarter trim panel.
G275801 en
11/2004 2005.25 Fiesta
501-05-23

TO MODEL INDEX
501-05-23

5. Detach the B-pillar upper trim panel.
3. Detach the retaining clips from the B-pillar.

from the safety belt webbing and remove
the B-pillar trim panel.
B-pillar trim panel.
Installation
CAUTION: Make sure that the rear end of
the safety belt lower anchor rail is
correctly located before tightening the
retaining bolt.
G275801 en
11/2004 2005.25 Fiesta
501-05-24

TO MODEL INDEX
501-05-24

C-Pillar Trim Panel 5-Door (43 618 0)
Removal
2. Remove the parcel shelf.

3. Remove the parcel shelf supports.
5. Detach the rear door opening weatherstrips.
6. Raise the rear seat cushion.

detaching the lower anchor from the floor
panel.
Detach the rear safety belt lower anchor
from the floor panel.
4. Remove the C-pillar trim panel retaining

clip.
G148247 en
11/2004 2005.25 Fiesta
501-05-25

TO MODEL INDEX
501-05-25

8. Remove the C-pillar trim panel.
C-pillar trim panel.
Installation
G148247 en
11/2004 2005.25 Fiesta
501-05-26

TO MODEL INDEX
501-05-26

C-Pillar Trim Panel 3-Door (43 618 0)
Removal
1. Detach the C-pillar trim panel from the
headliner.
1. Remove the screw covers.
5. Remove the safety belt upper anchor

cover.
6.

3. Lower the rear seat back rest.
4. Remove the parcel shelf support.
G275802 en

belt anchor is held captive by a paper
washer. The bolt, spacer and paper
washer must remain on the safety belt
anchor at all times when the safety belt
anchor is detached or removed.
Remove the safety belt upper anchor retaining bolt.
11/2004 2005.25 Fiesta
501-05-27

TO MODEL INDEX
501-05-27

7. Remove the C-pillar trim panel.
Installation
G275802 en
11/2004 2005.25 Fiesta
501-05-28

TO MODEL INDEX
501-05-28

Rear Quarter Trim Panel (43 731 0)
Removal
1. Detach the door opening weatherstrip from
the B-pillar.
2.

belt lower anchor rail is held captive by
a fibre washer. The bolt, three spacers
and fibre washer must remain on the
safety belt lower anchor rail at all times
when the safety belt lower anchor rail
is detached or removed. Failure to
follow this instruction may cause the
safety belt to jam on the anchor rail.
Remove the safety belt lower anchor rail
from the rear quarter trim panel.
retaining bolt.
2. Rotate the safety belt lower anchor rail 90
degrees.
3. Pull the safety belt lower anchor rail from
the rear quarter trim panel.
G275803 en
3. Detach the door scuff plate from the rear

quarter trim panel.

5. Lower the rear seat backrest.
6. Detach the rear seat backrest.
7. Remove the rear quarter trim panel retaining clip below the rear seat.
11/2004 2005.25 Fiesta
501-05-29

TO MODEL INDEX
501-05-29

8. Detach the rear quarter trim panel from the
B-pillar.
9. Remove the rear quarter trim panel.
Installation
CAUTION: Make sure that the rear end of
the safety belt lower anchor rail is
correctly located before tightening the
retaining bolt.
G275803 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
501-08-1
Exterior Trim and Ornamentation
501-08-1
SECTION 501-08 Exterior Trim and Ornamentation

CONTENTS
PAGE

Rocker Panel Moulding .....................................................................................................
501-08-2
11/2004 2005.25 Fiesta
501-08-2

TO MODEL INDEX
501-08-2

Rocker Panel Moulding
General Equipment
Trim clip remover
G428505 en
1. Raise and support the vehicle. .

table(s).
11/2004 2005.25 Fiesta

TO MODEL INDEX
501-08-3
501-08-3

Item
Part
Number
Description
Rocker panel moulding to

floor pan retaining clips
See Removal Detail
Rocker panel moulding

See Removal Detail
Item 2 : Rocker panel moulding

1. Remove the rocker panel moulding.
Pull the rocker panel moulding away from
the body side, to release the rocker panel
moulding to body side retaining clips.
Removal Details
Item 1 : Rocker panel moulding to floor pan
retaining clips
1. Remove the rocker panel moulding to floor
pan retaining clips (one shown).
1. Push the rocker panel moulding to floor pan
retaining clip center pin inwards.
2. Using a suitable trim clip remover, remove
the rocker panel moulding to floor pan retaining clips.
G428505 en
Item 2 : Rocker panel moulding
NOTE: Install new rocker panel moulding to body
side retaining clips if necessary.
11/2004 2005.25 Fiesta

TO MODEL INDEX
501-09-1
Rear View Mirrors
501-09-1
SECTION 501-09 Rear View Mirrors

CONTENTS
PAGE
SPECIFICATIONS
Specifications....................................................................................................................
501-09-2

Rear View Mirrors .............................................................................................................
Rear View Mirrors 2.0L Duratec-HE (MI4) ....................................................................
501-09-3
501-09-3
501-09-12
501-09-12

Exterior Mirror ............................................................................................... (43 364 0)
501-09-21
11/2004 2005.25 Fiesta
501-09-2

TO MODEL INDEX
Rear View Mirrors
501-09-2
SPECIFICATIONS
Item
External mirror retaining screw
G92000 en
Nm
11
lb-ft
8
lb-in
-
11/2004 2005.25 Fiesta

TO MODEL INDEX
501-09-3
Rear View Mirrors
501-09-3

Rear View Mirrors
mechanical and electrical damage.
Symptom
Mechanical
Exterior mirror(s)
Fuse(s)
Relay
Electrical
connector(s)
Switch
step.
Possible Sources
Action
The exterior mirrors are inopera- Exterior mirror control switch

tive
A single exterior mirror is inoperative
CARRY OUT the Exterior Mirror

Control Switch Component Test.
REFER to the Wiring Diagrams.
Circuit(s).
Exterior mirror control switch.

Exterior mirror motor(s).

Circuit(s).
A single exterior mirror does not Exterior mirror control switch.

function with switch logic
The heated exterior mirror is

inoperative
Electrical


Circuit(s).
Heated rear window control

switch.
CARRY OUT the Heated Rear

Window Control Switch Component Test. REFER to the Wiring Diagrams.
Relay.
Heated mirror element(s).
Circuit(s).
PINPOINT TEST A: THE EXTERIOR MIRRORS ARE INOPERATIVE

TEST CONDITIONS
NOTE: Use a digital multimeter for all electrical measurements.

A1: CHECK THE VOLTAGE TO THE EXTERIOR MIRROR CONTROL SWITCH
1 Disconnect Exterior Mirror Control Switch
C596.
G149911 en
11/2004 2005.25 Fiesta
501-09-4

TO MODEL INDEX
Rear View Mirrors
501-09-4

TEST CONDITIONS
2 Measure the voltage between the exterior mirror control switch C596 pin 6, circuit 29-AD12
(OG/YE), harness side and ground.

Yes
Go to A2
No
REPAIR circuit 29-AD12 (OG/YE). TEST the
A2: CHECK THE EXTERIOR MIRROR CONTROL SWITCH GROUND CIRCUIT FOR CONTINUITY
1 Measure the resistance between the exterior
mirror control switch C596 pin 4, circuit
31-AD12 (BK), harness side and ground.

Yes
No
REPAIR circuit 31-AD12 (BK). TEST the
PINPOINT TEST B: A SINGLE EXTERIOR MIRROR IS INOPERATIVE
TEST CONDITIONS

B1: CHECK THE EXTERIOR MIRROR MOTOR CIRCUIT FOR CONTINUITY
C596.
G149911 en
11/2004 2005.25 Fiesta
501-09-5

TO MODEL INDEX
Rear View Mirrors
501-09-5

TEST CONDITIONS
2 Measure the resistance between the:
Exterior mirror control switch C596 pin 3, circuit
32-AD16 (WH), harness side and the exterior
mirror control switch C596 pin 1, circuit 34-AD8
(BU/WH), harness side.
32-AD17 (WH/GN), harness side and the
exterior mirror control switch C596 pin 2, circuit
34-AD11 (BU/OG), harness side.
32-AD17 (WH/GN), harness side and the exterior mirror control switch C596 pin 1, circuit

Yes
No
Go to B2
B2: CHECK FOR CONTINUITY BETWEEN THE EXTERIOR MIRROR CONTROL SWITCH AND THE
EXTERIOR MIRROR
1 Disconnect Driver Side Exterior Mirror C599 or
Passenger Side Exterior Mirror C600.
32-AD16 (WH), harness side and the driver side
exterior mirror C599 pin 1, circuit 32-AD16
(WH), harness side.
32-AD17 (WH/GN), harness side and the passenger side exterior mirror C600 pin 1, circuit
32-AD17 (WH/GN), harness side.

Yes
INSTALL a new exterior mirror. REFER to
Exterior Mirror in this section. TEST the
No
REPAIR 32-AD16 (WH) or circuit 32-AD17
(WH/GN). TEST the system for normal operation.
G149911 en
11/2004 2005.25 Fiesta
501-09-6

TO MODEL INDEX
Rear View Mirrors
501-09-6

PINPOINT TEST C: A SINGLE EXTERIOR MIRROR DOES NOT FUNCTION WITH SWITCH LOGIC
TEST CONDITIONS

C1: CHECK THE EXTERIOR MIRROR FUNCTIONS WITH SWITCH LOGIC
2 Operate the exterior mirror control switch.
Does the exterior mirror function with switch
logic?
Yes
No
Driver side exterior mirror up/down function
inoperative GO to C2
Driver side exterior mirror left/right function is
inoperative GO to C4
Passenger side exterior mirror up/down
function is inoperative GO to C6
Passenger side exterior mirror left/right
function is inoperative GO to C8
C2: CHECK THE DRIVER SIDE EXTERIOR MIRROR UP/DOWN CIRCUIT
C596.

Yes
No
Go to C3
C3: CHECK FOR CONTINUITY BETWEEN THE EXTERIOR MIRROR CONTROL SWITCH AND THE
DRIVER SIDE EXTERIOR MIRROR
1 Disconnect Driver Side Exterior Mirror C599.
G149911 en
11/2004 2005.25 Fiesta
501-09-7

TO MODEL INDEX
Rear View Mirrors
501-09-7

TEST CONDITIONS
34-AD8 (BU/WH), harness side and the driver
side exterior mirror C599 pin 2, circuit 34-AD8
34-AD8 (BU/WH), harness side and the passenger side exterior mirror C599 pin 2, circuit
34-AD8 (BU/WH), harness side.

Yes
INSTALL a new driver side exterior mirror.
REFER to Exterior Mirror in this section.
No
REPAIR circuit 34-AD8 (BU/WH). TEST the
C4: CHECK THE DRIVER SIDE EXTERIOR MIRROR LEFT/RIGHT CIRCUIT
C596.
mirror control switch pin 7, circuit 33-AD7
(YE/RD), harness side.
mirror control switch pin 5, circuit 33-AD7

Yes
No
Go to C5
G149911 en
11/2004 2005.25 Fiesta
501-09-8

TO MODEL INDEX
Rear View Mirrors
501-09-8

TEST CONDITIONS
33-AD7 (YE/RD), harness side and the driver

Yes
No
REPAIR circuit 33-AD7 (YE/RD). TEST the
C6: CHECK THE PASSENGER SIDE EXTERIOR MIRROR UP/DOWN CIRCUIT
C596.

Yes
No
Go to C7
PASSENGER SIDE EXTERIOR MIRROR
1 Disconnect Passenger Side Exterior Mirror
C600.
G149911 en
11/2004 2005.25 Fiesta
501-09-9

TO MODEL INDEX
Rear View Mirrors
501-09-9

TEST CONDITIONS
34-AD11 (BU/OG), harness side and the
passenger side exterior mirror C600 pin 2,
circuit 34-AD11 (BU/OG), harness side.
34-AD11 (BU/OG), harness side and the passenger side exterior mirror C600 pin 2, circuit

Yes
INSTALL a new passenger side exterior
mirror. REFER to Exterior Mirror in this section. TEST the system for normal operation.
No
REPAIR circuit 34-AD11 (BU/OG) TEST the
C8: CHECK THE PASSENGER SIDE EXTERIOR MIRROR LEFT/RIGHT CIRCUIT
C596.
33-AD10 (YE/BK), harness side.

Yes
No
Go to C9
C600.
G149911 en
11/2004 2005.25 Fiesta
501-09-10

TO MODEL INDEX
Rear View Mirrors
501-09-10

TEST CONDITIONS
33-AD10 (YE/BK), harness side, and the
passenger side exterior mirror C600 pin 3,
circuit 33-AD10 (YE/BK), harness side.
33-AD10 (YE/BK), harness side, and the passenger side exterior mirror C600 pin 3, circuit

Yes
No
REPAIR circuit 33-AD10 (YE/BK). TEST the
PINPOINT TEST D: THE HEATED EXTERIOR MIRROR IS INOPERATIVE
TEST CONDITIONS

D1: CHECK THE OPERATION OF THE HEATED REAR WINDOW
2 Operate the heated rear window control switch.
Does the heated rear window function correctly?
Yes
Go to D2
No
REPAIR the heated rear window electrical
circuit. REFER to Section 501-11.[Glass,
Frames and Mechanisms, DIAGNOSIS AND
TESTING, Glass, Frames and Mechanisms]
D2: CHECK THE VOLTAGE TO THE INOPERATIVE EXTERIOR MIRROR
G149911 en
11/2004 2005.25 Fiesta
501-09-11

TO MODEL INDEX
Rear View Mirrors
501-09-11

TEST CONDITIONS
5 Measure the voltage between the:
Driver side exterior mirror C599 pin 4, circuit
15S-HB35 (GN/BK), harness side and ground.
Passenger side exterior mirror C600 pin 4, circuit 15S-HB36 (GN/OG), harness side and
ground.

Yes
Go to D3
No
REPAIR circuit 15S-HB35 (GN/BK) or circuit
15S-HB36 (GN/OG). TEST the system for
normal operation.
D3: CHECK THE INOPERATIVE EXTERIOR MIRROR GROUND CIRCUIT FOR CONTINUITY
31-HB35 (BK), harness side and ground.
Passenger side exterior mirror C600 pin 5, circuit 31-HB36 (BK), harness side and ground.

Yes
INSTALL a new heated exterior mirror glass.
No
REPAIR circuit 31-HB35 (BK) or circuit
31-HB36 (BK). TEST the system for normal
operation
G149911 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
501-09-12
Rear View Mirrors
501-09-12

Rear View Mirrors 2.0L Duratec-HE (MI4)
Symptom
The mirrors are inoperative
A single mirror is inoperative
Mechanical
Exterior mirror(s)
Fuse(s)
Relay
Electrical
connector(s)
Switch
step.
Possible Sources
Action

Circuit(s).


Circuit(s).
A single mirror does not function Exterior mirror control switch.

with switch logic
The heated exterior mirror is

inoperative
Electrical


Circuit(s).

switch.

Heated rear window relay.

Heated exterior mirror glass(es).
Circuit(s).
PINPOINT TEST E: THE MIRRORS ARE INOPERATIVE
TEST CONDITIONS

E1: CHECK FOR VOLTAGE TO THE EXTERIOR MIRROR CONTROL SWITCH
C596.
G428468 en
11/2004 2005.25 Fiesta
501-09-13

TO MODEL INDEX
Rear View Mirrors
501-09-13

TEST CONDITIONS
2 Measure the voltage between the exterior mirror control switch C596 pin 6, circuit 31-AD12A

Yes
Go to E2
No
REPAIR circuit 31-AD12A (BK). TEST the
E2: CHECK THE EXTERIOR MIRROR CONTROL SWITCH GROUND CIRCUIT FOR CONTINUITY
1 Measure the resistance between the exterior
31-AD12 (BK), harness side and ground.

Yes
No
PINPOINT TEST F: A SINGLE MIRROR IS INOPERATIVE
TEST CONDITIONS

F1: CHECK THE INOPERATIVE EXTERIOR MIRROR MOTOR CIRCUIT FOR CONTINUITY
C596.
G428468 en
11/2004 2005.25 Fiesta
501-09-14

TO MODEL INDEX
Rear View Mirrors
501-09-14

TEST CONDITIONS
Driver side exterior mirror
- Exterior mirror control switch C596 pin 3,
circuit 32-AD16 (WH), harness side and the
exterior mirror control switch C596 pin 1,
circuit 34-AD8 (BU/WH), harness side.
Passenger side exterior mirror
circuit 31-AD17 (BK), harness side and the
circuit 31-AD11 (BK), harness side.
Driver side exterior mirror
circuit 32-AD16 (WH), harness side and the
circuit 34-AD8 (BU/WH), harness side.
Passenger side exterior mirror
circuit 31-AD17 (BK), harness side and the
exterior mirror control switch C596 pin 1, circuit 31-AD11 (BK), harness side.

Yes
No
Go to F2
F2: CHECK FOR CONTINUITY BETWEEN THE EXTERIOR MIRROR CONTROL SWITCH AND THE
INOPERATIVE EXTERIOR MIRROR
Driver Exterior Mirror
32-AD16 (WH), harness side and the driver side
exterior mirror C599 pin 1, circuit 32-AD16
(WH), harness side.
Passenger Exterior Mirror
31-AD17 (BK), harness side and the passenger
(BK), harness side.

Yes
G428468 en
11/2004 2005.25 Fiesta
501-09-15

TO MODEL INDEX
Rear View Mirrors
501-09-15

TEST CONDITIONS
INSTALL a new exterior mirror. REFER to
Exterior Mirror in this section. TEST the
No
REPAIR 32-AD16 (WH) or circuit 31-AD17
(BK). TEST the system for normal operation.
PINPOINT TEST G: A SINGLE MIRROR DOES NOT FUNCTION WITH SWITCH LOGIC
TEST CONDITIONS

G1: CHECK THE EXTERIOR MIRROR FUNCTIONS WITH SWITCH LOGIC
1 Operate the exterior mirror control switch.
Does the exterior mirror function with switch
logic?
Yes
No
Driver side exterior mirror up/down function
inoperative GO to G2
Driver side exterior mirror left/right function is
inoperative GO to G4
Passenger side exterior mirror up/down
function is inoperative GO to G6
Passenger side exterior mirror left/right
function is inoperative GO to G8
G2: CHECK THE DRIVER SIDE EXTERIOR MIRROR UP/DOWN CIRCUIT
C596.

Yes
No
Go to G3
G3: CHECK FOR CONTINUITY BETWEEN THE EXTERIOR MIRROR CONTROL SWITCH AND THE
G428468 en
11/2004 2005.25 Fiesta
501-09-16

TO MODEL INDEX
Rear View Mirrors
501-09-16

TEST CONDITIONS

Yes
No
REPAIR circuit 34-AD8 (BU/WH). TEST the
G4: CHECK THE DRIVER SIDE EXTERIOR MIRROR LEFT/RIGHT CIRCUIT
C596.

Yes
No
Go to G5
G428468 en
11/2004 2005.25 Fiesta
501-09-17

TO MODEL INDEX
Rear View Mirrors
501-09-17

TEST CONDITIONS

Yes
No
REPAIR circuit 33-AD7 (YE/RD). TEST the
G6: CHECK THE PASSENGER SIDE EXTERIOR MIRROR UP/DOWN CIRCUIT
C596.
31-AD17 (BK), harness side and the exterior
31-AD11 (BK), harness side.

Yes
No
Go to G7
C600.
G428468 en
11/2004 2005.25 Fiesta
501-09-18

TO MODEL INDEX
Rear View Mirrors
501-09-18

TEST CONDITIONS
(BK), harness side.
(BK), harness side.

Yes
No
G8: CHECK THE PASSENGER SIDE EXTERIOR MIRROR LEFT/RIGHT CIRCUIT
C596.

Yes
No
Go to G9
C600.
G428468 en
11/2004 2005.25 Fiesta
501-09-19

TO MODEL INDEX
Rear View Mirrors
501-09-19

TEST CONDITIONS
31-AD10 (BK), harness side, and the passenger
(BK), harness side.
31-AD10 (BK), harness side, and the passenger
(BK), harness side.

Yes
No
PINPOINT TEST H: THE HEATED EXTERIOR MIRROR IS INOPERATIVE
TEST CONDITIONS

H1: CHECK THE OPERATION OF THE HEATED REAR WINDOW
Yes
Go to H2
No
REPAIR the heated rear window. REFER to
Section 501-11.[Glass, Frames and Mechanisms, DIAGNOSIS AND TESTING, Glass,
Frames and Mechanisms - 2.0L Duratec-HE
(MI4)] TEST the system for normal operation.
H2: CHECK THE VOLTAGE TO THE INOPERATIVE EXTERIOR MIRROR
G428468 en
11/2004 2005.25 Fiesta
501-09-20

TO MODEL INDEX
Rear View Mirrors
501-09-20

TEST CONDITIONS
31-HB35S (BK), harness side and ground.
Passenger side exterior mirror C600 pin 4, circuit 31-HB36S (BK), harness side and ground.

Yes
Go to H3
No
REPAIR circuit 31-HB35S (BK) or circuit
31-HB36S (BK). TEST the system for normal
operation.
H3: CHECK THE INOPERATIVE EXTERIOR MIRROR GROUND CIRCUIT FOR CONTINUITY
31-HB35 (BK), harness side and ground.
Passenger side exterior mirror C600 pin 5, circuit 31-HB36 (BK), harness side and ground.

Yes
INSTALL a new heated exterior mirror glass.
No
REPAIR circuit 31-HB35 (BK) or circuit
31-HB36 (BK). TEST the system for normal
operation
G428468 en
11/2004 2005.25 Fiesta
501-09-21

TO MODEL INDEX
Rear View Mirrors
501-09-21

Exterior Mirror (43 364 0)
Removal
Vehicles with manual mirrors
1. Remove the adjustment lever sleeve.
1. Rotate the sleeve counterclockwise.
2. Remove the sleeve.
CAUTION: Make sure the trim panel is

only moved rearwards enough to
detach the locating dowels.
NOTE: Note the position of the tangs.
Vehicles with power mirrors

3.
CAUTION: Make sure the trim panel is

only moved rearwards enough to
detach the locating dowels.
Detach the exterior mirror trim panel.
1. Move the trim panel rearwards.
2.
4. Remove the exterior mirror trim panel.

Disconnect the electrical connectors.
Remove the exterior mirror trim panel.

1. Depress the tangs.
2. Move the trim panel rearwards.
G92125 en
11/2004 2005.25 Fiesta
501-09-22

TO MODEL INDEX
Rear View Mirrors
501-09-22

All vehicles
5.
CAUTION: Make sure the exterior mirror

is removed in the direction shown.
Remove the exterior mirror (manual mirror
shown).
3. Remove the mirror.
Installation
1.
CAUTION: Make sure the exterior mirror

locating dowels are correctly located
in the door panel before installing the
retaining clips.
G92125 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
501-10-1
Seating
501-10-1
SECTION 501-10 Seating

CONTENTS
PAGE
SPECIFICATIONS
Specifications....................................................................................................................
501-10-2

Seats ................................................................................................................................
501-10-3
501-10-3

Front Seat .........................................................................................................................
Front Seat Backrest Cover 3-Door................................................................................
Front Seat Backrest Cover 5-Door................................................................................
Rear Seat Backrest Latch .................................................................................................
Rear Seat Backrest Cover.................................................................................................
501-10-6
501-10-7
501-10-13
501-10-19
501-10-21
11/2004 2005.25 Fiesta
501-10-2

TO MODEL INDEX
Seating
501-10-2
SPECIFICATIONS
Item
Front seat retaining bolts
Front seat cushion retaining bolts
Front seat backrest retaining bolts
Rear seat backrest retaining bolts
Rear seat backrest latch retaining bolts
Rear seat cushion retaining bolts
Rear center safety belt lower anchor and buckle
assembly retaining bolt
G149912 en
Nm
48
23
48
25
27
25
55
lb-ft
35
17
35
18
20
18
41
lb-in
-
11/2004 2005.25 Fiesta

TO MODEL INDEX
501-10-3
Seating
501-10-3

Seats
Mechanical
Damaged switch

Electrical
Fuse
Wiring harness
Electrical
Connector(s)
Switch

step.
Symptom Chart
Symptom
The heated seat is inoperative
Possible Sources
Heated seat control switch.
Circuit(s).
Action
CARRY OUT the Heated Seat
PINPOINT TEST A: THE HEATED SEAT IS INOPERATIVE

TEST CONDITIONS
A1: CHECK THE INOPERATIVE HEATED SEAT GROUND CIRCUIT
1 Disconnect Inoperative heated seat C663 or
C664.
Driver side heated seat cushion C663 pin 5,
circuit 31-HC1 (BK), harness side and ground;
or
Passenger side heated seat cushion C664 pin
5, circuit 31-HC2 (BK), harness side and
ground.

Yes
Go to A2
No
REPAIR circuit 31-HC1 (BK) or circuit
31-HC2 (BK). TEST the system for normal
operation.
A2: CHECK FOR VOLTAGE TO THE INOPERATIVE HEATED SEAT
G183790 en
11/2004 2005.25 Fiesta
501-10-4

TO MODEL INDEX
Seating
501-10-4

TEST CONDITIONS
Driver side heated seat cushion C663 pin 6,
circuit 15-HC15 (GN/YE), harness side and
ground; or
Passenger side heated seat cushion C664 pin
6, circuit 15-HC18 (GN/BK), harness side and
ground.

Yes
Go to A3
No
REPAIR circuit 15-HC15 (GN/YE) or circuit
15-HC18 (GN/BK). TEST the system for
normal operation.
A3: CHECK THE INOPERATIVE HEATED SEAT CUSHION HEATER MAT GROUND CIRCUIT
2 Connect Inoperative heated seat C663 or C664.
3 Disconnect Inoperative heated seat cushion
heater mat C1011 or C1012.
Driver side heated seat cushion heater mat
C1011 pin 1, circuit 31-HC1 (BK), harness side
and ground; or
Passenger side heated seat cushion heater mat
C1012 pin 1, circuit 31-HC2 (BK), harness side
and ground.

Yes
Go to A4
No
REPAIR circuit 31-HC1 (BK) or circuit
31-HC2 (BK). TEST the system for normal
operation.
A4: CHECK FOR VOLTAGE TO THE INOPERATIVE HEATED SEAT CUSHION HEATER MAT
G183790 en
11/2004 2005.25 Fiesta
501-10-5

TO MODEL INDEX
Seating
501-10-5

TEST CONDITIONS
2 Operate the heated seat control switch.

Driver side heated seat cushion heater mat
C1011 pin 2 (BK), harness side and ground; or
Passenger side heated seat cushion heater mat
C1012 pin 2 (BK), harness side and ground.
Yes
INSTALL a new heated seat cushion heater
mat. TEST the system for normal operation.
No
INSTALL a new heated seat control switch.
G183790 en
11/2004 2005.25 Fiesta
501-10-6

TO MODEL INDEX
Seating
501-10-6

Front Seat

deployment the air bag control module
personal injury.
Item
Part
Number
Front seat retaining bolts
Underseat electrical connector
Front seat

414-01.
table(s).
Description

G240075 en
11/2004 2005.25 Fiesta
501-10-7

TO MODEL INDEX
Seating
501-10-7

Front Seat Backrest Cover 3-Door
General Equipment
Hog ring pliers

table(s).
WARNING: Note the position of the wiring

harnesses to aid installation. An
incorrectly routed wiring harness could
become damaged when the seat is
moved. Failure to follow this instruction
1. Remove the front seat. For additional
information, refer to Front Seat in this
section.
G275567 en
11/2004 2005.25 Fiesta
501-10-8

TO MODEL INDEX
Seating
501-10-8
Item
Part
Number
Description
Cushion heater wiring harness electrical connector (if
equipped)
Cushion retaining screws
Cushion
G275567 en
Item
Part
Number
Description
Backrest recliner handwheel

See Removal Detail
Seat track inner upper trim

panel
See Removal Detail
11/2004 2005.25 Fiesta

TO MODEL INDEX
501-10-9
Seating
501-10-9

Item
Part
Number
Description
Seat track outer upper trim

panel
See Removal Detail
Head restraint
Head restraint guides

See Removal Detail
Backrest release lever

See Removal Detail
10
Backrest cover
See Removal Detail
11
Backrest cover tensioning

rods
See Removal Detail
Removal Details
Item 4 : Backrest recliner handwheel
Item 6 : Seat track outer upper trim panel

1. Remove the seat track outer upper trim
panel.
1. Detach the front retaining clip.
2. Detach the rear retaining tang.
Item 8 : Head restraint guides

1. Remove the head restraint guides.
1. Using a suitable screwdriver, depress the
locking tang.
2. Pull the guide upwards.
CAUTION: To avoid damage to the

backrest recliner handwheel, even
pressure must be applied to the opposite
sides of the handwheel.
Item 5 : Seat track inner upper trim panel
1. Remove the seat track inner upper trim
panel.
G275567 en
11/2004 2005.25 Fiesta
501-10-10

TO MODEL INDEX
Seating
501-10-10

Item 9 : Backrest release lever
1.
CAUTION: On the left-hand seat, the

backrest release lever lower locking
tang must be released before the
backrest release lever upper locking
tang.
CAUTION: On the right-hand seat, the

backrest release lever upper locking tang
must be released before the backrest
release lever lower locking tang.
NOTE: On the left-hand seat, the backrest release
lever upper locking tang is not accessible until the
backrest release lever lower locking tang has
been released and the backrest release lever
repositioned.
NOTE: On the right-hand seat, the backrest
release lever lower locking tang is not accessible
until the backrest release lever upper locking tang
has been released and the backrest release lever
repositioned.
Remove the backrest release lever
(left-hand seat shown).
1. Release the backrest release lever lower
locking tang.
2. Release the backrest release lever upper
locking tang.
Item 10 : Backrest cover

1. Detach the backrest cover from the
underside of the backrest.
Detach the retaining strip.
2. Roll the backrest cover up the backrest to

gain access to the lower ends of the
tensioning rods.
3. Detach the lower ends of the tensioning
rods from the backrest.

access the upper ends of the tensioning
rods.
G275567 en
11/2004 2005.25 Fiesta
501-10-11

TO MODEL INDEX
Seating
501-10-11

5. Detach the upper ends of the tensioning

access the upper end of the backrest
spring frame.
7. Detach the backrest cover retaining clip
from the backrest spring frame (if
equipped).

backrest pad.
Release the hook loop tape (if equipped).
10. Detach the side air bag deployment

sleeve from the backrest frame (if
equipped).
1. Locally detach the side air bag deployment
sleeve.
2. Detach the retaining strip.
8. Detach the backrest cover from the front of

the backrest pad.
Cut the hog rings.
Discard the hog rings.
G275567 en
11/2004 2005.25 Fiesta
501-10-12

TO MODEL INDEX
Seating
501-10-12

11. Remove the backrest cover.
Item 11 : Backrest cover tensioning rods

1. Remove the tensioning rods from the
backrest cover if a new backrest cover is to
be installed.
2. Push the backrest cover retaining clip

through the backrest pad cut-out (if
equipped).
3. Attach the backrest cover retaining clip to

the backrest spring frame (if equipped).
1. NOTE: If a replacement backrest cover is to be
installed, cut holes for the head restraint guides
and backrest release lever. Use the existing
backrest cover as a template.
NOTE: Use hog ring pliers to close the hog rings.
Do not use any other tool. The hog rings must be
closed to overlap as illustrated.
NOTE: Install new hog rings.
Using hog ring pliers, install the hog rings.
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Seating
501-10-13

Front Seat Backrest Cover 5-Door
General Equipment
Hog ring pliers

table(s).
WARNING: Note the position of the wiring

harnesses to aid installation. An
incorrectly routed wiring harness could
moved. Failure to follow this instruction
information, refer to Front Seat in this
section.
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Seating
501-10-14
Item
Part
Number
Description
Cushion heater wiring harness electrical connector (if
equipped)
Cushion retaining screws
Cushion
G240076 en
Item
Part
Number
Description
Backrest recliner handwheel

See Removal Detail
Seat track inner upper trim

panel
See Removal Detail
11/2004 2005.25 Fiesta

TO MODEL INDEX
501-10-15
Seating
501-10-15

Item
Part
Number
Description
Seat track outer upper trim

panel
See Removal Detail
Head restraint
Head restraint guides

See Removal Detail
Backrest cover
See Removal Detail
10
Backrest cover tensioning

rods
See Removal Detail
Item 6 : Seat track outer upper trim panel

panel.
Removal Details
Item 4 : Backrest recliner handwheel
pressure must be applied to the opposite
sides of the handwheel.
Item 8 : Head restraint guides

1. Remove the head restraint guides.
1. Using a suitable screwdriver, depress the
locking tang.
2. Pull the guide upwards.
Item 5 : Seat track inner upper trim panel

panel.
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Seating
501-10-16


gain access to the lower ends of the
tensioning rods.

rods.
G240076 en


access the upper end of the backrest
spring frame.
equipped).
8. Detach the backrest cover from the front of

the backrest pad.
Cut the hog rings.
Discard the hog rings.
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Seating
501-10-17

9. Detach the side air bag deployment sleeve
from the backrest frame (if equipped).
sleeve.
1. NOTE: If a replacement backrest cover is to be
installed, cut holes for the head restraint guides.
Use the existing backrest cover as a template.
NOTE: Install new hog rings.
Using hog ring pliers, install the hog rings.

2. Push the backrest cover retaining clip

through the backrest pad cut-out (if
equipped).
Item 10 : Backrest cover tensioning rods

1. Remove the tensioning rods from the
backrest cover if a new backrest cover is to
be installed.
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Seating
501-10-18

3. Attach the backrest cover retaining clip to
the backrest spring frame (if equipped).
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501-10-19
Seating
501-10-19

Rear Seat Backrest Latch
1. Remove the rear seat backrest cover. For
additional information, refer to Rear Seat
Backrest Cover in this section.

table(s).
Item
Part
Number
1. Detach the backrest latch cable from the

safety belt retractor.
Backrest latch to center

safety belt retractor locking
cable (if equipped)
See Removal Detail
Backrest latch retaining bolts
Backrest latch
Description
Removal Details
Item 1 : Backrest latch to center safety belt
retractor locking cable (if equipped)
NOTE: To aid installation, note the backrest latch
cable position on the safety belt retractor.
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Seating
501-10-20

Item 1 : Backrest latch to center safety belt
retractor locking cable (if equipped)
CAUTION: Check the backrest latch cable
routing, and the operation of the safety
belt retractor and interlock before fully
assembling the rear seat backrest.
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Seating
501-10-21

Rear Seat Backrest Cover
table(s).
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TO MODEL INDEX
Seating
501-10-22

Item
Part
Number
Description
Safety belt lower anchor and

buckle retaining bolt
See Removal Detail
Safety belt lower anchor and

buckle
Backrest retaining bolts
Backrest
Head restraints (if equipped)
Backrest release lever trim

panel
Center safety belt webbing

trim panel (if equipped)
See Removal Detail
Head restraint guides (if

equipped)
See Removal Detail
Backrest cover and pad

See Removal Detail
Removal Details
Item 7 : Center safety belt webbing trim panel

(if equipped)
WARNING: If the safety belt webbing
retracts further than the stop on the
webbing, a new safety belt retractor must
be installed.
CAUTION: Make sure the webbing retainer
is fitted at least 200 mm from the webbing
stop towards the retractor.
Item 8 : Head restraint guides (if equipped)
CAUTION: When detaching the retaining
strip take care not to damage the
backrest carpet.
1. Locally detach the backrest cover and pad
to gain access to the head restraint guides.
Detach the retaining strip
Item 1 : Safety belt lower anchor and buckle

retaining bolt
be installed.
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Seating
501-10-23

2. Remove the head restraint guides (if
equipped).
1. From the underside of the backrest pad
depress the locking tangs.
2. Slide the head restraint guides upwards
through the backrest cover.

1. Roll the backrest cover inwards to access
the pleating hog rings.
2. Cut the hog rings.
Item 9 : Backrest cover and pad
1.
CAUTION: When removing the backrest

cover take care not to detach the
safety belt webbing retainer.
Remove the backrest cover and pad.
backrest cover and pad.
Item 9 : Backrest cover and pad

be installed.
CAUTION: When installing the backrest
cover take care not to detach the safety
belt webbing retainer.
belt retractor and interlock before fully
installing the rear seat backrest cover.
CAUTION: After installation check for
correct operation of the center safety belt
retractor.
NOTE: If a replacement backrest pad is to be
installed, cut out a hole for the center safety belt
webbing trim panel. Use the existing backrest pad
as a template.
NOTE: If a replacement backrest cover is to be
installed, cut out holes for the head restraint guide
and center safety belt webbing trim panel. Use the
existing backrest cover as a template.
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Seating
501-10-24
Item 6 : Backrest release lever trim panel

NOTE: When installed, the trim panel may not
have the original retaining force.
Item 1 : Safety belt lower anchor and buckle
retaining bolt
CAUTION: After installation check for
correct operation of the center safety belt
retractor.
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501-11-1
Glass, Frames and Mechanisms
501-11-1
SECTION 501-11 Glass, Frames and Mechanisms

CONTENTS
PAGE
SPECIFICATIONS
Specifications....................................................................................................................
501-11-2

Glass, Frames and Mechanisms.......................................................................................
Component Tests.............................................................................................................
Glass, Frames and Mechanisms 2.0L Duratec-HE (MI4) ..............................................
Symptom Chart ................................................................................................................
Pinpoint Tests ..................................................................................................................
Component Tests.............................................................................................................
501-11-3
501-11-3
501-11-17
501-11-19
501-11-19
501-11-19
501-11-20
501-11-38

Windshield Glass .......................................................................................... (42 115 0)
Liftgate Window Glass ......................................................................................................
Front Door Window Glass 5-Door............................................................. (42 314 0)
Front Door Window Glass 3-Door............................................................. (42 314 0)
Front Door Window Regulator 5-Door....................................................... (42 338 0)
Front Door Window Regulator 3-Door....................................................... (42 338 0)
Front Door Window Regulator Motor............................................................. (33 782 0)
Rear Quarter Window Glass 5-Door ......................................................... (42 514 0)
Rear Quarter Window Glass 3-Door/Van.................................................. (42 514 0)
Rear Door Window Regulator ....................................................................... (42 338 0)
Rear Door Window Glass.............................................................................. (42 315 0)
501-11-39
501-11-46
501-11-50
501-11-52
501-11-54
501-11-57
501-11-60
501-11-61
501-11-64
501-11-67
501-11-70
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501-11-2
SPECIFICATIONS

Description
Cleaner/activator
Primer
2K Adhesive
2K Hardener/mixer
Item
Front door regulator motor retaining screws
Door module retaining screws
Door latch retaining nuts
Door window regulator retaining bolts
Door window glass clamp retaining bolts
Windshield wiper arm retaining nut
G149913 en
Specification
WSK-M2G342-A
WSK-M2G343-A
WSK-M11P57-A
WSK-M2G322-B2
Nm
4
8
12
2
7
18
lb-ft
9
13
lb-in
35
71
18
62
-
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501-11-3

Mechanical
Electrical
Window seal
Door window frame
Fuse(s)
Electrical
connector(s)
Switch(es)
Circuit(s)
step.
Symptom Chart
Symptom
Possible Sources
All power windows are inopera- Driver power window control

tive
switch.
A single power window is inoperative - driver side
A single power window is inoperative - passenger side.
The defrost system is inoperative.
G183791 en
Action
CARRY OUT the Driver Power
Circuit(s).
Driver power window control

switch

Window Control Switch Component Test. REFER to the Wiring diagrams.
Power window motor.

Circuit(s).
Driver power window control

switch.

Passenger power window control switch.
CARRY OUT the Passenger

Power Window Control Switch
Component Test. REFER to the
Wiring Diagrams.
Power window motor.

Circuit(s).

switch.

Heated windshield control

switch.
CARRY OUT the Heated Windshield Control Switch Component Test. REFER to the Wiring
Diagrams.
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501-11-4

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501-11-4

Possible Sources
Symptom
Action
Heated windshield relay.
CARRY OUT the Heated Windshield Relay Component Test.

REFER to the Wiring diagrams.

(GEM).
CARRY OUT the Generic Electronic Module Self-Test.

Heated rear window grid wire.
CARRY OUT the Grid Wire

procedure in this section.
Heated windshield grid wire.

Circuit(s).
The defrost system will not shut Heated rear window control
off automatically
switch.


switch.
Diagrams.


(GEM).
CARRY OUT the Generic Electronic Module (GEM) Self-Test.


measurements.
PINPOINT TEST A: ALL POWER WINDOWS ARE INOPERATIVE
TEST CONDITIONS
A1: CHECK THE DRIVER POWER WINDOW CONTROL SWITCH LEDS

Do the driver power window control switch LEDs
illuminate?
Yes
No
Go to A2
A2: CHECK FOR CONTINUITY BETWEEN THE DRIVER POWER WINDOW CONTROL SWITCH
AND GROUND
2 Disconnect Driver Window Control Switch
C310.
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TEST CONDITIONS
3 Measure the resistance between the driver
power window control switch C310 pin 3, circuit
31-AJ7 (BK), harness side and ground.

Yes
Go to A3
No
REPAIR circuit 31-AJ7 (BK). TEST the system for normal operation.
A3: CHECK FOR VOLTAGE TO THE DRIVER POWER WINDOW CONTROL SWITCH
2 Measure the voltage between the driver power
window control switch C310 pin 2, circuit 15-AJ7
(GN/BU), harness side and ground.

Yes
No
REPAIR circuit 15-AJ7 (GN/BU). TEST the
PINPOINT TEST B: A SINGLE POWER WINDOW IS INOPERATIVE - DRIVER SIDE
TEST CONDITIONS
B1: CHECK FOR VOLTAGE TO THE DRIVER POWER WINDOW CONTROL SWITCH
Does the driver power window control switch
LED illuminate?
Yes
Go to B2
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501-11-6

TEST CONDITIONS
No
Go to B4
B2: CHECK FOR CONTINUITY BETWEEN THE DRIVER POWER WINDOW CONTROL SWITCH
AND THE MOTOR DOWN CIRCUIT
2 Disconnect Driver Power Window Control
Switch C310.
3 Disconnect Driver Power Window Motor C529.
32-AJ26 (WH), harness side and the driver
power window motor C529 pin 2, circuit
32-AJ26 (WH), harness side.

Yes
Go to B3
No
REPAIR circuit 32-AJ26 (WH). TEST the
AND THE MOTOR UP CIRCUIT
33-AJ26 (YE), harness side and the passenger
power window motor C529 pin 1, circuit
33-AJ26 (YE), harness side.

Yes
INSTALL a new motor. TEST the system for
normal operation.
No
REPAIR circuit 33-AJ26 (YE). TEST the
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501-11-7

TEST CONDITIONS
AND GROUND
2 Disconnect Driver Power Window Control
Switch C310.

Yes
Go to B5
No
B5: CHECK FOR VOLTAGE TO THE DRIVER POWER WINDOW CONTROL SWITCH

Yes
No
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501-11-8

PINPOINT TEST C: A SINGLE POWER WINDOW IS INOPERATIVE - PASSENGER SIDE
TEST CONDITIONS
C1: DOES THE PASSENGER WINDOW OPERATE FROM THE DRIVER SIDE POWER WINDOW
CONTROL SWITCH
2 Operate the passenger power window from the
driver power window control switch.
Does the passenger power window operate?
Yes
REPAIR circuit 15-AJ18 (GN/WH). TEST the
No
Go to C2
C2: CHECK THE DRIVER SIDE PASSENGER POWER WINDOW CONTROL SWITCH LED
1 Observe the driver side passenger power window control switch LED.
Is the driver side passenger power window
control switch LED illuminated?
Yes
Go to C3
No
Go to C7
C3: CHECK THE DOWN CIRCUIT VOLTAGE TO THE PASSENGER POWER WINDOW CONTROL
SWITCH
2 Disconnect Passenger Power Window Control
Switch C699.
4 Operate the driver side passenger power window control switch to the DOWN position.
5 Measure the voltage between the passenger
33-AJ18 (YE/VT), harness side and ground.

Yes
Go to C4
No
REPAIR circuit 33-AJ18 (YE/VT). TEST the
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501-11-9

TEST CONDITIONS
C4: CHECK THE UP CIRCUIT VOLTAGE TO THE PASSENGER POWER WINDOW CONTROL
SWITCH
1 Operate the driver side passenger power window control switch to the UP position.
32-AJ18 (WH/VT), harness side and ground.

Yes
Go to C5
No
REPAIR circuit 32-AJ18 (WH/VT). TEST the
C5: CHECK FOR CONTINUITY BETWEEN THE PASSENGER POWER WINDOW CONTROL
SWITCH DOWN CIRCUIT AND THE PASSENGER POWER WINDOW MOTOR
2 Disconnect Power Window Motor C530.
3 Measure the resistance between the passenger
33-AJ27 (YE/VT), harness side and the passenger power window motor C530 pin 1, circuit
33-AJ27 (YE/VT), harness side.

Yes
Go to C6
No
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501-11-10

TEST CONDITIONS
C6: CHECK FOR CONTINUITY BETWEEN THE PASSENGER POWER WINDOW CONTROL
SWITCH UP CIRCUIT AND THE PASSENGER POWER WINDOW MOTOR
32-AJ27 (WH/VT), harness side and the passenger power window motor C530 pin 2, circuit
32-AJ27 (WH/VT), harness side.

Yes
INSTALL a new motor. TEST the system for
normal operation.
No
C7: CHECK FOR CONTINUITY BETWEEN THE DRIVER POWER WINDOW CONTROL SWITCH
AND GROUND
2 Disconnect Driver Side Passenger Power
Window Control Switch C311.

Yes
Go to C8
No
C8: CHECK FOR VOLTAGE TO THE DRIVER POWER WINDOW CONTROL SWITCH
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501-11-11

TEST CONDITIONS
(GN/BK), harness side and ground.

Yes
No
REPAIR circuit 15-AJ9 (GN/BK). TEST the
PINPOINT TEST D: THE DEFROST SYSTEM IS INOPERATIVE
TEST CONDITIONS
D1: CHECK THE OPERATION OF THE HEATED REAR WINDOW

Yes
Go to D2
No
Go to D3
D2: CHECK THE OPERATION OF THE HEATED WINDSHIELD
1 Operate the heated windshield control switch.
Does the heated windshield operate correctly?
Yes
No
Go to D5
D3: CHECK THE OPERATION OF THE HEATED EXTERIOR MIRRORS
Do the heated exterior mirrors operate correctly?
Yes
Go to D4
No
Go to D10
D4: CHECK THE HEATED REAR WINDOW GRID GROUND CIRCUIT
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501-11-12

TEST CONDITIONS
2 Disconnect Heated Rear Window C561A.
3 Measure the resistance between the heated
rear window C561A pin 1, circuit 31-HB19 (BK),

Yes
REPAIR circuit 15S-HB19 (GN/BU). TEST
No
REPAIR circuit 31-HB19 (BK). TEST the
D5: CHECK OPERATION OF THE HEATED WINDSHIELD RELAY
Does the heated windshield relay click?
Yes
Go to D6
No
Go to D12
D6: CHECK FOR VOLTAGE TO THE HEATED WINDSHIELD RELAY
2 Disconnect Heated Windshield Relay C312.
3 Measure the voltage between the heated
windshield relay C312 pin 3, circuit 30-HB8
(RD), harness side and ground.

Yes
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501-11-13

TEST CONDITIONS
Go to D7
No
REPAIR circuit 30-HB8 (RD). TEST the
D7: CHECK FOR VOLTAGE TO THE HEATED WINDSHIELD GRID WIRES
1 Connect Heated Windshield Relay C312.
2 Disconnect Heated Windshield Grid Wires
C335 and C350.
heated windshield left-hand grid wire C335 pin
1, circuit 20S-HB12 (PK/YE), harness side and
ground.
heated windshield right-hand grid wire C350 pin
1, circuit 20S-HB25 (PK/BU), harness side and
ground.

Yes
Go to D8
No
REPAIR circuit 20S-HB12 (PK/YE) or circuit
20S-HB25 (PK/BU). TEST the system for
normal operation.
D8: CHECK THE HEATED WINDSHIELD GRID WIRE GROUND CIRCUITS
windshield ground circuits and ground.
Are the resistances less than 5 ohms?
Yes
Go to D9
No
REPAIR the heated windshield ground circuit. TEST the system for normal operation.
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501-11-14

TEST CONDITIONS
D9: CHECK THE HEATED WINDSHIELD GRID WIRES

heated windshield left-hand grid wire C335 pin
ground.
heated windshield right-hand grid wire C350 pin
ground.
Are the resistances greater than 10,000 ohms?

Yes
INSTALL a new windshield. TEST the system for normal operation.
No
D10: CHECK FOR VOLTAGE TO THE HEATED REAR WINDOW CONTROL SWITCH
Does the heated rear window control switch ON
LED illuminate?
Yes
Go to D11
No
Go to D15
D11: CHECK FOR VOLTAGE TO THE CENTRAL JUNCTION BOX (CJB) FUSE 32 (7.5A) INPUT
SIDE
1
2
3
4
5

Disconnect Fuse 32 (7.5A).
Operate the heated rear window control switch.
Measure the voltage between the CJB fuse 32
(7.5A), input side and ground.

Yes
No
REPAIR circuit 15S-HB16 (GN/OG). TEST
D12: CHECK FOR VOLTAGE TO THE HEATED WINDSHIELD CONTROL SWITCH
Does the heated windshield control switch ON
LED illuminate?
Yes
Go to D13
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501-11-15

TEST CONDITIONS
No
Go to D17
D13: CHECK FOR VOLTAGE TO THE HEATED WINDSHIELD RELAY
1
2
3
4
5

Disconnect Heated Windshield Relay C312.
Operate the heated windshield control switch.
Measure the voltage between the heated
windshield relay C312 pin 1 circuit 15S-HB7

Yes
Go to D14
No
REPAIR circuit 15S-HB7 (GN/BU). TEST the
D14: CHECK FOR CONTINUITY BETWEEN THE HEATED WINDSHIELD RELAY AND THE
GENERIC ELECTRONIC MODULE (GEM)
windshield relay C312 pin 2, circuit 31S-HB7
(BK/BU), harness side and the GEM C319 pin
12, circuit 31S-HB7 (BK/BU), harness side.

Yes
No
REPAIR circuit 31S-HB7 (BK/BU). TEST the
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501-11-16

TEST CONDITIONS
D15: CHECK FOR CONTINUITY BETWEEN THE GENERIC ELECTRONIC MODULE (GEM) AND
GROUND
1
2
3
4

Disconnect GEM C320.
Measure the resistance between the GEM
C320 pin 11, circuit 31S-HB22 (BK/GN), harness side and ground.

Yes
Go to D16
No
REPAIR circuit 31S-HB22 (BK/GN). TEST
D16: CHECK FOR CONTINUITY BETWEEN THE GEM AND THE HEATED REAR WINDOW
CONTROL SWITCH
C320 pin 12, circuit 31S-HB31 (BK/OG), harness side and the heated rear window control
switch C714 pin 4, circuit 31S-HB31 (BK/OG),
harness side.

Yes
No
Repair circuit 31S-HB21 (BK/OG). TEST the
D17: CHECK FOR VOLTAGE TO THE HEATED WINDSHIELD CONTROL SWITCH
2 Disconnect Heated Windshield Control Switch
C714.
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501-11-17

TEST CONDITIONS
windshield control switch C714 pin 11, circuit
31S-HB9 (BK/WH), harness side and ground.

Yes
Go to D18
No
Repair circuit 31S-HB9 (BK/WH). TEST the
D18: CHECK FOR CONTINUITY BETWEEN THE GENERIC ELECTRONIC MODULE (GEM) AND
THE HEATED WINDSHIELD CONTROL SWITCH
windshield control switch C714 pin 8, circuit
31S-HB6 (BK/YE), harness side and the GEM
C320 pin 9, circuit 31S-HB6 (BK/YE), harness
side.
Component Tests
Heated Rear Window Grid Wire Test
1. Using a bright lamp inside the vehicle, visually

inspect the grid wire from the outside. A
G183791 en

Yes
No
REPAIR circuit 31S-HB22 (BK/GN). TEST
broken grid conductor line will appear as a
brown spot.
2. Run the engine at idle. Set the heated rear
window control switch and lights to ON. The
heated rear window indicator light should
illuminate.
3. Working inside the vehicle with a multimeter,
contact the broad red/brown strips on the
11/2004 2005.25 Fiesta
501-11-18

TO MODEL INDEX
501-11-18

heated rear window positive lead to battery
side and negative lead to ground side. The
meter should read 10-13 volts. A lower
voltage reading indicates a loose heated rear
window ground wire connection at the heated
rear window ground wire screw.
4. Contact a ground point with the negative lead
of the multimeter. The voltage reading should
not change.
5. With the negative lead of the multimeter
grounded, touch each grid line of the heated
rear window at its pinpoint with the positive
lead. A reading of approximately six volts
indicates that the line is OK. A reading of zero
volts indicates that the line is broken between
the midpoint and the battery side of the grid
line. A reading of 12 volts indicates that the
circuit is broken between the midpoint of the
grid line and ground.
6. INSTALL a new heated rear window glass.
REFER to Liftgate Window Glass in this
section.
G183791 en
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TO MODEL INDEX
501-11-19

Glass, Frames and Mechanisms 2.0L Duratec-HE (MI4)
Mechanical
Electrical
Door window seal

Door window frame
Fuse(s)
Electrical
connector(s)
Switch(es)
Circuit(s)
step.
Symptom Chart
Symptom
Possible Sources
Action
All power windows are inopera- Driver side power window control CARRY OUT the Driver Side
tive
switch.
Wiring Diagrams.
Circuit(s).
A single power window is inoperative - driver side
Driver side power window control CARRY OUT the Driver Side
switch.
Wiring Diagrams.
Driver side front door window
regulator motor.
Circuit(s).
A single power window is inoperative - passenger side
Driver side power window control CARRY OUT the Driver Side
switch.
Wiring Diagrams.
Passenger side power window
control switch.
CARRY OUT the Passenger

Side Power Window Control
Switch Component Test. REFER
to the Wiring Diagrams.
Passenger side front door

window regulator motor.
Circuit(s).
The defrost system is inoperative Heated rear window control

switch.
G428469 en

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501-11-20

Possible Sources
Symptom
Action

switch.
Diagrams.


(GEM).
CARRY OUT the Generic Electronic Module Self-Test. REFER

to Section 419-10.[Multifunction
Electronic Modules, DIAGNOSIS
AND TESTING, Generic Electronic Module (GEM)]
Heated rear window grid wire.

Window Grid Wire Component
Heated windshield grid wire.

Circuit(s).
The defrost system will not shut Heated rear window control
off automatically
switch.


switch.
Diagrams.


(GEM).
CARRY OUT the Generic Electronic Module (GEM) Self-Test.

[Multifunction Electronic
Modules, DIAGNOSIS AND
TESTING, Generic Electronic
Module (GEM)]
Pinpoint Tests
PINPOINT TEST E: ALL POWER WINDOWS ARE INOPERATIVE
TEST CONDITIONS

E1: CHECK THE DRIVER SIDE POWER WINDOW CONTROL SWITCH LEDS
Do the driver side power window control switch
LEDs illuminate?
Yes
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TO MODEL INDEX
501-11-21

TEST CONDITIONS
No
Go to E2
E2: CHECK FOR CONTINUITY BETWEEN THE DRIVER SIDE POWER WINDOW CONTROL
SWITCH AND GROUND
2 Disconnect Driver Side Power Window Control
Switch C310.
3 Measure the resistance between the driver side

Yes
Go to E3
No
E3: CHECK FOR VOLTAGE TO THE DRIVER SIDE POWER WINDOW CONTROL SWITCH
2 Measure the voltage between the driver side
15-AJ7 (GN/BU), harness side and ground.

Yes
No
G428469 en
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TO MODEL INDEX
501-11-22

PINPOINT TEST F: A SINGLE POWER WINDOW IS INOPERATIVE - DRIVER SIDE
TEST CONDITIONS

F1: CHECK THE DRIVER SIDE POWER WINDOW CONTROL SWITCH LEDS
Does the driver side power window control
switch LED illuminate?
Yes
Go to F2
No
Go to F4
F2: CHECK FOR CONTINUITY BETWEEN THE DRIVER SIDE POWER WINDOW CONTROL
SWITCH AND THE DRIVER SIDE FRONT DOOR WINDOW REGULATOR MOTOR DOWN CIRCUIT
Switch C310.
3 Disconnect Driver Side Front Door Window
Regulator Motor C529.
32-AJ26 (WH), harness side and the driver side
front door window regulator motor C529 pin 2,
circuit 32-AJ26 (WH), harness side.

Yes
Go to F3
No
REPAIR circuit 32-AJ26 (WH). TEST the
G428469 en
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TO MODEL INDEX
501-11-23

TEST CONDITIONS
SWITCH AND THE DRIVER SIDE FRONT DOOR WINDOW REGULATOR MOTOR UP CIRCUIT
33-AJ26 (YE), harness side and the driver side
front door window regulator motor C529 pin 1,
circuit 33-AJ26 (YE), harness side.

Yes
INSTALL a new driver side front door window
regulator motor. REFER to Front Door
Window Regulator Motor in this section.
No
REPAIR circuit 33-AJ26 (YE). TEST the
SWITCH AND GROUND
Switch C310.

Yes
Go to F5
No
G428469 en
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TO MODEL INDEX
501-11-24

TEST CONDITIONS
F5: CHECK FOR VOLTAGE TO THE DRIVER SIDE POWER WINDOW CONTROL SWITCH
15-AJ7 (GN/BU), harness side and ground.

Yes
No
PINPOINT TEST G: A SINGLE POWER WINDOW IS INOPERATIVE - PASSENGER SIDE
TEST CONDITIONS

G1: DOES THE PASSENGER SIDE WINDOW OPERATE FROM THE DRIVER SIDE PASSENGER
SIDE POWER WINDOW CONTROL SWITCH
2 Operate the passenger side power window from
the driver side passenger side power window
control switch.
Does the passenger side power window operate?
Yes
REPAIR circuit 31-AJ18 (BK). REFER to the
Wiring Diagrams. TEST the system for
normal operation.
No
Go to G2
G2: CHECK THE DRIVER SIDE PASSENGER SIDE POWER WINDOW CONTROL SWITCH LED
1 Observe the driver side passenger side power
window control switch LED.
Is the driver side passenger side power window
control switch LED illuminated?
Yes
Go to G3
No
Go to G7
G428469 en
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TO MODEL INDEX
501-11-25

TEST CONDITIONS
G3: CHECK THE DOWN CIRCUIT VOLTAGE TO THE PASSENGER SIDE POWER WINDOW
CONTROL SWITCH
2 Disconnect Passenger Side Power Window
Control Switch C699.
4 Operate the driver side passenger side power
window control switch to the DOWN position.
side power window control switch C699 pin 3,
circuit 31-AJ18C (BK), harness side and
ground.

Yes
Go to G4
No
REPAIR circuit 31-AJ18C (BK). TEST the
G4: CHECK THE UP CIRCUIT VOLTAGE TO THE PASSENGER SIDE POWER WINDOW
CONTROL SWITCH
1 Operate the driver side passenger side power
window control switch to the UP position.
circuit 31-AJ18A (BK), harness side and
ground.

Yes
Go to G5
No
G428469 en
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TO MODEL INDEX
501-11-26

TEST CONDITIONS
REPAIR circuit 31-AJ18A (WH/VT). TEST
G5: CHECK FOR CONTINUITY BETWEEN THE PASSENGER SIDE POWER WINDOW CONTROL
SWITCH DOWN CIRCUIT AND THE PASSENGER SIDE FRONT DOOR WINDOW REGULATOR
MOTOR
2 Disconnect Passenger Side Front Door Window
Regulator Motor C530.
circuit 33-AJ27 (YE/VT), harness side and the
passenger side front door window regulator
motor C530 pin 1, circuit 33-AJ27 (YE/VT),
harness side.

Yes
Go to G6
No
G6: CHECK FOR CONTINUITY BETWEEN THE PASSENGER SIDE POWER WINDOW CONTROL
SWITCH UP CIRCUIT AND THE PASSENGER SIDE FRONT DOOR WINDOW REGULATOR
MOTOR
circuit 32-AJ27 (WH/VT), harness side and the
passenger side front door window regulator
motor C530 pin 2, circuit 32-AJ27 (WH/VT),
harness side.

Yes
INSTALL a new passenger side front door
window regulator motor. REFER to Front
Door Window Regulator Motor in this section.
No
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TO MODEL INDEX
501-11-27

TEST CONDITIONS
G7: CHECK FOR CONTINUITY BETWEEN THE DRIVER SIDE PASSENGER SIDE POWER
WINDOW CONTROL SWITCH AND GROUND
2 Disconnect Driver Side Passenger Side Power
Window Control Switch C311.
passenger side power window control switch
C311 pin 3, circuit 31-AJ9 (BK), harness side
and ground.

Yes
Go to G8
No
G8: CHECK FOR VOLTAGE TO THE DRIVER SIDE PASSENGER SIDE POWER WINDOW
CONTROL SWITCH
passenger side power window control switch
C311 pin 2, circuit 15-AJ9 (GN/BK), harness
side and ground.

Yes
No
REPAIR circuit 15-AJ9 (GN/BK). TEST the
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TO MODEL INDEX
501-11-28

PINPOINT TEST H: THE DEFROST SYSTEM IS INOPERATIVE
TEST CONDITIONS

H1: CHECK THE OPERATION OF THE HEATED REAR WINDOW
Does the heated rear window operate correctly?
Yes
Go to H2
No
Go to H3
H2: CHECK THE OPERATION OF THE HEATED WINDSHIELD
Does the heated windshield operate correctly?
Yes
No
Go to H7
H3: CHECK THE OPERATION OF THE HEATED REAR WINDOW CONTROL SWITCH LED
Does the heated rear window control switch
LED illuminate?
Yes
Go to H4
No
Go to H13
H4: CHECK THE OPERATION OF THE EXTERIOR MIRROR HEATING ELEMENTS
Are the exterior mirrors warm to touch?
Yes
Go to H5
No
Go to H18
H5: CHECK THE HEATED REAR WINDOW GRID GROUND CIRCUIT
2 Disconnect Heated Rear Window C561A.
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TEST CONDITIONS
rear window C561A pin 1, circuit 31-HB19 (BK),

Yes
Go to H6
No
REPAIR circuit 31-HB19 (BK). TEST the
H6: CHECK FOR VOLTAGE TO THE HEATED REAR WINDOW
1 Disconnect Heated Rear Window C561.
3 Measure the voltage between the heated rear
window C561 pin 1, circuit 31-HB19S (BK),

Yes
Carry out the Heated Rear Window Grid Wire
Component Test in this procedure. TEST the
No
REPAIR circuit 31-HB19S (BK). TEST the
H7: CHECK THE OPERATION OF THE HEATED WINDSHIELD CONTROL SWITCH LED
Does the heated windshield control switch LED
illuminate?
Yes
Go to H8
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TO MODEL INDEX
501-11-30

TEST CONDITIONS
No
Go to H19
H8: CHECK THE OPERATION OF THE HEATED WINDSHIELD RELAY
Does the heated windshield relay click?
Yes
Go to H9
No
Go to H23
H9: CHECK FOR VOLTAGE TO THE HEATED WINDSHIELD RELAY
2 Disconnect Heated Windshield Relay C312.
windshield relay C312 pin 3, circuit 30-HB8
(RD), harness side and ground.

Yes
Go to H10
No
REPAIR circuit 30-HB8 (RD). TEST the
H10: CHECK FOR VOLTAGE TO THE HEATED WINDSHIELD GRID WIRES
1 Connect Heated Windshield Relay C312.
2 Disconnect Heated Windshield Grid Wires
C335 and C350.
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TEST CONDITIONS
Heated windshield left-hand grid wire C335 pin
ground.
Heated windshield right-hand grid wire C350 pin
ground.

Yes
Go to H11
No
REPAIR circuit 20S-HB12 (PK/YE) or circuit
20S-HB25 (PK/BU). TEST the system for
normal operation.
H11: CHECK THE HEATED WINDSHIELD GRID WIRE GROUND CIRCUITS
windshield ground circuits and ground.
Yes
Go to H12
No
REPAIR the heated windshield ground circuit(s). TEST the system for normal operation.
H12: CHECK THE HEATED WINDSHIELD GRID WIRES
Heated windshield left-hand grid wire C335 pin
1, circuit 20S-HB12 (PK/YE), component side
and ground.
Heated windshield right-hand grid wire C350 pin
1, circuit 20S-HB25 (PK/BU), component side
and ground.

Yes
G428469 en
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TO MODEL INDEX
501-11-32

TEST CONDITIONS
INSTALL a new heated windshield. REFER
to Windshield Glass in this section. TEST the
No
H13: CHECK THE HEATED REAR WINDOW CONTROL SWITCH GROUND CIRCUIT
2 Disconnect Heated Rear Window Control
Switch C714.
rear window control switch C714 pin 9, circuit
31-DK1 (BK), harness side and ground.

Yes
Go to H14
No
REPAIR circuit 31-DK1 (BK). TEST the
H14: CHECK FOR VOLTAGE TO THE HEATED REAR WINDOW CONTROL SWITCH
2 Measure the voltage between the heated rear
window control switch C714 pin 5, circuit
15-DK1 (GN/YE), harness side and ground.

Yes
Go to H15
No
REPAIR circuit 15-DK1 (GN/YE). TEST the
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TO MODEL INDEX
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TEST CONDITIONS
H15: CHECK FOR CONTINUITY BETWEEN THE GEM AND THE HEATED REAR WINDOW
CONTROL SWITCH
C320 pin 12, circuit 31S-HB31 (BK/OG), harness side and the heated rear window control
switch C714 pin 4, circuit 31S-HB31 (BK/OG),
harness side.

Yes
Go to H16
No
Repair circuit 31S-HB21 (BK/OG). TEST the
H16: CHECK THE GEM HEATED REAR WINDOW CONTROL GROUND CIRCUIT FOR
CONTINUITY
C320 pin 11, circuit 31S-HB22 (BK/GN), harness side and the heated rear window control
switch C714 pin 1, circuit 31S-HB22 (BK/GN),
harness side.

Yes
Go to H17
No
Repair circuit 31S-HB22 (BK/GN). TEST the
H17: CHECK FOR CONTINUITY BETWEEN THE GEM AND GROUND
1 Connect Heated Rear Window Control Switch
C714.
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TO MODEL INDEX
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TEST CONDITIONS
C320 pin 11, circuit 31S-HB22 (BK/GN), harness side and ground.

Yes
419-10.[Multifunction Electronic Modules,
REMOVAL AND INSTALLATION, Generic
Electronic Module (GEM)] TEST the system
No
INSTALL a new heated rear window control
switch. TEST the system for normal operation.
H18: CHECK FOR VOLTAGE TO THE CENTRAL JUNCTION BOX (CJB) FUSE 32 (7.5A) INPUT
SIDE
1
2
3
4
5

Disconnect Fuse 32 (7.5A).
Measure the voltage between the CJB fuse 32
(7.5A), input side and ground.

Yes
No
REPAIR circuit 15S-HB16 (GN/OG). REFER
to the Wiring Diagrams. TEST the system for
normal operation.
H19: CHECK FOR THE POWERTRAIN CONTROL MODULE (PCM) ENGINE RUN SIGNAL
1
2
3
4
G428469 en

Disconnect GEM C319.
Ignition switch in position III.
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TO MODEL INDEX
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TEST CONDITIONS
5 Measure the voltage between the GEM C319
pin 10, circuit 15-DK20 (GN/OG), harness side
and the GEM C319 pin 8, circuit 20-PA19
(PK/BK), harness side.

Yes
Go to H20
No
Go to H25
H20: CHECK THE GEM HEATED WINDSHIELD CONTROL GROUND CIRCUIT FOR CONTINUITY
1 Disconnect Heated Windshield Control Switch
C714.
side and the heated windshield control switch
side.

Yes
Go to H21
No
REPAIR circuit 31S-HB6 (BK/YE). TEST the
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TEST CONDITIONS
H21: CHECK FOR CONTINUITY BETWEEN THE GEM AND THE HEATED WINDSHIELD
CONTROL SWITCH
C320 pin 8, circuit 31S-HB9 (BK/WH), harness
side and the heated windshield control switch
side.

Yes
Go to H22
No
REPAIR circuit 31S-HB9 (BK/WH). TEST the
H22: CHECK FOR CONTINUITY BETWEEN THE GEM AND GROUND
1 Connect Heated Rear Window Control Switch
C714.
side and ground.

Yes
419-10.[Multifunction Electronic Modules,
REMOVAL AND INSTALLATION, Generic
Electronic Module (GEM)] TEST the system
No
INSTALL a new heated windshield control
switch. TEST the system for normal operation.
G428469 en
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TO MODEL INDEX
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TEST CONDITIONS
H23: CHECK FOR VOLTAGE TO THE HEATED WINDSHIELD RELAY

1
2
3
4

Disconnect Heated Windshield Relay C312.
Measure the voltage between the heated
windshield relay C312 pin 1 circuit 15S-HB7

Yes
Go to H24
No
REPAIR circuit 15S-HB7 (GN/BU). TEST the
H24: CHECK FOR CONTINUITY BETWEEN THE HEATED WINDSHIELD RELAY AND THE GEM
windshield relay C312 pin 2, circuit 31S-HB7
(BK/BU), harness side and the GEM C319 pin
12, circuit 31S-HB7 (BK/BU), harness side.

Yes
INSTALL a new heated windshield relay.
No
REPAIR circuit 31S-HB7 (BK/BU). TEST the
H25: CHECK FOR CONTINUITY BETWEEN THE GEM AND THE PCM
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TO MODEL INDEX
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TEST CONDITIONS
C319 pin 8, circuit 20-PA19 (PK/BK), harness
side and the PCM C343 pin M10, circuit
20-PA19 (PK/BK), harness side.
Component Tests
Heated Rear Window Grid Wire Test
1. Using a bright lamp inside the vehicle, visually

inspect the heated rear window grid wire from
the outside of the vehicle. A broken heated
rear window grid wire will appear as a brown
spot at the break point.
2. Run the engine at idle.
3. Set the heated rear window control switch and
the headlamp switch to ON. The heated rear
window control switch should be illuminated.
4. Working inside the vehicle with a multimeter,
contact the multimeter positive lead to the
heated rear window grid supply side and
contact the multimeter negative lead to the
heated rear window grid ground side. A
multimeter voltage reading of between 10-13
volts is expected. A lower voltage reading
indicates a loose heated rear window ground
wire connection at the heated rear window
ground screw.
5. With the negative lead of the multimeter
grounded, touch each heated rear window
grid wire at its midpoint with the positive lead.
The multimeter should show a voltage reading
of approximately six volts indicating that the
heated rear window grid wire is OK. A
G428469 en

Yes
INSTALL a new PCM. TEST the system for
normal operation.
No
REPAIR circuit 20-PA19 (PK/BK). TEST the
multimeter voltage reading of zero volts
indicates that the heated rear window grid
wire is broken between the midpoint and the
battery side of the heated rear window grid
wire. A multimeter voltage reading of 12 volts
indicates that the heated rear window grid
wire is broken between the midpoint of the
heated rear window grid wire and ground.
6. INSTALL a new heated rear window glass.
REFER to Liftgate Window Glass in this
section.
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TO MODEL INDEX
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Windshield Glass (42 115 0)
General Equipment
4. Remove the cowl panel grille side trim

panels.
Hot air gun

Direct glazing cutter for bonded glass
Direct glazing adhesive kit
Direct glazing adhesive oven
Glazing suction cups
Removal
All vehicles
1. Remove the polyurethane (PU) adhesive
cap and heat the PU adhesive for a minimum of 30 minutes.
2. Raise the hood.

3. NOTE: Make sure that the windshield wiper
motor is in the park position.
Remove the windshield wiper arms.
G149914 en
5. Remove the cowl panel grille.

1. Remove the screws.
2. Release the retaining strip.
6. Detach the front door opening weatherstrip

from the A-pillar on both sides.
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TO MODEL INDEX
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8. Disconnect the heated windshield electrical connectors (left-hand side shown).
All vehicles
9. Lower the hood.
Vehicles with cellular phone
10. Remove the cellular phone antenna. For
419-08.
501-12.
G149914 en

13. Disconnect the interior lamp electrical

connectors and remove the interior lamp.
All vehicles
14. Remove the interior mirror.
Release the interior mirror retaining clip.
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TO MODEL INDEX
501-11-41
16. Lever open the covers to expose the

screws and remove the sun visor retaining clips.
18.
WARNING: Wear gloves and eye

protection when working with the
glass cutting tool as the cutting
operation may produce splinters.
When using the cutter wear ear
protectors. Failure to follow these
injury.
CAUTION: Make sure the cutting blades

are changed where the cutting depth
changes to avoid damage to the body and
trim panels.
NOTE: Care must be taken when cutting in the
area of the locating blocks along the lower edge of
the windshield glass.
From inside the vehicle, using a suitable
direct glazing cutter, cut the PU adhesive
to the given maximum depths.
1. 23 mm.
2. 75 mm.
3. 160 mm.
17. Detach the leading edge of the headliner

and place two blocks of suitable material
between the headliner and the roof panel
to act as spacers.
19. With the aid of another technician, use
glazing suction cups to remove the
windshield glass.
G149914 en
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TO MODEL INDEX
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20. Remove the windshield glass locating
blocks.
Discard the locating blocks.
Installation
All vehicles
1.
CAUTION: Do not touch the adhesive

surface as re-bonding will be impaired.
Carefully trim the remaining polyurethane
(PU) adhesive from the windshield glass
flange to leave approximately 1 mm of
trimmed PU adhesive adhered to the
flange.
2. Install new windshield glass locating

blocks.
3. Check the windshield glass flange for

damaged sheet metal, rust or foreign
material which may have caused, or may
cause, glass breakage.
4.
CAUTION: To make sure that the PU

adhesive cures, it is essential that all
bonding surfaces are free of moisture.
Using a hot air gun, apply warm air (25C)

to the windshield glass flange and glass
bond line to remove all traces of moisture.
5. Prepare the glass, windshield glass flange
and trimmed PU adhesive in accordance
with the instructions supplied with the PU
adhesive kit.
6. NOTE: Discard the first 100 mm of PU adhesive
as this may have a reduced working time.
NOTE: To avoid water leaks, any breakage in the
continuous bead must be overlapped by 20 mm.
Apply the PU adhesive in a continuous
bead of between 8 and 10 mm in height to
the windshield glass flange along the bond
line.
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glazing suction cups to install the
windshield glass.
Press firmly and evenly into position.
10. Remove the spacers and attach the leading edge of the headliner to the roof
panel.
11. Install the sun visor retaining clips.

8.
CAUTION: During the curing period of

the PU adhesive, the door windows
must be left open to avoid a build up of
pressure when the doors are opened
and closed.
Using suitable tape, secure the windshield

glass in the correct position until the PU
adhesive has cured.
9. If the ambient temperature falls below 10C,
use a hot air gun and apply warm air (25C)
continuously for 15 minutes (inside or outside the vehicle).
12. Install the sun visors.
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13. Install the interior mirror.

14. Connect the interior lamp electrical connectors.

17. Connect the heated windshield electrical
connectors (left-hand side shown).
Vehicles with cellular phone

18. Install the cellular phone antenna. For
419-08.
All vehicles
19. Install the A-pillar trim panels.
15. Install the interior lamp.
20. Attach the front door opening weatherstrip to the A-pillar on both sides.

16. Install the overhead console. For
501-12.
21. Raise the hood.

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22. Install the cowl panel grille.
1. Locate the retaining strip.
2. Install the screws.
23. Install the cowl panel grille side trim panels.
24. Install the windshield wiper arms.
25. Lower the hood.
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Liftgate Window Glass
General Equipment
4. Remove the liftgate window wiper motor

spindle grommet.
Hot air gun

Removal
5. Disconnect the heated liftgate window

glass electrical connectors.
3. Remove the liftgate window wiper motor.

501-16.
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Installation
6.

instructions may result in a personal
injury.
1. Carefully remove the remaining part of the

locating pegs from the liftgate window
glass flange.
2.

Carefully trim the remaining polyurethane
(PU) adhesive from the liftgate window
glass flange to leave approximately 1 mm
of trimmed PU adhesive adhered to the
flange.

trim panels.
NOTE: Some resistance may be encountered
when cutting through the glass locating pegs in
the corners of the glass.
From inside the vehicle using a suitable
direct glazing cutter, cut the PU adhesive to
the given maximum depths.
1. 22 mm.
2. 51 mm.
3. Check the liftgate window glass flange for

damaged sheet metal, rust or foreign
4.

glazing suction cups to remove the liftgate
window glass.
G149936 en

the bonding surfaces are free of
moisture.

to the liftgate window glass flange and
glass bond line to remove all traces of
moisture.
5. Prepare the glass, liftgate window glass
flange and trimmed PU adhesive in
accordance with the instructions supplied
with the PU adhesive kit.
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TO MODEL INDEX
501-11-48

continuous bead must be overlapped by 20 mm.


the liftgate window glass flange along the
bond line.
10. Connect the heated liftgate window glass


glazing suction cups to install the liftgate
window glass.
11. Install the liftgate window wiper motor

spindle grommet.
8.

and closed.
Using suitable tape, secure the liftgate
window glass in the correct position until
the PU adhesive has cured.
12. Install the liftgate window wiper motor.
Section 501-16.
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TO MODEL INDEX
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13. Install the parcel shelf.
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501-11-50

Front Door Window Glass 5-Door (42 314 0)
Removal
All vehicles
1. Remove the front door trim panel. For
501-05.
2. Connect the power window control switch
All vehicles
4. Remove the grommets.
5. Loosen the front door window glass clamp

bolts.
Align the window glass clamp bolts with the
access holes.

3. Install the window regulator handle.
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6. Detach the front door window glass from
the window glass clamp.
1. Align the window glass clamp with the
access hole.
2. Depress the locking tang.
7. NOTE: The front door window glass must be

removed towards the outside of the window
opening.
Remove the front door window glass.
1. Lift the glass.
2. Tip the glass forwards and remove the glass
from the front door.
Installation
installed from the outside of the window
opening.
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Front Door Window Glass 3-Door (42 314 0)
Removal
All vehicles
501-05.
2. Connect the power window control switch
All vehicles
4. Remove the grommets.
5. Loosen the front door window glass clamp

bolts.
Align the window glass clamp bolts with the
access holes.

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6. Detach the front door window glass from
the window glass clamps.
1. Align the window glass clamps with the
access holes.

opening.
Remove the front door window glass.
1. Lift the glass.
2. Tip the glass forwards and remove the glass
from the front door.
Installation
opening.
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Front Door Window Regulator 5-Door (42 338 0)
Removal
All vehicles
1. Remove the front door window glass. For
additional information, refer to Front Door
Window Glass - 5-Door in this section.
2. Remove the front door window regulator
motor. For additional information, refer to
Front Door Window Regulator Motor in this
section.

5. Disconnect and detach the exterior mirror
electrical connector from the door.
All vehicles
6. Remove the front door latch retaining
screws.
All vehicles
4. Disconnect the wiring harness at the
A-pillar and push it into the door.
7. Remove the front door lock cylinder cover

retaining screw and remove the front door
lock cylinder cover.
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8. Remove the exterior front door handle.
11. Push the front door lock cylinder and exterior front door handle reinforcement
plate into the door by releasing the clips.
9. Remove the exterior front door handle

gasket.
12. Remove the front door inner panel retaining bolts (power window shown).

reinforcement plate retaining nut.
G183793 en
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13. NOTE: When lifting the inner panel away from
the lower edge of the door panel, make sure
the window regulator is clear of the door panel.
Remove the front door inner panel (power
window shown).
1. Rotate the front door inner panel
counterclockwise and push it forwards.
2. Lift the front door inner panel away from the
lower edge of the door panel.
3. Pull the front door inner panel downwards to
release it.
14. Rotate the front door inner panel to

access the window regulator.
15. Remove the front door window regulator.
2. Release the retaining clips.
Installation
G183793 en
11/2004 2005.25 Fiesta
501-11-57

TO MODEL INDEX
501-11-57

Front Door Window Regulator 3-Door (42 338 0)
Removal
All vehicles
additional information, refer to Front Door
Window Glass - 5-Door in this section.
2. Remove the front door window regulator
motor. For additional information, refer to
Front Door Window Regulator Motor in this
section.
3. Disconnect the power window control
All vehicles


All vehicles
screws.
G278586 en
11/2004 2005.25 Fiesta
501-11-58

TO MODEL INDEX
501-11-58


gasket.
G278586 en

reinforcement plate retaining nut.
12. Push the front door lock cylinder and exterior front door handle reinforcement
plate into the door by releasing the clips.
13. Remove the front door inner panel retaining bolts (power window shown).
11/2004 2005.25 Fiesta
501-11-59

TO MODEL INDEX
501-11-59

14. NOTE: When lifting the front door inner panel
away from the lower edge of the door panel,
make sure the window regulator is clear of the
door panel.
Remove the front door inner panel (power
window shown).
release it.
15. Rotate the front door inner panel to

access the window regulator.
16. Remove the front door window regulator.
2. Release the retaining clips.
Installation
G278586 en
11/2004 2005.25 Fiesta
501-11-60

TO MODEL INDEX
501-11-60

Front Door Window Regulator Motor (33 782 0)
Removal
501-05.
2. Detach the speaker from the door inner
panel.
3. Remove the speaker.
4. NOTE: Support the window regulator.

Remove the window regulator motor.
2. Remove the screws.
Installation
G183794 en
11/2004 2005.25 Fiesta
501-11-61

TO MODEL INDEX
501-11-61

Rear Quarter Window Glass 5-Door (42 514 0)
General Equipment
Hot air gun
Removal
5.

injury.

trim panels.

1. 17 mm.
2. 52 mm.
3. 30 mm.
4. 70 mm.
5. 32 mm.
3. Remove the C-Pillar trim panel. For

501-05.
G183795 en
11/2004 2005.25 Fiesta
501-11-62

TO MODEL INDEX
501-11-62

glazing suction cups to remove the rear
quarter window glass.
Installation
4.


to the rear quarter window glass flange and
moisture.
5. Prepare the glass, rear quarter window
glass flange and trimmed PU adhesive in
with the PU adhesive kit.
continuous bead should be overlapped by 20 mm.
the rear quarter window glass flange along
the bond line.

locating pegs from the rear quarter window
glass flange.
2.

Carefully trim the remaining PU adhesive
from the rear quarter window glass flange
to leave approximately 1 mm of trimmed PU
adhesive adhered to the flange.
7. Use glazing suction cups to install the rear

3. Check the rear quarter window glass flange

for damaged sheet metal, rust or foreign
G183795 en
11/2004 2005.25 Fiesta
501-11-63

TO MODEL INDEX
501-11-63
8.

and closed.
12. Install the parcel shelf.
Using suitable tape, secure the rear quarter

10. Install the parcel shelf support.
11. Install the C-Pillar trim panel. For

501-05.
G183795 en
11/2004 2005.25 Fiesta
501-11-64

TO MODEL INDEX
501-11-64

Rear Quarter Window Glass 3-Door/Van (42 514 0)
All vehicles
General Equipment
Hot air gun
Removal
All vehicles
4.

injury.

trim panels.
1. 50 mm.
2. 25 mm.
3. 30 mm.
4. 20 mm.
5. 85 mm.
6. 60 mm.
3-door
501-05.[Interior Trim and Ornamentation,
REMOVAL AND INSTALLATION, B-Pillar
Trim Panel - 3-Door]
3. Remove the C-pillar trim panel. For
REMOVAL AND INSTALLATION, C-Pillar
G278587 en
11/2004 2005.25 Fiesta
501-11-65

TO MODEL INDEX
501-11-65

glazing suction cups to remove the rear

moisture.
5.
CAUTION: Make sure that the PU

adhesive contact area on the rear
quarter window glass is free of paint.
Prepare the glass, rear quarter window

glass flange and trimmed PU adhesive in
with the PU adhesive kit. For additional
section.
continuous bead should be overlapped by 20 mm.
Installation
All vehicles
locating pegs from the rear quarter window
glass flange.
2.

the rear quarter window glass flange along
the bond line.

Carefully trim the remaining PU adhesive
from the rear quarter window glass flange
to leave approximately 1 mm of trimmed PU
adhesive adhered to the flange.

glazing suction cups to install the rear
3. Check the rear quarter window glass flange

for damaged sheet metal, rust or foreign
4.

to the rear quarter window glass flange and
G278587 en
11/2004 2005.25 Fiesta
501-11-66

TO MODEL INDEX
501-11-66
8.

and closed.
Using suitable tape, secure the rear quarter

3-door
10. Install the C-pillar trim panel. For
REMOVAL AND INSTALLATION, C-Pillar
11. Install the B-pillar trim panel. For
G278587 en
11/2004 2005.25 Fiesta
501-11-67

TO MODEL INDEX
501-11-67

Rear Door Window Regulator (42 338 0)
Removal
1. Remove the rear door trim panel. For
501-05.
3. Remove the grommet.
4. Detach the rear door window glass from

access hole.
5.
CAUTION: Make sure the door window

glass is adequately supported at the
top of the window opening.
Raise the door window glass by hand and

secure using a suitable wedge or tape.
6. Close the rear door.
7. Detach the wiring harness from the B-pillar.
G183796 en
11/2004 2005.25 Fiesta
501-11-68

TO MODEL INDEX
501-11-68

B-pillar and push it into the door.
9. Open the rear door.

10. Remove the rear door latch retaining
screws.
12. Remove the exterior rear door handle.
13. Remove the exterior rear door handle

gasket.
14. Remove the exterior rear door handle reinforcement plate retaining nut.
cover retaining screw and the exterior
rear door handle cover.
G183796 en
11/2004 2005.25 Fiesta
501-11-69

TO MODEL INDEX
501-11-69

15. Push the exterior rear door handle reinforcement plate into the door by releasing
the clips.
17. NOTE: When lifting the rear door inner panel

door panel.
Remove the rear door inner panel.
1. Rotate the rear door inner panel
2. Lift the rear door inner panel away from the
3. Pull the rear door inner panel downwards to
release it.
16. Remove the rear door inner panel retaining bolts.
18. Rotate the rear door inner panel to access

the window regulator.
19. Remove the rear door window regulator.
Installation
G183796 en
11/2004 2005.25 Fiesta
501-11-70

TO MODEL INDEX
501-11-70

Rear Door Window Glass (42 315 0)
Removal
501-05.

access hole.
5.


G183797 en
11/2004 2005.25 Fiesta
501-11-71

TO MODEL INDEX
501-11-71


10. Remove the rear door latch retaining
screws.

gasket.
G183797 en
11/2004 2005.25 Fiesta
501-11-72

TO MODEL INDEX
501-11-72

the clips.

door panel.
release it.
18. NOTE: Support the rear door window glass.

Remove the tape or wedge supporting the
rear door window glass.
19. Position the rear door window glass in the
door inner panel opening.
1. Lower the window glass.
2. Rotate the window glass 90 degrees
counterclockwise.
G183797 en
11/2004 2005.25 Fiesta
501-11-73

TO MODEL INDEX
501-11-73

20. NOTE: The rear door window glass must be
opening.
Remove the rear door window glass.
1. Lift the window glass.
2. Tip the window glass forwards and remove
the window glass from the rear door.
Installation
1. NOTE: The rear door window glass must be
opening.
G183797 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
501-12-1
Instrument Panel and Console
501-12-1
SECTION 501-12 Instrument Panel and Console

CONTENTS
PAGE

Instrument Panel........................................................................................... (43 644 0)
Floor Console ............................................................................................... (43 814 0)
Overhead Console ........................................................................................ (43 813 0)
501-12-2
501-12-6
501-12-9
11/2004 2005.25 Fiesta
501-12-2

TO MODEL INDEX
501-12-2

Instrument Panel (43 644 0)
Removal
CAUTION: When removing or installing
the instrument panel, care must be taken
not to scratch or damage the instrument
panel surface.
1. Remove the passenger air bag module.
501-20A / 501-20B.
2. Remove the floor console. For additional
information, refer to Floor Console in this
section.
3. Remove the steering column. For
211-04.
4. Remove the audio unit. For additional
5. Remove the instrument cluster finish
panel.
6. Detach the instrument cluster form the instrument panel.
G92138 en

remove the instrument cluster.
9. Detach the data link connector (DLC) from

the driver side lower instrument panel.
11/2004 2005.25 Fiesta
501-12-3

TO MODEL INDEX
501-12-3

10. Detach the hazard warning control switch
from the instrument panel.

remove the hazard warning control
switch.
12. Detach the liftgate remote release control

switch from the instrument panel.
G92138 en

remove the liftgate remote release control
switch.
14. Detach the passenger air bag deactivation

(PAD) switch from the instrument panel.

remove the passenger air bag deactivation (PAD) switch.
11/2004 2005.25 Fiesta
501-12-4

TO MODEL INDEX
501-12-4

16. Remove the instrument panel outer side
trim panels.
19. Remove the instrument panel center retaining nuts.
17. Remove the instrument panel inner side

trim panels.
20. Remove the audio unit support bracket.
18. Remove the instrument panel outer retaining screws and nut (left-hand side
shown).
G92138 en
21. Detach the glove compartment striker

from the cross-vehicle beam.
11/2004 2005.25 Fiesta
501-12-5

TO MODEL INDEX
501-12-5

22. NOTE: Detach the instrument panel from the
cross-vehicle beam to gain access to the
exterior lighting control switch electrical
connector.
Disconnect the exterior lighting control
23. Remove the instrument panel.
Installation
G92138 en
11/2004 2005.25 Fiesta
501-12-6

TO MODEL INDEX
501-12-6

Floor Console (43 814 0)
Removal
All vehicles
1. Remove the power outlet socket (if
equipped).
Disconnect the power outlet socket electrical connector.
2. Remove the parking brake trim panel.
4. Remove the floor console front retaining

screws (left-hand side shown).

5. Remove the gearshift lever boot retaining
trim panel.
Detach the gearshift lever boot from the
floor console trim panel.
3. Remove the floor console side trim panels

Remove the retaining screw.
G92139 en
11/2004 2005.25 Fiesta
501-12-7

TO MODEL INDEX
501-12-7

6. Remove the gearshift lever trim panel from
the floor console.
8. Remove the floor console.
7. Remove the floor console center retaining

screws.

9. Remove the gearshift lever trim panel from
the floor console.
G92139 en
11/2004 2005.25 Fiesta
501-12-8

TO MODEL INDEX
501-12-8

10. Remove the floor console center retaining
screws.
11. Remove the floor console.
Installation
G92139 en
11/2004 2005.25 Fiesta
501-12-9

TO MODEL INDEX
501-12-9

Overhead Console (43 813 0)
Removal
All vehicles
414-01.
2. Using a suitable screwdriver, detach the
interior light from the overhead console.

4. Detach the overhead console trim panel
from the overhead console.

remove the overhead console trim panel.

remove the interior light.
Vehicles with manual roof opening panel

6. Remove the roof opening panel regulator
handle.
G92140 en
11/2004 2005.25 Fiesta
501-12-10

TO MODEL INDEX
501-12-10

7. Remove the overhead console trim panel.
All vehicles
8. Remove the overhead console front retaining screws.
10. Detach the overhead console center retaining clips.
11. Remove the overhead console.

Detach the rear retaining clip from the roof
panel.
9. Detach the overhead console front retaining clips.
Installation
G92140 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
501-14-1
Handles, Locks, Latches and Entry Systems
501-14-1
SECTION 501-14 Handles, Locks, Latches and Entry

Systems
CONTENTS
PAGE
SPECIFICATIONS
Specifications....................................................................................................................
501-14-2

Locks, Latches and Entry Systems ...................................................................................
501-14-3
501-14-3
GENERAL PROCEDURES
Remote Transmitter Programming ................................................................ (41 004 0)
501-14-4

Front Door Latch ...........................................................................................
Rear Door Latch............................................................................................
Ignition Lock Cylinder....................................................................................
Liftgate Lock Cylinder....................................................................................
Door Lock Cylinder .......................................................................................
Liftgate Latch ................................................................................................
(41 351 0)
(41 352 0)
(33 513 0)
(41 664 0)
(41 336 0)
(41 666 0)
501-14-5
501-14-12
501-14-20
501-14-22
501-14-24
501-14-29
11/2004 2005.25 Fiesta
501-14-2

TO MODEL INDEX
501-14-2
SPECIFICATIONS
Description
Door inner panel retaining bolts
Door latch retaining screws
Door window glass clamp retaining nuts
Hood latch retaining bolts
Liftgate latch retaining bolts
Liftgate latch actuator retaining bolts
G148248 en
Nm
8
12
7
20
22
5
lb-ft
9
15
16
-
lb-in
71
62
44
11/2004 2005.25 Fiesta
501-14-3

TO MODEL INDEX
501-14-3

Locks, Latches and Entry Systems
General Equipment
(418-F224)

mechanical or electrical damage
Mechanical
Electrical
Latches
Door latch
actuator(s)
Misaligned door(s)
Misaligned luggage Battery
Fuse(s)
compartment lid
Misaligned hood
Loose or corroded
electrical connectors
Door latch(es)
Keyless
entry
Actuating rod(s)
remote transmitter
Exterior door
Keyless
entry
handle(s)
remote transceiver
Door latch remote
Wiring
Harness
control(s)
Door lock cylinder(s)
Luggage
compartment lock
cylinder
Cable(s)
step.
4. Carry out the Service Test Mode, refer to the
Diagnosis and Testing procedure. REFER to
Section 419-01A / 419-01B.
system.
G29060 en
11/2004 2005.25 Fiesta
501-14-4

TO MODEL INDEX
501-14-4
GENERAL PROCEDURES
Remote Transmitter Programming (41 004 0)
1. NOTE: A maximum of four remote transmitters
can be programmed to the generic electronic
module (GEM). Programming must be done at
the same time for all the transmitters.
NOTE: To enter programming mode, first make
sure that the vehicle battery is fully charged and
the anti-theft system is not armed or triggered (if
equipped).
Close all doors to make sure conflicting
chimes do not sound during programming.
2. Turn the ignition switch from position I to
position II four times in six seconds.
3. Turn the ignition switch to position 0.
4. A chime sounds to indicate that the GEM is
in the learning mode and it is possible to
program remote transmitters.
5. Press and hold one of the buttons on the
remote transmitter until a chime sounds.
This indicates a new transmitter code has
been successfully received.
6. After each successful programming,
another 10 second learning mode is
automatically entered, up to a maximum of
four times.
7. To program additional remote transmitters,
repeat step 5.
8. The system will leave the learning mode
after the ignition switch is turned to
position III, or if no new transmitter is
programmed during the 10 seconds, or if
four remote transmitters have been
programmed.
9. NOTE: An incorrect programming procedure
does not affect the stored codes.
After successful programming, only the
new programmed transmitters will be
accepted.
10. Test all the programmed transmitters, by
activating and deactivating the
locking/unlocking functions.
G100879 en
11/2004 2005.25 Fiesta
501-14-5

TO MODEL INDEX
501-14-5

Front Door Latch (41 351 0)
Removal
501-11.



gasket.
screws.
G148249 en
11/2004 2005.25 Fiesta
501-14-6

TO MODEL INDEX
501-14-6

8. Remove the exterior front door handle reinforcement plate retaining nut.

door panel.
Remove the front door inner panel.
release it.
9. Push the front door lock cylinder and exterior front door handle reinforcement plate
into the door by releasing the clips.
12. Detach the front door latch support panel

from the front door inner panel.
10. Remove the front door inner panel retaining bolts.
G148249 en
11/2004 2005.25 Fiesta
501-14-7

TO MODEL INDEX
501-14-7

13. Disconnect the front door latch electrical
connector.
Slide the locking tab.
14. Pull the front door latch remote cable and

grommet through the front door inner
panel.

screws.
17. Slide the front door latch off the front

door latch support panel.
18. Rotate the clip clockwise to release the

exterior front door handle connecting rod.
15. Detach the front door glass runner to reveal the front door latch retaining screw.
G148249 en
11/2004 2005.25 Fiesta
501-14-8

TO MODEL INDEX
501-14-8

19. Rotate the front door latch clockwise to
release the front door lock cylinder connecting rod.
2. Rotate the front door latch counterclockwise to install the front door lock cylinder
connecting rod.
20. Remove the front door latch remote cable

from the front door latch.
3. Rotate the clip counterclockwise to install

the exterior front door handle connecting
rod.
Installation
4. Slide the front door latch onto the front

1. Install the front door latch remote cable to

the door latch.
G148249 en
11/2004 2005.25 Fiesta
501-14-9

TO MODEL INDEX
501-14-9

5. Install the front door latch retaining
screws.
8. Connect the front door latch electrical

connector.
6. Install the front door glass runner.

9. Install the front door latch support panel to
the front door inner panel.
7. Install the front door latch remote cable

and grommet to the front door inner panel.
G148249 en
11/2004 2005.25 Fiesta
501-14-10

TO MODEL INDEX
501-14-10

10. NOTE: It is necessary to install the wiring
harness into the front door before installing the
front door inner panel.
12. Install the front door inner panel retaining

bolts.
Install the front door inner panel.

1. Push the front door inner panel upwards to
locate it.
2. Lower the front door inner panel into the
bottom of the door.
3. Rotate the front door inner panel clockwise
and push it rearwards.
13. Install the exterior front door handle reinforcement plate retaining nut.
11. Pull the front door lock cylinder and exterior front door handle reinforcement plate
into the door until the clips fully engage.
14. Install the exterior front door handle

gasket.
G148249 en
11/2004 2005.25 Fiesta
501-14-11

TO MODEL INDEX
501-14-11

15. Push and hold the front door latch connecting rod downwards with a screwdriver to allow the exterior front door
handle to install.

screws.
19. Connect and attach the exterior mirror

electrical connector to the door.
16. Install the exterior front door handle.
17. Install the front door lock cylinder cover

and the front door lock cylinder cover retaining screw.
20. Install the wiring harness into the front

door and connect the wiring harness at
the A-pillar.
21. Install the front door window glass. For

501-11.
G148249 en
11/2004 2005.25 Fiesta
501-14-12

TO MODEL INDEX
501-14-12

Rear Door Latch (41 352 0)
Removal
501-05.

1. Align the window clamp with the access
hole.
5.


G148250 en
11/2004 2005.25 Fiesta
501-14-13

TO MODEL INDEX
501-14-13


10. Remove the door latch retaining screws.

G148250 en

gasket.
11/2004 2005.25 Fiesta
501-14-14

TO MODEL INDEX
501-14-14

the clips.

door panel.
release it.
18. Detach the rear door latch support panel

from the rear door inner panel.
G148250 en
11/2004 2005.25 Fiesta
501-14-15

TO MODEL INDEX
501-14-15

19. Disconnect the rear door latch electrical
connector.
22. Detach the rear door latch from the rear

20. Pull the rear door latch remote cable and

grommet through the rear door inner
panel.
23. Remove the adjustment screw to disconnect the exterior rear door handle reinforcement plate from the rear door latch
rod.
21. Detach the rear door glass runner to reveal the rear door latch retaining screw.
24. Remove the rear door latch remote cable

from the rear door latch.
G148250 en
11/2004 2005.25 Fiesta
501-14-16

TO MODEL INDEX
501-14-16

Installation
4. Install the door glass runner.
1. Install the rear door latch remote cable to

the rear door latch.
5. Install the rear door latch remote cable and

grommet to the rear door inner panel.
2. NOTE: Do not tighten the adjustment screw at
this stage.
Install the adjustment screw to connect the
exterior rear door handle reinforcement
plate to the rear door latch rod.
6. Connect the rear door latch electrical

connector.
3. Attach the rear door latch to the rear door

latch support panel.
G148250 en
11/2004 2005.25 Fiesta
501-14-17

TO MODEL INDEX
501-14-17

7. Attach the rear door latch support panel to
the rear door inner panel.

harness into the rear door before installing the
rear door inner panel.
9. Pull the exterior rear door handle reinforcement plate into the rear door until the
clips fully engage.
10. Install the rear door inner panel retaining

bolts.
Install the rear door inner panel.

1. Push the rear door inner panel upwards to
locate it.
2. Lower the rear door inner panel into the
bottom of the door.
3. Rotate the rear door inner panel clockwise
11. Install the exterior rear door handle reinforcement plate retaining nut.
G148250 en
11/2004 2005.25 Fiesta
501-14-18

TO MODEL INDEX
501-14-18

12. Install the exterior rear door handle gasket.
13. Push and hold the rear door latch connecting rod downwards with a screwdriver to allow the exterior rear door handle to install.
15. Adjust the rear door latch connecting rod.

1. Push and hold the exterior rear door handle
flush with the rear door.
2. Tighten the adjustment screw.
16. Install the exterior door handle cover and

the exterior door handle cover retaining
screw.
14. Install the exterior rear door handle.

17. Install the rear door latch retaining
screws.
G148250 en
11/2004 2005.25 Fiesta
501-14-19

TO MODEL INDEX
501-14-19

19. Install the wiring harness into the rear
the B-pillar.
24. Install the rear door trim panel. For

501-05.
20. Attach the wiring harness to the B-pillar.

22. NOTE: An audible click should be heard as the
rear door glass engages into the retaining clip.
Install the rear door glass.
23. Install the grommet.
G148250 en
11/2004 2005.25 Fiesta
501-14-20

TO MODEL INDEX
501-14-20

Ignition Lock Cylinder (33 513 0)
Removal
All vehicles
1. Detach the audio remote control from the
equipped).
locking tang.
2. Remove the audio remote control (if

equipped).
G189091 en

to the steering column upper shroud retaining
clips.
two clips, (one each side).

11/2004 2005.25 Fiesta
501-14-21

TO MODEL INDEX
501-14-21

5. Disconnect the passive anti-theft (PATS)
transceiver electrical connector.
6. Remove the PATS transceiver (steering

column multifunction switch shown

Depress the 2 detents at the top and bottom
of the housing and pull out the cylinder.
Installation
7. Turn the ignition key to position 1.

Depress the detent in the housing and pull
out the cylinder.
G189091 en
11/2004 2005.25 Fiesta
501-14-22

TO MODEL INDEX
501-14-22

Liftgate Lock Cylinder (41 664 0)
Removal
1. Remove the liftgate trim panel.
2. Detach the liftgate latch cable from the

liftgate lock cylinder retaining plate.
3. Disconnect the liftgate latch cable from the

liftgate lock cylinder actuator.
G189092 en
4. Remove the liftgate lock cylinder retaining

plate retaining screws and the liftgate lock
cylinder actuator.
5. Remove the liftgate lock cylinder retaining

plate.
Rotate the retaining plate counterclockwise.
6. Remove the liftgate lock cylinder.

Push the liftgate lock cylinder through the
liftgate.
11/2004 2005.25 Fiesta
501-14-23

TO MODEL INDEX
501-14-23

Installation
G189092 en
11/2004 2005.25 Fiesta
501-14-24

TO MODEL INDEX
501-14-24

Door Lock Cylinder (41 336 0)
Removal
501-11.



gasket.
screws.
G189093 en
11/2004 2005.25 Fiesta
501-14-25

TO MODEL INDEX
501-14-25

8. Remove the exterior front door handle reinforcement plate retaining nut.

door panel.
Remove the front door inner panel.
release it.
9. Push the front door lock cylinder and exterior front door handle reinforcement plate
into the door by releasing the clips.
12. Remove the door lock cylinder.
10. Remove the front door inner panel retaining bolts.
G189093 en
11/2004 2005.25 Fiesta
501-14-26

TO MODEL INDEX
501-14-26

Installation
1. Install the door lock cylinder.

harness into the front door before installing the
front door inner panel.
3. Pull the front door lock cylinder and exterior front door handle reinforcement plate
into the door until the clips fully engage.
4. Install the front door inner panel retaining

bolts.
Install the front door inner panel.

1. Push the front door inner panel upwards to
locate it.
2. Lower the front door inner panel into the
bottom of the door.
3. Rotate the front door inner panel clockwise
5. Install the exterior front door handle reinforcement plate retaining nut.
G189093 en
11/2004 2005.25 Fiesta
501-14-27

TO MODEL INDEX
501-14-27

6. Install the exterior front door handle gasket.
7. Push and hold the front door latch connecting rod downwards with a screwdriver
to allow the exterior front door handle to
install.
8. Install the exterior front door handle.
G189093 en
9. Install the front door lock cylinder cover

and the front door lock cylinder cover retaining screw.

screws.
11. Connect and attach the exterior mirror

electrical connector to the door.
11/2004 2005.25 Fiesta
501-14-28

TO MODEL INDEX
501-14-28

12. Install the wiring harness into the front
the A-pillar.
13. Install the front door window glass. For

501-11.
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501-14-29

Liftgate Latch (41 666 0)
Removal
1. Remove the liftgate trim panel.
4. Disconnect the liftgate latch actuator cable

from the liftgate latch actuator.
1. Push the cable from the retaining bracket.
2. Rotate the end of the cable clockwise to
release it from the liftgate latch actuator.
2. Detach the liftgate latch cable from the

liftgate lock cylinder retaining plate
5. Detach the liftgate latch from the liftgate.
3. Disconnect the liftgate latch cable from the

liftgate lock cylinder actuator.
G189094 en
6. Detach the liftgate ajar switch and remove

the liftgate latch.
11/2004 2005.25 Fiesta
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501-14-30

Installation
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501-16-1
Wipers and Washers
501-16-1
SECTION 501-16 Wipers and Washers

CONTENTS
PAGE
SPECIFICATIONS
Specifications....................................................................................................................
501-16-2

Wipers and Washers.........................................................................................................
Inspection and Checking...................................................................................................
Symptom Chart ................................................................................................................
System Check ..................................................................................................................
Component testing, LHD: .................................................................................................
Component testing, RHD: ................................................................................................
501-16-3
501-16-3
501-16-3
501-16-4
501-16-29
501-16-30
GENERAL PROCEDURES
Wiper Blade and Pivot Arm Adjustment......................................................... (32 591 0)
501-16-32

Mounting Arm and Pivot Shaft.......................................................................
Windshield Wiper Motor ................................................................................
Windshield Washer Pump.............................................................................
Windshield Washer Reservoir .......................................................................
Rear Window Wiper Motor ............................................................................
(32 554 0)
(32 524 0)
(32 624 0)
(32 622 0)
(32 530 0)
501-16-33
501-16-34
501-16-37
501-16-38
501-16-39
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Wipers and Washers
501-16-2
SPECIFICATIONS
Angle of wiper arms to windshield

Description
Angle
- 5
+ 5
+ 5
Front (LHD)
Front (RHD)
Rear
Tightening torques
Description
Nut, windshield wiper arm
Bolts, crossbrace
Suspension strut top nuts
Bolts, windshield wiper motor unit to bulkhead
Bolts, windshield wiper motor
Nuts, windshield wiper linkage
Nut, rear wiper arm
Bolts, rear wiper motor
G115921 en
Nm
18
20
25
20
12
20
15
7
lb.ft
13
15
18
15
9
15
11
-
lb.in
62
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501-16-3
Wipers and Washers
501-16-3

Wipers and Washers
Special Tool(s)
Terminal Probe Kit
29-011 A
Mechanical
Electrical
3.
Wiper blade(s)
Fuse(s)
Wiper arm shaft
Connectors
Washer reservoir
Wiring harness
Hose(s)
Washer pump
Nozzles
Wiper motor(s)
the Symptom Chart.

2. Visually check for any obvious mechanical or
electrical damage.
Symptom Chart
Symptom
Possible Sources
Action
No communication with the generic electronic module (GEM)
Data bus (ISO 9141)

(GEM)
REFER to Section
418-00.[Module Communications Network, DIAGNOSIS AND
TESTING, Communications
Network]
Wipers inoperative
Fuse
Circuit(s)
Wash/wipe system switch
Windshield wiper motor
Rear wiper motor
(GEM)
Wipers permanently switched on Circuit(s)

Rear wiper motor
(GEM)
Slow/fast wipe not working

Circuit(s)
properly (intermittent mode OK) Wash/wipe system switch
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501-16-4
Wipers and Washers
501-16-4

Possible Sources
Symptom
Action
Intermittent wipe mode not

Circuit(s)
working properly (fast/slow wipe Wash/wipe system switch
OK)
(GEM)
Wash/wipe function inoperative
Circuit(s)
(GEM)
Windshield wipers do not return Circuit(s)

to park position after switching Wash/wipe system switch
off
Rear wiper motor
(GEM)
Washer pump motor inoperative Circuit(s)

Washer pump motor
Washer fluid level warning lamp Circuit(s)

not working properly
Washer fluid level switch
Instrument cluster
REFER to Section
Instrument Cluster]
System Check
NOTE:
Use a digital multimeter for
all electrical measurements.
PINPOINT TEST A: WIPERS INOPERATIVE
TEST CONDITIONS
Is the fuse OK?
Yes
GO to A2
No
the system.
A2: CHECK THE VOLTAGE AT FUSE F46 (CJB)

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501-16-5

TEST CONDITIONS
and ground.

Yes
GO to A3
No
A3: CHECK THE VOLTAGE AT THE WASH/WIPE SYSTEM SWITCH
2 Disconnect wash/wipe system switch from
connector C361.
4 Measure the voltage between the wash/wipe
system switch, connector C361, pin 6, circuit
15-KA19 (GN/OG), wiring harness side and
ground.

Yes
GO to A4
No
wash/wipe system switch using the Wiring
A4: CHECK THE WASH/WIPE SYSTEM SWITCH
2 Check the wash/wipe system switch according
to the component test in the Wiring Diagrams.
- Perform check on wash/wipe system switch,
connector C361 at pins 4,5,6,8 and 9.
Is the wash/wipe system switch OK?
Yes
- Windshield wipers inoperative:
GO to A14
- Rear window wiper inoperative:
GO to A5
No
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Wipers and Washers
501-16-6

TEST CONDITIONS
RENEW the wash/wipe system switch.

Is the fuse OK?
Yes
GO to A6
No
the system.
1
2
3
4

and ground.

Yes
GO to A7
No
A7: READ OUT THE FAULT MEMORY
1 Connect wash/wipe system switch to connector
C361.
Yes
No
GO to A8
A8: CHECK VOLTAGE AT THE REAR WINDOW WIPER MOTOR
2 Disconnect rear window wiper motor from
connector C562.
4 SWITCH ON rear window wiper.
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Wipers and Washers
501-16-7

TEST CONDITIONS
- Vehicles not equipped with anti-theft warning
system: rear window wiper motor, connector
C562, pin 1, circuit 15S-KA28 (GN/BU), wiring
- Vehicles with anti-theft warning system: rear
window wiper motor, connector C562, pin 1,
circuit 31-KA28S (BK), wiring harness side
and ground.

Yes
GO to A9
No
GO to A10
A9: CHECK THE GROUND CONNECTION OF THE REAR WINDOW WIPER MOTOR
2 Measure the resistance between the rear window wiper motor, connector C562, pin 3, circuit
31-KA28 (BK), wiring harness side and ground.

Yes
RENEW the wiper motor.
No
circuit between the wiper motor and soldered
4 SWITCH ON rear window wiper.
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Wipers and Washers
501-16-8

TEST CONDITIONS
20, circuit 32-KA35A (WH/RD), wiring harness
side and ground.

Yes
GO to A11
No
circuit between the wash/wipe system switch
of the system.
2, circuit 15-KA30 (GN/BU), wiring harness side
and ground.

Yes
GO to A12
No
circuit between fuse F47 (CJB) and the generic electronic module (GEM) using the
the system.
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Wipers and Washers
501-16-9

TEST CONDITIONS

side and ground.

Yes
GO to A13
No
the system.
A13: CHECK THE GROUND CONNECTION FROM THE GENERIC ELECTRONIC MODULE (GEM)
2, circuit 31-DK20 (BK), wiring harness side and
ground.

Yes
No
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Wipers and Washers
501-16-10

TEST CONDITIONS
(GEM) and soldered connection S15 using
the wiring diagrams.
A14: CHECK VOLTAGE AT THE WINDSHIELD WIPER MOTOR
C361.
2 Disconnect windshield wiper motor from connector C313.
4 SWITCH ON slow wipe speed.
- LHD: windshield wiper motor, connector C313,
pin 1, circuit 15S-KA10 (GN/BK), wiring
- RHD: windshield wiper motor, connector
C313, pin 5, circuit 15S-KA10 (GN/BK), wiring

Yes
GO to A15
No
and wiper motor using the Wiring Diagrams.
A15: CHECK THE GROUND CONNECTION OF THE FRONT WIPER MOTOR
2 Measure the resistance between:
pin 2, circuit 31-KA8 (BK), wiring harness side
and ground.
C313, pin 4, circuit 31-KA8 (BK), wiring harness side and ground.

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Wipers and Washers
501-16-11

TEST CONDITIONS
Yes
No
circuit between the wiper motor and soldered
PINPOINT TEST B: WIPERS PERMANENTLY SWITCHED ON

TEST CONDITIONS
B1: READ OUT THE FAULT MEMORY
Yes
No
- Front wiper is permanently switched on:
GO to B2
- Rear window wiper permanently switched
on: GO to B10
B2: NARROW DOWN THE FAULT CONDITION

NOTE: Switch off the wiper(s)

Yes
GO to B5
No
GO to B3
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Wipers and Washers
501-16-12

TEST CONDITIONS

pin 5, circuit 15S-KA11 (GN/OG), wiring
C313, pin 1, circuit 15S-KA11 (GN/OG), wiring

Yes
GO to B4
No
RENEW the windshield wiper motor.
B4: CHECK THE WASH/WIPE SYSTEM SWITCH
connector C361.

Yes
voltage in the circuit between the wash/wipe
system switch and wiper motor using the
the system.
No
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Wipers and Washers
501-16-13

TEST CONDITIONS
B5: CHECK CIRCUIT 15S-KA10 (GN/BK) FOR SHORT TO BATTERY VOLTAGE

connector C361.

Yes
system switch and wiper motor using the
the system.
No
GO to B6
B6: CHECK FOR A SHORT TO BATTERY VOLTAGE AT THE WASH/WIPE SYSTEM SWITCH ON
CIRCUIT 15S-KA19 (GN/OG)
15S-KA19 (GN/OG), wiring harness side and
ground.

Yes
GO to B7
No
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Wipers and Washers
501-16-14

TEST CONDITIONS
B7: CHECK CIRCUIT 15S-KA19 (GN/OG) FOR SHORT TO BATTERY VOLTAGE

ground.

Yes
system switch and generic electronic module
(GEM) using the Wiring Diagrams.
No
GO to B8
B8: CHECK FOR A SHORT TO BATTERY VOLTAGE AT THE WASH/WIPE SYSTEM SWITCH ON
CIRCUIT 15S-KA14(A) (GN/BK)
15S-KA14 (GN/BK), wiring harness side and
ground.

Yes
system switch and generic electronic module
(GEM) using the Wiring Diagrams.
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Wipers and Washers
501-16-15

TEST CONDITIONS
No
GO to B9
B9: CHECK GENERIC ELECTRONIC MODULE (GEM)
2 Connect generic electronic module (GEM) to
connector C320.
ground.

Yes
No
CHECK the wash/wipe system switch according to the component check in the Wiring
Diagrams and RENEW if necessary.
NOTE: Switch off the wiper(s)
connector C562.
and ground.

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Wipers and Washers
501-16-16

TEST CONDITIONS
Yes
GO to B11
No
B11: CHECK THE WASH/WIPE SYSTEM SWITCH

connector C361
.
and ground.

Yes
GO to B12
No
B12: CHECK CIRCUIT 15S-KA28 (GN/BU) FOR SHORT TO BATTERY VOLTAGE
and ground.

Yes
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Wipers and Washers
501-16-17

TEST CONDITIONS
voltage in the circuit between the generic
electronic module (GEM) and rear wiper
motor using the wiring diagrams.
No
PINPOINT TEST C: SLOW/FAST WIPE NOT WORKING PROPERLY (INTERMITTENT MODE OK)
TEST CONDITIONS
C1: DETERMINE THE FAULT CONDITION
2 SWITCH ON slow and fast wipe speed in succession.
3 Check the wipers.
Do the wipers operate at fast speed?

Yes
Slow wipe speed inoperative: RENEW the
wash/wipe system switch.
No
GO to C2
C2: CHECK VOLTAGE AT THE WINDSHIELD WIPER MOTOR
4 SWITCH ON fast wipe speed.

Yes
RENEW the windshield wiper motor.
No
GO to C3
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Wipers and Washers
501-16-18

TEST CONDITIONS
C3: CHECK THE WASH/WIPE SYSTEM SWITCH

connector C361.
3 CHECK the wash/wipe system switch
according to the component check in the Wiring
Diagrams.
connector C361 at pins 6 and 8.
Yes
and wiper motor using the Wiring Diagrams.
No
PINPOINT TEST D: INTERMITTENT WIPE MODE NOT WORKING PROPERLY (FAST/SLOW WIPE
OK)
TEST CONDITIONS
D1: READ OUT THE FAULT MEMORY
Yes
No
GO to D2
D2: CHECK THE WASH/WIPE SYSTEM SWITCH

connector C361.
3 CHECK the wash/wipe system switch
according to the component check in the Wiring
Diagrams.
connector C361 at pins 6 and 10.
Yes
GO to D3
No
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Wipers and Washers
501-16-19

TEST CONDITIONS
D3: NARROW DOWN THE POSSIBLE CAUSES FOR THE FAULT

C361.
3 SWITCH slow wipe ON and OFF.
4 Check the wipers.
Do the wipers return to the park position after
switching them off?
Yes
GO to D4
No
15S-KA19 (GN/OG) between the wash/wipe
system switch and the generic electronic
module (GEM) using the Wiring Diagrams.
D4: CHECK THE VOLTAGE AT THE GENERIC ELECTRONIC MODULE (GEM)
4 SWITCH ON intermittent wiping.
19, circuit 15S-KA14A (GN/BK), wiring harness
side and ground.

Yes
GO to D5
No
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Wipers and Washers
501-16-20

TEST CONDITIONS
3, circuit 15-KA13 (GN/YE), wiring harness side
and ground.

Yes
GO to D6
No
generic electronic module (GEM) using the
system.
side and ground.

Yes
GO to D7
No
the system.
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Wipers and Washers
501-16-21

TEST CONDITIONS
D7: CHECK THE GROUND CONNECTION FROM THE GENERIC ELECTRONIC MODULE (GEM)
2, circuit 31-DK20 (BK), wiring harness side and
ground.

Yes
No
(GEM) and soldered connection S15 using
the wiring diagrams.
PINPOINT TEST E: WASH/WIPE FUNCTION INOPERATIVE
TEST CONDITIONS
E1: READ OUT THE FAULT MEMORY
Yes
No
GO to E2
E2: DETERMINE THE FAULT CONDITION

Is the wash/wipe function inoperative at the front
and rear?
Yes
GO to E5
No
- Windshield wipe function inoperative
(washer OK): GO to E3
- Rear wipe function inoperative (washer
OK): GO to E4
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Wipers and Washers
501-16-22

TEST CONDITIONS
E3: CHECK THE VOLTAGE AT THE GENERIC ELECTRONIC MODULE (GEM) AT CIRCUIT 32-KA6
(WH/BK)
4 SWITCH OFF wiper.
3, circuit 32-KA6 (WH/BK), wiring harness side
and ground.

Yes
No
E4: CHECK THE VOLTAGE AT THE GENERIC ELECTRONIC MODULE (GEM) AT CIRCUIT 33-KA6
(YE/BK)
4 SWITCH OFF wiper.
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Wipers and Washers
501-16-23

TEST CONDITIONS
4, circuit 33-KA6 (YE/BK), wiring harness side
and ground.

Yes
No
E5: CHECK THE GROUND CONNECTION OF THE WASH/WIPE SYSTEM SWITCH
connector C361.
3 Measure the resistance between the wash/wipe
31-KA19 (BK), wiring harness side and ground.

Yes
No
the system.
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Wipers and Washers
501-16-24

PINPOINT TEST F: WINDSHIELD WIPERS DO NOT RETURN TO PARK POSITION AFTER
SWITCHING OFF
TEST CONDITIONS
F1: DETERMINE THE CAUSE OF THE FAULT

1 Determine the cause of the fault.
Is the wiper parking function defective?
Yes
GO to F2
No
Rear window wiper not returning to the initial
position: GO to F8
F2: NARROW DOWN THE FAULT CONDITION
2 SWITCH ON intermittent wiping.
3 Check windshield wipers.
Are the windshield wipers operative in intermittent mode?
Yes
GO to F3
No
F3: READ OUT THE FAULT MEMORY
Yes
No
GO to F4
F4: CHECK VOLTAGE AT THE WINDSHIELD WIPER MOTOR
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Wipers and Washers
501-16-25

TEST CONDITIONS
pin 4, circuit 15-KA9 (GN/RD), wiring harness
side and ground.
C313, pin 2, circuit 15-KA9 (GN/RD), wiring

Yes
GO to F5
No
wiper motor using the wiring diagrams.
F5: CHECK THE WINDSHIELD WIPER MOTOR
1 Check the wiper motor according to the component check at the end of this section.
Is the wiper motor OK?
Yes
GO to F6
No
F6: CHECK THE VOLTAGE AT THE WASH/WIPE SYSTEM SWITCH
2 Connect windshield wiper motor to connector
C313.
4 SWITCH ON slow wipe speed.
6 Wipers should NOT be in the parked position.
connector C361.
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Wipers and Washers
501-16-26

TEST CONDITIONS
ground.

Yes
No
GO to F7
F7: CHECK THE VOLTAGE AT THE GENERIC ELECTRONIC MODULE (GEM) AT CIRCUIT 32-KA9
(WH/BU)
NOTE: Wiper is still NOT in the park position
3, circuit 32-KA9 (WH/BU), wiring harness side
and ground.

Yes
No
circuit between the generic electronic module
(GEM) and the wiper motor using the wiring
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Wipers and Washers
501-16-27

TEST CONDITIONS
F8: CHECK VOLTAGE AT THE REAR WINDOW WIPER MOTOR

connector C562.
system: rear wiper motor, connector C562, pin
2, circuit 15-KA28 (GN/BU), wiring harness
side and ground.
wiper motor, connector C562, pin 2, circuit
31-KA28A (BK), wiring harness side and
ground.

Yes
No
circuit between fuse F47 and the wiper motor
using the Wiring Diagrams.
PINPOINT TEST G: WASHER PUMP MOTOR INOPERATIVE
TEST CONDITIONS
G1: DETERMINE CAUSE OF FAULT

1 Determine cause of fault.
Is the front and rear washer function inoperative?
Yes
GO to G2
No
Only washer function at rear or wash/wipe
function at front: RENEW the wash/wipe
system switch. CHECK the operation of the
system.
G2: CHECK THE VOLTAGE AT THE WASHER PUMP MOTOR
NOTE: Wash/wipe system switch in the OFF position
2 Disconnect washer pump motor at front/rear
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Wipers and Washers
501-16-28

TEST CONDITIONS
4 Measure the voltage between the washer pump
motor, connector C358, pin 1, circuit 32-KA34
(WH/BK), wiring harness side and ground.

Yes
GO to G3
No
and washer pump motor using the Wiring
G3: CHECK THE VOLTAGE AT THE WASHER PUMP MOTOR
1 Measure the voltage between the washer pump
motor, connector C358, pin 2, circuit 33-KA34
(YE/BK), wiring harness side and ground.

Yes
RENEW the washer pump motor.
No
and washer pump motor using the Wiring
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Wipers and Washers
501-16-29
Component testing, LHD:
2. Check the wiper motor in the FAST WIPE

setting.
Front wiper motor.
SWITCH OFF the ignition.

Detach the connector.
Connect the test cables as described below:
Connect an external 12 V DC supply for a
minimum current of 10 A (alternatively use a
fused auxiliary cable) to the vehicle battery.
1. Check the wiper motor in the SLOW WIPE
setting.
Connect the positive terminal of the voltage

supply to the positive terminal of the digital
multimeter.
Connect the negative terminal of the voltage
supply to the wiper motor, pin 2, or to the wiper
motor housing.
Connect the negative terminal of the digital
multimeter to the wiper motor, pin 5.
The wiper motor runs at fast wipe speed.
Measure the current

multimeter.
motor housing.
The wiper motor runs at slow wipe speed.
Is the reading on the digital multimeter approx. 2.2

A?
If yes, GO TO 3.
If not, RENEW the wiper motor.
3. Check the wiper motor in the PARK
POSITION
Measure the current

A?
If yes, GO TO 2.
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501-16-30

Measure the resistance at the windshield wiper
motor between pin 3 and pin 2 (or the housing of
the wiper motor).

If yes, GO TO 4.
4. Check the park position of the wiper motor

supply to the wiper motor, pin 4.
Connect a bridging cable to the wiper motor
between pins 1 and 3.
Check the condition
Does the wiper motor return to the PARK

POSITION?
If yes then the wiper motor is OK.
If not, RENEW the windshield wiper motor.
Component testing, RHD:

Front wiper motor.
SWITCH OFF the ignition.

Detach the connector.
Connect the test cables as described below:
Connect an external 12 V DC supply for a
minimum current of 10 A (alternatively use a
fused auxiliary cable) to the vehicle battery.
1. Check the wiper motor in the SLOW WIPE
setting.

multimeter.
motor housing.
The wiper motor runs at slow wipe speed.
Measure the current

A?
If yes, GO TO 2.
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501-16-31

2. Check the wiper motor in the FAST WIPE
setting.
If yes, GO TO 4.
4. Check the park position of the wiper motor

multimeter.
motor housing.
The wiper motor runs at fast wipe speed.
Measure the current

A?
If yes, GO TO 3.

Connect a bridging cable to the wiper motor
between pins 5 and 3.
Check the condition
Does the wiper motor return to the PARK

POSITION?
If yes then the wiper motor is OK.
If not, RENEW the windshield wiper motor.

3. Check the wiper motor in the PARK
POSITION
Measure the resistance at the windshield wiper

motor between pin 3 and pin 4 (or the housing of
the wiper motor).

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501-16-32
GENERAL PROCEDURES
Wiper Blade and Pivot Arm Adjustment (32 591 0)
Special Tool(s)
Aligner, Wiper Arm
501-027 (32-006)
4. NOTE: Lift the special tool away from the glass

when correcting the angle, in order to prevent
damage.
Using the special tool, check and adjust the
wiper arm. For additional information, refer
to Specifications in this section.
Using an open-ended wrench on the special
tool, adjust the angle.
Adjustment
1.
CAUTION: Make sure that the wiper

motor is in the park position.
Remove the wiper blade.

2. Insert the wiper arm in the special tool and
place the special tool on the windshield.
3. NOTE: All three support points of the special
tool must be in contact with the glass.
Using the special tool, read off the angle
between the wiper arm and the windshield.
6. Install the wiper blade.
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Mounting Arm and Pivot Shaft (32 554 0)
Removal
1. Remove windshield wiper motor. For
additional information, refer to Windshield
Wiper Motor in this section.
2. Unscrew and remove the nuts from the
windshield wiper linkage.
Remove the upper rubber bushes together
with the washers.
3. Remove the windshield wiper linkage.
Installation
order.
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Windshield Wiper Motor (32 524 0)
Removal
1.
CAUTION: Ensure that the wiper motor

is in the park position.
4.
CAUTION: Do not raise the vehicle.

Remove the suspension strut nuts.
1. Discard the retaining nuts.
Remove the windshield wiper arms.
2. Remove the air cowl grille.
3. Remove the water guide.
G105817 en
5. Detach the cross brace from the bracket for

the windshield wiper motor assembly.
6. Remove the bolts from the bracket for the

windshield wiper motor assembly.
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501-16-35

7. Detach the windshield wiper motor
assembly.
1. Pull the cross brace to one side.
2. Lift up the windshield wiper motor assembly.
10. Turn the windshield wiper motor lever

arm clockwise.

bracket retaining bolt.
assembly.
Disconnect the windshield wiper motor
12. Remove the windshield wiper motor.
9. Detach the windshield wiper linkage from

the windshield wiper motor lever arm.
G105817 en
11/2004 2005.25 Fiesta
501-16-36

TO MODEL INDEX
Wipers and Washers
501-16-36

Installation
1.
CAUTION: Move the windshield wiper

motor to park position before installing
the wiper arms.
NOTE: Install new suspension strut nuts.
Install the components in the reverse
order.
G105817 en
11/2004 2005.25 Fiesta
501-16-37

TO MODEL INDEX
Wipers and Washers
501-16-37

Windshield Washer Pump (32 624 0)
Removal
2. Disconnect the connector from the windshield washer pump.
Installation
1. NOTE: Coat the rubber seal on the windshield
washer pump with soap prior to installation.
Install the components in reverse order.
3. Disconnect the hoses from the windshield

washer pump.
4. Remove the windshield washer pump.
G105818 en
11/2004 2005.25 Fiesta
501-16-38

TO MODEL INDEX
Wipers and Washers
501-16-38

Windshield Washer Reservoir (32 622 0)
Removal
1. Remove the upper bolt on the windshield
washer fluid reservoir.

5. Disconnect the multiplug from the windshield washer pump.
2. Remove the centre bolt on the windshield

6. Remove the washer reservoir.
3. Disconnect the hoses from the windshield

Installation
G105819 en
11/2004 2005.25 Fiesta
501-16-39

TO MODEL INDEX
Wipers and Washers
501-16-39

Rear Window Wiper Motor (32 530 0)
Removal
1.
CAUTION: Check that the wiper motor

is in the parked position.
4. Remove the rear wiper motor.
Remove the rear wiper arm.
Installation
2. Remove the tailgate trim panel.
2. Disengage the clips.
1.
CAUTION: Move the wiper motor to the

parked position before installing the
wiper arm.
Install the components in reverse order.
3. Disconnect the rear wiper motor electrical

connector.
G98979 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
501-19-1
Bumpers
501-19-1
SECTION 501-19 Bumpers

CONTENTS
PAGE
SPECIFICATIONS
Specifications....................................................................................................................
501-19-2

Rear Bumper Cover ...................................................................................... (43 447 0)
Front Bumper Cover...................................................................................... (43 427 0)
Front Bumper ................................................................................................ (43 423 0)
501-19-3
501-19-10
501-19-13
11/2004 2005.25 Fiesta
501-19-2

TO MODEL INDEX
Bumpers
501-19-2
SPECIFICATIONS
Item
Front bumper retaining bolts
Radiator grille opening panel reinforcement retaining bolts
Rear bumper retaining bolts
Fender splash shield retaining screws
Bumper cover to fender retaining screws
Radiator support panel retaining bolts
G152587 en
Nm
25
10
lb-ft
18
7
lb-in
-
20
3
3
20
15
15
27
27
-
11/2004 2005.25 Fiesta
501-19-3

TO MODEL INDEX
Bumpers
501-19-3

Rear Bumper Cover (43 447 0)
General Equipment
4. Detach the bumper cover from the fender.

Remove the retaining screw on both sides.
Electric hand drill

Hole cutter 29 mm
Removal
All vehicles
1. Using a suitable electric hand drill, remove
the rivets.
5. Remove the pushpin retainers.

100-02.
3. Detach the bumper cover from the fender
splash shield on both sides.
G92157 en
11/2004 2005.25 Fiesta
501-19-4

TO MODEL INDEX
Bumpers
501-19-4

Vehicles with parking aid
7. NOTE: With the aid of another technician,
support the bumper cover.
NOTE: If the original sensor covers and housings
are to be installed, remove them from the bumper
cover.
Remove the parking aid sensors.
3. Remove the sensor.
8. Detach the parking aid sensor wiring harness from the bumper cover.
G92157 en
All vehicles
9. Remove the bumper cover.
Installation
Vehicles with parking aid
1. Attach the bumper cover to the fender.
Install the retaining screw on both sides.
2. NOTE: Use the templates supplied with the

manufacturers instructions.
NOTE: Templates shown for reference.
Cut out the parking aid sensor position
templates.
1. Left-hand side outer template.
2. Left-hand side inner template.
3. Right-hand side inner template.
4. Right-hand side outer template.
11/2004 2005.25 Fiesta
501-19-5

TO MODEL INDEX
Bumpers
501-19-5
3. NOTE: Bumper cover shown removed for

clarity.
NOTE: Note the position of the upper and lower
edges of the templates.
NOTE: Positional tolerance 5 mm.
Using suitable tape, secure the parking aid
sensor templates to the bumper cover as
shown.
1. Left-hand side outer template.
2. Left-hand side inner template.
3. Right-hand side inner template.
4. Right-hand side outer template.
G92157 en
11/2004 2005.25 Fiesta
501-19-6

TO MODEL INDEX
Bumpers
501-19-6
4. Using a suitable center punch and hammer,

mark the position of the parking aid sensor
location holes.
5. NOTE: Bumper cover shown removed for
clarity.
6. Using a suitable round file, cut the parking

aid sensor cover location grooves in the
bumper cover as shown (+0.5 mm, 0.0
mm).
Using a suitable electric hand drill and a 29

mm hole cutter, cut the bumper cover
(+1mm, -0.0 mm).
1. Left-hand side outer hole.
2. Left-hand side inner hole.
3. Right-hand side inner hole.
4. Right-hand side outer hole.
7. Detach the bumper cover from the fender.

Remove the retaining screw on both sides.
G92157 en
11/2004 2005.25 Fiesta
501-19-7

TO MODEL INDEX
Bumpers
501-19-7

8. Attach the parking aid sensor wiring har-
9. NOTE: Make sure the parking aid sensor

covers are installed flush with the bumper
cover.
ness to the bumper cover.
10. Install the parking aid sensor rings.
Install the parking aid sensor covers

G92157 en
11/2004 2005.25 Fiesta
501-19-8

TO MODEL INDEX
Bumpers
501-19-8

11. Install the parking aid sensors.
1. Install the housing.
3. Install the clamp.
4. Install the sensor.
All vehicles
100-02.
14. Install the bumper cover.
Install the pushpin retainers.
15. Attach the bumper cover to the fender.

Install the retaining screw on both sides.
12. NOTE: With the aid of another technician,

support the bumper cover.
Connect the parking aid sensor electrical
connectors.
16. Attach the bumper cover to the fender

splash shield on both sides.

G92157 en
11/2004 2005.25 Fiesta
501-19-9

TO MODEL INDEX
Bumpers
501-19-9

18. Using a suitable blind rivet gun-hand, install new rivets.
G92157 en
11/2004 2005.25 Fiesta
501-19-10

TO MODEL INDEX
Bumpers
501-19-10

Front Bumper Cover (43 427 0)
General Equipment
5. Detach the bumper cover from the fender

on both sides.
Drill bit 5 mm
Electric hand drill
Removal
6. Disconnect the fog lamp electrical connectors (if equipped).
2. Remove the headlamps. For additional

100-02.
4. Detach the fender splash shield from the
bumper cover on both sides.
G149915 en
7. Remove the bumper cover.
11/2004 2005.25 Fiesta
501-19-11

TO MODEL INDEX
Bumpers
501-19-11

8. Using a suitable screwdriver, remove the
retaining clips.
2. NOTE: Use the clips supplied with the

installation kit.
Install the retaining clips.
9. Remove the air deflector.

Detach the clips.
3. Using a suitable electric hand drill and a

drill bit 5 mm, drill the holes through the
bumper cover and the air deflector as
shown.
Installation
1. Install the air deflector.
Attach the clips.
4. NOTE: Make sure the rivets are installed from

below.
NOTE: Use the rivets supplied with the installation
kit.
Using a suitable blind rivet gun-hand, install the rivets.
G149915 en
11/2004 2005.25 Fiesta
501-19-12

TO MODEL INDEX
Bumpers
501-19-12

5. Install the bumper cover.
6. Connect the fog lamp electrical connectors

(if equipped).
8. Attach the fender splash shield to the

bumper cover on both sides.

10. Install the headlamps. For additional
7. Attach the bumper cover to the fender on

both sides.
G149915 en
11/2004 2005.25 Fiesta
501-19-13

TO MODEL INDEX
Bumpers
501-19-13

Front Bumper (43 423 0)
General Equipment
4. Remove the radiator air deflectors.
Transmission jack
Wooden block
Removal
additional information, refer to Front
Bumper Cover in this section.
2. Detach the fog lamp wiring harness from
the bumper (if equipped).
5. Detach the bumper from the radiator grille
opening panel reinforcement.
3. Using a suitable transmission jack and

wooden block, support the radiator.
6. Remove the radiator support panel (if
equipped).
Remove the radiator support panel retaining
G152588 en
11/2004 2005.25 Fiesta
501-19-14

TO MODEL INDEX
Bumpers
501-19-14

7. Remove the bumper.
Installation
G152588 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
501-20A-1
Safety Belt System
501-20A-1
SECTION 501-20A Safety Belt System

CONTENTS
PAGE
SPECIFICATIONS
Specifications...................................................................................................................
501-20A-2

Safety Belt System...........................................................................................................
Principles of Operation ....................................................................................................
Component Test..............................................................................................................
501-20A-3
501-20A-3
501-20A-3
501-20A-4

Safety Belt Buckle and Pretensioner ............................................................. (40 232 0)
Rear Center Safety Belt Retractor....................................................................................
Safety Belt Shoulder Height Adjuster ............................................................ (40 225 0)
Front Safety Belt Retractor 5-Door ........................................................... (40 222 0)
Front Safety Belt Retractor Vehicles Built Up To: 11/2004 3-Door ............ (40 222 0)
Front Safety Belt Retractor Vehicles Built From: 11/2004 3-Door ............. (40 222 0)
Rear Safety Belt Retractor 5-Door ............................................................ (40 248 0)
Rear Safety Belt Retractor 3-Door ............................................................ (40 248 0)
Safety Belt Retractor and Pretensioner 5-Door............................................................
Safety Belt Retractor and Pretensioner 3-Door............................................................
501-20A-6
501-20A-7
501-20A-9
501-20A-10
501-20A-12
501-20A-13
501-20A-14
501-20A-15
501-20A-16
501-20A-19
11/2004 2005.25 Fiesta
501-20A-2

TO MODEL INDEX
Safety Belt System
501-20A-2
SPECIFICATIONS
Item
Safety belt upper anchor retaining bolts
Safety belt lower anchor retaining bolts
Front safety belt retractor retaining bolts
Rear safety belt retractor retaining bolts
Rear center safety belt retaining nut
Safety belt buckle retaining bolt
Safety belt buckle and pretensioner retaining bolt
Safety belt shoulder height adjuster retaining bolts
Rear safety belt buckle retaining bolts
Rear seat backrest latch bracket retaining nuts
G149922 en
Nm
40
40
35
40
47
47
47
40
55
23
lb-ft
30
30
26
30
35
35
35
30
41
17
lb-in
-
11/2004 2005.25 Fiesta
501-20A-3

TO MODEL INDEX
Safety Belt System
501-20A-3

Safety Belt System
WARNING: All safety belt components
including retractors, buckles, front safety
belt buckle support assemblies (slider
bar), child safety seat tether brackets and
attaching hardware in use during a
collision must be removed and new
components installed. New safety belt
components should also be installed
where safety belts not in use during a
collision, are inspected and found to be
damaged or operate incorrectly. Failure
personal injury.
Vehicles equipped with the supplemental restraint
system (SRS) are equipped with a driver safety
belt retractor and pretensioner and a passenger
safety belt buckle and pretensioner. The safety
belt pretensioners are controlled as part of the
SRS. REFER to Section 501-20A / 501-20B. The
rear seat safety belt buckles are mounted directly
to the floor pan underneath the rear seat cushion.
When the ignition is turned on the RUN position
the SRS warning indicator will illuminate for three
seconds. If the SRS, including the safety belt
electrical system, is operating correctly the SRS
warning indicator will be extinguished. If a fault is
detected the SRS warning indicator will generate
a lamp fault code (LFC).
The safety belt retractor, mounted within the base
of the B-pillar, incorporates a torsion bar load
limiting device. The device consists of a retractor
reel which is mounted onto a spindle (torsion bar)
which, once the sensor has locked the retractor
reel and predetermined load is applied, twists and
pays out additional webbing into the system. The
deceleration force required to initiate this
sequence is approximately the same as that
required to initiate air bag deployment. The torsion
bar load limiting device will only react if the safety
belt is in use at the time of impact.
Rear seat safety belt retractors do not use this
type of retractor, they are equipped with a
conventional retractor.
Emergency Locking Retractor (ELR)
The retractors in all seat positions feature ELR.

The ELR is part of the safety belt system that in
normal operation allows free movement of the
belted occupant. In an emergency the ELR will
lock, preventing webbing payout and hence
forward movement of the occupant. Locking may
be achieved by one of two mechanisms:
Vehicle Motion Sensor (VMS)
VMS is operated by sudden deceleration of the

vehicle or excessive tilt. Once operated the VMS
causes a locking pawl to be engaged, thus locking
the retractor, preventing webbing payout. When
the vehicle is stationary, the VMS stabilizes,
causing the pawl to disengage and unlock the
retractor, allowing webbing payout.
Webbing Motion Sensor (WMS)
The ELR WMS is operated by rapid acceleration

of the webbing. Once operated, it causes a locking
pawl to be engaged thus locking the retractor.
Webbing payout is prevented in the same manner
as VMS.
Mechanical
3.
Safety belt retractor

Safety belt buckle and pretensioner
Safety belt retractor and pretensioner
stop.
Symptom Chart
Symptom
Normal mode - occupant restraint system inoperative.
G152589 en
Possible Sources
Safety belt retractor.
Action
CARRY OUT the Safety Belt
11/2004 2005.25 Fiesta
501-20A-4

TO MODEL INDEX
Safety Belt System
501-20A-4
Component Test
Poor Retraction
If a safety belt does not retract correctly, check

that the anchor covers and trim bezels are
correctly installed and not rubbing against the
safety belt webbing. Where necessary, check that
the safety belt webbing is not rubbing at one end
of the retractor cover slot and, if so, correct by
loosening the retaining bolt, aligning the retractor
to centralize the safety belt webbing and retighten
the bolt.
The safety belts are dual sensitive which means
that they have:
a vehicle motion sensor, which locks the
safety belt webbing under braking, cornering,
on steep hills and in adverse camber
conditions.
a webbing motion sensor, which locks when
the safety belt webbing is quickly extracted.
Both systems should be fully operational and can
be checked by the tests below:
Vehicle Motion Sensor Test
Either of the following two procedures may be

used to check correct operation of the vehicle
motion sensor. Both methods require two
technicians but note that technicians of larger than
normal build should not be asked to conduct these
tests. This is to avoid the possibility of a fully
unrolled safety belt webbing being mistaken for a
correctly locked safety belt retractor.
Test Method 1 (braking)
WARNING: It is important that during this

test, the driver and passenger allow the
safety belts to provide the restraint and
do not attempt to anticipate the sudden
deceleration. The steering wheel should
not be used as a brace. However, both
driver and passenger should prepare
themselves for the possibility that the
safety belt will not lock. The passenger
should hold their hands in front of them,
just clear of the instrument panel or front
seat backrest, depending on which safety
belt is being tested. Failure to follow
injury.
G152589 en
Select for this test a quiet or private stretch of

road. Make sure that the road is clear and that
full visibility is maintained at all times.
Both driver and passenger should adopt a
normal, comfortable seating position. Both
occupants should wear the safety belts and
the safety belt webbing must be correctly
adjusted, with no slack.
Proceed at a speed of 10 km/h (6 mph). Do not
exceed 10 km/h (6 mph) for this test.
Apply the foot brake sharply to stop the vehicle.
If the vehicle motion sensitive lock mechanism
is operating correctly, the safety belt webbing
will lock and restrain the wearer.
Conduct the test twice in each front and rear
passenger seat position.
Any safety belt retractor which does not
restrain the wearer during this test must not be
reused. A new safety belt must be installed.
Test Method 2 (turning circle)
This method requires a flat open area of private

road, sufficient for the vehicle to be driven in a
continuous circle on full steering lock.
The driver should wear the safety belt
provided and the belt webbing must be
correctly adjusted, with no slack.
The passenger should occupy a rear seat with
the safety belt correctly adjusted, with no
slack.
Start the engine and, with the steering on full
right-hand lock, drive the vehicle in a
continuous circle at 16 km/h (10mph). Do not
exceed 16 km/h (10 mph) for this test.
When the speed is stable, the passenger
should attempt to slowly extract the safety belt
webbing from each safety belt retractor in turn.
If the vehicle motion sensitive lock mechanism
is operating correctly, it will not be possible to
extract the webbing.
Any safety belt retractor from which it is
possible to extract the webbing during this test
must not be used. A new safety belt must be
installed.
Static Test
With the vehicle stationary and on level ground

take firm hold of the safety belt webbing (on the
tongue side of the upper safety belt anchor) and
11/2004 2005.25 Fiesta
501-20A-5

TO MODEL INDEX
Safety Belt System
501-20A-5

pull out quickly. The retractor should lock within
0.25 meter (10 inches), preventing further
webbing payout. Any safety belt retractor from
which it is possible to extract further webbing must
not be used. A new safety belt must be installed.
G152589 en
11/2004 2005.25 Fiesta
501-20A-6

TO MODEL INDEX
Safety Belt System
501-20A-6

Safety Belt Buckle and Pretensioner (40 232 0)
Removal
(SRS) component. Failure to follow this
501-10.[Seating, REMOVAL AND
INSTALLATION, Front Seat]
2.
Installation
other SRS component. Failure to follow
injury.
CAUTION: Note the position and

routing of the safety belt buckle and
pretensioner wiring harness to aid
installation. An incorrectly routed
wiring harness may lead to the wiring
harness becoming damaged on the
seat mechanism.
Detach the safety belt buckle pretensioner
electrical connector from the seat frame.
3. Remove the safety belt buckle and pretensioner.
G112963 en
11/2004 2005.25 Fiesta
501-20A-7

TO MODEL INDEX
Safety Belt System
501-20A-7

Rear Center Safety Belt Retractor
Removal
1. Fold the rear seat cushion forwards.
2. Detach the center safety belt and buckle
lower anchor from the floor pan.
4. Remove the center safety belt webbing trim

panel.
1. Raise the front of the trim panel.
2. Detach the trim panel from the seat
backrest.
trim panel.
3. Remove the center safety belt retractor

cover.
5. Detach the center safety belt retractor from
the rear seat backrest.
G112964 en
11/2004 2005.25 Fiesta
501-20A-8

TO MODEL INDEX
Safety Belt System
501-20A-8

6. NOTE: Note the backrest latch cable position
on the safety belt retractor to aid installation.
Remove the rear center safety belt
retractor.
1. Slide the backrest latch outer cable to the
side to detach it from the safety belt
retractor.
2. Detach the backrest latch inner cable from
the safety belt retractor.
Installation
1.

webbing, a new safety belt must be
installed. Failure to follow this
injury.
CAUTION: Make sure a webbing retainer
is fitted at least 200 mm towards the
safety belt retractor from the webbing
stop.
belt retractor and interlock.
G112964 en
11/2004 2005.25 Fiesta
501-20A-9

TO MODEL INDEX
Safety Belt System
501-20A-9

Safety Belt Shoulder Height Adjuster (40 225 0)
Removal
from the B-pillar.
4.

is detached or removed.
Detach the safety belt upper anchor from
the safety belt shoulder height adjuster.

5. Remove the safety belt shoulder height

adjuster.
Installation
1. NOTE: Make sure the safety belt shoulder
height adjuster locking control is correctly
located on the safety belt shoulder height
adjuster.
G112965 en
11/2004 2005.25 Fiesta
501-20A-10

TO MODEL INDEX
Safety Belt System
501-20A-10

Front Safety Belt Retractor 5-Door (40 222 0)
Removal
from the B-pillar.

floor panel.



the floor panel.
the anchor plate.
G149923 en
11/2004 2005.25 Fiesta
501-20A-11

TO MODEL INDEX
Safety Belt System
501-20A-11

6. Remove the cowl side trim panel.
9.
CAUTION: The safety belt retractor

retaining bolt must only be used five
times.
NOTE: After removal, stamp the safety belt
retractor retaining bolt with a center punch to
indicate usage.
Remove the front safety belt retractor.
1. Remove the bolt.
2. Lift the retractor to detach the locating tang.
7.

Installation
1.
8. Detach the guide loop from the B-pillar.

1. Rotate the guide clockwise.
2. Slide the guide downwards.
G149923 en
CAUTION: Make sure the safety belt

retractor locating tang is correctly
located.

times, inspect the markings on the
retaining bolt and install a new retaining
bolt if necessary.
NOTE: Make sure the safety belt shoulder height
adjuster locking control is correctly located on the
safety belt shoulder height adjuster.
11/2004 2005.25 Fiesta
501-20A-12

TO MODEL INDEX
Safety Belt System
501-20A-12

Front Safety Belt Retractor Vehicles Built Up To: 11/2004 3-Door (40 222 0)
Removal
2.
4.

times.
indicate usage.
Remove the safety belt retractor.
1. Remove the bolt.

Installation
1.
CAUTION: Make sure that the safety

belt retractor locating tang is correctly
located.

times, inspect the markings on the safety
belt retractor retaining bolt and install a
new safety belt retractor retaining bolt if
necessary.
NOTE: Make sure that the safety belt shoulder
height adjuster locking control is correctly located
on the safety belt shoulder height adjuster.
G278593 en
11/2004 2005.25 Fiesta
501-20A-13

TO MODEL INDEX
Safety Belt System
501-20A-13

Front Safety Belt Retractor Vehicles Built From: 11/2004 3-Door (40 222 0)
Removal
2.
4.
CAUTION: The front safety belt

retractor retaining bolt must only be
used five times.
NOTE: After removal, stamp the front safety belt
indicate usage.
Remove the front safety belt retractor.
1. Remove the front safety belt retractor
retaining bolt.
2. Lift the front safety belt retractor to detach
the locating tang.
CAUTION: The retaining bolt securing

the front safety belt upper anchor is
held captive by a paper washer. The
retaining bolt, spacer and paper
washer must remain on the front safety
belt upper anchor at all times when the
front safety belt is detached or
removed.
Detach the front safety belt upper anchor
from the B-pillar.
Installation
1.
3. Detach the front safety belt guide from the
B-pillar.
1. Rotate the front safety belt guide clockwise.
2. Slide the front safety belt guide downwards.
CAUTION: Make sure that the front

safety belt retractor locating tang is
correctly located.
CAUTION: The front safety belt retractor
times, inspect the markings on the front
safety belt retractor retaining bolt and
install a new front safety belt retractor
retaining bolt if necessary.
G428464 en
11/2004 2005.25 Fiesta
501-20A-14

TO MODEL INDEX
Safety Belt System
501-20A-14

Rear Safety Belt Retractor 5-Door (40 248 0)
Removal
1. Remove the C-pillar trim panel. For
501-05.
2.

Installation
1.

retractor locating tangs are correctly
located.

the D-pillar.
3. Remove the rear safety belt retractor.

2. Lift the retractor to detach the locating
tangs.
G149924 en
11/2004 2005.25 Fiesta
501-20A-15

TO MODEL INDEX
Safety Belt System
501-20A-15

Rear Safety Belt Retractor 3-Door (40 248 0)
Removal
2. Detach the safety belt upper anchor from
the C-pillar.
1. Remove the bolt cover.
2. Remove the bolt.
5. Remove the rear safety belt retractor trim

cover.
6. Remove the rear safety belt retractor.

1. Remove the bolt.
2. Lift the retractor to detach the locating
tangs.
3. Fold the seat backrest forwards.
Installation
1.

retractor locating tangs are correctly
located.
G284268 en
11/2004 2005.25 Fiesta
501-20A-16

TO MODEL INDEX
Safety Belt System
501-20A-16

Safety Belt Retractor and Pretensioner 5-Door
Removal
personal injury.

floor panel.
the floor panel.
the anchor plate.
WARNING: Always wear safety glasses

when working on an air bag equipped
vehicle and when handling an air bag
module. Failure to follow this instruction
personal injury.
414-01.
from the B-pillar.


G149925 en
11/2004 2005.25 Fiesta
501-20A-17

TO MODEL INDEX
Safety Belt System
501-20A-17


8.

10. Disconnect the safety belt retractor pretensioner electrical connector.

G149925 en
11/2004 2005.25 Fiesta
501-20A-18

TO MODEL INDEX
Safety Belt System
501-20A-18
11.

and pretensioner retaining bolt must
only be used five times.
retractor and pretensioner retaining bolt with a
center punch to indicate usage.
Remove the safety belt retractor and
pretensioner.
1. Remove the bolt.
2.
WARNING: In the event of a frontal

impact in which the front air bag
module(s) or safety belt
pretensioner(s) are deployed, a new
brake pedal must be installed. Failure
personal injury.
Install a new brake pedal if necessary. For
206-06.
Installation
1.

located.
CAUTION: The safety belt retractor and

pretensioner retaining bolt must only be
used five times, inspect the markings on
the retaining bolt and install a new
G149925 en
11/2004 2005.25 Fiesta
501-20A-19

TO MODEL INDEX
Safety Belt System
501-20A-19

Safety Belt Retractor and Pretensioner 3-Door
Removal
personal injury.


personal injury.
414-01.
2. Remove the rear quarter trim panel. For
501-05.
G278594 en
5.

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Safety Belt System
501-20A-20

8.

pretensioner retaining bolt must only
be used five times.
retractor and pretensioner retaining bolt with a
center punch to indicate usage.
Remove the safety belt retractor and
pretensioner.
1. Remove the bolt.
7. Disconnect the safety belt retractor pretensioner electrical connector.
Installation
1.

located.

pretensioner retaining bolt must only be
used five times, inspect the markings on
the retaining bolt and install a new
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501-20B-1
Supplemental Restraint System
501-20B-1
Page 1 of 2
SECTION 501-20B Supplemental Restraint System

CONTENTS
PAGE
SPECIFICATIONS
Specifications.................................................................................................................
Special Tool Usage .......................................................................................................
501-20B-3
501-20B-3

Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS) Vehicles Built Up To: 11/2004 ..............................................................................................
Supplemental Restraint System (SRS) .............................................................
Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS) Vehicles Built From: 11/2004................................................................................................
Supplemental Restraint System (SRS) .............................................................
501-20B-4
501-20B-4
501-20B-12
501-20B-12

Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS) Vehicles Built Up To: 11/2004 ..............................................................................................
Diagnosing Customer Concerns Without Hard DTCs/LFCs...........................................
Diagnosing Customer Concerns with Hard DTCs/LFCs ................................................
Deactivation ..................................................................................................................
Reactivation ..................................................................................................................
Glossary........................................................................................................................
Pinpoint Tests ...............................................................................................................
Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS) Vehicles Built From: 11/2004................................................................................................
Diagnosing Customer Concerns Without Hard DTCs/LFCs...........................................
Diagnosing Customer Concerns with Hard DTCs/LFCs ................................................
Deactivation ..................................................................................................................
Reactivation ..................................................................................................................
Glossary........................................................................................................................
Pinpoint Tests ...............................................................................................................
501-20B-18
501-20B-18
501-20B-18
501-20B-19
501-20B-19
501-20B-20
501-20B-20
501-20B-21
501-20B-26
501-20B-102
501-20B-102
501-20B-102
501-20B-103
501-20B-104
501-20B-104
501-20B-105
501-20B-106
501-20B-110
GENERAL PROCEDURES
Deployed Air Bag Disposal.............................................................................................
Unserviceable Air Bag Disposal .....................................................................................
Safety Belt Pretensioner Disposal ..................................................................................
Scrapped Vehicle Undeployed Air Bag Disposal ............................................................
501-20B-179
501-20B-180
501-20B-181
501-20B-183

Side Air Curtain Module 5-Door .................................................................................
Side Air Curtain Module 3-Door .................................................................................
Crash Sensor .................................................................................................................
Driver Air Bag Module ...................................................................................(40 700 0)
501-20B-186
501-20B-188
501-20B-190
501-20B-191
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501-20B-2
Page 2 of 2
Passenger Air Bag Module ........................................................................... (40 701 0)
Clockspring....................................................................................................................
Air Bag Control Module................................................................................. (33 650 0)
Side Impact Sensor 5-Door ...................................................................... (40 699 0)
Side Air Bag Module ..................................................................................... (40 698 0)
Side Impact Sensor 3-Door ...................................................................... (40 699 0)
Passenger Air Bag Deactivation (PAD) Switch ..............................................................
Driver Air Bag Module Wiring Harness ..........................................................................
501-20B-194
501-20B-198
501-20B-203
501-20B-204
501-20B-206
501-20B-210
501-20B-212
501-20B-213
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501-20B-3
SPECIFICATIONS
Special Tool Usage

Description
Driver air bag module
Passenger air bag module
Side air bag module
Side air curtain
Simulator
501-073A
501-073A
Test and Deployment Lead (Part of Test and

Deployment Lead, Air Bag/Pyrotechnic Safety Belt
[418-S055])
418-141
418-141
501-075
501-073A
418-142
418-141
Item
Air bag control module retaining nuts
Crash sensor retaining bolt
Passenger air bag module bracket to cross-vehicle
beam retaining bolts
Side air bag module retaining screws
Side air curtain module retaining bolts
Side impact sensor retaining bolt
G152593 en
Nm
9
9
10
lb-ft
-
lb-in
80
80
89
9
11
9
8
-
80
80
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501-20B-4

Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS)
Vehicles Built Up To: 11/2004
Supplemental Restraint System (SRS)
Overview
G163341 en
Item
Part
Number
Description
Seatbelt pretensioner, passenger side
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501-20B-5
501-20B-5

Item
Part
Number
Description
Side impact sensors
Side air curtains
Driver belt pretensioner
Airbag control module
Crash sensor
General
The SRS was developed to provide additional

protection for the driver and front passenger
against serious facial and upper chest injuries in
the event of a severe collision. Full occupant
protection is only provided in conjunction with the
conventional seatbelts.
SRS consists of the following components:
Airbag control module with integrated crash
sensor
Front airbag modules with two ignition stages
Side airbags
Side air curtains
Front seatbelt buckles with belt pretensioners
and seatbelt buckle switches
Clock spring
Crash sensor
Side airbag sensors (vehicles with side
airbags)
Airbag indicator lamp
Passenger airbag deactivated indicator lamp
The airbag control module is located in the centre

of the vehicle above the centre tunnel and behind
the gear lever. The installation orientation is
shown by a mark on the housing. The module
processes the signals from the crash sensors to
determine the severity of the impact.
In addition, the airbag control module also has a
mechanical sensor which measures the
acceleration/deceleration if an accident occurs.
The result is used as a confirmation signal.
If the deceleration due to a frontal or side impact
exceeds a certain value, then the airbag control
module compares the signals received from the
crash sensor or side impact sensor with stored
values and triggers the airbags as required.
The airbag control module supplies the airbags
with a backup voltage which ensures deployment
of the airbag(s) for at least 150 ms after a collision
even if the voltage supply from the vehicle
electrical system fails.
If a fault is detected by the airbag control module,
the airbag indicator lamp comes on. Diagnosis
can be performed using WDS.
The airbag control module can be reused up to 5
times after an accident in which one of the airbags
was deployed. The precondition for this is that it is
undamaged externally and that a self test reports
no faults.
Deployment is performed with a DC voltage.
Airbag control module
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501-20B-6

Crash sensors
Side airbag sensors
The side airbag sensors are located near the floor

panel behind a trim panel on the B-pillar. Their
external appearance is very similar to the front
crash sensor, but the side airbag sensors have
different colour markings.
In the event of a side impact the airbag control
module compares the value supplied by the side
impact sensor with stored data and deploys the
relevant side airbag module, both seatbelt
pretensioners and (if fitted) the relevant side
aircurtain module.
Item
Part
Number
Description
Front crash sensor
Hood switch connector

(alarm system)
Wiring loom
After they have been checked for external

damage and then self tested, the sensors can be
reused.
Front airbags
The crash sensor is located in the engine

compartment behind the radiator grille and is used
to assess the longitudinal severity of an impact.
The airbag control module compares the values
supplied by the front crash sensor to stored data
and triggers the front airbag modules and belt
pretensioners as required.
Power is supplied to the sensor from the airbag
control module. In the event of failure of the
sensor a trouble code is stored in the control unit.
The crash sensor can be re-used after an external
check for damage and a subsequent self-test.
Item
Part
Number
The external shape of the sensor prevents it from

being installed incorrectly.
G163341 en
Description
Connection for clock spring
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501-20B-7
501-20B-7

Description
This can vary between 70% and 100% of the total

volume.
Connection for stage 1

driver airbag (black connector)
Connection for stage 2

driver airbag (brown connector)
If during a crash it is not necessary to ignite the

second stage for protection of the occupants, then
the second stage is nonetheless triggered a
maximum of 100 ms after the first stage. This is a
safety measure for rescue operations.
Item
Part
Number
The airbag system features 2-stage airbags for

driver and front passenger. If the deceleration in a
frontal impact exceeds a certain value, then the
first gas generator on the drivers side is ignited
first, followed by the second one.
The time delay between igniting the first and
second gas generators depends on the severity of
the accident and, accordingly, on the signal
received by the airbag control module.
The gap between the two ignitions determines
how rapidly the airbag is filled, and therefore
defines the inflation characteristics of the airbag.
Item
Part
Number
Side air curtains
Retaining strap
G163341 en
Description
Side airbags
If present, the side airbags are integrated

inconspicuously in the backrests of the front seats.
If side airbags are installed, this is shown by a
label sewn into the outside edge of the seat
backrest.
If a side airbag is deployed, the seam of the seat
cover splits open, so that the airbag can emerge
unhindered from the front seat backrest. Each
side airbag has a volume of approx. 11 litres.
Side air curtains
Item
Part
Number
Description
Ignition unit
Connector for ignition unit

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501-20B-8

The side air curtains are located in the roof rail
between the A-pillar and C-pillar. They are
secured to the upper part of the quarter panel.
The electrical connections are located on the
C-pillar at the rear end of the roof in front of the
tailgate.
In the event of an impact these airbags inflate to
form a type of curtain between the side windows
and the head of the occupant. They have a
volume of approximately 22 litres.
The side air curtains are deployed simultaneously
with the side airbags.
Driver belt pretensioner
Item
Part
Number
Description
Ignition unit
Connector
Pyrotechnic seatbelt pretensioners are used as

before. However, a new feature is that the
seatbelt pretensioner on the drivers side is
integrated in the belt retractor. This is connected
to the airbag control module via an electrical
connector.
The seatbelt pretensioners are triggered
simultaneously with the first stage of the front
airbags.
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501-20B-9
501-20B-9
Seatbelt pretensioner, passenger side
Item
Part
Number
Description
Passenger side seatbelt

buckle cable
Drivers side seatbelt buckle

cable
Electrical connector to the

airbag control module
Pyrotechnic seatbelt pretensioner
Flexible connection
Rigid connection
On the passenger side, the seatbelt pretensioner

is still integrated in the seatbelt buckle cable. This
seatbelt buckle cable is connected to the airbag
control module via a connector.
The seatbelt pretensioners are also triggered
together with the first stage of the front airbags.
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501-20B-10
Deactivation of the passenger airbag
It is possible to deactivate the passenger airbag if

required. This feature is prepared at the factory,
but needs to be completed by the authorised
dealer. A kit is available for this purpose
consisting of a key-operated switch, a new switch
panel including the new indicator lamp and a TSB.
Indicator lamps
The key-operated switch is pushed onto the

existing connector on the wiring harness. This is
located behind a cover in the glove box.
Afterwards the key-operated switch is fitted into
the designated opening in the dash panel.
The airbag system must then be re-programmed
with WDS. This allows the passenger airbag to be
deactivated by turning the ignition key in the
key-operated deactivation switch.
An indicator lamp in the dash panel indicates if the
passenger airbag is deactivated.
The system features two airbag indicator lamps.

The yellow indicator lamp in the dash panel uses a
flash code to indicate faults in the system (5
flashes).
Afterwards the indicator lamp lights up
continuously. The corresponding trouble code
can be read out with the aid of WDS.
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501-20B-11

Another indicator lamp in the centre console
indicates deactivation of the passenger airbag.
The indicator lamp will light up continuously in this
case.
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501-20B-12

Vehicles Built From: 11/2004
Supplemental Restraint System (SRS)
System overview (5-door shown)
Item
Part
Number
G428465 en
Description
Front safety belt buckle and
pretensioner
Item
Part
Number
Description
Side impact sensor
Side air curtain module

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501-20B-13
501-20B-13

Description
installation marks on the air bag control module

are to make sure it is aligned correctly.
Side air bag module
Driver safety belt retractor

and pretensioner
Air bag control control module
A micromechanical sensor is incorporated into the

air bag control module; this measures the
acceleration/deceleration in the event of a
collision. The calculated value is evaluated by the
air bag control module to determine the severity of
the impact.
Clockspring
Passenger air bag module
Item
Part
Number
System structure
The following components form part of the

supplemental restraint system (SRS):
Air bag control module

Side impact sensors
Driver and passenger air bag modules
Side air curtain modules
Side air bag modules
Driver safety belt retractor and pretensioner 5-door
Front passenger safety belt buckle and
pretensioner - 5-door
Driver and passenger safety belt buckle and
pretensioner - 3-door
Clockspring
Air bag warning indicator
Passenger air bag deactivation (PAD) switch
The air bag control module compares the values it

receives from the side impact sensors and the
micromechanical sensor. If the deceleration due
to a frontal or side impact exceeds a stored value
then the air bag control module triggers the air
bags and safety belt pretensioners as required.
If the vehicle battery is destroyed in the collision, a
voltage hold circuit in the air bag control module
will still enable the air bags to be triggered up to
150 ms after the start of the impact.
If a system fault is detected by the air bag control
module, the air bag warning indicator is
illuminated. The fault can be located by carrying
out a diagnostic check using the Worldwide
Diagnostic System (WDS).
The air bag control module can be used again
after a collision for up to 5 times, provided that the
air bag control module is not physically damaged
and that it passes a self-test.
The air bag modules are triggered by a direct
current signal from the air bag control module.
Side Impact Sensors
Air Bag Control Module
The air bag control module is located under the

floor console, near to the gearshift lever. The
G428465 en
The side impact sensors are located at the bottom

of the B-pillars and transmit digitally encoded
acceleration/deceleration information to the air
bag control module.
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501-20B-14

The side impact sensor can be used again after a
collision, provided that the side impact sensor is
not physically damaged and that it passes a
self-test.
A new passenger air bag module must be installed

following deployment.
Side Air Curtain Modules
Driver and Passenger Air Bag Modules
The driver air bag module is fitted to the steering

wheel, the cover forming the outer surface of the
steering wheel boss. The cover has invisible 'split
lines' moulded in its surface allowing the air bag to
easily exit through the cover when the system
deploys. A new driver air bag module and driver
air bag module wiring harness must be installed
following deployment.
The side air curtain modules are located in the

roof rail between the A-pillar and D-pillar; decals in
the headliner indicate that the vehicle is equipped
with side air curtain modules. They are attached to
the upper part of the body panel and are hidden
behind the headliner and the D-pillar trim panels.
The electrical connections are located on the
C-pillar at the rear end of the roof in front of the
liftgate.
In the event of a side impact the relevant side air
curtain is deployed and forms a protective cushion
between the corresponding window and the head
of the person(s) sat on the front and rear seat.
The side air curtains are deployed simultaneously
with the side air bags.
Side Air Bag Modules
The passenger air bag module is located above

the glove compartment and is secured to the
in-vehicle crossbeam and the instrument panel.
The cover is intergrated into the instrument panel
to provide an unobtrusive appearance. The cover
has invisible 'split lines' moulded in its surface
allowing the air bag to easily exit through the cover
when the system deploys.
The side air bag modules are incorporated in the

front seat backrests; a sewn-on label on the
respective backrest indicates that the vehicle is
equipped with side air bag modules.
When a side air bag is deployed, the seam of the
seat cover tears open enabling the side air bag to
inflate unhindered from the front seat backrest.
The passenger air bag is deployed simultaneously

with the driver air bag.
The passenger air bag will not be deployed
simultaneously with the driver air bag if the PAD
switch has been activated.
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501-20B-15

Driver Safety Belt Retractor and Pretensioner
5-door
Driver and Front Passenger Safety Belt Buckle and

Pretensioner 3-door
The driver safety belt pretensioner is integrated in

the driver safety belt retractor.
The pretensioner for the driver and front

passenger safety belt is an integral part of the
driver and front passenger safety belt buckle
stalks.
A load limiter is built into the retractor spindle of

the driver safety belt retractor. The spindle is
designed as a torsion bar and, by turning, limits
the belt force on the shoulder to a predetermined
limit.
The driver safety belt pretensioner is designed to
remove the slack from the safety belt webbing in
the event of a frontal or near frontal collision over
the predetermined limit.
The pretensioner is designed to remove the slack

from the safety belt webbing in the event of a
frontal or near frontal collision over the
predetermined limit.
The driver and front passenger safety belt buckle
pretensioner is triggered simultaneously with the
front air bags
The driver safety belt pretensioner can only be

deployed once, a new driver safety belt retractor
and pretensioner must be installed if the driver
safety belt pretensioner has been deployed.
The safety belt buckle pretensioner can only be

deployed once, a new safety belt buckle and
pretensioner must be installed if the safety belt
buckle pretensioner has been deployed.
The driver safety belt pretensioner is triggered

simultaneously with the front air bags.
Clockspring
Front Passenger Safety Belt Buckle and

Pretensioner 5-door
The pretensioner for the front passenger safety

belt is an integral part of the front passenger
safety belt buckle stalk.
The passenger safety belt buckle pretensioner is
designed to remove the slack from the safety belt
webbing in the event of a frontal or near frontal
collision over the predetermined limit.
The front passenger safety belt buckle
pretensioner is triggered simultaneously with the
front air bags.
G428465 en
The clockspring is designed to carry signals

between the air bag control module and the driver
air bag module. The clockspring is installed on the
steering column and consists of fixed and moving
parts connected by a coiled Mylar tape with
internal conducting tracks. The Mylar tape is able
to 'wind up' and 'unwind' as the steering wheel is
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501-20B-16

rotated, maintaining electrical contact at all times
between the air bag control module and the driver
air bag module.
Vehicles equipped with stability assist have a
steering wheel rotation sensor incorporated in the
clockspring.
Air Bag Warning Indicator
A PAD switch can be installed by the dealer as an

optional extra; the PAD switch is located in the
glove compartment.
G428465 en
The air bag warning indicator is located in the

instrument cluster. In the event of a fault being
detected by the air bag control module, the air bag
warning indicator flashes a corresponding flash
code five times and then remains illuminated. The
corresponding Diagnostic Trouble Code (DTC)
can be read out with the aid of WDS.
Passenger Air Bag Deactivation
The PAD switch is activated/deactivated by the

use of a key.
When the ignition is switched on, a warning
indicator in the instrument panel indicates that the
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501-20B-17

passenger air bag has been deactivated. The air
bag warning indicator will be illuminated
continuously in this case.
After installing a PAD switch, the air bag control
module must be re-configured using WDS.
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501-20B-18

Vehicles Built Up To: 11/2004
Diagnosing Customer Concerns Without Hard
DTCs/LFCs
Special Tool(s)
Simulator Air Bag, Driver
Safety Belt Retractor and
Pretensioner
418-037 (40-001)
Test and Deployment Lead,
Driver Safety Belt Retractor
418-056 (40-007-01)

Driver; Passenger and Side
Air Curtain Module
418-141 (40-007-08)
Side Air Bag Module
418-555
Air Curtains
501-073A
Simulator, Occupant
Restraint Systems
501-092 (40-021)
General Equipment

personal injury.
NOTE: Following the pinpoint tests when a
diagnostic trouble code/lamp fault code
(DTC/LFC) is not present, or the air bag warning
lamp is not permanently illuminated, will result in
needless replacement of air bag system
components and repeat repairs.
Speak with the customer to determine if a
particular set of conditions must be met in order
for a fault to occur. If a LFC is reported by the
customer but is not present when the vehicle
comes in for repair, pinpoint test diagnostics
cannot be used. Instruct the customer on how to
count a LFC.
Diagnosing Customer Concerns with Hard
DTCs/LFCs
WARNING: Do not use substitute air bag
simulators when working on the SRS.
Use only the appropriate tool. Failure to
personal injury.
Most air bag system diagnostic procedures
require the use of system deactivation and system
reactivation procedures. These procedures
require the air bag module(s) and safety belt
pretensioners to be disconnected from the SRS,
thereby removing the risk of an air bag
deployment while diagnostics are carried out.
Air bag simulators are required to carry out
diagnosis and testing of the air bag system. The
simulator contains a resistor, used to simulate an
air bag module connection to the system. It is not
acceptable to short-circuit the air bag module
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501-20B-19

connections with a 0 ohm jumper wire. If a 0 ohm
jumper wire is used to short-circuit the air bag
module connections, a LFC will be displayed and
a DTC logged by the air bag control module.
Deactivation
WARNING: The back up power supply
must be depleted, before any work is
carried out on the SRS. Wait at least one
minute after disconnecting the battery
ground cable. Failure to follow this
1. Disconnect the battery ground cable. REFER
to Section 414-01.[Battery, Mounting and
Cables, GENERAL PROCEDURES, Battery
Disconnect]
2. Wait at least one minute for the backup power
supply in the air bag control module to deplete
its stored energy.
WARNING: Place the air bag module on a
ground wired bench, with the trim cover
facing up to avoid accidental deployment.
3. Remove the driver air bag module from the
vehicle. REFER to Driver Air Bag Module in
this section.
4. Connect the air bag simulators to the
sub-harnesses in place of the driver air bag
module at the top of the steering column.
5. Disconnect the passenger air bag module
electrical connectors. REFER to Passenger
Air Bag Module in this section.
6. Connect the air bag simulators to the wiring
harnesses in place of the passenger air bag
module.
7. Disconnect both side air curtain module
electrical connectors. REFER to Side Air
Curtain Module - 3-Door/ Side Air Curtain
Module - 5-Door in this section.
8. Connect the air bag simulators to the wiring
harnesses in place of the side air curtain
modules.
9. Disconnect the driver underseat air bag
10. Connect the driver occupant restraint systems
simulator to the floor harness.
11. Disconnect the driver safety belt retractor and
pretensioner at the base of the B-pillar.
REFER to Section 501-05.[Interior Trim and
Ornamentation, REMOVAL AND
G149926 en
INSTALLATION, B-Pillar Trim Panel - 3-Door]

12. Connect the driver safety belt retractor and
pretensioner simulator to the wiring harness in
place of the driver safety belt retractor and
pretensioner.
13. Disconnect the passenger underseat air bag
14. Connect the passenger occupant restraint
systems simulator to the floor harness.
15. Connect the battery ground cable. REFER to
Disconnect]
Reactivation
WARNING: The air bag simulators must
be removed and the air bag modules
reconnected when reactivated to avoid
non-deployment in a collision. Failure to
personal injury.
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501-20B-20

Disconnect]
its stored energy.
3. Remove the driver air bag simulators from the
sub-harnesses at the top of the steering
column.
4. Connect and install the driver air bag module.
REFER to Driver Air Bag Module in this
section.
5. Remove the passenger air bag simulators
from the passenger air bag module
harnesses.
6. Connect and install the passenger air bag
module. REFER to Passenger Air Bag Module
in this section.
7. Remove the side air curtain simulators from
the side air curtain module wiring harnesses.
8. Connect and install the side air curtain
modules. REFER to Side Air Curtain Module 3-Door/ Side Air Curtain Module - 5-Door in
this section.
9. Remove the driver occupant restraint systems
simulator.
10. Connect the driver underseat air bag electrical
connector.
11. Remove the driver safety belt retractor and
pretensioner simulator.
pretensioner electrical connector.
13. Remove the passenger occupant restraint
systems simulator.
14. Connect the passenger underseat air bag
Disconnect]
16. Prove out the system.
Glossary
Air Bag Simulator
Air bag simulators are used to simulate air bag

module connections to the system.
Deactivate The System
Deactivate the system means to carry out

deactivation. REFER to Deactivation in this
procedure.
Prove Out The System
The air bag warning indicator will illuminate for

three seconds.
Reactivate The System
Reactivate the system means to carry out

reactivation. REFER to Reactivation in this
procedure.
SRS Operation
The SRS is DC fired. All vehicles are equipped

with a crash sensor, vehicles equipped with side
air bags and side air curtains are also equipped
with side impact sensors.
In the event of a severe frontal or three-quarter
frontal impact, in excess of a predetermined limit,
the driver and passenger (if equipped) front air
bag(s) will deploy.
In the event of a severe full side impact, in excess
of a predetermined limit, either the driver or
passenger side air bags (if equipped) and side air
curtains (if equipped) will deploy.
Air bag deployment will only occur, in the event of
a severe collision when the ignition key is in the
RUN position.
The air bag control module is mounted

horizontally to the crossmember beneath the floor
console, to facilitate impact sensing along the
longitudinal axis. The air bag control module
retains full control of the whole system, providing
continual system checks and full diagnostic
capabilities. The non-volatile memory stores the
fault codes, which are down loaded through the
data link connector (DLC) to WDS. A visual
warning indicator that is housed within the
instrument cluster, is illuminated when the ignition
is switched ON for approximately three seconds
then goes out. If a fault occurs the warning
indicator, depending on the nature of the fault,
begins to flash or illuminates continuously after
five seconds.
In the event of a failure in the vehicle power supply
during an accident, the air bag control module
provides an auxiliary power supply, sufficient to
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deploy the front air bag(s) for a minimum of 150
ms. The auxiliary power supply is discharged by
the air bag control module within 60 seconds of
the battery ground cable being disconnected.
Thus making sure that the SRS remains
operational.
The air bag control module contains a
micro-controller to evaluate and process impact
data. In the event of a frontal impact, in excess of
a predetermined limit, the air bag control module
will evaluate the signal received from the crash
sensor against stored data and deploy the frontal
air bags and safety belt pretensioners.
a fault is detected the indicator will flash after five

seconds, illuminate continually from key ON or not
illuminate at all, depending on the nature of the
fault.
The automatic detach detect circuit is designed to
illuminate the air bag warning indicator
continuously, if the air bag control module circuit is
broken, either by loss of power or ground supply
or electrical connector disconnection.
Diagnostic evaluation of the SRS can be made
through the DLC and WDS to establish the nature
of the concern.
Crash Sensor and Side Impact Sensors
Both the crash sensor and the side impact

sensors contain an acceleration sensor, filter,
amplifier and an application specific integrated
circuit for signal transmitting.
The crash sensor sends a signal at a level
determined by the crash severity to the air bag
control module. The air bag control module will
evaluate the signal against stored data and deploy
the frontal air bags and safety belt pretensioners if
required.
The side impact sensor processes the impact data
against stored data. In the event of a side impact,
in excess of a predetermined limit, the side impact
sensor will send a signal to deploy the side air
bags and side air curtains (if equipped). A signal is
also sent to the air bag control module.
The air bag warning indicator is incorporated into

the instrument cluster, together with the automatic
detach detect circuit. The air bag warning indicator
illuminates for three seconds at key ON. If the
system self-tests OK the indicator extinguishes, if

system.
Electrical
3.
Fuse(s)
Air bag module(s)
Circuit(s)
step.
4. If the cause is not visually evident, connect the
diagnostic tool to the DLC and select the
vehicle to be tested from the diagnostic tool
menu.
5. Retrieve the DTCs and refer to the Symptom
Chart.
Symptom Chart
Symptom
Possible Sources
Action
NOTE: It is only allowed to repair circuits between connectors. If damage has occurred within a connector
a new wiring harness must be installed. Connectors must not be disassembled.
No communication with the
DLC.
module
Air bag control module.
Circuit(s).
DTC B1231: Longitudinal accel- Crash data memory full.
eration threshold exceeded.
Lamp flash code: 13
G149926 en
Clear down the data memory

using WDS. Repeat the self-test,
CLEAR the DTCs.
The data memory can be
cleared a maximum of five
times.
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Symptom
Possible Sources
Action
DTC B1317: Battery voltage high Charging system.
CHECK the charging system.

REFER to Section
414-00.[Charging System General Information, GENERAL
PROCEDURES, Battery Charging] Repeat the self-test, CLEAR
the DTCs.
DTC B1318: Battery voltage low Battery.

Charging system.
Circuit.
DTC B1342: Air bag control

module is defective. Lamp flash
code: 12
INSTALL a new air bag control

module. REFER to Air Bag
Control Module in this section.
REPEAT the self-test, CLEAR
the DTCs.
DTC B1869: Air bag warning

Instrument cluster.
indicator open circuit or short to Air bag control module.
ground. Lamp flash code: con- Circuit(s).
tinuous

indicator short to battery. Lamp
flash code: No lamp
Instrument cluster.
Circuit.
DTC B1877: Driver safety belt

Driver safety belt pretensioner.
pretensioner open circuit. Lamp Circuit(s).
flash code: 33

pretensioner short to battery.
Lamp flash code: 33

Circuit(s).

pretensioner short to ground.
Lamp flash code: 33

Circuit.
DTC B1881: Passenger safety

belt pretensioner open circuit.
Lamp flash code: 34
Passenger safety belt

pretensioner.
Circuit.
DTC B1882: Passenger safety Passenger safety belt

belt pretensioner short to battery. pretensioner.
Lamp flash code: 34
Circuit.
DTC B1883: Passenger safety

belt pretensioner short to
ground. Lamp flash code: 34
Passenger safety belt

pretensioner.
Circuit.
GO to Pinpoint Test J

pretensioner low resistance.
Lamp flash code: 33

Circuit.
GO to Pinpoint Test K
DTC B1886: Passenger safety Passenger safety belt

belt pretensioner low resistance. pretensioner.
Lamp flash code: 34
Circuit.
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Symptom
Possible Sources
Action
DTC B1916: Driver air bag first

stage short to battery. Lamp
flash code: 19
Clockspring.
Circuit.
GO to Pinpoint Test M
DTC B1921: Air bag diagnostic

monitor ground circuit open circuit. Lamp flash code: 14
Air bag control module internal

fault.

the DTCs.
DTC B1925: Passenger air bag Circuit(s).

first stage short to battery. Lamp
flash code: 21
GO to Pinpoint Test N

stage open circuit. Lamp flash
code: 19
Driver air bag module.

Clockspring.
Circuit(s).
GO to Pinpoint Test O
DTC B1933: Passenger air bag

first stage open circuit. Lamp
flash code: 21
Passenger air bag module.

Circuit(s).
GO to Pinpoint Test P
DTC B1934: Driver air bag first Driver air bag module.
stage low resistance. Lamp flash Clockspring.
code: 19
Circuit(s).
GO to Pinpoint Test Q
DTC B1935: Passenger air bag Passenger air bag module.

first stage low resistance. Lamp Circuit(s).
flash code: 21
GO to Pinpoint Test R

stage short to ground. Lamp
flash code: 19
GO to Pinpoint Test S
Driver air bag module.

Clockspring.
Circuit.

first stage short to ground. Lamp Circuit.
flash code: 21
GO to Pinpoint Test T
DTC B1992: Driver side air bag

short to battery. Lamp flash
code: 22
Circuit.
GO to Pinpoint Test U

short to ground. Lamp flash
code: 22
Driver side air bag module.

Clockspring.
Circuit.
DTC B1994: Driver side air bag Driver side air bag module.
open circuit. Lamp flash code: 22 Circuit.
GO to Pinpoint Test W

low resistance on squib. Lamp
flash code: 22
GO to Pinpoint Test X
Driver side air bag module.

Circuit.
DTC B1996: Passenger side air Passenger side air bag module. GO to Pinpoint Test Y
bag short to battery. Lamp flash Circuit.
code: 21
DTC B1997: Passenger side air Passenger side air bag module. GO to Pinpoint Test Z
bag short to ground. Lamp flash Circuit.
code: 21
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Symptom
Possible Sources
Action
DTC B1998: Passenger side air Passenger side air bag module. GO to Pinpoint Test AA
bag open circuit. Lamp flash
Circuit.
code: 21
DTC B1999: Passenger side air Passenger side air bag module
bag low resistance on squib.
circuit.
Lamp flash code: 21
Circuit.
GO to Pinpoint Test AB
DTC B2226: Front crash sensor Crash sensor.

internal fault. Lamp flash code:
42
INSTALL a new crash sensor.

REFER to Crash Sensor in this
section. REPEAT the self-test,
CLEAR the DTCs.
DTC B2227: Front crash sensor Circuit(s).

communications fault. Lamp
flash code: 42
GO to Pinpoint Test AC
DTC B2228: Driver air bag sec- Driver air bag module.
ond stage short to ground. Lamp Clockspring.
flash code: 19
Circuit(s).
GO to Pinpoint Test AD

second stage short to ground.
Lamp flash code: 21
GO to Pinpoint Test AE

Circuit(s).
DTC B2230: Driver air bag sec- Clockspring.

ond stage short to battery. Lamp Circuit(s).
flash code: 19
GO to Pinpoint Test AF

second stage short to battery.
Lamp flash code: 21
GO to Pinpoint Test AG

Circuit(s).
ond stage open circuit. Lamp
Circuit.
flash code: 19
GO to Pinpoint Test AH

second stage open circuit. Lamp Circuit(s).
flash code: 21
GO to Pinpoint Test AI
ond stage low resistance on
Circuit(s).
squib. Lamp flash code: 19
GO to Pinpoint Test AJ

second stage low resistance on Circuit(s).
GO to Pinpoint Test AK
DTC B2444: Driver side impact Driver side impact sensor.

sensor internal fault. Lamp flash
code: 43
INSTALL a new driver side impact sensor. REFER to Side

Impact Sensor - 3-Door / Side
Impact Sensor - 5-Door in this
CLEAR the DTCs.
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Symptom
Possible Sources
Action
DTC B2445: Passenger side

impact sensor internal fault.
Lamp flash code: 44
Passenger side impact sensor.
INSTALL a new passenger side

impact sensor. REFER to Side
CLEAR the DTCs.

module configuration failure.
Lamp flash code: 54
CONFIGURE the air bag control

module. REFER to WDS.
the DTCs.
DTC B2773: Driver side air cur- Driver side air curtain module.
tain low resistance on squib.
Circuit(s).
Lamp flash code: 24
GO to Pinpoint Test AL
DTC B2774: Driver side air cur- Driver side air curtain module.
tain open circuit. Lamp flash
Circuit(s).
code: 24
GO to Pinpoint Test AM
DTC B2775: Driver side air cur- Driver side air curtain module
tain short to ground. Lamp flash Circuit(s).
code: 24
GO to Pinpoint Test AN
DTC B2776: Driver side air cur- Circuit(s).

tain short to battery. Lamp flash
code: 24
GO to Pinpoint Test AO
DTC B2777: Passenger side air Passenger side air curtain

curtain low resistance on squib. module.
Lamp flash code: 25
Circuit(s).
GO to Pinpoint Test AP

curtain open circuit. Lamp flash module.
code: 25
Circuit(s).
GO to Pinpoint Test AQ

curtain short to ground. Lamp
module.
flash code: 25
Circuit(s).
GO to Pinpoint Test AR
DTC B2780: Passenger side air Circuit(s).

curtain short to battery. Lamp
flash code: 25
GO to Pinpoint Test AS
DTC B2791: Air bag cut-off

switch out of range. Lamp flash
code: 56
Circuit(s).
GO to Pinpoint Test AT

switch user fault. Lamp flash
code: 56
Passenger air bag deactivation

(PAD) switch.
Circuit
CARRY OUT the PAD Switch

Wiring Diagrams.
GO to Pinpoint Test AU
DTC C1414: Incorrect module

design level. Lamp flash code:
15

the DTCs.
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Possible Sources
Symptom
Action
DTC U2017: Driver side impact

sensor communications fault.
Lamp flash code: 43
Circuit(s).
GO to Pinpoint Test AV
DTC U2018: Passenger side

impact sensor communications
fault. Lamp flash code: 44
Circuit(s).
GO to Pinpoint Test AW
Air bag control module disconnected or inoperative. Lamp

flash code: continuous

Circuit(s).
GO to Pinpoint Test AX
Pinpoint Tests
PINPOINT TEST A: NO COMMUNICATION WITH THE MODULE
TEST CONDITIONS
WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any SRS electrical connector. Failure to follow this instruction may result in
personal injury.
A1: CHECK THE WDS IS COMMUNICATING THROUGH THE DLC
1 Select an alternative system to check the DLC.
Is WDS able to communicate with the selected
system?
Yes
Go to A2
No
CHECK the DLC. For additional information,
A2: CHECK THE AIR BAG WARNING INDICATOR
2 The air bag warning indicator should illuminate
when the ignition is in the ON position for three
seconds and then go out. If a fault is present,
the air bag warning light will then begin to flash.
Is the warning indicator operating?
Yes
Go to A3
No
CHECK the instrument cluster. REFER to
Section 413-01.[Instrument Cluster,
DIAGNOSIS AND TESTING, Instrument
Cluster]
A3: CHECK THE DLC CIRCUIT
2 Deactivate the SRS.
3 Disconnect Air Bag Control Module C500.
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TEST CONDITIONS
4 Measure the resistance between the DLC C308
pin 7, circuit 4-EE10 (GY/BK) and the air bag
control module C500 pin 17, circuit 4-EE7
(GY/RD), harness side.

Yes
INSTALL a new air bag control module.
REFER to Air Bag Control Module in this
section. REACTIVATE the system. If the air
bag warning indicator is flashing, count the
lamp flash code and REFER to the Symptom
Chart in this section.
No
REPAIR circuit 4-EE7 (GY/RD) or circuit
4-EE10 (GY/BK). REPEAT the self-test,
CLEAR the DTCs. REACTIVATE the system.
PINPOINT TEST B: DTC B1318: BATTERY VOLTAGE LOW
TEST CONDITIONS
personal injury.
B1: CHECK THE IGNITION SUPPLY CIRCUIT FOR AN OPEN CIRCUIT
3 Measure the voltage between the air bag control module C500 pin 1, circuit 15-JA10
(GN/OG), harness side and ground.
Is the voltage between 9 and 16 volts?

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TEST CONDITIONS
Yes
Go to B2
No
REPAIR circuit 15-JA10 (GN/OG). REPEAT
the self-test, CLEAR the DTCs.
REACTIVATE the system.
B2: CHECK THE AIR BAG CONTROL MODULE GROUND CIRCUIT
2 Measure the resistance between the air bag
control module C500 pin 20, circuit 91-JA10
(BK/RD), harness side and ground.

Yes
section. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system.
No
REPAIR circuit 91-JA10 (BK/RD). REPEAT
PINPOINT TEST C: DTC B1869: AIR BAG WARNING INDICATOR OPEN CIRCUIT OR SHORT TO
GROUND
TEST CONDITIONS
personal injury.
C1: CHECK THE AIR BAG WARNING INDICATOR
2 Check the air bag warning indicator.
Is the air bag warning indicator illuminated continuously?
Yes
Go to C2
No
Go to C5
C2: CHECK THE AIR BAG WARNING INDICATOR CIRCUIT
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TEST CONDITIONS
2
3
4
5
Deactivate the SRS.

Disconnect Air Bag Control Module C500.
Disconnect Instrument Cluster C332.
Measure the resistance between the instrument
cluster C332 pin 9, circuit 91S-JA14 (BK/GN),
harness side and the air bag control module
C500 pin 11, circuit 91S-JA14 (BK/GN), harness side.

Yes
Go to C3
No
REPAIR circuit 91S-JA14 (BK/GN). REPEAT
C3: CHECK THE AIR BAG WARNING INDICATOR FUNCTION
1 Connect Instrument Cluster C332.
2 Install a fused (7.5A) jumper wire between the
air bag control module C500 pin 11, circuit
91S-JA14 (BK/GN), harness side and ground.
- Turn the ignition to the ON position.
Is the air bag warning indicator illuminated?

Yes
to Section 413-01.[Instrument Cluster,
REMOVAL AND INSTALLATION, Instrument Cluster] REPEAT the self-test, CLEAR
the DTCs. REACTIVATE the system.
No
Go to C4
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TEST CONDITIONS
C4: CHECK THE AIR BAG WARNING INDICATOR FUNCTION

1 With the fused (7.5A) jumper wire between the
- Disconnect the fused jumper wire from the
ground.

Yes
No
REPEAT the self-test, CLEAR the DTCs.
C5: CHECK THE INSTRUMENT CLUSTER WARNING INDICATORS
personal injury.
4 Check the instrument cluster warning indicators.
Are the warning indicators illuminated when the
ignition is switched to the ON position?
Yes
Go to C6
No
Cluster]
C6: CHECK THE AIR BAG WARNING INDICATOR CIRCUIT
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TEST CONDITIONS
control module C500 pin 11, circuit 91S-JA14
(BK/GN), harness side and ground.

Yes
CHECK the air bag warning indicator LED.
No
PINPOINT TEST D: DTC B1870: AIR BAG WARNING INDICATOR SHORT TO BATTERY
TEST CONDITIONS
personal injury.
D1: CHECK THE AIR BAG WARNING INDICATOR
1
2
3
4
5
Deactivate the SRS.

Measure the voltage between the air bag control module C500 pin 11, circuit 91S-JA14
Is any voltage present?

Yes
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TEST CONDITIONS
No
Cluster] REPEAT the self-test, CLEAR the
PINPOINT TEST E: DTC B1877: DRIVER SAFETY BELT PRETENSIONER OPEN CIRCUIT
TEST CONDITIONS
personal injury.
E1: CHECK THE DRIVER SAFETY BELT PRETENSIONER CIRCUIT
3 Carry out the self-test with the simulators installed.
Does the system prove out correctly?
Yes
Go to E2
No
Go to E3
E2: PROVE OUT THE DRIVER SAFETY BELT PRETENSIONER CIRCUIT
2 Disconnect Driver Safety Belt Pretensioner
Simulator.
3 Connect Driver Safety Belt Pretensioner Connector C661.
5 Carry out the self-test.
Yes
No
INSTALL a new driver safety belt retractor
and pretensioner. REFER to Section
501-20A.[Safety Belt System, REMOVAL
AND INSTALLATION, Safety Belt Retractor
and Pretensioner - 3-Door]
REFER to Section 501-20A.[Safety Belt
Safety Belt Retractor and Pretensioner 5-Door] REPEAT the self-test, CLEAR the
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TEST CONDITIONS
E3: CHECK THE DRIVER SAFETY BELT PRETENSIONER FOR OPEN CIRCUIT OR HIGH
RESISTANCE
Simulator C661.
the air bag control module C501 pin 4, circuit
91S-JA33 (BK/BU), harness side and the driver
safety belt pretensioner C661 pin 2, circuit
91S-JA33 (BK/BU), harness side.
15S-JA33 (GN/BU), harness side and the driver
safety belt pretensioner C661 pin 1, circuit
15S-JA33 (GN/BU), harness side.

Yes
No
REPAIR circuit 15S-JA33 (GN/BU) or circuit
91S-JA33 (BK/BU). REPEAT the self-test,
PINPOINT TEST F: DTC B1878 DRIVER SAFETY BELT PRETENSIONER SHORT TO BATTERY
TEST CONDITIONS
personal injury.
F1: CHECK THE DRIVER SAFETY BELT PRETENSIONER CIRCUIT
Yes
Go to F2
No
Go to F3
F2: PROVE OUT THE DRIVER SAFETY BELT PRETENSIONER CIRCUIT
Simulator.
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TEST CONDITIONS

Yes
No
F3: CHECK THE DRIVER SAFETY BELT PRETENSIONER FOR A SHORT TO BATTERY
Simulator C661.
91S-JA33 (BK/BU), harness side and ground.
15S-JA33 (GN/BU), harness side and ground.

Yes
No
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PINPOINT TEST G: DTC B1879: DRIVER SAFETY BELT PRETENSIONER SHORT TO GROUND
TEST CONDITIONS
personal injury.
G1: CHECK THE DRIVER SAFETY BELT PRETENSIONER CIRCUIT
Yes
Go to G2
No
Go to G3
G2: CHECK THE DRIVER SAFETY BELT PRETENSIONER CIRCUIT
Simulator.
Yes
No
G3: CHECK THE DRIVER SAFETY BELT PRETENSIONER FOR A SHORT TO GROUND
2 Disconnect Air Bag Control Module C500 and
C501.
Simulator C661.
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TEST CONDITIONS
91S-JA33 (BK/BU), harness side and the air
bag control module C500 pin 20, circuit 91-JA10
(BK/RD) harness side.
15S-JA33 (GN/BU), harness side and the air
bag control module C500 pin 20, circuit 91-JA10
(BK/RD), harness side.
Yes
No
PINPOINT TEST H: DTC B1881 PASSENGER SAFETY BELT PRETENSIONER OPEN CIRCUIT
TEST CONDITIONS
personal injury.
H1: CHECK THE PASSENGER SAFETY BELT PRETENSIONER CIRCUIT
Yes
Go to H2
No
Go to H3
H2: PROVE OUT THE PASSENGER SAFETY BELT PRETENSIONER
2 Disconnect Passenger Safety Belt Pretensioner
Simulator.
3 Connect Passenger Safety Belt Pretensioner
Connector C664.
Yes
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TEST CONDITIONS
No
INSTALL a new passenger safety belt buckle
AND INSTALLATION, Safety Belt Buckle
and Pretensioner] REPEAT the self-test,
H3: CHECK THE PASSENGER SAFETY BELT PRETENSIONER FOR OPEN CIRCUIT OR HIGH
RESISTANCE
3 Disconnect Passenger Occupant Restraint
Systems Simulator.
15S-JA34 (GN/OG), harness side and the
passenger safety belt pretensioner C664 pin 2,
circuit 15S-JA34 (GN/OG) harness side.
91S-JA34 (BK/RD), harness side and the passenger safety belt pretensioner C664 pin 1,
circuit 91S-JA34 (BK/RD) harness side.

Yes
No
REPAIR circuits 15S-JA34 (GN/OG) and
91S-JA34 (BK/RD). REPEAT the self-test,
PINPOINT TEST I: DTC B1882 PASSENGER SAFETY BELT PRETENSIONER SHORT TO
BATTERY
TEST CONDITIONS
personal injury.
I1: CHECK THE PASSENGER SAFETY BELT PRETENSIONER CIRCUIT
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TEST CONDITIONS

Yes
Go to I2
No
Go to I3
I2: PROVE OUT THE PASSENGER SAFETY BELT PRETENSIONER CIRCUIT
Simulator.
Connector C664.
Yes
No
I3: CHECK THE PASSENGER SAFETY BELT PRETENSIONER FOR A SHORT TO BATTERY
Simulator C664.
15S-JA34 (GN/OG), harness side and ground.
91S-JA34 (BK/RD), harness side and ground.

Yes
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TEST CONDITIONS
REPAIR circuit 15S-JA34 (GN/OG) or circuit
No
PINPOINT TEST J: DTC B1883 PASSENGER SAFETY BELT PRETENSIONER SHORT TO

GROUND
TEST CONDITIONS
personal injury.
J1: CHECK THE PASSENGER SAFETY BELT PRETENSIONER CIRCUIT
Yes
Go to J2
No
Go to J3
J2: PROVE OUT THE PASSENGER SAFETY BELT PRETENSIONER
Simulator.
Connector C664.
Yes
No
J3: CHECK THE PASSENGER SAFETY BELT PRETENSIONER FOR A SHORT TO GROUND
2 Disconnect Safety Belt Pretensioner Module
C501.
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TEST CONDITIONS
Simulator.
the air bag control module C501 pin 12,

Yes
No
PINPOINT TEST K: DTC B1885 DRIVER SAFETY BELT PRETENSIONER LOW RESISTANCE
TEST CONDITIONS
personal injury.
K1: CHECK THE DRIVER SAFETY BELT PRETENSIONER CIRCUIT
Yes
Go to K2
No
Go to K3
K2: PROVE OUT THE DRIVER SAFETY BELT PRETENSIONER
Simulator.
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TEST CONDITIONS

Yes
No
K3: CHECK THE DRIVER SAFETY BELT PRETENSIONER FOR LOW RESISTANCE
Simulator.
(BK/BU), harness side and the air bag control
module C501 pin 5, circuit 15S-JA33 (GN/BU),
harness side.

Yes
No
REPAIR circuits 15S-JA33 (GN/BU) and
PINPOINT TEST L: DTC B1886 PASSENGER SAFETY BELT PRETENSIONER LOW RESISTANCE
TEST CONDITIONS
personal injury.
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TEST CONDITIONS
L1: CHECK THE PASSENGER SAFETY BELT PRETENSIONER CIRCUIT

Yes
Go to L2
No
Go to L3
L2: PROVE OUT THE PASSENGER SAFETY BELT PRETENSIONER
Simulator.
Connector C664.
Yes
No
L3: CHECK THE PASSENGER SAFETY BELT PRETENSIONER FOR LOW RESISTANCE
Simulator.
(GN/OG), harness side and the air bag control
module C501 pin 12, circuit 91S-JA34 (BK/RD),
harness side.

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TEST CONDITIONS
Yes
No
PINPOINT TEST M: DTC B1916 DRIVER AIR BAG FIRST STAGE SHORT TO BATTERY
TEST CONDITIONS
personal injury.
M1: CHECK THE DRIVER AIR BAG FIRST STAGE WIRING HARNESS FOR A SHORT TO
BATTERY OR IGNITION
2 Disconnect Driver Air Bag Module First Stage
Simulator.
91S-JA8 (BK/OG), harness side and ground.
15S-JA8 (GN/RD), harness side and ground.

Yes
Go to M2
No
CONNECT the driver air bag module first
stage simulator and the air bag control
module. REPEAT the self-test, CLEAR the
M2: CHECK THE CLOCKSPRING FOR A SHORT TO BATTERY OR IGNITION
2 Disconnect Clockspring C353 or C763.
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501-20B-44

TO MODEL INDEX
501-20B-44

TEST CONDITIONS

Yes
REPAIR circuits 15S-JA8 (GN/RD) and
91S-JA8 (BK/OG). REPEAT the self-test,
No
INSTALL a new Clockspring. REFER to
Clockspring in this section. REPEAT the
self-test, CLEAR the DTCs. REACTIVATE
the system.
PINPOINT TEST N: DTC B1925 PASSENGER AIR BAG FIRST STAGE SHORT TO BATTERY
TEST CONDITIONS
personal injury.
N1: CHECK THE PASSENGER AIR BAG FIRST STAGE WIRING HARNESS FOR A SHORT TO
BATTERY OR IGNITION
2 Disconnect Passenger Air Bag Module First
Stage Simulator.
G149926 en
11/2004 2005.25 Fiesta
501-20B-45

TO MODEL INDEX
501-20B-45

TEST CONDITIONS
15S-JA31 (GN/WH), harness side and ground.
91S-JA31 (BK/WH), harness side and ground.

Yes
REPAIR circuits 15S-JA31 (GN/WH) and
91S-JA31 (BK/WH). REPEAT the self-test,
No
CONNECT the passenger air bag module
first stage simulator and the air bag control
PINPOINT TEST O: DTC B1932 DRIVER AIR BAG FIRST STAGE OPEN CIRCUIT
TEST CONDITIONS
personal injury.
O1: CHECK THE DRIVER AIR BAG FIRST STAGE CIRCUIT RESISTANCE
Yes
Go to O2
No
Go to O3
O2: CHECK THE DRIVER AIR BAG MODULE SQUIB RESISTANCE
WARNING: Do not proceed with this test unless using WDS. Failure to follow this instruction
1 Connect the Test and Deployment Lead to the
driver air bag module - first stage.
2 Select DMM specific on WDS.
3 Connect the Test and Deployment Lead to
WDS.
G149926 en
11/2004 2005.25 Fiesta
501-20B-46

TO MODEL INDEX
501-20B-46

TEST CONDITIONS
driver air bag module - second stage.
5 Measure the resistance of the air bag module
squib.

Yes
No
INSTALL a new driver air bag module.
REFER to Driver Air Bag Module in this section. REPEAT the self-test, CLEAR the
O3: CHECK THE CLOCKSPRING FOR OPEN CIRCUIT OR HIGH RESISTANCE
NOTE: Vehicles with stability assist shown.
Vehicles with stability assist
91S-JA8 (BK/OG), harness side and the
clockspring C353 pin 3, circuit 91S-JA8
(BK/OG), harness side.
15S-JA8 (GN/RD), harness side and the
(GN/RD), harness side.
Vehicles without stability assist
Yes
G149926 en
11/2004 2005.25 Fiesta
501-20B-47

TO MODEL INDEX
501-20B-47

TEST CONDITIONS
the system.
No
PINPOINT TEST P: DTC B1933 PASSENGER AIR BAG FIRST STAGE OPEN CIRCUIT
TEST CONDITIONS
personal injury.
P1: CHECK THE PASSENGER AIR BAG FIRST STAGE CIRCUIT RESISTANCE
Yes
Go to P2
No
Go to P3
P2: CHECK THE PASSENGER AIR BAG MODULE SQUIB RESISTANCE
passenger air bag module - first stage.
WDS.
squib.
passenger air bag module - second stage.
squib.
G149926 en
11/2004 2005.25 Fiesta
501-20B-48

TO MODEL INDEX
501-20B-48

TEST CONDITIONS
Are the resistances between 2 and 3 ohms?

Yes
No
INSTALL a new passenger air bag module.
REFER to Passenger Air Bag Module in this
P3: CHECK THE PASSENGER AIR BAG FIRST STAGE WIRING HARNESS FOR OPEN CIRCUIT
OR HIGH RESISTANCE
3 Disconnect Passenger Air Bag First Stage
Simulator.
15S-JA31 (GN/WH), harness side and the
passenger air bag module C502 pin 1, circuit
15S-JA31 (GN/WH), harness side.
91S-JA31 (BK/WH), harness side and the
91S-JA31 (BK/WH), harness side.

Yes
No
PINPOINT TEST Q: DTC B1934 DRIVER AIR BAG FIRST STAGE LOW RESISTANCE
TEST CONDITIONS
personal injury.
Q1: CHECK THE DRIVER AIR BAG FIRST STAGE CIRCUIT RESISTANCE
G149926 en
11/2004 2005.25 Fiesta
501-20B-49

TO MODEL INDEX
501-20B-49

TEST CONDITIONS

Yes
Go to Q2
No
Go to Q3
Q2: CHECK THE DRIVER AIR BAG MODULE SQUIB RESISTANCE
WDS.
squib.
squib.

Yes
No
Q3: CHECK THE CLOCKSPRING FOR LOW RESISTANCE
G149926 en
11/2004 2005.25 Fiesta
501-20B-50

TO MODEL INDEX
501-20B-50

TEST CONDITIONS
(BK/OG), harness side and the air bag control
module C500 pin 10, circuit 15S-JA8 (GN/RD),
harness side.

Yes
the system.
No
PINPOINT TEST R: DTC B1935 PASSENGER AIR BAG FIRST STAGE LOW RESISTANCE
TEST CONDITIONS
personal injury.
R1: CHECK THE PASSENGER AIR BAG FIRST STAGE CIRCUIT RESISTANCE
Yes
Go to R2
No
Go to R3
R2: CHECK THE PASSENGER AIR BAG MODULE SQUIB RESISTANCE
WDS.
squib.
G149926 en
11/2004 2005.25 Fiesta
501-20B-51

TO MODEL INDEX
501-20B-51

TEST CONDITIONS
squib.

Yes
No
R3: CHECK THE PASSENGER AIR BAG FIRST STAGE WIRING HARNESS FOR LOW
RESISTANCE
2 Disconnect Passenger Air Bag First Stage
Simulator.
(GN/WH), harness side and the air bag control
module C500 pin 8, circuit 91S-JA31 (BK/WH),
harness side.

Yes
No
G149926 en
11/2004 2005.25 Fiesta
501-20B-52

TO MODEL INDEX
501-20B-52

TEST CONDITIONS
PINPOINT TEST S: DTC B1936 DRIVER AIR BAG FIRST STAGE SHORT TO GROUND
TEST CONDITIONS
personal injury.
S1: CHECK THE DRIVER AIR BAG FIRST STAGE CIRCUIT
Yes
Go to S2
No
Go to S3
S2: CHECK THE DRIVER AIR BAG MODULE
WDS.
4 Measure the resistance between each of the
terminals and the air bag module casing.

Yes
G149926 en
11/2004 2005.25 Fiesta
501-20B-53

TO MODEL INDEX
501-20B-53

TEST CONDITIONS
No
S3: CHECK THE DRIVER AIR BAG FIRST STAGE WIRING HARNESS FOR A SHORT TO GROUND
3 Disconnect Driver Air Bag Module First Stage
Simulator.
4 Measure the resistance, while turning the
steering wheel from lock to lock, between:

Yes
No
Go to S4
S4: CHECK THE CLOCKSPRING FOR A SHORT TO GROUND

Yes
G149926 en
11/2004 2005.25 Fiesta
501-20B-54

TO MODEL INDEX
501-20B-54

TEST CONDITIONS
the system.
No
PINPOINT TEST T: DTC B1938 PASSENGER AIR BAG FIRST STAGE SHORT TO GROUND
TEST CONDITIONS
personal injury.
T1: CHECK THE PASSENGER AIR BAG FIRST STAGE CIRCUIT RESISTANCE
Yes
Go to T2
No
Go to T3
T2: CHECK THE PASSENGER AIR BAG MODULE
WDS.
G149926 en
11/2004 2005.25 Fiesta
501-20B-55

TO MODEL INDEX
501-20B-55

TEST CONDITIONS

Yes
No
T3: CHECK THE PASSENGER AIR BAG FIRST STAGE WIRING HARNESS FOR A SHORT TO
GROUND
3 Disconnect Passenger Air Bag Module First
Stage Simulator.

Yes
No
91S-JA31 (BK/WH). REPEAT the self-test
G149926 en
11/2004 2005.25 Fiesta
501-20B-56

TO MODEL INDEX
501-20B-56

PINPOINT TEST U: DTC B1992 DRIVER SIDE AIR BAG SHORT TO BATTERY
TEST CONDITIONS
personal injury.
U1: CHECK THE DRIVER SIDE AIR BAG CIRCUIT
Yes
No
Go to U2
U2: CHECK THE DRIVER SIDE AIR BAG CIRCUIT FOR A SHORT TO BATTERY
1
2
3
4

Measure the voltage between:
the air bag control C501 pin 3, circuit 15S-JA37

Yes
REPAIR circuits 15S-JA37 (GN/BK) and
91S-JA37 (BK/GN). REPEAT the self-test,
No
PINPOINT TEST V: DTC B1993 DRIVER SIDE AIR BAG SHORT TO GROUND
TEST CONDITIONS
personal injury.
G149926 en
11/2004 2005.25 Fiesta
501-20B-57

TO MODEL INDEX
501-20B-57

TEST CONDITIONS
V1: CHECK THE DRIVER SIDE AIR BAG CIRCUIT

Yes
Go to V2
No
Go to V3
V2: CHECK THE DRIVER SIDE AIR BAG MODULE
driver side air bag module.
WDS.
terminals and the side air bag module casing.

Yes
No
INSTALL a new driver side air bag module.
REFER to Side Air Bag Module in this section. REPEAT the self-test, CLEAR the
V3: CHECK THE DRIVER SIDE AIR BAG CIRCUIT FOR A SHORT TO GROUND
3 Disconnect Driver Occupant Restraint Systems
Simulator.
G149926 en
11/2004 2005.25 Fiesta
501-20B-58

TO MODEL INDEX
501-20B-58

TEST CONDITIONS
the air bag control C501 pin 3, circuit 15S-JA37

Yes
No
PINPOINT TEST W: DTC B1994 DRIVER SIDE AIR BAG OPEN CIRCUIT
TEST CONDITIONS
personal injury.
W1: CHECK THE DRIVER SIDE AIR BAG CIRCUIT
Yes
Go to W2
No
Go to W3
W2: CHECK THE DRIVER SIDE AIR BAG MODULE SQUIB RESISTANCE
WDS.
G149926 en
11/2004 2005.25 Fiesta
501-20B-59

TO MODEL INDEX
501-20B-59

TEST CONDITIONS
squib.

Yes
No
W3: CHECK THE DRIVER SIDE AIR BAG WIRING HARNESS FOR OPEN CIRCUIT OR HIGH
RESISTANCE
3 Disconnect Driver Side Air Bag Module Simulator.
91S-JA37 (BK/GN), harness side and the driver
side air bag module connector C663 pin 3,
circuit 91S-JA37 (BK/GN), harness side.
15S-JA37 (GN/BK), harness side and the driver
side air bag module connector C663 pin 4, circuit 15S-JA37 (GN/BK), harness side.

Yes
No
G149926 en
11/2004 2005.25 Fiesta
501-20B-60

TO MODEL INDEX
501-20B-60

PINPOINT TEST X: DTC B1995 DRIVER SIDE AIR BAG LOW RESISTANCE ON SQUIB
TEST CONDITIONS
personal injury.
X1: CHECK THE DRIVER SIDE AIR BAG CIRCUIT
Yes
Go to X2
No
Go to X3
X2: CHECK THE DRIVER SIDE AIR BAG MODULE SQUIB RESISTANCE
WDS.
squib.

Yes
No
X3: CHECK THE DRIVER SIDE AIR BAG CIRCUIT FOR LOW RESISTANCE
3 Disconnect Driver Air Bag Simulator.
G149926 en
11/2004 2005.25 Fiesta
501-20B-61

TO MODEL INDEX
501-20B-61

TEST CONDITIONS
(BK/GN), harness side and the air bag control
module C501 pin 3, circuit 15S-JA37 (GN/BK),
harness side.

Yes
No
PINPOINT TEST Y: DTC B1996 PASSENGER SIDE AIR BAG SHORT TO BATTERY
TEST CONDITIONS
personal injury.
Y1: CHECK THE PASSENGER SIDE AIR BAG CIRCUIT
Yes
No
Go to Y2
Y2: CHECK THE PASSENGER SIDE AIR BAG CIRCUIT FOR A SHORT TO BATTERY
G149926 en
11/2004 2005.25 Fiesta
501-20B-62

TO MODEL INDEX
501-20B-62

TEST CONDITIONS
the air bag control C501 pin 21, circuit

Yes
No
PINPOINT TEST Z: DTC B1997 PASSENGER SIDE AIR BAG SHORT TO GROUND
TEST CONDITIONS
personal injury.
Z1: CHECK THE PASSENGER SIDE AIR BAG CIRCUIT
Yes
Go to Z2
No
Go to Z3
Z2: CHECK THE PASSENGER SIDE AIR BAG MODULE
passenger side air bag module.
WDS.
G149926 en
11/2004 2005.25 Fiesta
501-20B-63

TO MODEL INDEX
501-20B-63

TEST CONDITIONS
terminals and the side air bag module casing.

Yes
No
INSTALL a new passenger side air bag
module. REFER to Side Air Bag Module in
this section. REPEAT the self-test, CLEAR
Z3: CHECK THE PASSENGER SIDE AIR BAG CIRCUIT FOR A SHORT TO GROUND
1
2
3
4

Disconnect Passenger Side Air Bag Simulator.
Measure the resistance between:
the air bag control C501 pin 21, circuit

Yes
No
G149926 en
11/2004 2005.25 Fiesta
501-20B-64

TO MODEL INDEX
501-20B-64

PINPOINT TEST AA: DTC B1998 PASSENGER SIDE AIR BAG OPEN CIRCUIT
TEST CONDITIONS
personal injury.
AA1: CHECK THE PASSENGER SIDE AIR BAG CIRCUIT
Yes
Go to AA2
No
Go to AA3
AA2: CHECK THE PASSENGER SIDE AIR BAG MODULE SQUIB RESISTANCE
WDS.
squib.

Yes
No
AA3: CHECK THE PASSENGER SIDE AIR BAG WIRING HARNESS FOR OPEN CIRCUIT OR HIGH
RESISTANCE
2 Disconnect Disconnect Air Bag Control Module
C501.
G149926 en
11/2004 2005.25 Fiesta
501-20B-65

TO MODEL INDEX
501-20B-65

TEST CONDITIONS
3 Disconnect Passenger Side Air Bag Simulator.
91S-JA38 (BK/RD), harness side and the
passenger side air bag module connector C664
pin 3, circuit 91S-JA38 (BK/RD), harness side.
passenger side air bag module connector C664
pin 4, circuit 15S-JA38 (GN/OG), harness side.

Yes
No
PINPOINT TEST AB: DTC B1999 PASSENGER SIDE AIR BAG LOW RESISTANCE ON SQUIB
TEST CONDITIONS
personal injury.
AB1: CHECK THE PASSENGER SIDE AIR BAG CIRCUIT
Yes
Go to AB2
No
Go to AB3
AB2: CHECK THE PASSENGER SIDE AIR BAG MODULE SQUIB RESISTANCE
WDS.
G149926 en
11/2004 2005.25 Fiesta
501-20B-66

TO MODEL INDEX
501-20B-66

TEST CONDITIONS
squib.

Yes
No
AB3: CHECK THE PASSENGER SIDE AIR BAG CIRCUIT FOR LOW RESISTANCE
1
2
3
4

Disconnect Passenger Side Air Bag Simulator.
Measure the resistance between the air bag
(BK/RD), harness side and the air bag control
module C501 pin 21, circuit 15S-JA38 (GN/OG),
harness side.

Yes
No
G149926 en
11/2004 2005.25 Fiesta
501-20B-67

TO MODEL INDEX
501-20B-67

PINPOINT TEST AC: DTC B2227 FRONT CRASH SENSOR COMMUNICATIONS FAULT
TEST CONDITIONS
personal injury.
AC1: CHECK THE CRASH SENSOR CIRCUIT
1
2
3
4
Deactivate the SRS.

Disconnect Crash Sensor C662.
8-JA49 (WH), harness side and the crash
sensor C662 pin 1, circuit 8-JA49 (WH),
harness side.
9-JA49 (BN), harness side and the crash sensor
C662 pin 2, circuit 9-JA49 (BN), harness side.

Yes
Go to AC2
No
REPAIR circuits 8-JA49 (WH) and 9-JA49
(BN). REPEAT the self-test, CLEAR the
AC2: CHECK THE CRASH SENSOR FOR A SHORT CIRCUIT TO BATTERY
8-JA49 (WH), harness side and ground.
9-JA49 (BN), harness side and ground.

Yes
G149926 en
11/2004 2005.25 Fiesta
501-20B-68

TO MODEL INDEX
501-20B-68

TEST CONDITIONS
No
Go to AC3
AC3: CHECK THE CRASH SENSOR FOR A SHORT CIRCUIT TO GROUND
8-JA49 (WH) harness side and ground.
9-JA49 (BN) harness side and ground.
Are the resistance greater than 10,000 Ohms?

Yes
No
PINPOINT TEST AD: DTC B2228 DRIVER AIR BAG SECOND STAGE SHORT TO GROUND
TEST CONDITIONS
personal injury.
AD1: CHECK THE DRIVER AIR BAG SECOND STAGE CIRCUIT RESISTANCE
Yes
Go to AD2
No
Go to AD3
AD2: CHECK THE DRIVER AIR BAG MODULE
G149926 en
11/2004 2005.25 Fiesta
501-20B-69

TO MODEL INDEX
501-20B-69

TEST CONDITIONS
WDS.

Yes
No
AD3: CHECK THE DRIVER AIR BAG SECOND STAGE WIRING HARNESS FOR A SHORT TO
GROUND
3 Disconnect Driver Air Bag Module Second
Stage Simulator.
15S-JA48 (GN/BK), harness side and ground.

Yes
G149926 en
11/2004 2005.25 Fiesta
501-20B-70

TO MODEL INDEX
501-20B-70

TEST CONDITIONS
No
Go to AD4
AD4: CHECK THE CLOCKSPRING FOR A SHORT TO GROUND

Yes
the system.
No
PINPOINT TEST AE: DTC B2229 ERROR VALUE 19: PASSENGER AIR BAG SECOND STAGE
SHORT TO GROUND
TEST CONDITIONS
personal injury.
AE1: CHECK THE PASSENGER AIR BAG SECOND STAGE CIRCUIT RESISTANCE
Yes
Go to AE2
No
Go to AE3
G149926 en
11/2004 2005.25 Fiesta
501-20B-71

TO MODEL INDEX
501-20B-71

TEST CONDITIONS
AE2: CHECK THE PASSENGER AIR BAG MODULE

WDS.

Yes
No
AE3: CHECK THE PASSENGER AIR BAG SECOND STAGE WIRING HARNESS FOR A SHORT TO
GROUND
3 Disconnect Passenger Air Bag Module Second
Stage Simulator.
G149926 en
11/2004 2005.25 Fiesta
501-20B-72

TO MODEL INDEX
501-20B-72

TEST CONDITIONS
91S-JA32 (BK/YE), harness side and ground.
15S-JA32 (GN/YE), harness side and ground.

Yes
No
REPAIR circuits 15S-JA32 (GN/YE) and
91S-JA32 (BK/YE). REPEAT the self-test,
PINPOINT TEST AF: DTC B2230 DRIVER AIR BAG SECOND STAGE SHORT TO BATTERY
TEST CONDITIONS
personal injury.
AF1: CHECK THE DRIVER AIR BAG SECOND STAGE WIRING HARNESS FOR A SHORT TO
BATTERY OR IGNITION
2 Disconnect Driver Air Bag Module Second
Stage Simulator.

G149926 en
11/2004 2005.25 Fiesta
501-20B-73

TO MODEL INDEX
501-20B-73

TEST CONDITIONS
Yes
Go to AF2
No
CONNECT the driver air bag module second
stage simulator and the air bag control
AF2: CHECK THE CLOCKSPRING FOR A SHORT TO BATTERY OR IGNITION
1
2
3
4

Disconnect Clockspring C353 or C763.
Measure the voltage between:

Yes
No
the system.
PINPOINT TEST AG: DTC B2231 PASSENGER AIR BAG SECOND STAGE SHORT TO BATTERY
TEST CONDITIONS
personal injury.
AG1: CHECK THE PASSENGER AIR BAG SECOND STAGE WIRING HARNESS FOR A SHORT TO
BATTERY OR IGNITION
Stage Simulator.
G149926 en
11/2004 2005.25 Fiesta
501-20B-74

TO MODEL INDEX
501-20B-74

TEST CONDITIONS
91S-JA32 (BK/YE), harness side and ground.
15S-JA32 (GN/YE), harness side and ground.

Yes
No
second stage simulator and the air bag control module. REPEAT the self-test, CLEAR
PINPOINT TEST AH: DTC B2232 DRIVER AIR BAG SECOND STAGE OPEN CIRCUIT
TEST CONDITIONS
personal injury.
AH1: CHECK THE DRIVER AIR BAG SECOND STAGE CIRCUIT RESISTANCE
Yes
Go to AH2
No
Go to AH3
AH2: CHECK THE DRIVER AIR BAG MODULE SQUIB RESISTANCE
WDS.
G149926 en
11/2004 2005.25 Fiesta
501-20B-75

TO MODEL INDEX
501-20B-75

TEST CONDITIONS
squib.
squib.

Yes
No
AH3: CHECK THE CLOCKSPRING FOR OPEN CIRCUIT OR HIGH RESISTANCE
1
2
3
4

15S-JA48 (GN/BK), harness side and the
clockspring C353 or C763 pin 1, circuit
15S-JA48 (GN/BK), harness side.
91S-JA48 (BK/GN), harness side and the
clockspring C353 or C763 pin 2, circuit
91S-JA48 (BK/GN), harness side.

Yes
the system.
No
G149926 en
11/2004 2005.25 Fiesta
501-20B-76

TO MODEL INDEX
501-20B-76

TEST CONDITIONS
PINPOINT TEST AI: DTC B2233 PASSENGER AIR BAG SECOND STAGE OPEN CIRCUIT
TEST CONDITIONS
personal injury.
AI1: CHECK THE PASSENGER AIR BAG SECOND STAGE CIRCUIT RESISTANCE
Yes
Go to AI2
No
Go to AI3
AI2: CHECK THE PASSENGER AIR BAG MODULE SQUIB RESISTANCE
WDS.
squib.
squib.

Yes
No
G149926 en
11/2004 2005.25 Fiesta
501-20B-77

TO MODEL INDEX
501-20B-77

TEST CONDITIONS
AI3: CHECK THE PASSENGER AIR BAG SECOND STAGE WIRING HARNESS FOR OPEN
CIRCUIT OR HIGH RESISTANCE
Stage Simulator.
91S-JA32 (BK/YE), harness side and the
91S-JA32 (BK/YE), harness side.
15S-JA32 (GN/YE), harness side and the passenger air bag module C503 pin 1, circuit
15S-JA32 (GN/YE), harness side.

Yes
No
PINPOINT TEST AJ: DTC B2234 DRIVER AIR BAG SECOND STAGE LOW RESISTANCE ON
SQUIB
TEST CONDITIONS
personal injury.
AJ1: CHECK THE DRIVER AIR BAG SECOND STAGE CIRCUIT RESISTANCE
Yes
Go to AJ2
No
Go to AJ3
G149926 en
11/2004 2005.25 Fiesta
501-20B-78

TO MODEL INDEX
501-20B-78

TEST CONDITIONS
AJ2: CHECK THE DRIVER AIR BAG MODULE SQUIB RESISTANCE

WDS.
squib.
squib.

Yes
No
AJ3: CHECK THE CLOCKSPRING FOR LOW RESISTANCE
1
2
3
4

harness side.

G149926 en
11/2004 2005.25 Fiesta
501-20B-79

TO MODEL INDEX
501-20B-79

TEST CONDITIONS
Yes
the system.
No
PINPOINT TEST AK: DTC B2235 PASSENGER AIR BAG SECOND STAGE CIRCUIT LOW
RESISTANCE ON SQUIB
TEST CONDITIONS
personal injury.
AK1: CHECK THE PASSENGER AIR BAG SECOND STAGE RESISTANCE
Yes
Go to AK2
No
Go to AK3
AK2: CHECK THE PASSENGER AIR BAG MODULE SQUIB RESISTANCE
WDS.
squib.
squib.
G149926 en
11/2004 2005.25 Fiesta
501-20B-80

TO MODEL INDEX
501-20B-80

TEST CONDITIONS

Yes
No
AK3: CHECK THE PASSENGER AIR BAG SECOND STAGE WIRING HARNESS FOR LOW
RESISTANCE
Stage Simulator.
(BK/YE), harness side and the air bag control
module C500 pin 3, circuit 15S-JA32 (GN/YE),
harness side.

Yes
No
PINPOINT TEST AL: DTC B2773 DRIVER SIDE AIR CURTAIN LOW RESISTANCE ON SQUIB
TEST CONDITIONS
personal injury.
AL1: CHECK THE DRIVER SIDE AIR CURTAIN MODULE CIRCUIT RESISTANCE
G149926 en
11/2004 2005.25 Fiesta
501-20B-81

TO MODEL INDEX
501-20B-81

TEST CONDITIONS

Yes
Go to AL2
No
Go to AL3
AL2: CHECK THE DRIVER SIDE AIR CURTAIN MODULE SQUIB RESISTANCE
driver side air curtain module.
WDS.

Yes
No
INSTALL a new driver side air curtain module. REFER to Side Air Curtain Module 3-Door/ Side Air Curtain Module - 5-Door in
AL3: CHECK THE DRIVER SIDE AIR CURTAIN WIRING HARNESS FOR LOW RESISTANCE
2 Disconnect Driver Side Air Curtain Simulator.
G149926 en
11/2004 2005.25 Fiesta
501-20B-82

TO MODEL INDEX
501-20B-82

TEST CONDITIONS
harness side.

Yes
No
PINPOINT TEST AM: DTC B2774 DRIVER SIDE AIR CURTAIN OPEN CIRCUIT
TEST CONDITIONS
personal injury.
AM1: CHECK THE DRIVER SIDE AIR CURTAIN CIRCUIT RESISTANCE
Yes
Go to AM2
No
Go to AM3
AM2: CHECK THE DRIVER SIDE AIR CURTAIN MODULE SQUIB RESISTANCE
WDS.
G149926 en
11/2004 2005.25 Fiesta
501-20B-83

TO MODEL INDEX
501-20B-83

TEST CONDITIONS
4 Measure the resistance of the side air curtain
module squib.

Yes
No
AM3: CHECK THE DRIVER SIDE AIR CURTAIN WIRING HARNESS FOR OPEN CIRCUIT OR HIGH
RESISTANCE
1
2
3
4

Disconnect Driver Side Air Curtain Simulator.
15S-JA50 (GN/OG), harness side and the driver
side air curtain module C674 pin 1, circuit
15S-JA50 (GN/OG), harness side.
91S-JA50 (BK/RD), harness side and the driver
side air curtain module C674 pin 2, circuit
91S-JA50 (BK/RD), harness side.

Yes
No
G149926 en
11/2004 2005.25 Fiesta
501-20B-84

TO MODEL INDEX
501-20B-84

PINPOINT TEST AN: DTC B2775 DRIVER SIDE AIR CURTAIN SHORT TO GROUND
TEST CONDITIONS
personal injury.
AN1: CHECK THE DRIVER SIDE AIR CURTAIN CIRCUIT
Yes
Go to AN2
No
Go to AN3
AN2: CHECK THE DRIVER SIDE AIR CURTAIN MODULE
WDS.
terminals and the side air curtain module casing.

Yes
No
AN3: CHECK THE DRIVER SIDE AIR CURTAIN WIRING HARNESS FOR A SHORT TO GROUND
G149926 en
11/2004 2005.25 Fiesta
501-20B-85

TO MODEL INDEX
501-20B-85

TEST CONDITIONS
3 Disconnect Driver Side Air Curtain Module
Simulator.

Yes
No
91S-JA50 (BK/RD). REPEAT the self-test
PINPOINT TEST AO: TC B2776 DRIVER SIDE AIR CURTAIN SHORT TO BATTERY
TEST CONDITIONS
personal injury.
AO1: CHECK THE DRIVER SIDE AIR CURTAIN WIRING HARNESS FOR A SHORT TO BATTERY
OR IGNITION
2 Disconnect Driver Side Air Curtain Module
Simulator.
4 Key in ON position.
G149926 en
11/2004 2005.25 Fiesta
501-20B-86

TO MODEL INDEX
501-20B-86

TEST CONDITIONS

Yes
No
CONNECT the driver side air curtain module
simulator and the air bag control module.
PINPOINT TEST AP: DTC B2777 PASSENGER SIDE AIR CURTAIN LOW RESISTANCE ON SQUIB
TEST CONDITIONS
personal injury.
AP1: CHECK THE PASSENGER SIDE AIR CURTAIN MODULE CIRCUIT RESISTANCE
Yes
Go to AP2
No
Go to AP3
AP2: CHECK THE PASSENGER SIDE AIR CURTAIN MODULE SQUIB RESISTANCE
passenger side air curtain module.
WDS.
G149926 en
11/2004 2005.25 Fiesta
501-20B-87

TO MODEL INDEX
501-20B-87

TEST CONDITIONS
module squib.

Yes
No
INSTALL a new passenger side air curtain
module. REFER to Side Air Curtain Module 3-Door/ Side Air Curtain Module - 5-Door in
AP3: CHECK THE PASSENGER SIDE AIR CURTAIN WIRING HARNESS FOR LOW RESISTANCE
2 Disconnect Passenger Side Air Curtain Module
Simulator.
harness side.

Yes
No
G149926 en
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501-20B-88

TO MODEL INDEX
501-20B-88

PINPOINT TEST AQ: DTC B2778 PASSENGER SIDE AIR CURTAIN OPEN CIRCUIT
TEST CONDITIONS
personal injury.
AQ1: CHECK THE PASSENGER SIDE AIR CURTAIN CIRCUIT RESISTANCE
Yes
Go to AQ2
No
Go to AQ3
AQ2: CHECK THE PASSENGER SIDE AIR CURTAIN MODULE SQUIB RESISTANCE
WDS.
module squib.

Yes
No
AQ3: CHECK THE PASSENGER SIDE AIR CURTAIN WIRING HARNESS FOR OPEN CIRCUIT OR
HIGH RESISTANCE
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501-20B-89

TO MODEL INDEX
501-20B-89

TEST CONDITIONS
Simulator.
91S-JA51 (BK/BU), harness side and the
passenger side air curtain module C675 pin 2,
circuit 91S-JA51 (BK/BU), harness side.
15S-JA51 (GN/BU), harness side and the
passenger side air curtain module C675 pin 1,
circuit 15S-JA51 (GN/BU), harness side.

Yes
No
PINPOINT TEST AR: DTC B2779 PASSENGER SIDE AIR CURTAIN SHORT TO GROUND
TEST CONDITIONS
personal injury.
AR1: CHECK THE PASSENGER SIDE AIR CURTAIN CIRCUIT
Yes
Go to AR2
No
Go to AR3
AR2: CHECK THE PASSENGER SIDE AIR CURTAIN MODULE
WDS.
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501-20B-90

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501-20B-90

TEST CONDITIONS
terminals and the side air curtain module casing.

Yes
No
AR3: CHECK THE PASSENGER SIDE AIR CURTAIN WIRING HARNESS FOR A SHORT TO
GROUND
Simulator.

Yes
No
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501-20B-91

TO MODEL INDEX
501-20B-91

TEST CONDITIONS
PINPOINT TEST AS: DTC B2780 PASSENGER SIDE AIR CURTAIN SHORT TO BATTERY
TEST CONDITIONS
personal injury.
AS1: CHECK THE PASSENGER SIDE AIR CURTAIN WIRING HARNESS FOR A SHORT TO
BATTERY OR IGNITION
Simulator.

Yes
No
CONNECT the passenger side air curtain
module simulator and the air bag control
PINPOINT TEST AT: DTC B2791 AIR BAG CUT-OFF SWITCH OUT OF RANGE
TEST CONDITIONS
personal injury.
AT1: CHECK THE VOLTAGE TO THE PAD SWITCH
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501-20B-92

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501-20B-92

TEST CONDITIONS
2 Operate the PAD switch to the OFF position.
Does the pad indicator LED illuminate?

Yes
Go to AT2
No
Go to AT3
AT2: CHECK FOR CONTINUITY BETWEEN THE AIR BAG CONTROL MODULE AND THE PAD
SWITCH
1
2
3
4

Deactivate the SRS.
Operate the PAD control switch to the ON position.

Yes
No
REPAIR circuit 91S-JA10 (BK/RD). REPEAT
AT3: CHECK THE PAD CONTROL SWITCH GROUND CIRCUIT
3 Disconnect PAD Control Switch C713.
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501-20B-93

TEST CONDITIONS
4 Measure the resistance between the PAD control switch C713 pin 5, circuit 91-JA47 (BK/OG),

Yes
Go to AT4
No
REPAIR circuit 91-JA47 (BK/OG). REPEAT
AT4: CHECK FOR CONTINUITY BETWEEN THE PAD INDICATOR AND THE PAD SWITCH
1 Disconnect PAD Indicator C714.
2 Measure the resistance between the PAD indicator C714 pin 6, circuit 91S-JA56 (BK/RD),
harness side and the PAD switch C713 pin 4,
circuit 91S-JA56 (BK/RD), harness side.

Yes
Go to AT5
No
AT5: CHECK THE PAD INDICATOR SUPPLY CIRCUIT
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501-20B-94

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501-20B-94

TEST CONDITIONS
2 Measure the voltage between the PAD indicator
C714 pin 7, circuit 15-JA56 (GN/OG), harness
side and ground.

Yes
INSTALL a new PAD indicator. REPEAT the
the system.
No
Go to AT6
AT6: CHECK FOR CONTINUITY BETWEEN THE AIR BAG CONTROL MODULE AND THE PAD
INDICATOR
(GN/OG), harness side and the PAD indicator
C714 pin 7, circuit 15-JA56 (GN/OG), harness
side.

Yes
No
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501-20B-95

TO MODEL INDEX
501-20B-95

PINPOINT TEST AU: DTC B2791 AIR BAG CUT-OFF SWITCH USER FAULT
TEST CONDITIONS
personal injury.
AU1: CHECK THE PAD LED OPERATION
2 Operate the PAD control switch to the ON position.
Does the PAD indicator LED illuminate?
Yes
Go to AU2
No
Go to AU3
AU2: CHECK FOR CONTINUITY BETWEEN THE PAD LED AND GROUND
1
2
3
4

Deactivate the SRS.
Disconnect PAD control switch C713.
Operate the PAD switch to the ON position.

Yes
No
Go to AU3
AU3: CHECK THE PAD CONTROL SWITCH GROUND CIRCUIT

Yes
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501-20B-96

TEST CONDITIONS
No
PINPOINT TEST AV: DTC U2017 DRIVER SIDE IMPACT SENSOR COMMUNICATIONS FAULT
TEST CONDITIONS
personal injury.
AV1: CHECK THE DRIVER SIDE IMPACT SENSOR CIRCUIT
1
2
3
4
5

Deactivate the SRS.
Disconnect Driver Side Impact Sensor C665.
8-JA39 (WH), harness side and the driver side
impact sensor C665 pin 2, circuit 8-JA39 (WH),
harness side.
9-JA39 (BN), harness side and the driver side
impact sensor C665 pin 1, circuit 9-JA39 (BN),
harness side.

Yes
Go to AV2
No
AV2: CHECK THE DRIVER SIDE IMPACT SENSOR FOR A SHORT CIRCUIT TO BATTERY
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501-20B-97

TEST CONDITIONS

Yes
REPAIR circuit 8-JA39 (WH) or circuit
9-JA39 (BN). REPEAT the self-test, CLEAR
No
Go to AV3
AV3: CHECK THE DRIVER SIDE IMPACT SENSOR FOR A SHORT CIRCUIT TO GROUND

Yes
No
PINPOINT TEST AW: DTC U2018 PASSENGER SIDE IMPACT SENSOR COMMUNICATIONS
FAULT
TEST CONDITIONS
personal injury.
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501-20B-98

TO MODEL INDEX
501-20B-98

TEST CONDITIONS
AW1: CHECK THE PASSENGER SIDE IMPACT SENSOR CIRCUIT

2 Disconnect Passenger Side Impact Sensor
C666.
8-JA40 (WH/VT), harness side and the
passenger side impact sensor C666 pin 2,
circuit 8-JA40 (WH/VT), harness side.
9-JA40 (BN/WH), harness side and the passenger side impact sensor C666 pin 1, circuit
9-JA40 (BN/WH), harness side.

Yes
Go to AW2
No
REPAIR circuits 8-JA40 (WH/VT) and
9-JA40 (BN/WH). REPEAT the self-test,
AW2: CHECK THE PASSENGER SIDE IMPACT SENSOR FOR A SHORT CIRCUIT TO BATTERY
8-JA40 (WH/VT), harness side and ground.
9-JA40 (BN/WH), harness side and ground.

Yes
REPAIR circuit 8-JA40 (WH/VT) or circuit
No
Go to AW3
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501-20B-99

TEST CONDITIONS
AW3: CHECK THE PASSENGER SIDE IMPACT SENSOR FOR A SHORT CIRCUIT TO GROUND
Are the resistances greater than 10,000 Ohms?

Yes
No
PINPOINT TEST AX: AIR BAG CONTROL MODULE DISCONNECTED OR INOPERATIVE
TEST CONDITIONS
AX1: CHECK THE AIR BAG CONTROL MODULE ELECTRICAL CONNECTORS
2 Check the air bag control module electrical
connectors.
Are the air bag control module electrical connectors fully engaged?
Yes
Go to AX2
No
CONNECT the air bag control module electrical connectors. REPEAT the self-test,
AX2: CHECK THE IGNITION SUPPLY CIRCUIT FOR AN OPEN CIRCUIT
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501-20B-100

TEST CONDITIONS

Yes
Go to AX3
No
GO to AX4
AX3: CHECK THE AIR BAG CONTROL MODULE GROUND CIRCUIT

Yes
No
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501-20B-101

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501-20B-101

TEST CONDITIONS
AX4: CHECK THE IGNITION SUPPLY CIRCUIT


Yes
CHECK the charging circuit. REFER to Section 414-00.[Charging System - General Information, DIAGNOSIS AND TESTING,
Charging System] REPEAT the self-test,
No
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501-20B-102

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501-20B-102

Vehicles Built From: 11/2004
Diagnosing Customer Concerns Without Hard
DTCs/LFCs
Special Tool(s)
Simulator Air Bag, Driver
Safety Belt Retractor and
Pretensioner (5-door)
418-037 (40-001)
Driver Safety Belt Retractor
and Pretensioner (5-door)
418-056 (40-007-01)
Driver, Passenger and Side
Air Curtain Module
418-141 (40-007-08)
Side Air Bag Module
418-555
Air Curtains
501-073A
Simulator, Occupant
Restraint Systems
501-092 (40-021)
General Equipment
Driver air bag wiring harness

personal injury.
NOTE: Following the pinpoint tests when a
diagnostic trouble code/lamp fault code
(DTC/LFC) is not present, or the air bag warning
lamp is not permanently illuminated, will result in
needless replacement of air bag system
components and repeat repairs.
Speak with the customer to determine if a
particular set of conditions must be met in order
for a fault to occur. If a LFC is reported by the
customer but is not present when the vehicle
comes in for repair, pinpoint test diagnostics
cannot be used. Instruct the customer on how to
count a LFC.
Diagnosing Customer Concerns with Hard
DTCs/LFCs
adjustment to the SRS, or any
component(s) adjacent to the SRS
sensors. Failure to follow these
Most air bag system diagnostic procedures
require the use of system deactivation and system
reactivation procedures. These procedures
require the air bag module(s) and safety belt
pretensioners to be disconnected from the SRS,
thereby removing the risk of an air bag
deployment while diagnostics are carried out.
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501-20B-103

Air bag simulators are required to carry out
diagnosis and testing of the air bag system. The
simulator contains a resistor, used to simulate an
air bag module connection to the system. It is not
acceptable to short-circuit the air bag module
connections with a 0 ohm jumper wire. If a 0 ohm
jumper wire is used to short-circuit the air bag
module connections, a LFC will be displayed and
a DTC logged by the air bag control module.
Deactivation
adjustment to the SRS, or any
component(s) adjacent to the SRS
sensors. Failure to follow these
Disconnect]
its stored energy.
4. Connect a test driver air bag module wiring

harness to the clockspring.
5. Connect the driver air bag simulator to the
driver air bag module wiring harness in place
of the driver air bag module at the top of the
steering column.
6. Disconnect the passenger air bag module
electrical connector. REFER to Passenger Air
Bag Module in this section.
7. Connect the passenger air bag simulator to
the wiring harness in place of the passenger
air bag module.
8. Disconnect the side air curtain module
electrical connector on both sides. REFER to
Side Air Curtain Module - 3-Door / Side Air
Curtain Module - 5-Door in this section.
9. Connect the side air curtain simulators to the
wiring harnesses in place of the side air
curtain modules.
10. Disconnect the driver side underseat occupant
restraint systems electrical connector.
11. Connect the occupant restraint systems
simulator to the driver side underseat
occupant restraint systems electrical
connector in place of the driver safety belt
pretensioner (3-door only) and driver side air
bag module.
NOTE: This step is only necessary for 5-door
vehicles.
WARNING: Place the air bag module on a

ground wired bench, with the trim cover
facing up to avoid accidental deployment.
3. Remove the driver air bag module from the
vehicle. REFER to Driver Air Bag Module in
this section.
NOTE: REFER to FordEcat for a compatible
driver air bag module wiring harness to use as a
test lead.
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501-20B-104

12. Disconnect the driver safety belt retractor and
pretensioner at the base of the B-pillar.
pretensioner simulator to the wiring harness in
place of the driver safety belt retractor and
pretensioner.
14. Disconnect the passenger underseat air bag
side underseat occupant restraint systems
15. Connect the occupant restraint systems
simulator to the passenger side underseat
connector in place of the safety belt
pretensioner and side air bag module.
Disconnect]
Reactivation
WARNING: The air bag simulators must
be removed and the air bag modules
reconnected when reactivated to avoid
non-deployment in a collision. Failure to
personal injury.
Disconnect]
its stored energy.
NOTE: If a new driver air bag module wiring
harness has been used for testing the wiring
harness should be retained for future test use
only.
3. Remove the driver air bag simulators and test

driver air bag module wiring harness from the
top of the steering column.
4. Remove the driver air bag simulator from the
sub-harness at the top of the steering column.
5. Connect and install the driver air bag module.
REFER to Driver Air Bag Module in this
section.
6. Remove the passenger air bag simulator from
the passenger air bag module harness.
7. Connect and install the passenger air bag
module. REFER to Passenger Air Bag
Module in this section.
8. Remove the side air curtain simulators from
the side air curtain module wiring harnesses.
9. Connect and install the side air curtain
modules. REFER to Side Air Curtain Module 3-Door / Side Air Curtain Module - 5-Door in
this section.
10. Remove the driver side underseat occupant
restraint systems simulator.
11. Connect the driver side underseat occupant
restraint systems electrical connector.
vehicles.
12. Remove the driver safety belt retractor and
pretensioner simulator.
vehicles.
14. Remove the passenger side underseat
occupant restraint systems simulator.
15. Connect the passenger side underseat
connector.
Disconnect]
17. Prove out the system.
Glossary
Air Bag Simulator
Air bag simulators are used to simulate air bag

module connections to the system.
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501-20B-105

Deactivate The System
Deactivate the system means to carry out

deactivation. REFER to Deactivation in this
procedure.
Prove Out The System
The air bag warning indicator will illuminate for

three seconds.
Reactivate The System
Reactivate the system means to carry out

reactivation. REFER to Reactivation in this
procedure.
SRS Operation
The SRS is DC fired. Vehicles equipped with side

air bags and side air curtains are equipped with
side impact sensors.
In the event of a severe frontal or three-quarter
frontal impact, in excess of a predetermined limit,
the driver and passenger (if equipped) front air
bag(s) will deploy.
In the event of a severe full side impact, in excess
of a predetermined limit, either the driver or
passenger side air bags (if equipped) and side air
curtains (if equipped) will deploy.
Air bag deployment will only occur, in the event of
a severe collision when the ignition key is in the
RUN position. The passenger air bag deactivation
(PAD) switch (if equipped) will deactivate the
passenger air bag in the event of a severe frontal
or side impact; it will not deactivate the passenger
side air bag, passenger side air curtain or
passenger safety belt buckle pretensioner.
The air bag control module is mounted

horizontally to the floor pan beneath the floor
console, to facilitate impact sensing along the
longitudinal axis. The air bag control module
retains full control of the whole system, providing
continual system checks and full diagnostic
capabilities. The non-volatile memory stores the
fault codes, which are down loaded through the
data link connector (DLC) to WDS. A visual air bag
warning indicator housed within the instrument
cluster, is illuminated when the ignition is switched
ON for approximately three seconds and then
goes out. If a fault occurs, after five seconds the
air bag warning indicator either begins to flash or
G428951 en
illuminates continuously depending on the nature

of the fault.
In the event of a failure in the vehicle power supply
during an accident, the air bag control module
provides an auxiliary power supply, sufficient to
deploy the front air bag(s) for a minimum of 150
ms. The auxiliary power supply is discharged by
the air bag control module within 60 seconds of
the battery ground cable being disconnected.
Thus making sure that the SRS remains
operational.
The air bag control module contains a
micro-controller to evaluate and process impact
data. In the event of a frontal impact, in excess of
a predetermined limit, the air bag control module
will evaluate the signal received from the internal
crash sensor against stored data and deploy the
frontal air bags and safety belt pretensioners.
Side Impact Sensors
The side impact sensors contain an acceleration

sensor, filter, amplifier and an application specific
integrated circuit for signal transmitting.
The side impact sensor processes the impact data
against stored data. In the event of a side impact,
in excess of a predetermined limit, the side impact
sensor will send a signal to the air bag control
module. A signal is then sent from the air bag
control module to deploy the side air bags and
side air curtains (if equipped).
The air bag warning indicator is incorporated into

the instrument cluster, together with the automatic
detach detect circuit. The air bag warning indicator
illuminates for three seconds at key ON. If the
system self-tests OK the indicator extinguishes, if
a fault is detected the indicator will flash after five
seconds, illuminate continually from key ON or not
illuminate at all, depending on the nature of the
fault.
The automatic detach detect circuit is designed to
illuminate the air bag warning indicator
continuously, if the air bag control module circuit is
broken, either by:
11/2004 2005.25 Fiesta
501-20B-106

TO MODEL INDEX
501-20B-106

Loss of the air bag control module circuit
power supply.
Loss of the air bag control module circuit
ground circuit.
Disconnection of the air bag control module
Diagnostic evaluation of the supplemental
restraints system can be made through the DLC
and WDS to establish the nature of the concern.
Electrical
3.
Fuse(s)
Air bag module(s)
Circuit(s)
step.
4. If the cause is not visually evident, connect
WDS to the DLC and select the vehicle to be
tested from the WDS menu.
5. Retrieve the DTCs and refer to the Symptom
Chart.

Symptom Chart
Symptom
Possible Sources
Action
NOTE: It is only allowed to repair circuits between connectors. If damage has occurred within a connector
a connector replacement kit, if available, must be installed. If a connector replacement kit is not available
a new wiring harness must be installed. Connectors must not be disassembled.
No communication with the
DLC.
GO to Pinpoint Test AY
module
Circuit(s).
DTC B1231: Longitudinal accel- Crash data memory full.
eration threshold exceeded.
Lamp flash code: 13
NOTE: The crash data memory

can be cleared a maximum of five
times.
Clear down the crash data
memory using WDS. Repeat the
self-test, CLEAR the DTCs.
DTC B1317: Battery voltage

Charging system.
high. Lamp flash code: continuous
CHECK the charging system.

REFER to Section
414-00.[Charging System General Information, GENERAL
PROCEDURES, Battery Charging] Repeat the self-test, CLEAR
the DTCs.
DTC B1318: Battery voltage low. Battery.

Lamp flash code: continuous
Charging system.
Circuit.
GO to Pinpoint Test AZ

module is defective. Lamp flash
code: 12

the DTCs.

Instrument cluster.
indicator open circuit or short to Air bag control module.
ground. Lamp flash code: con- Circuit(s).
tinuous
GO to Pinpoint Test BA
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501-20B-107

Symptom
Possible Sources
Action

indicator circuit short to battery.
Lamp flash code: No lamp
Instrument cluster.
Circuit.
GO to Pinpoint Test BB
DTC B1877: Driver side safety

belt pretensioner open circuit.
Lamp flash code: 33
Driver side safety belt

pretensioner.
Circuit(s).
GO to Pinpoint Test BC
DTC B1878: Driver side safety Driver side safety belt

belt pretensioner short to battery. pretensioner.
Lamp flash code: 33
Circuit(s).
GO to Pinpoint Test BD
DTC B1879: Driver side safety

belt pretensioner short to
Driver side safety belt

pretensioner.
Circuit.
GO to Pinpoint Test BE

safety belt pretensioner open
circuit. Lamp flash code: 34
Passenger side safety belt

pretensioner.
Circuit.
GO to Pinpoint Test BF

safety belt pretensioner short to pretensioner.
battery. Lamp flash code: 34
Circuit.
GO to Pinpoint Test BG

safety belt pretensioner short to pretensioner.
Circuit.
GO to Pinpoint Test BH
DTC B1885: Driver side safety Driver side safety belt

belt pretensioner low resistance. pretensioner.
Lamp flash code: 33
Circuit.
GO to Pinpoint Test BI

safety belt pretensioner low resistance. Lamp flash code: 34
GO to Pinpoint Test BJ

pretensioner.
Circuit.
DTC B1916: Driver air bag short Clockspring.

to battery. Lamp flash code: 19 Circuit.
GO to Pinpoint Test BK

short to battery. Lamp flash
code: 21
GO to Pinpoint Test BL
Circuit(s).
DTC B1932: Driver air bag open Driver air bag module.
circuit. Lamp flash code: 19
Clockspring.
Circuit(s).
GO to Pinpoint Test BM

open circuit. Lamp flash code: 21 Circuit(s).
GO to Pinpoint Test BN
DTC B1934: Driver air bag circuit Driver air bag module.
low resistance. Lamp flash code: Clockspring.
19
Circuit(s).
GO to Pinpoint Test BO

circuit low resistance. Lamp flash Circuit(s).
code: 21
GO to Pinpoint Test BP
DTC B1936: Driver air bag circuit Driver air bag module.
short to ground. Lamp flash
Clockspring.
code: 19
Circuit.
GO to Pinpoint Test BQ
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TO MODEL INDEX
501-20B-108

Symptom
circuit short to ground. Lamp
flash code: 21
Possible Sources
Circuit.
DTC B1992: Driver side, side air Circuit.

bag circuit short to battery. Lamp
flash code: 22
Action
GO to Pinpoint Test BR
GO to Pinpoint Test BS
DTC B1993: Driver side, side air Driver side, side air bag module. GO to Pinpoint Test BT
bag circuit short to ground. Lamp Circuit.
flash code: 22
DTC B1994: Driver side, side air Driver side, side air bag module. GO to Pinpoint Test BU
bag circuit open circuit. Lamp
Circuit.
flash code: 22
DTC B1995: Driver side, side air Driver side, side air bag module. GO to Pinpoint Test BV
bag circuit low resistance on
Circuit.
DTC B1996: Passenger side,
side air bag circuit short to battery. Lamp flash code: 23
Passenger side, side air bag

module.
Circuit.
GO to Pinpoint Test BW

side air bag circuit short to

module.
Circuit.
GO to Pinpoint Test BX

side air bag circuit open circuit.
Lamp flash code: 23

module.
Circuit.
GO to Pinpoint Test BY

side air bag circuit low resistance module circuit.
on squib. Lamp flash code: 23
Circuit.
GO to Pinpoint Test BZ
DTC B2444: Driver side, side

impact sensor internal fault.
Lamp flash code: 43
Driver side, side impact sensor. INSTALL a new driver side, side
impact sensor. REFER to Side
CLEAR the DTCs.

Passenger side, side impact
side impact sensor internal fault. sensor.
Lamp flash code: 44
INSTALL a new passenger side,

side impact sensor. REFER to
Side Impact Sensor - 3-Door /
Side Impact Sensor - 5-Door in
this section. REPEAT the

module configuration failure.
Lamp flash code: 54
CONFIGURE the air bag control

module. REFER to WDS.
the DTCs.
DTC B2773: Driver side, side air Driver side, side air curtain
curtain circuit low resistance on module.
Circuit(s).
G428951 en
GO to Pinpoint Test CA
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501-20B-109

Symptom
Possible Sources
Action
curtain circuit open circuit. Lamp module.
flash code: 24
Circuit(s).
GO to Pinpoint Test CB
curtain circuit short to ground.
module.
Lamp flash code: 24
Circuit(s).
GO to Pinpoint Test CC
DTC B2776: Driver side, side air Circuit(s).

curtain circuit short to battery.
Lamp flash code: 24
GO to Pinpoint Test CD

Passenger side, side air curtain GO to Pinpoint Test CE
side air curtain circuit low resis- module.
tance on squib. Lamp flash code: Circuit(s).
25
side air curtain circuit open circuit. Lamp flash code: 25
Passenger side, side air curtain GO to Pinpoint Test CF

module.
Circuit(s).

side air curtain circuit short to
Passenger side, side air curtain GO to Pinpoint Test CG

module.
Circuit(s).

side air curtain circuit short to
battery. Lamp flash code: 25
Circuit(s).
GO to Pinpoint Test CH

switch out of range. Lamp flash
code: 56
Circuit(s).
GO to Pinpoint Test CI

switch in middle position. Lamp
flash code: 56
PAD switch.
Circuit
CARRY OUT the PAD Switch

Wiring Diagrams. REPEAT the
GO to Pinpoint Test CJ
DTC U2017: Driver side, side

impact sensor communications
fault. Lamp flash code: 43
Driver side, side impact sensor. CHECK the driver side, side
Circuit(s).
impact sensor calibration.
REFER to WDS. REPEAT the
GO to Pinpoint Test CK
DTC U2018: Passenger side,

Passenger side, side impact
side impact sensor communica- sensor.
tions fault. Lamp flash code: 44 Circuit(s).
CHECK the passenger side, side

impact sensor calibration.
REFER to WDS. REPEAT the
GO to Pinpoint Test CL
Air bag control module disconnected or inoperative. Lamp

flash code: continuous
GO to Pinpoint Test CM
G428951 en

Circuit(s).
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501-20B-110

Pinpoint Tests
PINPOINT TEST AY: NO COMMUNICATION WITH THE MODULE
TEST CONDITIONS
WARNING: To avoid accidental deployment, the air bag control module backup power supply
must be depleted. Wait at least one minute after disconnecting the battery ground cable(s)
before commencing any repair or adjustment to the SRS, or any component(s) adjacent to
the SRS sensors. Failure to follow these instructions may result in personal injury.
AY1: CHECK THAT WDS IS COMMUNICATING THROUGH THE DLC
1 Select an alternative system to check the DLC.
Is WDS able to communicate with the selected
system?
Yes
Go to AY2
No
CHECK the DLC. For additional information,
REFER to the Wiring Diagrams. REPEAT the
AY2: CHECK THE AIR BAG WARNING INDICATOR
2 The air bag warning indicator should illuminate
when the ignition is in the ON position for three
seconds and then go out. If a fault is present,
the air bag warning light will then begin to flash.
Is the warning indicator operating?
Yes
Go to AY3
No
Cluster]
AY3: CHECK THE DLC CIRCUIT
1
2
3
4
G428951 en

Deactivate the SRS.
Measure the resistance between the DLC C308
pin 7, circuit 4-EE10 (GY/BK) and the air bag
control module C500 pin 17, circuit 4-EE7
(GY/RD), harness side.
11/2004 2005.25 Fiesta
501-20B-111

TO MODEL INDEX
501-20B-111

TEST CONDITIONS
Yes
section. REACTIVATE the system. If the air
bag warning indicator is flashing, count the
lamp flash code and REFER to the Symptom
Chart in this section.
No
REPAIR circuit 4-EE7 (GY/RD) or circuit
4-EE10 (GY/BK). REPEAT the self-test,
PINPOINT TEST AZ: DTC B1318: BATTERY VOLTAGE LOW

TEST CONDITIONS
AZ1: CHECK THE IGNITION SUPPLY CIRCUIT FOR AN OPEN CIRCUIT

Yes
Go to AZ2
No
AZ2: CHECK THE AIR BAG CONTROL MODULE GROUND CIRCUIT
G428951 en
11/2004 2005.25 Fiesta
501-20B-112

TO MODEL INDEX
501-20B-112

TEST CONDITIONS

Yes
No
PINPOINT TEST BA: DTC B1869: AIR BAG WARNING INDICATOR OPEN CIRCUIT OR SHORT TO
GROUND
TEST CONDITIONS
BA1: CHECK THE AIR BAG WARNING INDICATOR
2 Check the air bag warning indicator.
Is the air bag warning indicator illuminated continuously?
Yes
Go to BA2
No
Go to BA5
BA2: CHECK FOR CONTINUITY BETWEEN THE AIR BAG CONTROL MODULE AND THE
INSTRUMENT CLUSTER
1
2
3
4
G428951 en

Deactivate the SRS.
11/2004 2005.25 Fiesta
501-20B-113

TO MODEL INDEX
501-20B-113

TEST CONDITIONS
cluster C332 pin 9, circuit 91S-JA14 (BK/GN),
harness side and the air bag control module
C500 pin 11, circuit 91S-JA14 (BK/GN), harness side.

Yes
Go to BA3
No
BA3: CHECK THE INSTRUMENT CLUSTER AIR BAG WARNING INDICATOR FUNCTION
1 Connect Instrument Cluster C332.
2 Install a fused (7.5A) jumper wire between the

Yes
No
Go to BA4
G428951 en
11/2004 2005.25 Fiesta
501-20B-114

TO MODEL INDEX
501-20B-114

TEST CONDITIONS
BA4: CHECK THE AIR BAG WARNING INDICATOR GROUND FUNCTION

1 With the fused (7.5A) jumper wire between the
2 Disconnect Fused Jumper Wire From Ground.

Yes
to Section 413-01.[Instrument Cluster,
REMOVAL AND INSTALLATION, Instrument Cluster] REPEAT the self-test, CLEAR
No
BA5: CHECK THE INSTRUMENT CLUSTER WARNING INDICATORS
personal injury.
4 Check the instrument cluster warning indicators.
Are the instrument cluster warning indicators
illuminated when the ignition is switched to the
ON position?
Yes
Go to BA6
No
BA6: CHECK THE AIR BAG WARNING INDICATOR CIRCUIT
G428951 en
11/2004 2005.25 Fiesta
501-20B-115

TO MODEL INDEX
501-20B-115

TEST CONDITIONS

Yes
No
PINPOINT TEST BB: DTC B1870: AIR BAG WARNING INDICATOR CIRCUIT SHORT TO BATTERY
TEST CONDITIONS
BB1: CHECK THE AIR BAG WARNING INDICATOR
1
2
3
4
G428951 en
Deactivate the SRS.

11/2004 2005.25 Fiesta
501-20B-116

TO MODEL INDEX
501-20B-116

TEST CONDITIONS
5 Measure the voltage between the air bag control module C500 pin 11, circuit 91S-JA14

Yes
No
PINPOINT TEST BC: DTC B1877: DRIVER SIDE SAFETY BELT PRETENSIONER OPEN CIRCUIT
TEST CONDITIONS
BC1: CHECK THE DRIVER SIDE SAFETY BELT PRETENSIONER CIRCUIT
Yes
3-door vehicles Go to BC2
No
G428951 en
11/2004 2005.25 Fiesta
501-20B-117

TO MODEL INDEX
501-20B-117

TEST CONDITIONS
BC2: PROVE OUT THE DRIVER SIDE SAFETY BELT PRETENSIONER CIRCUIT - 3-DOOR
VEHICLES
2 Disconnect Driver Side Underseat Occupant
Restraint Systems Simulator.
3 Connect Driver Side Underseat Occupant Restraint Systems Electrical Connector C663.
Yes
No
INSTALL a new driver side safety belt buckle
BC3: PROVE OUT THE DRIVER SIDE SAFETY BELT PRETENSIONER CIRCUIT - 5-DOOR
VEHICLES
2 Disconnect Driver Side Safety Belt Pretensioner Simulator.
3 Connect Driver Side Safety Belt Pretensioner
Electrical Connector C661.
Yes
No
INSTALL a new driver side safety belt retractor and pretensioner. REFER to Section
and Pretensioner - 5-Door] REPEAT the
the system.
BC4: CHECK THE DRIVER SIDE SAFETY BELT PRETENSIONER FOR OPEN CIRCUIT OR HIGH
RESISTANCE - 3-DOOR VEHICLES
G428951 en
11/2004 2005.25 Fiesta
501-20B-118

TO MODEL INDEX
501-20B-118

TEST CONDITIONS
Air bag control module C501 pin 4, circuit
electrical connector C663 pin 2, circuit
electrical connector C663 pin 1, circuit

Yes
No
BC5: CHECK THE DRIVER SIDE SAFETY BELT PRETENSIONER FOR OPEN CIRCUIT OR HIGH
RESISTANCE - 5-DOOR VEHICLES
side safety belt pretensioner C661 pin 2, circuit
side safety belt pretensioner C661 pin 1, circuit

Yes
No
G428951 en
11/2004 2005.25 Fiesta
501-20B-119

TO MODEL INDEX
501-20B-119

PINPOINT TEST BD: DTC B1878 DRIVER SIDE SAFETY BELT PRETENSIONER SHORT TO
BATTERY
TEST CONDITIONS
BD1: CHECK THE DRIVER SIDE SAFETY BELT PRETENSIONER CIRCUIT
Yes
3-door vehicles Go to BD2
No
BD2: PROVE OUT THE DRIVER SIDE SAFETY BELT PRETENSIONER CIRCUIT - 3-DOOR
VEHICLES
Yes
No
INSTALL a new driver safety belt buckle and
pretensioner. REFER to Section
BD3: PROVE OUT THE DRIVER SIDE SAFETY BELT PRETENSIONER CIRCUIT - 5-DOOR
VEHICLES
G428951 en
11/2004 2005.25 Fiesta
501-20B-120

TO MODEL INDEX
501-20B-120

TEST CONDITIONS
Connector C661.

Yes
No
the system.
BD4: CHECK THE DRIVER SIDE SAFETY BELT PRETENSIONER FOR A SHORT TO BATTERY 3-DOOR VEHICES
Simulator.

Yes
No
BD5: CHECK THE DRIVER SIDE SAFETY BELT PRETENSIONER FOR A SHORT TO BATTERY 5-DOOR VEHICES
Simulator.
G428951 en
11/2004 2005.25 Fiesta
501-20B-121

TO MODEL INDEX
501-20B-121

TEST CONDITIONS

Yes
No
PINPOINT TEST BE: DTC B1879: DRIVER SIDE SAFETY BELT PRETENSIONER SHORT TO
GROUND
TEST CONDITIONS
BE1: CHECK THE DRIVER SIDE SAFETY BELT PRETENSIONER CIRCUIT
Yes
3-door vehicles Go to BE2
No
G428951 en
11/2004 2005.25 Fiesta
501-20B-122

TO MODEL INDEX
501-20B-122

TEST CONDITIONS
BE2: PROVE OUT THE DRIVER SIDE SAFETY BELT PRETENSIONER CIRCUIT - 3-DOOR
VEHICLES
Yes
No
INSTALL a new driver safety belt buckle and
pretensioner. REFER to Section
BE3: PROVE OUT THE DRIVER SIDE SAFETY BELT PRETENSIONER CIRCUIT - 5-DOOR
VEHICLES
Connector C661.
Yes
No
the system.
BE4: CHECK THE DRIVER SIDE SAFETY BELT PRETENSIONER FOR A SHORT TO GROUND 3-DOOR VEHICLES
C501.
3 Disconnect Driver Side Occupant Restraint
Systems Simulator.
G428951 en
11/2004 2005.25 Fiesta
501-20B-123

TO MODEL INDEX
501-20B-123

TEST CONDITIONS
91-JA10 (BK/RD), harness side and the air bag
(BK/BU) harness side.
(GN/BU), harness side.

Yes
No
BE5: CHECK THE DRIVER SIDE SAFETY BELT PRETENSIONER FOR A SHORT TO GROUND 5-DOOR VEHICLES
C501.
(BK/BU) harness side.
(GN/BU), harness side.
Yes
No
G428951 en
11/2004 2005.25 Fiesta
501-20B-124

TO MODEL INDEX
501-20B-124

TEST CONDITIONS
PINPOINT TEST BF: DTC B1881 PASSENGER SIDE SAFETY BELT PRETENSIONER OPEN
CIRCUIT
TEST CONDITIONS
BF1: CHECK THE PASSENGER SIDE SAFETY BELT PRETENSIONER CIRCUIT
Yes
Go to BF2
No
Go to BF3
BF2: PROVE OUT THE PASSENGER SIDE SAFETY BELT PRETENSIONER CIRCUIT
2 Disconnect Passenger Side Underseat Occupant Restraint Systems Simulator.
3 Connect Passenger Side Underseat Occupant
Restraint Systems Electrical Connector C664.
Yes
No
BF3: CHECK THE PASSENGER SIDE SAFETY BELT PRETENSIONER FOR OPEN CIRCUIT OR
HIGH RESISTANCE
G428951 en
11/2004 2005.25 Fiesta
501-20B-125

TO MODEL INDEX
501-20B-125

TEST CONDITIONS
passenger side underseat occupant restraint
systems electrical connector C664 pin 2, circuit
91S-JA34 (BK/RD), harness side and the passenger side underseat occupant restraint systems electrical connector C664 pin 1, circuit

Yes
No
REPAIR circuit 15S-JA34 (GN/OG) and circuit 91S-JA34 (BK/RD). REPEAT the
the system.
PINPOINT TEST BG: DTC B1882 PASSENGER SIDE SAFETY BELT PRETENSIONER SHORT TO
BATTERY
TEST CONDITIONS
BG1: CHECK THE PASSENGER SIDE SAFETY BELT PRETENSIONER CIRCUIT
Yes
Go to BG2
No
Go to BG3
BG2: PROVE OUT THE PASSENGER SIDE SAFETY BELT PRETENSIONER CIRCUIT
G428951 en
11/2004 2005.25 Fiesta
501-20B-126

TO MODEL INDEX
501-20B-126

TEST CONDITIONS

Yes
No
INSTALL a new passenger side safety belt
buckle and pretensioner. REFER to Section
BG3: CHECK THE PASSENGER SIDE SAFETY BELT PRETENSIONER FOR A SHORT TO
BATTERY
3 Disconnect Passenger Side Underseat Occupant Restraint Systems Simulator C664.

Yes
No
PINPOINT TEST BH: DTC B1883 PASSENGER SIDE SAFETY BELT PRETENSIONER SHORT TO
GROUND
TEST CONDITIONS
G428951 en
11/2004 2005.25 Fiesta
501-20B-127

TO MODEL INDEX
501-20B-127

TEST CONDITIONS
BH1: CHECK THE PASSENGER SIDE SAFETY BELT PRETENSIONER CIRCUIT

Yes
Go to BH2
No
Go to BH3
BH2: PROVE OUT THE PASSENGER SIDE SAFETY BELT PRETENSIONER CIRCUIT
Yes
No
BH3: CHECK THE PASSENGER SIDE SAFETY BELT PRETENSIONER CIRCUIT FOR A SHORT
TO GROUND
Air bag control module C501 pin 12, 91S-JA34
G428951 en
11/2004 2005.25 Fiesta
501-20B-128

TO MODEL INDEX
501-20B-128

TEST CONDITIONS
Yes
No
PINPOINT TEST BI: DTC B1885 DRIVER SIDE SAFETY BELT PRETENSIONER LOW RESISTANCE
TEST CONDITIONS
BI1: CHECK THE DRIVER SIDE SAFETY BELT PRETENSIONER CIRCUIT
Yes
3-door vehicles Go to BI2
No
BI2: PROVE OUT THE DRIVER SIDE SAFETY BELT PRETENSIONER CIRCUIT - 3-DOOR
VEHICLES
Yes
No
G428951 en
11/2004 2005.25 Fiesta
501-20B-129

TO MODEL INDEX
501-20B-129

TEST CONDITIONS
INSTALL a new driver side safety belt buckle
BI3: PROVE OUT THE DRIVER SIDE SAFETY BELT PRETENSIONER CIRCUIT - 5-DOOR
VEHICLES
Electrical Connector C661.
Yes
No
INSTALL a new driver side safety belt retractor and pretensioner. REFER to Section
the system.
BI4: CHECK THE DRIVER SIDE SAFETY BELT PRETENSIONER FOR LOW RESISTANCE 3-DOOR VEHICLES
harness side.

Yes
G428951 en
11/2004 2005.25 Fiesta
501-20B-130

TO MODEL INDEX
501-20B-130

TEST CONDITIONS
No
REPAIR circuit 15S-JA33 (GN/BU) and circuit 91S-JA33 (BK/BU). REPEAT the
the system.
BI5: CHECK THE DRIVER SIDE SAFETY BELT PRETENSIONER FOR LOW RESISTANCE 5-DOOR VEHICLES
harness side.

Yes
No
the system.
PINPOINT TEST BJ: DTC B1886 PASSENGER SIDE SAFETY BELT PRETENSIONER LOW
RESISTANCE
TEST CONDITIONS
BJ1: CHECK THE PASSENGER SIDE SAFETY BELT PRETENSIONER CIRCUIT
G428951 en
11/2004 2005.25 Fiesta
501-20B-131

TO MODEL INDEX
501-20B-131

TEST CONDITIONS

Yes
Go to BJ2
No
Go to BJ3
BJ2: PROVE OUT THE PASSENGER SIDE SAFETY BELT PRETENSIONER CIRCUIT
Yes
No
BJ3: CHECK THE PASSENGER SIDE SAFETY BELT PRETENSIONER FOR LOW RESISTANCE
harness side.

Yes
No
G428951 en
11/2004 2005.25 Fiesta
501-20B-132

TO MODEL INDEX
501-20B-132

TEST CONDITIONS
the system.
PINPOINT TEST BK: DTC B1916 DRIVER AIR BAG SHORT TO BATTERY
TEST CONDITIONS
BK1: CHECK THE DRIVER AIR BAG WIRING HARNESS FOR A SHORT TO BATTERY OR
IGNITION
2 Disconnect Driver Air Bag Module Simulator.

Yes
Go to BK2
No
CONNECT the driver air bag module simulator and the air bag control module C500.
BK2: CHECK THE CLOCKSPRING FOR A SHORT TO BATTERY OR IGNITION
G428951 en
11/2004 2005.25 Fiesta
501-20B-133

TO MODEL INDEX
501-20B-133

TEST CONDITIONS

Yes
REPAIR circuit 15S-JA8 (GN/RD) and circuit
No
the system.
PINPOINT TEST BL: DTC B1925 PASSENGER AIR BAG SHORT TO BATTERY
TEST CONDITIONS
BL1: CHECK THE PASSENGER AIR BAG WIRING HARNESS FOR A SHORT TO BATTERY OR
IGNITION
2 Disconnect Passenger Air Bag Module Simulator.
G428951 en
11/2004 2005.25 Fiesta
501-20B-134

TO MODEL INDEX
501-20B-134

TEST CONDITIONS

Yes
REPAIR circuit 15S-JA31 (GN/WH) and
circuit 91S-JA31 (BK/WH). REPEAT the
the system.
No
simulator and the air bag control module
C500. REPEAT the self-test, CLEAR the
PINPOINT TEST BM: DTC B1932 DRIVER AIR BAG OPEN CIRCUIT
TEST CONDITIONS
BM1: CHECK THE DRIVER AIR BAG CIRCUIT RESISTANCE
Yes
Go to BM2
No
Go to BM3
Go to BM4
BM2: CHECK THE DRIVER AIR BAG MODULE SQUIB RESISTANCE
G428951 en
11/2004 2005.25 Fiesta
501-20B-135

TO MODEL INDEX
501-20B-135

TEST CONDITIONS
driver air bag module.
WDS.
4 Measure the resistance of the driver air bag
module squib.

Yes
No
BM3: CHECK THE CLOCKSPRING FOR OPEN CIRCUIT OR HIGH RESISTANCE - VEHICLES
WITH STABILITY ASSIST
1
2
3
4

Disconnect Clockspring C353.
Measure the resistance between the:

Yes
the system.
No
G428951 en
11/2004 2005.25 Fiesta
501-20B-136

TO MODEL INDEX
501-20B-136

TEST CONDITIONS
BM4: CHECK THE CLOCKSPRING FOR OPEN CIRCUIT OR HIGH RESISTANCE - VEHICLES
WITHOUT STABILITY ASSIST
1
2
3
4

Disconnect Clockspring C763.
Measure the resistance between the:
Clockspring C763 pin 8, circuit 91S-JA8
Clockspring C763 pin 9, circuit 15S-JA8

Yes
the system.
No
PINPOINT TEST BN: DTC B1933 PASSENGER AIR BAG OPEN CIRCUIT
TEST CONDITIONS
BN1: CHECK THE PASSENGER AIR BAG CIRCUIT RESISTANCE
Yes
Go to BN2
No
G428951 en
11/2004 2005.25 Fiesta
501-20B-137

TO MODEL INDEX
501-20B-137

TEST CONDITIONS
Go to BN3
BN2: CHECK THE PASSENGER AIR BAG MODULE SQUIB RESISTANCE
passenger air bag module.
WDS.
4 Measure the resistance of the passenger air
bag module squib.

Yes
No
BN3: CHECK THE PASSENGER AIR BAG WIRING HARNESS FOR OPEN CIRCUIT OR HIGH
RESISTANCE
15S-JA31 (GN/WH), harness side and the
15S-JA31 (GN/WH), harness side.
91S-JA31 (BK/WH), harness side and the
91S-JA31 (BK/WH), harness side.
G428951 en
11/2004 2005.25 Fiesta
501-20B-138

TO MODEL INDEX
501-20B-138

TEST CONDITIONS
Yes
No
the system.
PINPOINT TEST BO: DTC B1934 DRIVER AIR BAG CIRCUIT LOW RESISTANCE
TEST CONDITIONS
BO1: CHECK THE DRIVER AIR BAG CIRCUIT RESISTANCE
Yes
Go to BO2
No
Go to BO3
BO2: CHECK THE DRIVER AIR BAG MODULE SQUIB RESISTANCE
WDS.
4 Measure the resistance of the driver air bag
module squib.

G428951 en
11/2004 2005.25 Fiesta
501-20B-139

TO MODEL INDEX
501-20B-139

TEST CONDITIONS
Yes
No
BO3: CHECK THE CLOCKSPRING FOR LOW RESISTANCE
1
2
3
4

(BK/OG), harness side and the air bag control
module C500 pin 10, circuit 15S-JA8 (GN/RD),
harness side.

Yes
the system.
No
PINPOINT TEST BP: DTC B1935 PASSENGER AIR BAG CIRCUIT LOW RESISTANCE
TEST CONDITIONS
BP1: CHECK THE PASSENGER AIR BAG CIRCUIT RESISTANCE
G428951 en
11/2004 2005.25 Fiesta
501-20B-140

TO MODEL INDEX
501-20B-140

TEST CONDITIONS

Yes
Go to BP2
No
Go to BP3
BP2: CHECK THE PASSENGER AIR BAG MODULE SQUIB RESISTANCE
WDS.
4 Measure the resistance of the passenger air
bag module squib.

Yes
No
BP3: CHECK THE PASSENGER AIR BAG WIRING HARNESS FOR LOW RESISTANCE
1
2
3
4
G428951 en

Disconnect Passenger Air Bag Simulator.
(GN/WH), harness side and the air bag control
module C500 pin 8, circuit 91S-JA31 (BK/WH),
harness side.
11/2004 2005.25 Fiesta
501-20B-141

TO MODEL INDEX
501-20B-141

TEST CONDITIONS
Yes
No
the system.
PINPOINT TEST BQ: DTC B1936 DRIVER AIR BAG CIRCUIT SHORT TO GROUND
TEST CONDITIONS
BQ1: CHECK THE DRIVER AIR BAG CIRCUIT
Yes
Go to BQ2
No
Go to BQ3
BQ2: CHECK THE DRIVER AIR BAG MODULE
WDS.
terminals and the driver air bag module casing.
G428951 en
11/2004 2005.25 Fiesta
501-20B-142

TO MODEL INDEX
501-20B-142

TEST CONDITIONS

Yes
No
BQ3: CHECK THE DRIVER AIR BAG WIRING HARNESS FOR A SHORT TO GROUND
1
2
3
4

Disconnect Driver Air Bag Module Simulator.
Measure the resistance, while turning the
steering wheel from lock to lock, between the:

Yes
No
Go to BQ4
BQ4: CHECK THE CLOCKSPRING FOR A SHORT TO GROUND
steering wheel from lock to lock, between the:

Yes
G428951 en
11/2004 2005.25 Fiesta
501-20B-143

TO MODEL INDEX
501-20B-143

TEST CONDITIONS
the system.
No
PINPOINT TEST BR: DTC B1938 PASSENGER AIR BAG CIRCUIT SHORT TO GROUND
TEST CONDITIONS
BR1: CHECK THE PASSENGER AIR BAG CIRCUIT RESISTANCE
Yes
Go to BR2
No
Go to BR3
BR2: CHECK THE PASSENGER AIR BAG MODULE
WDS.
terminals and the passenger air bag module
casing.
G428951 en
11/2004 2005.25 Fiesta
501-20B-144

TO MODEL INDEX
501-20B-144

TEST CONDITIONS

Yes
No
BR3: CHECK THE PASSENGER AIR BAG WIRING HARNESS FOR A SHORT TO GROUND

Yes
No
the system.
PINPOINT TEST BS: DTC B1992 DRIVER SIDE, SIDE AIR BAG CIRCUIT SHORT TO BATTERY
TEST CONDITIONS
BS1: CHECK THE DRIVER SIDE, SIDE AIR BAG CIRCUIT
G428951 en
11/2004 2005.25 Fiesta
501-20B-145

TO MODEL INDEX
501-20B-145

TEST CONDITIONS

Yes
No
Go to BS2
BS2: CHECK THE DRIVER SIDE, SIDE AIR BAG CIRCUIT FOR A SHORT TO BATTERY
1
2
3
4

Measure the voltage between the:

Yes
REPAIR circuit 15S-JA37 (GN/BK) and circuit 91S-JA37 (BK/GN). REPEAT the
the system.
No
PINPOINT TEST BT: DTC B1993 DRIVER SIDE, SIDE AIR BAG CIRCUIT SHORT TO GROUND
TEST CONDITIONS
BT1: CHECK THE DRIVER SIDE, SIDE AIR BAG CIRCUIT
Yes
Go to BT2
G428951 en
11/2004 2005.25 Fiesta
501-20B-146

TO MODEL INDEX
501-20B-146

TEST CONDITIONS
No
Go to BT3
BT2: CHECK THE DRIVER SIDE, SIDE AIR BAG MODULE
driver side, side air bag module.
WDS.
terminals and the driver side, side air bag
module casing.

Yes
No
INSTALL a new driver side, side air bag
BT3: CHECK THE DRIVER SIDE, SIDE AIR BAG CIRCUIT FOR A SHORT TO GROUND
G428951 en
11/2004 2005.25 Fiesta
501-20B-147

TO MODEL INDEX
501-20B-147

TEST CONDITIONS
Air bag control C501 pin 3, circuit 15S-JA37

Yes
No
the system.
PINPOINT TEST BU: DTC B1994 DRIVER SIDE, SIDE AIR BAG CIRCUIT OPEN CIRCUIT
TEST CONDITIONS
BU1: CHECK THE DRIVER SIDE, SIDE AIR BAG CIRCUIT
Yes
Go to BU2
No
Go to BU3
BU2: CHECK THE DRIVER SIDE, SIDE AIR BAG MODULE SQUIB RESISTANCE
WDS.
G428951 en
11/2004 2005.25 Fiesta
501-20B-148

TO MODEL INDEX
501-20B-148

TEST CONDITIONS
4 Measure the resistance of the driver side, side
air bag module squib.

Yes
No
BU3: CHECK THE DRIVER SIDE, SIDE AIR BAG WIRING HARNESS FOR OPEN CIRCUIT OR
HIGH RESISTANCE
91S-JA37 (BK/GN), harness side and the driver
electrical module connector C663 pin 3, circuit
91S-JA37 (BK/GN), harness side.
15S-JA37 (GN/BK), harness side and the driver
electrical module connector C663 pin 4, circuit
15S-JA37 (GN/BK), harness side.

Yes
No
the system.
G428951 en
11/2004 2005.25 Fiesta
501-20B-149

TO MODEL INDEX
501-20B-149

PINPOINT TEST BV: DTC B1995 DRIVER SIDE, SIDE AIR BAG CIRCUIT LOW RESISTANCE ON
SQUIB
TEST CONDITIONS
BV1: CHECK THE DRIVER SIDE, SIDE AIR BAG CIRCUIT
Yes
Go to BV2
No
Go to BV3
BV2: CHECK THE DRIVER SIDE, SIDE AIR BAG MODULE SQUIB RESISTANCE
WDS.
air bag module squib.

Yes
No
BV3: CHECK THE DRIVER SIDE, SIDE AIR BAG CIRCUIT FOR LOW RESISTANCE
G428951 en
11/2004 2005.25 Fiesta
501-20B-150

TO MODEL INDEX
501-20B-150

TEST CONDITIONS
harness side.

Yes
No
the system.
PINPOINT TEST BW: DTC B1996 PASSENGER SIDE, SIDE AIR BAG CIRCUIT SHORT TO
BATTERY
TEST CONDITIONS
BW1: CHECK THE PASSENGER SIDE, SIDE AIR BAG CIRCUIT
Yes
No
Go to BW2
BW2: CHECK THE PASSENGER SIDE, SIDE AIR BAG CIRCUIT FOR A SHORT TO BATTERY
G428951 en
11/2004 2005.25 Fiesta
501-20B-151

TO MODEL INDEX
501-20B-151

TEST CONDITIONS

Yes
the system.
No
PINPOINT TEST BX: DTC B1997 PASSENGER SIDE, SIDE AIR BAG CIRCUIT SHORT TO GROUND
TEST CONDITIONS
BX1: CHECK THE PASSENGER SIDE, SIDE AIR BAG CIRCUIT
Yes
Go to BX2
No
Go to BX3
BX2: CHECK THE PASSENGER SIDE, SIDE AIR BAG MODULE
passenger side, side air bag module.
G428951 en
11/2004 2005.25 Fiesta
501-20B-152

TO MODEL INDEX
501-20B-152

TEST CONDITIONS
WDS.
terminals and the passenger side, side air bag
module casing.

Yes
No
INSTALL a new passenger side, side air bag
BX3: CHECK THE PASSENGER SIDE, SIDE AIR BAG CIRCUIT FOR A SHORT TO GROUND

Yes
No
G428951 en
11/2004 2005.25 Fiesta
501-20B-153

TO MODEL INDEX
501-20B-153

TEST CONDITIONS
the system.
PINPOINT TEST BY: DTC B1998 PASSENGER SIDE, SIDE AIR BAG CIRCUIT OPEN CIRCUIT
TEST CONDITIONS
BY1: CHECK THE PASSENGER SIDE, SIDE AIR BAG CIRCUIT
Yes
Go to BY2
No
Go to BY3
BY2: CHECK THE PASSENGER SIDE, SIDE AIR BAG MODULE SQUIB RESISTANCE
WDS.
4 Measure the resistance of the passenger side,
side air bag module squib.

Yes
No
G428951 en
11/2004 2005.25 Fiesta
501-20B-154

TO MODEL INDEX
501-20B-154

TEST CONDITIONS
INSTALL a new passenger side, side air bag
BY3: CHECK THE PASSENGER SIDE, SIDE AIR BAG WIRING HARNESS FOR OPEN CIRCUIT OR
HIGH RESISTANCE
2 Disconnect Disconnect Air Bag Control Module
C501..
91S-JA38 (BK/RD), harness side and the

Yes
No
the system.
PINPOINT TEST BZ: DTC B1999 PASSENGER SIDE, SIDE AIR BAG CIRCUIT LOW RESISTANCE
ON SQUIB
TEST CONDITIONS
BZ1: CHECK THE PASSENGER SIDE, SIDE AIR BAG CIRCUIT
Yes
G428951 en
11/2004 2005.25 Fiesta
501-20B-155

TO MODEL INDEX
501-20B-155

TEST CONDITIONS
Go to BZ2
No
Go to BZ3
BZ2: CHECK THE PASSENGER SIDE, SIDE AIR BAG MODULE SQUIB RESISTANCE
WDS.
4 Measure the resistance of the passengerside,
side air bag module squib.

Yes
No
BZ3: CHECK THE PASSENGER SIDE, SIDE AIR BAG CIRCUIT FOR LOW RESISTANCE
G428951 en
11/2004 2005.25 Fiesta
501-20B-156

TO MODEL INDEX
501-20B-156

TEST CONDITIONS
(BK/RD), harness side and the air bag control
module C501 pin 21, circuit 15S-JA38 (GN/OG),
harness side.

Yes
No
the system.
PINPOINT TEST CA: DTC B2773 DRIVER SIDE, SIDE AIR CURTAIN CIRCUIT LOW RESISTANCE
ON SQUIB
TEST CONDITIONS
CA1: CHECK THE DRIVER SIDE, SIDE AIR CURTAIN MODULE CIRCUIT RESISTANCE
Yes
Go to CA2
No
Go to CA3
CA2: CHECK THE DRIVER SIDE, SIDE AIR CURTAIN MODULE SQUIB RESISTANCE
driver side, side air curtain module.
G428951 en
11/2004 2005.25 Fiesta
501-20B-157

TO MODEL INDEX
501-20B-157

TEST CONDITIONS
WDS.
air curtain module squib.

Yes
No
INSTALL a new driver side, side air curtain
module. REFER to Side Air Curtain Module 3-Door / Side Air Curtain Module - 5-Door in
CA3: CHECK THE DRIVER SIDE, SIDE AIR CURTAIN WIRING HARNESS FOR LOW RESISTANCE
2 Disconnect Driver Side, Side Air Curtain Module Simulator.
harness side.

Yes
No
G428951 en
11/2004 2005.25 Fiesta
501-20B-158

TO MODEL INDEX
501-20B-158

TEST CONDITIONS
the system.
PINPOINT TEST CB: DTC B2774 DRIVER SIDE, SIDE AIR CURTAIN CIRCUIT OPEN CIRCUIT
TEST CONDITIONS
CB1: CHECK THE DRIVER SIDE, SIDE AIR CURTAIN CIRCUIT RESISTANCE
Yes
Go to CB2
No
Go to CB3
CB2: CHECK THE DRIVER SIDE, SIDE AIR CURTAIN MODULE SQUIB RESISTANCE
WDS.

Yes
No
G428951 en
11/2004 2005.25 Fiesta
501-20B-159

TO MODEL INDEX
501-20B-159

TEST CONDITIONS
CB3: CHECK THE DRIVER SIDE, SIDE AIR CURTAIN WIRING HARNESS FOR OPEN CIRCUIT OR
HIGH RESISTANCE
3 Disconnect Driver Side, Side Air Curtain
Simulator.
15S-JA50 (GN/OG), harness side and the driver
side, side air curtain module C674 pin 1, circuit
91S-JA50 (BK/RD), harness side and the driver
side, side air curtain module C674 pin 2, circuit

Yes
No
the system.
PINPOINT TEST CC: DTC B2775 DRIVER SIDE, SIDE AIR CURTAIN CIRCUIT SHORT TO GROUND
TEST CONDITIONS
CC1: CHECK THE DRIVER SIDE, SIDE AIR CURTAIN CIRCUIT
Yes
Go to CC2
G428951 en
11/2004 2005.25 Fiesta
501-20B-160

TO MODEL INDEX
501-20B-160

TEST CONDITIONS
No
Go to CC3
CC2: CHECK THE DRIVER SIDE, SIDE AIR CURTAIN MODULE
WDS.
terminals and the driver side, side air curtain
module casing.

Yes
No
CC3: CHECK THE DRIVER SIDE, SIDE AIR CURTAIN WIRING HARNESS FOR A SHORT TO
GROUND
G428951 en
11/2004 2005.25 Fiesta
501-20B-161

TO MODEL INDEX
501-20B-161

TEST CONDITIONS

Yes
No
the system.
PINPOINT TEST CD: TC B2776 DRIVER SIDE, SIDE AIR CURTAIN CIRCUIT SHORT TO BATTERY
TEST CONDITIONS
CD1: CHECK THE DRIVER SIDE, SIDE AIR CURTAIN WIRING HARNESS FOR A SHORT TO
BATTERY OR IGNITION
G428951 en
11/2004 2005.25 Fiesta
501-20B-162

TO MODEL INDEX
501-20B-162

TEST CONDITIONS

Yes
the system.
No
CONNECT the driver side, side air curtain
module simulator and the air bag control
module C501. REPEAT the self-test, CLEAR
PINPOINT TEST CE: DTC B2777 PASSENGER SIDE, SIDE AIR CURTAIN CIRCUIT LOW
RESISTANCE ON SQUIB
TEST CONDITIONS
CE1: CHECK THE PASSENGER SIDE, SIDE AIR CURTAIN MODULE CIRCUIT RESISTANCE
Yes
Go to CE2
No
Go to CE3
CE2: CHECK THE PASSENGER SIDE, SIDE AIR CURTAIN MODULE SQUIB RESISTANCE
G428951 en
11/2004 2005.25 Fiesta
501-20B-163

TO MODEL INDEX
501-20B-163

TEST CONDITIONS
WDS.
4 Measure the resistance of the passenger side

Yes
No
INSTALL a new passenger side, side air
curtain module. REFER to Side Air Curtain
Module - 3-Door / Side Air Curtain Module 5-Door in this section. REPEAT the self-test,
CE3: CHECK THE PASSENGER SIDE, SIDE AIR CURTAIN WIRING HARNESS FOR LOW
RESISTANCE
2 Disconnect Passenger Side, Side Air Curtain
Module Simulator.
harness side.

Yes
No
G428951 en
11/2004 2005.25 Fiesta
501-20B-164

TO MODEL INDEX
501-20B-164

TEST CONDITIONS
the system.
PINPOINT TEST CF: DTC B2778 PASSENGER SIDE, SIDE AIR CURTAIN CIRCUIT OPEN CIRCUIT
TEST CONDITIONS
CF1: CHECK THE PASSENGER SIDE, SIDE AIR CURTAIN CIRCUIT RESISTANCE
Yes
Go to CF2
No
Go to CF3
CF2: CHECK THE PASSENGER SIDE, SIDE AIR CURTAIN MODULE SQUIB RESISTANCE
passenger side, side air curtain module.
WDS.
4 Measure the resistance of the passenger side,
side air curtain module squib.

Yes
No
G428951 en
11/2004 2005.25 Fiesta
501-20B-165

TO MODEL INDEX
501-20B-165

TEST CONDITIONS
CF3: CHECK THE PASSENGER SIDE, SIDE AIR CURTAIN WIRING HARNESS FOR OPEN
CIRCUIT OR HIGH RESISTANCE
Module Simulator.
91S-JA51 (BK/BU), harness side and the
passenger side, side air curtain module C675
pin 2, circuit 91S-JA51 (BK/BU), harness side.
15S-JA51 (GN/BU), harness side and the
passenger side, side air curtain module C675
pin 1, circuit 15S-JA51 (GN/BU), harness side.

Yes
No
the system.
PINPOINT TEST CG: DTC B2779 PASSENGER SIDE, SIDE AIR CURTAIN CIRCUIT SHORT TO
GROUND
TEST CONDITIONS
CG1: CHECK THE PASSENGER SIDE, SIDE AIR CURTAIN CIRCUIT
G428951 en
11/2004 2005.25 Fiesta
501-20B-166

TO MODEL INDEX
501-20B-166

TEST CONDITIONS
Yes
Go to CG2
No
Go to CG3
CG2: CHECK THE PASSENGER SIDE, SIDE AIR CURTAIN MODULE
passenger side, side air curtain module.
WDS.
terminals and the passenger side, side air curtain module casing.

Yes
No
CG3: CHECK THE PASSENGER SIDE, SIDE AIR CURTAIN WIRING HARNESS FOR A SHORT TO
GROUND
Module Simulator.
G428951 en
11/2004 2005.25 Fiesta
501-20B-167

TO MODEL INDEX
501-20B-167

TEST CONDITIONS

Yes
No
the system.
PINPOINT TEST CH: DTC B2780 PASSENGER SIDE, SIDE AIR CURTAIN CIRCUIT SHORT TO
BATTERY
TEST CONDITIONS
CH1: CHECK THE PASSENGER SIDE, SIDE AIR CURTAIN WIRING HARNESS FOR A SHORT TO
BATTERY OR IGNITION
Module Simulator.
G428951 en
11/2004 2005.25 Fiesta
501-20B-168

TO MODEL INDEX
501-20B-168

TEST CONDITIONS

Yes
the system.
No
CONNECT the passenger side, side air
curtain module simulator and the air bag
control module C501. REPEAT the self-test,
PINPOINT TEST CI: DTC B2791 AIR BAG CUT-OFF SWITCH OUT OF RANGE
TEST CONDITIONS
CI1: CHECK THE VOLTAGE TO THE PAD SWITCH
2 Operate the PAD switch to the OFF position.
Yes
Go to CI2
No
Go to CI3
CI2: CHECK FOR CONTINUITY BETWEEN THE AIR BAG CONTROL MODULE AND THE PAD
SWITCH
1
2
3
4
G428951 en

Deactivate the SRS.
11/2004 2005.25 Fiesta
501-20B-169

TO MODEL INDEX
501-20B-169

TEST CONDITIONS

Yes
No
CI3: CHECK THE PAD SWITCH GROUND CIRCUIT
1
2
3
4

Deactivate the SRS.
Disconnect PAD Switch C713.
Measure the resistance between the PAD
switch C713 pin 5, circuit 91-JA47 (BK/OG),

Yes
Go to CI4
No
REPAIR circuit 91-JA47 (BK/OG). REPEAT
G428951 en
11/2004 2005.25 Fiesta
501-20B-170

TO MODEL INDEX
501-20B-170

TEST CONDITIONS
CI4: CHECK FOR CONTINUITY BETWEEN THE PAD WARNING INDICATOR AND THE PAD
SWITCH
1 Disconnect PAD Warning Indicator C714.
2 Measure the resistance between the PAD
switch C713 pin 4, circuit 91S-JA56 (BK/RD),
harness side and the PAD warning indicator
C714 pin 6, circuit 91S-JA56 (BK/RD), harness
side.

Yes
Go to CI5
No
CI5: CHECK THE PAD WARNING INDICATOR SUPPLY CIRCUIT
2 Measure the voltage between the PAD warning
indicator C714 pin 7, circuit 15-JA56 (GN/OG),

Yes
INSTALL a new PAD warning indicator.
No
Go to CI6
CI6: CHECK FOR CONTINUITY BETWEEN THE AIR BAG CONTROL MODULE AND THE PAD
WARNING INDICATOR
G428951 en
11/2004 2005.25 Fiesta
501-20B-171

TO MODEL INDEX
501-20B-171

TEST CONDITIONS
(GN/OG), harness side and the PAD warning
indicator C714 pin 7, circuit 15-JA56 (GN/OG),
harness side.

Yes
No
PINPOINT TEST CJ: DTC B2791 AIR BAG CUT-OFF SWITCH IN MIDDLE POSITION
TEST CONDITIONS
CJ1: CHECK THE PAD WARNING INDICATOR OPERATION
2 Operate the PAD switch to the ON position.
Does the PAD warning indicator illuminate?
Yes
Go to CJ2
No
Go to CJ3
CJ2: CHECK FOR CONTINUITY BETWEEN THE PAD WARNING INDICATOR AND GROUND
1
2
3
4

Deactivate the SRS.
Disconnect PAD switch C713.
Does the PAD warning indicator illuminate?

Yes
G428951 en
11/2004 2005.25 Fiesta
501-20B-172

TO MODEL INDEX
501-20B-172

TEST CONDITIONS
No
Go to CJ3
CJ3: CHECK THE PAD SWITCH GROUND CIRCUIT

Yes
No
PINPOINT TEST CK: DTC U2017 DRIVER SIDE, SIDE IMPACT SENSOR COMMUNICATIONS
FAULT
TEST CONDITIONS
CK1: CHECK THE DRIVER SIDE, SIDE IMPACT SENSOR CIRCUIT
1
2
3
4
G428951 en

Deactivate the SRS.
Disconnect Driver Side Impact Sensor C665.
11/2004 2005.25 Fiesta
501-20B-173

TO MODEL INDEX
501-20B-173

TEST CONDITIONS
8-JA39 (WH), harness side and the driver side,
side impact sensor C665 pin 2, circuit 8-JA39
(WH), harness side.
9-JA39 (BN), harness side and the driver side,
side impact sensor C665 pin 1, circuit 9-JA39
(BN), harness side.

Yes
Go to CK2
No
REPAIR circuit 8-JA39 (WH) and circuit
CK2: CHECK THE DRIVER SIDE, SIDE IMPACT SENSOR FOR A SHORT CIRCUIT TO BATTERY

Yes
No
Go to CK3
G428951 en
11/2004 2005.25 Fiesta
501-20B-174

TO MODEL INDEX
501-20B-174

TEST CONDITIONS
CK3: CHECK THE DRIVER SIDE, SIDE IMPACT SENSOR FOR A SHORT TO GROUND

Yes
No
PINPOINT TEST CL: DTC U2018 PASSENGER SIDE, SIDE IMPACT SENSOR COMMUNICATIONS
FAULT
TEST CONDITIONS
CL1: CHECK THE PASSENGER SIDE, SIDE IMPACT SENSOR CIRCUIT
2 Disconnect Passenger Side, Side Impact
Sensor C666.
8-JA40 (WH/VT), harness side and the
passenger side, side impact sensor C666 pin 2,
circuit 8-JA40 (WH/VT), harness side.
9-JA40 (BN/WH), harness side and the passenger side, side impact sensor C666 pin 1,
circuit 9-JA40 (BN/WH), harness side.
G428951 en
11/2004 2005.25 Fiesta
501-20B-175

TO MODEL INDEX
501-20B-175

TEST CONDITIONS

Yes
Go to CL2
No
REPAIR circuit 8-JA40 (WH/VT) and circuit
CL2: CHECK THE PASSENGER SIDE, SIDE IMPACT SENSOR FOR A SHORT CIRCUIT TO
BATTERY

Yes
No
Go to CL3
CL3: CHECK THE PASSENGER SIDE, SIDE IMPACT SENSOR FOR A SHORT TO GROUND
Are the resistances greater than 10,000 Ohms?

Yes
G428951 en
11/2004 2005.25 Fiesta
501-20B-176

TO MODEL INDEX
501-20B-176

TEST CONDITIONS
No
PINPOINT TEST CM: AIR BAG CONTROL MODULE DISCONNECTED OR INOPERATIVE

TEST CONDITIONS
CM1: CHECK THE AIR BAG CONTROL MODULE ELECTRICAL CONNECTORS
3 Check the air bag control module electrical
connectors.
Are the air bag control module electrical connectors fully engaged?
Yes
Go to CM2
No
CONNECT the air bag control module electrical connectors. REPEAT the self-test,
CM2: CHECK THE IGNITION SUPPLY CIRCUIT FOR AN OPEN CIRCUIT

Yes
Go to CM3
No
G428951 en
11/2004 2005.25 Fiesta
501-20B-177

TO MODEL INDEX
501-20B-177

TEST CONDITIONS
GO to CM4
CM3: CHECK THE AIR BAG CONTROL MODULE GROUND CIRCUIT

Yes
No
CM4: CHECK THE IGNITION SUPPLY CIRCUIT

Yes
CHECK the charging circuit. REFER to Section 414-00.[Charging System - General Information, DIAGNOSIS AND TESTING,
Charging System] REPEAT the self-test,
No
G428951 en
11/2004 2005.25 Fiesta
501-20B-178

TO MODEL INDEX
501-20B-178

TEST CONDITIONS
G428951 en
11/2004 2005.25 Fiesta
501-20B-179

TO MODEL INDEX
501-20B-179
GENERAL PROCEDURES
Deployed Air Bag Disposal
WARNING: After deployment, the air bag

module surface may contain deposits of
sodium hydroxide, a product of the gas
generate combustion, that is irritating to
the skin. Use protective gloves when
handling any deployed air bag module.
1. Remove the deployed air bag module(s).
For additional information, refer to the
relevant procedure in this section.
2. Seal the deployed air bag module(s) in the
packaging from the new air bag module(s)
or a suitable polythene bag, and then
dispose of in accordance with local
contaminated waste regulations.
G18618 en
11/2004 2005.25 Fiesta
501-20B-180

TO MODEL INDEX
501-20B-180
GENERAL PROCEDURES
Unserviceable Air Bag Disposal
1.
WARNING: To minimize the possibility

of injury in the event of premature
deployment, always carry a live air bag
module with the bag and trim cover
pointed away from the body. Failure to
personal injury.
WARNING: To prevent premature

deployment, live air bag modules must
only be placed on work benches which
have been ground bonded. Failure to
personal injury.
NOTE: All unserviceable air bag modules have
been placed on the Mandatory Return List. All
discolored or damaged air bag modules should be
treated the same as any unserviceable live air bag
module being returned.
Remove the unserviceable air bag module.
For additional information, refer to the
relevant procedure in this section.
NOTE: A prepaid, return postcard is provided with
the new air bag module. The new air bag module
serial number and the vehicle identification
number (VIN) must be recorded on the air bag
module verification card.
2. Before installing the air bag module, record
the necessary information. Return the air
bag module verification card to Ford Motor
Company (driver air bag module verification card shown).
G18617 en
3.
WARNING: Under no circumstances is

an unserviceable air bag module(s) to
be returned through the local mailing
system. Failure to follow this
injury.
Seal the unserviceable air bag module(s) in

the packaging from the new air bag
module(s) and address to the appropriate
manufacturer. The package should then be
forwarded to the Exchange Plan Center (as
appointed through the national sales
company) who will arrange forwarding to
the manufacturer.
4. NOTE: Autoliv air bag modules and seat belt
pretensioners.
Autoliv Gmbh, Theodor Heuss Strasse 2,
85221, Dachau, Germany.
5. NOTE: TRW air bag modules.
TRW Occupant Restraint Systems, FAO
Rene Getto, Industriestr 20, 73551, Aldorf,
Germany.
6. NOTE: TRW seat belt pretensioners.
TRW Occupant Restraint Systems, FAO
Helmut Goss, Industriestr 20, 73551, Aldorf,
Germany.
7. NOTE: Takata Petri air bag modules.
Takata Petri AG, Grossostheimer Strasse
223, D-63741 Aschaffenburg, (Supplier
Code P790M) Germany.
11/2004 2005.25 Fiesta

TO MODEL INDEX
501-20B-181
501-20B-181
GENERAL PROCEDURES
Safety Belt Pretensioner Disposal
2. NOTE: Certain vehicles require the removal of
the front seat to access the safety belt
Special Tool(s)
Air Bag/Pyrotechnic Safety
Belt
418-S055 (40-007A)
General Equipment
12v Battery
Deploy
personal injury.
WARNING: Before deploying the air bag
module or safety belt pretensioner, make
sure that all personnel in the vicinity are
aware that a loud noise (bang) is about to
occur. Do not let anybody approach
closer than six meters. Failure to follow
injury.
Remove the front seat (if necessary). For

501-10.
3. Detach the safety belt pretensioner
electrical connector from the front seat.
4. Install the front seat (if necessary). For
501-10.
5.
CAUTION: Make sure the seat mounting

bolts are installed.
Connect the deployment lead to the safety
belt pretensioner electrical connector. For
additional information, refer to Specifications in this section.
6. Connect the deployment lead to the

adapter lead.
WARNING: The air bag module or the

safety belt pretensioner should not be
handled immediately following
deployment as the air bag module or
safety belt pretensioner will be very hot.
414-01.
G18619 en
11/2004 2005.25 Fiesta
501-20B-182

TO MODEL INDEX
501-20B-182
7. Move as far away as possible from the vehicle and connect the deployment lead to
the battery.
8. Depress both switches to deploy the safety

belt pretensioner.
11.
WARNING: Under no circumstances is

an unserviceable air bag module or
safety belt buckle pretensioner to be
returned through the local mailing
system. Failure to follow this
injury.
NOTE: All unserviceable air bag modules have
been placed on the Mandatory Return List. All
discolored or damaged air bag modules should be
treated the same as any unserviceable live air bag
module being returned.
If an air bag module or safety belt buckle
pretensioner fails to deploy, seal the
unserviceable air bag module or safety
belt buckle pretensioner in suitable
packaging and return to the Exchange
Plan Center, as appointed through the
local National Sales Company.
9. Remove the safety belt buckle and

pretensioner. For additional information,
refer to Section 501-20A / 501-20B.
10. Deployed air bag module(s) and safety
belt pretensioners should be sealed in
suitable bags and then disposed of in
accordance with local contaminated
waste regulations.
G18619 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
501-20B-183
501-20B-183
GENERAL PROCEDURES
Scrapped Vehicle Undeployed Air Bag Disposal
Two stage air bag modules
Special Tool(s)
Air Bag/Pyrotechnic Safety
Belt
418-S055 (40-007A)
4.
CAUTION: Do not connect both test

leads to the adapter. Both air bag
module inflators must be deployed
separately.
Connect two test leads to the air bag module and the other end of one of the test
leads to the adapter (driver air bag module
shown).
General Equipment
12 volt battery
All vehicles
injury in the event of premature
personal injury.
premature deployment, live air bag
modules must only be placed on work
benches which have been ground
bonded. Failure to follow this instruction
414-01.
2. Remove the air bag module(s) to be
deployed. For additional information, refer
to the relevant procedure(s) in this section.
Single stage air bag modules
3. Connect the test lead to the air bag module
and the adapter (driver air bag module
shown).
G18616 en
All air bag modules

5.
CAUTION: To protect the test lead

electrical connector(s) from damage
during deployment, raise the air bag
module off the ground on two wooden
blocks.
Place the air bag module inside a suitable
rigid wire cage with the air bag module
cover uppermost.
11/2004 2005.25 Fiesta
501-20B-184

TO MODEL INDEX
501-20B-184
6. Connect the deployment lead to the

adapter.
8.
CAUTION: The air bag module should

not be handled immediately following
deployment as the air bag module will
be very hot.
CAUTION: After deployment, the air bag
Depress both switches to deploy the air
bag.
7.
WARNING: Before proceeding make

sure that all personnel in the vicinity
are aware that a loud noise (bang) is
about to occur. Do not let anybody
approach closer than six meters.
Move as far away as possible from the air
bag module and connect the deployment
lead to the battery.
9. Connect the second test lead to the
adapter.
G18616 en
11/2004 2005.25 Fiesta
501-20B-185

TO MODEL INDEX
501-20B-185
10.
WARNING: Before proceeding make

sure that all personnel in the vicinity
are aware that a loud noise (bang) is
about to occur. Do not let anybody
approach closer than six meters.
CAUTION: The air bag module should not
be handled immediately following
deployment as the air bag module will be
very hot.
CAUTION: After deployment, the air bag
Depress both switches to deploy the air
bag.
All air bag modules

11. Deployed air bag module(s) should be
sealed in a suitable bag and then
disposed of in accordance with local
contaminated waste regulations.
G18616 en
11/2004 2005.25 Fiesta
501-20B-186

TO MODEL INDEX
501-20B-186

Side Air Curtain Module 5-Door
Removal
personal injury.
2. NOTE: It may be necessary to use a pair of

pointed nose pliers to to release the electrical
connector locking tangs.
Disconnect the side air curtain module

personal injury.
3. NOTE: Note the routing of the retaining cord, to

aid installation.
Detach the front retaining cord from the
A-pillar.

personal injury.
bonded and with the trim cover facing up.
1. Remove the headliner. For additional
G92158 en
11/2004 2005.25 Fiesta
501-20B-187

TO MODEL INDEX
501-20B-187

4. Remove the side air curtain module front
retaining bolt.
7. Remove the side air curtain module.

Remove the front ramp retaining screws
from behind the air curtain.
5. Remove the side air curtain module rear

retaining bolts.
Installation
WARNING: Make sure the air bag
electrical connectors are correctly
installed and are secure. Failure to follow
injury.
6. Detach the side air curtain module rear
ramp from the roof panel.
Remove the rear ramp retaining screws

personal injury.
G92158 en
11/2004 2005.25 Fiesta
501-20B-188

TO MODEL INDEX
501-20B-188

Side Air Curtain Module 3-Door
Removal
personal injury.
2. NOTE: It may be necessary to use a pair of

pointed nose pliers to to release the electrical
connector locking tangs.
Disconnect the side air curtain module

personal injury.
3. NOTE: Note the routing of the retaining cord, to

aid installation.
Detach the front retaining cord from the
A-pillar.

personal injury.
1. Remove the headliner. For additional
G278610 en
11/2004 2005.25 Fiesta
501-20B-189

TO MODEL INDEX
501-20B-189

4. Remove the side air curtain module front
retaining bolt.
7. Remove the side air curtain module.

Remove the front ramp retaining screws
5. Remove the side air curtain module rear

retaining bolt and nut.
Installation
WARNING: Make sure the air bag
injury.
6. Detach the side air curtain module rear
ramp from the roof panel.
Remove the rear ramp retaining screws

personal injury.
G278610 en
11/2004 2005.25 Fiesta
501-20B-190

TO MODEL INDEX
501-20B-190

Crash Sensor
Removal
personal injury.
personal injury.
414-01.
2. Detach the hood latch from the radiator
3. Detach the crash sensor from the radiator

4. Remove the crash sensor.

1. Hold the rear of the connector.
2. Slide the cover of the connector rearwards.
Installation
WARNING: Make sure the crash sensor
locating tang is correctly located in the
radiator grille opening panel. Failure to
personal injury.
G92159 en
11/2004 2005.25 Fiesta
501-20B-191

TO MODEL INDEX
501-20B-191

Driver Air Bag Module (40 700 0)
Removal
personal injury.
personal injury.
WARNING: Painting over the driver air

bag module trim cover or instrument
panel could lead to deterioration of the
trim cover and air bag modules. Do not
for any reason attempt to paint
discolored or damaged air bag module
trim covers or instrument panel. Install a
new component. Failure to follow this
Disconnect]
(steering wheel removed for clarity).

personal injury.
G152594 en
11/2004 2005.25 Fiesta
501-20B-192

TO MODEL INDEX
501-20B-192

air bag module retaining clips.
5. Disconnect the driver air bag module

ground connector.
Using a thin bladed screwdriver, detach the

driver air bag module upper clips from the
steering wheel (driver air bag module removed for clarity).
6. Remove the driver air bag module.

Disconnect the driver air bag module electrical connector.
4. Detach the driver air bag module from the
steering wheel.
1. Pull the top of the air bag module away from
the steering wheel.
2. Push the air bag module upwards to detach
the lower retaining clips.
Installation
personal injury.
G152594 en
11/2004 2005.25 Fiesta
501-20B-193

TO MODEL INDEX
501-20B-193

personal injury.
WARNING: Painting over the driver air
bag module trim cover or instrument
panel could lead to deterioration of the
trim cover and air bag modules. Do not
CAUTION: Make sure that the driver air
bag module retaining clips are correctly
engaged and the trim cover is flush with
the steering wheel.
G152594 en
11/2004 2005.25 Fiesta
501-20B-194

TO MODEL INDEX
501-20B-194

Passenger Air Bag Module (40 701 0)
Removal
All vehicles
personal injury.
WARNING: Painting over the air bag

module trim covers or instrument panel
could lead to deterioration of the trim
cover and air bags. Do not for any reason
attempt to paint discolored or damaged
air bag module trim covers or instrument
panel. Install a new component. Failure to
personal injury.
Disconnect]
2. Remove the glove compartment retaining
screws.

personal injury.
personal injury.
3. Remove the glove compartment.

Press the sides of the glove compartment
towards the center to release the glove
compartment stops.

G152595 en
11/2004 2005.25 Fiesta
501-20B-195

TO MODEL INDEX
501-20B-195
4. Detach the passenger air bag module

bracket from the in-vehicle crossbeam.
6.

instrument panel, use the plastic edge
on the air bag module wiring harness
shield to support the passenger air
bag module on the instrument panel.
Support the passenger air bag module.
5. NOTE: If necessary, use a trim pad removal

tool to aid the release of the passenger air bag
module cover retaining clips from the
instrument panel.
Detach the passenger air bag module from
the instrument panel.
Push the air bag module upwards to detach
the air bag cover from the instrument panel.
Vehicles built up to 11/2004

7.

passenger air bag module electrical
connectors, use a pair of circlip pliers
to release the passenger air bag
module electrical connector locking
tangs.
Disconnect the passenger air bag module
G152595 en
11/2004 2005.25 Fiesta
501-20B-196

TO MODEL INDEX
501-20B-196

Detach the passenger air bag module wiring
harness from the wiring harness shield.

Detach the passenger air bag module wiring
harness from the wiring harness shield.

9.

passenger air bag module electrical
connector, use a pair of circlip pliers to
release the passenger air bag module
electrical connector locking tangs.
Disconnect the passenger air bag module
Installation
WARNING: Make sure the air bag module
injury.
personal injury.
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WARNING: Painting over the air bag
module trim covers or instrument panel
could lead to deterioration of the air bag
module trim cover and air bags. Do not
CAUTION: Make sure that all the
passenger air bag module trim cover
retaining clips are correctly engaged and
the passenger air bag module trim cover
is flush with the instrument panel.
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Clockspring
General Equipment
Worldwide diagnostic system (WDS)

equipped).
locking tang.
Removal
personal injury.
personal injury.

equipped).

1. Remove the steering wheel. For additional
2. Remove the spring.
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5. Detach the steering column upper shroud
from the lower shroud.
8. Disconnect the clockspring electrical

connector.
9. Remove the clockspring retaining screw.

6. Remove the steering column lower shroud.
10. Remove the clockspring.

Release the locking tangs from the steering
column.
7. Detach the multifunction switches from the
clockspring and position them to one side.
Depress each locking tang in turn and slide
each switch upwards.
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Installation
All vehicles
3. Connect the clockspring electrical connector.

1. Install the clockspring.
Make sure the retaining tangs lock into position on the steering column.
4. Attach the multifunction switches to the

clockspring.
2. Install the clockspring retaining screw.
5. Install the steering column lower shroud.

Lock the steering column locking lever.
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6. Install the audio control switch (if
equipped).
Connect the electrical connector.
7. Attach the steering column upper shroud

to the lower shroud.
G152596 en

8.
WARNING: Incorrect centralization may

result in premature component failure.
If in doubt when centralizing the
clockspring, repeat the centralizing
procedure. Failure to follow this
injury.
Centralize the clockspring.
1. Turn the clockspring in a counterclockwise
direction until resistance is felt
(approximately two and one half turns).
2.Turn the clockspring in a clockwise direction,
until the arrow marked on the rotor of the
clockspring aligns with the raised 'V' section
at the 12 o'clock position on the outer cover
of the clockspring (approximately two and
one half turns).
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9.
WARNING: Incorrect centralization may

result in premature component failure.
If in doubt when centralizing the
clockspring, repeat the centralizing
procedure. Failure to follow this
injury.
Centralize the clockspring.
1. Turn the clockspring in a counterclockwise
direction until resistance is felt
(approximately two turns).
2.Turn the clockspring in a clockwise direction,
until the arrow marked on the rotor of the
clockspring aligns with the raised 'V' section
at the 12 o'clock position on the outer cover
of the clockspring (approximately two
turns).
11.
CAUTION: If there is any break

between centralizing the clockspring
and installing the steering wheel, or
the vehicle is left unattended by the
technician, the centralizing procedure
MUST be repeated.
Install the steering wheel. For additional

12.
WARNING: The electronic stability

program must be re-configured.
Configure the electronic stability program
using worldwide diagnostic system
(WDS).
All vehicles
10. Install the spring.
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Air Bag Control Module (33 650 0)
General Equipment
4. Disconnect the air bag control module

Removal
personal injury.
5. Remove the air bag control module.

personal injury.
Disconnect]
2. Raise the parking brake control lever.
3. Remove the parking brake control lever
trim panel.
Installation
2.
WARNING: New air bag control

modules must be configured following
installation. Failure to follow this
injury.
If installing a new air bag control module,
configure the air bag control module using
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Side Impact Sensor 5-Door (40 699 0)
Removal

personal injury.
personal injury.


414-01.
2. Detach the weatherstrips from the B-pillar.
5. Disconnect the side impact sensor

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6. Remove the side impact sensor.
Installation
WARNING: Make sure the side impact
sensor locating tangs are correctly
located into the floor pan. Failure to
personal injury.
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Side Air Bag Module (40 698 0)
Removal
All vehicles
vehicle and when handling the air bag
supplemental restraint system (SRS).
2.
WARNING: Note the position of the side

air bag module wiring harness to aid
installation. An incorrectly routed side
air bag module wiring harness could
moved. Failure to follow this
injury.
Disconnect the side air bag module electrical connector.

personal injury.
injury.
Disconnect]
G220364 en
Vehicles with fold flat seat

3. Release the backrest rear panel from the
backrest cover and frame.
1. Lift the lower edge of the rear panel 5 cm to
detach the retaining clips at the upper edge
of the panel.
2. Remove the rear panel.
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All vehicles
4.

pressure must be applied to the
opposite sides of the handwheel.

panel.
Remove the backrest recliner handwheel.

panel.


access the lower ends of the tensioning
rods.
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rods.

access the upper end of the spring frame.
13. Detach the backrest cover from the front
of the backrest pad.
Cut the hog rings.
14. Detach the side air bag deployment

sleeve from the backrest frame (if
equipped).
sleeve.

equipped).
16. Detach the side air bag module wiring

harness from the seat frame.
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17. Detach the side air bag module wiring
harness from the backrest frame.
Installation
1.

vehicle and when handling the air bag
module. Failure to follow this
injury.
SRS. Failure to follow this instruction
18. Remove and discard the side air bag

module retaining nuts.

personal injury.
19. Remove the side air bag module.

injury.
WARNING: Install new side air bag
module retaining nuts. Failure to follow
injury.
NOTE: The side air bag module is handed for
left-hand and right-hand seats. The side air bag
module wiring harness must face the seat base
when installed.
NOTE: Using suitable hog ring pliers, install new
hog rings as necessary.
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Side Impact Sensor 3-Door (40 699 0)
Removal
personal injury.
personal injury.
4. Locally detach the floor covering to gain

access to the side impact sensor.
5. Remove the adhesive tape.

414-01.
3. Remove the front scuff plate.
6. Detach the side impact sensor from the
floor panel.
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7. Remove the side impact sensor.
Installation
WARNING: Make sure the side impact
sensor locating tangs are correctly
located into the floor panel. Failure to
personal injury.
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Passenger Air Bag Deactivation (PAD) Switch
Removal
personal injury.
personal injury.
414-01.
2. Detach the passenger air bag deactivation
(PAD) switch from the instrument panel.
G154226 en
3. Remove the PAD switch.

Installation
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Driver Air Bag Module Wiring Harness
Removal
All vehicles
1. Disconnect the horn switch electrical

connector (two stage air bag module
shown).

module with the air bag and trim cover
personal injury.
2. Disconnect the driver air bag module

ground connector (two stage air bag module shown).

(SRS) component. Failure to follow this
deployment, do not work on the air bag
module with the trim cover facing
downwards. Support the air bag module
vertically and work to the side of the air
bag module. Failure to follow these

3. Detach the driver air bag module wiring
CAUTION: Note the position and routing

of the driver air bag module wiring
harness to aid assembly. An incorrectly
routed driver air bag module wiring
harness may become damaged when the
steering wheel is rotated.
CAUTION: This procedure must only be
used if referred to from the Diagnosis and
Testing procedure in this section. Under
no other circumstance must the driver air
bag module wiring harness be
disconnected from the air bag module.
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501-20B-214

harness.
Release the driver air bag module wiring
harness locking tangs.
Installation
personal injury.
Single stage air bag modules

5. Detach the driver air bag module wiring

injury.
1.

harness.
Release the driver air bag module wiring
harness locking tangs.

bag module electrical connectors are
free from any wiring harness
connector fragments.
bag module wiring harness is correctly
routed and is secure under the locating
clips. An incorrectly routed driver air bag
module wiring harness may become
damaged when the steering wheel is
rotated.
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501-25A-1
Body Repairs - General Information
501-25A-1
SECTION 501-25A Body Repairs - General

Information
CONTENTS
PAGE

Body Repairs ....................................................................................................................
Introduction ......................................................................................................................
Introduction ......................................................................................................................
Integral body-frame ..........................................................................................................
Design features of an integral body-frame........................................................................
Safety passenger cell .......................................................................................................
Crumple zones .................................................................................................................
Off-road vehicles ..............................................................................................................
High-strength low alloy steel.............................................................................................
Anti-corrosion protection ..................................................................................................
Accident damage and diagnosis.......................................................................................
Planning a repair ..............................................................................................................
Obtaining spare parts .......................................................................................................
Straightening repairs ........................................................................................................
Cutting out body parts ......................................................................................................
Carrying out the repairs....................................................................................................
Panel beating ...................................................................................................................
Heat-treatment of panels..................................................................................................
Lead loading of panels .....................................................................................................
Welding and soldering repairs ..........................................................................................
Safety measures ..............................................................................................................
Resistance spot welding...................................................................................................
MIG / MAG welding ..........................................................................................................
Brazed connections..........................................................................................................
Bonded connections.........................................................................................................
Removing and installing bonded windows ........................................................................
Special body repairs.........................................................................................................
Protective equipment and safety at work ..........................................................................
501-25A-2
501-25A-2
501-25A-2
501-25A-2
501-25A-3
501-25A-3
501-25A-3
501-25A-4
501-25A-5
501-25A-6
501-25A-6
501-25A-11
501-25A-11
501-25A-11
501-25A-12
501-25A-13
501-25A-16
501-25A-16
501-25A-17
501-25A-17
501-25A-17
501-25A-18
501-25A-18
501-25A-19
501-25A-19
501-25A-20
501-25A-21
501-25A-22
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Body Repairs
Introduction
The body plays a significant role in the increasing
trend of ever more rapidly changing model
variants. The different customer groups are
strongly influenced by the design and shape of the
body. At the same time the stability of the body
plays the most important part in ensuring
passenger and driver safety. Lightweight
construction, alternative materials, composite
materials, plastics and appropriate joining
processes are all design features that
characterise modern Ford vehicle bodies.
In terms of manufacturing technology, modern
safety cell bodies can be produced almost without
any problems. Ford guarantee high quality
standards by ensuring that mechanical strength
properties are tried and tested in numerous
computer simulations, crash tests, by testing
materials and by employing sophisticated
manufacturing technologies. In the event of
repairs it is vital that the production quality
standards are upheld. This requires a
well-equipped workshop, and places particular
emphasis on the qualifications of the workshop
technicians. Up-to-date knowledge of current
manufacturing technologies and continuous
training on new repair methods and techniques
are vital for high-quality body repairs. The
model-specific repair manuals and the general
repair techniques provide valuable support when
undertaking body repairs.
Introduction
Body development is becoming more and more
complex, and as a result the topics covered in the
body repair manual are changing. In future, only
the most important repair methods and techniques
will be described in the general section. Extensive
knowledge of fundamental body repair techniques
G33911 en
is assumed. For example, any repairs that are

repeated will be covered for all vehicle models in
the body-specific section. The model-specific
sections of the repair manuals will only cover
important repair steps or will point out special
features. Specific training courses for new models
will provide additional practical information as well
as tips and tricks for body repairs.
Integral body-frame
The integral body-frame design has established
itself in the car market.
Its main advantages are:
Maximum safety for driver and passengers.
Significant reduction in weight.
Economical manufacturing technology.
The integral body-frame is completed with
assembly parts like doors, hood, bumpers etc.
Once assembled, this design is particularly
advantageous regarding stability and rigidity,
featuring:
Stable passenger cell behaviour.
Exactly defined deformation behaviour at front
and rear.
Additional lateral stability.
High torsional rigidity.
High flexural strength.
In the event of repairs the following repair
instructions should be observed:
Only carry out straightening work with the
complete body shell assembled.
Do not cut out bonded windows during
straightening.
Keep the body free of stress.
If possible keep the body shell assembled
during repairs.
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Integral Body-frame Design
Design features of an integral body-frame

The safety of driver and passengers is paramount
for every body design. There are two key safety
aspects in the body:
Safety passenger cell
Crumple zones
A safety passenger cell is characterised by the
following design features:
- Stable pillars, door sills and door profiles.
- Integrated side impact protection in the
doors.
- The doors are designed to open even in the
event of extreme deformation.
deformation characteristics. The crumple

zones serve the following purposes:
- Dynamic absorption of deforming forces.
- Protection of the passenger cell.
Always follow the repair instructions published
in the workshop literature, particularly on
repairs in the crumple zone. Failure to observe
this instruction can result in serious
impairment of vehicle safety, under certain
circumstances. For instance, no cuts must
ever be made in the immediate vicinity of the
axle mounting fixing points, nor must any
reinforcement plates be welded in randomly.
All of the specified safety requirements must
be met after the work has been carried out.
Crumple zones
A safety passenger cell is protected by front
and rear crumple zones with well-defined
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Crumple Zones - Safety Passenger Cell
Item
Part
Number
Description
Crumple zone
Off-road vehicles
Off-road vehicles differ from the integral
body-frame principle in their 2-part body design.
An extremely stable chassis frame forms the base
to which all vehicle components like axles, engine
etc. are attached. The actual body is bolted onto
G33911 en
the chassis frame. This design has the following

advantages:
High pay load and large trailer capacity.
Excellent strength properties for off-road use.
Extremely high ground clearance.
If any repairs are to be carried out on an off-road
vehicle then the following notes should be
observed:
It is quite common for the two longitudinal
members of the frame to be displaced parallel
to one another.
If necessary the bolted-on body should be
taken off before straightening the chassis
frame.
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501-25A-5
501-25A-5
Off-road Vehicle Design
Item
Part
Number
Description
Body
Frame
Bolted connection
High-strength low alloy steel

General
High-strength low alloy steel is used on Ford
bodies mainly for beams, joining plates,
mountings and struts.
The model-specific chapters explain where
high-strength low alloy steel is used.
Stronger tendency to retain deformed shape.

More force is required for straightening work.
As a result of the tendency to retain the
deformed shape, any deformed components
need to be pulled well beyond straight when
working on a straightening jig.
Any tools used to remove metal from the
surface (e.g. weld-spot mill) have a reduced
life expectancy because of the higher degree
of hardness.
Do not apply heat during straightening work,
as losses of mechanical strength can occur
already at temperatures of approx. 400 C.
Bake-hardening steel achieves its final
hardness during production when it is placed
into the paint drying oven.
Special features of high-strength low alloy steel:
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Flame
galvanised
thin sheet
Low alloy thin
metal - zinc
sheet metal plated electrolytically
galvanised Galvannealed Galfan thin sheet
metal - zinc - aluminium-gal
vanised
zinc-nickel
Special properties
Type of steel
180
180
High-strength
Very good plasticity on complex pressed panels or
low-alloy steel
low stability areas (e.g. inner door panel or wheel
housing)
180. 220. 260. 180. 220. 260
Bake-hardening
Good plasticity; additional surface hardness is
300
steel
achieved in combination with heat treatment
(painting) (e.g. flat parts like outer door panel or
hood).
Good elasticity on pressed parts in moderate sta- 220. 260. 300
220. 260. 300
Phosbility areas (e.g. wheel housing)
phor-alloyed
steel
Micro-alloyed
High degree of rigidity for weight-bearing body
260. 300. 340. 340. 380. 420
steel
components
380. 420. 460
220. 260
260. 300. 340
Isotropic steel
Good elasticity in moderate stability areas as a
result of high stretching capacity and isotropic deformation properties (e.g. flat parts like outer door
panel, hood)
Table: Minimum stretch limit for high-strength low alloy steel in N/mm
High-strength low alloy steel (example: Mondeo)
Anti-corrosion protection
Accident damage and diagnosis

General notes
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Exact diagnosis of the extent of damage
enables proper repair planning.
Do not weld in any extra reinforcing plates.
All body repairs must be carried out in
accordance with the guidelines in the Body
Repair Manual.
The stability and strength properties of the
body must be taken into account during body
repairs. Integral body frames have exactly
defined deformation patterns that must not be
affected by any repair work.
For instance, the crumple zones absorb the
bulk of the impact energy. If any
unprofessional repair techniques or methods
are used in these areas then this can pose a
fundamental threat to vehicle safety.
Hidden damage
As well as looking at external indicators like
flaked off paint, it is vital to check for hidden
body damage or deformation that is not visible
from the outside. Large attached parts like
bumpers and inner fenders often need to be
removed to allow accurate assessment of
damage to underlying body parts.
Pre-determined folding points
The pre-determined deformation points should
always be checked when assessing body
damage. Pre-determined deformation points
take the initial force of the impact, and are
designed as "cross-sectional weaknesses"
which are achieved by partial joggling or by
other means of shaping.
Pre-determined deformation points by the use of

different material thicknesses
Item
Part
Number
Description
Material thickness 2.0 mm
Node welds
Node welds are key points in the body shell of
a vehicle. Indications of damage such as
flaking paint in the area of node welds are
often a clear sign of substantial damage. For
this reason all body parts attached at a node
weld must be checked very carefully for any
sign of damage when assessing the damage.
Pre-determined deformation points by special

shaping of the body panels
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Flow of forces around node welds
Gap dimensions
Gap dimensions offer another alternative for
diagnosis by visual inspection. If any changes
or misaligned edges are apparent, then this
usually indicates that the dimensions of the
affected part are incorrect.
Changes in gap dimensions
G33911 en
Item
Part
Number
Description
Gap too wide
Gap too narrow
Impact effects on the body
NOTE: Vehicle components like drive shafts and

trailer attachments transfer forces. If a vehicle is
subjected to a rear impact then all connected body
parts and mechanical components (e.g.
transmission mountings) should be thoroughly
checked. Electronic components should be
checked to ensure that they still operate correctly.
Furthermore it is possible to deduce the
overall extent of damage from the direction
and magnitude of the impact forces. This does
however require extensive body-specific
knowledge.
If, for instance, an impact occurs at the front
left-hand side member, then the right-hand
side member is usually also affected as a
result of the rigid body-shell design
(crossmember). Often the length of this side
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501-25A-9
501-25A-9

member will not have changed, but because of
the rigid body-shell design it may have moved
from its original position (often only by a very
small amount). If any deviations are present
this can usually be detected by checking the
gap dimensions between door and fender or
by checking for changes in dimension.
In the case of more severe impacts, the front
part of the body cannot absorb all of the impact
energy, and the passenger cell is also
deformed. Here the impact energy is
transferred via the side member to the A-pillar
(see diagram). This results in deformations in

the area of the roof and the door sill.
The body reacts quite differently to side
impacts where there is hardly any crumple
zone. As the passenger cell is extremely
stable, there are comparatively few local
deformations at the site of the impact.
However, the impact forces are transferred to
the entire vehicle floor, which often results in
so-called "banana damage", where the vehicle
is bent into a banana shape across the length
of its longitudinal axis.
Impact energy is transferred via the side member to the A-pillar
Item
Part
Number
Description
Deformation area - roof rail
Deformation area - roof
Deformation area - door sill
Measurements with a compass

- The compass is a very useful instrument for
checking the vehicle underbody. It can be
used to detect dimensional variations across
the length and the width (but not the height)
by means of comparison measurements
and diagonal measurements. For this
purpose, always select body reference
points from the data sheet for body frame
dimensions.
Measuring the underbody
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Symmetry measurements with a compass
Body measurements
Measuring options
- Comparison measurements can also be
made on the outside of the body. Depending
on the damage, comparison measurements
and diagonal measurements can be carried
out using compass, telescopic rod, tape
measure or ruler.
NOTE: The same reference points must be
chosen on both sides when checking for changed
dimensions (e.g. bores, edges, beads/swage lines
etc.).
- All of the important external body
dimensions are listed in the model-specific
body repair descriptions.
Measurements with a measuring/straightening
jig
- A measuring/straightening jig is required for
accurate measurements of the floor pan of
the body. The measuring systems are
categorised by their means of operation:
- Mechanical measuring system
- Optical measuring system
Quick and accurate measuring results can be
obtained using computerised measuring
systems.
A minimum of three intact measuring points on
the floor pan are required for measurements of
length, width and height dimensions.
In some cases this may mean making the
measuring points accessible. All of these
G33911 en
measuring systems can be used to make body

measurements, provided all the equipment is
available.
Measuring fixture for body measurements
Item
Part
Number
Description
Base frame
Measuring bar
Telescopic measuring rod

with measuring probe
Measuring bridge
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501-25A-11

Alignment jig
Obtain all the data for the vehicle, including

type, vehicle identification number, trim code,
engine identification letters, initial registration
etc.
Establish all of the metal parts that need to be
renewed.
Establish all of the attached parts that need to
be renewed, including small parts like rivets,
clips etc.
After receiving all of the spare parts, check
them on the vehicle to make sure they are
correct and complete.
Straightening repairs
Planning a repair
The following decisions have to be made before
the repairs are started:
Does the vehicle need to be put on a
straightening jig, or can it be straightened by
other means?
Does the floor pan need to be measured?
Do aggregates like engine or axles need to be
removed?
NOTE: It is preferable to repair body parts rather

than to renew them, as this keeps the complete
body-shell intact.
Which body parts need to be renewed?
Which body parts can be repaired?
Obtaining spare parts
The availability of spare parts often determines
how easily the body repairs can be carried out.
The following procedure is recommended:
G33911 en
Straightening repairs are often required to restore

the body to its original shape after an accident.
This can be done with:
Alignment jigs
Universal straightening and measuring jigs
Welding jig system
The following points must be followed to ensure
that the repairs are carried out professionally and
that all the dimensions are correct after the repairs
have been carried out.
Structure:
- The repair sequence depends on the
individual repair plan (taking any necessary
disassembly work into account).
- Clean the attachment areas.
- Anchor the vehicle free of stress on the
relevant system.
- Support the aggregates to take strain off the
body.
- Decide on at least three
measuring/mounting points that are
undamaged and as far apart as possible (for
basic adjustment).
- Check the dimensions of the
measuring/mounting points.
Straightening:
NOTE: Check dimensions and gaps continuously
during straightening.
- A body is always straightened in the
opposite direction to that of the impact.
Always carry out straightening repairs with
the complete body shell assembled (do not
cut out any parts beforehand). Carry out the
straightening work in several stages. This
prevents the risk of overstretching or of
welded joints tearing out. During the
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individual straightening steps, relieve
tension by striking with an aluminium
hammer while the part is subjected to a
tensile load (in the area of pre-determined
folding points, dents, welded joins etc.).
Special features:
- High-strength low alloy steel has a greater
tendency to retain its deformed shape.
- If necessary, open doors or hood during
straightening.
- Never apply heat during straightening.
- Follow the instructions in the chapter
"Protective Equipment/Safety at Work".
- Any spot welds that are inaccessible for the

spot-weld mill (diameter > 8 mm) should be
ground out using a rod sander. The same
applies to MIG spot welds or seams.
Rod sander
Cutting out body parts

Depending on how the parts are joined/connected,
different tools are suitable for cutting/separating
body parts.
NOTE: All other parts like interior equipment,

window glass etc. must be protected against flying
sparks.
NOTE: Ensure that the milling depth is set
correctly to prevent the remaining flange from
being weakened.
Spot-weld mill
Spot-weld mill
Severance cuts
NOTE: Underlying metal parts, wiring harnesses,
hoses etc. must not be damaged - remove them
beforehand if necessary.
- Body saws are particularly versatile and are
therefore very suitable for making
severance cuts on body parts.
Short stroke saw
- Body parts are usually separated with a
short stroke saw. It proves to be very flexible
even in areas where access is very limited.
Short stroke saw
Rod sander
NOTE: Wear protective clothing. Protect any
vulnerable body or glass areas against flying
sparks. Remove explosive materials from the
vicinity.
G33911 en
Reciprocating saw
- In addition to the short stroke saw, the
reciprocating saw can be used. With this, it
is possible to make narrow and straight cuts
to an exact depth.
- The lifetime of the blade can be substantially
increased by cooling it with oil. Any swarf
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caused by sawing must always be removed
from cavities (using suction) to prevent the
risk of corrosion.
- If there are any brazed connections on the
part that is to be cut out, then use a welding
torch to heat them evenly until the brazing
solder melts. Then peel off the old part.
Reciprocating saw
- In many cases it makes technical and

economical sense to carry out a sectional
replacement. The two main considerations
are firstly, maintaining the original overall
body shell structure and secondly, keeping
the repair costs to a minimum.
- There are three different methods for
sectional replacement:
Butt joints
- New part and old part are joined with a
continuous MIG weld seam.
- Butt joints are most commonly used for
sectional replacements on members and
pillars, or on short severance cuts.
Butt joint
Carrying out the repairs

Complete replacement
- In a complete replacement the entire
damaged old part is removed at its original
joins/connections, and a complete new part
is then installed. The following illustration
shows a replacement with a new back panel
(Mondeo).
Replacement with a new back panel (Mondeo)
Edge-setting
NOTE: Although the width of the set edge is 12
mm, only 10 mm should be given as material
allowance on the new part. This automatically
produces the required welding gap between the
set edge of the old panel and the edge of the new
panel. For corrosion protection reasons, the set
edge created is shortened to 6 mm before
inserting the new part.
Sectional replacement
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- Edge-setting is mostly done on the old part
which is still attached. The old part and the
new part are joined by an intermittent seam.
Edge-setting
Item
Part
Number
Description
Resistance spot weld
MIG welded intermittent

seam
Example
Repair panel sections - Ford Ka
Metal backing strip

- A metal backing strip (approx. 30 mm wide)
from the left-over old part or new part is spot
welded to the back of the join.
NOTE: Edge-setting or metal backing strips are
most commonly used on longer severance cuts.
NOTE: The severance cuts should always be kept
as short as possible on sectional replacements.
Only cut at the severance lines shown in the
model-specific chapters.
- Do not make any cuts near reinforcements
or pre-determined folding lines.
NOTE: Do not start cutting out the old part until the
new part has arrived (repair sections can vary in
size).
- Special repair sections are available for
sectional repairs, and they are listed
separately in the Spare Parts microfiche.
Metal backing strip
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Sectional replacement - side member, Ford Puma
Prepare parts remaining on the vehicle / new

parts.
- Reshape the adjoining surface of any
dented body parts that are to remain on the
vehicle using a hammer and a counterhold
(ensure that the old part matches the shape
of the new part). Grind off left over spot
welds or seams with an angle grinder.
- Cut the new parts to shape.
- If necessary punch or drill holes for spot
welding.
NOTE: Do not use a welding torch to remove paint
residue (the heat could cause the metal to
deform).
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- Grind all joining flanges to bare metal on
both sides. Do not use an angle grinder for
this purpose (this could weaken the metal
and damage the zinc layer). Suitable tools:
rotating wire brush, belt sander or plastic
disc.
- Except for brazed joints, apply welding
primer liberally to all weld flanges.
- The primer must be well stirred before use.
NOTE: When using aerosols, take care not to
contaminate adjacent parts with spray mist.
NOTE: For additional information, refer to
subsection 501-25B "Body Repairs - Corrosion
Protection".
profiled parts line up. The edge is then tack

welded to ensure that it lines up.
Aligning and tack welding
Fit the new part.

It must be ensured that the new part fits
exactly to the specified dimensions. Suitable
equipment:
- Alignment jig
- Universal measuring system
- Jig system
- Ruler or tape measure
- Compass
- Frame dimensions can be found in the
model-specific repair manuals.
NOTE: Any attached body parts that require

accurate alignment and fitting must be
incorporated in this step; for instance bumpers,
seals, headlamps, rear lamps and lock assembly
components. If this is not done carefully it may
result in water leaks, wind noises and substantial
follow-on work.
Ensure that edges line up with adjacent parts
and check that gaps are consistent (compare
left and right-hand sides). Make sure that the
shape of the vehicle is retained.
Item
Part
Number
Description
Tack welds
Using a screwdriver to align
Longer joins are usually tack welded to

prevent the panel from warping. It is important
to carry out the tack welds in the correct
sequence (see diagram).
Weld in the new part following the instructions
in the repair manual. Read and observe the
notes in the chapter "Welding and Soldering
Repairs".
Correct tack welding sequence
Secure the new part
NOTE: The need for subsequent follow-on work

can be significantly reduced if aligning and
tack-welding are carried out with due care.
Depending on accessibility the following
methods for securing are available:
- Grip pliers (set of)
- Screw clamp (set of)
- Self-tapping screws
- Tack welds
Use a staking tool or a screwdriver to ensure
that the edges of sectional replacements of
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Follow-on repairs/corrosion protection

This step basically covers the following work:
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- Grinding welded seams and lead loading
them if necessary.
- Priming any bare metal.
- Sealing welded seams.
- Applying underbody protection.
- Sticking damping matting in place.
- Filling cavities with foam.
NOTE:
For additional information,
refer to Section 501-25A / 501-25B / 501-25C /
501-25D / 501-25E / 501-25F / 501-25G. "Body
Repairs - Corrosion Protection"
- Cavity wax (after painting).
- Advantage: Low risk of overstretching the

panel.
- Used for repairs of small dents on panels
that are accessible from both sides.
- These two panel beating tools are usually
used for "finishing repairs".
Fine straightening with an aluminium hammer and
a universal dolly
Panel beating
Types of steel used in body manufacture
Vehicle bodies are manufactured using thin
steel with a thickness ranging from 0.5 to 2.75
mm. There are two main types:
- Pressed steel quality body panels
- High-strength low alloy steel
Pressed steel quality body panels:
- These body panels are softer and more
easily mouldable. They stretch extremely
well and therefore are not susceptible to
unwanted cracking.
High-strength low alloy steel:
- High-strength low alloy steel is much stiffer
to mould or otherwise work on than for
instance steel ST14. It also has a higher
stretch limit.
Fundamentals of panel beating
Before carrying out any sectional
replacements or complete replacements of
body panels, always check carefully whether
the damaged panel(s) can be rectified by
panel beating.
Panel beating is usually the easiest and most
economical method of repairing a damaged
panel.
Examples of applications of different panel
beating techniques:
Aluminium hammer and mallet
Sliding hammer
- If the damaged panel is only accessible from
the outside, use a sliding hammer to pull it
back into shape. The discs or studs needed
to mount the sliding hammer are welded
onto the bare surface. Dents in the panel
can be flattened out using controlled
application of the sliding hammer.
Heat-treatment of panels
It is usually inevitable that some parts of the
body panels show excess material as a result
of mechanical strain. If there are any areas of
excess material this will cause localised
instabilities due to differences in tension.
These localised instabilities can be stabilised
by applying heat-treatment techniques.
NOTE: This rule does not apply to high-strength

low alloy steel.
Rule: Flattening panels by heat-treatment
reduces the amount of excess material by
more than they were originally stretched.
Different heat-treatment techniques
NOTE: Different heat-treatment techniques are
used depending on the amount of excess
material.
Flattening using a flame
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- A welding torch is used if the material
excess extends over a larger area (torch
size 0.5 - 1.0 mm). Use a soft flame.
- The surface of the metal is briefly
spot-heated and then immediately cooled
with a wet sponge.
- Requirement: Ability to handle a welding
torch safely and knowledge of annealing
colours of steel.
- Advantage: No damage to the surface of the
metal.
Flattening using a flame, supported by
hammer and counterhold
NOTE: The flattening effect is increased by
speeding up the heating and cooling stages.
- If the material excess is concentrated, then
the flattening effect can be increased after
heating by carefully using an aluminium or
wooden hammer.
- Requirement: Ability to recognise material
tension by feeling the surface that is to be
flattened.
Flattening using a carbon electrode
- If panel areas are only accessible from one
side, or the panel is only slightly destabilised,
then the preferred method is flattening using
a carbon electrode.
- Requirement: Bare metal surface.
- Disadvantage: Scarring and hardening of
the surface.
Flattening using a copper electrode
- Small, sharp dents that face outwards can
be worked on with a copper electrode.
Flattening using a flame and body files
NOTE: When applied correctly, this method can
be used with all the attached parts still in place
(roof headlining, wiring harnesses etc.).
- Small, soft dents (only slight stretching):
Working at the edges of the dent in an
inward spiral pattern, the dent is heated with
an oxyacetylene torch (torch size 1 - 2 mm,
excess gas flame) to approx. 250 C.
- Working rapidly with a body file extracts heat
from the edge area until the dent is flattened.
Preferably alternate between two files. This
increases the amount of heat that can be
extracted.
rectifying small uneven areas on a panel

surface.
Advantages:
- Excellent bonding on bare metal surfaces.
- Very good moulding properties.
- Good properties for re-shaping.
- Permanent shape.
- Heat expansion is the same as steel.
NOTE: Tin alloy: PB 25% / 75%. Use an extraction

unit. Breathing equipment.
Process: Hammer the applied lead loading
before finishing it to remove air bubbles.
Welding and soldering repairs
Safety measures
NOTE: Refer to the notes in the chapter

"Protective Equipment/Safety at Work".
Lead loading of panels

Lead loading is the best repair method for
smoothing joins on sectional repair joins or for
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Disconnect the battery negative terminal and

cap the terminals in order to protect the
electronic modules in the vehicle (ABS, airbag
etc.).
Do not allow electronic units or lines to come
into contact with the ground connection or the
welding electrode.
Remove the battery before carrying out
welding work in its vicinity.
Utmost care must be taken when welding near
the fuel tank or other components that contain
fuel. If the tank filler neck or a fuel line must be
detached to allow access for welding work,
then the fuel tank must be drained and
removed.
Never weld, braze or solder on components of
a filled air conditioning system. The same
applies if there is a risk of the air conditioning
system heating up.
Connect the ground connection of the
electrical welder directly to the part that is to be
welded. Ensure that there are no electrically
insulating parts between the ground
connection and the welding point.
Adjacent vehicle parts and adjacent vehicles
must be shielded against flying sparks and
heat.
Resistance spot welding

90% of welding in production is done by
resistance spot welding. As a rule, the joining
technique used in production should also be used
for repairs. The number and diameter of repair
spot welds must be the same as in production.
Alternative joining techniques must only be used
in exceptional cases.
Setting up the equipment and co-ordinating the
welding parameters
Equipment:
- Follow the equipment manufacturer's
instructions for the equipment settings.
- Select the correct electrode arms (as short
as possible).
- Align the electrode arms and tips exactly.
- Electrode tips should be convex (rough
shaping with a file, fine shaping with a
sanding block).
Body:
G33911 en
- Ensure that the flanges to be joined lie

perfectly flat to one another.
- Prepare a bare metal joint surface (inside
and outside).
Notes on technique/method:
- Carry out a test weld on a sample piece of
the material coated in welding paste.
- If any metal parts are located between the
electrode arms then there will be a loss of
induction and therefore power (adjust
current setting).
- The power needs to be adjusted for
high-strength low alloy steel.
- Repeated welding on old welding points
often leads to poor quality welds.
- Keep the electrode tips as near as possible
to an angle of 90 to the contact surface.
- Keep the pressure on the electrodes for a
short period after finishing the weld.
NOTE: Cool the electrodes in water after about 10
spot welds to ensure that the welding results are
consistent (not necessary on cooled electrodes).
- The electrodes work best if their shape is
convex. Clean the contact surface of the
electrodes regularly.
Resistance spot welding panels where the total
thickness is 3 mm or more
For all repairs to modern Ford vehicles,

spot-welding equipment should be suitable for
reliable welding of zinc-plated, high-strength and
high-tensile steels in three or more layers, up to 5
mm total thickness. If these requirements are not
fulfilled, puddle welding must be used for safety
reasons. The electrical specifications (current,
resistance, heat) of the spot-welding equipment
have different validity, depending upon the type of
equipment. Therefore, it is essential that the
manufacturer's instructions are observed with
regard to the actual welding performance.
MIG / MAG welding
Setting up the equipment and co-ordinating the
welding parameters
Any joins that are MIG/MAG welded in
production must also be MIG/MAG welded
during repairs. Also during repairs, some
resistance spot welds need to be replaced by
puddle welds.
If access is difficult, or if a suitably powerful
spot welder (see above) for total panel
thicknesses of 3 mm or more is not available,
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resistance spot welding must be partially
replaced by puddle welding during repairs. In
this case, the increased time needed and the
correspondingly more demanding corrosion
protection requirements, must be taken into
account.
Welding repairs can only be carried out
properly if the equipment is set up correctly
and all the welding parameters are
co-ordinated.
Equipment:
- Set up the equipment as directed by the
manufacturer.
- The hoses must be untwisted.
- The core must be free of abraded rod
particles.
- The gas and current nozzles must be free of
slag and scale residue.
- Pay attention to the quality of the welding
rod and the throughput of gas.
Body:
- Ensure that the joint surface is perfect.
- Prepare a bare metal joint surface.
- Maintain the correct gaps (formation of
roots).
Notes on technique/method:
NOTE: The increased application of heat during
MIG welding destroys the welding primer/zinc
layer over a much larger area than during
resistance spot welding, as a result of which much
more care needs to be taken when applying
anti-corrosion protection afterwards.
NOTE: A test weld should always be carried out to
ensure that the welded joint is not just a surface
connection.
- Attach the ground cable right next to the

welding point (ensure that good contact is
made).
- During puddle welding start welding on the
lower panel to ensure adequate penetration.
Puddle welding
Item
Part
Number
Description
Welding direction: circular

pattern working from the inside outwards
Welding starting point: centre

of hole on lower panel
Brazed connections
Never replace production brazed connections
with any other type of connection.
NOTE: Remove all traces of flux residue to

prevent risk of corrosion.
Brazed connections require particularly careful
preparation. It is extremely important that the
joint surfaces are exactly aligned and that a
bare metal joint surface is prepared.
Bonded connections
Adhesive technology is finding more and more
applications in modern vehicle construction. Some
areas of the body are increasingly affected. All
bonded connections must be remade during
repairs.
Application and safety instructions
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- Always follow the handling instructions
supplied by the manufacturer when using
adhesives or sealants.
NOTE: Observe the manufacturer's safety
instructions.
- Adhesives are chemicals and as such are
subject to specific safety regulations.
Bonded clinched flanges
- The bonded clinched flanges of the hood,
tailgate and doors are bonded in production
and during repair on many Ford models.
- These bonds are mainly for sealing
purposes (anti-corrosion) rather than for
adhesive strength.
Bonds that rely on adhesive strength
- Adhesive bonds that rely on adhesive
strength are used for adhesive strength
purposes, sealing purposes and
anti-corrosion purposes (e.g. Escort/Orion
'91 in the rear region of the roof, near the
transition to the C-pillar).
- The adhesive used for this purpose is 2K
epoxy resin.
Adhesive bonding of the outer roof skin (Escort
'91)
- On nearly all models, the windscreen is

bonded directly onto the window frame on
the body. In addition, the side and rear
windows are bonded on most model
variants.
- The windows are bonded primarily for
reasons of adhesive strength. Bonded
glazing provides additional torsional
stiffness to the body.
Adhesive bonding of bonded windows
Item
Part
Number
Description
Rubber strip
Window frame
Adhesive
Window glass
Removing and installing bonded windows

Safety measures
Bonded glazing
The following safety measures must always be

followed to prevent personal injury:
- Wear protective gloves.
- Wear protective goggles.
Preparations
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Before cutting out a bonded window, undo and
remove any attached parts in the cutting area
that are at risk, e.g. trim panels and decorative
strips, as well as all electrical connections.
Mask any painted areas that are adjacent to
the window.
Cut off any surplus adhesive, as this makes it
easier to cut out the window.
Secure vertical windows against dropping out.
Cutting out the window
Cut into the adhesive bead at easily
accessible points using the cutting tool.
Carefully guide the cutting tool around the
window, cutting through the adhesive bead.
Avoid touching the window frame and the body
flange.
Use cup suction tools to lift the cut-out window
out of the window aperture.
General preparations for bonding
Follow the manufacturer's instructions.
Cut back the remaining adhesive bead on the
metal flange to a residual height of about 1mm.
Do not touch or clean the cut surface
afterwards.
Carefully rectify any paint damage (apply
primer and top coat).
Renew the window stops as necessary.
- Carry out a visual inspection to ensure that

the gaps and joints are even.
Thoroughly clean the window glass.
Special body repairs
Convertible
The body of a convertible is considerably
different to a saloon. These differences not
only apply to its looks and functionality.
Constructional reinforcements are needed to
achieve the required stability.
An enclosed body shell design is not possible
as there are no roof rails. Therefore, other
means are used to ensure that a convertible is
sufficiently stable, particularly with regard to its
torsional rigidity. This is achieved by making
constructional changes to existing saloon
body parts and by installing additional
strengthening parts.
Reinforcements to the door sill area
Bonding the window glass

Apply an even bead of adhesive to the window
or to the body flange.
Insert the window glass into the window
aperture and centre it (2 technicians required).
Check the gaps.
NOTE: Open the windows and doors while the

window is left to dry and do not move the vehicle
(slamming doors creates excess pressure which
could cause the window to become loose).
Use adhesive tape to prevent the window from
falling out or slipping.
NOTE: If a damaged vehicle is placed on the

straightening jig with all its aggregates still in place,
then the body needs to be supported to take some
of the load.
The following design features should be noted
during body repairs:
Finishing operations
Reconnect all electrical connections and
check that the components operate correctly.
Install the attached parts and check that the fit
is accurate and secure.
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- Higher material thickness for instance in the
door sill area.
- Different behaviour during straightening.
- Particularly high fitting accuracy is required
for example on the convertible roof
mounting points.
The fit of the convertible roof and its adjacent
body parts must be checked during and after
repairs to ensure that it is water tight, free of
wind noises and closes properly.
Extraction unit
Off-road vehicles
NOTE: If the body is bolted to the chassis then all

of the bolted connections between body and
chassis must be checked for damage during
straightening work.
NOTE: The body must be lifted off the chassis if
the damage to body and chassis is more serious.
Both parts are then straightened separately.
Off-road vehicles consist of a weight-bearing
chassis, onto which the body is bolted.
If any straightening work becomes necessary
during repairs, then special universal
mounting sets or alignment jigs are used.
Protective equipment and safety at work
Various safety measures and legal
requirements must be met when carrying out
repairs. All regulations relating to health and
safety at work must be followed.
Welding safety precautions
The following safety precautions must be
observed to prevent the risk of personal injury:
- Safety hood (face protection)
- Welding shield
- Safety gloves
- Safety shoes
- Extraction unit for welding smoke
Welding should always be carried out in well
ventilated areas. A fire extinguisher must also
always be within reach.
General body repair safety measures
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Sealing compound, underbody protection etc.
must not be burned off with a naked flame.
This would produce toxic gases. If for instance
PVC is burned, then gases containing
hydrochloric acid are produced. For this
reason a suitable extraction unit should always
be used when performing grinding, welding or
soldering work.
Always ensure good ventilation when working
with materials that contain solvents, wear
breathing equipment and use an extraction
unit.
Ear defenders should always be worn when
cutting, grinding or straightening metal, as the
noise levels can reach or even exceed 85 - 90
dB(A).
Take care not to look directly into any laser
measuring systems, for instance used to
measure the floor pan.
When removing components from a vehicle
mounted on a lifting ramp, watch out for a shift
in its centre-of-gravity. When first placing the
vehicle on the ramp, take into account that it
may need to be secured against tipping over.
Chains and chain clamps must be secured
with safety ropes during straightening work.
Safety rope
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501-25B-1
Body Repairs - Corrosion Protection
501-25B-1
SECTION 501-25B Body Repairs - Corrosion

Protection
CONTENTS
PAGE

Corrosion Protection .........................................................................................................
General ............................................................................................................................
Corrosion protection of new components .........................................................................
Welded components ........................................................................................................
Partial renewal .................................................................................................................
501-25B-2
501-25B-2
501-25B-2
501-25B-3
501-25B-3
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Corrosion Protection
General
The corrosion protection provided in production
must be carefully maintained and/or reproduced
during and after body repair work. It is only then
that the long-term warranty against penetrative
rust damage can be assured (refer to the
Warranty Booklet/Service Booklet).
Only Ford original bodywork components and
Ford approved repair materials (sealer, paint etc.),
are to be used for bodywork repairs.
All Ford bodywork components have a cathodic
base coating. Individual bodywork components
are zinc plated on one or both sides (in different
areas depending on vehicle model).
Together with elastic paint coating, this
guarantees an optimum, highly resistant
protection against corrosion caused by the impact
of small objects such as gravel.
NOTE: If possible, the individual protective layers
(zinc, cathodic base coat) on Ford bodywork
components must not be damaged or destroyed
by sanding or other mechanical operations.
The Ford logo is stamped onto every Ford original
bodywork component for identification. This
symbol is a registered trademark and is a
requirement for any later warranty claim.
it must be ensured that the corrosion protection

provided in production is recreated. The complete
paint covering must be re-created if necessary.
The same applies to reshaping work on heavily
profiled bodywork components (e.g. floor pan).
Renew or touch-up the paint coating, sealing
beads and underbody protection as necessary.
After repair, any interior surfaces which are no
longer visible or accessible must be primed before
cavity wax is applied. To be certain of an even
coating on inner surfaces, careful application of
spray (twice, with drying time in-between) must be
carried out throughout the whole cavity.
If bodywork panels are strongly heated during
repair work, this will invariably result in damage to
or even destruction of the applied corrosion
protection material. The effectiveness of the cavity
protection material is reduced if heating occurs.
Reworking of the affected areas is therefore vital.
Welded areas should be ground flat before
corrosion protection is applied.
The corrosion protection measures to be taken
when bodywork components are renewed are
described on the following pages.
Corrosion protection of new components
Ford original spare part
All new components must be inspected for

transport or storage damage such as scratches or
dents. The following operations may be necessary,
depending on the extent of damage:
If repair work is necessary on vehicle bodywork,

the repair instructions given in the model specific
chapters of this manual and the instructions in the
paint and corrosion protection manual must be
followed.
If hairline cracks at "bodywork connection areas"
appear after reshaping work (e.g. at door hinges),
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1. Undamaged new component
Do not grind the cathodic dip primer.
Thoroughly clean with silicone remover and
rub dry.
2. Slightly damaged new component
Sand out scratches.
Finely sand the surrounding surfaces.
rub dry.
Apply corrosion protection primer to bare
areas.
3. Damaged new component (bumps, dents)
Beat out the dented area and sand down to
bare metal.
Apply polyester filler (only onto bare metal).
Apply fine filler.
Lightly sand the whole component.
rub dry.
Apply corrosion protection to bare areas.
Depending on the vehicle, the clinched flanges on
the hood, doors, tailgate and trunk lid must be
sealed with clinched flange sealer. The model
specific body repair manuals contain detailed
information.
After repair the paint finish must be recreated
according to the paint and corrosion protection
manual.
Welded components
Use a rotating tress wire brush to remove the dip
coat on the inside and outside of the area to be
welded, taking care not to damage the zinc
coating.
NOTE: The area to be ground should be kept as
small as possible, the corrosion protection applied
in production (cathodic primer) should be retained
as much as is possible.
NOTE: The welding primer must be stirred well
before application.
Clean the repair area thoroughly (silicone
remover).
Apply welding primer evenly to all weld flanges
(old and new components).
Apply welding primer
All weld beads must be ground down after all

welding is completed, taking care not to weaken
the material.
Any unevenness at joints is removed using lead
loading.
If necessary, spot weld missing T-pins for trim
strip clamps into position. The vehicle must be
completely cleaned of sanding dust and metal
swarf because of the danger of corrosion.
Clean and prime all internal areas and those to be
sealed.
Seal all welded areas and joints, apply underbody
protection.
NOTE: The primer must be dry before sealing
mastic or underbody protection is applied. Do not
use thinner when applying sealing mastic (the
mastic would not dry).
The noise damping mats and cavity foam applied
in production must be re-applied.
After painting, apply cavity protection to all cavities
in all parts which have been renewed (especially
at weld seams).
Partial renewal
The procedure to follow when partially renewing
components is the same as described in the
section "Welded components".
The main difference when components are
partially rather than completely renewed concerns
the preparation of butt or lap joints.
NOTE: The welding primer must be allowed to dry

before welding is carried out.
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When bodywork components are cut through,
attention must be paid to the adequate
removal of the paint and zinc coatings on inner
areas. This specially applies to areas which
are difficult to access internally.
It is important for the weld quality that the inner
area is bare metal. Zinc and paint residues in
the weld area burn and cause serious hole
formation during welding.
If the zinc layer and the paint coating are not
removed, the zinc and paint will burn during
welding. The soot produced prevents
satisfactory cavity protection.
Procedure
The paint layer must be removed for a width of

30mm from the line of the weld using a rotating
tress wire brush.
This operation must be carried out on both the
new and the old parts of the bodywork.
Depending on the bodywork component, a
10mm width of the underlying zinc layer must
also be removed along the weld line.
NOTE: A flat scraper or a wire brush can be used
instead of the rotating brush if the cavity is small.
Do not use an angle grinder, which would weaken
the structure.
Application of cavity protection on a door sill after partial repair.
Item
Part
Number
Description
Weld bead
Spray head
Distance maintainer
Spray gun
A hole may be drilled in a suitable place for areas

which are not accessible for the application of
cavity wax. The diameter depends on the size of
plugs available. When this is done it is vital to
make sure that no drilling swarf remains in the
cavity (rust will be formed if any remains). The
edge of the hole must be treated with cavity wax.
Finally close with a plug and seal with underseal.
Classification of the different corrosion protection measures for dent removal

Accessible inner
Inaccessible inner
surfaces
surfaces
Corrosion protection method
Exterior surfaces
Painting
X
X
Cavity protection
X
Classification of different corrosion protection measures for installation of new components
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Corrosion protection
method
Welding primer
Painting
Clinched flange protection
Cavity protection
G33914 en
Weld flanges before

welding in place
All bare
(contact surfaces) sanded areas
X
X
Weld flange
area
accessible
Weld flange
area not
accessible
X
X
X
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501-25C-1
Body Repairs - Plastic Repairs
501-25C-1
SECTION 501-25C Body Repairs - Plastic Repairs

CONTENTS
PAGE

Plastic Repairs ..................................................................................................................
General ............................................................................................................................
Plastic identification..........................................................................................................
Thermoelastic straightening .............................................................................................
Plastic welding .................................................................................................................
Plastic reciprocal welding .................................................................................................
Plastic bonding.................................................................................................................
GRP repairs .....................................................................................................................
Safety measures ..............................................................................................................
501-25C-2
501-25C-2
501-25C-2
501-25C-3
501-25C-3
501-25C-6
501-25C-7
501-25C-9
501-25C-11
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501-25C-2

Plastic Repairs
General
Thermoplastics (plastomers)
Duroplastics (duromers)
Because of their various constructions, repair

work to plastic parts involves various repair
methods:
Thermoplastic straightening
Plastic welding technology (PC, PP/EPDM
etc.)
Plastic bonding technology (all plastic parts)
Plastic laminating technology (GRP parts with
polyester resin only)
In repair work, the material characteristics of
plastics are highly significant. Two main groups
can be distinguished:
Plastics used by Ford

Abbreviation
ABS
PA
PC
PP
PP/EPDM
PC/PBT
PBT/PC
PUR
GF
Thermoplastics (plastomers)
Heat causes thermoplastics to change from

solid state to thermoelastic state and then to
thermoplastic state.
When thermoplastics are cooled, they return
to solid state.
Duroplastics (duromers)
Duroplastics are much harder and more brittle

than thermoplastics.
- Their strength remains largely unchanged
when they are heated.
- Duroplastics are destroyed when the critical
temperature point is exceeded.
- Cooling down will not restore the original
state.
Description
Acrylonitrile butadiene styrene (polymer)
Polyamide
Polycarbonate
Polypropylene
Polypropylene/ethylene propylene rubber
Polycarbonate/polybutylene terephthalate
Polybutylene terephthalate/polycarbonate
Polyurethane
Glass fiber reinforced
Plastic identification
If a plastic has no identifying marks, the type can
be established using two different
procedures/methods:
Visual Inspection
Mechanical Check
Visual Inspection
Visual inspections mainly serve to identify PUR

and GRP materials. Thermoplastic components
(e.g. bumpers) are often painted and are therefore
difficult to identify.
Identification characteristics:
The identification of a type of plastic is required for

the plastic welding process in order to determine
the correct allocation of the respective welding
rod.
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PUR: if cracks form or similar damage occurs,
visible pores of foam.
GRP: identifiable glass fiber structure on the
inside.
Mechanical Check
Degree of hardness; the higher-pitched the

tone, the harder the plastic.
Elasticity; the more muffled the tone, the
higher the elasticity of the plastic.
NOTE: Mechanical checks can identify the
plastics group, but not the plastic type.
According to damage statistics, plastic bumper
bars are most often subject to repairs.
NOTE: The PUR foam must not be removed for
repair purposes if the foam polyurethane on the
inside is bonded to the outer shell of the bumper
bar. If there is serious damage such as cracking or
fracturing (splitting) to the outer shell, do not
perform any repairs to the foam area. The rule is
this case is: renew the part.
The outer shell of plastic bumper bars is mainly
comprised of thermoplastic materials. Depending
on the degree of damage and accessibility, the
following repair procedures can be applied:
Thermoelastic straightening
Bonding
Welding
Thermoelastic straightening
Bumper bars often have deformations which occur
in the elastic area. These normally take the form of
dents, indentations and bends. Many of these
deformations (e.g. to bumper bars) correct
themselves of their own accord immediately or
after a certain period of time. This self-correction
depends on the extent of the damage and the
temperature. Most flat deformations in the elastic
area revert to their original form when heated with
a hot air blower.
Flat indentations or dents should be heated

evenly to approx. 200C using a hot air blower,
if possible apply heat to both sides in turn.
Provided there is no overstretching, the
deformation reverts to its original form.
To an extent, the "straightening" can be
supported using mechanical tools such as the
handle of a hammer, a plastic wedge, etc.
Stretch cracks and kinks
If there are stretch cracks or even kinks in the

damage area, then the possibilities of
thermoelastic straightening are limited. Bonding
repairs are most suited to this kind of damage.
To prevent tension in the material, cut off the
cracked or kinked areas (using a hacksaw).
Heat the depression to approx. 200C (evenly,
both outside and inside) and adjust to the
original form using a narrow spatula or
hammer handle.
Plastic welding
NOTE: Do not carry out plastic welding in the area
of fixed foam backing.
Plastic welding is the most suitable repair method
for cracks to plastic bumper bars, where the rear
side of the damaged area is unsuited to repairs by
bonding. Examples: Ribbed section, box section,
narrow rounded sections in reinforced areas.
Required tools and materials
In addition to the tools available in the

workshop (such as scrapers, grinders, etc.)
the following tools are required for plastic
welding:
Flat elastic deformations
NOTE: The necessary application of heat varies

according to the type of plastic. The application of
heat must not go beyond the elastic area.
Deformation to plastic cannot be reversed. Never
use a naked flame!
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-
Hot air blower (approx. 1500 W)

Welding nozzles
Various welding rods
Face cutter 5.5 mm for processing the
welding groove.
- Scraper (heart-shaped).
V-groove weld seam
Plastic welding gun
Item
Part
Number
Description
Part to be repaired
Weld additive (shaped)
Preparing the V-groove weld seam:

Item
Part
Number
Description
Plastic welding gun
Rapid welding nozzle
Wedge nozzle (fixed nozzle)
Face cutter
Form the welding groove using the scraper

(face cutter).
Keep the angle of the joint at 60 - 70.
NOTE: Boring out the end of the cracked (3mm

drill bit) prevents further cracking. Where the edge
alignment is uneven, fix the start of the crack using
clamp pliers before starting welding.
Finally, bore out the end of crack.
Preparing the repair location (crack)
Preparing the hot air blower and welding rod
Prepare cracking for the welding process in

V-formation.
Convert the hot air blower into a plastic welding

gun (extension nozzle and rapid welding nozzle).
Set the weld temperature (200C -700C)
according to the prescribed values.
Weld temperature
Two factors determine the weld temperature:

Plastic material
Thickness of the welding rod
Values for the most important materials and conventional welding rod thickness (5.7 mm x 3.7
mm)
Weld temperature in C
Potentiometer control setting for plastic
(guide value)
welding gun
Thermoplastic
5.7mm
Wedge nozzle
ABS
350
4,5
5,3
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501-25C-5
Thermoplastic
Weld temperature in C
(guide value)
PP
300
PP/EPDM
300
PBT/PC
300
PA
400
PC
350
PC/PBTP
350
Only weld PBT/PC plastic using a PP welding
rod.
Glass fiber reinforced plastics cannot be
welded.
Blue-dyed plastic parts on the Ford Ka cannot
be painted and are therefore not suited to
plastic repairs.
Rear side of the plastic welding gun
Potentiometer control setting for plastic

welding gun
5.7mm
Wedge nozzle
3,8
4,5
3,8
4,5
3,8
4,5
5,1
5,6
4,5
5,3
4,5
5,3
The temperatures given are air temperatures
for the plastic welding gun. The temperature of
the material is much lower.
Observe the manufacturer's instructions when
setting the temperature.
Preheat the welding equipment to the
preselected welding temperature for 3-4
minutes.
Bevel the welding rod at the front to ensure
gradual filling at the start of the crack groove.
Carrying out the welding
The following requirements must be met for plastic

welding:
Correct temperature setting
Even welding speed
Even operating pressure
Push the beveled welding rod through the heated
pre-heating chamber of the rapid welding nozzle
until the tip of the welding rod emerges from the
underside.
Item
Part
Number
Description
Air intake opening
Temperature control unit
Rocker switch
Air volume switch
Aligning the rapid welding nozzle
The underside of the rapid welding nozzle must

run parallel to the repair surface in a lengthways
direction. Parallel alignment in a lengthways
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501-25C-6

direction is achieved with the welding equipment
at the appropriate inclination.
Position of the plastic welding gun
The operating pressure when welding is only

exerted across the welding rod.
Welding errors
Deformation:
Repair area was overheated.
Material tension present when welding parts.
Plastic material too thin.
Poor welded joint:
Weld temperature too low.
Weld speed too fast.
Welding together differing materials.
Weld seam sinks:
Move the plastic welding gun in such a way
that the welding rod is exactly vertical to the
welding groove.
The welding procedure can be started when
the welding rod and the plastic to be welded
are in a plastic state.
Weld seam
Crack groove too wide

Weld temperature too high.
Re-working the weld seam
After cooling down, the raised part of the weld

seam can be sanded down using an angle
sander and abrasive paper of P80 grit.
Surface grinding is then carried out using the
orbital sander and abrasive paper of P120 P220 grit.
Clean the ground repair surface using plastic
cleaner.
Apply plastic primer thinly to the repair
surface.
Plastic reciprocal welding
Reciprocal welding is the preferred method for
crack damage in hard-to-reach areas.
Item
Part
Number
Description
Bead of weld
Heightening of weld seam
Base of weld seam
NOTE: The optimal connection is achieved when

a small and even bead of weld has formed along
the edge of the weld seam. It is essential to weld
through the crack seam. Check the weld seam
from the rear side and re-weld if necessary.
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501-25C-7

The welding rod is moved freely in reciprocal
welding.
The preparation of the crack groove is the
same.
Carrying out the welding
The plastic welding gun is only fitted with the

extension nozzle.
The welding rod and the crack groove are
brought into plastic state by means of vertical
reciprocating movements.
The welding rod is pressed into the crack
groove vertically in a plastic state.
Reciprocal welding
Plastic bonding
General
Bonding technology has some advantages over

welding technology:
Within the group of thermoelastics, all
semi-rigid ancillary components (such as
bumper bars, front grilles, etc.) can be
repaired without identification.
A two-component adhesive with a
polyurethane basis must be used for all
thermoplastic parts.
Reinforcement strips can be attached to crack
grooves (cracks up to max. 100mm) and
fractures to ensure the original tensile
properties.
Required tools and equipment
Tools and equipment from the paint shop can be

used to carry out bonding repairs to thermoplastic
parts. Angle grinders and belt sanders can be
used to grind out scratches and crack damage.
Orbital sanders with extractors are used for fine
sanding. An infrared heater ensures fast and
effective drying.
Plastic repair set
Item
Part
Number
Description
Welding rod
Plastic welding gun
Welding groove
Direction of welding
Plastic cleaner
Plastic primer
Adhesive repair set
- Three double cartridges
- Three emulsion tubes
Metal reinforcement strips
Reinforcing fiber
Tools and auxiliary equipment
The following requirements must be met for

reciprocal welding:
Equal heating of welding rod and welding
groove.
Even welding speed.
Vertical positioning and even pressure on the
welding rod.
All other repair steps are described in the chapter
Plastic Welding - Re-working the Weld Seam.
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Item
Part
Number
Description
Angle grinder with speed

control
Orbital sander
Plastic stopper
Scraper
Paint spatula
Clamp pliers
Preparing the repair location (scratch)
Before the repair, clean plastic parts on both sides

using a high-pressure cleaner, and then dry.
Clean the repair surface using plastic cleaner.
Thoroughly clean the repair location using

plastic cleaner and paper towels.
Spray plastic primer evenly onto the repair
location.
Preparing the repair location (crack)
Grind out the crack on the front side so that it is

flat using an angle grinder or belt sander.
Grinding surface 40-60mm wide
Regrind with an orbital sander. Abrasive
paper: P120 grit.
Bore out the end of the crack ( 3 mm) to
prevent further cracking.
Rub down the rear side along the crack.
Clean the repair location on both sides using
plastic cleaner and paper towels.
Spray plastic primer evenly onto the repair
location.
Grinding out the scratch

Preparation for bonding
The two-component adhesive is applied to the

cleaned and primed repair location using a
hand gun.
Operating the gun lever pushes the resin and
hardener components from the double
cartridge into the attached emulsion tube.
Scratch bonding
Item
Part
Number
Description
Preparation of the scratch
Preparation of the crack
Grind out the scratches thoroughly flat using

an orbital sander. Abrasive paper, P80 - P120
grit
Fine sanding with orbital sander: Abrasive
paper, P120 grit
NOTE: Wear protective gloves for cleaning.
Even slight depressions such as cracks require

preparation. The surface of the repair area also
has to be processed to provide sufficient priming
for the adhesive. This also prevents the repair
area from subsequently sinking.
After cleaning and priming, over-fill the ground
out scratch cavity with adhesive.
Dip the end of the emulsion tube in adhesive
during the material application to prevent the
ingress of air.
Spread and smooth the adhesive using a
flexible plastic stopper.
Set using an infrared heater or in a drying
oven.
Crack bonding with reinforcement
The repair location is reinforced to increase

torsional strength in the case of cracking and
fracture damage over a large area. To this end,
suitable reinforcement materials (metal strips,
reinforcement fibers) are affixed to the rear side.
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501-25C-9

Cover the crack on the front side with a PE
sheet and with adhesive tape.
From the rear side, fill the ground out crack
groove with plastic adhesive.
A wide strip of reinforcing fiber is fixed over the
crack groove in the bead of adhesive.
The ends of the crack are reinforced by
affixing a metal strip that is fastened to the
plastic part using pliers.
Then level out the reinforcement material over
the whole surface.
Dry using an infrared heater or in a drying
oven.
The PE sheet prevents the adhesive from
overflowing at the front side of the crack.
Pull off the PE sheet after drying the adhesive.
Spread adhesive over the repair location on
the front side.
Set using an infrared heater or in a drying
oven.
Cool the adhesive to room temperature to
prevent the adhesive being pulled off when
sanding, and to prevent the abrasive paper
becoming worn.
Sanding
NOTE: In the case of dry sanding, use an

extraction unit and wear a dust mask.
Sand down protruding adhesive using an
orbital sander. Abrasive paper: P120 - P220
grit.
Re-work sags and curved areas manually.
Use an abrasive pad to roughen painted
surfaces.
Thoroughly clean the plastic part using plastic
cleaner and paper towels.
NOTE: Thoroughly dry out the plastic primer (matt

surface).
Spray plastic primer for the subsequent 2K
filler application thinly onto the repair areas
and sanded-through areas.
After drying, cool the 2K filler to room

temperature and sand down using an orbital
sander and fine abrasive paper.
Re-work sags and curved areas manually
(wet) using fine abrasive paper.
Check the contour of the repair location and
re-work if the contours are uneven.
Perform painting in accordance with the
GRP repairs
General
GRP material is hard and brittle in its tensile

properties. Because of these material properties,
cracks and fractures often result in cases of
serious damage. The stability and safety of GRP
parts is impaired if the glass fiber reinforcement is
cracked. This must be replaced in cases of
serious damage that affect the structure of the part.
Minor damage (such as abrasion, cracks up to
80mm, holes up to approx. 60mm diameter, etc.)
can be repaired to a technically and visually
perfect standard, provided that the damage does
not occur in heavily used or hard-to-reach areas.
To ensure excellent repairs, observe the following
points:
The room temperature should be at least 15C
and the air should be as dry as possible.
NOTE: Fingerprints leave behind a film that

prevents a proper joint.
Two-component filler application
To prevent porosity at the edges and to smooth

out uneven areas, it is advisable to apply 2K filler
(MS, HS) with an elasticising additive.
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The repair location must be thoroughly dry and
clean.
Before the repair, the GRP part being repaired
must be dried using an infrared heater or in a
drying oven.
In cases of large cracks and fractures, the
strength of the outer skin can be
re-established by backing with a reinforcement
material.
Grinding with the angle grinder creates heat

that causes a change in the surface structure
of the resin. This results in reduced adhesive
properties.
GRP repair material
GRP repair components
Required tools and auxiliary equipment
Hacksaw (body saw) for separating cracks.

Axial grinder, angle grinder or belt sander for
grinding out repair locations.
Orbital sander for grinding out and grinding
down the repair surface.
Hand sanding block for grinding small
surfaces.
Grinding the repair location
Grind out the edge of the hole, in a V form and

flat, using an angle grinder - abrasive paper
P80 - P120 grit.
Remove layers of filler and paint.
If cracks have formed, these are ground out at
the base of the crack by 3mm. This eliminates
any tension.
Careful, flat grinding is important for the
subsequent adhesion of the repair material.
NOTE: The surface must be re-ground by hand.
Item
Part
Number
Description
Polyester resin
Hardener
Glass fiber mats
Scissors
Brush
Apply polyester resin
The polyester resin is mixed with hardener and

applied thinly to the clean repair location with a
brush.
Insert the glass fiber mat
Cut the glass fiber mat to size and insert it into

the applied polyester resin.
Applied more polyester resin over the glass
fiber mat, and add a second or third mat if
necessary.
NOTE: Completely soak the glass fiber mat in

polyester resin. No air may be trapped in the
repair area.
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501-25C-11

Apply polyester resin using a brush.
Allow the polyester resin to dry at room
temperature.
Back larger cracks and fractures with
reinforcement material to restore the strength
of the outer skin.
Apply stopper
The depression on the front side is filled with

polyester fiber stopper to achieve a smooth,
flat surface.
Repeat the procedure if necessary.
Final application of stopper
Re-create the surface contours by applying

stopper or polyester filler.
Grinding with the orbital sander
Sand down protruding polyester material using

an orbital sander. Abrasive paper, P120 P220 grit.
The repair surface can be painted after
grinding.
Safety measures
Polyester resin, adhesive, solvents and
thinners are inflammable and must be kept
away from naked fire or flames.
Sawing and grinding operations must only be
carried out in rooms equipped with extraction
systems.
If no rooms with extraction systems are
available, only use tools with extraction
systems.
Protective equipment such as gloves,
protective goggles, aprons and breathing
masks are essential.
Apply stopper
Item
Part
Number
GRP part being repaired
Polyester fiber stopper
Glass fiber insert
G33917 en
Description

501-25A / 501-25B / 501-25C / 501-25D / 501-25E
/ 501-25F / 501-25G. It is also important to
observe all applicable regulations, accident
prevention legislation, information sheets, safety
notices and guidelines for the processing of
adhesives containing isocyanate, polyester resin,
adhesives, solvent and thinners.
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501-25D-1
Body Repairs - Water Leaks
501-25D-1
SECTION 501-25D Body Repairs - Water Leaks

CONTENTS
PAGE

Water Leaks......................................................................................................................
General ............................................................................................................................
Practical execution of tests and checks............................................................................
Rectifying the leak using recommended tools, auxiliary equipment and materials ............
Water leaks according to mileage or running time ............................................................
Water leaks after body repairs..........................................................................................
Water drainage system ....................................................................................................
Water leaks, diagnosis and corrective action: Front passenger compartment ..................
501-25D-2
501-25D-2
501-25D-2
501-25D-3
501-25D-4
501-25D-4
501-25D-4
501-25D-5
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501-25D-2

Water Leaks
General
If water leaks occur after bodywork repairs, the
cause can be established using the checks
described below. A systematic and logical
procedure is required to locate water leaks.
Before beginning extensive checks, a
thorough visual inspection must be carried out.
Visual Inspection
- The following characteristics may indicate
existing leaks:
- Check the clearance and accurate fit of
ancillary components such as the hood,
tailgate, doors, and so on.
- Check for correct fit and possible damage to
sealing elements such as blanking plugs,
rubber door seals, and so on.
- Check water drain holes for unhindered flow.
Various tests can be used to provide further
information on possible leaks:
- Water test
- Washer test
- Road test
- Test with UV lamp
- Special mirror test
- Chalk (powder) test
- Flow tube (smoke) test
Practical execution of tests and checks
Water test
NOTE: Never aim a jet of water directly at a rubber

seal.
Carry out the water test with a second person
present (passenger compartment).
Use variable washer nozzles (concentrated
water jet to fine spray mist).
Start in the lower section and spray the whole
area, working upwards in stages.
The following are suitable for the water test:
G33920 en
- softened water (liquid soap additive)

- Special mirror
- Test with UV lamp
Washer test
Further tests can be carried out in the washer

system.
Some leaks originate here, or only occur here.
The relevant passenger compartment should
be checked using a torch during the wash
procedure.
Road test
If no leaks are located during the tests above,

road tests should be carried out on wet roads.
Road tests under various conditions:
- At various speeds.
- On various road surfaces (asphalt to
cobbles).
- With loaded or unloaded vehicle.
- Driving through puddles (splash water).
Test with UV lamp
Wet the test area with clear water from the

outside.
Prepare test liquid (see Owner's Handbook)
and apply it from the outside using a suitable
water sprayer.
Illuminate the relevant area from the inside
using the UV lamp.
The test liquid will make the leak visible.
UV lamp
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Benefits of the UV lamp:
- No need to dry out wet areas before the test.
- The ingress of water and its subsequent
path can be identified precisely.
- No need to remove most ancillary
components from the vehicle.
Special mirror test
The special mirror can be used to see into

hard-to-reach areas.
- Set the interior ventilation to the highest

setting.
- An assistant creates smoke in the test area
(interior) using the flow tube.
- A second assistant locates points at which
the smoke escapes on the outside.
Other test equipment
Other equipment such as stethoscopes or

ultrasound measuring instruments can be
used to locate leaks.
Special mirror
Rectifying the leak using recommended tools,

auxiliary equipment and materials
Benefits
A switchable light is built into the mirror area.
The angle of inclination of the mirror can be set
manually using the handle.
The connector between the handle and the
mirror is flexible.
Chalk test (powder test)
In this test, the clamping load and the bearing

surface of the seal are checked.
Performing the test:
- Dust the door seal with powder or coat with
chalk.
- Coat the bearing surface of the seal with a
thin film of grease.
- Slowly close the door and open it again.
- Check the width and continuity of the imprint
on the door seal.
Tools and auxiliary equipment:

- Dry, absorbent cloths
- Variable washer nozzle
- Torch, fluorescent tube
- Mirror
- Compressed air
- Seal lip installer
- Wet/dry vacuum cleaner
- Sealing compound compressor
- Remover for interior trim
- Cutter blade or pocket knife
- Wedge (wood or plastic)
- Hot air blower
- UV lamp
- Special mirror for concealed leaks
- Stethoscope
- Air flow checker
- Ultrasound measuring instrument
Materials: (refer to spare parts microfiche)
Flow tube test (smoke test)
Test for locating leaks.
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501-25D-4

- Sealing compound (tape and plastic
compound)
- Multi-purpose sticker
- Clinched flange sealer
- Window sealing compound
- Water shield (PVC)
- Foam watershield
- Double-sided adhesive tape for water shield
- Butyl tape for foam watershield
- Methylated spirit (available from trade
outlets)
- PU adhesive
- Silicone remover
- Tar remover
Water leaks according to mileage or running
time
Increasing mileage has an effect on the problem
of leaks in a vehicle. Possible influencing factors
are:
Servicing and maintenance of seals:
- No maintenance, lack of maintenance or
incorrect maintenance
- Using an incorrect agent
Damaged seals:
- As a result of aging, wear or incorrect
handling/assembly.
Heavy soiling of the vehicle:
- Heavy soiling of a vehicle can seriously
impair the function of water drainage
channels in particular, and also of rubber
seals.
Age-related factors:
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- Environmental factors
- UV radiation
- Extreme climatic conditions
Corrosion can have a serious impact on
bodywork, in particular as a result of:
- Lightly or heavily rusted seal carriers
- Rusted body seal welds
- Perforation corrosion
Water leaks after body repairs
If a vehicle develops a leak after body repairs, the
following points must be taken into consideration
in particular:
The correct seating of ancillary components
and their seals (e.g. rear lamps, etc.) must be
checked.
The correct alignment of doors and luggage
compartment lids/tailgates must be checked.
The associated seals must not be damaged
and must be installed correctly.
Check that welded seams are correctly
sealed.
The correct seating of rubber grommets must
be checked.
The seals of windows fitted using rubber seals
must be installed precisely and make contact
all the way round.
Directly-glazed windows must have correct
and complete bonding.
Water drainage system
If a vehicle develops water leaks, then areas into
which water is routed or drained should be
checked first.
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501-25D-5
501-25D-5
Water drainage systems
Item
Part
Number
Water drainage, front
Water drainage, side and

rear
Sliding roof drainage
Drainage water tank
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Description
Water leaks, diagnosis and corrective action:

Front passenger compartment
Windscreens (rubber fitted)
Diagnosis:
- Ingress of water into A-pillar area
Cause:
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501-25D-6

- An old or incorrectly fitted seal can cause
insufficient or irregular clamping load of the
rubber seal on the windscreen or window
frame. This results in water ingress between
the rubber seal and the windscreen or
between the rubber seal and the window
frame.
Corrective action:
- Seal the problem area using window sealing
compound between the rubber seal and the
windscreen, or between the seal and the
window frame. Wipe off excess sealing
compound immediately.
- If a new leak is found after the necessary
leak check, then the rubber seal must be
renewed.
The leak can be identified from outside by

the escaping air.
- The second test method is by means of a
water test. The outer cover must also be
raised carefully using a plastic wedge. The
leak should be located from inside by a
second assistant.
Diagnosis of a water leak
Windscreen seal
Item
Part
Number
Description
Compressed air test
Water test
Side windows
Item
Part
Number
Description
Window frame seal
Window seal
In the case of fixed side windows (rubber fitted or

directly glazed), the same problems can arise as
for a windscreen. The same corrective actions
must therefore be used.
Side windows
Windscreens (directly-glazed version)
Diagnosis:
- Ingress of water into A-pillar area or
instrument cluster area
Cause:
- Breaks in adhesive beads
Corrective action:
NOTE: The repair must be carried out in line with
approved methods (service microfiche/TIS CD
group 42/501-11).
- The breaks in adhesive beads can be
located from inside by using compressed air.
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501-25D-7

Door seal
Diagnosis:
- Water ingress in the lower part of the interior
door trim or in the rocker panel area.
Cause:
- The water shield or foam watershield fitted
behind the interior door trim exists to drain
off water that has entered the door via the
drainage holes, either downwards or
outwards. If the water shield or foam
watershield is damaged or has been fitted
incorrectly, then water can get into the
passenger compartment.
- In addition to this, the drainage holes can
become clogged with leaves, dirt or excess
cavity protection agents. Water gathers in
the door and ingresses into the passenger
compartment.
NOTE: If a water shield or foam watershield
becomes damaged in any way, then it must
always be renewed.
- Check water shield or foam watershield for
damage or correct fitting.
NOTE: When detaching a foam watershield, the
butyl tape must be cut with a knife.
- If the water shield needs to be re-bonded,
then double-sided adhesive tape must be
used. Butyl tape is used for the foam
watershields.
- Before the water shield or foam watershield
is installed, the drainage holes must be
checked for unhindered flow.
Corrective action:
NOTE: When installing the butyl tape, do not
touch the mating surface (this impairs the
adhesion).
- Detach the interior door trim.
Door seal
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Item
Part
Number
Description
Drainage holes
Foam watershield
Interior door trim
Door seals
Diagnosis:
- Ingress of water into the rocker panel area
Cause:
- Insufficient clamping load between seal and
door.
Corrective action:
- Check clamping load:
- The easiest way to check the clamping load
of a seal to the respective bearing surface is
by means of a paper strip test. This consists
of trapping strips of paper at various points
between the door and the seal, and fully
closing the door. If it is possible to pull out
the paper with no great resistance, then the
clamping load is too low.
- Adjust the clamping load:
NOTE: When adjusting the clamping load, the
edge alignment of the relevant components must
always be taken into consideration.
- The clamping load is normally adjusted
using the striker. When doing so, the edge
alignment from the door to the side panel, or
from the front door to the rear door must be
taken into account.
- Another setting method is to realign the
panel flange for the seal mounting. The
clamping load is increased by moving the
flange towards the door.
NOTE: Do not realign the flange too far in the
direction of the door, as this can reduce the
bearing surface of the seal to the door.
- Check the bearing surface:
- Apply chalk evenly to the surface of the seal.
Evenly coat the bearing surface of the door
with vaseline.
- Close the door fully, the lock must engage.
Open the door. The imprint of the chalk
(bearing surface) can be identified in the film
of grease.
- The bearing surface should be at least 5mm
across at all points.
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501-25D-8
Checking the seal
Item
Part
Number
Description
Panel flange bent too far inwards: small bearing surface
Panel flange adjusted correctly: correct bearing surface
Check clamping load with a

strip of paper
Other causes:
- The door seal must completely seal the door
where it meets the bodywork.
- Water can ingress directly or indirectly into
the interior of the vehicle if the seal is
damaged at any point.
Corrective action:
- A damaged or worn door seal must always
be renewed in full.
- When renewing the seal, the following must
be taken into account:
- Always fit the seal first in the area of the
narrow radii (corner points).
- Next, secure the seal to the flange evenly by
tapping lightly with a rubber hammer. The
installed seal must not be kinked at any
point.
NOTE: The prescribed length of a seal must not
be shortened.
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Correct installation of the door seal
Other cause:
- The door seal is attached to the welded
flange all the way round. If this welded
flange is uneven or damaged at any point
(usually in areas with narrow radii) then this
point could be subject to leaks.
- A stretched seal carrier can also cause a
leak.
- In both cases, water gets into the vehicle
interior under the seal carrier.
Corrective action:
- Align the deformed welded flange using a
hammer and anvil block, prevent and if
necessary repair any paint damage.
NOTE: If the seal has a connecting joint, this must
always be at the bottom of the door surround.
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501-25D-9
501-25D-9

- A stretched seal carrier must be realigned by
hand. If this is no longer possible, the seal
must be renewed.
Door seal leaks
Item
Part
Number
Correct seal carrier
Stretched seal carrier
Seal on connecting joint
- Check the water trap for leaks.

- Check the drain hoses for leaks and for
correct connection to the water trap.
- Check the drainage system for unhindered
flow, and blow out with compressed air if
necessary.
- Check the external seal and the correct
adjustment of the sliding roof.
Description
Sliding roof/tilting roof
Diagnosis:
- Ingress of water at sliding roof aperture
Cause:
- The sliding roof/tilting roof is installed in a
water trap. The water drains off via the water
trap, water drain holes and drain hoses. The
drain hoses lead downwards on both sides
via the A-pillar and C-pillar.
- The drain holes or drain hoses can become
clogged with leaves, dirt, underbody
protection and so on.
Corrective action:
NOTE: In the case of a sliding or tilting roof, the
external rubber seal and the lock actuator or latch
mechanism must be checked first of all.
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501-25D-10
Sliding roof/tilting roof
Item
Part
Number
Description
Roof
Roof moulding
Water trap with drainage flow
Apron panel and heating/ventilation
Diagnosis:
- Ingress of water into the front footwell area
Cause:
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501-25D-11

- The apron panel is sealed in several places
to adjacent components, such as at the
joints to the A-pillar or to the floor pan. These
seals can be broken.
- The heater and ventilation housing is
attached to the apron panel. The through
area is sealed with a foam watershield that is
fixed to the housing.
- The housing has drain holes to allow the
water to drain off.
- If the foam watershield is defective or the
drain hole is clogged, water can ingress into
the front footwell area.
Item
Part
Number
Description
Foam watershields
Water drain holes
Other causes:
- Fastening bolts and routing holes for cables
and hoses must be checked for leaks in the
area of the apron panel and instrument
cluster (rubber grommets in particular).
- If the footwell area is wet, then the door
hinge seal, the door light switch and cable
routing holes must also be checked.
Heater and ventilation housing seal

Door light switch seal
Corrective action:
- Seal the broken seal welds.
- If a leak is found in the heater or ventilation
housing, the drain holes must be checked
first.
NOTE: Damaged foam watershield must always
be renewed.
- The housing may have to be removed to
check the foam watershield and its bearing
surface for damage.
Checking foam watershields and water drain holes
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Rear drip rail seal
Diagnosis:
- Ingress of water into side headlining area
Cause:
- The roof outer panel is sealed with a seal
weld at the connection point to the side
panel. This seal weld can be concealed with
a bezel or trim strip.
- In the case of estate and hatchback vehicles,
there is an additional seal to the rear roof
crossmember.
- Water can enter here if there is a break in
the seal weld.
Corrective action:
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501-25D-12

- Remove trim strip or bezel. Check and
re-seal the seal weld.
Drip rail seal
- The adjustment of the lid is made using the

lock striker or the lock.
- Rubber bump stops are attached to both
sides of the luggage compartment opening.
These are normally adjustable, and the
clamping load can be modified.
- The narrow radii of the luggage
compartment lid seal are also problem
areas.
Check the seal for correct installation position
Luggage compartment seal
Diagnosis:
- Ingress of water into the luggage
compartment
Cause:
- The luggage compartment lid seal
corresponds to the door seal.
- If there is a water leak, the seal must be
checked for damage and the seal carrier
must be checked for correct seating.
- The clamping load and the bearing surface
of the lid must also be checked for leaks.
Corrective action:
Other cause:
- The seal is not attached evenly around the
lid because of a deformed or uneven welded
flange.
Corrective action:
- Check the seal and bearing surface.
- Re-align a deformed or uneven welded
flange.
Uneven welded flange.
Other cause:
NOTE: The seal carrier covers a defective weld.
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501-25D-13

- Leaking weld on welded flange (melted
through). Water can ingress into the luggage
compartment under the seal carrier.
Corrective action:
- Pull the seal from the seal carrier.
- Seal the leaking weld using sealing
compound.
- Check the rubber grommets and renew if

necessary.
- Check the hinge mounting points, and
re-seal with sealing compound if necessary.
Check the routing holes for rubber grommets,
cables and hoses
Welds melted through
Forced air extraction

Tailgate
Diagnosis:
- Ingress of water into rear headlining area
Cause:
- The leak problems of the tailgate
correspond to those of the doors.
- In addition to this, the area to be sealed is
much bigger. The routing holes for cables
and hoses must also be sealed.
- The rubber grommets for the routing holes
must be checked for damage and correct
seating (fully unhooked).
- The mounting points of the tailgate hinges
may leak.
Corrective action:
G33920 en
Diagnosis:
- Ingress of water into side luggage
compartment area
Cause:
- The forced air extraction for the vehicle
interior is often located in the lower side
panel area of the luggage compartment. The
ventilation housing is sealed with a foam
watershield on the bodywork side.
- The rubber flap of the forced air extraction
must be able to move freely.
Corrective action:
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501-25D-14

- Remove the forced air extraction. Detach
the bumper if required.
- Check the seal area between the bodywork
and housing, as well as the rubber flap.
- Renew a damaged foam watershield if
necessary.
Check the seal for the forced air extraction.
- Rear lights are leaking. There are two

sealing methods:
- Sealing with a foam watershield
- Sealing with plastic sealing compound
- If a rear light has a leak, this usually means
that the seal was fitted incorrectly.
Corrective action:
- Remove the rear light. Check the housing
and glass for damage. Check the plastic
seal for leaks.
NOTE: The sealing compound must always be
removed during repair work.
Check the seal for the rear lights
Rear window
Diagnosis:
compartment area
Cause:
- Rear window leaking.
- Check for leak in the same way as for
leaking windscreen.
Rear lights
Diagnosis:
- Ingress of water into rear luggage
compartment area
Cause:
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Panel connections with seal welds
Diagnosis:
compartment area
Cause:
- Several panel connections must be fitted in
production in the wheelhouse and luggage
compartment areas. These connections are
sealed with sealing compound.
- Uneven application of sealing compound
can lead to a break in a seal weld.
Corrective action:
- Expose the seal weld.
- Locate the leak in the seal weld.
- Re-seal using sealing compound.
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501-25D-15
Possible water leaks at the panel connections in the luggage compartment
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501-25E-1
Body Repairs - Wind Noise
501-25E-1
SECTION 501-25E Body Repairs - Wind Noise

CONTENTS
PAGE

Wind Noise .......................................................................................................................
General ............................................................................................................................
Normal air flow noises ......................................................................................................
Noises caused partly by changes in the direction of air flow and by air flow around
separate components ....................................................................................................
Noise caused by vibrating seals .......................................................................................
Escaping noises ...............................................................................................................
Cavity noises....................................................................................................................
Wind noise with the sliding roof open ...............................................................................
Wind noises from the door seals ......................................................................................
Wind noises .....................................................................................................................
Summary..........................................................................................................................
Problem sources in practice .............................................................................................
Sequence for performing a wind noise diagnosis (diagram) .............................................
Workshop diagnosis.........................................................................................................
501-25E-2
501-25E-2
501-25E-2
501-25E-2
501-25E-3
501-25E-4
501-25E-4
501-25E-4
501-25E-4
501-25E-5
501-25E-5
501-25E-6
501-25E-9
501-25E-9
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501-25E-2

Wind Noise
General
Vehicle noises when driving cannot be avoided.
The aim of all development efforts is to reduce
wind noise. The quieter that noise producing
components such as the engine, drive train, tyres
etc. become, the more the wind noise at high
speeds will be heard.
breaks up at the edge. Eddies are formed, which

collapse again after a certain time or distance.
Change in the direction of air flow
Apart from general wind noise, some noises can

arise which are heard as an irritating hissing or
whistling. The causes of these noises may be
partly caused by production or repair factors. They
are mostly caused by poorly mounted
components, which must be located and installed
in the correct position.
Most noise experienced in the vehicle interior is
wind noise. As speed increases, the level of sound
in the vehicle interior increases with it.
Item
Part
Number
Eddy
Sound wave
Flow
Normal air flow noises

At high speed, as air flows past uniform flat
surfaces such as the roof, side windows, etc.,
turbulent air layers form, in which air pressure
variations occur. Part of this pressure variation
spreads in the form of sound waves and is
transferred to the vehicle interior by the side
windows and seals. Here the noise is particularly
loud because of the closeness of the side window
to the driver or passenger. The noise experienced
is mostly a low roaring, which becomes louder as
speed increases.
Description
The build-up and decay of turbulence and the

associated pressure changes lead to creation of
sound waves. A similar effect can be observed at
the A-pillar on a vehicle. Here the area where
eddies are usually formed is directly above the
side window. This makes it easy for the noise
(roaring) to be passed to the vehicle interior.
Noises caused partly by changes in the

direction of air flow and by air flow around
separate components
If air flows over an edge on a vehicle, the air flow
cannot fully the contour of the surface, and it
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501-25E-3
501-25E-3
Eddy current zone
Item
Part
Number
Description
Air flow
Build up of eddies
Origin of vibrations (diagram)
Eddy currents are also formed underneath the

vehicle, and so associated noise is also produced.
When air flows past smaller components or
through smaller gaps (such as the radiator grill),
the roaring noise becomes a whistling, which
increases in pitch and becomes louder as speed
increases.
Noise caused by vibrating seals
Seals which are not making firm contact in the
window and door areas can also lead to vibrations
caused by pressure variations on the outside of
the vehicle which then means transfer of noise
into the vehicle interior. The vibrating part of the
seal operates here in the same way as
loudspeaker membrane.
G33923 en
Item
Part
Number
Description
Vibrating seal
Radiation into the vehicle

interior
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501-25E-4

Escaping noises
Small leaks in the vehicle interior sealing system
allow small currents of air to enter. This leads to
the creation of "free stream noise" (a stream of air
mixes with still air and in doing so causes
turbulence). The loudness of free stream noise
increases strongly with increasing escape speed
and can be heard as a hissing noise (for example,
letting the air out of a tyre).
Cavity noises
If a bodywork cavity is open to the outside of the
vehicle, this can cause the air volume in the cavity
to resonate. The note produced depends on the
volume of the cavity and the size of the opening.
(For example, making a note by blowing across
the top of a bottle).
Wind noise with the sliding roof open

Problem:
When the sliding roof is open at about 60 km/h

a low frequency noise is produced
(drumming).
Cause:
When the sliding roof is fully open, perceptible

air pressure variations occur inside the vehicle
because of the air current over the opening.
Corrective action:
At speeds above about 60km/h, close the

sliding roof slightly until the drumming noise is
no longer heard.
Wind noises from the door seals
Because of the air currents passing by the
sides of the bodywork and over the roof, the
pressure outside is slightly lower. Because of
the heating and ventilation system the
pressure inside the vehicle is slightly higher.
This pressure difference causes, for example,
the doors to lift away from the seals by several
millimetres at certain speeds. If there is also a
side wind affecting the moving vehicle, this
effect is increased.
The resulting differences in gap are
compensated for by the use of flexible door
seals (when the door seals are intact).
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501-25E-5
501-25E-5
Routes by which external sound is transferred to the inside of a vehicle
Item
Part
Number
Description
Interior ventilation
Windscreen seal
Door window seal
Sliding roof seal
Item
Part
Number
Description
Door seals
Boot lid seal
Interior ventilation
Door handles
Wind noises
Overview
Normal
Serious
Type of wind noise

Where do they arise?
Normal air flow noises
Roof, side windows
Noises caused partly by changes in the A-pillars, side mirrors, antennas, windscreen wipers
direction of air flow and by air flow
around separate components
Noises caused by vibrations seals
Door gaps too wide, door/window seals
not seated firmly
Air escape and air passage noises
Leaks in the bodywork sealing system
Cavity noises
Unsealed bodywork cavities
The factors listed

under "serious"
require corrective
action.
Summary
The creation and intensity of wind noise on a
vehicle depends on the fundamental shape and
structure of the different components.
G33923 en
There are two subjective evaluation and service

diagnosis methods in which sound levels can be
reduced and sound nature improved in a vehicle
interior:
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501-25E-6

Reduction in the intensity of the noise sources
Reduction of the transmission routes
In order to achieve a general improvement in the
wind noise situation in the vehicle, both factors
must be taken into account.
The sealing systems of the doors, windows and
tailgate have a major influence on the acoustic
comfort in a vehicle.
- Re-align the door with the side window open

- Check the door seal to sealing surface
contact area. The width of the sealing area
must be at least 5mm.
The correct gap between the door and A-pillar or
door and roof
Problem sources in practice

Seal on driver and passenger door
Diagnosis:
- Wind noise from the door seal at the top
Cause:
- The alignment of the door frame to the roof
is incorrect
Corrective action:
Adjustment of the tailgate
Diagnosis:
- Wind noise coming from where the roof
meets the top edge of the tailgate
Cause:
- Tailgate is set too high
Corrective action:
- Loosen the tailgate where it is attached at
the hinges and move the tailgate further
down. When doing so, pay attention to the
gaps with adjacent components.
- Reset the lock if necessary.
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501-25E-7
Tailgate too high
Sliding roof adjustment
Diagnosis:
- Wind noise from the sliding roof
Cause:
- Sliding roof incorrectly adjusted
Corrective action:
G33923 en
- Adjust the sliding roof according to the

following requirements:
- There must be an equal gap all round the
sliding roof.
- The sliding roof must be adjusted to suit the
roof contour.
- The front edge of the sliding roof should
close flush with the top face of the roof itself,
or slightly lower.
- The seal around the sliding roof must touch
it evenly all round.
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501-25E-8
Correct installation of the sliding roof
Adjustment of the right-hand windscreen wiper

arm
Diagnosis:
- Wind noise from the area of the right-hand
windscreen wiper
Cause:
- Windscreen wiper arm is set too high
- Free the wiper arm from its shaft and adjust

it so that it lies below the air turbulence
which exists at the wind guide plate when it
is in its rest position.
Adjustment of the wiper arm
Corrective action:
G33923 en
Item
Part
Number
Description
Too high
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501-25E-9
501-25E-9

Item
Part
Number
Description
Correct
Sequence for performing a wind noise

diagnosis (diagram)
1. Customer concern
What is the customer concern and what
details can he supply about the wind noise?
2. Under which conditions does the wind noise
appear?
1. Sequence A: A diagnosis is possible based
on the details supplied by the customer.
Carry out corrective measures to remedy
the wind noise.
Road test the vehicle to check that the
concern is resolved. The vehicle must be
driven in the exactly same way as when
the wind noise was produced earlier.
If the corrective measures based on the
information supplied by the customer
were not successful, further testing must
be carried out in the workshop (see
sequence B).
2. Sequence B: A diagnosis based on details
supplied by the customer is not possible
Test for faults in the workshop, referring to
any TSB (Technical Service Bulletin)
which may be relevant.
Visually check external seals, check
gaps.
Visual check: Have any components been
fitted to the vehicle after manufacture or
has the vehicle been repaired after an
accident?
Perform a diagnosis based on the road
test.
Carry out corrective measures based on
the diagnosis.
Perform another road test. The vehicle
must be driven in the exactly same way as
when the wind noise was produced
earlier.
If this road test does not show that the
work has been successful, additional
techniques such as powder testing,
stethoscope testing or ultrasonic
detection must be employed.
Workshop diagnosis
Before repair work is carried out, a visual check of
the vehicle must be performed, paying special
attention to the fit of the doors. When the doors
are adjusted to fit exactly, development of wind
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noise can often be eliminated at high speeds
(lifting of doors off the seals).
Stethoscope testing
The stethoscope is a simple and appropriate

tool for finding bodywork air leaks. If the
blower is turned on at the highest speed and
all the doors, windows and other openings are
closed, the air pressure inside the vehicle can
be made higher than that outside. The outside
of the vehicle is then checked for streams of
escaping air.
Powder test
By coating the contact surface of the door seal

with white powder, door seals that do not
make close contact can be found. To do this,
the door is carefully closed and re-opened. In
this way, the sealing surfaces which do not
touch will be visible.
Ultrasonic detector
It is also possible to detect leaks using an

ultrasonic detector and a tone generator. To
do this, the ultrasonic tone generator is put
inside the vehicle and the outside of the
vehicle is tested using the detector tuned to
the generator. The detector will quite easily
show any leaks present.
Road tests
The causes and origins of wind noises can

often be located by a road test. Attention
should be paid to the following points:
- Choose a dry, flat and straight road with as
little traffic as possible.
- Make sure that the tyres are at the correct
pressure, to avoid tyre noise.
Driving technique
Perform the road test at all speed ranges,

using the highest gears (fourth or fifth).
The road test should be performed by two
persons, and different seating positions should
be tested.
Prepare the vehicle as necessary (use
adhesive tape to blank off areas).
Pay special attention to door openings and
door seals during the road test.
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501-25F-1
Body Repairs - Paintless Dent Removal
501-25F-1
SECTION 501-25F Body Repairs - Paintless Dent

Removal
CONTENTS
PAGE

Paintless Dent Removal....................................................................................................
General ............................................................................................................................
Economic considerations .................................................................................................
Extent of the damage .......................................................................................................
Pre-requirement for the repair ..........................................................................................
Repair procedure .............................................................................................................
Repair tools/aids ..............................................................................................................
Repair Procedure .............................................................................................................
Unstable pressure area ....................................................................................................
Stable pressure area........................................................................................................
Accessibility of individual bodywork components..............................................................
Renewal of the corrosion protection. ................................................................................
Quality control ..................................................................................................................
501-25F-2
501-25F-2
501-25F-2
501-25F-2
501-25F-3
501-25F-3
501-25F-3
501-25F-3
501-25F-4
501-25F-5
501-25F-5
501-25F-6
501-25F-6
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Paintless Dent Removal
particularly suitable for damage arising from
hail, parking and transport.
General
Small minor dents can be repaired without
damage to paintwork. The dent is worked from the
inside using special levering tools (pressure tools).
The pre-conditions are that the diagnosis is
certain, the correct repair method is identified and
that the technician has enough experience in the
use of the special tools and knowledge of the
working materials.
This option is limited to those bodywork
surfaces which are accessible from both sides.
This repair technique is seldom possible on
double skinned bodywork components or
closed bodywork profiles. The same applies to
edge areas, beads and folds in bodywork
components which are very rigid.
Satisfactory results are only possible for minor
dents that are shallow and with a small
deformation radius. This method is therefore
Economic considerations
Whether it is economically worthwhile to carry
out paintless dent removal depends on:
- The area and depth of the dent.
- Access to the repair area.
- Rigidity of the repair area.
- Suitability of the material
- The number of dents over a particular body
panel area.
- Whether there is already any paint damage
present
Extent of the damage
The repair method is suitable for dents up to
approx. 50 mm diameter.
Damage assessment according to the size of the dent
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Item
Part
Number
Centre of the dent
Edge of the dent
over each other. The point where the lines

cross is the pressure point for the pressure
tool.
Description
Light reflection when pressing
Pre-requirement for the repair

The material at the centre of the dent must not
have stretched.
Repair procedure
Diagnose the damaged area.

Mark the dent.
Prepare the area to be repaired.
Put the adjustable lamp in position.
Reshape the dent.
Renew the corrosion protection.
Carry out quality control.
Repair tools/aids
Item
Part
Number
Description
No pressure on the dent
Pressure applied to the dent
Special dent removal levering tools

Adjustable lamp
Repair Procedure
1. Decide on the repair method.
2. Mark the dent
NOTE: Do not use a pen containing solvent (paint
damage).
The dent is marked in the repair area to help
recognition.
3. Prepare the repair area
It must be certain that the inside of the dent
is accessible. Repair openings must not be
made.
Clean the bodywork in the damaged area.
Good visual checking is vital to success.
Polish the repair surface if it is matt. The
repair procedure can only be checked
exactly if there is enough reflection of light.
4. Place the adjustable lamp in position.
The adjustable lamp should be positioned
and adjusted so that the dent can be clearly
seen in the reflection on the paintwork (oval
shape).
When pressure on the dent is increased the
oval shape changes into lines which cross
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5. Position the pressure tool
Position the tip of the pressure tool on the
edge of the dent.
By moving back and forth with light pressure
applied on the dent with the tip of the tool,
the reflected light shows the position of the
pressure tool.
6. Working principle while applying pressure
The operation concentrates on forming a
half circle, working chronologically.
To restore the surface, all that is needed is
to work on one half of the dent.
The unworked half of the dent restores on
its own, through tension produced by the
pressure.
Diagram
High edge
Item
Part
Number
Description
High edges
Pressure tool
Exception:
- Sharp edged dents with minimal material
stretching are first worked on at the centre.
- After pressing out the dent, slightly raised
areas can be seen. This is caused by the
excess steel in the centre of the dent,
caused by material stretching.
- Use a plastic drift to even out the slightly
raised area.
Description
Unstable pressure area
Sequence of pressure
Starting position
If large, relatively weak body areas are worked on,

the path of the pressure tool while pressure is
applied is correspondingly larger. The restoration
process takes longer.
Item
Part
Number
1
2
NOTE: Never begin in the centre of the dent. If a

dent is worked from the centre first, the edge will
be lifted up and will remain visible as a high area
(material stretching). This lifted edge can only
then be restored by lengthy reworking.
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Large area dent
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501-25F-5

Item
Part
Number
Description
Reforming path
Pressure tool
Stable pressure area
NOTE: Work areas near internal reinforcing with

only light pressure, so that high areas are not
formed (material stretching).
Stable pressure bodywork areas with inner
braces have a much more stable surface than
weak pressure areas. Only short pressure
movements are required here because the
steel of the bodywork is less sprung.
Particular care must be taken with the
pressure procedure if tools with a small
contact face are used.
Optical check:
- It is only possible completely to remove all
remaining unevenness by making continual
visual checks of the surface using the
adjustable lamp. In addition, towards the
end of the pressure procedure, the dent
must be checked several times from
different directions. To do this, change
position by about 90.
Pressing out a dent near a brace
Item
Part
Number
Description
Roof brace
Accessibility of individual bodywork

components
Roof area
Support (pivot) of the pressure tool using an
S-shaped hook
Item
Part
Number
Description
Pivoted using an S-hook
Pressure tool
In order to make it possible to exert force in the

roof area, a pivot in the form of an S-hook must
be used.
Only loosen the headlining locally, depending
on the number of dents and their location.
Dents near interior components can be
reached by removing the component (interior
lamp).
Check accessibility before starting repair work
if the dent is near the sliding roof.
Repairs near inner braces are worked using
the special tools found in the tool kit.
Item
Part
Number
Description
Roof surface
Pressure tool
Adhesive bead
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- Separate the adhesive bead of the brace
using a metal spatula, so that the pressure
tool can be put in position.
Special lever for dents near inner braces.
Item
Part
Number
Description
Protective assembly
Plastic wedge
The pressure is applied in this case without

use of an additional support by simply turning
the bent pressure tool.
Pressing out a dent through the window channel.
Item
Part
Number
Description
Contact point
Direction of movement
Hood
Door area
Dents in the upper half of the door can usually

be worked on without removing the inner trim.
When the window is open, access is obtained
through the window cavity. A protective
assembly is inserted into the window cavity to
prevent damage to the window.
The plastic wedge ensures access.
Equipment
The hood is moved into working position using

telescopic struts and held in position using the
"rubber cords".
In the region of the braces the adhesive bead
must be partially opened using a metal spatula
to give access to the dent.
Renewal of the corrosion protection.
All repair inner areas must be reworked, where
accessible the paintwork must be refinished.
- Clean the inner area with silicone remover.
- Prime and paint the inner repair area.
- Finally, spray in cavity protection where the
repair is not accessible.
Quality control
In order to achieve a repair quality that meets
production standards, the following points
must be observed:
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- Check the repair area for unevenness. Do
this optically by looking at the surface from
different angles.
- Paint the repaired surface area, clean it and
polish it if necessary.
- Check that the attached components and
inner trim are seated correctly and are not
damaged.
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501-25G-1
Body Repairs - Noise, Vibration and Harshness
501-25G-1
SECTION 501-25G Body Repairs - Noise, Vibration

and Harshness
CONTENTS
PAGE

Noise, Vibration and Harshness........................................................................................
Introduction ......................................................................................................................
What is understood by NVH in vehicle technology ...........................................................
Types of noise in NVH technology....................................................................................
Noise transmission through air .........................................................................................
Sound transmission through a body .................................................................................
Combination of transmission through air and bodies ........................................................
Vibration technology.........................................................................................................
Noise and oscillation behaviour in a vehicle .....................................................................
Noise and oscillation behaviour of intake and exhaust systems .......................................
Bodywork .........................................................................................................................
501-25G-2
501-25G-2
501-25G-2
501-25G-2
501-25G-2
501-25G-3
501-25G-3
501-25G-4
501-25G-6
501-25G-8
501-25G-10
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Introduction
This chapter gives an overview of how noise,
vibration and harshness (NVH) can be produced
in a vehicle, and which corrective measures are
possible.
- Low notes - growling, droning

- Mid-pitch notes - buzzing, whirring
- High notes - howling, whistling, squeaking
Loud howling and whistling is painful to the
ears.
Where the different notes come from in a vehicle:
What is understood by NVH in vehicle

technology
N = Noise - Sound, can be heard
V = Vibration - Oscillation, can be felt
H = Harshness - Roughness, can be heard and
felt
Types of noise in NVH technology
Noises in a vehicle are classified by their
notes:
Low notes are mostly produced by the engine.

Low notes are also caused by the road surface,
especially if the surface is rough. This is a form
of droning which can be felt by the vehicle
occupants as vibration or roughness.
High notes however, which are experienced
as howling or whistling noises are often air
currents (wind noise) or come from attached
components such as the generator, power
steering pump or drivebelt.
There are also clattering noises which can
occur when driving over an uneven road.
These jerking noises are produced by, for
example, the shock absorbers, chassis
components or loose articles inside the
vehicle.
Noise transmission through air
Spreading of sound waves in the air
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Item
Part
Number
Description
Sound source e.g. Engine
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Item
Part
Number
Description
Sound wave
Amplitude
The sound is spread by longitudinal waves in

the form of pressure changes in the air.
Sound transmission through a body
Sound is passed through liquids or solids e.g.
through the car bodywork.
The speed of transmission (speed of sound) in

liquids or solids depends on the material, but is
generally faster than that in air (about 5 times
faster).
Combination of transmission through air and
bodies
NOTE: Sound transmission through both air and
bodies is of prime importance in vehicle
technology.
Noise transmission in a vehicle
Item
Part
Number
Description
Sound through air
Sound vibrations
Example
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- The source of the noise is the engine Engine
noises are:
- radiated directly through the air
- transmitted as vibrations from the engine to
the bodywork and radiated into the
passenger compartment as air borne sound,
for instance by the bulkhead,.
Vibration technology
Frequencies below 20 Hz (low frequencies)
and those above 20,000 Hz (20 kHz; high
frequencies) are not heard by the human ear.
The engine is made to oscillate vertically in its
flexible mountings by unevenness in the road.
Engine mountings which are not tuned will
transmit oscillations to the bodywork and
hence to the occupants.
The following basic rules apply:
- In vehicle technology, not only audible

frequencies but also inaudible (low)
frequencies must be considered.
- Low frequency oscillations can usually be
seen (large amplitudes).
- High frequency vibrations can be heard, but
will also be felt as vibrations in the floor,
steering wheel or seat.
Resonance
Every body has a natural frequency of

vibration.
If a system able to vibrate (a vehicle) is excited
at its natural frequency of vibration, it will start
to resonate.
Uneven engine running appears for instance
when the resonant frequency is reached
(critical engine speed).
Once the engine speed increases above this
speed, the engine will very soon run smoothly
again.
Damping
If a damper is installed parallel to a spring, the

damping characteristic acts to reduce the
movement of a body.
This is also the way in which a shock absorber
on a vehicle works.
Damping affects the resonance of an object or
system.
The mass being moved is damped by a
correctly operating shock absorber, so that
shaking of the bodywork stops immediately.
The shock absorber in a vehicle is an
oscillation damper, which allows the bodywork
to oscillate in a damped manner.
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Item
Part
Number
Undamped oscillation
Damped oscillation
Oscillation
Description
Isolation
In oscillation technology, the term isolation means

decoupling (separation) of components and
systems.
Example:
- An engine is mounted in sprung elements,
so that as little oscillation as possible is
passed to the vehicle.
- In automotive technology, the isolation
technique used is nearly always rubber
mounting. The elasticity of the rubber acts
like a spring.
- The effectiveness of this type of decoupling
depends on the construction of the
component.
Directional loading of a rubber mounting in order to achieve optimum isolation
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501-25G-6

Item
Part
Number
Description
Engine
Engine mounting
Item
Part
Number
Reflection of sound waves
Absorption of sound waves
Absorption
Sound waves are reflected from hard surfaces

If they meet soft surfaces, they are absorbed.
Here both the material and the material
thickness play important roles.
Description
Example:
- All sound deadening components such as
door trim, carpets, headlining, parcel
shelves and the seats are removed from a
vehicle.
- The result of this is that the sound is directly
reflected (the sound level rises), and a
concert hall effect is produced.
Noise and oscillation behaviour in a vehicle
The occupants of a vehicle experience different
levels of sound or noise depending on where they
are sitting.
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Sound/noise wave (standing wave) in a vehicle
Item
Part
Number
Driver sits in a "wave calm"
Rear passenger sits in a

"wave swell"
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Description
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Noise and oscillation behaviour of intake and
exhaust systems
The vehicle intake system as an air borne sound
and solid body sound source
order to keep this proportion as small as

possible, it is necessary for these type of
oscillating components to be connected to
the body using stiff connection points.
- The exhaust system especially is an
oscillating component and requires optimal
isolation through its connection to the floor
and also good routing and positioning of the
fixing points in order to reduce the solid body
sound transmission.
Intake system
Intake system
The vehicle exhaust system as an air borne sound

and solid body sound source
Ways in which sound is transmitted

- The top illustration shows the ways in which
sound can be transmitted from intake and
exhaust systems.
- Apart from air borne sound, solid body
sound is predominant in both systems. In
G33929 en
Item
Part
Number
Description
Intake manifold
Connection hose
Fixing component (rubber

mounted)
Air cleaner
Resonator
The volume and length of intake systems are

matched exactly. No changes may be carried
out during service or repair work. When
attaching components (hoses and tubes), pay
attention that all connections are air-tight.
The surfaces of all components affected by the
strong pressure variations in the intake system
are especially subject to strong oscillations.
The effects of temperature, such as warming
of the air filter housing can cause changes in
the rigidity of surfaces.
In order to prevent solid body sound caused by
surface oscillations of the intake system from
being transmitted to the vehicle body, the
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following points must be observed during
service:
- The whole intake system must be isolated

from the bodywork and mounted in rubber
bushes without tension.
- The air channels of the intake system must
not contact the bodywork components.
- Insert foam insulation at points of contact
with bodywork or other components.
Exhaust system
Exhaust system construction
Item
Part
Number
Description
Catalytic converter
Decoupling element
Front silencer
Rear silencer
have a solid connection to the engine (no splits

in brackets).
Simple problem testing:
Exhaust systems must be installed without

strain.
NOTE: The rubber mountings in which an exhaust

system is suspended also transmit oscillations
and under some circumstances can also cause a
noise problem. For this reason it is important that
the exhaust system is installed free of strain.
The rubber mountings must not be
over-stretched.
The exhaust manifold and catalytic converter
(if it is mounted directly at the engine) must
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- Remove all mountings from which the
exhaust system is suspended.
- Support the exhaust system with rope at two
positions at the most.
- Check the noise level in the passenger
compartment during a road test.
- If this solves the problem, the exhaust
mountings are the source of the noise.
- Put back the exhaust supports one at a time,
and road test the vehicle after fitting each
one.
- By proceeding in steps in this way, the
mounting that is causing the noise in the
passenger compartment can be found.
Bodywork
Function
Different types of demand are made on the

bodywork of a vehicle, particularly when it is
being driven. Predominant here are vibrations
caused mainly by other vehicle components,
such as the engine and mountings. The
bodywork is therefore one of the most
important vehicle components where NVF is
concerned.
The vehicle components described so far were,
according to their function, individual
self-contained noise sources. The bodywork
however, connects and houses all the vehicle
components.
The bodywork is subject to vibration from both
air borne sound and solid body sound.
The bodywork must absorb all oscillations and
impulses from all components and if possible
transmit none of these to the vehicle interior.
The largest proportion of NVH behaviour of a
bodyshell is in the steel panels of the roof,
sides and floor. They are strongly stimulated
by the bodyshell structure and work like a
loudspeaker transmitting noise.
G33929 en
Further demands on the bodywork
Good crash behaviour

Large interior space
Corrosion resistance
Low weight
Good aerodynamic shape
A compromise must be made on some of these

points. One example is between high body rigidity
for good NVH performance and good energy
absorption in an accident by the use of crumple
zones.
Example:
Watertight does not mean sound tight,
therefore the following points must be taken
into account:
- Correct installation of the windows.
- Correct installation of the seals.
Further points
- Openings into the engine compartment
- Door and window sealing
- Heater and ventilation openings
- Sliding roof drainage hoses
The side- and crossmembers in the body
structure are often linking channels allowing
sound transmission. Possible corrective
measures are:
- Installation of dividing walls at critical points
such as the joint between the sidemember
and the A-pillar in order to ensure good air
borne sound insulation.
NOTE: Foam pieces and foam filling are used in
production to seal air borne sound transmission
routes. If wind, tyre, engine or road noise is a
problem, the position of the pieces of foam should
be checked.
- Installation of foam plugs in affected areas.
- Filling hollow sections with foam.
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TO MODEL INDEX
501-26-1
Body Repairs - Vehicle Specific Information and
501-26-1
Tolerance Checks
SECTION 501-26 Body Repairs - Vehicle Specific

Information and Tolerance Checks
CONTENTS
PAGE

Body and Frame ...............................................................................................................
501-26-2
GENERAL PROCEDURES
Underbody Tolerance Check.............................................................................................
Frame Tolerance Check....................................................................................................
Body Tolerance Check......................................................................................................
501-26-10
501-26-12
501-26-16
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Tolerance Checks
501-26-2

Body and Frame
Introduction
The bodywork of Fiesta 2002 is a completely new

development and comprises the following model
variants:
3-door version (anticipated for the second half
of 2002 onwards)
5-door version
absorbed by the crossmember and is dissipated

through the deformation elements for an impact
below 15 Km/h. It is attached to the bodywork by
threaded connections.
Crash element
The model variants of Fiesta 2002 are identical in

the front area up to the A-pillar, but differ in
technical construction in the centre and rear
areas.
Construction features
The front and rear side members, windshield

frames, doors and D-pillar inner reinforcement are
made of thick walled body panels. Because of the
shape of the individual components and the
built-in reinforcements, the bodywork is very
resistant to torsion. For the first time, body panels
reformed from tailored blanks are integrated into
the crash and strength relevant areas. Because of
this, the deformation performance of the chassis
and the occupant protection are distinctly
improved.
Overall, the bodywork of the Fiesta proves to be
very easy to repair. The overall body structure is
made and assembled in such a way that individual
body panels can be replaced without problem.
Body components which are prone to deformation
(e.g. front side member, A-pillar inner panel etc.)
are made of several individual parts which are
joined together. The majority of the welded joints
which may need to be repaired can be re-created
using resistance spot welding.
Other changes relate to the increase in wheel
base, overall length and vehicle height,
deformation areas on the front and rear side
members and the front and rear crash elements.
Front crash element
The front crash element consists of a steel

crossmember with two deformation elements
welded onto it. The energy of an impact is
G204052 en
Item
Part
Number
Description
Retaining bolts
Pre-determined folding
points
Threaded bore for the towing

eye
Hood lock panel
The hood lock panel is made of plastic and is

reinforced with high-resistance foam in the areas
of most load. Attachment to the crossmember and
to the upper side members is achieved by
threaded connections. The hood lock panel
supports a variety of other components (e.g. the
radiator, radiator fan and hood lock). Minor
damage can be repaired using the applicable
plastic repair process.
NOTE: If there are penetrating cracks, partial
breaking away of material or part of it is missing, a
new hood lock panel must be installed.
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Tolerance Checks
501-26-3

Front module
Item
Part
Number
Description
Crash element
Hood lock panel
High-resistance foam reinforcement
(intentional yield points). If there is deformation

inside the engine compartment, the front section
can be replaced individually.
Front side member
In the case of repairs, the front module, consisting

of the crash element and the hood lock panel, can
be detached as a unit together with the
components which are bolted to it.
Front side member
In contrast to the previous model, the side

member is made of several parts, and the inner
sides are made of tailored blanks. If the frontal
damage extends past the crash element (impact
above 15 Km/h), the impact energy is absorbed by
the side members and dissipated in the area of the
intentional yield points (deformation area). A
deformation area has no inner reinforcement.
Sectional replacement is possible if the damage
does not extend past the deformation area
G204052 en
Item
Part
Number
Description
Side member (multiple part)
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Tolerance Checks
501-26-4

Item
Part
Number
Description
impacts this prevents deformation of the side

members and therefore of the vehicle body also.
points
Rear side member
Laser butt weld
Resistance spot weld joint
Rear crossmember
The rear crossmember is secured to the side

members by threaded connections. Because the
crossmember is curved, impact energy is more
easily converted into deformation energy. For light
If a heavier rear impact occurs, in addition to the

crossmember, the ends of the side members are
deformed. The remaining energy is dissipated in a
controlled manner in the area of the intentional
yield points. Sectional replacement is possible if
the damage does not extend past the deformation
areas.
Rear side member
NVH measures
Item
Part
Number
Left-hand side member
Laser butt weld
points
Right-hand side member
G204052 en
Description
In order to prevent air conduction of noise to the

vehicle interior, three NVH elements are installed
on each side of the vehicle, clipped to the vehicle
bodywork. When carrying out repair work, either
the original NVH elements must be put back in
position or new ones installed. On vehicles with a
sliding roof, the opening must be left in the A-pillar
NVH element for the water drain hose.
11/2004 2005.25 Fiesta
501-26-5

TO MODEL INDEX

Tolerance Checks
501-26-5

NOTE: Gases harmful to health will be released if
the insulation material is heated too much. Make
sure that the insulation material installed in
production is not damaged by cutting or sanding

tools when cutting out bodywork parts.
NVH measures
Item
Part
Number
Description
C-pillar inner NVH element
C-pillar outer NVH element
A-pillar NVH element
Opening for sliding roof water

drain hose
Tailored blanks
By employing a combination of materials with

different thicknesses and properties, tailored
blanks make it possible to produce an exact match
to the required strength and rigidity in different
areas within one bodywork component. The
number of steel panels can be decreased by
installing tailored blanks and so the weight of the
bodywork can be reduced.
G204052 en
11/2004 2005.25 Fiesta
501-26-6

TO MODEL INDEX

Tolerance Checks
501-26-6

Tailored blanks with laser welds
Item
Part
Number
Front side member
Front door frame
Roof frame
Rear door frame
Rear right-hand side member
G204052 en
Description
Item
Part
Number
Description
Rear left-hand side member
Rocker panel reinforcement
High-strength steel parts
Reinforced high-strength steel parts are used on

all Fiesta models.
11/2004 2005.25 Fiesta
501-26-7

TO MODEL INDEX

Tolerance Checks
501-26-7

NOTE: The working methods given in Part I of the
Body Repair Manual (501-25A) must be observed
in all repair work.
Overview of parts, front end
Item
Part
Number
Galvanised steel panels
High strength and galvanised

steel panels
G204052 en
Description
Item
Part
Number
Description
High-strength low alloy steel
11/2004 2005.25 Fiesta
501-26-8

TO MODEL INDEX

Tolerance Checks
501-26-8

Overview of parts, floor pan (5-door version)
Item
Part
Number
G204052 en
Description
Item
Part
Number
Description
steel panels
11/2004 2005.25 Fiesta
501-26-9

TO MODEL INDEX

Tolerance Checks
501-26-9

Overview of parts, side view (5-door version)
Item
Part
Number

steel panels
High-strength steel parts
G204052 en
Description
11/2004 2005.25 Fiesta
501-26-10

TO MODEL INDEX

Tolerance Checks
501-26-10
GENERAL PROCEDURES
Underbody Tolerance Check
1. Body frame dimensions
A tolerance of 3 mm applies to all
measurements given. All detailed
illustrations correspond to the left-hand side
of the vehicle.
All measurements have been taken from
production data and are the length of the
straight line between the measurement
points. All measurements can therefore be
G204053 en
made using a symmetrically adjusted

measuring gauge.
The measurement points were measured
with assemblies removed and with the
exception of oval bodywork holes, refer to
the centre of the hole.
The measurement points for oval bodywork
holes relate to the foremost position of the
curve (as seen from the driver's seat).
11/2004 2005.25 Fiesta
501-26-11

TO MODEL INDEX

Tolerance Checks
501-26-11
GENERAL PROCEDURES
2. Body frame dimensions
A tolerance of 3 mm applies to all
measurements given. All detailed
illustrations correspond to the left-hand side
of the vehicle.
All measurements have been taken from
production data and are the length of the
straight line between the measurement
points. All measurements can therefore be
G204053 en
made using a symmetrically adjusted

measuring gauge.
The measurement points were measured
with assemblies removed and with the
exception of oval bodywork holes, refer to
the centre of the hole.
The measurement points for oval bodywork
holes relate to the foremost position of the
curve (as seen from the driver's seat).
11/2004 2005.25 Fiesta
501-26-12

TO MODEL INDEX

Tolerance Checks
501-26-12
GENERAL PROCEDURES
Frame Tolerance Check
1. Body dimensions, vehicle front
All dimensions with tolerance 3mm. All
dimensions were determined from the
center of the hole or panel edge using a
symmetrically adjusted measuring gauge.
1- 3 = 1378 mm; 2 - 3 = 1416 mm; 4 - 5 =
1462 mm; 4 - 6 = 1524 mm; 7 - 8 = 1157
mm; 8 - 9 = 473 mm; 10 - 11 = 1433 mm.
Measurement point 11 is measured in the
curve and corresponds to the greatest distance to the opposite measurement point.
G204054 en
11/2004 2005.25 Fiesta
501-26-13

TO MODEL INDEX

Tolerance Checks
501-26-13

2. Body dimensions, side view
12 - 13 = 1290 mm; 14 - 15 = 840 mm; 14 17 = 824 mm; 16 - 17 = 876 mm; 18 - 19 =
G204054 en
1105 mm; 20 - 21 = 720 mm; 22 - 23 = 964

mm.
Measurement points 12, 19 and 22 are
measured in the curve and correspond to
the largest distance to the opposite measurement point.
11/2004 2005.25 Fiesta
501-26-14

TO MODEL INDEX

Tolerance Checks
501-26-14
GENERAL PROCEDURES
3. Body dimensions, rear view

24 - 25 = 1139 mm; 26 - 27 = 1086 mm; 28 29 = 818 mm.
4. Passenger compartment, body dimensions


30 - 31 = 1349 mm; 32 - 33 = 1343 mm; 34 35 = 1332 mm.
G204054 en
11/2004 2005.25 Fiesta
501-26-15

TO MODEL INDEX

Tolerance Checks
501-26-15
G204054 en
11/2004 2005.25 Fiesta
501-26-16

TO MODEL INDEX

Tolerance Checks
501-26-16
GENERAL PROCEDURES
Body Tolerance Check
1. Body gap dimensions
The gap dimension given must be the same
along the whole length of the gap.
2. Body gap dimensions

The gap dimension given must be the same
along the whole length of the gap.
G204055 en
11/2004 2005.25 Fiesta
501-26-17

TO MODEL INDEX

Tolerance Checks
501-26-17
G204055 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
501-27-1
Front End Sheet Metal Repairs
501-27-1
SECTION 501-27 Front End Sheet Metal Repairs

CONTENTS
PAGE

Fender Apron Panel Reinforcement .............................................................. (44 277 4)
Front Side Member Extension...........................................................................................
Front Side Member and Fender Apron Panel LH .......................................... (44 283 1)
Front Side Member Section........................................................................... (44 281 7)
501-27-2
501-27-3
501-27-5
501-27-7
11/2004 2005.25 Fiesta
501-27-2

TO MODEL INDEX
501-27-2

Fender Apron Panel Reinforcement (44 277 4)
Name
Specification
Apron panel
reinforcement
1. Cut lines for partial replacement

1. Rear cut line.
2. Front cut line.
Removal
1. General Notes.
The hood, windshield, doors and fenders
are already removed before repair work
starts.
Necessary removal work: water trap cover
and wheelhouse cover.
2. Apron panel reinforcement
1. Preliminary separating cut.
2. Mill out the spot welds.
3. Mill out the spot welds (two panel
thicknesses).
4. Grind out the weld seam
5. Grind out the spot welds.
2. Apron panel reinforcement

1. Resistance spot weld
2. Puddle welding
3. Continuous MIG weld seam.
Installation
NOTE: Partial replacement of the apron panel is
possible, depending on the damage. The
instructions concerning welding equipment given
in Section 501-25A must be observed before
resistance spot welding body panels with a total
thickness of 3 mm and greater.
G204056 en
11/2004 2005.25 Fiesta
501-27-3

TO MODEL INDEX
501-27-3

Front Side Member Extension
General Equipment
Measurement or alignment angle system
Name
Specification
3. Bulkhead reinforcement
2. Mill out the spot welds (two panel thicknesses).
Side member front

extension
Bulkhead
reinforcement
Removal
1. General Notes.
The front side member with apron panel and
apron panel reinforcement are already
removed before the repair work starts.
Necessary removal work: Facia crash
padding and seats.
Fold back the carpets and move the wiring
back away from the working area.
2. Side member
Mill out the spot welds.
G204058 en
11/2004 2005.25 Fiesta
501-27-4

TO MODEL INDEX
501-27-4

Installation
1. Side member
Drill holes for puddle welding (10 mm diameter).
NOTE: : before welding, secure the side member

using the measurement or alignment angle
system.
2. Side member
Puddle welding
Puddle welding
5. Side member
Puddle welding
G204058 en
11/2004 2005.25 Fiesta
501-27-5

TO MODEL INDEX
501-27-5

Front Side Member and Fender Apron Panel LH (44 283 1)
General Equipment
Name
Mill out the spot welds (two panel thicknesses).
Specification
Side member with

apron panel
Apron panel
reinforcement
Removal
1. General Notes.
Fenders, hood, doors and apron panel
reinforcement are already removed before
repair work starts.
2. Side member with apron panel
1. Separating cut.
thicknesses).

Installation
NOTE: The instructions concerning welding
equipment given in Section 501-25A must be
observed before resistance spot welding body
panels with a total thickness of 3 mm and greater.
G204059 en
11/2004 2005.25 Fiesta
501-27-6

TO MODEL INDEX
501-27-6

1. Drill holes for puddle welding.
2. Mill out spot welds (diameter: 10 mm)

1. Mill out spot welds (diameter: 10 mm).

Puddle welding
Puddle welding

Puddle welding
G204059 en
11/2004 2005.25 Fiesta
501-27-7

TO MODEL INDEX
501-27-7

Front Side Member Section (44 281 7)
2. Inner side member
Separating cut.
General Equipment
Name
Specification
Outer side member

Inner side member
Crossmember retaining
flange
Removal
1. General Notes.
1. Right-hand side cut line.
2. Left-hand side cut line.
The fine cut lines are not the same on the
right-hand and left-hand sides.
Hood lock panel, front crash element, hood,
and fender are already removed before
repair work starts.
3. Outer side member

1. Separating cut.
Installation
NOTE: Separate the side member completely on
the inside along the fine cut line.
G204141 en
1. Inner side member

Continuous MIG weld seam.
11/2004 2005.25 Fiesta
501-27-8

TO MODEL INDEX
501-27-8

2. Outer side member
NOTE: : Before welding, secure the retaining

flange for the cross member using the
measurement or alignment angle system and the
installed hood closing panel.
3. Inner crossmember retaining flange
Intermittent MIG weld seam.
4. Outer crossmember retaining flange

G204141 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
501-28-1
Roof Sheet Metal Repairs
501-28-1
SECTION 501-28 Roof Sheet Metal Repairs

CONTENTS
PAGE
SPECIFICATIONS
Specifications....................................................................................................................
501-28-2

Roof Panel .................................................................................................... (44 174 0)
501-28-3
11/2004 2005.25 Fiesta
501-28-2

TO MODEL INDEX
501-28-2
SPECIFICATIONS

Clinched flange sealant
G251655 en
Specifications
ESK-M4G245-A
11/2004 2005.25 Fiesta
501-28-3

TO MODEL INDEX
501-28-3

Roof Panel (44 174 0)
Name
1. Roof
Apply clinched flange protection.
Specification
Roof
Removal
1. General Notes.
Necessary removal work: windshield,
tailgate, headliner and interior trim.
2. NOTE: Heat the bonded areas on the roof panel
before removal.
Roof
Installation
G204073 en
11/2004 2005.25 Fiesta
501-28-4

TO MODEL INDEX
501-28-4

2. Roof
1. Offer up the roof and drill holes for puddle
welding. Then puddle weld.
G204073 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
501-29-1
Side Panel Sheet Metal Repairs
501-29-1
SECTION 501-29 Side Panel Sheet Metal Repairs

CONTENTS
PAGE
SPECIFICATIONS
Specifications....................................................................................................................
501-29-2

A-Pillar Outer Panel Section and Reinforcement........................................... (44 331 5)
Rocker Panel ................................................................................................ (44 447 0)
Rocker Panel Section 3-Door ................................................................... (44 475 0)
Rocker Panel Inner Reinforcement ............................................................... (44 479 4)
B-Pillar and Reinforcement 3-Door ........................................................... (44 584 2)
B-Pillar and Reinforcement 5-Door ........................................................... (44 584 2)
Front Door Skin Panel.......................................................................................................
501-29-3
501-29-7
501-29-8
501-29-9
501-29-11
501-29-12
501-29-17
11/2004 2005.25 Fiesta
501-29-2

TO MODEL INDEX
501-29-2
SPECIFICATIONS

1K glass adhesive (150 ml)
2K metal adhesive
Specifications
ESK-M4G245-A
WSK-M11P57-A1
WSK-M2G400-A / B
G251656 en
11/2004 2005.25 Fiesta
501-29-3

TO MODEL INDEX
501-29-3

A-Pillar Outer Panel Section and Reinforcement (44 331 5)
General Equipment
Beam compasses
Name
Specification
A-pillar outer panel

A-pillar reinforcement
A-pillar inner panel
Bulkhead
reinforcement
2. A-pillar outer panel

1. Separating cut.
4. Warm the area (about 170 C) and release
the NVH elements.
Removal
1. General Notes.
The apron panel reinforcement and inner
reinforcement of the A-pillar are already
removed before the repair starts.
Necessary removal work: door, hood,
windshield, facia crash padding, A-pillar trim
and rocker panel trim.
NOTE: If the inner and outer A-pillar
reinforcements are being completely replaced,
drill out the spot welds on the A-pillar outer panel
by two panel thicknesses.
3. A-pillar inner reinforcement

2. Warm the area (about 170 C) and release
the NVH elements.
G204074 en
11/2004 2005.25 Fiesta
501-29-4

TO MODEL INDEX
501-29-4

4. A-pillar inner reinforcement with rocker
panel reinforcement
thicknesses).
4. Separating cut.
5. Remove the NVH element.
5. A-pillar inner reinforcement with rocker

panel reinforcement
Grind out the weld seams.
Installation
G204074 en
11/2004 2005.25 Fiesta
501-29-5

TO MODEL INDEX
501-29-5

1. Inner A-pillar with rocker panel
reinforcement
Drill a hole for puddle welding (diameter: 10
mm).

reinforcement

reinforcement
2. Puddle welding
4. Install the NVH element (bond).

Drill holes for puddle welding (diameter: 10
mm).
G204074 en
11/2004 2005.25 Fiesta
501-29-6

TO MODEL INDEX
501-29-6

1. Apply bond to the NVH element.
2. Puddle welding

1. Seal the NVH area.
3. Puddle welding

1. Separating cut.
2. Drill holes for puddle welding (diameter: 10
mm).
G204074 en
11/2004 2005.25 Fiesta
501-29-7

TO MODEL INDEX
501-29-7

Rocker Panel (44 447 0)
1. Rocker panel
Drill holes for puddle welding.
General Equipment
Measuring stick
Name
Specification
Rocker panel
Removal
1. General Notes
The fenders, doors and door hinges are
already removed before repair work starts.
Required disassembly operations: Rocker
panel trim, front and rear seats.
harness out of the working area.
2. NOTE: Make the cut location on the C-pillar a
maximum of 200 mm above the edge of the
rocker panel, to prevent damage to the
underlying NVH element.
Rocker panel
1. Cut location.
2. Grind out the wheel arch joint.
2. Rocker panel
2. Apply two-component metal adhesive
immediately prior to installation of the new
part. Then clinch the wheel arch joint.
3. Resistance spot weld.
4. Puddle welding.
Installation
NOTE: Before resistance spot welding of body
panels with a total panel thickness of 3 mm and
greater, the welding equipment instructions
contained in chapter 501-25A must be followed.
G204075 en
11/2004 2005.25 Fiesta
501-29-8

TO MODEL INDEX
501-29-8

Rocker Panel Section 3-Door (44 475 0)
Name
Specification
1. Panel insert
Resistance spot weld panel insert.
Rocker panel
Removal
1. General Notes
Required removal operations: Rocker panel
trim, door rubber seal and side panel interior
trim.
2. Rocker panel
1. Cut location.
2. Grind out the wheel arch joint.
2. Rocker panel
1. Apply two-component metal adhesive to the
clinched flange and clinch the wheel arch
flange.
2. Continuous MIG weld.
3. MIG intermittent weld seam.
Installation
G357597 en
11/2004 2005.25 Fiesta
501-29-9

TO MODEL INDEX
501-29-9

Rocker Panel Inner Reinforcement (44 479 4)
3. Rocker panel inner reinforcement
General Equipment
Name
Specification
Rocker panel inner

reinforcement
Removal
1. General Instructions
The A-pillar outer panel, A-pillar
reinforcement, B-pillar with reinforcement,
side panel, wheel house with reinforcement
and inner side panel are already removed
before the repair starts.
Sectional replacement is possible,
depending on the damage.
1. Front separation area (only for sectional
replacement).
2. Rear separation area (only for sectional
replacement).

Grind out the spot welds.
Installation
G204076 en
11/2004 2005.25 Fiesta
501-29-10

TO MODEL INDEX
501-29-10


Resistance spot welding.

Puddle weld.
G204076 en
11/2004 2005.25 Fiesta
501-29-11

TO MODEL INDEX
501-29-11

B-Pillar and Reinforcement 3-Door (44 584 2)
General Equipment
Installation

1. B-Pillar reinforcement
Name
Specification
B-Pillar reinforcement
Removal
1. General Notes
The side panel is removed before starting
the repair.
Required removal operations: Side panel
interior trim, seats and rocker panel trim.
1. Cut location.
2. Mill out the spot welds (one panel
thickness).
G357605 en
11/2004 2005.25 Fiesta
501-29-12

TO MODEL INDEX
501-29-12

B-Pillar and Reinforcement 5-Door (44 584 2)
General Equipment
Name
Specification
B-pillar outer panel

B-Pillar reinforcement
B-pillar inner panel
G204077 en
11/2004 2005.25 Fiesta
501-29-13

TO MODEL INDEX
501-29-13

Removal
1. General Notes.
The front door, rear door and rear door
hinges are already removed before the
repair starts.
Necessary removal work: seat and rocker
panel trim.
harness back away from the working area.
It is not possible to perform a partial
replacement in the upper area of the B-pillar
reinforcement because of the
reinforcements which are inside.
NOTE:
When the outer and inner reinforcements are
being completely replaced, the spot welds in
the region of the door seal must be drilled out
as far as the inner panel.
Make the front cut line on the rocker panel far
enough forward to allow access to the B-pillar
inner panel (see weld flange).
2. B-pillar outer panel
1. Separating cut.
G204077 en
1. Separating cut.
11/2004 2005.25 Fiesta
501-29-14

TO MODEL INDEX
501-29-14

4. B-pillar inner panel
1. Separating cut.
1. B-pillar inner panel

Installation
G204077 en
11/2004 2005.25 Fiesta
501-29-15

TO MODEL INDEX
501-29-15

G204077 en

11/2004 2005.25 Fiesta
501-29-16

TO MODEL INDEX
501-29-16

3. Puddle welding
G204077 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
501-29-17
501-29-17

Front Door Skin Panel
Installation
Name
Specification
Door skin panel
1. Door skin panel

Apply clinched flange protection in the joint
area.
Removal
1. General Notes.
Necessary removal work: door trim, exterior
mirror, door window glass, door outer
handle and door hinges already removed
2. NOTE: Before opening the door outer skin
seam, remove the clinched flange protection
using a plaited wire brush.
Door skin panel
1. Open the clinched seam.
2. Detach the adhesive bonds.
2. Door skin panel
Apply clinched flange protection.
G207179 en
11/2004 2005.25 Fiesta
501-29-18

TO MODEL INDEX
501-29-18

3. Door skin panel
Clinch the seam and apply clinched flange
protection.
G207179 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
501-30-1
Rear End Sheet Metal Repairs
501-30-1
SECTION 501-30 Rear End Sheet Metal Repairs

CONTENTS
PAGE
SPECIFICATIONS
Specifications....................................................................................................................
501-30-2

Quarter Panel RH ......................................................................................... (44 511 0)
Inner Quarter Panel and Wheelhouse ........................................................... (44 519 3)
Water Drain Panel Reinforcement................................................................. (44 532 8)
Back Panel.................................................................................................... (44 642 0)
Rear Floor Panel........................................................................................... (44 654 1)
Rear Floor Panel Section .............................................................................. (44 654 5)
Rear Side Member Section ........................................................................... (44 683 5)
Rear Outer Wheelhouse Half ............................................................................................
Quarter/Side Panel Rear Section RH ............................................................ (44 513 0)
Quarter Panel RH 3-Door ......................................................................... (44 511 0)
Rear Wheelhouse Outer 3-Door ...................................................................................
Water Drain Panel Reinforcement 3-Door ................................................ (44 532 8)
501-30-3
501-30-6
501-30-9
501-30-11
501-30-12
501-30-14
501-30-15
501-30-16
501-30-18
501-30-20
501-30-22
501-30-24
11/2004 2005.25 Fiesta
501-30-2

TO MODEL INDEX
501-30-2
SPECIFICATIONS

1K glass adhesive (150 ml)
2K metal adhesive
Specifications
ESK-M4G245-A
WSK-M11P57-A1
WSK-M2G400-A / B
G251657 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
501-30-3
501-30-3

Quarter Panel RH (44 511 0)
Removal
Name
Quarter panel
G204078 en
Specification
1. General Notes
The doors and tailgate are already removed
before repair work starts.
Required disassembly operations: Bumper,
rear lamp, weatherstrip, inner trims and side
window.
Depending on the extent of the damage, the
forced air extraction gusset should also be
replaced.
2. Quarter panel
1. Cut location.
4. Grind down one panel thickness at the
wheel arch edge.
5. Heat the area (approx. 170 C) and release
the NVH elements.
11/2004 2005.25 Fiesta
501-30-4

TO MODEL INDEX
501-30-4

3. Quarter panel
2. Quarter panel
flange.
2. Apply clinched flange protection to the NVH
element.
5. Puddle welding.
Installation
1. Quarter panel
G204078 en
11/2004 2005.25 Fiesta
501-30-5

TO MODEL INDEX
501-30-5

3. Quarter panel
Puddle welding.
G204078 en
11/2004 2005.25 Fiesta
501-30-6

TO MODEL INDEX
501-30-6

Inner Quarter Panel and Wheelhouse (44 519 3)
General Equipment
Name
2. Inner quarter panel reinforcement

1. Separating cut.
Specification
Inner quarter panel with

wheel housing and
Wheelhouse reinforcement
NVH element
Removal
Quarter panel, back panel, lamp mounting
panel and water drain panel are already
removed before the start of repairs.
Necessary removal work: side panel trim.
back away from the working area.
NOTE: When separating the side panel, do not
exceed the maximum displacement of the cut line
in relation to the roof edge.
G204079 en
11/2004 2005.25 Fiesta
501-30-7

TO MODEL INDEX
501-30-7

3. Inner side panel with reinforcement
1. Separating cut.
2. Separating cut (two panel thicknesses).
Installation
1. Inner side panel
2. Inner side panel

2. Resistance spot welding.
3. Puddle weld.

1. Separating cut.
G204079 en
11/2004 2005.25 Fiesta
501-30-8

TO MODEL INDEX
501-30-8

1. Bond the NVH element in place.
4. Puddle weld.
G204079 en
11/2004 2005.25 Fiesta
501-30-9

TO MODEL INDEX
501-30-9

Water Drain Panel Reinforcement (44 532 8)
Name
Specification
Water drain panel

reinforcement
3. Water drain panel reinforcement

1. Separating cut.
Removal
1. General Notes.
Side panel and lamp mounting panel and
back panel with reinforcement are already
removed before the start of repairs.
The cut may vary depending on damage.
Installation
G204080 en
11/2004 2005.25 Fiesta
501-30-10

TO MODEL INDEX
501-30-10


Resistance spot weld
G204080 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
501-30-11
501-30-11

Back Panel (44 642 0)
Installation
Name
Specification
Back panel
1. Back panel
Removal
Necessary removal work: rear panel trim.
2. NOTE: Do not damage the weld flanges
remaining on the bodywork.
Back panel
2. Back panel
Puddle weld.
3. Back panel
3. Back panel
G204082 en
11/2004 2005.25 Fiesta

TO MODEL INDEX
501-30-12
501-30-12

Rear Floor Panel (44 654 1)
General Equipment
Name
Specification
3. Luggage compartment floor panel

1. Exact separating cut.
Luggage compartment
floor panel
Spare wheel retainer
Removal
The tailgate and rear panel with gussets are
already removed before the start of repairs.
Necessary removal work: rear seat,
luggage compartment carpet, side panel
trim left and right.

Grind out the spot welds.
Installation
NOTE: The new part overlaps in the connection
area at the front by 10 mm. To install it, because of
space limitations, cut the left-hand part panel and
re-install separately. The instructions concerning
welding equipment given in Section 501-25A must
be observed before resistance spot welding body
G204083 en
11/2004 2005.25 Fiesta
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501-30-13

2. Exact separating cut.


2. Intermittent MIG weld seam.

1. Puddle weld.
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501-30-14

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501-30-14

Rear Floor Panel Section (44 654 5)
Name
Specification
Rear floor panel
Installation
1. Right-hand rear floor panel
Removal
1. General Notes
Tailgate, back panel, rear crossmember,
quarter panel and lamp mounting panel
the start of repairs.
Required removal operations: Interior trim.
Fold back the carpets out of the working
area.
2. Left-hand rear floor panel
1. Preliminary cut location.
3. Mill out the spot welds from below
2. Rear floor panel

3. Puddle weld.
3. Right-hand rear floor panel

1. Preliminary cut location.
3. Mill out the spot welds from below
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501-30-15
501-30-15

Rear Side Member Section (44 683 5)
Installation
General Equipment
Name
Specification
Rear side member
Removal
1. NOTE: The instructions concerning welding

panels with a total thickness of 3 mm and
greater.
Side member
Continuous MIG weld seam.
1. General Notes.
The luggage compartment floor (part for
partial replacement), back panel, forced air
extraction gusset and side panel are
already removed before the repair work
starts.
The separating cut may vary on the
right-hand side, depending on the damage.
2. Left-hand side member
Separating cut.
3. Right-hand side member

Possible separating cuts.
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501-30-16

Rear Outer Wheelhouse Half
Name
Specification
Wheelhouse outer half

Wheelhouse reinforcement
3. Wheelhouse outer half

1. Separating cut.
NVH element
Removal
side panel, back panel, lamp mounting
panel and lamp mounting panel
the start of repairs.
NOTE: Make the separating cut on the wheel
house reinforcement offset from the wheel house
outer halves.
2. Wheelhouse reinforcement
1. Separating cut.
3. Warm the area and detach the NVH element.
Installation
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501-30-17


1. Bond the NVH element in place.
4. Puddle weld.

3. Puddle weld.
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501-30-18

Quarter/Side Panel Rear Section RH (44 513 0)
1. Replacement parts
Quarter panel sectional part
Luggage compartment water drain panel
Quarter panel reinforcement extension
3. Quarter panel and quarter panel

reinforcement extension
1. Cut point.
Removal
NOTE:
Sectional repair of the rear
right quarter panel can be performed with the back
panel both installed and removed.
In the operational procedure described here, the
back panel has already been removed.
1. General notes
Required removal operations: wheelhouse
trim panel, rear lamp, rear bumper, quarter
panel trim.
Move the carpeting and the wiring away
from the working area.
2. Overview of repair
1. Quarter panel sectional repair.
2. Luggage compartment water drain panel.
3. Quarter panel reinforcement extension.
G410694 en
4. Quarter panel and luggage compartment

water drain panel
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501-30-19

Installation
1. Quarter panel reinforcement extension
2. Puddle weld.

water drain panel
1. Continuous MIG weld (butt weld).
3. Puddle weld.
2. Quarter panel

water drain panel
Puddle weld.
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501-30-20

Quarter Panel RH 3-Door (44 511 0)
Name
Specification
3. Side panel
Side panel
Removal
1. General Notes
The doors and tailgate are already removed
before starting the repair.
Required removal operations: Bumper, rear
lamp, side window, wheelhouse liner, side
panel interior trim and rocker panel cover.
Depending on the extent of the damage, the
forced air extraction gusset should also be
replaced.
2. Side panel
1. Cut location.
3. Grind through panel edge (one panel
thickness).
Installation
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501-30-21

1. Side panel
3. Side panel
Puddle weld
2. Side panel
flange.
4. Puddle weld.
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501-30-22

Rear Wheelhouse Outer 3-Door
Name
Specification
Outer wheelhouse half
3. Outer wheelhouse half

1. Cut location.
Removal
1. General Notes
The side panel is removed before starting
the repair.
Required removal operations: Door rubber
seals, rocker panel cover, side panel interior
trim and seats.
Installation
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501-30-23

3. Puddle weld.
2. Puddle weld.
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501-30-24

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501-30-24

Water Drain Panel Reinforcement 3-Door (44 532 8)
Name
Specification

Water drain panel

reinforcement
Removal
1. General Notes
Side panel, lamp mounting panel and back
panel with reinforcement are already
removed before starting the repair.
The cut location may vary depending upon
the extent of the damage.
1. Cut location.
Installation
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501-30-25

3. Puddle weld.

Resistance spot weld.
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502-00-1
Uni-Body, Subframe and Mounting System
502-00-1
SECTION 502-00 Uni-Body, Subframe and Mounting

System
CONTENTS
PAGE
SPECIFICATIONS
Specifications....................................................................................................................
502-00-2

Crossmember ...................................................................................................................
502-00-3
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502-00-2
SPECIFICATIONS
Item
Stabilizer bar connecting link to stabilizer bar
Lower arm ball joint to wheel knuckle
Steering gear retaining bolts
Crossmember front retaining bolts
Crossmember rear retaining bolts
nuts - Vehicles with 1.25L, 1.4L or 1.6L engine
Exhaust flexible pipe to muffler and tailpipe assembly retaining nuts - Vehicles with diesel engine
nuts - Vehicles with 2.0L engine
G152599 en
Nm
55
48
80
48
70
175
44
lb-ft
41
35
59
35
52
129
32
lb-in
-
47
35
47
35
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502-00-3
502-00-3

Crossmember
3.
Special Tool(s)
205-524 (15-122)

General Equipment
Securing strap
Transmission jack
5 mm Allen key
Name
Grease
Specification
SA-M1C9107-A
Removal
All vehicles
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502-00-4

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502-00-4
5.


7.

retaining nuts.
Disconnect the exhaust flexible pipe from
the catalytic converter.
Remove and discard the exhaust flexible
pipe to catalytic converter gasket and retaining nuts.
6.

prevent damage.
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502-00-5

8.
9.

exhaust flexible pipe to muffler and tailpipe
the muffler and tailpipe assembly.
pipe to muffler and tailpipe assembly retaining nuts.

retaining nuts.
the catalytic converter.
pipe to catalytic converter gasket and retaining nuts.
All vehicles
10. Detach the steering gear from the
crossmember.
Using cable ties, support the steering gear
on both sides.
11. Using a transmission jack and wooden

block, support the crossmember and
lower arm assembly.
12. Secure the crossmember and lower arm
assembly to the transmission jack using a
securing strap.
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502-00-6

13. Remove the crossmember retaining bolts
on both sides.
Installation
All vehicles
1. NOTE: If installing a new crossmember, install
the lower arms.
NOTE: Do not fully tighten the lower arm to
crossmember retaining bolts at this stage.
Install the lower arms.
14. Using the transmission jack and wooden

block, remove the crossmember and
lower arm assembly.
15. NOTE: If a new crossmember is to be installed
remove the lower arms.
Remove the lower arms.
2. Using the transmission jack and wooden
block, position the crossmember and lower
arm assembly.
3. NOTE: Use the inner crossmember retaining
bolt to locate the special tools.
Install the special tools on both sides.
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502-00-7
4.
CAUTION: While tightening the

crossmember retaining bolts, make
sure the crossmember does not move.
8. Attach the steering gear to the crossmember.
Install the crossmember retaining bolts on

both sides.

retaining nuts.
NOTE: Coat the exhaust flexible pipe to catalytic
converter studs with grease.
9.

6. Install the crossmember inner retaining
Connect the exhaust flexible pipe to the

7. Remove the transmission jack and wooden

block.
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502-00-8

10.
11.
CAUTION: Twisting the exhaust

flexible pipe more than two degrees
may cause damage resulting in failure.
exhaust flexible pipe to muffler and tailpipe
NOTE: Coat the exhaust flexible pipe to muffler
and tailpipe assembly studs with grease.
NOTE: Install new exhaust flexible pipe to muffler
and tailpipe assembly retaining nuts.
CAUTION: Twisting the exhaust

flexible pipe more than two degrees
may cause damage resulting in failure.
retaining nuts.
NOTE: Coat the exhaust flexible pipe to catalytic
converter studs with grease.


All vehicles
12.

prevent damage.
Check the exhaust hanger insulator for
damage. Install a new exhaust hanger
insulator if required.
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502-00-9
13.

wrap or splint.
16.

wheel knuckle.
Attach the lower arm ball joint to the

ball joint from rotating.
15.

to the ball joint.
Attach the heat shield to the wheel
G152600 en

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502-00-10

19. NOTE: The lower arm to crossmember
retaining bolts must be tightened with the
vehicle weight on the road wheels.
Tighten the lower arm to crossmember
retaining bolts on both sides.
1. Tighten the lower arm to crossmember front
bolt in two stages.
Stage 1: 80 Nm.
2. Tighten the lower arm to crossmember rear
retaining bolts.

G152600 en
11/2004 2005.25 Fiesta

Fiesta ST 150 Manual de Taller

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BACK TO FRONT PAGE

FORD FIESTA ST150 2005.25 WRM

2005.25 Ford Fiesta ST150 South Africa

Group 5 Body and Paint

FORD FIESTA ST150 2005.25 WRM

BACK TO MAIN INDEX

11/2004 2005.25 Fiesta

FORD FIESTA ST150 2005.25 WRM

BACK TO CHAPTER INDEX

SECTION 100-00 General Information

DESCRIPTION AND OPERATION

11/2004 2005.25 Fiesta

BACK TO CHAPTER INDEX

FORD FIESTA ST150 2005.25 WRM

11/2004 2005.25 Fiesta

BACK TO CHAPTER INDEX

FORD FIESTA ST150 2005.25 WRM

DESCRIPTION AND OPERATION

A warning, caution or note is placed at the

This manual provides general descriptions for

How to Use This Manual

This manual is structured into groups and sections,

The special tool(s) table provided at the beginning

This manual covers diagnosis and testing, service

A group covers a specific portion of the vehicle.

Overview procedures contain an exploded view

As you read through this manual, you will come

11/2004 2005.25 Fiesta

BACK TO CHAPTER INDEX

FORD FIESTA ST150 2005.25 WRM

DESCRIPTION AND OPERATION (Continued)

Install new component

Apply petroleum jelly

Inspection and Verification

Visual Inspection Charts, Symptom Charts and

The symptom chart indicates symptoms, sources

For electrical systems, pinpoint test steps are

The boxed numbers indicate the order in which

A component test is used when a component is

Test graphics show the measurement or test to be

11/2004 2005.25 Fiesta

BACK TO CHAPTER INDEX

FORD FIESTA ST150 2005.25 WRM

DESCRIPTION AND OPERATION (Continued)

11/2004 2005.25 Fiesta

BACK TO CHAPTER INDEX

FORD FIESTA ST150 2005.25 WRM

DESCRIPTION AND OPERATION

an air bag inflator as this will lead to the risk of

The list is not exhaustive and all operations and

Deployed air bags should be disposed of in a

Before using any product the Materials Safety

Following any direct contact with gas generant.

Acids and Alkalis

After normal deployment, gloves and safety

wash affected areas thoroughly with water.

11/2004 2005.25 Fiesta

BACK TO CHAPTER INDEX

FORD FIESTA ST150 2005.25 WRM

DESCRIPTION AND OPERATION (Continued)

Highly flammable, flammable, combustible

Follow manufacturers instructions.

Those based on polymer emulsions and rubber

Skin contact may result in frostbite.