Ford Fiesta B299 2010.75 PDF

FOREWORD
To the best of our knowledge, the illustrations, technical information, data and
descriptions in this issue were correct at the time of going to print. The right to
change prices, specifications, and equipment and maintenance instructions at
any time without notice is reserved as part of FORD policy of continuous
development and improvement for the benefit of our customers.
No part of this publication may be reproduced, stored in a data processing

system or transmitted in any form, electronic, mechanical, photocopy, recording,
translation or by any other means without prior permission of Ford Motor
Company. No liability can be accepted for any inaccuracies in this publication,
although every possible care has been taken to make it as complete and
accurate as possible.
GROUP
FORD FIESTA
FORD FIESTA B299
B299 2010.75MY
2010.75MY
SECTION TITLE
Body and Paint 5 PAGE
Body and Paint

Body System - General Information...............................................................................501-00
Front End Body Panels..................................................................................................501-02
Body Closures................................................................................................................501-03
Interior Trim and Ornamentation....................................................................................501-05
Exterior Trim and Ornamentation...................................................................................501-08
Rear View Mirrors..........................................................................................................501-09
Seating...........................................................................................................................501-10
Glass, Frames and Mechanisms....................................................................................501-11
Instrument Panel and Console.......................................................................................501-12
Handles, Locks, Latches and Entry Systems................................................................501-14
Wipers and Washers......................................................................................................501-16
Bumpers.........................................................................................................................501-19
Safety Belt System.........................................................................................................501-20A
Supplemental Restraint System.....................................................................................501-20B
Body Repairs - General Information..............................................................................501-25
Body Repairs - Vehicle Specific Information and Tolerance Checks.............................501-26
Front End Sheet Metal Repairs......................................................................................501-27
Roof Sheet Metal Repairs..............................................................................................501-28
Side Panel Sheet Metal Repairs....................................................................................501-29
Rear End Sheet Metal Repairs......................................................................................501-30
Paint - General Information............................................................................................501-36
Frame and Mounting
Uni-Body, Subframe and Mounting System...................................................................502-00
2011 Fiesta
501-00-1 Body System - General Information 501-00-1
.
SECTION 501-00 Body System - General Information

VEHICLE APPLICATION: 2011 Fiesta
CONTENTS PAGE
DESCRIPTION AND OPERATION

Body (Overview)................................................................................................................. 501-00-2
General............................................................................................................................... 501-00-2
A- and B-pillar reinforcement.............................................................................................. 501-00-2
Bumpers and radiator grille................................................................................................ 501-00-3
Trailer towbar...................................................................................................................... 501-00-4
Body – Overview
General The equipment level can be chosen from the
following:
At introduction the following vehicle variants are • Ambiente (standard equipment level),
initially available: • Trend (medium equipment level),
• 3-door and • Ghia (high equipment level),
• 5-door. • Titanium (high equipment level),
• Sport (high equipment level).
A- and B-pillar reinforcement
E103380
The A- and B-pillar reinforcement is made of the

highest strength boron steel.
These sheet metal parts can only be replaced as
a complete unit during repairs and that section
repairs are not possible.
Special installation and removal requirements must
be observed during repairs. Special tools are also
required. Relevant instructions are available in the
current service literature.
2011 Fiesta 08/2010 G1071723en

Bumpers and radiator grille Item Description
1 Front bumper.
1 2 Fog lights
3 Air deflector
4 Rear bumper.
5 Rear fog lamp
6 Cover, bumper
The bumpers are painted in the body color as
standard for all vehicle variants.
3 2 The bumper cover is only available in grey.
6 5
E103394
2011 Fiesta 08/2010 G1071723en

Trailer towbar
4 3 2
E103409
Item Description Item Description

1 Module, trailer towbar 3 Hand wheel for locking ball neck
2 Towbar socket 4 Removable ball neck
At introduction, a removable towbar is made

available for the vehicle.
If the vehicle is delivered from the factory with a
towbar, then this is equipped with a 13-pin socket.
For aftermarket installation, both a variant with a
13-pin socket and also a variant with a 7 pin socket
are available in service.
The fundamental difference between the two
variants:
• The 7-pin version does not support deactivation
of the parking aid (if it is installed in the vehicle).
The trailer towbar module is connected to constant
positive at the passenger compartment fuse box
(terminal 30, fuse 23).
For the 13-pin version, the trailer towbar module
is connected with the parking aid module. As soon
as a connector is inserted into the socket, the rear
parking aid is deactivated.
2011 Fiesta 08/2010 G1071723en

501-02-1 Front End Body Panels 501-02-1
.
SECTION 501-02 Front End Body Panels

CONTENTS PAGE
REMOVAL AND INSTALLATION

Cowl Panel Grille................................................................................................................ 501-02-2
Fender Splash Shield......................................................................................................... 501-02-3
Cowl Panel Grille

General Equipment
Two Leg Puller
Removal
NOTE: Removal steps in this procedure may 1. CAUTION: Make sure that the motor is
contain installation details. in the park position.
General Equipment: Two Leg Puller
Torque: 24 Nm
x2
x6
E104229
Installation
1. CAUTION: Make sure that the motor is
in the park position.
To install, reverse the removal procedure.
2. Refer to: Windshield Wiper Blade and Pivot Arm
Adjustment (501-16 Wipers and Washers,
General Procedures).
2011 Fiesta 08/2010 G1079881en

Fender Splash Shield
Removal
NOTE: Removal steps in this procedure may 1. Refer to: Wheel and Tire (204-04 Wheels and
contain installation details. Tires, Removal and Installation).
2. If equipped.
E108080
3.
E108081
Installation
1. To install, reverse the removal procedure.
2011 Fiesta 08/2010 G1079883en

501-03-1 Body Closures 501-03-1
.
SECTION 501-03 Body Closures

CONTENTS PAGE
GENERAL PROCEDURES
Front Door Alignment.......................................................................................................... 501-03-2
Rear Door Alignment.......................................................................................................... 501-03-11
Hood Alignment.................................................................................................................. 501-03-14
Liftgate Alignment............................................................................................................... 501-03-20
501-03-2 Body Closures 501-03-2
GENERAL PROCEDURES
Front Door Alignment
Inspection
1.
+-
+-
+- +-
+-
+-
E113373
2011 Fiesta 08/2010 G1155351en

501-03-3 Body Closures 501-03-3
GENERAL PROCEDURES
Adjustment 3.
2.
E104236
4. On driver's side:
E113374
E103088
Loosen: 1 turn(s)
2011 Fiesta 08/2010 G1155351en

501-03-4 Body Closures 501-03-4
GENERAL PROCEDURES
E113376
7. On front passenger's side:

6. On front passenger's side: Loosen: 1 turn(s)
E103060
2011 Fiesta 08/2010 G1155351en

501-03-5 Body Closures 501-03-5
GENERAL PROCEDURES
E113377
8. 1. Loosen: 1 turn(s)
2. If equipped.
Loosen: 1 turn(s)
2011 Fiesta 08/2010 G1155351en

501-03-6 Body Closures 501-03-6
GENERAL PROCEDURES
1 2
E113378
10. 1. Torque: 25 Nm
9. 2. If equipped.
Torque: 12 Nm
E113379
2011 Fiesta 08/2010 G1155351en

501-03-7 Body Closures 501-03-7
GENERAL PROCEDURES
1 2
E113378

Torque: 25 Nm
2011 Fiesta 08/2010 G1155351en

501-03-8 Body Closures 501-03-8
GENERAL PROCEDURES
E113376
12. On front passenger's side:

Torque: 25 Nm
2011 Fiesta 08/2010 G1155351en

501-03-9 Body Closures 501-03-9
GENERAL PROCEDURES
E113377
Inspection Adjustment
+-
x2
E113381 E113382
2011 Fiesta 08/2010 G1155351en

501-03-10 Body Closures 501-03-10
GENERAL PROCEDURES
15.
E113383
16. Torque: 20 Nm
x2
E113382
2011 Fiesta 08/2010 G1155351en

501-03-11 Body Closures 501-03-11
GENERAL PROCEDURES
Rear Door Alignment
Inspection
17.
E112257
Adjustment
18.
2011 Fiesta 08/2010 G1155349en

501-03-12 Body Closures 501-03-12
GENERAL PROCEDURES
E105030

19. Loosen: 1 turn(s) 2. If equipped.
Loosen: 1 turn(s)
4. Torque: 25 Nm
x2 5. If equipped.
Torque: 12 Nm
3
4 1
E112259
2 5
E112260
2011 Fiesta 08/2010 G1155349en

501-03-13 Body Closures 501-03-13
GENERAL PROCEDURES
21. Torque: 25 Nm 24.
x2
E112259 E112263
Inspection 25. Torque: 20 Nm
22.
x2
+-
E112262
E112261
Adjustment
23. Loosen: 1 turn(s)
x2
E112262
2011 Fiesta 08/2010 G1155349en

501-03-14 Body Closures 501-03-14
GENERAL PROCEDURES
Hood Alignment
Check
26. 1. 3.9 mm ± 1.5 mm
2. 0.1 mm ± 1.5 mm
1 1
2 2
E117089
Adjustment 28.
x2
x2
E117090
2011 Fiesta 08/2010 G1208539en

501-03-15 Body Closures 501-03-15
GENERAL PROCEDURES
E117102
31.
x2
E117092
E117096
32. Torque: 12 Nm
30.
x2
x2
E117090
E117093
33. Check the area for paintwork damage and repair

if necessary.
2011 Fiesta 08/2010 G1208539en

501-03-16 Body Closures 501-03-16
GENERAL PROCEDURES
34. Torque: 20 Nm 35.
x2
E117096
E117102
Check
36. 1. 1 mm ± 1.5 mm
2. 4.5 mm ± 2 mm
3. 6 mm ± 1.5 mm
2011 Fiesta 08/2010 G1208539en

501-03-17 Body Closures 501-03-17
GENERAL PROCEDURES
1 1
2 2
3 3
E117094
Adjustment 38.
37. On both sides.
Loosen: 1 turn(s)
x2
E117095
2011 Fiesta 08/2010 G1208539en

501-03-18 Body Closures 501-03-18
GENERAL PROCEDURES
E117102
41.
x2
E117097
E117096
42. On both sides.

40. Torque: 25 Nm
x2
E117098 E117095
43. Check the area for paintwork damage and repair

if necessary.
2011 Fiesta 08/2010 G1208539en

501-03-19 Body Closures 501-03-19
GENERAL PROCEDURES
44. Torque: 20 Nm 45.
x2
E117096
E117102
2011 Fiesta 08/2010 G1208539en

501-03-20 Body Closures 501-03-20
GENERAL PROCEDURES
Liftgate Alignment
Check
46. 1. 2 mm ± 1.5 mm
2. 4.2 mm ± 1.5 mm
3. 6.2 mm ± 2 mm
12
2 2
E117028
Adjustment 48. Loosen: 1 turn(s)

x2 x2
E117032
E117029
2011 Fiesta 08/2010 G1208540en

501-03-21 Body Closures 501-03-21
GENERAL PROCEDURES
49. 51. Torque: 11 Nm
x2 x2
E117030 E117029
50. 52. Check the area for paintwork damage and repair
if necessary.
53. Torque: 24 Nm
E117033
E117032
Check
54. 1. 6.7 mm ± 1.5 mm
2. 2.3 mm ± 1.5 mm
2011 Fiesta 08/2010 G1208540en

501-03-22 Body Closures 501-03-22
GENERAL PROCEDURES
2 2
E117062
Adjustment 5-door
56.
3-door
55.
E105850
E107792
3-door and 5-door
57.
2011 Fiesta 08/2010 G1208540en

501-03-23 Body Closures 501-03-23
GENERAL PROCEDURES
1 1
E117035

58. On both sides.
Loosen: 1 turn(s)
E117032
E117036
60.
E117037
2011 Fiesta 08/2010 G1208540en

501-03-24 Body Closures 501-03-24
GENERAL PROCEDURES
61. 63. Torque: 24 Nm
E117034 E117032
62. On both sides. 64.

Torque: 48 Nm
E117036
3 3 2 3 3
E117038
2011 Fiesta 08/2010 G1208540en

501-03-25 Body Closures 501-03-25
GENERAL PROCEDURES
3-door
65.
E107792
5-door
66.
E105850
2011 Fiesta 08/2010 G1208540en

501-05-1 Interior Trim and Ornamentation 501-05-1
.
SECTION 501-05 Interior Trim and Ornamentation

CONTENTS PAGE

A-Pillar Trim Panel.............................................................................................................. 501-05-2
B-Pillar Trim Panel — 5-Door............................................................................................. 501-05-3
C-Pillar Trim Panel — 4-Door............................................................................................. 501-05-5
C-Pillar Trim Panel — 5-Door............................................................................................. 501-05-8
Front Door Trim Panel........................................................................................................ 501-05-10
Loadspace Trim Panel — 4-Door....................................................................................... 501-05-12
Loadspace Trim Panel — 5-Door....................................................................................... 501-05-16
Liftgate Trim Panel.............................................................................................................. 501-05-20
Rear Door Trim Panel......................................................................................................... 501-05-21
Rear Quarter Trim Panel.................................................................................................... 501-05-23
Headliner — 4-Door............................................................................................................ 501-05-25
Headliner — 5-Door............................................................................................................ 501-05-31
A-Pillar Trim Panel
Removal
1. 1. If equipped.
E105000
Installation
2011 Fiesta 08/2010 G1084530en

B-Pillar Trim Panel — 5-Door
Removal
NOTE: Removal steps in this procedure may 1.
contain installation details.
E105030
2. Torque: 40 Nm
E105031
2011 Fiesta 08/2010 G1084526en

3.
E105032
Installation
2011 Fiesta 08/2010 G1084526en

C-Pillar Trim Panel — 4-Door
Removal
NOTE: Removal steps in this procedure may 1. Torque: 45 Nm
E106840
2.
2011 Fiesta 08/2010 G1091111en

E106825
3.
E106826
2011 Fiesta 08/2010 G1091111en

Installation
2011 Fiesta 08/2010 G1091111en

C-Pillar Trim Panel — 5-Door
Removal
NOTE: Removal steps in this procedure may 1. Torque: 40 Nm
E105073
2.
2011 Fiesta 08/2010 G1084532en

E105072
Installation
2011 Fiesta 08/2010 G1084532en

Front Door Trim Panel

General Equipment General Equipment
Flat-bladed screwdriver Interior Trim Remover
TORX screwdriver
Removal
NOTE: Removal steps in this procedure may Vehicles with manual windows
3.
1. General Equipment: Flat-bladed screwdriver
General Equipment: Interior Trim Remover
E107105
E104645
Vehicles with power windows
2. 4. General Equipment: Interior Trim Remover
E104646
2011 Fiesta 08/2010 G1079890en

x2
E107268
All vehicles
5. 1. If equipped.
General Equipment: TORX screwdriver
General Equipment: Interior Trim Remover
x8
E104647
Installation
2011 Fiesta 08/2010 G1079890en

Loadspace Trim Panel — 4-Door
Removal
1.
E106791
2.
E106789
2011 Fiesta 08/2010 G1091120en

3. 4.
E105862
1
2
E106790
2011 Fiesta 08/2010 G1091120en

5.
E106792
6.
2011 Fiesta 08/2010 G1091120en

E106824
Installation
2011 Fiesta 08/2010 G1091120en

Loadspace Trim Panel — 5-Door
Removal
1.
E105850
2.
1
E105861
2011 Fiesta 08/2010 G1088491en

3. 4.
E105862
E105863
2011 Fiesta 08/2010 G1088491en

5.
E105864
6.
2011 Fiesta 08/2010 G1088491en

E106842
7.
E105865
Installation
2011 Fiesta 08/2010 G1088491en

Liftgate Trim Panel
Removal
1.
x10
E107805
E107803 Installation
2.
E107804
2011 Fiesta 08/2010 G1087640en

Rear Door Trim Panel

General Equipment
Interior Trim Remover
Removal
NOTE: Removal steps in this procedure may Vehicles with manual windows
2.
1.
E107105
E107104
3. General Equipment: Interior Trim Remover
x6
E107107
Vehicles with power windows

2011 Fiesta 08/2010 G1079891en

x6
E107106
Installation
2011 Fiesta 08/2010 G1079891en

Rear Quarter Trim Panel

General Equipment
Flat-bladed screwdriver
Removal
NOTE: Removal steps in this procedure may 1. General Equipment: Flat-bladed screwdriver
x3
E107762
2.
E107792
2011 Fiesta 08/2010 G1108886en

3. 4. Refer to: Rear Seat Backrest (501-10 Seating,
Removal and Installation).
2 5.
1
E105861
E107817
6. Torque: 40 Nm
E107800
Installation
2011 Fiesta 08/2010 G1108886en

Headliner — 4-Door
General Equipment
Removal
NOTE: Removal steps in this procedure may 5. On both sides.
1. On both sides.
Refer to: A-Pillar Trim Panel (501-05 Interior
Trim and Ornamentation, Removal and
Installation).
2. Move the front seats backwards and fully recline
the front seats backrests.
3.
E105852
4. On both sides.
E105849
Torque: 45 Nm
6. On both sides.
E105031
2011 Fiesta 08/2010 G1091112en

E106791
7. On both sides.
E106826
2011 Fiesta 08/2010 G1091112en

8. General Equipment: Flat-bladed screwdriver 9. On both sides.
E104243
E104244
2011 Fiesta 08/2010 G1091112en

10. Vehicles with roof opening panel
12. If equipped.
E107069
E106260
11.
All vehicles
13. Support the headliner.
E107070
x2
E107071
2011 Fiesta 08/2010 G1091112en

14. NOTE: This step is not necessary when 15. CAUTIONS:
installing a new component.
Take extra care not to damage the wiring
harnesses.
Take extra care not to crease the
headliner.
E107072
x2
E107073
NOTE: Note the position of each component

16. NOTE: This step is not necessary when before removal.
2011 Fiesta 08/2010 G1091112en

x2
E107074
Installation
1. NOTE: Make sure that these components are
installed to the noted removal position.
Using a suitable adhesive, bond the roof wiring
harness to the headliner.
2011 Fiesta 08/2010 G1091112en

Headliner — 5-Door
Removal
contain installation details. Torque: 40 Nm
1. On both sides.
Installation).
2.
E105031
5. On both sides.
E105852
3.
E104301
E105849
6. On both sides.
2011 Fiesta 08/2010 G1084522en

E105850
8. On both sides.
7.
E104243
2011 Fiesta 08/2010 G1084522en

E104244
10. If equipped.
9. If equipped.
1
1 2
2
E65693
E65692
11. If equipped.
E74631
2011 Fiesta 08/2010 G1084522en

12. If equipped. 14.
E111888 E105853
13. If equipped. 15.
E111936
x2
E105851
2011 Fiesta 08/2010 G1084522en

16. NOTE: This step is only necessary when 17. NOTE: This step is only necessary when
installing a new component. installing a new component.
NOTE: Note the position of each component
before removal.
E106259
2011 Fiesta 08/2010 G1084522en

x2
E106261
Installation
1. NOTE: Make sure that the components are
installed to the position noted before removal.
To install, reverse the removal procedure.
2011 Fiesta 08/2010 G1084522en

501-08-1 Exterior Trim and Ornamentation 501-08-1
.
SECTION 501-08 Exterior Trim and Ornamentation

CONTENTS PAGE

Exterior Trim (Component Location)................................................................................... 501-08-2
Exterior Trim (System Operation and Component Description)......................................... 501-08-3
System Operation............................................................................................................... 501-08-3
Component Description...................................................................................................... 501-08-3
Windshield strip............................................................................................................... 501-08-3
Roof strip......................................................................................................................... 501-08-3
Trim strip - front door window......................................................................................... 501-08-3
Sticker - front door window............................................................................................. 501-08-3
Trim strip - rear door window.......................................................................................... 501-08-4
Sticker - rear door window.............................................................................................. 501-08-4
Trim strip - rear side window (4-door)............................................................................. 501-08-4
Trim strip - rear side window (5-door)............................................................................. 501-08-4
Lettering - luggage compartment lid (4-door)................................................................. 501-08-4
Lettering - tailgate (5-door)............................................................................................. 501-08-5
Emblem - luggage compartment lid (4-door).................................................................. 501-08-5
Emblem - tailgate (5-door).............................................................................................. 501-08-5
Trim strip - luggage compartment lid (4-door)................................................................. 501-08-5
Trim strip - tailgate (5-door)............................................................................................ 501-08-6
Variant sign - luggage compartment lid (4-door)............................................................. 501-08-6
Variant sign - tailgate (5-door)......................................................................................... 501-08-6
S-sign - luggage compartment lid (4-door)..................................................................... 501-08-7
S-sign - tailgate (5-door)................................................................................................. 501-08-7

Rear Spoiler........................................................................................................................ 501-08-8
Exterior Trim – Component Location
1 2 3 2 1 3 8
7 9
4 5 6 10
11
7 10
4 5 6
11
E108231

1 Windshield strip 8 Lettering - tailgate / luggage compartment
lid
2 Sticker - front door window
9 Emblem - tailgate / luggage compartment
3 Roof strip lid
4 Trim strip - front door window 10 Trim strip - tailgate / luggage compartment
5 Trim strip - rear door window lid
6 Trim strip, rear side window 11 Variant signs - tailgate / luggage

compartment lid
7 Sticker - rear door window
2011 Fiesta 08/2010 G1109832en

Exterior Trim – System Operation and Component Description

System Operation A new trim strip will need to be fitted after the old
one has been removed.
Depending on the way in which they are attached,
the components can either be reused or need to
be replaced. Trim strip - front door window
Components which are attached with adhesive
take should be detached with a plastic wedge.
Component Description
Windshield strip
1 E106467
The trim strip is a push-fit.

The trim strip can be reused after it has been
2 removed.
Sticker - front door window

E106466
The trim strip comes in two parts. Part 1 is inserted

in part 2 and can be pulled out to the top.
Part 2 is glued and only becomes accessible once
the windshield has been removed.
Both parts will need to be replaced with new ones
after the old ones have been removed.
Roof strip
E112470
The sticker comes in two parts and a new one will

need to be fitted after the old one has been
removed.
E108232
The trim strip is glued.
2011 Fiesta 08/2010 G1109833en

Trim strip - rear door window A new trim strip will need to be fitted after the old
Trim strip - rear side window (5-door)
E106465

The trim strip can be reused after it has been
E106463
removed.
The strip is secured with adhesive tape.
Sticker - rear door window A new trim strip will need to be fitted after the old
Lettering - luggage compartment lid

(4-door)
65 mm
E112471
The sticker comes in two parts and a new one will

need to be fitted after the old one has been
removed.
E108234
Trim strip - rear side window (4-door) The lettering is retained with adhesive tape.
A new replacement will needed after the old one
has been removed.
The lettering must be horizontally centered.
E108233
The trim strip is glued.
2011 Fiesta 08/2010 G1109833en

Lettering - tailgate (5-door) A new one will need to be fitted after the old one
has been removed.
Emblem - tailgate (5-door)
50 mm
E106473
The emblem is secured with adhesive tape.

A new one will need to be fitted after the old one
has been removed.
27 mm
Trim strip - luggage compartment lid

(4-door)
E108235
There are different positions on the vehicle

depending on the vehicle specification. Before
replacing, determine the dimensions from this or
a similar vehicle and fit accordingly.
The lettering is retained with adhesive tape.
A new replacement will needed after the old one
has been removed.
The lettering must be horizontally centered.
E108237
Emblem - luggage compartment lid (4-door) The trim strip is a push-fit.

It can be re-used after removal.
E108236
The emblem is secured with adhesive tape.
2011 Fiesta 08/2010 G1109833en

Trim strip - tailgate (5-door) A new one will need to be fitted after the old one
has been removed.
The variant sign must be horizontally centered.
Variant sign - tailgate (5-door)
E106474
50 mm
It can be re-used after removal.
Variant sign - luggage compartment lid

(4-door)
84 mm
65 mm
36 mm
E108239
There are different variant signs and positions on

the vehicle depending on the vehicle specification.
Before replacing, determine the dimensions from
this or a similar vehicle and fit accordingly.
The sign is secured with adhesive tape.
has been removed.
65 mm
The variant sign must be horizontally centered.
E108238
There are different variant signs and positions on

the vehicle depending on the vehicle specification.
Before replacing, determine the dimensions from
this or a similar vehicle and fit accordingly.
2011 Fiesta 08/2010 G1109833en

S-sign - luggage compartment lid (4-door) A new one will need to be fitted after the old one
has been removed.
5 mm
60 mm
E108625

has been removed.
S-sign - tailgate (5-door)

10 mm
20 m
m
93 mm
26
mm
E108626
There are different positions on the vehicle

depending on the vehicle specification. Before
replacing, determine the dimensions from this or
a similar vehicle and fit accordingly.
2011 Fiesta 08/2010 G1109833en

Rear Spoiler
Removal
E107708
2.
2011 Fiesta 08/2010 G1079904en

x2
x4
E107709
Installation
2011 Fiesta 08/2010 G1079904en

501-09-1 Rear View Mirrors 501-09-1
.
SECTION 501-09 Rear View Mirrors

CONTENTS PAGE
DIAGNOSIS AND TESTING

Rear View Mirrors............................................................................................................... 501-09-2
Inspection and Verification.................................................................................................. 501-09-2
Rear View Mirrors — Vehicles With: Double Locking......................................................... 501-09-4

Exterior Mirror..................................................................................................................... 501-09-5
Rear View Mirrors

Refer to Wiring Diagrams Section 501-09, for
Visual Inspection Chart
schematic and connector information.
Mechanical Electrical
Inspection and Verification • Exterior mirror(s) • Fuse(s)

• Loose or corroded
1. Verify the customer concern. connector(s)
2. Visually inspect for obvious signs of mechanical • Switch
and 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 cause is not visually evident, verify the
symptom and refer to the Symptom Chart.
Symptom Possible Sources Action
• The exterior mirrors are inoper- • Exterior mirror control switch • CARRY OUT the Exterior
ative Mirror Control Switch
Component Test. REFER to the
Wiring Diagrams.
• Circuit(s). • REFER to the wiring diagrams.
• A single exterior mirror is inop- • Exterior mirror control switch. • CARRY OUT the Exterior
erative Mirror Control Switch
Wiring Diagrams.
• Exterior mirror motor(s). • REFER to the wiring diagrams.
• Circuit(s).
• A single exterior mirror does • Exterior mirror control switch. • CARRY OUT the Exterior
not function with switch logic Mirror Control Switch
Wiring Diagrams.
• Exterior mirror motor(s). • REFER to the wiring diagrams.
• Circuit(s).
• The heated exterior mirror is • Heated rear window control • CARRY OUT the Heated Rear
inoperative switch. Window Control Switch
Wiring Diagrams.
• Heated rear window relay. • REFER to the wiring diagrams.
• Heated exterior mirror
element(s).
• Circuit(s).
• The power folding mirrors do • Generic electronic module • CARRY OUT the GEM Self-
not operate (GEM). Test.
REFER to: Generic Electronic
Module (GEM) (419-10 Multi-
function Electronic Modules,
Diagnosis and Testing).
2011 Fiesta 08/2010 G1055876en

• Exterior mirror control switch. • CARRY OUT the Exterior
Mirror Control Switch
Wiring Diagrams.
• The power folding mirrors do • Generic electronic module • CARRY OUT the GEM Self-
not operate correctly (GEM). Test.
• Exterior mirror control switch. • CARRY OUT the Exterior
Mirror Control Switch
Wiring Diagrams.
• Power fold mirror motor(s). • REFER to the wiring diagrams.
• Circuit(s).
symptom and refer to the Ford approved
diagnostic tool to diagnose the system.
2011 Fiesta 08/2010 G1055876en

Rear View Mirrors — Vehicles With: Double Locking

General Equipment
Ford diagnostic equipment
Inspection and Verification

1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical
• Exterior mirror(s) • Fuse(s)
• Relay
• Electrical
connector(s)
• Switch
• Generic electronic
module (GEM)

symptom and refer to the diagnostic tab within
the Ford diagnostic equipment.
2011 Fiesta 08/2010 G1055881en

Exterior Mirror
Removal
NOTE: Removal steps in this procedure may 1. Refer to: Front Door Trim Panel (501-05 Interior
contain installation details. Trim and Ornamentation, Removal and
Installation).
2.
E104706
3. Torque: 13 Nm
E104707
Installation
2011 Fiesta 08/2010 G1079907en

501-10-1 Seating 501-10-1
.
SECTION 501-10 Seating

CONTENTS PAGE

Seats (Overview)................................................................................................................ 501-10-2
Overview of components.................................................................................................... 501-10-2
Manually adjustable lumbar supports................................................................................. 501-10-3
Seat occupancy sensor, passenger side............................................................................ 501-10-3
Front seat cushion heating mat.......................................................................................... 501-10-3

Seats................................................................................................................................... 501-10-4

Front Seat....................................................................................................... (40 100 0;
40 100 4;
40 101 0) 501-10-5
Front Seat Cushion Cover.............................................................................. (40 105 0) 501-10-7
Front Seat Cushion Heater Mat...................................................................... (33 401 0;
33 401 4) 501-10-10
Front Seat Cushion......................................................................................... (40 104 0) 501-10-11
Front Seat Backrest Cover............................................................................. (40 108 0) 501-10-12
Rear Seat Cushion............................................................................................................. 501-10-16
Rear Seat Backrest............................................................................................................. 501-10-17
Rear Seat Backrest Latch................................................................................................... 501-10-18
Seat Occupant Sensor........................................................................................................ 501-10-21
DISASSEMBLY AND ASSEMBLY

Front Seat Backrest............................................................................................................ 501-10-22
Rear Seat Cushion............................................................................................................. 501-10-28
Rear Seat Backrest............................................................................................................. 501-10-30
501-10-2 Seating 501-10-2
Seats – Overview
Overview of components
12
5
1
11
7
2
9 10
E101994

1 Backrest trim cover 8 Seat occupancy sensor, passenger side
2 Front seat cushion cover 9 Front seat cushion heating mat
3 Seat frame 10 Seat height adjustment lever
4 Head restraint adjustment. 11 Side airbag
5 Head restraint guide Refer to: Air Bag and Safety Belt
Pretensioner Supplemental Restraint
6 Manually adjustable lumbar supports System (SRS) (501-20 Supplemental
7 Front belt buckle Restraint System, Description and
Operation).
Refer to: Safety Belt System (501-20 ,
Safety Belt System, Description and
Operation). 12 Folding backrest lever
2011 Fiesta 08/2010 G1063149en

501-10-3 Seating 501-10-3
Manually adjustable lumbar supports Front seat cushion heating mat
2
E102002
The manually adjustable lumbar support is adjusted

using a hand-wheel on the side of the backrest The
hand-wheel is connected with a cable to a flexible
plate mounted behind the backrest squab. As the
hand-wheel rotates, the plate is distorted and is E102004
forced to bow toward or away from the seat squab.
The manual adjustment system means the lumbar Item Description
support can be adjusted with a great deal of 1 Front seat cushion heating mat
accuracy.
2 Seat heating module
Seat occupancy sensor, passenger side The following components can be replaced
separately or as a unit:
• Front seat cushion heating mat
• Seat heating module
E102003
Pay attention to the following when removing,

installing or renewing the passenger side
occupancy sensor:
• The seat occupancy sensor is glued to the seat
cushion. It is available as an individual spare
part and can be renewed separately.
2011 Fiesta 08/2010 G1063149en

501-10-4 Seating 501-10-4
Seats
General Equipment

• Switch • Fuse
• Wiring harness
• Electrical
Connector(s)
• Switch

symptom and refer to the Ford diagnostic
equipment to diagnose the system.
2011 Fiesta 08/2010 G1055885en

501-10-5 Seating 501-10-5
Front Seat(40 100 0; 40 100 4; 40 101 0)

4.
Removal
WARNINGS:
The supplemental restraint system (SRS)
is active for a certain length of time after
the power supply has been disconnected.
Wait for a minimum of 3 minutes before
disconnecting or removing any SRS
components.
Make sure that the vehicle electrical
system is fully depowered and no other E97535
power source is connected.

Wear safety goggles. 5.
NOTE: Removal steps in this procedure may

1. Refer to: Supplemental Restraint System (SRS)
Health and Safety Precautions (100-00
General Information, Description and
Operation).
2. Refer to: Battery Disconnect and Connect
(414-01 Battery, Mounting and Cables,
3.
1 1
2
E104300
E86253
Installation
1. Torque: 35 Nm
2011 Fiesta 08/2010 G1063151en

501-10-6 Seating 501-10-6
4 3
3 4
2 1 1 2
E120934
2011 Fiesta 08/2010 G1063151en

501-10-7 Seating 501-10-7
Front Seat Cushion Cover(40 105 0)

General Equipment 3.
Hog Ring Plier
Removal
1. Refer to: Front Seat (501-10 Seating, Removal
and Installation).
2. If equipped.
E103718
4.
E103717
2011 Fiesta 08/2010 G1082648en

501-10-8 Seating 501-10-8
x2
x2
E103719
5. 4. If equipped.
2 4
3
E102236
2011 Fiesta 08/2010 G1082648en

501-10-9 Seating 501-10-9
Installation
2. General Equipment: Hog Ring Plier
V4001063
2011 Fiesta 08/2010 G1082648en

501-10-10 Seating 501-10-10
Front Seat Cushion Heater Mat(33 401 0; 33 401 4)

Installation
Removal
1. 1. NOTE: This step is only necessary when
1. Refer to: Front Seat Cushion Cover (501-10 installing a new component.
Seating, Removal and Installation). NOTE: Make sure that these components
2. CAUTION: Touching the adhesive are installed to the noted removal position.
surface will impair rebonding.
NOTE: Note the position of the component
before removal. 1
E107546
2
E107545
2. Refer to: Front Seat Cushion Cover (501-10

Seating, Removal and Installation).
2011 Fiesta 08/2010 G1082654en

501-10-11 Seating 501-10-11
Front Seat Cushion(40 104 0)
Removal
2. If equipped.
Refer to: Front Seat Cushion Heater Mat
(501-10 Seating, Removal and Installation).
3. If equipped.
Refer to: Seat Occupant Sensor (501-10
Installation
2011 Fiesta 08/2010 G1082651en

501-10-12 Seating 501-10-12
Front Seat Backrest Cover(40 108 0)

General Equipment 3. General Equipment: Flat-bladed screwdriver
Hog Ring Plier
Removal
and Installation).
2.
1 1
2
2
E104810
E104698
2 2
1 1
E104928
2011 Fiesta 08/2010 G1082652en

501-10-13 Seating 501-10-13
5. If eqipped. 8.
E104817
6.
E104696
9.
E103718
7.
E104697
E104304
2011 Fiesta 08/2010 G1082652en

501-10-14 Seating 501-10-14
10. 11.
E105700
2 2
x3
E100401
Installation
2. NOTE: This step is only necessary when
NOTE: Use the original seat backrest cover as
a template.
2011 Fiesta 08/2010 G1082652en

501-10-15 Seating 501-10-15
V4001063
2011 Fiesta 08/2010 G1082652en

501-10-16 Seating 501-10-16
Rear Seat Cushion
Removal
1.
1
E105861
Installation
2011 Fiesta 08/2010 G1063152en

501-10-17 Seating 501-10-17
Rear Seat Backrest

General Equipment
Removal
NOTE: Removal steps in this procedure may Installation
1. Torque: 40 Nm
x2
E105751
2
1
E105752
E105753
2011 Fiesta 08/2010 G1063153en

501-10-18 Seating 501-10-18
Rear Seat Backrest Latch

General Equipment
Removal
1. Refer to: Rear Seat Cushion (501-10 Seating,
2. Torque: 40 Nm
x2
E105751
E99780
2011 Fiesta 08/2010 G1063154en

501-10-19 Seating 501-10-19
2 2
E95294

Torque: 23 Nm
2011 Fiesta 08/2010 G1063154en

501-10-20 Seating 501-10-20
x2
3
E88968
Installation
2011 Fiesta 08/2010 G1063154en

501-10-21 Seating 501-10-21
Seat Occupant Sensor
Removal

2. If equipped.
Refer to: Front Seat Cushion Heater Mat
(501-10 Seating, Removal and Installation).
3.
E120769
Installation
2011 Fiesta 08/2010 G1225895en

501-10-22 Seating 501-10-22
Front Seat Backrest
Disassembly
NOTE: Removal steps in this procedure may 3. 1. If equipped.
contain installation details. 2. If equipped.
1. Refer to: Front Seat Backrest Cover (501-10
2.
E102619
2011 Fiesta 08/2010 G1090218en

501-10-23 Seating 501-10-23
2 3
1 4
E107381
5. NOTE: Note the position of the electrical

4. connectors.
E106230
2011 Fiesta 08/2010 G1090218en

501-10-24 Seating 501-10-24
E107387
7. If equipped.
6. Torque: 6 Nm Torque: 3 Nm
E100044
E106989
2011 Fiesta 08/2010 G1090218en

501-10-25 Seating 501-10-25
8. If equipped. 9. If equipped.
E106990
E106991
2011 Fiesta 08/2010 G1090218en

501-10-26 Seating 501-10-26
3-door
10.
E107591
11.
2
2
E106244
2011 Fiesta 08/2010 G1090218en

501-10-27 Seating 501-10-27
All vehicles
12. Torque: 35 Nm
x4
E107592
Assembly
2011 Fiesta 08/2010 G1090218en

501-10-28 Seating 501-10-28
Rear Seat Cushion

General Equipment
Hog Ring Plier
Disassembly
1. Refer to: Rear Seat Cushion (501-10 Seating,

2.
0
x1
x2
x2
E107640
3.
2011 Fiesta 08/2010 G1090219en

501-10-29 Seating 501-10-29
x20
E105755
Assembly
V4001063
2011 Fiesta 08/2010 G1090219en

501-10-30 Seating 501-10-30
Rear Seat Backrest

Flat-bladed screwdriver Hog Ring Plier
Webbing Retainer
Disassembly
NOTE: Removal steps in this procedure may 1. Refer to: Rear Seat Backrest (501-10 Seating,
contain installation details. Removal and Installation).
E107692
2011 Fiesta 08/2010 G1090220en

501-10-31 Seating 501-10-31
E107693
2011 Fiesta 08/2010 G1090220en

501-10-32 Seating 501-10-32
4. NOTE: If the safety belt webbing retracts further 5. Torque: 35 Nm
than the safety belt webbing stop, a new safety
belt retractor must be installed.
General Equipment: Webbing Retainer
mm 2
1
E105814
200
6. Torque: 35 Nm
E105815
E51474 7.
2011 Fiesta 08/2010 G1090220en

501-10-33 Seating 501-10-33
1 2
E105816
8.
1 2
E105817
2011 Fiesta 08/2010 G1090220en

501-10-34 Seating 501-10-34
9. 1. Torque: 23 Nm 3. Torque: 40 Nm
2. Torque: 23 Nm
2
3 1
x2
x2
E108814
Assembly
V4001063
2011 Fiesta 08/2010 G1090220en

501-11-1 Glass, Frames and Mechanisms 501-11-1
.
SECTION 501-11 Glass, Frames and Mechanisms

CONTENTS PAGE

Glass, Frames and Mechanisms (Overview)...................................................................... 501-11-2
Driver's door switch unit...................................................................................................... 501-11-2
Switches - passenger door and rear doors ........................................................................ 501-11-2
Window regulator motors.................................................................................................... 501-11-3
Service instructions......................................................................................................... 501-11-3
Diagnostic Information.................................................................................................... 501-11-3

Glass, Frames and Mechanisms........................................................................................ 501-11-4
Component Tests................................................................................................................ 501-11-5
Glass, Frames and Mechanisms — Vehicles With: Double Locking.................................. 501-11-7
Component Tests................................................................................................................ 501-11-7

Front Door Window Glass................................................................................................... 501-11-8
Rear Door Window Glass................................................................................................... 501-11-12
Liftgate Window Glass........................................................................................................ 501-11-14
Rear Quarter Window Glass............................................................................................... 501-11-17
Rear Window Glass............................................................................................................ 501-11-28
Front Door Window Regulator Motor.................................................................................. 501-11-35
Rear Door Window Regulator Motor.................................................................................. 501-11-36
Front Door Window Regulator............................................................................................ 501-11-37
Rear Door Window Regulator............................................................................................. 501-11-41
Windshield Glass................................................................................................................ 501-11-45
Glass, Frames and Mechanisms – Overview

The function is based on that of the Fiesta 2002.25. • Two 4-way switch units:
The main difference is the adoption of automatic – one for LHD (left-hand drive),
operation with anti-trap protection on the driver – one for RHD (right-hand drive).
side. To do this, the switch for the driver's door • Four 2-way switch units:
window on the driver's door switch unit is designed
– one for LHD with three doors,
as a two-stage switch.
– one for LHD with five doors,
In addition, the window regulator motor on the
– one for RHD with three doors,
driver's door is provided with two Hall sensors. The
Hall sensors detect the speed of the window – one for RHD with five doors.
regulator motor and therefore recognize any Because of the shape of the components, it is not
obstruction as the window rises. possible to mix up the switch units for LHD and
RHD vehicles.
Driver's door switch unit NOTE:
• The 2-way switch units for the 3-door and the
5-door variants are identical on the outside.
A They must not however be mixed up as the
software in the switch unit is matched to the
particular type of window and frame. The part
number suffix is used to determine which switch
unit is correct for the vehicle.
Switches - passenger door and rear

1
doors
E102753
These doors are equipped with a simple switch for

E102752 the window regulator motors.
This switch only has a simple up and down function
Item Description (no anti-trap protection).
A 4-way switch unit Note:The window regulator motors in the rear
B 2-way switch unit doors can be deactivated using the disable switch
in the driver's door switch unit.
1 Rear window disable switch
In total there are six driver door switch units
available:
2011 Fiesta 08/2010 G1071724en

Window regulator motors Diagnostic Information
The switch unit and the window regulator motors

are not connected to the communication network.
The system cannot therefore be diagnosed using
2 the DLC (data link connector).
Instructions if there is a operating concern with
the driver's door window regulator motor:
1
• After the window regulator motors have been
deactivated, they continue to turn for a short
time. During "Ignition ON" the switch unit detects
5
the run-on phase via the Hall sensors.
• If however the ignition is switched off while the
driver's door window regulator motor is
operating, the power supply of the Hall sensors
is immediately interrupted. The run-on phase
3 of the window regulator motor then can no
4
longer be detected.
E102755
• In order to maintain the power supply for this
situation, the driver's door switch unit is
Item Description
protected by an additional fuse F26 (in the
1 Rear left-hand door window regulator engine compartment fuse box).
motor • If the fuse fails the driver's door window
2 Window regulator motor, driver's side regulator motor will no longer operate.
3 Window regulator motor, passenger's side Instruction if there is a malfunction of both front
window regulator motors:
4 Rear right-hand door window regulator
• Both window regulator motors are protected in
motor
common by fuse F25 (passenger compartment
5 Driver's door switch unit fuse box).
NOTE: If a window regulator is operated at the Instruction if there is a malfunction of both rear
same time from the driver's door switch unit and window regulator motors:
from the respective simple switch, the relevant • Both window regulator motors are protected in
window stops immediately. common by fuse F31 (passenger compartment
Each window regulator motor can be controlled fuse box).
from the driver's door switch unit.
In addition, the motors for the passenger's door
and the rear doors (when equipped) can be
controlled using the corresponding simple switches
on the doors.
Service instructions
After the battery has been disconnected or the

driver's door switch unit has been changed, the
window regulator motor in the driver's door must
be reprogrammed (see current service literature).
2011 Fiesta 08/2010 G1071724en

Glass, Frames and Mechanisms

Inspection and Verification • Window seal • Fuse(s)

• Door window frame • Electrical
1. Verify the customer concern. connector(s)
2. Visually inspect for obvious signs of mechanical • Switch(es)
or electrical damage. • Circuit(s)

symptom and refer to the Symptom Chart.
Symptom Chart
• All power windows are inoper- • Driver power window control • CARRY OUT the Driver Power
ative switch. Window Control Switch
Component Test in this
procedure.
• A single power window is inop- • Driver power window control • CARRY OUT the Driver Power
erative - driver side switch. Window Control Switch
procedure.
• Power window motor. • REFER to the wiring diagrams.
• Circuit(s).
• A single power window is inop- • Driver power window control • CARRY OUT the Driver Power
erative - passenger side switch. Window Control Switch
procedure.
• Passenger power window • CARRY OUT the Passenger
control switch. Power Window Control Switch
procedure.
• Power window motor. • REFER to the wiring diagrams.
• Circuit(s).
• The one-touch down window is • Driver power window control • CARRY OUT the Driver Power
inoperative switch. Window Control Switch
procedure.
• The defrost system is inoper- • Heated rear window control • CARRY OUT the Heated Rear
ative switch. Window Control Switch
procedure.
2011 Fiesta 08/2010 G1055889en

• Heated windshield control • CARRY OUT the Heated
switch. Windshield Control Switch
procedure.
• Rear Window Heater Relay. • CARRY OUT the Rear Window
Heater Relay Component Test
in this procedure.
• Generic electronic module • CARRY OUT the Generic
(GEM). Electronic Module Self-Test.
• Heated rear window grid wire. • CARRY OUT the Heated Rear
Window Grid Wire Component
Test in this procedure.
• Heated windshield grid wire. • REFER to the wiring diagrams.
• Circuit(s).
• The defrost system will not shut • Heated rear window control • CARRY OUT the Heated Rear
off automatically switch. Window Control Switch
procedure.
• Heated windshield control • CARRY OUT the Heated
switch. Windshield Control Switch
procedure.
• Rear Window Heater Relay. • CARRY OUT the Rear Window
Heater Relay Component Test
in this procedure.
• Generic electronic module • CARRY OUT the Generic
(GEM). Electronic Module Self-Test.
Component Tests 4. If the resistances are not as specified, INSTALL

a new heated rear window switch.
Heated Rear Window Switch

Rear Window Heater Relay
1. Remove the heated rear window switch.
2. Measure the resistance between pins 1 and 2 1. Remove the heated rear window relay.
of the switch while operating the switch. 2. Using a jumper wire, connect one end to
3. The resistance should be less than 5 ohms terminal 1 of the relay. Connect the other end
when the switch is in the ON position and to ground.
greater than 10,000 ohms when in the OFF 3. Using a second jumper wire, connect one end
position. to terminal 2 of the relay.
2011 Fiesta 08/2010 G1055889en

4. Connect one lead of an ohmmeter to terminal
3 of the relay. Connect second lead to terminal
5 of the relay. Observe the resistance.
5. Momentarily tap the unconnected end of the
second jumper wire to the battery power. An
audible click should be heard and the resistance
on the ohmmeter should drop to zero.
6. If the relay does not click and the resistance
does not drop to zero, INSTALL a new relay.
Heated Rear Window Grid Wire Test
1. Using a bright lamp inside the vehicle, visually

inspect the wire grid from the outside. A broken
grid conductor will appear as a brown spot.
2. Start the engine and set the heated rear window
switch to ON, the indicator light should
illuminate.
3. Work inside the vehicle with a 12 volt DC
voltmeter. Contact the broad red-brown strips
on the rear window, positive lead to the battery
side and the negative lead to ground side. The
meter reading should be 10-12 volts. A lower
voltage reading indicates a loose heated rear
window ground wire connection at the heated
rear window ground wire screws.
4. Contact a ground point with the negative lead
of the meter. The voltage reading should not
change.
5. With the negative lead of the meter grounded,
touch each grid line of the heated rear window
at its midpoint with the positive meter lead. A
reading of approximately six volts indicates that
the line is good. A reading of zero volts indicates
that the line is broken between the midpoint and
the B+ 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 using the
procedures as described under the general
procedures if necessary.
2011 Fiesta 08/2010 G1055889en

Glass, Frames and Mechanisms — Vehicles With: Double Locking

Refer to Wiring Diagrams Section 501-11, for A multimeter voltage reading of between 10-13
schematic and connector information. volts is expected. A lower voltage reading
General Equipment indicates a loose liftgate window glass heated
grid ground wire connection at the liftgate
The Ford diagnostic equipment
window glass heated grid ground screw.
5. With the negative lead of the multimeter
Inspection and Verification grounded, touch each liftgate window glass
heated grid wire at its midpoint with the positive
1. Verify the customer concern. lead. The multimeter should show a voltage
2. Visually inspect for obvious signs of mechanical reading of approximately six volts indicating that
or electrical damage. the liftgate window glass heated grid wire is OK.
A multimeter voltage reading of zero volts
Visual Inspection Chart indicates that the liftgate window glass heated
Mechanical Electrical grid wire is broken between the midpoint and
the battery side of the liftgate window glass
• Door window seal • Fuse(s) heated grid wire. A multimeter voltage reading
• Door window frame • Electrical of 12 volts indicates that the liftgate window
connector(s) glass heated grid wire is broken between the
• Switch(es) midpoint of the liftgate window glass heated grid
wire and ground.
• Window regulator
motor 6. INSTALL a new liftgate window glass (as
required).
• Circuit(s)
REFER to: Liftgate Window Glass (501-11
Glass, Frames and Mechanisms, Removal
and Installation).
Component Tests
Liftgate Window Glass Heated Grid Wire

Test
1. Using a bright lamp inside the vehicle, visually

inspect the liftgate window glass heated grid
wire from the outside of the vehicle. A broken
liftgate window glass heated grid wire will
appear as a brown spot at the break point.
2. Run the engine at idle.
3. Set the heated liftgate window glass control
switch and the headlamp switch to ON. The
heated liftgate window glass control switch
should be illuminated.
4. Working inside the vehicle with a multimeter,
contact the multimeter positive lead to the
liftgate window glass heated grid supply side
and contact the multimeter negative lead to the
liftgate window glass heated grid ground side.
2011 Fiesta 08/2010 G1055891en

Front Door Window Glass

General Equipment
Removal
NOTE: Removal steps in this procedure may 3-door
3.
1. Refer to: Front Door Trim Panel (501-05 Interior
Installation).
2.
x3
E106771
4.
E106266
E106772
2011 Fiesta 08/2010 G1079939en

x2
2
1
1
E106770
2011 Fiesta 08/2010 G1079939en

5-door
6.
E106262
7. Torque: 7 Nm
E106263
2011 Fiesta 08/2010 G1079939en

All vehicles
8.
E106267
Installation
2011 Fiesta 08/2010 G1079939en

Rear Door Window Glass
Removal
1. Refer to: Rear Door Trim Panel (501-05 Interior
Installation).
2.
E107457
5.
E107456
3.
x2
E107458
6. Torque: 7 Nm
E107454
2011 Fiesta 08/2010 G1079940en

x2
x2
E107459
Installation
2011 Fiesta 08/2010 G1079940en

Liftgate Window Glass

General Equipment
Materials
Direct Glazing Removal/Replacement Equipment
Name Specification
Hot Air Gun
Windshield Adhesive Kit WSS-M11P57-A5
Knife
General Equipment
Laminated Card
Adhesive Tape
Removal
5.
1. Refer to: Window Glass Health and Safety
Precautions (100-00 General Information,
Description and Operation). CAUTION: Make sure that the cutting
2. Remove the polyurethane (PU) adhesive cap blades are changed where the cutting
and heat the PU adhesive for a minimum of 30 depth changes.
minutes. Use laminated card to prevent paint damages.
Material: Windshield Adhesive Kit General Equipment: Direct Glazing
(WSS-M11P57-A5) Removal/Replacement Equipment
General Equipment: Laminated Card
TIE0022871
3. Refer to: Rear Spoiler (501-08 Exterior Trim and

Ornamentation, Removal and Installation). x2
Refer to: Rear Window Wiper Motor (501-16
Wipers and Washers, Removal and
Installation). E107840
4. On both sides.
Installation
1. NOTE: Minimum 1 mm bead thickness.
NOTE: Make sure that the mating faces are
clean and free of foreign material.
E107936
2011 Fiesta 08/2010 G1079941en

NOTE: Touching the adhesive surface will NOTE: Make sure that any breakage in the
impair rebonding. continuous bead of adhesive is overlapped by
20 mm.
General Equipment: Knife
General Equipment: Hot Air Gun General Equipment: Direct Glazing
Removal/Replacement Equipment
Material: Windshield Adhesive Kit
(WSS-M11P57-A5)
8 - 10mm
E107843
E107842 4. CAUTION: During the curing time of the

polyurethane (PU) adhesive, the door
windows must be left open.
2. NOTE: This step is only necessary if the original
component is to be reused. General Equipment: Adhesive Tape
NOTE: Minimum 1 mm bead thickness.

NOTE: Touching the adhesive surface will
impair rebonding.
General Equipment: Hot Air Gun
x2
E107841
E107844
3. NOTE: Discard the first 100 mm of adhesive as

this may have a reduced working time.
2011 Fiesta 08/2010 G1079941en

5. On both sides.
E107936
6. Refer to: Rear Window Wiper Motor (501-16

Wipers and Washers, Removal and
Installation).
Refer to: Rear Spoiler (501-08 Exterior Trim and
Ornamentation, Removal and Installation).
2011 Fiesta 08/2010 G1079941en

Rear Quarter Window Glass

General Equipment
Materials
Adhesive Tape
Name Specification
Windscreen Adhesive WSK-M11P57-A3 /
Kit - 1 Component 7U7J-T03863-AA Knife
Windshield Adhesive Kit WSS-M11P57-A5 Laminated Card
Removal
2. 1. Material: Windshield Adhesive Kit
1. CAUTION: (WSS-M11P57-A5)
Refer to: Window Glass Health and Safety 2. Remove the polyurethane (PU) adhesive cap
Precautions (100-00 General Information, and heat the 2K-PU adhesive for a minimum
Description and Operation). of 30 minutes.
General Equipment: Direct Glazing
3. Repairs under warranty:
Material: Windscreen Adhesive Kit - 1
Component (WSK-M11P57-A3 /
7U7J-T03863-AA)
TIE0022871
3-door
3. General Equipment: Adhesive Tape
2011 Fiesta 08/2010 G1226512en

E119627
NOTE: Some resistance may be encountered

4. WARNING: Make sure that the
when cutting through the glass locating spacers.
component paintwork is not damaged.
2011 Fiesta 08/2010 G1226512en

x2
E119626
5-door
5.
2011 Fiesta 08/2010 G1226512en

E105072
6. General Equipment: Adhesive Tape
E119654
2011 Fiesta 08/2010 G1226512en

7. WARNING: Make sure that the NOTE: Some resistance may be encountered
component paintwork is not damaged. when cutting through the glass locating spacers.
x2
E119652
2011 Fiesta 08/2010 G1226512en

Installation
1. 1. NOTE: Minimum 1 mm bead thickness.
2. NOTE: Make sure that the mating faces are
3. NOTE: Touching the adhesive surface will
impair rebonding.
Prepare the rear quarter window glass, rear
quarter window glass flange and trimmed PU 1 2
E114059
adhesive in accordance with the instructions
supplied with the glass adhesive kit.
3-door
2. Apply the activator/ primer in accordance with
the instructions supplied with the glass adhesive
kit.
E119628
2011 Fiesta 08/2010 G1226512en

3. Apply the activator/ primer in accordance with NOTE: Make sure that any breakage in the
the instructions supplied with the glass adhesive continuous bead of adhesive is overlapped by
kit. 20 mm.
(WSS-M11P57-A5)
7U7J-T03863-AA)
E119650

E119651
5. • Press firmly and evenly into position.

• CAUTION: During the curing time of
the polyurethane (PU) adhesive, the
door windows must be left open.
Using tape, secure the rear quarter window
glass in the correct position until the PU
adhesive has cured.
General Equipment: Adhesive Tape
2011 Fiesta 08/2010 G1226512en

E119649
5-door
kit.
2011 Fiesta 08/2010 G1226512en

E119657
NOTE: Make sure that any breakage in the

7. Apply the activator/ primer in accordance with continuous bead of adhesive is overlapped by
the instructions supplied with the glass adhesive 20 mm.
kit.
(WSS-M11P57-A5)
7U7J-T03863-AA)
E119655

E119656
2011 Fiesta 08/2010 G1226512en

9. • Press firmly and evenly into position. door windows must be left open.
General Equipment: Direct Glazing Using tape, secure the rear quarter window
Removal/Replacement Equipment glass in the correct position until the PU
• CAUTION: During the curing time of adhesive has cured.
the polyurethane (PU) adhesive, the General Equipment: Adhesive Tape
E119653
10.
2011 Fiesta 08/2010 G1226512en

E105072
2011 Fiesta 08/2010 G1226512en

Rear Window Glass

General Equipment
Materials
Adhesive Tape
Name Specification
Hot Air Gun
Knife
Laminated Card
Removal
3. On both sides.
1. Refer to: Window Glass Health and Safety
Description and Operation).
2. Remove the polyurethane (PU) adhesive cap
and heat the PU adhesive for a minimum of 30
minutes.
(WSS-M11P57-A5)
TIE0022871
2011 Fiesta 08/2010 G1155354en

E106791
4. On both sides.
E106826
2011 Fiesta 08/2010 G1155354en

5. On both sides. 7.
E112169 E112171
6. 8.
CAUTION: If the original window glass

is to be installed, take care not to
damage the electrical connectors and
the weatherstrip (if equipped).
Use appropriate cutting wire with suitable
handles to cut the glass adhesive. Use adhesive
tape and laminated card to prevent paint
damages. Use suction cups to handle the
window glass.
E107069
x2
E112172
2011 Fiesta 08/2010 G1155354en

9. NOTE: Note the position of the components 2. Apply the primer supplied with the glass
before removal. adhesive kit.
E114261
E112173
3. NOTE: Make sure that the component is

Installation installed to the position noted before removal.
1. NOTE: Minimum 1 mm bead thickness.
impair rebonding.
Prepare the windshield glass, windshield glass
flange and trimmed PU adhesive in accordance
with the instructions supplied with the PU
adhesive kit.
General Equipment: Knife E112173
4. NOTE: This step is only necessary if the original
component is to be reused.
NOTE: Minimum 1 mm bead thickness.
impair rebonding.
E112174
E112194
2011 Fiesta 08/2010 G1155354en

5. Apply the primer supplied with the glass NOTE: Make sure that any breakage in the
adhesive kit. continuous bead of adhesive is overlapped by
20 mm.
(WSS-M11P57-A5)
E114262

this may have a reduced working time. E112175
7. CAUTION: During the curing time of the

polyurethane (PU) adhesive, the door
windows must be left open.
Use suction cups to handle the window glass.
x2
E112176
2011 Fiesta 08/2010 G1155354en

8. If the ambient temperature falls below 10°C, 9. On both sides.
apply warm air (25°C) continuously for 15
minutes.
50 mm
E112169
10. On both sides.

E112177
E106826
11. On both sides.
2011 Fiesta 08/2010 G1155354en

E112170
13.
12.
E112168
E112171
2011 Fiesta 08/2010 G1155354en

Front Door Window Regulator Motor
Removal
1. Refer to: Front Door Trim Panel (501-05 Interior
Installation).
2. Torque: 3.5 Nm
x3
E104724
Installation
2011 Fiesta 08/2010 G1079942en

Rear Door Window Regulator Motor
Removal
1. Refer to: Rear Door Trim Panel (501-05 Interior
Installation).
2. Torque: 3.5 Nm
x3
E107435
Installation
2011 Fiesta 08/2010 G1079943en

Front Door Window Regulator

General Equipment
Removal
NOTE: Removal steps in this procedure may 1. Refer to: Front Door Trim Panel (501-05 Interior
Installation).
Refer to: Front Door Window Glass (501-11
and Installation).
3-door
2. CAUTION: Take extra care not to
damage the clips.
General Equipment: Flat-bladed screwdriver
x3
x12
E106788
3. If equipped.
Torque: 3.5 Nm
2011 Fiesta 08/2010 G1079944en

x3
x3
E106768
4-door and 5-door

4. Torque: 3.5 Nm
5. CAUTION: Take extra care not to
damage the clips.
General Equipment: Flat-bladed screwdriver
Torque: 8 Nm
x4
x3
E106769
2011 Fiesta 08/2010 G1079944en

x3
x10
E106282
6. If equipped.
Torque: 3.5 Nm
x3
x3
E106768
2011 Fiesta 08/2010 G1079944en

7. Torque: 3.5 Nm
x3
E106269
Installation
2011 Fiesta 08/2010 G1079944en

Rear Door Window Regulator

Adhesive Tape Flat-bladed screwdriver
Removal
NOTE: Removal steps in this procedure may 1. Refer to: Rear Door Trim Panel (501-05 Interior
Installation).
2. Torque: 7 Nm
x2
x2
E107460
2011 Fiesta 08/2010 G1079945en

3. General Equipment: Adhesive Tape Vehicles with manual windows
Torque: 8 Nm
E107461
x3
x8
E107466
2011 Fiesta 08/2010 G1079945en

5. Torque: 3.5 Nm Vehicles with power windows
Torque: 8 Nm
x3
E107462
x3
x8
E107465
2011 Fiesta 08/2010 G1079945en

7. Torque: 3.5 Nm
x3
E107463
All vehicles
8. Torque: 3.5 Nm
x3
x2
E107464
Installation
2011 Fiesta 08/2010 G1079945en

Windshield Glass
General Equipment
Materials
Adhesive Tape
Name Specification
Windscreen Adhesive WSK-M11P57-A3 /
Kit - 1 Component 7U7J-T03863-AA Knife
Removal
3. Refer to: Cowl Panel Grille (501-02 Front End
1. CAUTION: Body Panels, Removal and Installation).
Refer to: Window Glass Health and Safety
2. 1. Material: Windshield Adhesive Kit
(WSS-M11P57-A5)
2. Remove the polyurethane (PU) adhesive cap
and heat the 2K-PU adhesive for a minimum
of 30 minutes.
E114896
3. Repairs under warranty:
Component (WSK-M11P57-A3 / Vehicles with heated windshield
7U7J-T03863-AA)
4. Refer to: A-Pillar Trim Panel (501-05 Interior
Installation).
5. On both sides.
TIE0022871
E104437
2011 Fiesta 08/2010 G1079946en

Vehicles with manual dimming interior mirror 8.
6.
2 E103426
1 9.
E103429
Vehicles with autolamps and rain sensor

7.
E103427
E103425
2011 Fiesta 08/2010 G1079946en

10. All vehicles
11.
Use a suitable awl to thread the cutting wire.

E103428
E113701
damage the electrical connectors and

12. the weatherstrip (if equipped).
Use a suitable brace to prevent trim damages.
CAUTION: If the original window glass General Equipment: Direct Glazing
is to be installed, take care not to Removal/Replacement Equipment
2011 Fiesta 08/2010 G1079946en

x2
E113702
13. Installation
1. 1. NOTE: Minimum 1 mm bead thickness.
2. NOTE: Make sure that the mating faces are
3. NOTE: Touching the adhesive surface will
impair rebonding.
Prepare the windshield glass, windshield
glass flange and trimmed PU adhesive in
accordance with the instructions supplied
E73226 with the glass adhesive kit.
1 2
E114059
2011 Fiesta 08/2010 G1079946en

2. Apply the activator/ primer in accordance with kit.
E114060

3. NOTE: Touching the adhesive surface will the instructions supplied with the glass adhesive
impair rebonding. kit.
E114061
E73226 5. NOTE: Discard the first 100 mm of adhesive as

2011 Fiesta 08/2010 G1079946en

NOTE: Make sure that any breakage in the 6. • Press firmly and evenly into position.
continuous bead of adhesive is overlapped by General Equipment: Direct Glazing
20 mm. Removal/Replacement Equipment
General Equipment: Direct Glazing • CAUTION: During the curing time of
Removal/Replacement Equipment the polyurethane (PU) adhesive, the
Material: Windshield Adhesive Kit door windows must be left open.
(WSS-M11P57-A5) Using tape, secure the windshield glass in
Material: Windscreen Adhesive Kit - 1 the correct position until the PU adhesive has
Component (WSK-M11P57-A3 / cured.
7U7J-T03863-AA)
8-10mm
E103487
x2
E88280
2011 Fiesta 08/2010 G1079946en

7. Vehicles with autolamps and rain sensor
10.
E103458
x2
8. Refer to: Cowl Panel Grille (501-02 Front End
Body Panels, Removal and Installation).
Vehicles with manual dimming interior mirror x2

9. E103504
11.
E103501
E103502
2011 Fiesta 08/2010 G1079946en

12. Vehicles with heated windshield
14. On both sides.
Torque: 11 Nm
E103426
13. E104437
15. Refer to: A-Pillar Trim Panel (501-05 Interior

Installation).
E103425
2011 Fiesta 08/2010 G1079946en

501-12-1 Instrument Panel and Console 501-12-1
.
SECTION 501-12 Instrument Panel and Console

CONTENTS PAGE

Floor Console..................................................................................................................... 501-12-2
Floor Console — Vehicles With: 6-Speed Automatic Transaxle (6DCT250)...................... 501-12-4
Instrument Panel — Vehicles With: Manual Temperature Control...................................... 501-12-6
Instrument Panel — Vehicles With: Automatic Temperature Control................................. 501-12-30
In-Vehicle Crossbeam......................................................................................................... 501-12-54
Floor Console
Removal
2.
1. On both sides.
E103053
E103054
3.
2011 Fiesta 08/2010 G1083689en

x2
E103055
Installation
2011 Fiesta 08/2010 G1083689en

Floor Console — Vehicles With: 6-Speed Automatic Transaxle

(6DCT250)
Removal
3.
1. On both sides.
x2
E126823
x2
2.
E126824
4.
x4
E126825
E126821 5.
2011 Fiesta 08/2010 G1260706en

x2
E126822
Installation
2011 Fiesta 08/2010 G1260706en

Instrument Panel — Vehicles With: Manual Temperature Control

Special Tool(s) Special Tool(s)
303-435 501-153
Mounting Stand Support, Control Panel
21187
E106985
General Equipment
Adhesive Tape
Draw Cord
Hose Clamp(s)
TORX screwdriver
Removal
NOTE: Removal steps in this procedure may Climate Control System - General Information,
contain installation details. General Procedures).
1. CAUTION: Make sure that the steering 3. Refer to: Cowl Panel Grille (501-02 Front End
wheel lock is engaged. Body Panels, Removal and Installation).
NOTE: Make sure that the road wheels are in 4. On both sides.
the straight ahead position.
E99259
2. NOTE: This step is only necessary on vehicles

with air conditioning.
E104298
Refer to: Air Conditioning (A/C) System
Recovery, Evacuation and Charging (412-00
5.
2011 Fiesta 08/2010 G1083862en

E104230

1. Torque: 10 Nm
2. Torque: 8 Nm
2011 Fiesta 08/2010 G1083862en

E104231
8. CAUTION: Make sure that all openings

7. Torque: 25 Nm are sealed.
NOTE: Vehicles without air conditioning.
1. General Equipment: Hose Clamp(s)
E104235
2011 Fiesta 08/2010 G1083862en

2
4
E128389
9. CAUTION: Make sure that all openings NOTE: Vehicles with air conditioning.
are sealed.
1. Torque: 8 Nm
2011 Fiesta 08/2010 G1083862en

1
2
E103119
10. Remove the driver side front door. 14.

11. Remove the driver seat.
Refer to: Front Seat (501-10 Seating, Removal
and Installation).
with manual transmission. 1

with automatic transmission. 2
E103057
2011 Fiesta 08/2010 G1083862en

15. 18. On both sides.
E103060 E103088
E104242 E104236
17. On both sides.

Installation).
2011 Fiesta 08/2010 G1083862en

20. 21. WARNING: Make sure that a new bolt is
installed.
1. Torque: 28 Nm
E104237
E104238
22. 2. Torque: 8 Nm
E104864
2011 Fiesta 08/2010 G1083862en

E104241
25.
24.
E104243
2011 Fiesta 08/2010 G1083862en

E104244
27. CAUTION: Take extra care not to crease

26. the headliner.
5. Attach a suitable draw cord to the antenna
cable.
General Equipment: Draw Cord
E104301
2011 Fiesta 08/2010 G1083862en

1 1
2
4
4
3 5
E104245
29. Torque: 25 Nm
28. Torque: 25 Nm
E104247
2011 Fiesta 08/2010 G1083862en

x2
E104248
30. 1. Remove the tolerance absorber.

2. Special Tool(s): 303-435, 501-153
3. Torque: 10 Nm
4. Turn the tolerance absorber to the stop.
2011 Fiesta 08/2010 G1083862en

501-153
x2
303-435
E106877
2011 Fiesta 08/2010 G1083862en

31. Refer to: Supplemental Restraint System (SRS) 33.
Operation). Torque: 8 Nm
32.
x6
E100581
x6
E100582
34. Depending on the vehicle variant, steering

wheels with a different design for cut marks can
be fitted.
2011 Fiesta 08/2010 G1083862en

E104747
On both sides.
35.
2011 Fiesta 08/2010 G1083862en

3mm
E100617
36.
2011 Fiesta 08/2010 G1083862en

E100618
38.
37. CAUTION: Make sure that the
clockspring rotor does not rotate.
Torque: 48 Nm
2
E102995
2011 Fiesta 08/2010 G1083862en

E104718
40.
E105762
E102968
2011 Fiesta 08/2010 G1083862en

41. 42. Torque: 10 Nm
E103087
E104801
2011 Fiesta 08/2010 G1083862en

43. 44.
E104348 E103073
45.
E103074
2011 Fiesta 08/2010 G1083862en

46. 48.
E103075 E103709
47. 49.
E103078
E103070
2011 Fiesta 08/2010 G1083862en

50. 51.
E104808
E104361
52.
2011 Fiesta 08/2010 G1083862en

E104362
2011 Fiesta 08/2010 G1083862en

E104351
55.
E104349
E104364
2011 Fiesta 08/2010 G1083862en

56.
E104443
Installation
2011 Fiesta 08/2010 G1083862en

Instrument Panel — Vehicles With: Automatic Temperature Control

Special Tool(s) Special Tool(s)
303-435 501-153
Mounting Stand Support, Control Panel
21187
E106985
General Equipment
Adhesive Tape
Draw Cord
Hose Clamp(s)
TORX screwdriver
Removal
NOTE: Removal steps in this procedure may Climate Control System - General Information,
contain installation details. General Procedures).
1. CAUTION: Make sure that the steering 3. Refer to: Cowl Panel Grille (501-02 Front End
wheel lock is engaged. Body Panels, Removal and Installation).
NOTE: Make sure that the road wheels are in 4. On both sides.
E99259

with air conditioning.
E104298
Refer to: Air Conditioning (A/C) System
Recovery, Evacuation and Charging (412-00
5.
2011 Fiesta 08/2010 G1087881en

E104230

1. Torque: 10 Nm
2. Torque: 8 Nm
2011 Fiesta 08/2010 G1087881en

E104231
8. CAUTION: Make sure that all openings

7. Torque: 25 Nm are sealed.
NOTE: Vehicles without air conditioning.
E104235
2011 Fiesta 08/2010 G1087881en

2
4
E128389
9. CAUTION: Make sure that all openings NOTE: Vehicles with air conditioning.
are sealed.
1. Torque: 8 Nm
2011 Fiesta 08/2010 G1087881en

1
2
E103119
10. Remove the driver side front door. 14.

11. Remove the driver seat.
Refer to: Front Seat (501-10 Seating, Removal
and Installation).
with manual transmission. 1

with automatic transmission.
2
E103057
2011 Fiesta 08/2010 G1087881en

E103060 E103088
E104242 E104236
17. On both sides.

Installation).
2011 Fiesta 08/2010 G1087881en

20. 21. WARNING: Make sure that a new bolt is
installed.
1. Torque: 28 Nm
E104237
E104238
22. 2. Torque: 8 Nm
E104864
2011 Fiesta 08/2010 G1087881en

E104241
25.
24.
E104243
2011 Fiesta 08/2010 G1087881en

E104244
27. CAUTION: Take extra care not to crease

26. the headliner.
5. Attach a suitable draw cord to the antenna
cable.
General Equipment: Draw Cord
E104301
2011 Fiesta 08/2010 G1087881en

1 1
2
4
4
3 5
E104245
29. Torque: 25 Nm
28. Torque: 25 Nm
E104247
2011 Fiesta 08/2010 G1087881en

x2
E104248
30. 1. Remove the tolerance absorber.

2. Special Tool(s): 303-435, 501-153
3. Torque: 10 Nm
4. Turn the tolerance absorber to the stop.
2011 Fiesta 08/2010 G1087881en

501-153
x2
303-435
E106877
2011 Fiesta 08/2010 G1087881en

31. Refer to: Supplemental Restraint System (SRS) 33.
Operation). Torque: 8 Nm
32.
x6
E100581
x6
E100582

be fitted.
2011 Fiesta 08/2010 G1087881en

E104747
On both sides.
35.
2011 Fiesta 08/2010 G1087881en

3mm
E100617
36.
2011 Fiesta 08/2010 G1087881en

E100618
38.
Torque: 48 Nm
2
E102995
2011 Fiesta 08/2010 G1087881en

E104718
40.
E105762
E102968
2011 Fiesta 08/2010 G1087881en

41. 42. Torque: 10 Nm
E103087
E104801
2011 Fiesta 08/2010 G1087881en

43. 44.
E104348 E103073
45.
E103074
2011 Fiesta 08/2010 G1087881en

46. 48.
E103075 E103072
47. 49.
E103078
2011 Fiesta 08/2010 G1087881en

E104799
50.
E104361
2011 Fiesta 08/2010 G1087881en

51.
E104366
2011 Fiesta 08/2010 G1087881en

E104351
54.
E104349
E104365
2011 Fiesta 08/2010 G1087881en

55.
E104443
Installation
2011 Fiesta 08/2010 G1087881en

In-Vehicle Crossbeam
Adhesive Tape TORX screwdriver
Removal
1. Refer to: Heater Core Housing (412-01 Climate Torque: 8 Nm
Control, Removal and Installation).
Refer to: Heater Core and Evaporator Core
Housing - Vehicles With: Manual Temperature
Control (412-01 Climate Control, Removal and
Installation).
Refer to: Heater Core and Evaporator Core
Housing - Vehicles With: Automatic
Temperature Control (412-01 Climate Control,
2. Refer to: Supplemental Restraint System (SRS) x6
Operation).
3.
x6
E100582

E100581
be fitted.
2011 Fiesta 08/2010 G1083866en

E104747
On both sides.
6.
2011 Fiesta 08/2010 G1083866en

3mm
E100617
7.
2011 Fiesta 08/2010 G1083866en

E100618
9.
Torque: 48 Nm
2
E102995
2011 Fiesta 08/2010 G1083866en

E104718
11.
E105762
E102968
2011 Fiesta 08/2010 G1083866en

12. 13. Torque: 10 Nm
E103087
E104801
2011 Fiesta 08/2010 G1083866en

14. 15.
E104348 E103073
16.
E103074
2011 Fiesta 08/2010 G1083866en

17. 19.
E104808
20.
E103075
18.
E103078 E104349
2011 Fiesta 08/2010 G1083866en

21. Torque: 8 Nm Vehicles with manual temperature control
22.
E104351
E103070
23.
2011 Fiesta 08/2010 G1083866en

E104362
2011 Fiesta 08/2010 G1083866en

Vehicles with electronic automatic temperature
control (EATC)
24.
E103067
25.
E104366
2011 Fiesta 08/2010 G1083866en

All vehicles 26.
E104361
27.
2011 Fiesta 08/2010 G1083866en

E104364
28.
E104443
2011 Fiesta 08/2010 G1083866en

29. 31.
1 2
E105806
30.
E102947
32. 1. Torque: 8 Nm
2. Torque: 10 Nm
E100558
2
E100560
33. WARNING: Make sure that new nuts are

installed.
Torque: 22 Nm
2011 Fiesta 08/2010 G1083866en

x2
x2
E104812
34. Torque: 8 Nm
E104813
2011 Fiesta 08/2010 G1083866en

Installation
2011 Fiesta 08/2010 G1083866en

501-14-1 Handles, Locks, Latches and Entry Systems 501-14-1
.
SECTION 501-14 Handles, Locks, Latches and Entry

Systems
CONTENTS PAGE

Handles, Locks, Latches and Entry Systems (Component Location)................................. 501-14-2
Handles, Locks, Latches and Entry Systems (Overview)................................................... 501-14-4
General............................................................................................................................... 501-14-4
Handles, Locks, Latches and Entry Systems (System Operation and Component
Description)....................................................................................................................... 501-14-5
Control Diagram................................................................................................................. 501-14-5
Unlocking the vehicle...................................................................................................... 501-14-6
Locking the vehicle......................................................................................................... 501-14-6
Emergency unlocking/locking......................................................................................... 501-14-7
Start the engine............................................................................................................... 501-14-8
Start the engine............................................................................................................... 501-14-9
Switching off the engine.................................................................................................. 501-14-9
Start/stop button.............................................................................................................. 501-14-9
Steering Column Lock Control Unit................................................................................ 501-14-10
Emergency starting function........................................................................................... 501-14-11
Service Instructions........................................................................................................ 501-14-11
Vehicles with Keyless Vehicle System............................................................................ 501-14-11
Vehicles without Keyless Vehicle System....................................................................... 501-14-11

Locks, Latches and Entry Systems.................................................................................... 501-14-12
Principles of Operation (Vehicles with Remote Keyless Entry (RKE)................................. 501-14-12
Inspection and Verification (Vehicles with Remote Keyless Entry (RKE)........................... 501-14-12

Ignition Lock Cylinder......................................................................................................... 501-14-13
Front Door Latch................................................................................................................. 501-14-14
Rear Door Latch................................................................................................................. 501-14-15
Exterior Front Door Handle................................................................................................. 501-14-16
Exterior Rear Door Handle................................................................................................. 501-14-18
Front Door Lock Cylinder.................................................................................................... 501-14-19

Door Lock Cylinder............................................................................................................. 501-14-20
Ignition Lock Cylinder......................................................................................................... 501-14-25
Handles, Locks, Latches and Entry Systems – Component

Location
2 3 4
10 5
7 6
E102856
2011 Fiesta 08/2010 G1071733en

1 Start/stop button 7 Interior antenna
Comments:
2 Electronic steering lock unit
3 units (one behind the instrument panel,
3 RF remote receiver one in the middle of the vehicle under
the center console, one on the luggage
4 keyless vehicle module compartment floor)
5 Tailgate release switch 8 Outside door handle with antenna and
6 Luggage compartment antenna lock/unlock button
9 BPP (brake pedal position) switch
10 Instrument cluster
2011 Fiesta 08/2010 G1071733en

Handles, Locks, Latches and Entry Systems – Overview

A keyless vehicle system is available as an option
or dependent on the vehicle equipment level.
General
The keyless vehicle system allows the vehicle to
be operated without conventional keys or without
active actuation of the radio remote control. With
this system, the user only needs to carry a valid
radio remote control (a passive key).
The system features the following modifications in
addition to the usual components:
• keyless system vehicle module,
• Passive key (pure radio remote control without
conventional key blade),
• additional lock/unlock buttons in the front door
handles,
• External and internal antennae to localize a valid
passive key:
– external antennae in both door handles and
at the luggage compartment as well as three
interior antennae,
• electronic steering lock unit (replaces the
mechanical steering lock),
• Start/stop button for starting/switching off the
engine; the conventional ignition lock is
dispensed with.
In order to gain access to the vehicle, a passive
vehicle key must be located in the vicinity of the
vehicle.
A passive key is identified via low-frequency (LF)
polling. When a valid vehicle key is identified, the
vehicle can be unlocked directly via the appropriate
lock/unlock button on the front door handles or via
the tailgate release switch.
A passive vehicle key must be present in the
vehicle interior in order to start the engine. A
passive key is identified via low-frequency (LF)
polling.
When a valid key is recognized, the ignition can
be switched on via the Start/Stop button in the
instrument panel or the engine started directly.
After switching on the ignition or for directly
starting the engine
• the clutch pedal must be pressed on vehicles
with manual transaxles.
• the brake pedal must be pressed on vehicles
with automatic transaxles.
2011 Fiesta 08/2010 G1071734en

Handles, Locks, Latches and Entry Systems – System Operation

and Component Description
Control Diagram
System overview
4
1
MS-CAN
9
5
2
A
6 10
B A
7
E102872

1 Tailgate release switch 4 GEM (generic electronic module)
2 Lock/unlock button - door handle 5 keyless vehicle module
3 RF remote receiver 6 Electronic steering lock unit
2011 Fiesta 08/2010 G1071735en

7 Passive vehicle key A Radio signal
Comments:
8 Door locking units
from one of the external antennae to
9 External antennae - door handle passive vehicle keys
Comments:
B Radio signal
2 units, integrated into the front door
Comments:
handles
from passive vehicle key to radio
10 External antennae - tailgate frequency receiver
System Operation The encoded radio signal from the passive key is
received by the radio frequency receiver.
With the keyless vehicle system, there is a choice The radio frequency receiver transfers the signal
between individual door unlocking and global to the keyless vehicle module.
unlocking. The programming process is the same
as on vehicles without a keyless vehicle system. If the keyless vehicle module recognizes a valid
key signal, the actuated door or liftgate is unlocked.
The Unlocking is performed by the GEM. For this
Unlocking the vehicle the GEM receives an appropriate signal via the
MS-CAN (controller area network) from the keyless
Exterior antennas: approximate detection range (in vehicle module.
mm)
The electronic steering column lock unit is unlocked
mm 1800 as soon as the driver's door is opened (signal from
1700
2000 the door contact switch).
1400
If more than 45 seconds elapse after the vehicle
2000
is unlocked but without the ignition being switched
1700 on, then the electronic steering column lock unit is
re-locked.
1500 The electronic steering column lock unit re-locks

if a time of 45 seconds has elapsed after the
ignition is switched off.
1700 If the vehicle goes over 5 days without being
unlocked, the system enters energy saving mode.
2000 This mode prevents excessive loading of the
1400 vehicle battery. In this mode, the response time of
2000 the keyless vehicle system during unlocking is
1800 1700 slightly longer. The energy saving mode is
E91094 deactivated again if the vehicle is unlocked once
after more than 5 days.
Three exterior antennas are installed on the
vehicle:
• one in the driver door handle, Locking the vehicle
• one in the passenger door handle, There are two options for central locking of the
• one under the luggage compartment/tailgate vehicle:
(behind the bumper). • actuating the door lock button once,
When a door handle lock/unlock button or the • actuating the relevant button on the radio remote
tailgate release switch is operated, the control of the passive key once.
corresponding external antenna emits a low
frequency signal. In order to activate double locking, the door lock
button or the button on the remote control must be
The passive vehicle key is thereupon activated and pressed twice within 3 seconds.
emits an encoded radio signal.
2011 Fiesta 08/2010 G1071735en

When the central or the double locking system has Emergency unlocking/locking
been activated, the vehicle remains locked for 3
seconds. During this time the vehicle cannot be
opened using the door handle lock/unlock button,
tailgate release switch or the remote control.
This allows the driver to check whether the vehicle
is locked. This delay time can be changed or
switched off via IDS (Integrated Diagnostic
System).
The global locking function can only be activated
via the remote control. To do this, the lock button
and the unlock button of the remote control must
be pressed for about 4 seconds.
Lock/unlock button - driver's door handle:
• Depending on what is set, this button either
unlocks the driver's door or the whole vehicle.
Lock/unlock button - passenger's door handle:
E102879
• Regardless of what is set, the whole vehicle will
be unlocked when this button is pressed.
If the keyless vehicle system is unable to detect
Note, when locking the vehicle with another key, the passive key, the vehicle can be unlocked using
if a key remains in the vehicle: the emergency key. The emergency key is
• In this case the key which remains in the vehicle integrated in the passive key.
will be deactivated after about one minute. For detailed instructions on assembly of the
Background: If an unauthorized person enters emergency key, please refer to the Owner's
the vehicle, the engine cannot be started Handbook.
because the deactivated passive key does not
send a radio signal. Only the driver door features a conventional door
lock for the purpose of emergency unlocking.
• The passive key remaining in the vehicle will be
re-activated by pressing one of the buttons on
the remote control once.
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Start the engine
4
1
MS-CAN
2 5
HS-CAN
6 10
B A
7
E102880

1 Start/stop button 6 Electronic steering lock unit
Comments:
2 BPP with transceiver for emergency start
3 RF remote receiver 7 Passive vehicle key
4 Instrument cluster 8 PCM (powertrain control module)
5 keyless vehicle module 9 ABS (anti-lock brake system)/ESP module
2011 Fiesta 08/2010 G1071735en

10 Interior antenna A Radio signal
Comments: Comments:
in total 3 units from one of the external antennae to
passive vehicle keys
B Radio signal
Comments:
from passive vehicle key to radio
frequency receiver
Start the engine When the start/stop button is pressed, the interior
antennas of the keyless vehicle module are
Interior antennas: approximate detection ranges activated.
The passive vehicle key is thereupon activated and
emits a coded radio signal.
The coded radio signal from the passive key is
received by the radio frequency receiver.
The radio frequency receiver transfers the signal
to the keyless vehicle module.
If the keyfree module recognizes a valid code, a
coding enquiry is made to the PCM.
The coding enquiry is made over the HS-CAN.
E91135 Only when the PCM approves the coding enquiry
is the start enable issued.
NOTE: In order for engine starting to be enabled
it is necessary for a valid passive key to be present
inside the vehicle. Switching off the engine
Three interior antennas are installed in the vehicle:
• one behind the instrument panel, The engine is switched off by actuating the
start/stop button, provided the vehicle is stationary
• one under the floor console, (vehicle speed = 0 km/h).
• one behind the rear seat bench.
The engine can be stopped in an emergency as
Three states can be switched to via the start/stop follows:
button:
• Press the Start/Stop button three times within
• Switch on the ignition two seconds or
• directly start the engine, • press the Start/Stop button and hold it pressed
• switch off the engine. for three seconds.
The following options are available:
• Ignition ON: Component Description
– actuate the start/stop button.
• Starting the engine from ignition ON or directly
from ignition OFF: Start/stop button
– Vehicles with manual transmission: Depress
the clutch pedal and press the Start/Stop For safety reasons the Start/Stop button is
button. designed with two switch functions. It therefore
sends the actuation signal to the keyless vehicle
– Vehicles with automatic transmission: module over two separate cables.
Depress the brake pedal and press the
Start/Stop button. When a valid key is recognized, the engine is
switched on or off or started via the Start/Stop
2011 Fiesta 08/2010 G1071735en

button, depending on the previous status. Please refer to the table for the individual sequences.
Status prior to performance of Action Status after performance of the

the action action
ignition OFF Clutch or brake pedal and start/ Ignition ON, engine starts
stop button actuated
ignition OFF Only start/stop button actuated Ignition ON
Ignition ON Clutch or brake pedal and start/ Engine starts
stop button actuated
Ignition ON Only start/stop button actuated ignition OFF
Engine running and vehicle Start/stop button actuated ignition OFF
stationary
Engine running and vehicle Long or repeated actuation of the ignition OFF
speed > 0 km/h start/stop button
Steering Column Lock Control Unit The steering lock unit is unlocked:
• by opening the driver's door:
– Signal from the door contact switch to the
GEM, then from the GEM via the MS-CAN
to the keyless system module.
• when the ignition is switched on (if the Start/Stop
button is not pressed within 45 seconds of the
driver's door being unlocked),
• when the clutch or brake pedal is depressed.
When the vehicle is unlocked or the ignition is
1
switched on, the steering column lock unit is
2 supplied with battery voltage from the keyless
E104299
vehicle module. The unlocking routine then
commences:
Item Description
• The keyless vehicle module checks the status
1 Steering Column Lock Control Unit of the steering lock unit. In addition, the
2 PATS (passive anti-theft system) identification code is queried (i.e. whether a
transceiver correctly programmed steering lock unit is
Comments: connected).
only relevant for the emergency start • Following successful completion of the
function check/identification, the DC motor is actuated
by the control electronics and the steering lock
The steering lock unit is attached to the steering is released.
column.
The steering column lock will be locked when the
The steering lock unit comprises: vehicle is locked or after 45 seconds, if the
• a DC motor with a locking pin, following conditions are met:
• integrated control electronics. • Engine OFF,
Actuation is via the keyless vehicle module. • Ignition OFF,
• vehicle speed 0 km/h.
The steering lock unit communicates with the
keyless vehicle module via a private data bus – Depending on the software version, the steering
(K-wire). wheel lock can only be locked if there is no
passive key in the vehicle.
2011 Fiesta 08/2010 G1071735en

Emergency starting function 3. Turn off the ignition and leave the ignition key
in the ignition lock. A signal tone sounds to
If the keyless vehicle system is unable to recognise confirm that programming mode is active.
the passive key, the vehicle can be started via the 4. Press any button on the remote control within
emergency starting function. 10 seconds. A signal tone sounds to confirm
To do this, a conventional transceiver is installed that the remote control has been programmed.
on the steering column lock unit. 5. Repeat step 4 with all other existing remote
To start the engine, the passive key must be held controls.
near the steering column lock unit (see current Programming mode is deactivated if:
Owner's Manual). Then press the Start/Stop button • No buttons on a remote control are pressed
with the clutch or brake pedal depressed. within 10 seconds after the signal tone,
• The position of the ignition lock is changed,
Service Instructions • The maximum number of 8 remote controls has
been programmed.
The unlocking function of the central locking
Vehicles with Keyless Vehicle System works in two ways:
A total of up to eight passive vehicle keys can • Pressing the unlock button on the remote control
be programmed. unlocks all doors.
• Pressing the unlock button on the remote control
All available passive vehicle keys must be
unlocks only the driver's door. Pressing the
reprogrammed using IDS if one or more passive
unlock button again within 3 seconds unlocks
keys are to be added.
all doors.
After the keyless vehicle module has been
To reprogram the unlocking function, run
changed, all the available passive vehicle keys
through the following steps:
must be reprogrammed using IDS.
1. Switching the ignition OFF.
In addition, the keyless vehicle module must be
initialized with the following modules using IDS: 2. Simultaneously hold down the unlocking and
locking buttons on the remote control for at least
• PCM,
4 seconds.
• steering lock unit.
3. Reprogramming is confirmed by the turn signals
After a new steering lock unit is installed, flashing twice.
initialization must be performed with the keyless
Repeat these steps to revert to the previous
vehicle module using IDS.
functioning.
After a new PCM has been installed IDS must be
used to initialize it with the keyless vehicle module.
Vehicles without Keyless Vehicle System
Up to eight remote controls can be programmed.

All available remote controls must be
reprogrammed if one or more remote controls are
to be added.
The remote controls can be programmed either
using IDS or by running through the following steps:
1. Disable the alarm system (if installed) and
unlock the vehicle.
2. Turn the ignition on and off four times within 6
seconds.
2011 Fiesta 08/2010 G1071735en

Locks, Latches and Entry Systems

General Equipment to a minimum to extend the period of time the
vehicle can remain dormant without discharging
the vehicle battery.
Principles of Operation (Vehicles with Inspection and Verification (Vehicles

Remote Keyless Entry (RKE) with Remote Keyless Entry (RKE)
RKE locking system overview
This system consists of mechanical/electrical or electrical damage.
operated door latches driven by outputs from the Visual Inspection Chart
generic electronic module (GEM). The system uses
a radio frequency transmitter and receiver to
operate the remote lock/unlock functions and – Misaligned door(s), – Fuse(s)
normal key or inner door handle inputs for standard tailgate, luggage – Relay(s)
central and double locking functions. compartment and
– Wiring harness
When the normal key or inner door handle is hood
– Electrical
operated, switching contacts within the door latch – Door latch(es)
connector(s)
supply a command signal to the GEM. Dependant – Liftgate latch
– Door latch(s)
upon the current state of the locking system, the – Luggage compart-
GEM allows battery voltage to be applied to the – Remote transmitter
ment lid latch
door latch motors. batteries
– Hood latch
– Vehicle battery
The liftgate or luggage compartment lid is opened – Actuating Cable(s)
when the vehicle is in the unlocked mode by a – Remote transmitter
– Exterior door
ground signal from the liftgate or compartment lid – Radio frequency
handle(s)
release switch to the GEM. The GEM will supply receiver
a voltage to the liftgate or compartment lid latch – Door latch remote
– Liftgate exterior
motor. control(s)
release switch
If the vehicle is locked, the input from the liftgate – Door lock cylinder
– Luggage compart-
or compartment lid release switch will be ignored. ment lid release
The RKE functions are operated by sending a radio switch
frequency signal from the key transmitter and the – Door control
signal is received by the GEM. For vehicles module(s)
equipped with the keyless system the radio – GEM
frequency signal is transferred to the keyless
vehicle module and a signal is transmitted to the 3. If an obvious cause for an observed or reported
corresponding lock sent via controller area network concern is found, correct the cause (if possible)
(CAN) to the GEM module. before proceeding to the next step.
Keyless Vehicle System Overview symptom and refer to the diagnostic tab within
The keyless vehicle system also incorporates RKE
functions, however the main purpose of the system
is to allow the operator of the vehicle to gain access
to and operate the vehicle without carrying out any
actions with a key or remote buttons.
Vehicles equipped with keyless vehicle systems,
will be delivered from production in shipping mode.
Shipping mode reduces the vehicle battery drain
2011 Fiesta 08/2010 G1055895en

Ignition Lock Cylinder
Removal
NOTE: Removal steps in this procedure may Left-hand drive vehicles
4.
1.
2
1
E103032
2. 3
E106774
Right-hand drive vehicles

5.
2
E100556
3.
3
E117525
Installation
E106773
2011 Fiesta 08/2010 G1087172en

Front Door Latch
Removal
NOTE: Removal steps in this procedure may 1. Refer to: Front Door Window Regulator (501-11
contain installation details. Glass, Frames and Mechanisms, Removal
and Installation).
Refer to: Exterior Front Door Handle (501-14
Handles, Locks, Latches and Entry Systems,
Refer to: Front Door Lock Cylinder (501-14
2. 2. Torque: 8 Nm
2 x3
E106283
Installation
2011 Fiesta 08/2010 G1079956en

Rear Door Latch
Removal
NOTE: Removal steps in this procedure may 1. Refer to: Rear Door Window Regulator (501-11
contain installation details. Glass, Frames and Mechanisms, Removal
and Installation).
Refer to: Exterior Rear Door Handle (501-14
2. 2. Torque: 8 Nm
2 x3
E107267
Installation
2011 Fiesta 08/2010 G1079957en

Exterior Front Door Handle
Removal
1.
E101203
E107455 Vehicles with keyless entry

3. Refer to: Front Door Window Regulator (501-11
and Installation).
4.
2 1
E101202
2011 Fiesta 08/2010 G1079958en

Vehicles without keyless entry
5.
2
1
E101200
Installation
2011 Fiesta 08/2010 G1079958en

Exterior Rear Door Handle
Removal
1.
2
1
E101200
E107467 Installation
2.
E101203
2011 Fiesta 08/2010 G1079959en

Front Door Lock Cylinder
Removal
1.
E107455
2.
E70063
Installation
2011 Fiesta 08/2010 G1079960en

Door Lock Cylinder

2 mm Punch 4 mm Punch
4 mm Drill Bit Electric Drill
Disassembly
1.
E117695
3. General Equipment: Electric Drill

2. General Equipment: 4 mm Drill Bit
E117680 E117696
2011 Fiesta 08/2010 G1213679en

4. General Equipment: 2 mm Punch 6.
E117679 E117681
5. 7. CAUTION: Note the position of the

components before removal.
E117678
2011 Fiesta 08/2010 G1213679en

E117677
Assembly 8. CAUTION: Make sure that the

components are installed to the position
NOTE: Make sure that new components are noted before removal.
installed.
E117400
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9. 11. NOTE: The component can only be installed in
1 position.
E117404
E117403
10.
12. General Equipment: 4 mm Punch
E117401
E117402
13.
2011 Fiesta 08/2010 G1213679en

E117405
2011 Fiesta 08/2010 G1213679en

Ignition Lock Cylinder
Disassembly
NOTE: Disassemble the old ignition lock cylinder. 3.
1.
E121499
E121497
4.
2.
E121500
E121498
5.
2011 Fiesta 08/2010 G1246544en

E121504
6.
E121503
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7. CAUTION: Note the position of the 8.
components before removal.
NOTE: One group of tumblers is signed with a
one digit number (1 to 5), the other group of
tumblers is signed with a two digit number (11
to 15).
x8
x8
E121497
9.
E121574
NOTE: Disassemble the new ignition lock cylinder.
E121498
10.
2011 Fiesta 08/2010 G1246544en

E121506
11.
E121571
2011 Fiesta 08/2010 G1246544en

Assembly 15.

components are installed to the position
noted before removal.
NOTE: One group of tumblers is signed with a
one digit number (1 to 5), the other group of
tumblers is signed with a two digit number (11
to 15).
x8 E121498
x8
16.
E121574
13.
E121497
E121573
14.
E121572
2011 Fiesta 08/2010 G1246544en

501-16-1 Wipers and Washers 501-16-1
.
SECTION 501-16 Wipers and Washers

CONTENTS PAGE

Wipers and Washers (Component Location)...................................................................... 501-16-2
Wipers and Washers (Overview)........................................................................................ 501-16-3
WINDSHIELD WIPERS...................................................................................................... 501-16-3
Front Wipers................................................................................................................... 501-16-3
Automatic wiper system.................................................................................................. 501-16-3
Rear wiper....................................................................................................................... 501-16-3
Combined rain sensor/light sensor..................................................................................... 501-16-3
Windshield washers............................................................................................................ 501-16-4
Wipers and Washers (System Operation and Component Description)............................ 501-16-5
Control Diagram................................................................................................................. 501-16-5
Front wiper / washer system........................................................................................... 501-16-6
Intermittent wipe.............................................................................................................. 501-16-6
Auto................................................................................................................................. 501-16-6
Front washer system...................................................................................................... 501-16-6
Rear windshield wash/wipe system................................................................................ 501-16-7
Switch, wash/wipe system.............................................................................................. 501-16-7
Rain Sensor.................................................................................................................... 501-16-7
Front windshield wiper motor.......................................................................................... 501-16-8
Rear wiper motor............................................................................................................ 501-16-8

Wipers and Washers.......................................................................................................... 501-16-10
GENERAL PROCEDURES
Windshield Wiper Blade and Pivot Arm Adjustment........................................................... 501-16-11

Windshield Wiper Motor...................................................................................................... 501-16-13
Rear Window Wiper Motor................................................................................................. 501-16-16
Windshield Washer Pump.................................................................................................. 501-16-17
Windshield Washer Reservoir............................................................................................ 501-16-18
Wipers and Washers – Component Location
1 2 3 4
12
11
10
9
8 7 6
E107049

1 Windshield wiper arms and linkage 7 Front windshield wiper motor
2 Combined rain sensor/light sensor 8 Washer reservoir
3 Switch, wash/wipe system 9 Washer pump
4 Rear window washer nozzle 10 Cap, washer reservoir
5 rear window wiper arm 11 BCM (bodywork control module)
6 Rear wiper motor 12 Front washer jets
2011 Fiesta 08/2010 G1079965en

Wipers and Washers – Overview

The window wipers and the window washer system
are controlled by the BCM (Body Control Module).
Rear wiper
WINDSHIELD WIPERS
Front Wipers 1 2 3
E107101
Item Description
2 3 1 Rear wiper motor
E107100 2 Wiper pivot arms
3 Rear window washer nozzle
Item Description
1 Wiper arms When reverse gear is engaged the rear wiper is
automatically switched on if
2 Wiper linkage assembly
• the rear wiper is switched off and
3 Front windshield wiper motor • the front wipers are switched on or
The front wiper blades are flat blades. These offer • automatic wipe mode is selected (optional in
the following advantages over conventional wiper certain markets) and the rain sensor (optional
blades: in certain markets) has switched on the front
wipers.
• reduced noise when operating
• improved wiping because of the reduced The rear wiper delay interval is regulated according
tendency to lift up at high vehicle speeds to the speed of the front wipers.
• lower installed height
Combined rain sensor/light sensor
Automatic wiper system The combined rain sensor/light sensor is optional
in certain markets.
Some models without a combined rain sensor/light
sensor are equipped with a speed-dependent wiper
interval for the front wipers. If the vehicle is
decelerated to walking speed or a standstill, then
the system automatically changes to the next
slower interval setting. If the speed is increased,
the wiper speed returns to the manually selected
setting. If the wiper lever is moved while the system
is switched on the system is switched off. If the
vehicle is decelerated to walking speed or a
standstill again, then the system is switched back
on again.
E107399
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The rain sensor is built into a housing which is The rain sensor evaluates optical conditions.
mounted behind the rear view mirror on the Contamination such as oil, grease or dust will
windshield. prevent correct operation. Before switching on the
automatic windshield wipers, the windshield must
be clean in the area of the rain sensor.
Windshield washers
E107102

1 Front washer jets 3 Washer reservoir
2 Washer reservoir closure 4 Washer pump
5 Rear window washer nozzle
Water is pumped to both the front window washer

and the rear window washer from a washer
reservoir via a washer pump.
2011 Fiesta 08/2010 G1071749en

Wipers and Washers – System Operation and Component

Description
Control Diagram
4
2
10
3
5
6
8
E107365

1 TCM (transmission control module) 4 Rear wiper motor
(Vehicles with automatic transmission) 5 Front windshield wiper motor
2 Instrument cluster 6 Washer pump
3 BCM (Body Control Module) input 7 BCM
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8 Switch, wash/wipe system 9 Reversing lamp switch (vehicles with
manual transmission)
10 Combined rain sensor/light sensor
System Operation – Wiper delay in level 4 = 12 seconds

– Wiper delay in level 5 = 17.5 seconds
The window wash/wipe system is controlled by the
– Wiper delay in level 6 = 25 seconds
BCM (Body Control Module). To do this, the BCM
primarily uses the signal from the window These values apply to a stationary vehicle. The
wash/wipe switch. Secondary signals include the intervals are shortened with increasing vehicle
signal from the combined rain sensor/light sensor speed.
(optional in certain markets) and the signal of the
reversing lamp switch (vehicles with manual
transmission) or the TCM (vehicles with automatic Auto
transmission).
The automatic wipe function is optionally available
in some markets.
Front wiper / washer system
The signal from the combined rain sensor/light
The front window wash/wipe system will only sensor is transmitted via a LIN (local interconnect
operate if the ignition switch is in position II. network) bus to the BCM (Body Control Module),
where it is processed together with the signal from
The front and rear windshield wash/wipe systems the window wiper rotary switch which is used to
use a shared window washer pump and cannot be adjust the sensitivity of the sensor. The BCM then
used simultaneously. actuates the wiper motor and sets the wiper speed
Four wipe functions are available: and wiper delay interval.
• single wipe
• intermittent wipe or automatic wipe (depending Front washer system
on the vehicle specification)
• normal wipe When the front washer system is switched on the
• fast wipe speed BCM (Body Control Module) switches on the
window washer pump. The BCM delays wiper
The setting of the window wash/wipe switch is operation for 360 ms after operation of the window
transmitted to the BCM (Body Control Module). washer switch. If the window washer switch is not
The BCM then actuates the wiper motor via relays operated for at least 360 ms, then the BCM does
and sets the wiper speed. not switch on the window wiper. The BCM activates
Normal wipe speed remains available in the event the window wiper for as long as the window washer
of failure of the BCM. switch is operated. The window washer pump is
switched off after a maximum of 10 seconds. After
clearance from the switch the BCM allows the
Intermittent wipe wipers to wipe two or three times more.
This additional wiping function allows the front
The setting of the window wiper rotary switch is wiper blades to wipe one more time 4 seconds
transmitted to the BCM (Body Control Module). after the last wiping movement to remove any
The BCM then actuates the wiper motor via a relay remaining water from the windshield.
and sets the wiper delay interval.
The additional wiping function is activated if:
The window wiper rotary switch has six settings
ranging from a short delay to a long delay: • the windshield wipers are off when the front
windshield washer system is operated
– Wiper delay in level 1 = 1.2 seconds
• the windshield wipers are set to intermittent
– Wiper delay in level 2 = 4 seconds mode and have not wiped in the last 4 seconds
– Wiper delay in level 3 = 8 seconds
2011 Fiesta 08/2010 G1079966en

Rear windshield wash/wipe system
1 2 3
The rear window wash/wipe system will only
operate if the ignition switch is in position II.
The front and rear windshield wash/wipe systems
use a shared window washer pump and cannot be
used simultaneously.
Depending on the wiper speed of the front wipers,
the rear wipers run with a delay interval of
6 seconds, 10 seconds or continuously. The time
delay is controlled by the BCM (Body Control E107396
Module).
The rear windshield wiper is switched on if: Item Description
• the window wash/wipe switch is in the 'rear 1 Switch, wash/wipe system

wiper' position 2 Window wiper rotary switch
– The BCM actuates the rear wiper motor. The
3 Windshield washer switch
windshield wiper runs in intermittent mode.
• the rear windshield washer system is operated Switches and switch positions:
– The BCM switches on the rear window • Switch, wash/wipe system
washer system. The washer pump is supplied – One-touch function downwards for single
with power. Reversing the polarity of the front wipe
pump enables the washing fluid to flow to the
rear washer jets instead of the front washer – 3 fixed positions upwards for front intermittent
jets. The BCM activates the window wiper wipe / automatic wipe (optional in some
for as long as the window washer switch is markets), normal wipe, fast wipe
operated. The window washer pump is – Fixed position towards the steering wheel for
switched off after a maximum of 10 seconds. rear intermittent wipe
After clearance from the switch the BCM – One-touch function beyond the fixed position
allows the wipers to wipe two or three times towards the steering wheel for the rear
more. washer system
• the signal "Reverse gear engaged" is received • Window wiper rotary switch
from the reversing lamp switch or from the TCM – 6 fixed switch positions for wiper
and the front window wash/wipe switch is in the intervals/rain sensor sensitivity (optional in
position for normal or fast wipe speed, or it is some markets). The switch positions start
set to automatic wipe (optional in certain from 1 (wide symbol) at the upper end point
markets) or intermittent wipe at high speed. and end with 6 (narrow symbol) at the lower
– The BCM actuates the rear wiper motor until end point
the gear lever is moved to neutral. • Windshield washer switch
– One-touch function for front washer system
Component Description
Rain Sensor
Switch, wash/wipe system
The rain sensor is optionally available in some
The window wash/wipe switch is a simple electrical markets.
switch which is inserted into the steering wheel The sensor contains a number of transmitter and
module. receiver diodes which emit and receive infrared
light. By comparing the received signal with the
known transmitted signal, the rain sensor can
determine the moisture on the outside of the
windshield and request that the windshield wipers
are switched on.
2011 Fiesta 08/2010 G1079966en

• Window wiper rotary switch at the top corner:
1 high sensitivity
– The wipers wipe even if only a small amount
5 of water has been measured on the
windshield.
• Window wiper rotary switch at the bottom
corner: low sensitivity
2
– The wipers only wipe if a large amount of
water has been measured on the windshield.
4 3 The rain sensor is self-calibrating.
E92596
The rain sensor supplies LIN signals with values
Item Description between 0 and 7 to the BCM (Body Control
Module).
1 Raindrop
Meaning of signals from rain sensor:
2 LED
• Signal "0": window is dry.
Comments:
(transmitter diode) • Signal "1-5": Windshield is damp. The BCM
activates normal wiping.
3 Lens • Signal "6-7": Windshield is receiving severe
4 Photodiode precipitation. The BCM activates the fast wipe
Comments: speed whenever the signal value is greater than
(receiver diode) 4.
5 Light loss due to deflection
The LED emits a beam of light with a known Front windshield wiper motor
intensity. The emitted beam emerges through the
The front windshield wiper motor is a DC motor
lens and is then reflected by the windshield.
with 3 brush type contacts. One brush type contact
The reflected light beam enters back through the is for ground and one is for normal wiping speed.
lens and then reaches the photodiode. The The third brush type contact is activated for high
corresponding value taken without moisture on the wiping speed.
windshield is used as the reference value for
The integrated home switch is directly connected
automatic calibration.
to the BCM (Body Control Module). The home
Subsequent deviations from this value cause the switch contacts are open in all wiper motor
windshield wipers to be switched on. positions except the home position. When the
If precipitation falls on the windshield, part of the home switch contacts are open, the wiper motor
light beam is deflected. This reduces the intensity remains switched on even if a signal from the
of the light reflected by the windshield. This loss steering wheel module requests that the wipers
of intensity is registered by the photodiode and stop. In home position, the home switch contacts
reported via an LIN signal to the BCM (Body create a ground connection. The BCM recognizes
Control Module). this ground connection and switches the wiper
motor off.
When the automatic wipe function is switched on
(window wash/wipe lever set to intermittent wiping)
the wipers are only activated automatically if the Rear wiper motor
rain sensor registers water on the windshield.
The sensitivity of the rain sensor can be changed The rear windshield wiper motor is a DC motor with
by adjusting the window wiper rotary switch. 2 brush type contacts. It is controlled by a voltage
supply.
The integrated home switch is directly connected
to the BCM (Body Control Module). The home
switch contacts are closed in all wiper motor
positions except the home position. When the
2011 Fiesta 08/2010 G1079966en

home switch contacts are closed, the wiper motor
is supplied with a voltage by the BCM. When the
wiper motor reaches the home position, the home
switch contacts are opened and the power supply
is interrupted by the BCM. While the window
wash/wipe switch remains in the "rear washer"
position, the wiper motor is again supplied with a
voltage by the BCM and continues to run. This
process is repeated during every revolution of the
wiper motor.
2011 Fiesta 08/2010 G1079966en

Wipers and Washers

General Equipment
Ford diagnostic equipment • Wiper blade(s) • Fuse(s)
• Rotating shaft – • Connectors
wiper arm • Wiring harness
Inspection and Verification • Washer reservoir • Washer pump
• Hose(s) • Front/rear window
NOTE: Before retrieving the vehicle-specific data
make sure that all electrical connections in the • Nozzles wiper motor
vehicle are reconnected so that the module and • Check the
the Ford diagnostic equipment can communicate passenger-side
correctly. windshield wiper for
residue-free wiping
NOTE: If a new generic electronic module (GEM)
in the vicinity of the
is being installed, the new module must be
rain sensor.
configured following installation. For this purpose,
the vehicle-specific data is retrieved from the • Check the adhesive
module to be changed using the Ford diagnostic pad between the
equipment and is transferred to the new module. rain sensor and the
windshield for
1. Verify the customer concern. trapped air.
2. Visually check for any obvious mechanical or • Clean wax residues
electrical damage. from the windshield
in the vicinity of the
rain sensor.
• Check the wind-
shield for
damage/cracks in
the vicinity of the
rain sensor.
• Check that the rain
sensor retaining
frame is correctly
attached to the
windshield.

symptom and refer to the Ford diagnostic
equipment to diagnose the system.
2011 Fiesta 08/2010 G1086960en

GENERAL PROCEDURES
Windshield Wiper Blade and Pivot Arm Adjustment

Special Tool(s) Using the special tool, read off the angle
between the wiper arm and the glass.
501-027
Aligner, Wiper Arm Special Tool(s): 501-027, 501-027-01
501-027
ES32006
501-027-01 501-027-01
Adapter for 501-027
E73710 E73759
3. CAUTION: Make sure that the special

tool is lifted off the glass when adjusting
Adjustment the angle.
1. CAUTION: Make sure that the motor is Adjust the wiper arm to an angle of 5°±2°.
E115857
E77631
4.
2. NOTE: The angle of the wiper on the scale must
point from the zero center line to the center of
the windshield/rear window. Ignore the 501-027
plus/minus (+/-) signs on the adjusting tool.
NOTE: Make sure that the 3 marked points of 501-027-01
the special tool are in contact with the glass.
E77670
2011 Fiesta 08/2010 G1079972en

GENERAL PROCEDURES
5.
E77669
2011 Fiesta 08/2010 G1079972en

Windshield Wiper Motor
Removal
NOTE: Removal steps in this procedure may 1. Refer to: Cowl Panel Grille (501-02 Front End
contain installation details. Body Panels, Removal and Installation).
2.
E104298
3.
2011 Fiesta 08/2010 G1079976en

E104230

1. Torque: 10 Nm
2. Torque: 8 Nm
2011 Fiesta 08/2010 G1079976en

E104231
5. 1. NOTE: Note the position of the component

before removal.
Torque: 18 Nm
2. Torque: 9 Nm
2
x3
E104297
Installation
2011 Fiesta 08/2010 G1079976en

Rear Window Wiper Motor
Removal
NOTE: Removal steps in this procedure may Installation
Torque: 9 Nm
E107795
2. Refer to: Liftgate Trim Panel (501-05 Interior

Installation).
3. Torque: 8 Nm
x3
E107796
2011 Fiesta 08/2010 G1108842en

Windshield Washer Pump
Removal
3. WARNING: Be prepared to collect
1. Refer to: Jacking and Lifting (100-02 Jacking escaping fluid.
and Lifting, Description and Operation).
2.
E116213
x2
E116214
Installation
2011 Fiesta 08/2010 G1190655en

Windshield Washer Reservoir
Removal
3.
1. Refer to: Jacking and Lifting (100-02 Jacking
2.
E116215
E116217
2011 Fiesta 08/2010 G1190661en

4. CAUTION: Make sure the open end of in the reservoir.
the hose is secured above the fluid level
x2
x2
E116216
Installation
2011 Fiesta 08/2010 G1190661en

501-19-1 Bumpers 501-19-1
.
SECTION 501-19 Bumpers

CONTENTS PAGE

Front Bumper Cover........................................................................................................... 501-19-2
Rear Bumper Cover............................................................................................................ 501-19-8
Rear Bumper Cover — 4-Door........................................................................................... 501-19-13
501-19-2 Bumpers 501-19-2
Front Bumper Cover

Cable Ties Interior Trim Remover
Removal
NOTE: Removal steps in this procedure may 1. Refer to: Jacking and Lifting (100-02 Jacking
contain installation details. and Lifting, Description and Operation).
2. On both sides.
E108563
3.
2011 Fiesta 08/2010 G1091219en

501-19-3 Bumpers 501-19-3
E108556
Vehicles with parking aid

4. General Equipment: Cable Ties
2011 Fiesta 08/2010 G1091219en

501-19-4 Bumpers 501-19-4
x2
E108564
All vehicles
5. General Equipment: Cable Ties
6. On both sides.
E108565
E108555
2011 Fiesta 08/2010 G1091219en

501-19-5 Bumpers 501-19-5
7. If equipped, on both sides. 8. If equipped, on both sides.
E108559
x4
E108558
2011 Fiesta 08/2010 G1091219en

501-19-6 Bumpers 501-19-6
x2
x2
x2
E108557
10.
E108562
11.
2011 Fiesta 08/2010 G1091219en

501-19-7 Bumpers 501-19-7
x1
8
x1
8
x1
6
E108560

12.
Installation
2011 Fiesta 08/2010 G1091219en

501-19-8 Bumpers 501-19-8
Rear Bumper Cover

5 mm Drill Bit Electric Drill
Removal
NOTE: Removal steps in this procedure may Vehicles with parking aid
4.
2. Both sides, If equipped.
E111777
All vehicles
E111776
5.
3. On both sides.
E111778
2011 Fiesta 08/2010 G1155629en

501-19-9 Bumpers 501-19-9
E111779
6.
2011 Fiesta 08/2010 G1155629en

501-19-10 Bumpers 501-19-10
x2
E111783
7.
2011 Fiesta 08/2010 G1155629en

501-19-11 Bumpers 501-19-11
2
x1
x2
x2
E111782
3-door
8. If equipped.
General Equipment: Electric Drill
General Equipment: 5 mm Drill Bit
2011 Fiesta 08/2010 G1155629en

501-19-12 Bumpers 501-19-12
2
x1
x2
x2
x12
x6
5mm
x6
E111781

9. Refer to: Rear Parking Aid Sensor (413-13
Parking Aid, Removal and Installation).
Installation
2011 Fiesta 08/2010 G1155629en

501-19-13 Bumpers 501-19-13
Rear Bumper Cover — 4-Door
Removal
NOTE: Removal steps in this procedure may 1. Refer to: Jacking and Lifting (100-02 Jacking
contain installation details. and Lifting, Description and Operation).
2.
E111787
3.
2011 Fiesta 08/2010 G1091220en

501-19-14 Bumpers 501-19-14
E111788
5. On both sides.
4. Both sides, If equipped.
E111785
E111776
2011 Fiesta 08/2010 G1091220en

501-19-15 Bumpers 501-19-15
Vehicles with parking aid All vehicles
6. 7.
E111786
E111784
8.
2011 Fiesta 08/2010 G1091220en

501-19-16 Bumpers 501-19-16
x6
x6
E111789
x2
10. If equipped.
9.
x4
E111790
2011 Fiesta 08/2010 G1091220en

501-19-17 Bumpers 501-19-17
x14
E112047

11. Refer to: Rear Parking Aid Sensor (413-13
Parking Aid, Removal and Installation).
Installation
2011 Fiesta 08/2010 G1091220en

501-20A-1 Safety Belt System 501-20A-1
.
SECTION 501-20A Safety Belt System

CONTENTS PAGE

Safety Belt System (Overview)........................................................................................... 501-20A-2
Overview............................................................................................................................. 501-20A-2

Safety Belt System............................................................................................................. 501-20A-3
Principles of Operation ...................................................................................................... 501-20A-3
Inspection and Verification ................................................................................................. 501-20A-3
Component Test ................................................................................................................ 501-20A-4

Front Safety Belt Retractor and Pretensioner..................................................................... 501-20A-6
Front Safety Belt Buckle..................................................................................................... 501-20A-7
Rear Safety Belt Retractor.................................................................................................. 501-20A-8
Rear Safety Belt Buckle...................................................................................................... 501-20A-10
Rear Center Safety Belt...................................................................................................... 501-20A-11
Rear Center Safety Belt Buckle.......................................................................................... 501-20A-12
Safety Belt System – Overview
Overview
E102017
Item Description
1 Retractor - front seat belt and belt
tensioner
Refer to: Air Bag and Safety Belt
Pretensioner Supplemental Restraint
System (SRS) (501-20 Supplemental
Restraint System, Description and
Operation).
2011 Fiesta 08/2010 G1063173en

Safety Belt System

General Equipment Rear seat safety belt retractors do not use this type
of retractor, they are equipped with a conventional
retractor.
Emergency Locking Retractor

Principles of Operation
The retractors in all seat positions feature
WARNING: All safety belt components emergency locking retractor(s). The emergency
including retractors, buckles, front safety locking retractor is part of the safety belt system
belt buckle support assemblies (slider bar), that in normal operation allows free movement of
child safety seat tether brackets and the belted occupant. In an emergency the
attaching hardware in use during a emergency locking retractor will lock, preventing
collision must be removed and new webbing payout and hence forward movement of
components installed. New safety belt the occupant. Locking may be achieved by one of
components should also be installed where two mechanisms:
safety belts not in use during a collision,
are inspected and found to be damaged or Vehicle Motion Sensor
operate incorrectly. Failure to follow these vehicle motion sensor is operated by sudden
instructions may result in personal injury. deceleration of the vehicle or excessive tilt. Once
Vehicles equipped with the supplemental restraint operated the vehicle motion sensor causes a
system (SRS) are equipped with a driver and locking pawl to be engaged, thus locking the
passenger safety belt retractor(s) and pretensioner. retractor, preventing webbing payout. When the
The safety belt pretensioners are controlled as part vehicle is stationary, the vehicle motion sensor
of the SRS. stabilizes, causing the pawl to disengage and
unlock the retractor, allowing webbing payout.
REFER to: Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) (501-20 Webbing Motion Sensor
Supplemental Restraint System, Description and The emergency locking retractor webbing motion
Operation). sensor is operated by rapid acceleration of the
The rear seat safety belt buckles are mounted webbing. Once operated, it causes a locking pawl
directly to the floor pan underneath the rear seat to be engaged thus locking the retractor. Webbing
cushion. When the ignition is turned on the RUN payout is prevented in the same manner as vehicle
position the SRS warning indicator will illuminate motion sensor.
for three seconds. If the SRS, including the safety
belt electrical system, is operating correctly the
SRS warning indicator will be extinguished. If a Inspection and Verification
fault is detected the SRS warning indicator will
generate a lamp fault code. 1. Verify the customer concern.
REFER to: Air Bag and Safety Belt Pretensioner 2. Visually inspect for obvious signs of mechanical
Supplemental Restraint System (SRS) (501-20 and electrical damage.
Supplemental Restraint System, Description and
Operation). Visual Inspection Chart
The safety belt retractor, mounted within the base Mechanical
of the B-pillar, incorporates a torsion bar load • Safety belt retractor
limiting device. The device consists of a retractor
• Safety belt buckle
reel which is mounted onto a spindle (torsion bar)
which, once the sensor has locked the retractor • Safety belt retractor and pretensioner
reel and predetermined load is applied, twists and
pays out additional webbing into the system. The 3. If an obvious cause for an observed or reported
deceleration force required to initiate this sequence concern is found, correct the cause (if possible)
is approximately the same as that required to before proceeding to the next stop.
initiate air bag deployment. The torsion bar load 4. If the cause is not visually evident, verify the
limiting device will only react if the safety belt is in symptom and refer to the Symptom Chart.
use at the time of impact.
2011 Fiesta 08/2010 G1055906en

Symptom Chart
• Normal mode - occupant • Safety belt retractor. • CARRY OUT the Safety Belt
restraint system inoperative. Component Test in this section.
Component Test belt is being tested. Failure to follow these

instructions may result in personal injury.
Poor Retraction • Select for this test a quiet or private stretch of
If a safety belt does not retract correctly, check that road. Make sure that the road is clear and that
the anchor covers and trim bezels are correctly full visibility is maintained at all times.
installed and not rubbing against the safety belt • Both driver and passenger should adopt a
webbing. Where necessary, check that the safety normal, comfortable seating position. Both
belt webbing is not rubbing at one end of the occupants should wear the safety belts and the
retractor cover slot and, if so, correct by loosening safety belt webbing must be correctly adjusted,
the retaining bolt, aligning the retractor to centralize with no slack.
the safety belt webbing and retighten the bolt. • Proceed at a speed of 10 km/h (6 mph). Do not
The safety belts are “dual sensitive” which means exceed 10 km/h (6 mph) for this test.
that they have: • Apply the foot brake sharply to stop the vehicle.
If the vehicle motion sensitive lock mechanism
• A vehicle motion sensor, which locks the safety
is operating correctly, the safety belt webbing
belt webbing under braking, cornering, on steep
will lock and restrain the wearer.
hills and in adverse camber conditions.
• Conduct the test twice in each front and rear
• A webbing motion sensor, which locks when the
passenger seat position.
safety belt webbing is quickly extracted.
• Any safety belt retractor which does not restrain
Both systems should be fully operational and can the wearer during this test must not be reused.
be checked by the tests below: A new safety belt must be installed.
Vehicle Motion Sensor Test
Either of the following two procedures may be used Test Method 2 (turning circle)
to check correct operation of the vehicle motion
sensor. Both methods require two technicians but This method requires a flat open area of private
note that technicians of larger than normal build road, sufficient for the vehicle to be driven in a
should not be asked to conduct these tests. This continuous circle on full steering lock.
is to avoid the possibility of a fully unrolled safety • The driver should wear the safety belt provided
belt webbing being mistaken for a correctly locked and the belt webbing must be correctly adjusted,
safety belt retractor. with no slack.
• The passenger should occupy a rear seat with
Test Method 1 (braking) the safety belt correctly adjusted, with no slack.
• Start the engine and, with the steering on full
WARNING: It is important that during this right-hand lock, drive the vehicle in a continuous
test, the driver and passenger allow the circle at 16 km/h (10mph). Do not exceed 16
safety belts to provide the restraint and do km/h (10 mph) for this test.
not attempt to anticipate the sudden • When the speed is stable, the passenger should
deceleration. The steering wheel should attempt to slowly extract the safety belt webbing
not be used as a brace. However, both from each safety belt retractor in turn. If the
driver and passenger should prepare vehicle motion sensitive lock mechanism is
themselves for the possibility that the operating correctly, it will not be possible to
safety belt will not lock. The passenger extract the webbing.
should hold their hands in front of them, • Any safety belt retractor from which it is possible
just clear of the instrument panel or front to extract the webbing during this test must not
seat backrest, depending on which safety be used. A new safety belt must be installed.
2011 Fiesta 08/2010 G1055906en

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
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.
symptom and refer to theFord diagnostic
equipmentto diagnose the system.
2011 Fiesta 08/2010 G1055906en

Front Safety Belt Retractor and Pretensioner
Removal
WARNINGS: 3. Torque: 45 Nm
components.
system is fully depowered and no other
1. Refer to: Health and Safety Precautions (100-00
Operation).
Refer to: Battery Disconnect and Connect
Refer to: B-Pillar Trim Panel - 5-Door (501-05
Interior Trim and Ornamentation, Removal
and Installation).
2. Torque: 45 Nm
E104723
Installation
E104702
2011 Fiesta 08/2010 G1087428en

Front Safety Belt Buckle
Removal
and Installation).
2.
E103543
3. Torque: 50 Nm
E103712
Installation
2011 Fiesta 08/2010 G1063178en

Rear Safety Belt Retractor
Removal
NOTE: Removal steps in this procedure may All vehicles
4.
Operation).
5-door
2.
E105052
5. Torque: 45 Nm
E105050
3.
E105053
6. Torque: 45 Nm
E105051
2011 Fiesta 08/2010 G1087429en

E105054
Installation
2011 Fiesta 08/2010 G1087429en

Rear Safety Belt Buckle
Removal
1. Refer to: Rear Center Safety Belt (501-20 Safety

Belt System, Removal and Installation).
Installation
2011 Fiesta 08/2010 G1087431en

Rear Center Safety Belt
Removal
Operation).
2.
E105067
3. Torque: 45 Nm
E105231
Installation
2011 Fiesta 08/2010 G1088808en

Rear Center Safety Belt Buckle
Removal
Operation).
2.
E105067
3. Torque: 45 Nm
E105071
Installation
2011 Fiesta 08/2010 G1087432en

501-20B-1 Supplemental Restraint System 501-20B-1
.
SECTION 501-20B Supplemental Restraint System

CONTENTS PAGE

Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS) (Component
Location)........................................................................................................................... 501-20B-2
Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS) (Overview). 501-20B-3
Overview............................................................................................................................. 501-20B-3
Driver airbag module, passenger airbag module............................................................... 501-20B-4
Retractor - front seat belt and belt tensioner...................................................................... 501-20B-4
Restraints control module (RCM)....................................................................................... 501-20B-4
Front crash sensor.............................................................................................................. 501-20B-4
Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS) (System
Operation and Component Description)........................................................................... 501-20B-5
Control Diagram................................................................................................................. 501-20B-5
System Operation............................................................................................................... 501-20B-5
General........................................................................................................................... 501-20B-5
Component Description...................................................................................................... 501-20B-6
Front crash sensor.......................................................................................................... 501-20B-6
Driver and passenger front air bag system..................................................................... 501-20B-6
Retractor - front seat belt and belt tensioner.................................................................. 501-20B-6

Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS)................... 501-20B-7
Inspection and Verification.................................................................................................. 501-20B-7
Diagnosing Customer Concerns Without Hard DTCs........................................................ 501-20B-8
Diagnosing Customer Concerns with Hard DTCs.............................................................. 501-20B-8
Deactivation........................................................................................................................ 501-20B-8
Reactivation........................................................................................................................ 501-20B-9
Glossary............................................................................................................................. 501-20B-10
Principles of Operation....................................................................................................... 501-20B-10
GENERAL PROCEDURES
Clockspring Adjustment...................................................................................................... 501-20B-12
Deployed Air Bag Disposal................................................................................................. 501-20B-13
Unserviceable Air Bag Disposal......................................................................................... 501-20B-14
Scrapped Vehicle Air Bag and Safety Belt Pretensioner Disposal - In-Vehicle Disposal.... 501-20B-15
All air bag modules............................................................................................................. 501-20B-18

Restraints Control Module (RCM)...................................................................................... 501-20B-19
Front Impact Severity Sensor............................................................................................. 501-20B-20
Driver Air Bag Module......................................................................................................... 501-20B-21
Passenger Air Bag Module................................................................................................. 501-20B-24
Side Air Bag Module........................................................................................................... 501-20B-25
Side Air Curtain Module...................................................................................................... 501-20B-27
Clockspring......................................................................................................................... 501-20B-29
Air Bag and Safety Belt Pretensioner Supplemental Restraint

System (SRS) – Component Location
2
5
3
E105803

1 Front crash sensor 4 Front safety belt buckle
2 Driver air bag 5 Restraints control module (RCM)
3 Retractor - front seat belt and seat belt 6 Front passenger airbag
tensioner
2011 Fiesta 08/2010 G1087471en


System (SRS) – Overview
Overview
2
5
3
E105803

1 Front crash sensor 4 Front safety belt buckle
2 Driver air bag 5 Restraints control module (RCM)
3 Retractor - front seat belt and belt 6 Front passenger airbag
tensioner
2011 Fiesta 08/2010 G1087472en

Driver airbag module, passenger airbag Restraints control module (RCM)
module
E98729
E98735
The RCM is located underneath the floor console
near the gearshift lever.
Retractor - front seat belt and belt The following instructions must be followed when
tensioner removing, installing or replacing the RCM:
• After an accident, the RCM can only be used
again if it is not physically damaged and if it
passes a self-test without any faults. For further
information refer to TECHNICAL SERVICE
BULLETIN 35/2006.
• A new RCM must be programmed using the
diagnostic unit.
1
2 Front crash sensor
E103042
Item Description
1 Electrical connector
2 Ignition unit
The pyrotechnic belt tensioners on the driver’s side
and front passenger’s side are integrated into the
retractor mechanism.
The following instructions must be followed when E105794
removing, installing or replacing the safety belt
tensioner: The impact sensor is installed at the front of the
• Note the position and routing of the safety belt vehicle next to the hood lock.
buckle pretensioner wiring harnesses to aid The following instructions must be followed when
installation. An incorrectly routed wiring harness removing, installing or replacing the front crash
may lead to the wiring harness becoming sensor:
damaged on the seat mechanism.
• Continued use of the impact sensor is
permissible provided it has not been physically
damaged and it passes a self-test.
• Make sure that the front crash sensor is installed
in the correct position.
2011 Fiesta 08/2010 G1087472en


System (SRS) – System Operation and Component
Description
Control Diagram
1 2
E106245

1 Front crash sensor 4 Front passenger airbag
2 Restraints control module (RCM) 5 Retractor - front seat belt and belt
tensioner
3 Driver air bag
System Operation
General
The RCM performs a self-diagnosis when the seconds can the airbag control lamp be used as a
ignition is switched on. fault indicator.
All components of the restraints control system are After an airbag has been deployed, a new RCM
checked. If an error is found, the airbag control must be installed. If the RCM is changed, the
lamp is activated for 8 seconds after the ignition is module must be configured with IDS.
switched on. The first 8 seconds of the ignition
cycle always follow the same pattern: first 3.2
seconds on, then 4.8 seconds off. Only after 8
2011 Fiesta 08/2010 G1087473en

Component Description Retractor - front seat belt and belt tensioner
Front crash sensor
E103042
Item Description
E99051
1 Electrical connector
Data from the crash sensor are evaluated by the 2 Ignition unit
RCM to assess the severity of a frontal impact. The
crash sensor transmits digitally encoded The belt tensioner is built into the belt retractor and
acceleration information to the RCM. installed on the driver and passenger sides. On
the outside of the seat belt retractor there is a metal
The RCM will store a trouble code (DTC) if one of tube, at the upper end of which is located a
the crash sensors fails. pyrotechnic ignition unit. It is connected with the
metal tube via a joining connector.
Driver and passenger front air bag system.
E98735
The driver and passenger air bags are single-stage

air bags.
2011 Fiesta 08/2010 G1087473en


System (SRS)
Refer to Wiring Diagrams Section 501-20B, for
Electrical
Special Tool(s)
Test and Deployment Lead, • Fuse(s)
Side Air Bag Module • Loose or corroded electrical connector(s)
418-555 • Circuit(s)
• Safety belt buckle switch(es)
• Passenger seat occupant sensor
418142
• Safety belt retractor pretensioner(s)
• Driver frontal air bag
Simulator, Driver and • Passenger frontal air bag
Passenger Air Bags, Driver
• Driver lower air bag (if equipped)
Lower Air Bag, Side Air
Curtains and Driver and • Driver and passenger side air bags (if
Passenger Safety Belt equipped)
501073 Retractor Pretensioners • Driver and passenger side air curtains (if
501-073A equipped)
Simulator, Side Air Bags 3. If an obvious cause for an observed or reported

501-401 concern is found, correct the cause (if possible)
E102676 the Ford diagnostic equipment.
General Equipment Air Bag Warning Indicator

The air bag warning indicator is incorporated into
Driver air bag module wiring harness
the instrument cluster, together with the automatic
detach detect circuit. The air bag warning indicator
Inspection and Verification illuminates for 3.2 seconds at key ON and goes
OFF for 4.8 seconds. If the system self-tests OK
1. Verify the customer concern. the indicator will stay OFF, but if there is a fault
condition, the air bag warning indicator will come
2. Visually inspect for obvious signs of mechanical ON again and stay illuminated.
or electrical damage.
The system is designed to illuminate the air bag
warning indicator continuously if the RCM circuit
is broken, either by loss of power, ground supply,
module disconnect or CAN BUS failure.
Diagnostic evaluation of the SRS should be made
through the DLC using the Ford diagnostic
equipment to establish the nature of the concern.
2011 Fiesta 08/2010 G1055910en

Diagnosing Customer Concerns Deactivation
Without Hard DTCs
WARNING: To avoid accidental
WARNING: To avoid accidental deployment, the RCM backup power supply
deployment, the restraints control module must be depleted. Wait at least one minute
(RCM) backup power supply must be after disconnecting the battery ground
depleted. Wait at least one minute after cable(s) before commencing any repair or
disconnecting the battery ground cable(s) adjustment to the SRS, or any
before commencing any repair or component(s) adjacent to the SRS sensors.
adjustment to the supplemental restraint Failure to follow these instructions may
system (SRS), or any component(s) result in personal injury.
adjacent to the SRS sensors. Failure to 1. Disconnect the battery ground cable.
follow these instructions may result in
personal injury. REFER to: Battery Disconnect and Connect
NOTE: Following the pinpoint tests when a General Procedures).
diagnostic trouble code (DTC) is not present, or
• Wait at least one minute for the backup power
the air bag warning lamp is not permanently
supply in the RCM to deplete its stored energy.
illuminated, will result in needless replacement of
air bag system components and repeat repairs. WARNING: To minimize the possibility of
premature deployment, live air bag
Speak with the customer to determine if a particular
modules must only be placed on work
set of conditions must be met in order for a fault to
benches which have been ground bonded
occur. If an illuminated air bag warning lamp is
and with the trim cover facing up. Failure
reported by the customer but is not present when
to follow these instructions may result in
the vehicle comes in for repair, pinpoint test
personal injury.
diagnostics cannot be used.
• Remove the driver air bag module from the
vehicle.
Diagnosing Customer Concerns with REFER to: Driver Air Bag Module (501-20
Hard DTCs Supplemental Restraint System, Removal and
Installation).
WARNING: Do not use substitute air bag
simulators when working on the SRS. Use • NOTE: REFER to FordEcat for a compatible
only the appropriate tool. Failure to follow driver air bag module wiring harness to use as
these instructions may result in personal a test lead.
injury. Connect a test driver air bag module wiring
Most air bag system diagnostic procedures require harness to the clockspring.
the use of system deactivation and system • Connect the simulator (501-073A) to the driver
reactivation procedures. These procedures require air bag module wiring harness in place of the
the air bag module(s) and safety belt retractor driver air bag module at the top of the steering
pretensioners to be disconnected from the SRS, column.
thereby removing the risk of air bag deployment
while diagnostics are carried out. • Remove the driver lower air bag module from
the vehicle.
Air bag simulators are required to carry out
diagnosis and testing of the air bag system. The • Connect the simulator (501-073A) to the wiring
simulator contains a resistor, used to simulate an harness in place of the driver lower air bag
air bag module connection to the system. It is not module.
acceptable to short-circuit the air bag module • Disconnect the passenger air bag module
connections with a 0 ohm jumper wire. If a 0 ohm electrical connector.
jumper wire is used to short-circuit the air bag
module connections, an illuminated air bag warning REFER to: Passenger Air Bag Module (501-20
lamp will be displayed and a DTC logged by the Supplemental Restraint System, Removal and
RCM. Installation).
2011 Fiesta 08/2010 G1055910en

• Connect the simulator (501-073A) to the wiring Reactivation
harness in place of the passenger air bag
module. WARNING: The air bag simulators must be
• Disconnect the side air curtain module electrical removed and the air bag modules
connectors on both sides. reconnected when reactivated to avoid
non-deployment in a collision. Failure to
REFER to: Side Air Curtain Module (501-20 follow this instruction may result in
Supplemental Restraint System, Removal and personal injury.
Installation). 1. Disconnect the battery ground cable.
• Connect the simulators (501-073A) to the wiring REFER to: Battery Disconnect and Connect
harnesses in place of the side air curtain (414-01 Battery, Mounting and Cables,
modules. General Procedures).
• Disconnect the side air bag module electrical • Wait at least one minute for the backup power
connectors on both sides. supply in the RCM to deplete its stored energy.
REFER to: Side Air Bag Module (501-20 • NOTE: If a new driver air bag module wiring
Supplemental Restraint System, Removal and harness has been used for testing, the wiring
Installation). harness should be retained for future test use
• Connect the simulators (501-401) to the wiring only.
harnesses in place of the side air bag modules. Remove the simulator (501-073A) from the
• Detach the driver side B-pillar trim panel to gain driver air bag module wiring harness at the top
access to driver side safety belt retractor of the steering column.
pretensioner electrical connector. REFER to: • Remove the driver air bag module wiring
B-Pillar Trim Panel - 5-Door (501-05 Interior harness from the clockspring.
Installation). • Connect and install the driver air bag module.
• Disconnect the driver side safety belt retractor REFER to: Driver Air Bag Module (501-20
pretensioner electrical connector. Supplemental Restraint System, Removal and
Installation).
• Connect the simulator (501-073A) to the wiring
harness in place of the driver side safety belt • Remove the simulator (501-073A) from the
retractor pretensioner. sub-harness at the driver lower air bag module.
• Detach the passenger side B-pillar trim panel • Connect and install the driver lower air bag
to gain access to passenger side safety belt module.
retractor pretensioner electrical connector. • Remove the simulator (501-073A) from the
REFER to: passenger air bag module wiring harness.
B-Pillar Trim Panel - 5-Door (501-05 Interior
• Connect and install the passenger air bag
module.
Installation).
REFER to: Passenger Air Bag Module (501-20
• Disconnect the passenger side safety belt
Supplemental Restraint System, Removal and
retractor pretensioner electrical connector.
Installation).
• Connect the simulator (501-073A) to the wiring
• Remove the simulators (501-073A) from the
harness in place of the passenger side safety
side air curtain module wiring harnesses.
belt retractor pretensioner.
• Connect and install the side air curtain modules.
• Connect the battery ground cable.
REFER to: Side Air Curtain Module (501-20
REFER to: Battery Disconnect and Connect
Supplemental Restraint System, Removal and
Installation).
• Remove the simulators (501-41) from the side
air bag module wiring harnesses.
2011 Fiesta 08/2010 G1055910en

• Connect and install the side air bag modules. Reactivate the System
REFER to: Side Air Bag Module (501-20 Reactivate the system means to carry out the
Supplemental Restraint System, Removal and reactivation procedure. REFER to Reactivation in
Installation). this procedure.
• Remove the simulator (501-073A) from the
driver side safety belt retractor pretensioner Principles of Operation
wiring harness.
• Connect the driver side safety belt retractor
pretensioner electrical connector. SRS Operation
• Attach the driver side B-pillar trim panel. REFER The vehicle is equipped with a DC fired sensing
to: system.
B-Pillar Trim Panel - 5-Door (501-05 Interior
Trim and Ornamentation, Removal and In the event of a severe frontal or three-quarter
Installation). frontal impact, in excess of a predetermined limit,
the driver and passenger front air bags and safety
• Remove the simulator (501-073A) from the belt retractor pretensioners and driver knee air bag
passenger side safety belt retractor (if equipped) will deploy.
pretensioner.
In the event of a severe full side impact, in excess
• Connect the passenger side safety belt retractor of a predetermined limit, either the driver or
pretensioner electrical connector. passenger side air bag, side air curtain (if
• Attach the passenger side B-pillar trim panel. equipped) will deploy.
REFER to: Air bag deployment will only occur, in the event of
B-Pillar Trim Panel - 5-Door (501-05 Interior a severe collision, when the ignition key is in the
Trim and Ornamentation, Removal and RUN position. The passenger air bag deactivation
Installation). (PAD) switch (if equipped) will deactivate the
• Connect the battery ground cable. passenger frontal air bag in the event of a severe
frontal impact; it will not deactivate any other
REFER to: Battery Disconnect and Connect deployable device.
• Prove out the system. RCM
The RCM retains full control of the whole system,

Glossary providing continual system checks and full
diagnostic capabilities. The non-volatile memory
Air Bag Simulator stores the diagnostic trouble codes, which can then
Air bag simulators are used to simulate air bag be downloaded through the data link connector
module connections to the system. (DLC) to the Ford diagnostic equipment.
In the event of a failure in the vehicle supply during
Deactivate the System an accident, the RCM provides a backup power
Deactivate the system means to carry out the supply, sufficient to deploy the air bag(s) for a
deactivation procedure. REFER to Deactivation in minimum of 150 ms. The backup power supply is
this procedure. discharged by the RCM within 60 seconds of the
battery ground cable being disconnected.
Prove Out the System
The RCM contains electronic acceleration sensors
The air bag warning indicator will illuminate for which measure the longitudinal acceleration and
three seconds. If there is a fault condition, the air the lateral acceleration and provide both signals
bag warning indicator will stay illuminated or to the micro-controller proportional to the amount
illuminate after a five second delay. of acceleration measured. The RCM also contains
a safing sensor, which prevents unintentional
deployment of the front air bags and safety belt
retractor pretensioners and knee air bag (if
equipped) in the event of a fault within the
2011 Fiesta 08/2010 G1055910en

electronic acceleration sensor(s). The RCM
compares the values it receives from the crash
sensor, side impact sensors, safing sensor and the
internal electronic sensors. If the deceleration due
to a frontal or side impact exceeds a stored
threshold value then the RCM triggers the air bags
and safety belt pretensioners as required.
Front Crash Sensor
The front crash sensor contains an acceleration

sensor, filter, amplifier and an application specific
integrated circuit for signal transmitting and is
mounted on the radiator grille opening panel
reinforcement. The crash sensor sends a signal at
a level determined by the crash severity to the
RCM. The RCM will evaluate the signal against
stored data and deploy the frontal air bags and
safety belt retractor pretensioners and knee air bag
(if equipped) when required. Both the crash sensor
and the internal RCM longitudinal acceleration
sensor must exceed a preset limit to initiate the air
bag.
Side Impact Sensor
The side impact sensors are mounted at the base

of the B-pillar on either side of the vehicle, to
facilitate remote lateral impact sensing. Each side
impact sensor contains an acceleration sensor,
filter, amplifier and an application specific
integrated circuit for signal transmitting. In the event
of an impact, in excess of a predetermined limit,
the side impact sensor sends a signal at a level
determined by the crash severity to the RCM. The
RCM will evaluate the signal against stored data
and deploy the side air bag on the side the
deployment request was initiated. Both the side
impact sensor and the internal RCM lateral
acceleration sensor must exceed a preset limit to
initiate the air bag. The RCM retains control of the
side air bags, side air curtains.
2011 Fiesta 08/2010 G1055910en

GENERAL PROCEDURES
Clockspring Adjustment
General Equipment
Adhesive Tape
WARNINGS:
If there is a break between installing the
clockspring and steering wheel rotation
sensor assembly and installing the
steering wheel, the centralizing of the
clockspring must be repeated.
If the centralization of the clockspring is
in doubt, the centralizing of the clockspring
must be repeated.
NOTE: Make sure that the road wheels are in the
straight ahead position.
1. 1. Turn the clockspring in a clockwise direction
until a resistance is felt.
2. Turn the clockspring in a counterclockwise
direction 2.5 revolutions, until the arrow
marked on the rotor of the clockspring aligns
with the raised 'V' section on the outer cover
of the clockspring.
2 1
2
E103063

E102968
2011 Fiesta 08/2010 G1063191en

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.
Failure to follow this instruction may result
in personal injury.
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.
2011 Fiesta 08/2010 G18618en

GENERAL PROCEDURES
Unserviceable Air Bag Disposal

Takata Petri AG, Grossostheimer Strasse
1. WARNINGS:
223, D-63741 Aschaffenburg, (Supplier Code
To minimize the possibility of injury in P790M) Germany.
the event of premature deployment, always
carry a live air bag module with the bag and
trim cover pointed away from the body.
in personal injury.
To prevent premature deployment, live

air bag modules must only be placed on work
benches which have been ground bonded.
in 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.
2.
WARNING: Under no circumstances is
an unserviceable air bag module(s) to be
returned through the local mailing system.
in personal 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.
3. NOTE: Autoliv air bag modules and seat belt
pretensioners.
Autoliv Gmbh, Theodor Heuss Strasse 2,
85221, Dachau, Germany.
4. NOTE: TRW air bag modules.
TRW Occupant Restraint Systems, FAO Rene
Getto, Industriestr 20, 73551, Aldorf,
Germany.
5. NOTE: TRW seat belt pretensioners.
TRW Occupant Restraint Systems, FAO
Helmut Goss, Industriestr 20, 73551, Aldorf,
Germany.
6. NOTE: Takata Petri air bag modules.
2011 Fiesta 08/2010 G18617en

GENERAL PROCEDURES
Scrapped Vehicle Air Bag and Safety Belt Pretensioner Disposal

- In-Vehicle Disposal
Special Tool(s) air bag module will be very hot. Failure to
follow this instruction may result in
Test and Deployment Lead,
personal injury.
Air Bag/Pyrotechnic Safety
Belt After deployment, the inflator(s) becomes
418-S055C (40-007D) inert, direct contact to the skin or eyes of
any free pyrotechnic residues should be
40007A avoided. Failure to follow this instruction
may result in personal injury.
Always wear gloves and safety glasses
Adapter Box (AC) when handling deployed air bag modules
418-143 (40-007-10) and safety belt pretensioners, Failure to
follow this instruction may result in
personal injury.
If the air bag module or safety belt
418143 pretensioner pyrotechnic residue should
contact the eyes, wash the eyes with clean
General Equipment water and seek medical assistance. Failure
to follow this instruction may result in
12 volt battery personal injury.
1. This procedure must only be carried out by If a large amount of air bag or safety belt
authorised scrap vehicle dismantlers. pretensioner pyrotechnic residue is
inhaled, seek medical assistance. Failure
WARNINGS: to follow this instruction may result in
To avoid accidental deployment, the personal injury.
restraints control module (RCM) backup 2. Disconnect the battery ground cable.
power supply must be depleted. Wait at
least one minute after disconnecting the For additional information, refer to: Battery
battery ground cable(s) before Disconnect and Connect (414-01 Battery,
commencing any repair or adjustment to Mounting and Cables, General Procedures).
the supplemental restraint system (SRS), 3. Remove the floor console.
or any component(s) adjacent to the SRS
sensors. Failure to follow these For additional information, refer to: Floor
instructions may result in personal injury. Console (501-12 Instrument Panel and
Console, Removal and Installation).
To minimize the possibility of premature
deployment, do not use radio key code 4. Disconnect the RCM electrical connectors.
savers when working on the SRS. Failure
to follow this instruction may result in
personal injury.
Before deploying the air bag module or
safety belt pretensioner pyrotechnic 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 6 meters. Failure to follow this
instruction may result in personal injury.
The air bag module or the safety belt
E58422
pretensioner should not be handled
immediately following deployment as the
5. Connect the special tools as shown.
2011 Fiesta 08/2010 G953458en

GENERAL PROCEDURES
1. 12 volt battery. 4. Deployment lead (40-007-15 (part of Test
2. Adapter box (AC). and Deployment Lead, Air Bag/Pyrotechnic
3. Deployment lead (part of Test and Safety Belt)).
Deployment Lead, Air Bag/Pyrotechnic
Safety Belt).
2
4
E58700
• For the pin numbers, refer to the special tool

6. Release the adapter box AC button.
usage table below.
TIE0024562 TIE0026423
7. To deploy an air bag or safety belt

pretensioner, connect the deployment leads
to the RCM electrical connector.
2011 Fiesta 08/2010 G953458en

GENERAL PROCEDURES
8. Move as far away as possible from the 9. To deploy the remaining air bags and safety
vehicle and depress both switches to deploy belt pretensioners, refer to the special tool
the air bag or safety belt pretensioner. usage table below for the RCM electrical
connector pin numbers.
• Repeat steps six and seven.
DTL4003010
Special Tool Usage

Description Electrical Red Deployment Black Deployment
connector Lead Lead
Driver air bag module A Pin 3 Pin 4
Driver lower air bag module A Pin 8 Pin 7
Passenger air bag module A Pin 9 Pin 10
Side air bag module - driver side B Pin 20 Pin 19
Side air bag module - passenger B Pin 7 Pin 8
side
Safety belt retractor and preten- B Pin 2 Pin 1
sioner - driver side
Safety belt retractor and preten- B Pin 3 Pin 4
sioner - passenger side
Side air curtain - passenger side B Pin 10 Pin 9
Side air curtain - driver side B Pin 17 Pin 18
10. RCM electrical connectors.
2011 Fiesta 08/2010 G953458en

GENERAL PROCEDURES
E58551
All air bag modules appointed through the local National Sales
Company.
1. 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.
2. 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
pretensioner fails to deploy, remove the
component.
3.
WARNING: Under no circumstances is
an unserviceable air bag module or safety
belt pretensioner to be returned through the
local mailing system. Failure to follow this
instruction may result in personal injury.
If an air bag module or safety belt
pretensioner fails to deploy, seal the
unserviceable air bag module or safety belt
pretensioner in suitable packaging and
return to the Exchange Plan Center, as
2011 Fiesta 08/2010 G953458en

Restraints Control Module (RCM)

General Equipment
Ford approved diagnostic tool
Removal
WARNINGS: 5. Torque: 10 Nm
Wait for a minimum of 3 minutes before x3
components.
x3
Wear safety goggles.
E103432

Installation
Health and Safety Precautions (100-00 1. To install, reverse the removal procedure.
2. When a new RCM is installed, configure the
Operation).
RCM using the diagnostic tool.
2. Refer to: Battery Disconnect and Connect General Equipment: Ford approved diagnostic
(414-01 Battery, Mounting and Cables, tool
3. Refer to: Floor Console (501-12 Instrument
Panel and Console, Removal and Installation).
4.
E104864
2011 Fiesta 08/2010 G1087482en

Front Impact Severity Sensor
Removal
WARNINGS:
components.
Operation).
3. Torque: 9 Nm
E103295
Installation
2011 Fiesta 08/2010 G1087483en

Driver Air Bag Module
Removal
WARNINGS: 1. Refer to: Supplemental Restraint System (SRS)
The supplemental restraint system (SRS) Health and Safety Precautions (100-00
is active for a certain length of time after General Information, Description and
the power supply has been disconnected. Operation).
components.
system is fully depowered and no other 3. Depending on the vehicle variant, steering
power source is connected. wheels with a different design for cut marks can
be fitted.
E104747
On both sides.
4.
2011 Fiesta 08/2010 G1063211en

3mm
E100617
5.
2011 Fiesta 08/2010 G1063211en

E100618
Installation
2011 Fiesta 08/2010 G1063211en

Passenger Air Bag Module
Removal
WARNINGS: 4.
is active for a certain length of time after Torque: 6 Nm
disconnecting or removing any SRS x8
components.
E103107
Operation).
Installation
(414-01 Battery, Mounting and Cables, 1. To install, reverse the removal procedure.
3.
E103060
2011 Fiesta 08/2010 G1063213en

Side Air Bag Module
Removal
NOTE: Removal steps in this procedure may 3. NOTE: Note the position of the electrical
contain installation details. connectors.
1. Refer to: Front Seat Backrest Cover (501-10
2.
E102619
2011 Fiesta 08/2010 G1063214en

E107387
4. Torque: 6 Nm
E100044
Installation
2011 Fiesta 08/2010 G1063214en

Side Air Curtain Module

Flat-bladed screwdriver Long Nose Pliers
Removal
WARNINGS: 1. Refer to: Supplemental Restraint System (SRS)
The supplemental restraint system (SRS) Health and Safety Precautions (100-00
is active for a certain length of time after General Information, Description and
the power supply has been disconnected. Operation).
Wait for a minimum of 3 minutes before Refer to: Battery Disconnect and Connect
disconnecting or removing any SRS (414-01 Battery, Mounting and Cables,
components. General Procedures).
Refer to: Headliner - 4-Door (501-05 Interior
Make sure that the vehicle electrical Trim and Ornamentation, Removal and
system is fully depowered and no other Installation).
power source is connected. Refer to: Headliner - 5-Door (501-05 Interior
Wear safety goggles. Trim and Ornamentation, Removal and
Installation).
NOTE: Removal steps in this procedure may 2. 1. If equipped.
General Equipment: Long Nose Pliers
E103471
2011 Fiesta 08/2010 G1063215en

3. General Equipment: Flat-bladed screwdriver 4. 3. Torque: 10 Nm
4. Torque: 10 Nm
1
E103472
E103470
Installation
2011 Fiesta 08/2010 G1063215en

Clockspring
General Equipment
Removal
NOTE: Removal steps in this procedure may 2. Refer to: Steering Wheel (211-04 Steering
contain installation details. Column, Removal and Installation).
1. 3.
1
E102601
E104718
2011 Fiesta 08/2010 G1063218en

2 1
E103001
Installation
2. Refer to: Clockspring Adjustment (501-20
Supplemental Restraint System, General
Procedures).
2011 Fiesta 08/2010 G1063218en

501-25-1 Body Repairs - General Information 501-25-1
.
SECTION 501-25 Body Repairs - General Information

CONTENTS PAGE
PAGE 1 OF 2
SPECIFICATIONS
Specifications...................................................................................................................... 501-25-3

Description and Usage of Body Repair Literature.............................................................. 501-25-4
Symbols.............................................................................................................................. 501-25-5
Health and Safety Precautions........................................................................................... 501-25-8
General............................................................................................................................... 501-25-8
Personal protection............................................................................................................. 501-25-8
Protection of the vehicle..................................................................................................... 501-25-8
Protective equipment.......................................................................................................... 501-25-9
Electronic components....................................................................................................... 501-25-9
Liquefied gas vehicles........................................................................................................ 501-25-9
Refrigerated conversion vehicles....................................................................................... 501-25-10
Environmental Regulations................................................................................................. 501-25-11
Body Construction.............................................................................................................. 501-25-12
General............................................................................................................................... 501-25-12
Integral body-frame............................................................................................................ 501-25-12
Convertible......................................................................................................................... 501-25-13
Non-monocoque bodywork................................................................................................. 501-25-14
Special points:.................................................................................................................... 501-25-15
Deformation behavior......................................................................................................... 501-25-16
Crash element:................................................................................................................... 501-25-16
Diagnosis and Damage Evaluation.................................................................................... 501-25-17
Noticeable damage to the bodywork structure................................................................... 501-25-17
No noticeable damage to the bodywork structure.............................................................. 501-25-17
Non-monocoque bodywork................................................................................................. 501-25-18
Body Sheet Metal............................................................................................................... 501-25-19
Types of steel..................................................................................................................... 501-25-19
Tools and Equipment for Body Repairs.............................................................................. 501-25-21
Alignment systems............................................................................................................. 501-25-21
Measuring systems............................................................................................................. 501-25-22
Welding gear...................................................................................................................... 501-25-24
Establish Repair Method.................................................................................................... 501-25-26
General............................................................................................................................... 501-25-26
Planning.............................................................................................................................. 501-25-26
Chronological sequence of repair....................................................................................... 501-25-26
Alignment Check................................................................................................................. 501-25-27
Straightening....................................................................................................................... 501-25-30
General............................................................................................................................... 501-25-30
Special features of non-monocoque bodywork.................................................................. 501-25-30
Complete Panel Replacement/Partial Replacement.......................................................... 501-25-31
Complete replacement....................................................................................................... 501-25-31
Corrosion Prevention.......................................................................................................... 501-25-33
Panel coatings and corrosion protection............................................................................ 501-25-33
.
PAGE 2 OF 2
Corrosion protection measures during repair work............................................................ 501-25-33
Corrosion protection for the floor pan (example)................................................................ 501-25-37
Corrosion Damage/Corrosion Repair................................................................................. 501-25-38
Sealer, Underbody Protection Material and Adhesives...................................................... 501-25-40
Cutting Technique............................................................................................................... 501-25-41
Spot weld milling tool.......................................................................................................... 501-25-41
Rod sander......................................................................................................................... 501-25-42
Short stroke saw................................................................................................................. 501-25-42
Orbital saw.......................................................................................................................... 501-25-42
Panel Beating Technique and Smart Repairs..................................................................... 501-25-43
General............................................................................................................................... 501-25-43
Dent removal using special panel beating levers............................................................... 501-25-43
Dynamic puller with counter bearing ................................................................................. 501-25-44
Hollow leveling (removing dent without a dolly)................................................................. 501-25-44
Dent removal using hammer and dolly............................................................................... 501-25-45
Heat-induced material shrinking......................................................................................... 501-25-45
Lead loading....................................................................................................................... 501-25-46
Paintless Dent Removal..................................................................................................... 501-25-47
Plastic Repairs.................................................................................................................... 501-25-49
General............................................................................................................................... 501-25-49
Plastic welding.................................................................................................................... 501-25-51
Plastic adhesive bonding.................................................................................................... 501-25-52
GRP repairs........................................................................................................................ 501-25-53
Special Repair Techniques................................................................................................. 501-25-55
Cabriolet vehicles............................................................................................................... 501-25-55
Liquefied gas vehicles........................................................................................................ 501-25-55
Refrigerated conversion vehicles....................................................................................... 501-25-56
Joining Techniques............................................................................................................. 501-25-57
Welding............................................................................................................................... 501-25-57
Soft soldering...................................................................................................................... 501-25-63
Rivets.................................................................................................................................. 501-25-64
Bonding.............................................................................................................................. 501-25-64
Bonding and welding.......................................................................................................... 501-25-65
Bonding and riveting........................................................................................................... 501-25-65
Impact of Insufficient Repair Quality................................................................................... 501-25-66
Water Leaks........................................................................................................................ 501-25-68
General............................................................................................................................... 501-25-68
Test method........................................................................................................................ 501-25-68
Test with UV lamp............................................................................................................... 501-25-69
Chalk/powder test............................................................................................................... 501-25-69
Smoke test.......................................................................................................................... 501-25-70
Stethoscope test................................................................................................................. 501-25-70
Ultrasonic detection............................................................................................................ 501-25-71
Ultrasonic test device......................................................................................................... 501-25-71
Workflow for tracing water entry......................................................................................... 501-25-71
Possible complaints and corrective actions........................................................................ 501-25-72
Wind Noise......................................................................................................................... 501-25-77
General information............................................................................................................ 501-25-77
Diagnosis............................................................................................................................ 501-25-80
Possible concerns with corrective measures..................................................................... 501-25-82
Noise, Vibration and Harshness......................................................................................... 501-25-86
SPECIFICATIONS
Description Finis Code Specification
Underbody protection 5 030 492 -
Anti-corrosion wax 1 219 834 WSK-M7C89-A
Cavity wax 5 030 081 -
Profiled butyl seal 1 128 983 S-M3G4620-A
Weld primer 1 205 996 -
Clinched flange protection 1 136 479 WSK-M4G245-B
Seam sealing compound 1 205 817 WSS-M4G364-A
Body sealing compound 1 143 255 -
Metal adhesive kit 1 203 241 -
Windshield sealant 1 613 838 WSK-M4G329-A
Adhesive spoiler set 1 219 837 -
2011 Fiesta 08/2010 G468061en

Description and Usage of Body Repair Literature

The purpose of this document is to give the vehicle
body specialist a general overview of possible
repair techniques for body repair on Ford vehicles.
Likewise, information about materials and tools to
be used is given.
No model-specific information is given. Such
information is saved in the respective Ford Etis
workshop manual. Supplementary or updated
information can be found in the Technical Service
Information.
Information on repair techniques, materials or tools,
which are not necessary for body repair on Ford
vehicles or which are not considered as
conventionally in use, are not listed in this
document.
Layout:
The general section is divided into the following
subject areas:
• How to use the document, with information on
the symbols used
• Health and safety information on using materials
and tools
• Information on bodywork construction and
materials used
• Workshop equipment and use of tools
• Damage Assessment and determining the
extent of the repair area
• Explanation of possible repair techniques for
body repair
• Possibilities of the repair or remedying leaks,
noises
Training:
The Ford Service Organization offers basic and
more in-depth training on much of the content of
this document. You can obtain an overview of the
entire training offering from the Ford Service
Organisation or on the Internet at
www.ford-training.de.
2011 Fiesta 08/2010 G468062en

Symbols
to follow them at all may result in damage
Warnings and hazard notices to the vehicle or to components.
Warnings and hazard notices are shown in this NOTE: This notice is used when the operator
literature by WARNING, CAUTION and NOTE should be made aware of special or extra
indicators. These notices are always shown before information.
a job step which can be associated with an
immediate personal or material danger. Symbols used
WARNING: This notice is used when failure Symbols are used to graphically represent
to exactly follow the instructions given in additional information about the operation, tool or
this literature or failure to follow them at materials. This information will not be shown
all may result in a hazard to persons and/or separately again in the text.
in persons being injured. The symbols used in this and other body repair
CAUTION: This notice is used when failure manuals may be used alone as well as in
to exactly follow the instructions or test combination in a diagram.
procedures given in this literature or failure
Des Description Des Description

cript cript
ion ion
1 Measuring tape 8 Drill through two panel thicknesses with
a 5 mm dia. drill
2 Saw
9 Drill through one panel thickness
3 Abrasive cutter
10 Drill through two panel thicknesses
4 hot air blower
11 Apply substance
5 Temperature specification (170°C in this
example) 12 Soldering iron
6 Drill with 6mm diameter 13 Metal-Inert Gas (MIG) weld
7 Drill through one panel thickness with a 14 Resistance Spot Weld
5 mm dia. drill
15 Welded seam (full or intermittent seam)
2011 Fiesta 08/2010 G468063en

Color coding
Different colors or shading can be used to depict
special areas and components.
Magnified and detailed views

If a detail cannot be clearly seen in the illustration
because of its size or location, it is shown enlarged
in a separate window.
• Blue: Main component which will be removed

or installed. Only actual movements will be
shown in blue in the diagram.
• Magenta: Materials or fixings, e.g. spot welds
or adhesives.
In an assembly operation, the colors show the
sequence of removal steps.
• Green: First component or the first partial
replacement section.
• Blue: Second component or the second partial
• Brown: Third component or the third partial
Movement arrows
Necessary work such as clinching flanges or
moving lugs etc. will be represented by broken
arrows.
Position lines within a diagram
A position line is used to indicate a special position
or a component. A spot weld which must be drilled
out through two panel thicknesses is indicated
here, different to all the others.
2011 Fiesta 08/2010 G468063en

2011 Fiesta 08/2010 G468063en

Health and Safety Precautions

Do not weld in damp areas, if necessary use an
insulation mat. Welding and grinding work near the
General battery presents the danger of explosion. For this
reason, it must be removed before the work is
Appropriate repair methods and their correct started.
implementation are very important for both vehicle
operating safety and personal safety. Cutting, grinding and alignment work on metal
panels can cause a noise level of 85 to 90 dB (A)
WARNING: There is danger of injury or even more. For this reason, you must always
through: wear ear defenders.
• High voltage when electrical welding.
The various body areas are subject to very high
– Do not perform welding work in a damp forces during realignment work. Should any
environment or on a wet substrate. Use component suddenly become detached during this
suitable insulation underneath. process, there is a very great danger of injury. For
• Flammable substances in the welding area. this reason, pulling chains and pulling shackles
– Remove flammable substances from the must be secured with arrester cables.
danger area. Remove the fuel tank and, NOTE: Work on airbag systems may only be
where required, those components which performed by persons who have a relevant
supply fuel. certificate of competence.
– Completely remove the battery before
Some special instructions must be followed when
carrying out any welding in that area.
working on airbag systems:
• Welding fumes, which are harmful to health.
• Always stand to the side of it when removing or
– Always ventilate the workplace well and use
installing an airbag.
an extraction system.
• Always store an airbag or an airbag/steering
• Welding spatter and UV radiation.
wheel with the airbag side pointing upwards and
– Wear protective clothing, gloves and welding in a safe place.
mask or welding goggles.
• Only install the airbag again when the vehicle
• Pyrotechnic components. is fully repaired and the complete electrical
– Disconnect the battery negative clamp and systems has been tested.
cover the battery terminal. Remove any • Take into account the location of air curtains
airbag components. and shoulder airbags.
All the regulations governing Health and Safety at
Work must be complied with during body repairs.
Protection of the vehicle
Personal protection Protect affected areas from weld spatter and dust
during all welding and grinding work on the vehicle.
Welding gases and grinding dusts can be harmful If metallic dust stays on the vehicle for some time,
to the health. For this reason, make sure that there is the likelihood of film rust formation.
rooms are well ventilated and work using the Grinding or sanding work produce tiny spots of
welding fumes extraction system. Sealants, damage to the paint surface, which may cause
underbody protection and paint residues must not corrosion.
be burnt down with an unshielded flame, as this For this reason, make sure to:
will produce gases which are damaging to health.
A dedicated extraction system must always be • Use carbon fibre blankets to protect the vehicle
used when welding or brazing. body.
• Use covering film to protect the vehicle body
When working with substances containing solvents,
from sanding dust and metal dust.
good ventilation must be provided, respiratory
protection must be worn and an extraction system • Take appropriate measures to protect the
must be used. interior equipment of the vehicle during any
repair work.
2011 Fiesta 08/2010 G468064en

In addition, take into account: For additional information, refer to:
• Remove fuel supply components as necessary. Side Air Curtain Module (501-20 Supplemental
• Protect working areas which are in danger of Restraint System, Removal and Installation),
catching fire with a fireproof blanket. Side Air Bag Module (501-20 Supplemental
Restraint System, Removal and Installation),
• The welding must not cause components of the
Driver Air Bag Module (501-20 Supplemental
air conditioning system to become heated.
Restraint System, Removal and Installation),
• Removal of any attached components in the Passenger Air Bag Module (501-20
space adjoining the repair area. Supplemental Restraint System, Removal and
• Use covering paper to protect the interior from Installation),
grinding dust. Air Bag and Safety Belt Pretensioner
• Create a definite barrier between the work area Supplemental Restraint System (SRS) (501-20
and the interior by using a carbon fibre blanket. Supplemental Restraint System, Diagnosis
and Testing).
Protective equipment
Liquefied gas vehicles
The following protective equipment must always
be used: Alternative fuel vehicles often require special
handling in the workshop area. Above all, assembly
• Protective helmet or welding mask. operations to some extent require particular
• Ear defenders and breathing protection. knowledge when dealing with the special
• Protective gloves and safety boots. technology and the safety regulations.
• Welding fume extraction. NOTE: Only fully trained personnel are permitted
to work on alternative fuel vehicles.
Electronic components These special requirements must be understood
and taken into account in the body shop as well.
Increased use of comfort and safety electronics in CAUTION: Danger of fire and explosion.
modern motor vehicles also requires the greatest The safety instructions must always be
attention to be paid during body work. Overvoltages followed when performing service work on
produced during welding and in alignment work fuel/gas systems. Failure to observe this
during bodyshell rectification may cause electronic instruction can lead to injury.
systems to be damaged. In particular, the safety
instructions for performing welding work on vehicles If the smell of liquefied petroleum gas (LPG) or
with airbag systems must be adhered to. compressed natural gas (CNG) is noticed in the
workshop, instruct everyone present as follows:
NOTE: After disconnecting the power supply and
before performing further work, a wait time of up • No smoking and extinguish all naked flames.
to 15 minutes must be maintained, depending on • Shut off all electrical and air powered
the vehicle. Work on airbag systems may only be equipment.
performed by persons who have a relevant • Evacuate the area.
certificate of competence.
• Ventilate the area.
Pay attention to the following points: • Contact the fire control authorities.
• Disconnect the battery negative clamp and • Move the vehicle to a dedicated, well ventilated
cover the battery terminal. area.
• Disconnect the electrical connector at the airbag Alternative fuels require special handling:
control module.
• Handle them in a specially dedicated, well
• If welding is to be performed directly near a
ventilated area, which is only accessible to
control module, it must be removed beforehand.
authorized persons.
• Never connect the negative cable of the welder
• Identify the designated area with new warning
near an airbag or a control module.
notices.
• Connect the negative cable of the welder close
• If possible close the main shut-off valve and run
to the location of the weld.
the vehicle on alternative fuel until it switches
2011 Fiesta 08/2010 G468064en

automatically to petrol operation. Only then is it NOTE: Basic and in-depth training is offered on
allowed to drive the vehicle into the workshop the following topics. You will find an overview of
or service area. the complete range listed in the Training brochure
• If possible do not allow any liquefied gas (LPG) published by the Ford Service Organization.
to escape. The plastic conversion has developed into a light,
• The ambient temperatures must not exceed clean and economical alternative because of
40°C. For this reason the LPG and CNG fuel constant further development of materials and
tanks must be removed on vehicles with LPG working techniques.
or CNG operation before using a drying oven NOTE: The material combinations, the
to dry the paint where the temperature exceeds workmanship and the working methods must
40°C. comply with the current food hygiene regulations.
Avoid situations in which fuel from an LPG or CNG For this reason, service and repair work on the
fuel tank can escape. These situations include: refrigerated conversion may only be performed by
authorized and specially trained technicians.
• Extremely hot ambient temperatures.
• Parking near a heating device. Refrigerated compartment constructions are often
made using both materials. The floor pan is made
• Raising the vehicle near a ceiling heater.
of structured, slip-proof aluminum panels and the
wall and ceiling cladding is made of smooth
Refrigerated conversion vehicles surfaced plastic elements.
CAUTION: PUR hard foam is flammable. If
Apart from the special materials used in building PUR hard foam is overheated, it will burn
the structure of the refrigerated compartment, such on its own with a brilliant yellowish flame.
vehicles have special energy and refrigeration It produces unpleasant choking and toxic
systems which require special handling during fumes. Special measures must be taken
repair. when welding the vehicle body.
CAUTIONS: Polyurethane wall and ceiling elements are
manufactured using a sandwich principle. An
Danger of injury. Work on the 230<SP>volt
insulating polyurethane core is coated with food
system of the refrigeration equipment must
grade ABS plastic on one side.
only be carried out by trained specialist
personnel. PUR hard foam does not decompose, is rot
resistant and is odorless. These properties make
The refrigeration system is filled with it suitable for use as insulation.
refrigerant R134a. This can cause frostbite
if it contacts the skin. Pay attention to the Because of its closed cell structure, water uptake
corresponding warning notices and by PUR hard foam is for the most part only a
instructions in the chapter Air Conditioning problem at edges. Cut edges or other mechanically
Systems. worked surfaces must however be sealed with the
greatest care.
NOTE: Work on the refrigerant circuit may only be
performed by persons who have a relevant The conversion to a refrigerated vehicle is
certificate of competence. performed as made-to-order production. The large
surfaces of the wall and ceiling cladding can be
Vehicles with a refrigerated compartment are often changed and are particularly easy to repair.
used to transport foodstuffs. For this reason,
additional hygiene regulations must be complied If access to the back of a body panel section is
with during repair work. needed because of body straightening work, in
some circumstances it is cheaper to perform a
Aluminum and plastic are used to construct the cut-out repair instead of removing an element.
two different types of compartment found on
refrigerated vehicles. The repair process is fully described in the Student
Information booklet Refrigeration System
The aluminum conversion is a very stable and Technology, Transit 2000.5 Freshline.
technically perfect variant. However, against this
the relatively high production costs and a lower
payload must be taken into account, because of
the weight of the aluminum conversion itself.
2011 Fiesta 08/2010 G468064en

Environmental Regulations
Orderly and responsible waste management is not
only very important for the protection of health and
the environment, but it also has great importance
where saving natural resources is concerned.
In body repair shops, since the introduction of the
EU directives on the avoidance of vehicle waste
and the promotion of return, re-use and recycling
of vehicles and their components (2000/53/EU),
more rigorous attention than before is also paid to
avoidance and recycling of waste materials.
NOTE: The organization of disposal in the
operation must comply with the country specific
waste regulations:
In this respect, body repair shops must take into
account and comply with the following
requirements:
• Separate waste according to its recycling and
disposal methods.
• Produce evidence for the correct transport and
disposal of waste.
NOTE: The organization of disposal in the plant
must comply with the requirements of the Waste
Avoidance and Management Act.
The avoidance and recycling of waste must always
take priority. However, despite all measures which
may be taken, waste cannot be completely
avoided.
NOTE: Useable waste which is not allowed in
household rubbish, must be disposed of as special
waste
All remaining waste must be treated as commercial
waste and disposed of according to the local
requirements.
Only applies to the EU:

The vehicle manufacturer is also under a legal
obligation since the older vehicle legislation came
into force throughout Europe in 2002.
This law covers the surrender, withdrawal and
environmentally friendly disposal of older vehicles
through the manufacturer.
The older vehicle legislation contains all the
necessary information for the environmentally
compatible disposal of older vehicles, starting with
preliminary handling involving the removal of all
operating fluids, deactivation of pyrotechnic
components, elimination of pollutants and then
further handling by dismantling components for
re-use and recycling.
2011 Fiesta 08/2010 G468065en

Body Construction
General
Integral body-frame
Under bodywork construction, a general distinction
is made between monocoque and non-monocoque In this method of construction, coverings,
bodywork. The safety of the occupants is the main reinforcements, retaining panels and profiles are
consideration for all types of bodywork permanently joined together using a variety of
construction. The front and rear sections are joining techniques (gluing, spot welding, laser
designed so that they absorb the energy of the welding, soft soldering or brazing). The
impact via crumple zones. The use of modern load-bearing function of the structure must always
design and manufacturing methods and the use of be achieved in each case.
newly developed body panels (relating to their
deformation and strength properties) mean that, There is no distinction made between components
despite the continuous weight-savings, all which are purely subject to bending/torsion or thrust
safety-related requirements made of the loads and parts which perform sealing/covering
construction can be met. functions (as in non-monocoque bodywork for
example). In modern passenger vehicles,
monocoque bodywork is very widespread and
offers the advantages of a lightweight and low-cost
construction.
The rigidity of the bodywork is achieved by a panel The mounting points for ancillary components such
skin and panel cross-section with the largest as doors and wings are permanently built into the
possible profile and therefore the largest resisting monocoque bodywork.
torque (such as for instance the rocker panel). High rigidity of the bodywork is vitally important to
Swage lines in the outer area of the bodywork keep the elastic deformations low at the joins to
increase the stiffness and the natural vibration the ancillary components and to prevent noise
frequency, to prevent possible drumming noises. when driving. Small gap dimensions are therefore
2011 Fiesta 08/2010 G468066en

only possible on vehicles with very stiff bodywork. The protected passenger compartment with strong
With high bodywork stiffness, the construction can pillars, rocker panels and doors with integral side
exert an influence on the handling of the vehicle impact protection increase occupant protection.
(e.g. on poor road surfaces). Opening of the doors is ensured, even if there is
Advantages of monocoque bodywork: extreme deformation.
• Weight reduction. NOTE: Repair work must always be performed

according to the established workshop literature.
• Economical manufacturing technology. All the safety requirements must be guaranteed
• High torsional rigidity and high flexural strength. after any repair work has been performed !
• Defined deformation behavior at the front and
rear.
• Maximum passive safety due to the strong
passenger compartment
Convertible
Des Description Des Description

cript cript
ion ion
1 Body components adopted from the 5 Maximum-strength sheet steel
Focus 2004.75 (07/2004-)
6 Aluminium, can be subjected to high
2 Conventional bodywork construction steel stresses
3 High-strength sheet steel The body of a convertible differs from the principle
4 Super-high strength sheet steel of the integral body-frame of a saloon due to the
lack of a roof construction. The body has a high
2011 Fiesta 08/2010 G468066en

degree of torsional stiffness. This is achieved by • Use of heavily structured reinforcing panels in
using high, super-high and maximum-strength the rocker panel and pillar area.
sheet steel and body reinforcements in • In the area of the windshield frame and A-pillars,
specifically-targeted areas. thick-walled reinforcing tubes are used (roll-over
These reinforcements can be installed in the area protection).
of the doors (diagonal braces etc.) or on the • Because there is no roof, the bridge construction
underfloor. In contrast to the saloon (or other principle cannot be used as it is on the saloon
non-convertibles) with square-section side for example. Flexural and torsional rigidity must
members (closed profile), these reinforcements be ensured by other components.
have a profile which is open on the underside
(U-section).
Non-monocoque bodywork
Special constructional changes within the bodywork
structure: Non-monocoque bodywork is built onto a frame or
• Reinforcing or increase in the thickness of the a chassis. Frames used for this have various
sheet steel in the pillar area. construction forms, e.g. the ladder frame or tube
frame. Non-monocoque bodywork is the original
• Reinforcing or increase in the thickness of the
way of constructing vehicles.
sheet steel in the floor pan structure (rocker
panel area).
Des Description The ladder frame is still commonly used today for
cript truck and off-road vehicles. The bodywork is placed
ion on the frame or chassis. The total load which
occurs while driving is transferred to the chassis.
1 Vehicle body.
More sporting vehicles can be built with
2 Frame Assembly non-monocoque bodywork, mostly using a lattice
3 Bolted connection tube frame. Limitations in the design are accepted
for the benefit of low weight. The outer skin here
2011 Fiesta 08/2010 G468066en

is usually made of plastic or alloy. This type of suction power during straightening repairs.
construction is also common in touring car racing Frequently, the body also has to be detached from
for instance. the frame structure in order to carry out separate
Special features of non-monocoque bodywork repair.
construction: Due to the very stable frame structure, please note
• Partly large surface panels and high volume that the straightening behavior is completely
shaped parts. different to that of a passenger vehicle. The frame
and the attached body must be repaired
• Thicker materials and greater reinforcements independently of each other.
in the frame area.
Further information can be found in the respective
• Floor pan as frame structure with high torsional
body repair manual.
rigidity and flexural strength.
• Side panels only make a small contribution to
the overall stability of the body. Special points:
Instructions for repair:
Tailored blanks
A different repair technique is necessary during
repairs. A deformed frame structure requires high
Blue: Tailored blank in repair procedures that would re-create joins of

the same quality.
Arrows: Laser weld seam
NOTE: No cutting, no welding and therefore no
The term "tailored blanks" describes the connection sectional repairs are permitted in the immediate
of two different panel thicknesses and/or strengths area of the laser weld seams. The model specific
in the bodywork carcass. This connection is done requirements are documented in the respective
using laser weld seams. Cut locations exactly on Body Repair Manuals.
the laser weld seams are not permitted, as at
present no joining techniques are approved for use Typical application areas are:
2011 Fiesta 08/2010 G468066en

• Side member • Rocker panel inner reinforcement
• Door inner reinforcement/door frames • Roof rail inner reinforcement
• Wheelhouses
Deformation behavior
Des Description The rear of the vehicle, like the front of the vehicle,
cript has structures which protect the passenger cell
ion through staged deformation in the event of an
accident. The design layouts, however, are adapted
1 Bolted crash element to the requirements of the rear area.
2 Front side member
3 Rear side member
Different materials and design features lead to

staged deformation of the front and rear of the
vehicle in an accident.
Crash element:
At the front of the vehicle there is a crash element
which is connected to the side member by threaded
connections. This crash element can absorb light
impacts of up to about 15 km/hr. Because of the
threaded connections, the crash element can be
changed very quickly.
NOTE: Deformed crash elements must not be
straightened or repaired.
Heavier impacts which can no longer be absorbed
by the crash element must be absorbed by the side
members or the floor pan structure. Depending on
the extent of the damage, a part or complete
replacement can be performed on the side
member.
2011 Fiesta 08/2010 G468066en

Diagnosis and Damage Evaluation

Assessment of the extent of the damage includes • Outer panel including seam seals for cracks or
visual inspection and dimensional inspection of the flakes in the paint caused by the accident.
vehicle. In order to correctly determine the extent • Size of the gap on doors and hoods for
of the damage caused by an accident, in-depth evenness.
technical knowledge, practical experience with the • Freedom of movement of door and hood/tailgate
technical equipment and the testing and measuring locks.
devices is required. • The vehicle roof for folds (gap measurement on
vehicles with sunroof)
Noticeable damage to the bodywork • Dotted flange in door section for deformation
structure and cracked weld spots.
• The side members and crash components for
Positive accidental damage assessment can only crumpling and folding.
be achieved if the service technician is able to • Trunk floor and floor pan from above and below
reconstruct the effect of an impact on the body for crumpling.
structure.
For example:
No noticeable damage to the bodywork
If the impact occurs on the front left-hand side structure
member, the right-hand side member will usually
also have been damaged. Often the length of this In addition to external indicators such as flaking
side member will not have changed, but because paintwork or cracks in the underbody protection, it
of the rigid body design, it may have become is vital to check for damage to the body structure
deformed. This damage can be detected through that is not visible from the outside (hidden body
the size of the gap between the door and fender damage) during a damage assessment. Unless
or by measuring the vehicle. ancillary components are removed, it is often
In the case of more severe impacts, in which the impossible to achieve accurate diagnosis of the
front part of the vehicle cannot absorb all of the underlying body parts.
impact energy, the passenger cell is also used to NOTE: In order to determine the damage as
absorb the energy. Here, the energy is transferred accurately as possible, it may be necessary to
via the A pillar and distributed there. This results remove ancillary components in the area of the
in deformations in the roof and the door sill. damage.
NOTE: Because of existing damage to the Particular attention must be paid to the following
bodywork structure, damage diagnosis on a vehicle components:
lift may give extra incorrect diagnosis results.
• The A, B and C pillars in the roof area.
NOTE: Training courses are offered on this subject. • Floor pan.
For an overview, please refer to the Ford Service
• Rear ancillary components, such as bumper,
Organisation's training course brochure.
lights, etc.
If for instance the Ford Focus Coupé/Cabriolet is • Trunk floor, spare wheel cavity.
raised on a vehicle lift, the dead weight of the
• Rear coverings, such as interior trim, carpet,
vehicle will cause the front end to drop by approx.
etc.
2 to 3 mm.
• Lower rubber seals, e.g. in door area (welded
The altered door position is clearly recognizable flange).
by stiffness of the lock; the door moves upwards.
• Area under the rear seat.
This causes the lock pin to contact the guide
element of the door lock. • Attachment points of transmission system,
steering, engine, drive shafts, front and rear
It is possible to draw conclusions about the extent axles.
of the damage through a visual inspection of the
• Electrical components, e.g. the radio (damage
external damage. In general, the following areas
through shaking or through voltage peaks).
are to be checked during the visual inspection:
2011 Fiesta 08/2010 G468067en

Non-monocoque bodywork
The chassis and bodywork must always be
checked during damage diagnosis on vehicles with
non-monocoque bodywork.
It is also important here to inspect closely for
damage the impact area and the areas absorbing
forces.
With these vehicles, simple inspections can already
give an indication of possible deformations.
In addition, you must check for the following for
vehicles with frame structures:
• Cracks in the paint on the frame welds.
• Traces of deformation on frame components.
• Check attachment points (silent blocks) for
position changes and damage.
• Changed position of rubber seals.
• Fit and function of the ancillary components.
2011 Fiesta 08/2010 G468067en

Body Sheet Metal

Types of steel • Normal strength steel has a minimum yield
strength of up to about 210 N/mm².
Steel body panels are still the most important • High strength steels have a minimum yield
materials used in the fabrication of stressed skin strength of about 150 to 600 N/mm².
vehicle bodies. In addition to the familiar types of • Ultra-high-strength steels have a minimum yield
steel, reinforced high-strength and also strength of about 400 to 1200 N/mm².
ultra-high-strength special steels are used in
vehicle body construction. High-strength and ultra-high-strength steels are
mostly installed in safety relevant locations
Types of steels are classified by their properties of (structural components). Among others, these are
strength and elasticity. side members, pillars, roof frames.
Pos. Used type of steel Application range Pos. Used type of steel Application range
1 Ultra High Strengh Impact carriers, 5 Normal strength Outer Panel, ...
Steel (UHSS) Bumper carriers, steels
Reinforcements ...
2 Extra High Strengh Frame side
Steel (EHSS) member, ... Normal strength steels
3 Very High Strengh Wheel house, ... Normal strength steels are most often used in body
Steel (VHSS) construction. They are relatively soft and are
4 High Strengh Steel Roof sticks, ... therefore particularly suitable for the deep drawing
(HSS) processes used in body manufacturing. As well as
very good reshaping properties, the panels also
have a relatively high rigidity.
2011 Fiesta 08/2010 G468068en

High strength steel panels Because of the use of such steels, some special
points must be taken into account during body
The strength of the material and the nature of the repair:
surface can be changed as required by different
• Increased force required during straightening.
engineering processes. In order to achieve suitable
configuration and a good match between • Strong springback tendency during alignment
construction specifications and what is possible in work.
production, a large range of high strength panels • Cutting tools have a shorter useful life.
is available. • NOTE: High-strength and ultra-high-strength
The range of the minimum yield strength is from steel panels must not be heated during
180 N/mm² to 460 N/mm². High strength thin steel straightening work.
panels usually have a surface finish. Electrolytic Work without applying heat when carrying out
surface sealing is preferred. Within the group of straightening work. Losses of strength will occur
high strength steels, various types of steel are used at temperatures as low as 400°C. The basic
in body construction: working methods and the tools to be used are
• Micro-alloyed high strength steels for very the same however.
difficult drawn components such as fenders, the
internal components of doors, hoods and
luggage compartment lids or load bearing Coated steel panels
components such as sidemembers,
crossmembers etc. In a similar way to high-strength steel panels,
coated steel panels are finding more applications
• Bake-hardening steels and phosphorus because of the better corrosion protection which
alloyed steels for external panel components they offer. There are basically two different process
with higher draw depth and subject to higher which are used to apply a zinc layer:
operational demands.
• Isotropic materials for flat shaped outer steel • Hot dip zinc coating (no longer used in vehicle
panels on doors, hoods, luggage compartment construction).
lids, roofs. • Electrolytic zinc plating.
The following points must be noted when welding:
Ultra-high-strength steels NOTE: Welding fumes are harmful to health. Make
certain that the workspace is well ventilated and
These steels are predominately used for body use welding fume extraction.
structural components which are relevant to safety. • Zinc starts to melt at about 420°C.
Despite the reduced thicknesses of the panels
• The zinc vaporizes at a temperature of about
used, weight reduction is often achieved together
900°C.
with greater strength. As with high-strength steels,
special types of steel are used in the • The amount of heating determines the damage
ultra-high-strength steels group: to the zinc coating, and therefore to the
corrosion protection.
• Complex phase steels are used for door side
• NOTE: Coated panels have a higher electrical
impact carriers, bumper carriers and body
resistance, but this can be compensated for by
components relevant to crashes. Besides high
increasing the welding current by 10 - 20% .
strength, they have good cold reshaping
properties and are easily welded. Resistance spot welding is particularly suitable
• Dual phase steels have the same properties for welding zinc-coated panels, because no
as complex phase steels. Because of their high widespread warming occurs.
strengthening properties they are suitable for • With electrolytically zinc-plated panels there is
body reinforcements. no need for any special preparation because
• Residual austenite steels and martensite the zinc coating does not need to be removed.
phase steels have very high strength levels of
up to 1200 N/mm² and are mostly used in body
structures relevant to crashes.
2011 Fiesta 08/2010 G468068en

Tools and Equipment for Body Repairs

Alignment systems Straightening and alignment repairs are often
required to restore a vehicle body to its original
NOTE: Please refer to the Ford Service Equipment shape after accident damage.
Catalog for information on the body tools Universal aligning and measuring systems and
recommended by Ford. universal alignment angle systems are suitable for
this work.
Des Description • Simple to use.

cript – Stationary design with drive-on ramp.
ion – Height-adjustable aligning platform.
1 Universal aligning and measuring system – Universal gauge extensions with fast
2 Universal alignment angle system anchoring ability around the whole
circumference of the aligning platform.
Basically, the aligning and measuring system must • Facility to test individual body measurement
satisfy the following requirements: points, with or without aggregates being
removed.
• Universally applicable to all types of passenger
car. Can also be used on light commercial and Alignment angle devices survey the vehicle at
off-road vehicles. several points on the body. These are usually
• Accepts the forces involved during straightening. points which are also used in production. In
addition, a recording over the rocker panels is
• High stability and mobility.
possible. A measuring system is not needed,
• Can accept all or part of the weight of the because the necessary body points are specified
vehicle. with gauges. For this purpose, vehicle specific or
• Quick to set up. universal gauges are available.
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Universal alignment systems consist of a vehicle As a basic principal, body reference points should
mounting (universal clamps at the rocker panels) be chosen which are shown in the body frame
and a pulling device. In addition, a measuring measurement data sheet.
system is required.
NOTE: To be able to determine difference in
NOTE: Because universal clamps are used, the measurements, the same reference points must
rocker panel area must be reworked for optical and always be chosen on both sides. For this purpose
corrosion protection reasons after the repair is the beam compass must be positioned
completed. symmetrically.
Pay attention to the following points: Comparison measurements can also be made on
• Clean the attachment areas. the outside of the body. Depending on the damage,
left/right measurements (symmetry measurements)
• Anchor the vehicle free of stress on the relevant and diagonal measurements can be made using
system. the beam compass, telescopic rod or a measuring
• Support the aggregates to take strain off the tape.
body.
Laser measuring systems
Measuring systems These systems use laser beams which are

projected in one or more planes.
In order to exactly diagnose a damaged vehicle
body, measuring systems are required. Depending
on the measuring method, the systems vary in
having mechanical, optical, acoustic and electronic
measuring devices. In some cases, hybrid versions
of particular systems are found.
NOTE: When working with each measuring system,
the manufacturer's instructions provided in the
description of the measuring equipment must be
followed.
Basically, the measuring systems must meet the
following requirements:
• Universally applicable to all types of passenger By the use of two parallel laser heads which can
car. Also can be used on light commercial and be turned, symmetrical points of a vehicle body
off-road vehicles. can be tested and compared. Using the linear
scales which are attached to the measuring points,
• Suitable for all accident damage.
the measurement data is read off with the aid of
• Fast capture of body measurement points in the the projected laser beams.
underfloor and external areas.
The integral inclination gauge also allows
• Data catalog to record all measurement points
differences in height to be quickly checked.
(length, width and height) both with and without
the aggregates being installed. Mechanical measuring system
NOTE: Basic and in-depth training is offered on The use of mechanical measuring equipment is an
the following topics. You will find an overview of easy and effective way to check a vehicle frame
the complete range of training offered in the Ford and chassis assembly quickly, exactly and reliably.
Service Organization training brochure.
In many cases an assessment of the damage can
Beam compass be made with the help of this system, without the
need for elaborate setting up.
The beam compass is a very practical and
straightforward aid for measuring bodywork and
especially floor assemblies. The beam compass
can be used to detect dimensional variations
across the length and the width by means of
comparison measurements and diagonal
measurements.
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Measuring systems which are firmly mounted on
an aligning platform require more work in setting
them up. They are used to constantly check
measurements during alignment work.
This type of mechanical measuring system has
measuring scales and measuring slides in three
measuring axes. So that the body can be
measured, the vehicle is secured on the aligning
platform base frame using four universal chassis
clamps. The exact fixing points are given in each
respective data sheet.
Ultrasonic and mechanical-electronic measuring

Because of its self-centering mount, measurement systems
can be carried out by one person.
These measuring systems can be combined with
Further advantages: all current aligning platforms. In addition these
• Fast deployment. measuring systems can be used independently of
• Simple to use. an aligning platform by using a vehicle lift or
suitable support stands.
• Can be extended using adapters, measuring
probes and measuring tubes.
Des Description Acoustic or ultrasonic measuring systems use

cript ultrasonic emitters and sensors to survey a body.
ion To do this, ultrasonic emitters are mounted on the
1 Ultrasound measuring instrument vehicle using special attachments. During the
measuring process the ultrasonic emitters
2 Mechanical-electronic measuring system constantly send out signals which are received by
sensors (microphones) and then passed to a
2011 Fiesta 08/2010 G468069en

computer. The measurements are displayed on Welding gear
the computer screen and are compared with the
required values supplied by the vehicle As in the past, the dominant process in body
manufacturer. construction is resistance welding, in particular
The ways in which mechanical-electronic spot welding. Depending on body type, up to 5000
measuring systems can be used are similar to spot welds are applied, either by welding robots or
those of the acoustic measuring systems. They in the multi-point welding machine.
can also be set up on a suitable understructure, Resistance spot welding permits very high energy
without an alignment jig. After this system has been to be concentrated on a relatively small area of the
arranged under the vehicle floor and adjusted to workpiece in the shortest possible time and when
three undamaged vehicle measuring points, the high pressure is applied, a permanent joint is
measuring arm is brought up to the required formed. During repairs the resistance spot welds
measuring points and the readings compared with used in production must be re-created accordingly.
the reference values. The data is transmitted to a
computer where it is evaluated and the results
displayed on a screen.
Des Description therefore cannot reliably join panel thicknesses

cript greater than 3 mm.
ion Equipment with inverter technology allows better
1 MIG welding machine spot weld quality because of a constant high
welding current. In addition the high welding current
2 Resistance spot welding machine makes shorter welding times possible and the
electrodes therefore have a longer working life.
NOTE: If a suitably powerful welding machine is Inverter welding is a further development of
not available and multi-layer panel joints with a electrode welding.
total thickness of over 3 mm need to be made,
puddle welding must be used. Further advantages of the new inverter welding
equipment are:
Although in principle, high and super high-strength
panels are adequately or well suited to resistance • good welding performance with constant quality,
spot welding, considerable problems may arise even with high switch-on times
because of low welding power, especially where • recognition of and compensation for disruptive
thicker panels or three layers of panel must be factors: e.g. primer, adhesive, rust-prevention
welded together in the workshop. In particular, paint
older welding equipment does not have the latest • own and pre-set welding programs which can
welding technology nor welding power and be saved and called up
2011 Fiesta 08/2010 G468069en

• quality confirmation through logging of all
important welding data
• fast changing of spot welding clamps or spot
welding guns as required
The following functions can be controlled and
monitored by programming the welding equipment:
• Control of the start conditions by resistance
measurement (dirt, paint, bodywork adhesive,
shunt circuit through the next spot weld).
• Ensuring the optimum welded connection.
• Checking the energy balance, resistance and
quality.
In the case of resistance spot welded connections,
faults in the weld are difficult to see from the
outside. It is therefore absolutely vital to know the
particular properties of the welding machine being
used. A test weld with subsequent peeling test will
provide information on the quality of the weld. The
spot weld itself must not separate, it must tear
away leaving a hole.
In the production of vehicle bodies, MIG welding
plays a minor role as a joining technique. It is used
for components subject to high demands, such as
threaded plates for axle mountings, or at locations
which cannot be spot welded for access reasons.
2011 Fiesta 08/2010 G468069en

Establish Repair Method

General • Separate and remove the old part.
– Take into account the special features
Before starting accident repair work, make sure particular to the vehicle.
that the necessary spare parts and repair material
are available. • Prepare the joint locations.
– - Sand and align the weld flanges.
– Apply corrosion protection measures.
Planning
– Offer up the new part.
NOTE: The body interconnection is to be • Attach the new component.
maintained if possible. Repair is preferred to • Rework the welded joints (grind welded seams).
renewal of body components. Furthermore, check
if it is possible to perform a partial repair.
During planning the following job steps must be
observed and adhered to:
• Determine the repair method taking into account
the information made available in ETIS.
• Work out which repair components will be
needed and obtain them.
• Establish what disassembly work is needed.
• Check for specific features such as airbags,
route of water drain hoses, electric cables and
the location of NVH elements.
• Cut out the old parts (only when the new parts
are waiting ready).
• Prepare the joint locations.
• Attach the new parts.
• Prepare the area of the repair for painting
(grinding welded beads).
• Perform any solder work which is required at
the repair location.
Chronological sequence of repair

NOTE: Refer to each vehicle specific chapter in
the workshop literature for details on the individual
points.
The actual sequence of repair can be divided into
the following steps:
Job steps for the coachbuilder:
• Straightening
• Establish separating cuts and mark them.
– Take into account the requirements given in
the repair instructions.
– Place the new part ready for use and include
it in the repair plan.
2011 Fiesta 08/2010 G506656en

Alignment Check
General Data sheets with the body frame dimensions for
If there is concern that the body has been body measurement are specified in the
deformed, the body must be measured. Several model-specific repair instructions in each case.
measuring procedures and tools can be used for Pay attention to the position of the measuring
this purpose. probes for each of the measurements given. A
tolerance of ± 3 mm applies to all specified
With simple measuring systems, it is possible in dimensions.
most cases to draw a conclusion about the extent
of the damage through a quick measurement Measuring points that are specified in a curve are
without time-consuming assembly work to be measured so that the greatest distance from
(straightening jig). the opposite measuring point is reflected. For exact
determination of the measuring points, enlarged
NOTE: For the floor pan and the exterior of the sections are shown.
vehicle, measuring data is contained in the
vehicle-specific repair instructions for each vehicle. Example of measuring the vehicle
Manufacturers of measuring and straightening jigs superstructure
create data sheets for this purpose for each
vehicle.
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Example of measuring the floor pan
2011 Fiesta 08/2010 G506657en

2011 Fiesta 08/2010 G506657en

Straightening
General Special features of non-monocoque

bodywork
Straightening repairs are often required to restore
the original body shape. To do this, the vehicle Straightening is different to monocoque body
must be placed on a straightening jig so that a construction because of separate straightening for
pulling device can be used. bodywork and chassis.
NOTE: Basic and advanced training courses are If only the body is damaged in an accident, light
offered for the following contents. For an overview straightening repairs can be carried out while still
of all training courses offered, please refer to the mounted on the chassis.
Ford Service Organisation training course NOTE: With strong straightening forces, these
brochure. bolted connections may be damaged (bodywork
Straightening is considered as the process of to chassis frame). Monitor the bolted connections
pulling out the deformed body parts, up to cutting continuously during the straightening work. Holding
out the parts that need replacing. If distorted clamps or alignment angles must be attached
components remain on the vehicle, then the term directly to the chassis frame.
alignment work is used. Straightening of chassis frames
Body straightening requires practice and NOTE: High-strength steels must not be heated.
experience. Before starting body straightening, the
If the body and chassis frame have to be
exact direction of impact must be determined. The
straightened, they must first be separated from
straightening force must be applied in the opposite
each other.
direction to that of the impact. Only in this way can
it be guaranteed that the original shape will be The following conditions must be met:
achieved again. • The repair must be economically justified.
Note the following points during the process of • The production quality and stability of a frame
body straightening: must be achieved again after carrying out the
• Secure the pulling unit with a safety cable. repair.
• Do not remove bonded glass prior to • In principle, the driving and operating safety of
straightening. the vehicle is paramount.
• Never apply heat during straightening. • Cold straightening of deformed areas with sharp
edged folds cannot be carried out.
• If necessary, open doors or hoods/lids/liftgates
during straightening. • Straightening with the application of heat
(welding torch) requires much experience and
• Check dimensions and gaps continuously during
accurate knowledge of the behavior of steel
straightening.
panels when heated.
• High-strength steel panels have a stronger
• The temperature and duration of application of
tendency to retain their deformed shape.
the heat are to be considered in particular.
• During the straightening repairs, monitor the
• Individual components of the frame, such as
attachment of the pulling unit to the vehicle.
cross members, brackets, etc. can be replaced.
• Carry out the straightening work in several
stages, never in one pulling process. This
prevents the risk of overstretching and of joints
tearing out.
• During individual straightening steps (under a
pulling load), relieve tension by striking the
deformed areas with an aluminum hammer while
they are still under tension.
2011 Fiesta 08/2010 G506658en

Complete Panel Replacement/Partial Replacement

NOTE: Basic and advanced training is offered for the model-specific body literature. These
the following contents. For an overview of all requirements must be complied with.
training courses offered, please refer to the Ford
Depending on the damaged areas, further facts
Service Organisation's training course brochure.
are to be taken into account when deciding for or
Repairs always mean intervention in the body shell against partial replacement:
structure and thus also intervention in the vehicle's
• Severance cuts should be as short as possible.
passive security system.
• The effort for follow-on work on the connections
NOTE: From an economic perspective, the must not be too great.
possibility of a partial replacement (sectional repair)
• It must be possible to reproduce the optical path
must be considered when assessing an
of visible edges on door openings.
accident-damaged vehicle.
• Inner reinforcement panels must not limit the
Partial Replacement straightening work.
• Inner reinforcement profiles in the pillar areas
must allow for separation.
• The Ford regulations for partial replacements
on structural frame sections must be taken into
account.
• The large surface welding seams at the
connections must be restored.
Advantages of a partial replacement
A partial replacement repair offers many
advantages for a professional repair of accident
damage:
• Repairs can be made both in the outer panel
Item Description area (e.g. side frame) and in the inner areas
1 Join area (e.g. structural member, trunk floor).
2 Original welding • The repair can be limited to the actual damaged
area.
Decision criteria • Reduction of repair costs, as aggregates and
other components can usually remain in the
The following are always crucial for the decision: vehicle.
• How economical the repair is.
• Retention of the original join. Complete replacement
In addition, Ford must have given its approval for
a sectional replacement solution in the damaged In a complete replacement, the original connections
area. For those partial replacements approved by are largely reused.
the factory and described in the model-specific
body workshop literature/technician's information,
some spare parts (service parts) specially prepared
for partial replacements are offered through the
spare parts sales department.
Sectional replacement (sectional repair) means
the replacement of a section of the body shell
structure. Sectional repairs fulfill their purpose
above all if the replacement of a complete part is
too time-consuming and thus not economical.
Approved sectional repairs are clearly defined in
2011 Fiesta 08/2010 G506659en

A complete replacement is advantageous if the
damaged body part can be detached from its
original connections and a completely new part
can be fitted without creating additional joints (e.g.
liftgate).
A complete replacement is necessary if there is no
sectional replacement solution.
2011 Fiesta 08/2010 G506659en

Corrosion Prevention
The corrosion protection provided in production
must be carefully maintained and reproduced Corrosion protection measures during
during body repair work, in order to ensure the repair work
long-term warranty for Ford vehicles.
NOTE: Please take the notes in the model-specific CAUTION: Always be extremely careful
repair descriptions into account. Please also note when handling solvents, sealants and
the manufacturer's instructions when handling the adhesives. Some products contain
different anti-corrosion agents. substances harmful to health or give off
harmful or poisonous vapors. Always
Only Ford original bodywork components and Ford follow the manufacturer's instructions. If
approved repair materials are to be used for body there is any doubt as to whether a
repairs. The Ford logo is stamped onto every Ford particular solvent is suitable, it must NOT
original spare part. be used.
All Ford bodywork components have a cathodic
Panel coatings and corrosion primer. Moreover, most parts are zinc-plated on
protection one or both sides. If possible, these protective
layers must not be damaged.
Body steel panels are provided with a coating for
corrosion protection purposes. The coating material Before welding
is predominantly zinc in a variety of composition Interior surfaces of new bodywork components
forms. Aluminum is also used to some extent. which will no longer be accessible after installation
Basically, all types of steel sheet can be coated. must be painted beforehand. The welding flanges
A variety of coating processes are used: are treated with a special welding primer. The joint
areas are not always accessible from inside later.
• Hot dip zinc coating (no longer used in vehicle Therefore, prepare these areas so that no soot is
construction). produced by burning paint during welding.
• Electrolytic zinc plating. NOTE: In order to ensure that the corrosion
• Organic coating. protection produced in production is not destroyed,
• Hot dip aluminum coating. the working area must be kept as small as possible.
NOTE: Welding fumes are harmful to health. Make NOTE: Do not touch cleaned bare metal any more
certain that the workspace is well ventilated and with the bare hands. The dampness of your hands
use welding fume extraction. will corrode the metal.
The following points must be noted when welding: Procedure:
• Zinc starts to melt at about 420°C. • Remove the primer or paint/zinc layer in the
• The zinc vaporizes at a temperature of about welding area using a tress wire brush to prevent
900°C. the formation of soot from the paint.
• The amount of heating determines the damage • Thoroughly clean the welding area with a metal
to the zinc coating, and therefore to the cleaning agent and rub dry.
corrosion protection. • Coat the welding flange with welding primer on
• Resistance spot welding is particularly suitable all sides and allow to dry.
for welding zinc-coated panels, because no NOTE: The welding primer must only be applied
widespread warming occurs. thinly to the spot welding area, to minimize
• With electrolytically zinc-plated panels there is spattering when welding.
no need for any special preparation because
the zinc coating does not need to be removed.
After welding
NOTE: Coated panels have a higher electrical
resistance, but this can be compensated for by During repair work, body panels are often heated
increasing the welding current by 10 - 20% . at very high temperatures, which results in the
destruction of the corrosion protection.
2011 Fiesta 08/2010 G506660en

Reworking of the affected areas is therefore vital: Apply clinched flange protection to the clinched
• Grind the welded seams flat and clean flange using one of the flat nozzles supplied. The
thoroughly with silicone remover. Dry with a nozzle must be cut to the necessary width
lint-free cloth. beforehand and the guide stop cut as required.
• If the join area is accessible from the inside, the During application the clinched edge must be
transition area to the paint must be abraded for covered with an overlap of at least 3 mm. The
all types of join so that good adhesion of the beginnings, ends and edges or interruptions in the
primer is achieved later. sealer bead need to be reworked by forming with
a brush or a spatula, to ensure a 100% tight sealing
• If the join area is not accessible from the inside,
of the flange.
the cleaning and sanding work is not done. For
this reason, ensure that there is as little The speed and angle of application are decisive
contamination as possible in the area of the for a good appearance and a bubble-free bead.
repair. This allows the cavity wax applied later Always apply the sealer with as few as possible
to penetrate the join area without hindrance. interruptions to avoid sealer rework. Never use
solvents or thinners as this will considerably slow
NOTE: Only apply a small amount of panel cleaner
down the hardening process of the sealer.
to the cleaning cloth when cleaning the repair area.
Make sure that no cleaner reaches the connecting For an application thickness of 3 mm of the
flange, so that the welding primer is not washed clinched flange sealer it is recommended to allow
away again. to dry over night at room temperature. A minimum
hardening time of 5 hours is required anyhow
Priming after welding
before a 2-component primer can be applied.
Primer is applied to the welded flanges after
cleaning. A check must also be made that the Clinched flange protection applied to the correct
production corrosion protection is present in the width and thickness.
area of the flanges. Any damage must also be
re-primed.
Sealing work
Depending on the type of repair, the clinched

flanges on the hood, doors, tailgate and trunk lid
must be sealed with clinched flange sealer.
Clinched flange protection with flat nozzle
Underbody protection/stone chip

protection
The underbody protection is used as corrosion

protection and must also be applied such that it
matches the original condition, from a visual
perspective.
Two main application methods are used in
production:
Clean the clinched flange area of the new
• The underbody protection is applied as a
component with silicone remover and dry with a
sprayable sealing compound.
lint-free cloth.
• In the area around the structural members, the
The sealant must be applied to the dry primed underbody protection is sprayed on and spread
surface (i.e. dip priming as for delivery). across a wide area.
2011 Fiesta 08/2010 G506660en

Because of the coarse surface structure of the • Guide the cavity wax probe carefully in the area
stone chip protection material, it is recommended of the repair so that targeted corrosion
to only perform a repair over the whole surface, if protection is achieved.
there is damage over visible areas. Otherwise there • Pay special attention to edges and swage line
is the danger of serious irregularities on the on stepped joints, the wax must cover the inner
surface. edge areas.
The thickness and appearance of the underbody • The cavity wax must flow along the stepped
protection and stone chip protection must be sheets so that the wax is drawn between them
matched to the original. Special spray guns are by capillary action.
used to work the materials for this reason. A test
A hole may be drilled in a suitable place for areas
spray must always be performed beforehand
which are not accessible for the application of
however, to determine the correct appearance and
cavity wax. The diameter depends on the size of
layer thickness.
plugs available. When this is done it is vital to make
sure that no drilling swarf remains in the cavity (rust
will form if any remains). The edge of the hole must
Cavity protection
be treated with cavity wax. Finally close with a plug
and seal with underseal.
After painting work has been completed, a general
check is made of the work that has been done. Only on components with clinched flange edges:
Before final reassembly of the vehicle, the cavity After painting, the inner clinched flange edge must
wax protection in the area of the repair must be be sealed as far as is possible with cavity wax. For
renewed. Cavity wax protection must be performed this, the repaired component should be positioned
carefully so that the quality of the repair conforms upright and corrosion protection wax sprayed into
with Ford standards: the water drainage holes and/or the thread holes
for the hinges in both directions (50 ml corresponds
to about 20 seconds spraying time).
For doors, tilt and turn the component to spread
the corrosion protection wax over the whole edge
of the flange.
Wax application
2011 Fiesta 08/2010 G506660en

2011 Fiesta 08/2010 G506660en

Corrosion protection for the floor pan (example)
Item Description
1 Injection points for cavity wax protection
2 PVC stone chip protection at the wheel arches
3 PVC underbody protection
4 PVC stone chip protection
5 PU primer
2011 Fiesta 08/2010 G506660en

Corrosion Damage/Corrosion Repair

Modern vehicle bodies are protected from corrosion • Poorly installed or damaged covers and stone
by elaborate measures. Multilayer coatings on the chip protection fixtures must always be renewed.
panel surface prevent direct contact between the
• Check seals and seal carriers for wear and
metal and oxygen, and so protect it from corrosion.
correct mounting. Any damaged seals must be
In the long-term however, corrosion on a vehicle renewed.
cannot be completely prevented. • All rubber grommets and blanking plugs must
NOTE: Basic and in-depth training is offered on be present and correctly installed.
the following topics. You will find an overview of • A damp or wet floor inside the vehicle indicates
the complete range of training in the Training that there are leaks in the bodywork. The interior
Brochure issued by the Ford Service Organization. must be dried out and the leaks must be
What is corrosion? completely rectified.
Corrosion is destruction of a subsurface caused The corrosion formation can vary in extent.
by chemical or electrochemical effects which With rust film or edge rust formation, the surface
operate from the outer surface. of the paint has small traces of corrosion present.
If the protective layers become damaged, The traces of corrosion can possibly be removed
electrochemical conversion processes are initiated, in such cases by polishing the paint surfaces. If
which allow the metal to oxidize. This leads to the this is not possible however, the traces of corrosion
formation of corrosion. must be rectified by using a touch-up technique.
The following factors lead to corrosion: If the corrosion is just starting, with up to 1 mm
rusting below (in the form of a dot or a line) the
• Mechanical damage such as stone chips and damage is rectified as follows:
scratches which penetrate through to the steel
panel. • Clean the defective location.
• Damp interiors. • Mechanically remove the rusting which is
starting below the surface.
• Unfavorable weather or environmental
conditions, as may occur in areas with high • If the area is small, apply primer and allow it to
humidity, high salt content in the air or serious dry, then use the paint pencil to touch up the
air pollution due to aggressive gases and dusts. area - if not, respray the damaged area.
• Insufficient corrosion protection after repairs. If rust is already under the paint finish to the steel
• Lack of care by the vehicle owner of the painted panel, then the whole paint finish in the affected
and corrosion proofed surfaces or areas on the area must be sanded away.
vehicle. Furthermore, the existing traces of corrosion in the
In order to maintain long-term corrosion protection, body panel must be carefully and completely
the vehicle must be checked at regular intervals. removed.
In doing so, the follow areas must be inspected Finally a new paint finish must be applied in this
and any damage rectified: area. In the case of rusting through, the affected
body panel is already completely destroyed. Such
• Damage to the paint surface cause by scratches damage requires complete or at least partial
or stone impact must be suitably rectified replacement.
according to the specifications.
NOTE: : In the general section there are several
• Damage to the PVC underbody protection or chapters which present the techniques necessary
the PU stone chip protection must be refinished. for a professional corrosion repair.
• Damage to the PVC underbody protection or
the PU stone chip protection must be refinished. The outcome of this is the following repair
sequence:
• Incomplete or damaged sealing at clinched
flanges must be renewed. • Remove the rusted-through part.
• Check the cavity protection and renew it if • Remove the remaining traces of corrosion.
incomplete. • Offer up the new part.
• Prepare the joint areas.
2011 Fiesta 08/2010 G506661en

• Weld the new part into place.
• Produce the corrosion protection.
For a professional repair it is essential to reproduce
the corrosion protection during and after the repair.
2011 Fiesta 08/2010 G506661en

Sealer, Underbody Protection Material and Adhesives

Sealants, adhesives, cavity wax and underbody It is very durable and has good resistance to
protection materials are used during the various abrasion,
body repairs. In this area Ford offers a range of
Cavity wax
products which have been tested and matched to
each other. This touch-proof, transparent corrosion protection
wax is used for the preservation of cavities and
CAUTION: Always be extremely careful flange joints.
when handling solvents, sealants and
adhesives. Some products contain Anti-corrosion wax
substances harmful to health or give off Anti-corrosion wax is a coating material which can
harmful or poisonous vapors. Always be applied in fine spray, forming a very thin and
follow the manufacturer's instructions. If grease-like protective film, therefore offering very
there is any doubt as to whether a good corrosion protection.
particular solvent is suitable, it must NOT
be used. 2-component metal adhesive
Clinched flange protection For joining metal to metal and plastic to metal. The
adhesive reduces droning noises and improves
One-component adhesive/sealer which can be corrosion protection.
applied by brush or spraying, based on MS
polymer, with a flat nozzle for application and with Windshield sealant
the following properties: Solvent-containing, stable sealing material. The
• Can be sanded sealer is permanently elastic and does not form a
skin on the surface.
• Permanently elastic
1-component window glass adhesive kit
• Non-corrosive
For direct glazing. The vehicle is ready to drive
• Very good adhesion after 6 hours (passenger airbag). Prevents contact
• Rapid hardening and resistant to ageing corrosion.
• Can be over-painted with almost all proprietary 2-component window glass adhesive kit
paints For direct glazing. The vehicle is ready to drive
Seam sealant T Anthracite after 1 hour (passenger airbag). The adhesive is
not an electrical conductor and permits
One-component sealer based on MS polymer, for interference-free radio reception. Prevents contact
sealing joints and seams, with the following corrosion. Using a 150ml additional cartridge, the
properties: adhesive can also be used for large windows or to
• Silicon-free produce a double seam of adhesive.
• Solvent-free and low-odor PU glass adhesive
• suitable for gluing HVH elements into position 150ml additional/replacement cartridge for direct
in their respective body areas glazing using 2-component window adhesive kit.
Suitable for double beads or larger windows. Also
Body sealant T beige
suitable for sealing NVH elements.
Sealer with the following properties:
• Stable
• Contains solvent
• Especially suitable for visible seams
• After hardening can be overpainted with
two-pack paint
Underbody Coating
Underbody protection is necessary for permanently
elastic corrosion protection of vehicle underbodies.
2011 Fiesta 08/2010 G468070en

Cutting Technique
NOTE: Without exception, before starting work you NOTE: After all separation work, make certain that
must read the safety and warning instructions in the metal swarf is completely removed from the
the chapter "Safety Instructions". In addition, pay vehicle body.
attention to the warning instructions of the particular
equipment manufacturer.
Possible cut lines (example)
Depending on the separating tools used, there are

some fundamental points to bear in mind:
• Only start the cutting work once the new part is
to hand.
• Compare the new part with the old part for
shape and size.
• The straightening work must be completed
before any body components to be replaced are
cut out.
• Before separation work is started, all welded
connections which cannot be seen must be
freed of underbody protection, sealant etc.
NOTE: Steplessly variable machines increase the
working life of the cutting tool. Use of a suitable
Spot weld milling tool lubricant can increase this even further.
Resistance spot welds are separated using a spot A spot weld milling tool usually has an adjustable
weld drilling machine or a spot weld milling tool. depth stop and a safety fixing system. These
prevent the machine from drilling too deep and the
cutter from slipping while working.
2011 Fiesta 08/2010 G468071en

Rod sander
Another option for separating resistance spot welds
is to use the rod sander.
The cutting depth of the orbital saw can be set.

This allows separating cuts to be made, despite
panels or other components lying in danger behind.
Straight cut lines can be more easily made using
the orbital saw.
If spot welds and MIG welds are difficult to reach,
a rod sander may offer an alternative.
Short stroke saw

The short stroke saw is suitable for separating
vehicle body components and for making a
separating cut for partial repairs.
NOTE: In order not to damage panels, wiring

harnesses, hoses or similar components which lie
behind, remove them beforehand as necessary.
The narrow design of the saw blade permits cutting
in tight curves. Straight cuts require a relatively
great deal of practice.
Orbital saw
Where use of the short stroke saw is difficult
because of the body construction, the orbital saw
can be used.
2011 Fiesta 08/2010 G468071en

Panel Beating Technique and Smart Repairs

General
Smaller scale body repairs, where damaged panels
do not need to be replaced, can often be carried
out by realignment work. Whether the repair is
economical however, often depends on the
accessibility of the affected body area.
NOTE: Basic and in-depth training courses are
offered on the topics which follow. An overview of
the complete range of training offered is provided
by the Ford Service Organization Training
brochure.
During damage assessment, the following technical
Des Description
points must be taken into account:
cript
• Small mild dents (without damage to the paint), ion
which are in areas that make access from the
1 Deflection by a hook arrangement
inside possible, can be rectified using
undamaged paint panel beating. 2 Pressure tool
• If the inner side of the damaged area (with paint
damage) can be accessed, then conventional This panel beating technique with pressure is
panel beating techniques can be used. mainly used to rectify smaller dents as a result of
hail impact, transportation or parking, without the
• If the damaged area has no access from inside,
paint being damaged.
then it can only be rectified using outside panel
beating techniques. Small dents are removed from the inside of the
body panel by pushing them outwards in a
mechanical process using panel beating levers.
Dent removal using special panel
beating levers Because of the great variety of shapes of these
levers, it is possible to use this panel beating
NOTE: In the Undamaged Paint Dent Removal technique on almost all areas of the vehicle body.
section, you will find more information on pressure
techniques.
2011 Fiesta 08/2010 G468072en

Dynamic puller with counter bearing
Des Description
cript Hollow leveling (removing dent without
ion a dolly)
1 Puller device for minor damage, with Hollow leveling can only be used on areas which
integral copper electrode are accessible from the rear.
2 Puller device for more extensive damage
3 U-washers spot-welded in place
4 Puller bits spot-welded in place
5 Attachment for U-washers or puller bits
This method can be used to reshape dents or more

extensive damage from the outside.
For minor damage, the copper electrode in the tool
is secured onto the panel surface by spot-welding
and the puller device is used to pull out the damage
without jolting.
For more extensive damage, puller bits or
U-washers (depending on the application area) are
spot-welded to the panel surface and the area
pulled out using the puller device.
Because of the versatile puller and the variable
counter bearing, a wide variety of damage can be
worked and rectified using this repair method.
Because of the mechanical lever operation, the
variable counter bearing and the optimum
controlled application of power, this external dent
removal system allows dents in almost all vehicle
body areas to be pulled out.
2011 Fiesta 08/2010 G468072en

Des Description damage, the box file should be used as opposite
cript support. Because of its serrated surface, the box
ion file prevents normal stretching of the body panel
which would otherwise occur.
1 Center of dent
2 Spoon Heat-induced material shrinking
During hollow leveling, the dent is removed from Material shrinking, also called settling in, can be
the inside a using suitable panel beating tool and performed in a variety of ways depending on the
applying knocking or pressing movements. High extent of the damage and the access to the repair
spots around the edge of the dent area are area.
flattened with blows from the aluminum or wooden
headed hammer. These repair processes differ depending on the
type of heating and subsequent working of the
The usual tools are for instance hammers of heated surface. They sub-divide into two basic
various designs, dollies, levering irons and various processes:
spoon irons. The correct choice of tool is made
depending on the shape of the dent and the access • Heating using a carbon electrode.
which is possible. • Heating using the oxy-acetylene torch.
In the carbon electrode process the working is done
Dent removal using hammer and dolly exclusively by warming. In this case the access to
the repair position is only from the outside.
Panel beating can only be performed using a
hammer and dolly if access can be gained from
the rear side.
Des Description
cript
ion
1 Aluminum hammer
2 Box file
The purpose of the dolly in this case is to transfer

the force of the impacts from the hammer to the
steel panel which is in between. As this is done,
the deformed body panel is smoothed (dressed)
Des Description
and the tension fields in the body panel are
cript
removed.
ion
The favored tool for this repair process is the
aluminum hammer and as opposite support the 1 Carbon electrode
universal hand dolly. To rectify minor panel 2 Spiral shaped heating pattern
2011 Fiesta 08/2010 G468072en

If the damage is concentrated in a spot and is in extraction unit and, if required, a protective
the form of a more rigid raised area, then the mask.
carbon electrode must be replaced by a copper NOTE: Since 07/2003, lead compounds have been
electrode. As heat is applied, slightly more pressure ruled out for production. Appropriate lead-free tin
is applied to the raised area. solders and pastes must also be used in the
In the method using heating by the oxy-acetylene workshop.
torch, material shrinking is achieved by a Typical application areas:
combination of heat and mechanical working of the
damaged area. • Body components with limited or no access from
the rear.
• Body components with very narrow
cross-section.
• Body components which are particularly
exposed or which can move.
• Weld seams of partial repairs.
• Rocker panel areas, wheel arch edges, side
panel areas.
• Doors, hood, luggage compartment lid.
• Swage lines and joint areas.
Tin has the following advantages:
• Excellent bonding on bare metal surfaces.
Des Description • Good moulding properties.
cript • Good properties for the production of shapes
ion and contours.
1 Overstretched area • Permanent shape.
2 Point heating using the oxy-acetylene • Heat expansion is the same as steel.
torch To create a basis for the actual lead loading
3 Spiral shaped knocking back with dolly process, a lead loading paste is first applied to the
panel. The paste is then heated and wiped away
The repair area must always be accessible from with a cloth. Now the tin can be applied and
both sides, so that the heated area can be properly moulded with a brazing block.
worked mechanically. After the repair site has cooled down, it is worked
The combination of heating and mechanical using for example the body plane until the surface
working is very effective. is smooth and has no transitions.
As soon as the warm point is established,

hammering is immediately started using the
aluminum hammer together with a suitable dolly
on the inside of the repair surface, working in spiral
movements towards the warm point. This causes
material to build up in the center of the warmed
area.
Lead loading
Despite good external panel beating techniques,
it is not always possible to rectify every surface
unevenness. For this reason, application of lead
loading is an important part of panel beating.
CAUTION: Poisonous gases and dust can
be produced when working solder. Use an
2011 Fiesta 08/2010 G468072en

Paintless Dent Removal

NOTE: Basic and in-depth training is offered on
the following topics. You will find an overview of
the complete range listed in the Training brochure
published by the Ford Service Organization.
General
Application is restricted to body surfaces which are
accessible from both sides. This repair technique
is seldom feasible on double-skinned body
components or closed body profiles. The same
applies to edge areas, swage lines and seams on
body components, which are very dimensionally
stable.
The following characteristics must be present for
a dent to be removed:
• The diameter must be no more than 50 mm.
• No material stretching in the centre of the dent.
• Repair area must be accessible
Furthermore, sufficient experience in the use of
special tools and knowledge of materials are also
requirements for a successful repair.
Satisfactory repair results are only possible on mild

dents with little depth and small deformation radii.
Therefore this repair method is particularly suitable
for hail, parking and transportation damage.
Dent with material stretching
Item Description
1 Deflection by a hook arrangement
2 Pressure tool
Mild dent
2011 Fiesta 08/2010 G506662en

If strong and direct force during the damage

process causes the material to stretch in the middle
of a dent, then the result is a small and sharp
edged dent. Such damage cannot be rectified
without visible deformation.
Advantages of a planishing technique:
• Economical in time and materials
• The original paint is retained
• Environmentally friendly (no sanding or painting
work)
While carrying out the repair, the following itemized
repair route and process flow must be complied
with:
1. Damage diagnosis
2. Repair preparations
3. Perform repair
4. Paint finishing, corrosion protection and quality
control
In order to ensure corrosion protection, all inner
areas of the repair must be treated afterwards.
Where it is possible, the paint is repaired. In every
case the inner area of the repair must be treated
with cavity wax.
2011 Fiesta 08/2010 G506662en

Plastic Repairs
General above the critical temperature. Also, the original
state will no longer be restored on cooling.
The proportion of plastics used in vehicle
construction continues to rise. Up to now damaged Brief Plastic
plastic components often had to be replaced. descrip-
These days, plastic repairs are becoming more tion
and more widely accepted because of the GRP Glass reinforced plastic
increasing cost of spare parts.
PUR Close-meshed cross-linked poly-
NOTE: Plastic adhesives are chemical products
urethane
and are subject to the safety instructions of the
manufacturer. PUR Wide-meshed cross-linked poly-
In repair work, the material properties of plastics urethane
are highly significant. There are two main groups:
• Thermoplastics. Plastic identification
• Thermosets.
NOTE: Elastomers make up a third group of Normally the appropriate identifier is marked on
plastics. These are not mentioned below because the plastic components used in vehicle
they have no plastics repair applications. construction.
Thermoplastics The capital letter sequences used for this are

standardized in DIN EN ISO 1043-1 and DIN ISO
Heat causes thermoplastics (also called TP 1629 (for rubber) and can be looked up in the
polymers) to transform from the solid state into the tables which they contain. In addition the string of
thermoelastic state and then into the thermoplastic characters provides information about the exact
state. When thermoplastics are cooled, they return mixture ratio and the proportion of certain fillers.
to solid state.
Examples of the identification of plastics
Brief Plastic
descrip-
tion
ABS Acrylonitrile butadiene styrene
copolymer
PA Polyamide
PC Polycarbonate
PP Polypropylene
PP/EPDM Polypropylene/ethylene propylene
diene copolymer
PC/PBT Polycarbonate/polybutylene tereph-
thalate
Hard PVC Polyvinylchloride
/ soft PVC
Thermosets
Thermosets (also called TS polymers) are much
harder and more brittle than thermoplastics. Their
strength remains largely unchanged when they are
heated. Thermosets are destroyed when heated
2011 Fiesta 08/2010 G506663en

In this a place is chosen which will not be visible
later, and the finger belt sander is used to sand the
plastic.
The plastic group can be determined using the
pattern of the dust:
• Thermosets produce a white dust.
• Thermoplastics smear and do not produce dust.
Float test in water:
Take a small piece of plastic from the component
to be repaired and test whether it floats on water
(PP-EPDM, HD-PE, PP) or sinks (PVC/U, PVC/P,
ABC, PC).
Nature of the surface
The surface of plastics can be categorized as rigid
(PVC-U, PVC-P) and waxy (PP/EPDM, HD/PE,
PP).
Adherence test using welding rod
Heat a welding rod that is identified with the type
of material and the plastic component using the
hot air gun. Press the welding rod onto the plastic
component to be welded. When the welding rod
cools down, if it remains stuck to the component
NOTE: The identification of the type of plastic is or can only be removed with great difficulty, then
necessary for the plastic welding process in order it can be assumed that the two are made of the
to determine the correct welding rod (welding same plastic. When pulling away from PP/EPDM,
material) to use. HD/PE and PP, this can lead to strings.
If an identifier is missing or cannot be made out, CAUTION: Danger of poisoning! When
the following easy to perform tests will help: burned, most plastics release vapors
harmful to health. Ventilate the room well
Visual Inspection and use respiratory protection. Where
Visual inspections mainly serve to identify PUR possible work using an extraction system.
and GRP materials. Thermoplastic components Burning test
are often painted and are therefore difficult to
identify. Every plastic has a characteristic behavior and
smell when burned. Using a knife, cut off a small
Identification characteristics: piece from the component to be repaired, remove
• When PUR cracks or similar damage occurs, any dirt and paint residues and set light to the small
pores of foam can be seen. chip. Now observe the burning behavior. Compare
the color, type and smell of the smoke with the
• GRP can be recognized by the glass fiber
results from the following table.
structure on the inside.
Mechanical test: Short Plastic recognition using a
descrip- burning test
The plastic group can be determined by a sound
tion
test:
• Degree of hardness - the higher-pitched the ABS Blackish smoke, the material drips
sound, the harder the plastic. like a candle when burning and
smells like wax.
• Elasticity - the more muffled the sound, the
higher the elasticity of the plastic. PA No smoke, draws filaments, smells
like burnt horn.
Sanding test
2011 Fiesta 08/2010 G506663en

Short Plastic recognition using a • Thermoplastic straightening.
descrip- burning test • Plastic welding.
tion • Plastic adhesive bonding.
PC Yellowish, sooty smoke. Smells • Plastic lamination techniques.
sweetish. Thermoplastic straightening
PP No smoke, the material drips like a Damage to thermoplastics can be rectified by
candle when burning and smells like heating using the hot air gun (temperature about
burnt oil. 100°C) while the deformation is pressed out until
PP/EDM No smoke, the material drips like a the shape is regained.
candle when burning and smells like
burnt oil. Plastic welding
PC/PBT Hard and shiny, burns yellow, fluffy
soot. Splits formed in plastic bumpers are typical
possible plastic repairs.
Hard PVC Blackish smoke and acrid smell.
/ soft PVC NOTE: Do not carry out plastic welding in the area
of fixed foam backing. The foam backing will
usually be destroyed and the function of the
Safety instructions component is then no longer guaranteed.
If repair using adhesive methods is not possible
In addition to the general safety instructions, the because of unfavorable conditions at the rear of
relevant regulations and accident prevention the repair location, plastic welding is a possible
legislation must be observed. repair process.
NOTE: Without exception, before starting work you There are two methods of welding: hot air draw
must read the safety and warning instructions in welding and hot air fanning welding.
the chapter "Safety Instructions". In addition, pay
attention to the warning instructions of the particular Plastic welding set
equipment manufacturer.
Information sheets, safety notices and guidelines
for the processing of adhesives containing
isocyanate, polyester resin, adhesives, solvent and
thinners provide more details on their use.
The following instructions must always be followed:
• Polyester resin, adhesive, solvents and thinners
are inflammable and must not be used near
naked fire or flames.
• Sawing and grinding operations must only be
carried out in rooms equipped with extraction
systems.
Item Description
• If no rooms with extraction systems are
available, only use tools with extraction 1 Various welding rods
equipment.
2 Scraper (heart-shaped)
• Protective equipment such as gloves, protective
goggles, aprons and breathing masks are 3 Hot air blower (approx. 1500 W)
essential. 4 Clamps
Because of the various compositions of plastics, 5 Welding nozzles
repair work to plastic parts involves a variety of
repair methods. In addition to the components listed, plastic welding
The following methods are used: requires tools already found in the workshop such
as scrapers, sanders, face cutters etc.
2011 Fiesta 08/2010 G506663en

As with all other welding processes, only certain Brief Plastic Temperat
material combinations can be joined together using descrip- ure
plastic welding. tion
NOTE: Basic and in-depth training is offered on PC Polycarbonate 370°
the following topics. You will find an overview of
the complete range listed in the Training brochure PP Polypropylene 280°
published by the Ford Service Organization. PP/EPDM Polypropylene/ethylene 280°
NOTE: The manufacturer's data must be taken into propylene diene
account when choosing welding materials and the copolymer
correct temperature setting of the hot air gun.
PUR Polyurethane 300°
Repair sequence during plastic welding:
Hard PVC Polyvinylchloride 340°
• To prepare the location for welding, remove
paint residues and sand the weld area. Soft PVC Polyvinylchloride 370°
• If parts of the material have been pushed in by • Even pressure:
an impact, the damaged area can be brought
back to shape by heating. – When rod welding, the pressure is applied
by pressing on the welding rod.
• Drill out the ends of the split to stop it spreading
further. Machine the location of the weld into a • Steady speed:
90° V-shaped groove, to accept the welding rod. – To achieve a good weld, care must be taken
• Lay the welding rod in the groove. that the working speed is steady.
• Perform the welding. Hot air draw welding or Possible causes of weld faults:
hot air fanning welding. • Deformation caused by overheating of the repair
• Rework the weld seam. After cooling, sand the area or tensions in the material while welding
raised weld seam. the component.
• Clean the sanded repair surface using plastic • Plastic material too thin.
cleaner. Apply plastic primer thinly to the repair • Poor weld joint because the weld temperature
surface and paint it. was too low or the welding speed was too fast.
Despite good preparation and the correct choice • Welding different materials together.
of welding materials, weld faults may occur. • Weld seam dropped because the split gap was
The following points must be noted when welding too wide or the welding temperature was too
plastic: high.
• Weld together like with like: A good weld is recognized by a slightly raised,
– With very few exceptions, only the same smooth and even weld bead on the surface of the
materials can be welded together, e.g. PP component.
with PP. The weld bead must only be worked once it has
• Correct temperature: fully cooled down.
– The correct choice of temperature is
important for the success of the repair. The Plastic adhesive bonding
plastic must be warmed until it plasticizes
(dough-like, soft). Adhesive bonding of plastics has some advantages
Guideline values for welding temperature: over welding methods:
• Within the group of thermoelastic plastics, all
Brief Plastic Temperat semi-rigid ancillary components (such as
descrip- ure bumpers, front grilles, etc.) can be repaired
tion without identification.
ABS Acrylonitrile butadiene 360° • A two-component polyurethane based adhesive
styrene copolymer is used for all thermoplastic parts.
PA Polyamide 400° • Reinforcement strips can be attached behind
splits (split length up to max. 100mm) and
2011 Fiesta 08/2010 G506663en

openings to ensure the original strength surface using plastic cleaner. Apply plastic
properties. primer thinly to the repair surface. Apply paint.
Tools and equipment also familiar from paint
repairs can be used in making adhesive repairs to GRP repairs
thermoplastic components.
Angle grinders and belt sanders can be used to GRP material is hard and brittle in its strength
grind out scratches and splits. Orbital sanders with properties. Because of these material properties,
extractors are used for fine sanding. splits and openings often result in cases of serious
damage.
The infrared heater is used to provide fast and
certain drying throughout. The stability of GRP parts is impaired if the glass
fiber reinforcement is cracked. The component
Plastic adhesive set must be replaced in cases of serious damage that
affect the structure.
Minor damage (such as abrasion, splits 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 perfect repair results, observe the
following points:
• The room temperature should be at least 15°C
and the air should be as dry as possible.
• The repair location must be thoroughly dry and
clean.
Item Description • Before the repair, the GRP part being repaired
1 2-component adhesive must be dried using an infrared heater or in a
drying oven.
2 Cartridge gun
• In cases of large splits and fractures, the
3 Mixing tube strength of the outer skin can be re-established
by backing with a reinforcement material.
Apart from the components shown, other materials
Tools and equipment from the paint shop can be
may be needed to bond plastics, depending on the
used to carry out repairs to GRP parts. Angle
repair position.
grinders and belt sanders can be used to grind out
For large scale repairs, it may be necessary to scratches and splits. Orbital sanders with extractors
insert reinforcement panel strips and reinforcement are used for fine sanding.
matting as fixing aids.
GRP repair set
Repair sequence during plastic adhesive bonding:
NOTE: Follow the manufacturer's guidelines when
using adhesives.
• Prepare the location of the bond. Remove paint
residues and sand the area to be bonded. Drill
out the ends of the split to stop it spreading
further. Prepare the bond location into a
V-shape and clean it with plastic cleaner.
• Apply the adhesive. The two-component
adhesive is applied to the cleaned and primed
repair location using a hand gun. Spread and
smooth the adhesive using a flexible plastic
spatula.
• Rework the bond location. After cooling, sand
the raised adhesive. Clean the sanded repair
2011 Fiesta 08/2010 G506663en

Item Description
1 Polyester resin
2 Glass fiber mats
3 Hardener
Scissors, paintbrush and cleaning materials are

other materials which will be needed to perform a
GRP repair.
NOTE: Follow the manufacturer's instructions when
using the repair materials.
The repair process for a GRP repair is as follows:
• Prepare the repair location. Remove paint
residues and sand the repair area.
• Drill out the ends of the split to stop it spreading
further.
• The repair location must be sanded by hand. If
machine working is attempted, the resin will be
heated so much that the surface structure will
be changed. The result is inadequate adhesion.
• Perform the GRP repair. Apply polyester resin
thinly to the repair location. Lay the glass fiber
mat in place and apply polyester resin over it
again.
• Rework the location of the repair. Sand away
any polyester resin which stands proud after it
has hardened.
• Clean the sanded repair surface using plastic
cleaner. Apply plastic primer thinly to the repair
surface and after it has dried apply the paint
finish.
2011 Fiesta 08/2010 G506663en

Special Repair Techniques

Cabriolet vehicles the special roof construction (folding top). The
stability requirements must therefore be ensured
The body of a cabriolet vehicle is different to the by construction changes within the body structure.
self-supporting body of a saloon car because of
These are for instance: work, securing using clamps at the rocker panel
• Longitudinal and torsional reinforcing area is not always adequate for the cabriolet.
components which compensate for the lack of • To avoid damage to the doors, they must always
the roof. be open during straightening work. In the case
• Reinforcements to the floor assembly, of more severe damage, additional tension and
particularly in the rocker panel area. compression spindles must be used to stabilize
the door cut-outs (between the A- and B-pillars).
• Reinforcements in the pillar areas.
• In load bearing areas such as the rocker panels,
• High-strength and ultra-high-strength steel side members and floor pan, increased
panels with single panel thicknesses of up to straightening forces are necessary due to the
2.5 mm, which in combination can become up additional reinforcements.
to 6mm thick (e.g. reinforcements in the floor
area, rocker panels). • NOTE: Additional information on welding can
be found in the section Welding Equipment and
If deformation to load carrying components occurs, Joining Techniques.
the stability of the whole body shell can be
adversely affected. High-power welding equipment for panel
thicknesses in overall combination of up to 6
On a cabriolet, accident damage repair to the mm total material thickness.
components mentioned above is considerably • The fitting accuracy and longitudinal rigidity of
different in certain aspects compared with the usual the affected component is especially important
repairs (closed body construction): to ensure that the doors, door windows and the
• A model specific alignment angle system must roof fit and close correctly.
always be used during straightening and repair
Liquefied gas vehicles
Alternative fuel vehicles often require special
handling in the workshop area. Above all, assembly
operations to some extent require particular
2011 Fiesta 08/2010 G506664en

knowledge when dealing with the special NOTE: The material combinations, the
technology and the safety regulations. workmanship and the working methods must
NOTE: Only fully trained personnel are permitted comply with the current food hygiene regulations.
to work on alternative fuel vehicles. For this reason, service and repair work on the
refrigerated conversion may only be performed by
These special requirements must be understood authorized and specially trained technicians.
and taken into account in the body shop as well.
Refrigerated compartment constructions are often
CAUTION: Danger of fire and explosion. made using both materials. The floor pan is made
The safety instructions must always be of structured, slip-proof aluminum panels and the
followed when performing service work on wall and ceiling cladding is made of smooth
fuel/gas systems. Failure to follow these surfaced plastic elements.
instructions may result in personal injury.
CAUTION: PUR hard foam is flammable. If
NOTE: You will find further information about PUR hard foam is overheated, it will burn
working on liquefied gas vehicles in the section on its own with a brilliant yellowish flame.
Health and Safety Information. It produces unpleasant choking and toxic
fumes. Special measures must be taken
when welding the vehicle body.
Refrigerated conversion vehicles
Polyurethane wall and ceiling elements are
Apart from the special materials used in building manufactured using a sandwich principle. An
the structure of the refrigerated compartment, such insulating polyurethane core is coated with food
vehicles have special energy and refrigeration grade ABS plastic on one side.
systems which require special handling during PUR hard foam does not decompose, is rot
repair. resistant and is odorless. These properties make
CAUTION: Danger of injury. Work on the it suitable for use as insulation.
230<SP>volt system of the refrigeration Because of its closed cell structure, water uptake
equipment must only be carried out by by PUR hard foam is for the most part only a
trained specialist personnel. problem at edges. Cut edges or other mechanically
NOTE: Work on the refrigerant circuit may only be worked surfaces must however be sealed with the
performed by persons who have a relevant greatest care.
certificate of competence. The conversion to a refrigerated vehicle is
Vehicles with a refrigerated compartment are often performed as made-to-order production. The large
used to transport foodstuffs. For this reason, surfaces of the wall and ceiling cladding can be
additional hygiene regulations must be complied changed and are particularly easy to repair.
with during repair work. If access to the back of a body panel section is
Aluminum and plastic are used to construct the needed because of body straightening work, in
two different types of compartment found on some circumstances it is cheaper to perform a
refrigerated vehicles. cut-out repair instead of removing an element.
The aluminum conversion is a very stable and The repair process is fully described in the Student
technically perfect variant. However, against this Information booklet Refrigeration System
the relatively high production costs and a lower Technology, Transit 2000.5 Freshline.
payload must be taken into account, because of NOTE: You will find further information about
the weight of the aluminum conversion itself. working on vehicles with a refrigerated
NOTE: Basic and in-depth training is offered on compartment in the section Health and Safety
the following topics. You will find an overview of Information.
the complete range listed in the Training brochure
published by the Ford Service Organization.
The plastic conversion has developed into a light,
clean and economical alternative because of
constant further development of materials and
working techniques.
2011 Fiesta 08/2010 G506664en

Joining Techniques
Welding Resistance spot welding and MIG welding are the
most common techniques used in body
Before welding work is performed on a vehicle construction. During repair work, the welded
body, all safety measures for the protection of connection must be restored to be equivalent to
people, modules and electrical components must the original.
be observed.
NOTE: Before beginning the work, please refer to
Resistance spot welding.
the safety instructions and warnings in the chapter
Safety Instructions. Please also note the warnings NOTE: Before starting the work, please refer to
of the respective equipment manufacturer. the chapter on safety instructions.
In doing so, the repair welds must match the NOTE: The welding equipment settings and the
standard of those produced in production in number adjustment of the individual parameters are to be
and diameter. made in accordance with the device manufacturer's
Preconditions for resistance spot welding: specifications.
• The panels to be welded overlap. Well-prepared welding flanges are a prerequisite

for a problem-free welded joint. This means:
• The weld spot is accessible on both sides for
the electrodes. • The welding flanges must lie perfectly flat to one
another.
• The shape and alignment of the weld electrodes
is correct. • The welding flanges must be clean and free of
oil or grease on both sides.
• The resistance welding equipment is powerful
enough to be able to reproduce the production • Welding primer (zinc-coated and conductive)
spot weld diameter. must be applied as corrosion prevention.
2011 Fiesta 08/2010 G468073en

Only in limited cases can welding errors in NOTE: The increased application of heat during
resistance spot weld joints be detected from the MIG welding destroys the corrosion protection
outside . Therefore, a test weld should be carried layers over a much larger area than during
out before each repair weld. The peel test carried resistance spot welding. For this reason, greater
out after the welding gives information on the care must be taken when applying the corrosion
quality of the welding. The spot weld must not flake protection afterwards.
off.
Welding repairs can only be carried out properly if
the equipment is set up correctly and all
welding-related preparations are complied with
MIG welding accurately.
Basically, three methods of MIG welding are used: • Please note the instructions of the respective
welding equipment manufacturer.
• Puddle weld.
• The hose assembly must be untwisted.
• Continuous bead welding
• The core must be free from particles of wire
• Intermittent bead welding
debris.
Fields of application • The gas and current nozzles must be free of
• Any joins that are MIG welded in production slag and scale residue.
must also be replaced by MIG welds. • Pay attention to the quality of the welding wire
• Puddle welding may be used in certain cases, and the gas flow rate.
if there is insufficient access. • Ensure that the joint surface is perfect.
• If the overall panel thickness is greater than 3 • Prepare a bare metal joint surface.
mm, without correspondingly powerful spot
• Maintain the correct gaps (root formation).
welding equipment, puddle welding should be
used. • Produce a test weld.
• When dealing with any MIG brazed joints which Plug Weld
are present, follow the vehicle-specific repair
instructions.
2011 Fiesta 08/2010 G468073en

Special features to note when puddle welding:
• The panels to be joined must lie perfectly flat to
one another.
• The panel flanges must be treated with
corrosion protection. The position of the weld
must be bare.
• Prepare the holes depending on the thickness
and number of the panels. The hole size should
be 6-10 mm, or match the original weld spot.
• Start the welding procedure on the panel at the
bottom so that the hole is filled completely.
Continuous bead welding

A welded joint with a full seam is suitable for joining
highly profiled body parts. Pillar and sill areas are
typical application areas.
Special features to note during bead welding:

• Both parts of the panel must be bare on both
sides over a width of 5 mm.
• Align the parts precisely with clamps.
• To prevent the panel from warping, tack longer
joints before welding them.
Intermittent bead welding

Intermittent bead welding is used when the
connecting flanges are stepped. This form of seam
is mainly used on the external panel area for
sectional repairs.
2011 Fiesta 08/2010 G468073en

Special features to note when intermittent bead • Weld gap.

welding: • Spot weld interval.
• Apply alternate tack welding across the entire
length of the seam. This keeps warping to a
minimum.
2011 Fiesta 08/2010 G468073en

MIG brazes
Des Description In areas where resistance spot welding is not

cript possible due to limited space or higher strength
ion requirements, MIG welding was previously used.
1 Rear side member / wheelhouse reinforce- Increasingly, these MIG welded seams are being
ment replaced by MIG brazes. The temperature range
used during MIG brazing is significantly lower. This
2 Apron panel reinforcement / A-pillar keeps the damage to the anti-corrosion zinc layer
on zinc-coated panels to a minimum.
Metal Inert Gas (MIG) brazing is increasingly used
in production for certain body areas. This results in the following advantages of the MIG
brazed seam:
2011 Fiesta 08/2010 G468073en

• No corrosion of the brazed seam. smallest amount of brazing solder can result in a
• Low erosion of the zinc coating in the joining reduction in the strength of the weld seam.
area. MIG brazing requires a new generation of welding
• Low level of heating and thus little warping. equipment and training in the technique.
• Easy finishing of the brazed seam.
• Good for bridging gaps.
Joining techniques
NOTE: MIG welds must not be carried out on or
near existing MIG brazed seams as even the Butt joints
Des Description • Sanding the connection areas bare on both

cript sides.
ion • Removal of the zinc layer in the welding area.
1 Join areas • Carrying out welding tests on an equivalent
sample panel before the actual welding, if
2 Profile necessary.
3 Full seam • Tack welding in the join area: From the edges
to the centre, then check the shape.
The butt joint is a joining technique frequently used • Joining new and old parts with a full seam weld.
in body repairs. The butt joint is typically used for
repairs in the pillar and rocker panel area. Joggled joint
Areas that are suitable for the use of the butt joint:
• short seam lengths.
• highly profiled structures.
The edges of the panels to be joined are placed
against each other and are joined with a full seam
in whilst maintaining a required welding gap
(welding gap same as panel thickness).
NOTE: The butt joint requires a high degree of
accuracy and care when trimming and cutting. For
correct execution of the welding, an exact, even
welding gap must be maintained.
Preparation of the joint areas includes:
2011 Fiesta 08/2010 G468073en

Des Description • Sanding the connection areas bare on both
cript sides.
ion • Removal of the zinc layer in the welding area.
1 Body part • Preparation of a joggled strip.
• Carrying out welding tests on an equivalent
2 Joggled area sample panel before the actual welding, if
3 New panel necessary.
• Joining the new and old panel with continuous
The joggled joint variant is restricted to body areas seam welding.
with a good surface condition without beads/swage • Lead loading the weld seam.
lines or profiles. A sectional replacement with a
joggled joint is welded using a continuous seam.
This procedure is used, for example, at the Soft soldering
transition from the side panel to the rocker panel
(3-door vehicles). WARNING: The roof repair may only be
When cutting the new part, slight measuring carried out in Ford-approved special
tolerances are permitted, as these are covered by workshops and only by specially trained
the joggled area. personnel.
Preparation of the joint areas includes: NOTE: The roof is secured to the side walls with
laser soldered seams in production. When repairs
are carried out, these laser-soldered seams must
be replaced by soft-soldered seams.
WARNING: Poisonous gases and dust can NOTE: Ford offers basic and in-depth training on
be produced when working solder. Use an the following topics.
extraction unit and, if required, a protective NOTE: Areas for soft soldered joints require careful
mask. preparation. It is extremely important that the joint
2011 Fiesta 08/2010 G468073en

surfaces are exactly aligned and that a bare metal Pop rivets are used if only one side of the panel is
joint surface is prepared. accessible. In this process, overlapping panels are
drilled and connected with a pop rivet.
This means:
Pop rivets can be inserted pneumatically,
• Thorough cleaning of the surfaces to be brazed.
hydraulically or manually with rivet guns.
• Close contact of the panels at the brazing
position.
• Use the soldering iron to warm the location of Bonding
the seam to be joined.
• The liquid brazing material is drawn between
the panels through capillary action.
Rivets
With riveting, two or more panels are joined
together using a joining element (rivet). In body
construction, pop rivets and punched rivets are
used.
Advantages of riveted connections:
• Metallic and non-metallic materials can be joined
together.
• Different thicknesses of materials can be used.
• The material does not have to be heated, and
therefore does not warp.
• Low level of preparation required.
NOTE: For detailed instructions on the procedure,
please refer to the equipment manufacturer's
operating manual.
Disadvantage:
• During dismantling procedures, swarf/rivet
remains can fall into inaccessible cavities, which
can lead to rattling and rusting.
Des Description
cript
ion
1 Butt joints
2 Bonded connection
Bonded connections are used more and more in

modern body designs. Here, a distinction is made
between bonds for stabilization purposes and
bonds for adhesive strength. Bonds for stabilization
purposes are found on clinched flanges and on
cross beams in doors or on the roof.
Des Description WARNING: Risk of poisoning! Adhesive

cript can be harmful to health. Ventilate rooms
ion well and use breathing protection. Where
possible, work with an extraction unit.
1 Panels
2 Pop rivet
2011 Fiesta 08/2010 G468073en

NOTE: Adhesives are chemical products and are • The material does not have to be heated, and
subject to the safety regulations of the therefore does not warp.
manufacturer. • The rivet connection stabilizes the connected
Please refer to the specifications in the general components during the adhesive hardening
part of the particular manual for information on the phase.
repair adhesive which is to be used.
Advantages of glued joints:
• They are air and watertight.
• High corrosion protection
• Different materials can be connected.
• Bonding can be combined with resistance spot
welding.
NOTE: The quality of the bonded connection is
largely dependent on the care taken during
preparatory work. When gluing bodywork parts,
follow the work instructions from the adhesive
manufacturer.
Bonding and welding

On some vehicle models, (such as the Ford Ka),
bonding is combined with resistance spot welding.
This connection technique has the following
advantages:
• Tight, anti-corrosion connection seam.
• High strength due to additional resistance weld
spots.
Please note the following points during the repair
work:
• Only use adhesive suitable for welding
(conductive).
• Carry out resistance spot welding on the
connection flanges before the adhesive
hardening process.
• Carry out test welding with the adhesive applied.
• If MIG welding is carried out during a sectional
repair on a connection flange with adhesive
material, the adhesive material must be applied
at a distance of approx. 10 mm from the weld
spot.
Bonding and riveting

As with welding, bonding can also be combined
with riveting. This connection technique has
additional advantages. These are:
• Metallic and non-metallic materials can be joined
together.
• Different thicknesses of materials can be used.
2011 Fiesta 08/2010 G468073en

Impact of Insufficient Repair Quality

Body repairs usually require a significant level of Final assembly, ancillary components, functional
intervention in the existing body shell structure. tests
The corrosion protection, seals and NVH
components are destroyed and must be replaced. After final assembly, not only a visual inspection
is required, but also the functionality of many
To prevent the vehicle quality from being reduced components must be checked:
due to a poor quality repair, all repairs carried out
in all repair sections must be inspected during and • Check repair area for originality.
after the accident repair. • Check ancillary components for correct
Simply checking the vehicle at the time of delivery installation.
is not sufficient to guarantee the repair quality. • Check precision fitting of all parts.
Rather, continuous checking of the work carried • Check that the doors and flaps are working
out is recommended. correctly.
NOTE: Logs of the acceptance of individual • Check that all mechanical parts, such as the
operations are a useful tool for quality assurance. window winder are working correctly.
A comprehensive final inspection can be carried • Check for leaks in the repair area.
out based on a final acceptance log.
Vehicle delivery
In the process, the entire repair sequence must be
split into meaningful sections, with the creation of Vehicle delivery again offers the opportunity of
check points to which particular attention must be checking the repair quality. In the process, the
paid. following points are to be checked again:
The following are some possible sections: • Corrosion protection, sound damping matting
and rubber seals.
• During and after body work.
• Check for traces of leftover paint.
• Final assembly, ancillary components, functional
tests. • Check the cleanliness of the vehicle.
• Vehicle delivery. • Functional check of the mechanical and
electrical components.
NOTE: The following points offer an indication of • Road test the vehicle.
possible test logs. They can be combined and
supplemented differently, depending on the • Check for noise, vibration and harshness (NVH).
individual operating procedures. • Check for wind noises.
After repair work on the body and vehicle, not only
During and after body work the following areas
the visual restoration of the damaged vehicle, but
should be checked:
also the functional restoration must be guaranteed.
After completion of the body repairs, the following
Customers are making increasingly high demands
areas should be checked:
of vehicles, particularly in terms of driving comfort.
• Manufacturing inspection for functionality and Customers find noise, vibrations and harshness
originality in the accident area. (NVH) as well as squeaking and rattling annoying,
• Check snug fitting of metal panel parts (welding particularly after repair work. It is therefore
and screw connections). important that the condition of the vehicle at the
• Check snug fitting of ancillary components time of production be restored after an accident
(doors, hoods, glazing). repair.
• Check surface condition of the welded seams. After body repairs, the entire repair area must be
• Check seals, blanking plugs, NVH components. checked for any water leaks. It is crucial that a leak
test be carried out as part of the final inspection so
• Check corrosion prevention measures that water leaks can be detected and eliminated
• Check that the repair work is in the correct even before delivery of the vehicle to the customer.
condition for painting.
The requirements of the vehicle manufacturer are
to be taken into consideration during all
inspections. Only in this way can it be guaranteed
2011 Fiesta 08/2010 G506665en

that the vehicle quality is not reduced through
insufficient repair quality.
2011 Fiesta 08/2010 G506665en

Water Leaks
Water leaks can occur after body repair work, but
can also occur on new vehicles. The test methods Test method
described below allow the various causes to be
identified. In all cases, a systematic and logical Water test
procedure is required to locate water leaks.
NOTE: Do not use a power washer. Use a normal
garden hose with a spray nozzle or sprinkler head.
General Make certain that all windows and doors are
completely closed.
When searching for faults, it must be taken into
Water leaks into the vehicle passenger
account that water can enter the vehicle passenger
compartment cannot usually be located
compartment in various ways and circumstances.
immediately, as the water often spreads across a
Therefore, it is sometimes not sufficient to perform
large area. For this reason, the passenger
a water test on a stationary vehicle.
compartment must be dried before the leak tests.
Before beginning extensive checks, a thorough Any ancillary components that block the view must
visual inspection must be carried out. The following be removed. During the water test, the vehicle is
points are to be taken into account in the process: sprayed or sprinkled with water at the suspected
• Check the clearance and accurate fit of ancillary location of the leak. At the same time, a second
components such as the trunk lid and doors. person checks the passenger compartment for
places where water enters the vehicle. Depending
• Check for correct installation and possible on the test and the vehicle, it may take some time
damage to sealing elements such as blanking before there is any sign of water entering the
plugs, seals and rubber door seals. vehicle. We recommend laying blotting paper under
• Check that the water runoff openings and pipes the location being tested so that the water entry
are free of obstructions can be localized.
Example: Water test with sprinkler head (rain
test)
2011 Fiesta 08/2010 G468074en

Car wash test NOTE: The equipment manufacturer's instructions

Certain leak problems only appear in a car wash must be followed when using a UV lamp and
or can only be simulated there. The concerned contrast agent.
area of the passenger compartment should be Procedure for using a UV lamp.
inspected with a torch during the wash procedure.
• Wet the test area with clear water from the
Road Test outside.
Some leaks only appear when the vehicle is • Prepare test liquid and apply it from the outside
moving. If no leaks are detected during the using a suitable water sprayer.
above-mentioned tests, road tests should be • Illuminate the relevant area from the inside using
carried out on wet roads: the UV lamp. The test liquid which enters will
• At various speeds. make the leak visible.
• On various road surfaces (asphalt to cobbles).
• With loaded or unloaded vehicle. Chalk/powder test
• Driving through puddles (splash water).
This test checks the contact surfaces of seals on
doors, hatches and lids.
Test with UV lamp Process using a door seal as an example:
A leak test can also be performed using a UV lamp To do this, the door seal is coated with powder or
and a special contrasting agent. The advantages brushed with chalk. A thin layer of grease is applied
of using contrast agent are: to the contact area of the seal. The door must then
be slowly closed and reopened. The width and
• No need to dry out wet areas beforehand. continuity of the imprint can now be checked on
• The water entry and its subsequent path can the seal.
be seen more clearly.
• No need to remove most ancillary components
from the vehicle.
2011 Fiesta 08/2010 G468074en

Smoke test Flow checking device
Des Description • Close all doors so that a slight overpressure can

cript build up in the passenger compartment.
ion • Move the smoke pipe along the outside of the
1 Test pipe body to the areas to be checked.
• Leaks can be detected through the irregular
2 Test pipe opener movement of the smoke.
3 Puffer ball
Operating principle
Stethoscope test
The flow checking device is a set made up of a This procedure is very similar to the smoke test.
flow-testing pipe, a test pipe opener, puffer ball Instead of the smoke pipe, move a stethoscope
and closing-off caps for the pipe. past the areas of the body that are at risk. Leaks
The test pipe contains a filling layer which is can now be detected acoustically.
impregnated with fuming sulfuric acid. When air is Stethoscope
blown through the pipe by the puffer ball, sulfuric
acid is emitted as an aerosol in the form of a white
smoke.
NOTE: Pay attention to the instructions for use and
the safety directions issued by the manufacturer.
The smoke test can only be performed in a
draft-free environment.
This test can be used to detect leaks visually.
Procedure:
• Break off both tips of the pipe in the pipe opener,
in exceptional cases in the top of the packaging.
• Insert the pipe into the puffer ball so there are
no leaks.
• Close the hole in the puffer ball with your thumb
and press the air contained in the ball through
the pipe.
• Set the ventilation blower in the passenger
compartment to the highest setting.
2011 Fiesta 08/2010 G468074en

Ultrasonic detection Sta Testing Res Action
ge ult
This test uses ultrasonic waves to locate the
positions of leaks. When an ultrasonic transmitter No Step 2.
is placed inside the vehicle, it sends out ultrasonic 2nd Perform an initial Yes Dry out vehicle.
waves. A leak is located by running a detector visual inspection Repair damage.
along the suspected area. The position with the on the vehicle. Perform a water
loudest reception of the escaping ultrasonic waves Look for signs of test as a check
is the location of the leak. water entry. Can (see test
Procedure: the cause of the method).
leak be identified
• Place the ultrasonic transmitter in the vehicle. immediately?
• Completely close the vehicle.
No Step 3.
• Search the exterior of the vehicle using the
detector. 3rd Is it possible that Check the seal
• The detector provides a simple indication of a water is getting for damage.
leak. into the vehicle Check the
through a seal creation of the
(door seal, trunk seal using the
Ultrasonic test device lid seal)? chalk test (see
test methods).
Step 4.
No Step 5.
4th Is the contact Yes Step 5.
area for the seal
adequate?
No Perform work as
described under
Areas with
possible water
leaks - Door
seals. Dry out
vehicle. Repair
damage.
Perform a water
test as a check
(see test
method).
5th Before starting Yes Dry out vehicle.
Workflow for tracing water entry any further work, Repair the
use the VIN to damage using
Sta Testing Res Action look for model- the information
ge ult specific informa- found. Perform a
tion in eTIS. water test as a
1st Ask customer for Yes Dry out the
Perform Oasis check (see test
a detailed list of vehicle and
query and check method).
possible reasons repair the
TSIs. Does this
for the water damage.
information allow
entry. Does this Perform a water
the cause of the
information allow test as a check
leak to be identi-
the cause of the (see test
fied?
leak to be identi- method).
fied? No Step 6.
2011 Fiesta 08/2010 G468074en

Sta Testing Res Action vibrations, roughness chapters may be useful in
ge ult identifying the fault.
6th Establish the Yes Dry out vehicle. An outline of the possible complaints due to water
extent of the Repair leak. leaks is provided below. The causes of water leaks
damage. To do Perform a water and the possible remedies are presented using
this, expose wet test as a check selected examples. They are intended to provide
areas. Remove (see test troubleshooting tips and suggestions for the user
parts. Investigate method). but do not represent an exhaustive faults list.
the suspected
area for signs of
water. Does an Glued windows
investigation of
the suspected A broken pasted seam can cause water to enter
area allow the around the window. A broken pasted seam can be
cause of the leak located using a water test or by carefully blowing
to be identified? compressed air onto the inside of the window seal.
No Step 7.
7th Check exterior Yes Dry out vehicle.
areas (seals, Repair leak.
seal welds). Perform a water
Check interior test as a check
areas: Signs of (see test
water, plugs, method).
seal welds. Can
the cause of the
leak be identi-
fied?
No Step 8.
Corrective action
8th Perform water Yes Dry out vehicle.
test or ultra- Repair leak. Broken adhesive seams -Arrow- can be sealed
sound test. Can Perform a water from inside using PU glass adhesive.
the cause of the test as a check If this seal does not resolve the problem or the
leak be found? (see test broken pasted seam is too extensive, it is
method). necessary to remove the window and glue it back
into place.
No The water entry
may only occur
under dynamic
Door seals
driving condi-
tions. This
If water appears at the bottom of the door, it is
requires
possible that the door seal behind the door trim is
intensive tests to
damaged. If the door is intact, water can enter
be repeated with
through the window weatherstrip and flow out
the corres-
through gaps on the underside of the door. If the
ponding climatic
door seal adhesion is faulty or the door seal is
influences (rain).
damaged, water can get into the interior.
Possible complaints and corrective

actions
NOTE: Water leaks and changed vehicle acoustics
can have similar causes. For this reason,
information from the Wind noise or Noise,
2011 Fiesta 08/2010 G468074en

Fastening bolts could be loose or clips incorrectly
positioned on door modules.
Corrective action
Depending on the door seals used, different sealing
methods can be used.
NOTE: The drainage holes on the underside of the
door may not be blocked - if they are, clean them.
Defective films and foam seals must be replaced.
Once the adhesive surfaces have been cleaned,
plastic films must be stuck with double-sided
adhesive tape or replaced.
Des Description Leaky foam seals are sealed with Butyl tape or
cript replaced.
ion
Plastic door modules are fitted with a weatherstrip,
1 Seal/adhesion which cannot be replaced. Seal the leaky point with
Butyl tape or replace the part.
2 Clips
3 Door speaker
Door weatherstrip
Leaks can be caused by badly fitted seals. In • Uneven welded flange thickness because of
particular, areas with radii -Arrow- must be several layers of body panels or production
thoroughly checked. tolerances.
Door seals can develop leaks due to: • Kinks.
• Damaged or expanded seals. The contact pressure of a seal can be determined
• Ageing. using a strip of paper. If a strip of paper trapped in
• Insufficient contact pressure. the closed door can be pulled out easily, the
contact pressure is too low.
• Inadequate contact area for seal on body part.
To resolve
2011 Fiesta 08/2010 G468074en

• Replace damaged or aged seals. Prevent kinks.
• The contact pressure can be changed by
adjusting the catch bolt or correcting the panel
flange.
• Even out the uneven welded flange thicknesses.
Properly repair any paint damage that occurs.
If the bodywork flanges are very uneven,
appropriate alignment work must be performed.
Pay particular attention here to the new
corrosion protection which needs to be applied
afterwards.
• If water entry is caused by a spot weld (burr on
the surface), this must be rectified and
appropriate corrosion protection applied. Des Description
cript
Tailgate sealing rubber ion
1 Hinge seal
2 Cable duct
Leaks can be caused by badly fitted or damaged

rubber grommets and plugs.
Damaged cable insulation can also cause leaks.
Where components are bolted on, water can enter
if there are inadequate seals at the connection
point.
To resolve
• Correctly fit rubber grommets / plugs. During
fitting, ensure that the sealing lips are not
trapped and are applied properly.
• The contact area of the rubber grommets / plugs
can also be sealed with PU sealing compound.
• Replace the damaged rubber grommets and
Leaks at the tailgate rubber seal have the same repair the damaged cable insulation.
causes and remedial measures as for door rubber
seals. Especially vulnerable areas -arrows- must • Smooth the panel deformations in the contact
be thoroughly checked. area of the plugs.
Rubber grommets / plugs Heater housing/ventilation
Rubber grommets or plugs are fitted at numerous Loose butyl sealing strips, damaged sealing
points on the body. They are frequently used as surfaces or a trapped carpet can cause leaks
seals for cables, hoses or actuating links. Rubber around the heater housing / ventilation Arrow.
plugs are frequently used for gaps caused during Badly positioned or badly fitted hoses can also be
production. responsible for water entry. Water drains must not
be blocked
Example: Possible problem locations in the
tailgate area
2011 Fiesta 08/2010 G468074en

be removed and re-applied properly. Make sure
that any residual moisture is effectively removed
before a new seal is applied.
Attached parts
The add-on parts include:

• Exterior mirros, handles, controls.
• Mouldings, roof mouldings, lettering.
• Roof aerial, roof rack or connections for roof
rack systems.
NOTE: A large quantity of water flows through the • Bumper mountings.
water tank. If there are leaks in this area, it is • Injection nozzles, door contact switches, bump
essential to ensure that the water drainage stop rubber.
mechanisms function correctly. Drainage openings
may not be blocked or stuck. Leaves and other dirt • Control unit seals.
must be removed before troubleshooting. • Tail lamps.
• All kind of screwed connections (pedal block,
Corrective action door and tailgate hinges)
Before the actual repair, make sure that the water Example: Possible water entry points at the
drains are not blocked or stuck. rear lamp
Remove the heater housing / ventilation and fit a
new Butyl sealing strip. Damaged sealing surfaces
must first be adjusted. A trapped carpet must be
removed.
Seal welds
Des Description
PU sealing beads are applied to welded or riveted cript
connections Arrows to seal the interior of the ion
vehicle. Incorrectly applied or damaged seal welds 1 Clips
can allow moisture to penetrate into the interior of
the vehicle. It is also possible that sealing beads 2 Gaskets.
whose shape and size appear to be intact actually 3 Rubber grommet
have poor adhesion.
Add-on body parts must be fitted with seals,
Corrective action grommets or sealing compound to prevent water
Incomplete seal welds must be supplemented with entry. However, even when a sealing system is
PU sealing compound. Damaged seal welds must fitted, the screw thread may still cause leaks.
2011 Fiesta 08/2010 G468074en

Corrective action
Seals must be tested and, if necessary, replaced.
Check contact surface and adjust if necessary.
Points sealed with sealing compound must be
thoroughly cleaned and the seal replaced. Check
grommets and replace if necessary. At all screwed
connections, seal the thread with an appropriate
sealing material.
2011 Fiesta 08/2010 G468074en

Wind Noise
Wind noises as well as other general noises are There are various causes of wind noises. They can
dealt with under Noise, Vibration and Harshness be due to the design of the vehicle, or they can
(NVH). occur after a repair. They are mostly caused by
NOTE: Basic and in-depth training is offered on poorly mounted components, which must be
the following topics. You will find an overview of located and installed in the correct position.
the complete range of courses in the Training
Brochure issued by the Ford Service Organization. General information
Due to the continuous reduction in drivetrain
noises, wind noises have come to the fore in the In order to carry out targeted diagnosis, it is
vehicle and are perceived to a greater extent by important to know the basics of noise formation
the customer. and sound transmission.
Potential areas of wind noises

1 Wiper arms 8 Door seals
2 Windscreen seal 9 Headlamps
3 Antenna/antenna base 10 Radiator grille.
4 Sun roof/roof rail Noises are categorized according to their type and
5 Tailgate formation as follows:
6 Door handles "Normal" air flow noises:
7 Exterior Rear View Mirror Normal air flow noises are caused by air blowing
against even, flat vehicle surfaces, such as the
2011 Fiesta 08/2010 G468075en

roof, doors and side windows. When the vehicle is Workshop diagnosis
moving fast, air layers (turbulence) form, which
cause variations in air pressure. These variations Assessm Type of wind Place of origin
in air pressure spread in the form of sound waves ent noises
and are transferred to the vehicle interior via the
side windows and seals. Normal "Normal" wind Roof, side
noises windows
Noises caused by deviations in air flow and
circulation around separate components: Normal Noises caused A-pillars, outside
partly by mirrors,
If air flows over an edge on a vehicle, the air flow changes in the antennas
cannot follow the shape of the surface, but direction of air
separates at the edge. Eddies are formed, which flow and by air
collapse again after a certain time or distance. The flow around
associated fluctuations in air pressure create a separate
corresponding sound wave which is noticeable by components
for instance a rushing noise at the A-pillar or the
outside mirror. Serious Noises caused Door gaps too
by vibrating large, door/
Turbulence and the associated radiation of noise
seals window seals not
can also occur at the vehicle underbody. Air
making firm
circulation around small components and also flow
contact
through small gaps (e.g. the radiator grille) cause
the rushing noise to change to a whistling, which Serious Air escape and Leaks in the
rises and becomes louder as the vehicle speed air passage bodywork/
increases. noises sealing system
Noises caused by vibrating seals: Serious Cavity noises Unsealed body-
Seals which do not make firm contact at the door work cavities
or window area can be made to vibrate by pressure
variations outside the vehicle, which in turn mean Those noises listed under "Serious" indicate a
noise radiating into the interior of the vehicle. possible source of the fault.
Noises caused by air flowing out: Workshop diagnosis
Noises caused by air flowing out are created by There are two ways that the level of noise in the
leaks at the vehicle interior sealing system, when vehicle interior can be reduced and the character
stationary air mixes with flowing air. As a result, of the noise can be improved through assessment
the noise increases as the speed of the air flowing and diagnosis in the service department:
out increases. Example: Letting air out of a tire. • Reducing the intensity of the noise sources.
Cavity noises: • Reducing the noise transfer routes.
Cavity noises are those created when the air Before carrying out repair work, a visual inspection
volumes found in bodywork cavities are caused to of the vehicle must be carried out. The gaps in the
vibrate by an opening located in the airflow. The doors, the sunroof and at all other body parts must
frequency of the tone does not vary with the vehicle be checked in particular.
speed but depends on the volume of the cavity and When the doors are adjusted to fit exactly,
the size of the opening. Example: Blowing across development of wind noises at high speeds can
the top of a bottle. often be eliminated (lifting of doors off the seals).
Wind noises overview: Furthermore, the following points should be noted:
• The windows and doors must be fully closed.
• The air guides and air grilles must be correctly
seated.
• All of the trim strips and plastic components
must be firmly fixed down without gaps.
• All blanking plugs present.
2011 Fiesta 08/2010 G468075en

Test method • Carry out the road test in all speed ranges. Use
a high gear so that the engine noise is low.
The test procedures given in the chapter Noise, • Do not perform a road test near any sound
Vibration and Harshness can also be used to reflecting objects.
diagnose wind noises.
If it is difficult to detect the noise sources, the
Road tests search can be made easier by masking potential
Wind noises can usually only be localized by road areas.
tests Chalk/powder test
NOTE: There should always be two people present This test checks the contact surfaces of seals on
during road tests to find noises. A driver who doors, hatches and lids.
reconstructs the situation causing the noise, and
a person to carry out the checks. Process using a door seal as an example:
The following points should be taken into account To do this, the door seal is coated with powder or
for such road tests: brushed with chalk. A thin layer of grease is applied
to the surface against which the seal makes
• Check that the tire pressure is correct. contact. The door must then be slowly closed and
• Remove non-standard ancillary components reopened. The width and continuity of the imprint
from the vehicle. can now be checked on the seal.
• Choose a dry, flat road with as little traffic as Smoke test
possible.
Flow checking device
Item Description acid aerosol is emitted in the form of a white

smoke.
1 Test pipe
NOTE: Pay attention to the instructions for use and
2 Test pipe opener the safety directions issued by the manufacturer.
3 Puffer ball The smoke test can only be performed in a
draft-free environment.
Mode of operation: This test can be used to detect leaks visually.
The flow checking device is a set made up of a Procedure:
flow-testing pipe, a test pipe opener, puffer ball
• Break off both tips of the pipe in the pipe opener,
and closing-off caps for the pipe.
in exceptional cases in the top of the packaging.
The test pipe contains a filling layer which is • Insert the pipe into the puffer ball so there are
impregnated with fuming sulfuric acid. When air is no leaks.
blown through the pipe by the puffer ball, sulfuric
2011 Fiesta 08/2010 G468075en

• Close the hole in the puffer ball with your thumb
and press the air contained in the ball through
the pipe.
• Set the ventilation blower in the passenger
compartment to the highest setting.
• Close all doors so that a slight overpressure can
build up in the passenger compartment.
• Move the smoke pipe along the outside of the
body to the areas to be checked. Leaks can be
detected through the irregular movement of the
smoke.
Ultrasonic test
This test searches for leaks in the system of seals
or rather acoustic bridges. When an ultrasonic
transmitter is placed inside the vehicle, it sends
out ultrasonic waves. A leak is located by running
a detector along the suspected area. The position
with the loudest reception of the escaping
ultrasonic waves indicates places where noises Diagnosis
occur.
Ultrasonic test device Wind noises often have similar causes as the
general NVH noises. For instance, a windshield
which is incorrectly bonded in position can cause
normal driving noises to become more noticeable.
Asking the customer detailed questions and a road
test together with the customer are the
requirements for a targeted diagnosis.
NOTE: Take the customer concern seriously. But
do not confirm that a noise is a problem until you
are sure that it is something which is not normal
for the vehicle series.
Possible questions:
• How long has the noise been there?
• Has any work been done on the vehicle?
• Where does the noise come from?
• In which driving situation does the noise
appear?
• Is there any special situation in which the noise
Procedure: appears?
• Place the ultrasonic transmitter in the vehicle. Remember that a noise is often more or less
• Completely close the vehicle. noticeable depending on where you are sitting in
• Search the exterior of the vehicle using the the vehicle.
detector.
• The detector provides a simple indication of a
leak.
Stethoscope test
Stethoscope
2011 Fiesta 08/2010 G468075en

Sta to test Res Reference or Sta to test Res Reference or
ge ult Action ge ult Action
1st Road test the Yes Step 2. 3rd Before starting Yes Take the action
vehicle with the any further work, specified in the
customer. First use the VIN to Oasis or TSB
let the customer look for model- information.
drive to demon- specific informa- Check whether
strate the noise, tion in eTIS. the measures
before you drive Perform Oasis have been
the vehicle your- query and check successful.
self. Check that TSBs. Can a
the concern is cause for the
justified. Is this a noise be determ-
noise which ined based on
gives cause for the information
concern? available?
No Explain the noise No Step 4.
and tell the
4th Localize the Yes Step 5.
customer what is
noise. In doing
causing it.
so, check
Possibly offer a
whether it is an
comparable
unusual noise or
vehicle for a road
if it is a usual
test.
driving noise that
2nd Visually inspect Yes Eliminate the is more notice-
the vehicle. Look noise or carry able because of
for loose, out a repair as inadequate
damaged or the case may be. sealing. Is it an
missing compon- Check whether unusual noise?
ents. Check that the measures
No Step 7.
the vehicle is to have been
standard produc- successful. 5th Determine the Yes Eliminate the
tion series source of the noise or carry
specification. In noise. Can the out a repair as
particular, check cause be the case may be.
for any after- determined? Check whether
market compon- the measures
ents which may have been
have been successful.
installed.
Depending on No Step 6.
the type of noise, 6th Determine the Yes Eliminate the
check the path of the noise noise or carry
suspected area. using the stetho- out a repair as
Could a cause of scope. By way of the case may be.
the noise be a trial, mask the Check whether
found? suspected area the measures
No Step 3. or components have been
or remove them. successful.
Can the cause
be determined?
No Step 7.
2011 Fiesta 08/2010 G468075en

Sta to test Res Reference or Seals
ge ult Action
In general, seals are very important when
7th Check the Yes Renew the seal eliminating wind noises. Special attention should
vehicle for inad- or perform the always be paid here to the possible causes of wind
equate or appropriate noises.
damaged seals. repair as neces-
The sealing of a sary. Check
vehicle can be whether the
checked using measures have
the stethoscope, been successful.
the powder test,
the smoke test
and the ultra-
sonic detector.
(See under test
method.) Could
a leak be
detected?
No Step 8.
8th Under certain
circumstances
there may be a
constructional
problem which is
not yet known
about. Record
the problem in
an Express
Service Report
and send it on by
the usual
method. Take the following points into account:
• Seals age, i.e. they become porous and with
Possible concerns with corrective time they lose their original elasticity. If the
measures vehicle is relatively old and there are already
visible signs of distortion or damage to a seal,
NOTE: Instructions on general noise are then it should be replaced.
summarized separately in the Noise, Vibration and • At high speeds the doors or hatches may lift
Harshness section. These can be useful when slightly from the seal surfaces because of
searching for the causes of wind noises. variations in air pressure. Wind noises are
caused when the preload on the sealing surface
There follows an outline of the possible concerns
is not sufficient. The preload depends on the
relating to wind noises. Selected examples are
installation position of the components, the
given showing the causes of wind noises and the
elasticity of the seal and the location of the
ways in which they can be eliminated. They are
sealing flange.
intended to provide troubleshooting tips and
suggestions for the user but do not represent an • The contact surface of the seal must be
exhaustive faults list. The topics are subdivided by sufficient. This can be checked using the chalk
the different groups of components. test. If the specifed width of the contact surface
is not known, you must determine it on another
The test procedures described in the Noise, component of identical construction.
Vibration and Harshness section can be used when
• A bulging seal carrier indicates that the sheet
troubleshooting.
metal of the retaining flange is uneven.
2011 Fiesta 08/2010 G468075en

• Seals must be correctly installed. Special • The window must be bonded without any gaps
attention must be paid at corners -arrow- that -arrow-. Leaks can be found using the ultrasonic
the installation follows the contours. tester or compressed air carefully blown from
• The seal must not show any kinks or folds or inside onto the window glass bonding.
any other damage. • The installed position of the window glass must
• Seals must seal all around their circumference. be correct. It must not have been bonded into
Gaps in seals result in openings which lead to a position which is too low or offset to one side.
an increased incidence of noise. In this respect, • The sealing or trim strips must fit tightly and the
it is especially important to pay attention to the glass must be mounted so that it is fully
seals in the area of the windows. enclosed. If a sealing or trim strip has not been
applied with enough pressure, high air speeds
Remedial Action can cause it to lift up. This can lead to wind
Renew older seals which no longer have adequate noises at higher speeds. Apply masking tape to
preload. Deformed or widened retaining flanges these areas for test purposes.
must be reworked and provided with a new seal.
Corrective measures
Leaking areas of the window glass bonding
material can be sealed using PU sealing
compound. Pay special attention at the front
windshield, that any breaks in the bonding are not
too large. Otherwise the glass must be removed
and bonded in place again.
The installed location of a window glass cannot be
corrected. It must be removed and bonded into
place again.
Replace the trim strips or secure the lip seal using
PU adhesive.
The corner areas -arrow- of a seal must be
properly seated. In some circumstances, a butyl
Gaps, edges
sealing strip must be affixed to support the sealing
at a corner. Door gaps and edges are places where air
turbulence can form. This causes noises which can
be perceived as troublesome.
Bonded joints
Gaps and edges - problem areas
Glass is usually installed today using a bonded
joint. Gaps in the bonded joint can lead to noises
in the vehicle interior. If there are noises which are
believed to be associated with window glass, the
following points should be checked:
Gap in window bonding
Doors, hood and tailgate can cause wind noises

because of gaps -arrow- which are too large. If the
components are not installed flush to the bodywork
or the neighboring component, air break edges can
arise, which in turn can create a wind noise.
2011 Fiesta 08/2010 G468075en

The sun roof may be the cause of whistling noises Noises may come from the roof rail if the seal
in the roof area. The sun roof may be incorrectly between it and the roof is not correctly installed or
adjusted or the seal on the sun roof may be is cracked. Gaps at the mounting grooves of the
damaged. carrier can also create wind noises.
Noises from the door area could come from a The roof antenna and antenna foot seal must be
window which does not fully close. Side guides correctly secured. The seal must lie completely on
(seals) can also be the cause of wind noises. the roof and must not be damaged.
The covers of window frames can be incorrectly Roof moldings mounting
mounted or aligned. The quarter-lights in doors
must also be checked for correct installation.
Corrective measures
Check the gaps and adjust them according to the
specifications. If there are problems at the sun roof,
correct the adjustment and if necessary replace
the seals.
Problem area at side windows
If the original mounting points of the roof moldings

are in good condition, the fixing can be improved
using silicone sealant -arrow- if necessary. Align
or renew the seals of the roof rail. Reduce the
clearances of the mounting grooves.
Corrective measures
If the original mounting points of the roof moldings
are in good condition, the fixing can be improved
if necessary using silicone sealant -arrow-.
Side windows which do not fully shut -arrows- must
be adjusted. If the vehicle is equipped with electric Exterior mirrors
window regulators, the remedy may be to perform Exterior mirrors or covers of exterior mirrors which
the window regulator learning process again. In all are not correctly mounted cause noises. The cover
cases, make certain that the glass enters far must lie evenly on the component and must not lift
enough into the seal. during driving. There are ducts present on the
doors for the electrical or mechanical adjusters for
the exterior mirrors. If there are leaks, wind noises
Ancillary Components will be caused. Holes can also be present at the
transition to other components.
Components installed on the bodywork may cause
noises when they are not correctly mounted. Exterior mirror seals
When troubleshooting it may be helpful to remove

the suspected component or, when this is not
possible, to mask it off with suitable covering tape.
Roof moldings, roof rail, roof antennas
Moldings and roof moldings must touch the
bodywork along their whole length without any gap.
Check the end sections in particular. These must
neither have any splits nor stand away from the
bodywork.
2011 Fiesta 08/2010 G468075en

Remedial Action
Openings which are used to secure trim panels
must be checked for leaks. Any leaks found can
be rectified using butyl strips.
There are ducts present on the doors for the

electrical or mechanical adjusters for the exterior
mirrors. If there are leaks, wind noises will be
caused. Holes can also be present at the transition
to other components.
Remedial Action
If there is inadequate sealing of the foam seals -2-
they must be replaced or supplemented with
suitable material. Transitions to other components
can be sealed with butyl sealing compound -1-.
Moldings, covers, door handles, windshield
wiper arms
Moldings and covers especially tend to cause wind
noises because of their location. These
components interrupt smooth bodywork surfaces
and air turbulence therefore arises at the edges.
If there are noise concerns in the area of the doors, Loose or damaged outer trim on the pillars -arrow-
check especially for gaps and projections. Moldings must be secured or replaced.
must not stand away from the bodywork or the
door. There must not be any gaps or discontinuities
at the location of joints.
Incorrectly adjusted windshield wiper arms can
cause wind noises. Especially if they are too far
over the glass surface when in the rest position.
Wind noises in the transition area between the air
cowl cover and the wing or the windshield can be
caused by an incorrectly installed air cowl cover.
At high air speeds the air cowl cover may lift and
noises will then occur.
Because of their necessary mechanical features,
door handles have a range of openings and edges A butyl sealing strip -1- can be laid underneath the
which allow noise to be generated. The door handle cover in the transition area between the air cowl
can be masked off for testing purposes. If a cover and the wing or windshield.
reduction in wind noises is noticed, inadequate
sealing may be the reason for the noises. The sealing of the door handles must be renewed
when required. In addition, noise absorbing
material can be applied to the back of the door
handles.
2011 Fiesta 08/2010 G468075en

Noise, Vibration and Harshness

Noise, coming from the vehicle and which can be • High tones however, which are experienced as
heard inside and outside the vehicle. howling or whistling noises, are often air
Vibrations, oscillations that are felt and noticeable currents (wind noises) or come from ancillary
inside the vehicle. components such as the generator, power
steering pump or drivebelt.
Harshness, noises which come from the vehicle
and which can be heard, felt and noticed inside • There are also clattering noises which can occur
and outside the vehicle. when driving over an uneven road. These
jerking noises are produced by, for example,
These terms are grouped together under the title the shock absorbers, chassis components or
Noise, Vibration, Harshness, or NVH for short. loose articles inside the vehicle.
The task of vehicle development and production Noises can already be contained where they occur
is to ensure that noises caused by the vehicle do or, if this is not possible, can be confined with
not disturb the driver and passengers. Moreover, suitable measures.
the the external noises emitted by the vehicle must
not exceed the thresholds set by law. The basic procedures here are the damping of
oscillating parts, the insulation of components or
NOTE: Basic and advanced training courses are the absorption of the noises through appropriate
offered for the following contents. For an overview materials.
of all courses offered, please refer to the Ford
Service Organisation's training course brochure. Damping
Noise types and causes

If a damper is installed next to an oscillating mass,
the characteristic of the damper will reduce the
Noises in and around the vehicle are assigned movement of this mass accordingly (e.g. bumper
specific descriptions: on chassis).
• Humming and droning are perceived as low Damping affects the resonance of an object or
tones. system.
• Buzzing and whirring are middle tones. Isolation
• Howling, whistling, squeaking are assigned to
the high tones. In oscillation technology, the term isolation means
decoupling (separation) of components and
Low to middle tones are considered to be systems. An engine is mounted in sprung elements,
unpleasant. They are palpable and noticeable as so that as little oscillation as possible is passed to
oscillations and vibrations throughout the body. the vehicle.
Loud howling and whistling is painful to the ears.
In automotive technology, the isolation technique
A noise usually consists of a superimposition of used is nearly always rubber mounting. Rubber
different tones which spread as oscillations. has a large internal damping capacity. The
Each of these oscillations has a specific oscillating elasticity of the rubber acts like a spring.
time and can be measured in frequencies. The Absorption
frequency describes the number of oscillations per
second. The frequency unit is specified in Hertz Sound waves are reflected from hard surfaces
(Hz). Through the use of absorption material, sound
waves hit soft surfaces and are absorbed by them.
The human ear can perceive frequencies between
20 and 20000 Hz. The composition and thickness of the material used
plays an important role here. A soft surface,
Where the different notes come from in a depending on its composition, absorbs the sound
vehicle: waves and reduces their energy.
• Low notes are mostly produced by the engine.
NVH elements
• Low tones can also be produced by the
roadbed, particularly on rough surfaces. This is NVH elements are installed to prevent airborne
a form of droning which can be felt by the sound transfers to the passenger compartment in
vehicle occupants as vibration or roughness. different body cavities.
2011 Fiesta 08/2010 G468076en

Item Description C. At this temperature the isolation material

expands to seal the gap between the carrier plate
1 C-pillar area and the bodywork.
2 B-pillar area NOTE: NVH elements must not be damaged during
3 A-pillar area work on the vehicle body. NVH elements deformed
through impact must always be replaced. PU
On the Focus 2004.75 (07/2004-) these elements adhesive must always be applied to the edges of
are located in the cavities of the A, B and C pillars. new and reused NVH elements during repair work.
On the estate version, they are also located in the
D pillars.
The NVH material consists of a carrier plate which
has compressed isolation material at the edges.
In the drying system of the painting equipment used
in production, the body is heated to approx. 170°
2011 Fiesta 08/2010 G468076en

• condition history, especially any relationship to
repairs or sudden change.
• knowledge of probable causes.
• application of diagnosis procedures in which the
vehicle is split into corresponding areas.
NOTE: The diagnosis of droning problems is one
of the most difficult tasks in the NVH area. With
the exception of installed components under stress,
a certain diagnosis of droning problems (or boom)
on customer vehicles makes great demands on
the automotive technician. The performance of
measuring equipment and their practice-orientated
application can only be obtained through suitable
Item Description
instruction (NVH training). The successful use of
1 NVH element these devices requires a great deal of experience
on the part of the user.
2 PU adhesive
The diagnosis and correction of noise, vibration
For the exact installation position of an NVH and harshness concerns requires:
element, please refer to the vehicle-specific repair • a road or system test to determine the exact
instructions. nature of the concern.
If an NVH element is to be reused, the bonding on Analysis of possible causes:
the body panel must be detached. To do this, the
body panel must be heated in the area around the • checking of the cause and elimination of the
NVH element. The bonding can be detached at faults found.
approx. 170° C. The damaged panel part can now • a road test or system test to make sure the
be carefully dismantled. concern has been corrected or brought back to
Before installing the new panel part, a PU adhesive within an acceptable range.
must be applied to the contact areas between the • It is often very difficult to locate noises that are
panel and the NVH element. audible in the passenger compartment based
on the problem description provided by the
Test techniques, measuring devices customer and the road tests performed. The
The shortest route to an accurate diagnosis results direction of the noise can be detected
from: subjectively, but the source of the noise cannot
be found.
• general information on the problem vehicle and
a comparison test with a vehicle of the same NOTE: For a selection of simple test tools, see the
construction, without NVH problems. wind noises section.
• vehicle history, including repair history and Electronic NVH tester
usage patterns.
• condition history, especially any relationship to
repairs or sudden change.
• knowledge of probable causes.
• application of diagnosis procedures in which the
vehicle is split into corresponding areas.
The diagnosis and correction of noise, vibration
and harshness concerns requires:
• general information on the problem vehicle and
a comparison test with a vehicle of the same
construction, without NVH problems.
• vehicle history, including repair history and
usage patterns.
2011 Fiesta 08/2010 G468076en

• There is an amplifier on the test device with
which the signal strength and the corresponding
channel can be set.
• Only the noises from a transmitter are
transferred to the headphones.
• All connected cables can be visually illustrated
individually or simultaneously on the display.
• The test device saves the recorded data.
• The recorded data can be imported to a PC and
evaluated.
The NVH tester is equipped in addition with mobile
magnetic sensors which are particularly suitable
for the following noise tests:
• Internal noises at the dashboard
• Engine noise
• Electrical noises (sparking/voltage
NOTE: Before using the NVH tester in the service, transmissions)
the service technician should take part in an NVH • Wind noises
training course to ensure effective use of this • Vacuum - leaks
device during the road test. A description of the
Chassis noise tester (chassis ear)
function and application of the NVH tester is
enclosed with the device.
The measuring device described below is used for
diagnosis of the solid-borne sound and solid-borne
sound transmission paths. The device is particularly
suitable for medium and high frequency noise
analyses. It principally enables noise diagnosis in
the area of solid-borne sound and helps to identify
solid-borne sound transmission routes.
In order to obtain a positive diagnosis of droning
problems (low frequency noises) and their sources,
you must have sufficient experience of how to use
this measuring device.
The device works according to the following
operating principle: Accelerometers (transmitters)
are fitted on various vehicle components or body
areas. The signals recorded here can be listened
to one after the other on headphones or speakers
via the different channels. Simultaneous illustration Used to diagnose solid-borne sound and its
of several or all measuring channels (for transmission routes. The device is particularly
comparison) is only possible visually on the display suitable for medium and high frequency noise
of the measuring device. analysis and principally enables noise diagnosis
Layout and operation: in the area of solid-borne sound and helps to
identify solid-borne sound transmission routes.
• The test device has six different channels for
noise diagnosis. In order to obtain a positive diagnosis of droning
• Each channel is marked in color on the terminal, problems (low frequency noises) and their sources,
cable and test device. you must have sufficient experience of how to use
this measuring device.
• The solid-borne sound recorded is transmitted
to the test device or the headphones by the Layout and operation:
magnetic accelerometers (transmitters).
2011 Fiesta 08/2010 G468076en

The test device has six different channels for noise
diagnosis. This means that six microphones
equipped with clamps can be attached to different
components on the vehicle. The emitted or
transmitted solid-borne sound will be transferred
from microphone to the headphones. There is an
amplifier between the microphone and the
headphones at which the signal strengths and the
corresponding channel can be set.
Only the noises from one microphone are
transferred to the headphones. Each channel is
color-coded on the clamp, cable and amplifier.
NOTE: In order to be able to relate the positions
of the different microphones during the test
process, they are entered in a special test sheet
according to their colors. Microphones, clamps and
cables must be carefully routed and attached.
Test process (example for transmission noise):
• Attach microphones to various positions on the
transmission or mountings. This first allows the
source of the noise to be determined, and then
the possible transfer routes.
• A road test can be performed after all the
clamps have been attached to the vehicle and
all the cables connected to the amplifier.
• Firstly, all the channels are switched through
one after the other in neutral, to check the
operation of the different channels as well as
the noise level in neutral.
• During the road test, all channels are listened
to in the different gears, engine speeds, vehicle
speeds and loads. This procedural method
permits unambiguous diagnosis of the cause of
the noise and the route of the noise until it
enters the bodywork structure.
• The characteristics of the noise which is the
cause of the concern should match those of the
noise which is heard. This means compare the
sound.
• Depending on the input signal level, there may
be a great deal of difference in the noise level
in the individual channels.
• Always set the amplifier volume to zero before
switching to another channel.
• In order to be able to make any comparisons,
the volume settings of the different channels
must be recorded on the test sheet.
2011 Fiesta 08/2010 G468076en

501-26-1 and Tolerance Checks 501-26-1
.
SECTION 501-26 Body Repairs - Vehicle Specific

Information and Tolerance Checks
CONTENTS PAGE

Body and Frame (Component Location)............................................................................ 501-26-2
Body and Frame (Overview)............................................................................................... 501-26-7
Introduction......................................................................................................................... 501-26-7
High-strength and super-high-strength steels.................................................................... 501-26-7
Usibor steel......................................................................................................................... 501-26-8
Crash elements.................................................................................................................. 501-26-9
Sheet metal parts for quarter panel partial replacement.................................................... 501-26-11
Anti-corrosion protection..................................................................................................... 501-26-12
Laser weld seams on the front side members.................................................................... 501-26-14
GENERAL PROCEDURES
Underbody Tolerance Check.............................................................................................. 501-26-15
Frame Tolerance Check..................................................................................................... 501-26-17
Body and Frame – Component Location

Body, 3-door version
E101843
2011 Fiesta 08/2010 G1080182en

Body, 5-door version
E101844
Location of the VIN plate
E87496
2011 Fiesta 08/2010 G1080182en

Lifting Points
E101825
2011 Fiesta 08/2010 G1080182en

Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS)
14
2
13 3
12
11
10
6
9
8 7
E103036

1 Front crash sensor 5 Side airbag (driver and passenger side)
Comments:
2 Front passenger airbag optional
3 PAD (passenger air bag deactivation) 6 Crash sensor (driver and passenger side)
deactivator switch Comments:
Comments: optional
optional
7 RCM (restraints control module)
4 Seat occupant sensor (passenger side
only) 8 Safety belt buckle switch (driver and
passenger side)
2011 Fiesta 08/2010 G1080182en

9 Head airbag (driver and passenger side) 12 Driver air bag
Comments:
13 Knee air bag
optional
Comments:
10 Belt pretensioner in the retractor (driver optional
and passenger side)
14 Instrument cluster with airbag indicator
11 PAD indicator light light and safety belt warning light
Comments:
optional
NVH expandables
E116026
2011 Fiesta 08/2010 G1080182en

Body and Frame – Overview

Introduction the vehicle weighs less than its predecessor.
However, it offers increased occupant safety
With the 2008.75 model year, the Ford Fiesta is through the use of high-strength and
superseded by a completely new vehicle. The super-high-strength steels. The high-strength and
Fiesta is based on the B2e platform which has super-high-strength steels used make extra
been developed in co-operation with Mazda. 3-door demands on the tools to be employed for some
and 5-door body versions are offered. Within the body repairs.
company the model designation is B299. Overall
High-strength and super-high-strength steels
E116044
Yield strength
1 UHSS (> 800 MPa) 3 VHSS (280 - 380 MPa)
2 EHSS (380 - 800 MPa) 4 HSS (180 - 280 MPa)
5 MS (< 180 MPa)
2011 Fiesta 08/2010 G1080183en

Usibor steel
E103380
The reinforcements at the A- and B-pillars are • For welding work (resistance spot welding and
made of Usibor steel. This material has a yield inert gas puddle welding), additional preparation
strength of 1300 MPa. work and/or special welding equipment are
• Sectional repairs must NOT be performed on required.
components made of Usibor ! • Refer to: Body Sheet Metal (501-25 Body
• The required continuous MIG weld seam in the Repairs - General Information, Description
cut area would cause structural changes in the and Operation)
steel and lead to a significant loss in strength. / Tools and Equipment for Body Repairs (501-25
• In the event of damage, the complete Body Repairs - General Information,
component must therefore always be renewed. Description and Operation)
/ Joining Techniques (501-25 Body Repairs -
• Also, because of the strength of these General Information, Description and
components, it is not always possible to work Operation).
them with conventional body repair tools.
2011 Fiesta 08/2010 G1080183en

Crash elements
Front crash module
E116045
Item Description
1 Crash element (ZStE260; 1,6 mm)
2 Bumper (DP100; 2 mm)
2011 Fiesta 08/2010 G1080183en

Rear crash module
E116046
Item Description
1 Crash element (DP600; 1,6 mm)
2 Bumper (QStE340; 1,4 mm)
On each of the side members at the front and rear connection between the ends of the two side
of the vehicle there is a crash element attached by members and therefore contributes to an increase
threaded connections. These crash elements can in passive safety.
absorb light impacts of up to about 15 km/hr.
NOTE: Deformed crash elements must not be
Because of the threaded connections, a crash
straightened or repaired.
element can be changed relatively quickly. The
crash elements are joined to each other by a Heavier impacts which can no longer be absorbed
transverse mounted bumper. This forms a by the crash element must be absorbed by the side
members or the floor pan structure.
2011 Fiesta 08/2010 G1080183en

Sheet metal parts for quarter panel partial replacement
E116047
2011 Fiesta 08/2010 G1080183en

Anti-corrosion protection
Underbody
E116048
Item Description
1 Underbody PVC stone chip protection
2 Injection points for cavity wax protection
2011 Fiesta 08/2010 G1080183en

Door cavity wax protection
100 mm 50 mm
E116049
All vehicle variants (shown on the 5-door)
2011 Fiesta 08/2010 G1080183en

Laser weld seams on the front side members
Tailored blank
E116050
Item Description
1 DP600 - 1,4 mm
2 DP600 - 1,6 mm
There are laser weld seams on the front side

members. These laser weld seams are used to
join body components of different quality and/or
different material thickness (tailored blanks).
Cut locations exactly on the laser weld seams are
not permitted, as at present no joining techniques
are approved for use in repair procedures that
would re-create joins of the same quality.
Refer to: Front Side Member Section (501-27 Front
End Sheet Metal Repairs, Removal and
Installation)
/ Front Side Member and Fender Apron Panel LH
(501-27 Front End Sheet Metal Repairs, Removal
and Installation).
2011 Fiesta 08/2010 G1080183en

GENERAL PROCEDURES
Underbody Tolerance Check

the panel, using the Allvis system, with
1. Body dimensions, all versions (quick
component assemblies installed.
measurements using the Allvis system)
• A tolerance of ± 3 mm applies to all
• All dimensions are measured from the middle measurements given. All detailed illustrations
of the hole or bolt head or from the edge of correspond to the left-hand side of the
vehicle.
Allvis specifications
Point of measurement Adapter Height setting of the test
probes
1 15 mm (Socket) 200 mm
2 25 mm (Probe) 240 mm
2011 Fiesta 08/2010 G1080185en

GENERAL PROCEDURES
A
1
3
4
1 2 3 0 4 5 6
1279 799 894 1484 1668
11
91 168
3
88
4
1 184
91 1 10 9
14
E116064
2011 Fiesta 08/2010 G1080185en

GENERAL PROCEDURES
Frame Tolerance Check

1. Front end body dimensions, all models 1 - 3 = 320 mm 1 - 8 = 1189 mm
• All dimensions with tolerance ± 3 mm. All 1 - 4 = 495 mm 1 - 9 = 1204 mm
dimensions were determined starting from 1 - 5 = 1132 mm 1 - 10 = 1512 mm
the centre of each hole or panel edge using
a symmetrically adjusted measuring gauge. 1 - 6 = 1202 mm
Messpunkte und Maße

1 - 2 = 196 mm 1 - 7 = 1009 mm
2011 Fiesta 08/2010 G1080186en

GENERAL PROCEDURES
2
3
1 4
10
8 2
7
6 3
5 4
6
5
8
9
10
7
E116065
the edge of the steel panel using a

2. Body dimensions, side view (3-door version)
symmetrically adjusted measuring gauge.
• All dimensions with tolerance ± 3 mm. All
dimensions were determined starting from
2011 Fiesta 08/2010 G1080186en

GENERAL PROCEDURES
• Measuring points 1, 2, 4 and 5 are measured Measuring points and dimensions
in the curve and represent the greatest 1 - 4 = 1469 mm
distance to the measuring point opposite.
• The detailed views of measuring points 3 and 2 - 5 = 1142 mm
6 are shown looking from the vehicle interior 3 - 6 = 1028 mm
outwards.
2011 Fiesta 08/2010 G1080186en

GENERAL PROCEDURES
3
1 2
5
6
E116066

• All dimensions with tolerance ± 3 mm. All • Measuring points 1, 2, 3, 4, 6, 7, 10 and 11
dimensions were determined starting from are measured in the curve and represent the
2011 Fiesta 08/2010 G1080186en

GENERAL PROCEDURES
greatest distance to the measuring point Measuring points and dimensions
opposite. 1 - 10 = 920 mm 4 - 7 = 1077 mm
• The detailed views of measuring points 5, 8,
9 and 12 are shown looking from the vehicle 2 - 11 = 1306 mm 5 - 8 = 711 mm
interior outwards. 3 - 6 = 958 mm 9 - 12 = 797 mm
2011 Fiesta 08/2010 G1080186en

GENERAL PROCEDURES
5
4
1 2 3
2 3
4
12
11 10 7 6
6
12
11 10 7
9 8
E116067

• All dimensions with tolerance ± 3 mm. All • Measuring points 1, 2, 3, 4, 6, 7, 10 and 11
dimensions were determined starting from are measured in the curve and represent the
2011 Fiesta 08/2010 G1080186en

GENERAL PROCEDURES
greatest distance to the measuring point Measuring points and dimensions
opposite. 1 - 10 = 923 mm 4 - 7 = 1092 mm
• The detailed views of measuring points 5, 8,
9 and 12 are shown looking from the vehicle 2 - 11 = 1305 mm 5 - 8 = 710 mm
interior outwards. 3 - 6 = 985 mm 9 - 12 = 795 mm
2011 Fiesta 08/2010 G1080186en

GENERAL PROCEDURES
5
4
1 2 3
2 3
4
1
12
11 10 6
7
6
12
11 10 7
9 8
E116068
the center of the welded flange using a

5. Body dimensions, rear (3-door version)
2011 Fiesta 08/2010 G1080186en

GENERAL PROCEDURES
Measuring points and dimensions 2 - 6 = 773 mm 4 - 8 = 1025 mm
1 - 5 = 1064 mm 3 - 7 = 1063 mm
2 3 4
1
1 3
8 4
7 6 5
8 7 6 5
E116069

6. Body dimensions, rear (4-door version)
2011 Fiesta 08/2010 G1080186en

GENERAL PROCEDURES
the center of the welded flange using a 2 - 7 = 502 mm 5 - 9 = 992 mm
3 - 8 = 986 mm
Measuring points and dimensions
1 - 6 = 985 mm 4 - 10 = 1089 mm
1 3
2
10 5
8
9 6
7
E116070
2011 Fiesta 08/2010 G1080186en

GENERAL PROCEDURES
7. Body dimensions, rear (5-door version) Measuring points and dimensions
• All dimensions with tolerance ± 3 mm. All 1 - 5 = 1062 mm 3 - 7 = 1062 mm
dimensions were determined starting from 2 - 6 = 774 mm 4 - 8 = 1024 mm
2 3 4
1
3
1
8 4
7 5
6
8 7 6 5
E116071
2011 Fiesta 08/2010 G1080186en

GENERAL PROCEDURES
8. Body dimensions, interior (3-door version) • The detailed views of measuring points 1, 2,
3 and 4 are shown looking from the vehicle
1. All dimensions with tolerance ± 3 mm. All
interior outwards.
the center of the welded flange using a Measuring points and dimensions
1 - 2 = 1366 mm 3 - 4 = 1365 mm
2011 Fiesta 08/2010 G1080186en

GENERAL PROCEDURES
1 2
1 2
4 3
4 3
E116072

9. Body dimensions, interior (4-door version)
2011 Fiesta 08/2010 G1080186en

GENERAL PROCEDURES
• The detailed views of measuring points 1, 2, Measuring points and dimensions
3, 4, 5 and 6 are shown looking from the 1 - 4 = 1366 mm 5 - 6 = 1288 mm
vehicle interior outwards.
2 - 3 = 1366 mm
2 3
1 4
6 5
E116073
2011 Fiesta 08/2010 G1080186en

GENERAL PROCEDURES
10. Body dimensions, interior (5-door version) • The detailed views of measuring points 1, 2,
3, 4, 5 and 6 are shown looking from the
vehicle interior outwards.
the center of the welded flange using a Measuring points and dimensions
1 - 4 = 1366 mm 5 - 6 = 1288 mm
2 - 3 = 1365 mm
2011 Fiesta 08/2010 G1080186en

GENERAL PROCEDURES
2 3
1 4
6 5
E116074
2011 Fiesta 08/2010 G1080186en

501-27-1 Front End Sheet Metal Repairs 501-27-1
.
SECTION 501-27 Front End Sheet Metal Repairs

CONTENTS PAGE

Front Fender....................................................................................................................... 501-27-2
Fender Apron Panel Reinforcement................................................................................... 501-27-4
Front Side Member Section................................................................................................ 501-27-9
Front Side Member and Fender Apron Panel LH............................................................... 501-27-17
Front Fender
Removal
1.
E115873
E104298 4. Torque: 6 Nm
2. Torque: 6 Nm
x1
E115880
E115877
2011 Fiesta 08/2010 G1080193en

5. Refer to: Fender Splash Shield (501-02 Front 8. Torque: 6 Nm
End Body Panels, Removal and Installation).
6. Torque: 6 Nm
x2
E115876
x2
E115874 9. CAUTION: Take extra care not to scratch

the bumper cover.
7. Torque: 6 Nm
x3
E115878
E115875
Installation
2011 Fiesta 08/2010 G1080193en

Fender Apron Panel Reinforcement

8 mm Drill Bit Metal Inert Gas (MIG) Welding Equipment
Air Body Saw Spot weld drill Bit
Removal
1. • Refer to: Front Fender (501-27 Front End
Sheet Metal Repairs, Removal and
Installation).
Refer to: Fog Lamps (417-01 Exterior
Lighting, Diagnosis and Testing).
Refer to: Headlamps (417-01 Exterior
Installation).
Refer to: Front Bumper Cover (501-19
Bumpers, Removal and Installation).
• Door
• Hood
• Bumper
• Hood Closing Panel
2. • Partial Replacement
• Possible cut line.
General Equipment: Air Body Saw
E108669
3. • Grind out the MIG brazed joints.
2011 Fiesta 08/2010 G1080195en

E108670
4. • Mill out the spot welds. 5. • Mill out the spot welds.
General Equipment: Spot weld drill Bit General Equipment: Spot weld drill Bit
E108672 E108673
6. • Mill out the spot welds.

General Equipment: Spot weld drill Bit
2011 Fiesta 08/2010 G1080195en

E108671
Installation General Information, Description and

Operation).
1. NOTE: Before resistance spot welding of body
panels with a total panel thickness of 3 mm and 3. NOTE: Replacement of MIG brazed joints by
greater, the manufacturer's welding equipment MIG welds.
instructions and sub-section 501-25 must be • The factory-installed MIG brazed joints must
followed. be replaced by MIG welds in a different
Refer to: Tools and Equipment for Body Repairs position.
(501-25 Body Repairs - General Information, • These MIG welds must not be carried out on
Description and Operation). or in the immediate vicinity of existing MIG
brazed seams as even the smallest amount
2. NOTE: Sealer or adhesive must not be applied of brazing solder can result in a reduction in
in welding zones. Areas which were bonded or the strength of the weld seam.
sealed needs to be thoroughly sealed
afterwards. Refer to: Joining Techniques (501-25 Body
Repairs - General Information, Description
Refer to: Sealer, Underbody Protection Material and Operation).
and Adhesives (501-25 Body Repairs - 4. • General Equipment: 8 mm Drill Bit
8 mm
E108674
2011 Fiesta 08/2010 G1080195en

5. • Resistance spot weld - Panel thickness 3 mm and greater!
E108675
6. • General Equipment: Metal Inert Gas (MIG)

Welding Equipment
E108676
2011 Fiesta 08/2010 G1080195en

7. • Resistance spot weld - Panel thickness 3
mm and greater!
E108677
8.
E108678
2011 Fiesta 08/2010 G1080195en

Front Side Member Section

Air Body Saw Spot weld drill Bit
Removal
NOTE: Equipment: 1. • Refer to: Front Fender (501-27 Front End
Measurement and alignment angle system Sheet Metal Repairs, Removal and
Installation).
Refer to: Fog Lamps (417-01 Exterior
Refer to: Headlamps (417-01 Exterior
Installation).
Refer to: Front Bumper Cover (501-19
• Door
• Hood
• Bumper
• Hood Closing Panel
2. • WARNING: Cut line positions
• Due to the positions of inner
reinforcements, it is very important that
the dimension quoted for the separating
cuts is accurately met.
3. • NOTE: The cut shown is the final cut for the
inner part.
Separating cut through outer and inner part
of the front side member.
45 mm
E108679
4. • General Equipment: Spot weld drill Bit
2011 Fiesta 08/2010 G1080196en

E108680
5. • CAUTION: Do not cut into inner part

or reinforcements of the side
member!
Separating cut through outer part of the front
side member.
2011 Fiesta 08/2010 G1080196en

35 mm
E117484
Installation General Information, Description and

Operation).
1. NOTE: Before resistance spot welding of body 3. • General Equipment: Air Body Saw
panels with a total panel thickness of 3 mm and
greater, the manufacturer's welding equipment
instructions and sub-section 501-25 must be
followed.
Refer to: Tools and Equipment for Body Repairs
(501-25 Body Repairs - General Information,
2. NOTE: Sealer or adhesive must not be applied
in welding zones. Areas which were bonded or 35 mm
afterwards. E108681
Refer to: Sealer, Underbody Protection Material
and Adhesives (501-25 Body Repairs -
4. • General Equipment: Air Body Saw
2011 Fiesta 08/2010 G1080196en

45 mm
E108682

mm and greater!
General Equipment: Metal Inert Gas (MIG)
Welding Equipment
2011 Fiesta 08/2010 G1080196en

E108683

Welding Equipment
E108684
2011 Fiesta 08/2010 G1080196en

7. • General Equipment: Metal Inert Gas (MIG) Welding Equipment
E117485
8. • General Equipment: 8 mm Drill Bit

Welding Equipment
2011 Fiesta 08/2010 G1080196en

E108685
2011 Fiesta 08/2010 G1080196en

Welding Equipment
E108686

Welding Equipment
E108687
2011 Fiesta 08/2010 G1080196en

Front Side Member and Fender Apron Panel LH

Metal Inert Gas (MIG) Welding Equipment Spot weld drill Bit
Removal
NOTE: Equipment: 1. Refer to: Fender Apron Panel Reinforcement
Measurement and alignment angle system (501-27 Front End Sheet Metal Repairs,
E111874
3. • Equipment: Spherical cutter

2011 Fiesta 08/2010 G1133568en

E111875
E111876
2011 Fiesta 08/2010 G1133568en

E111877
2011 Fiesta 08/2010 G1133568en

6. • General Equipment: Spot weld drill Bit 7. • Equipment: Spherical cutter
• Grind out from inside.
E112045
E112052
Installation
followed.
in welding zones. Areas which were bonded or
afterwards.
Operation).
2011 Fiesta 08/2010 G1133568en

3. • Equipment: 10 mm drill bit 4. • Equipment: 10 mm drill bit
10 mm
E112669
10 mm
10 mm
E111881
2011 Fiesta 08/2010 G1133568en

5. • General Equipment: Metal Inert Gas (MIG) 6. • General Equipment: Metal Inert Gas (MIG)
Welding Equipment Welding Equipment
E112046
E111883
2011 Fiesta 08/2010 G1133568en

E111884

mm and greater!
2011 Fiesta 08/2010 G1133568en

E111885

Welding Equipment
E111886
2011 Fiesta 08/2010 G1133568en

mm and greater!
E112053
11. Refer to: Fender Apron Panel Reinforcement

(501-27 Front End Sheet Metal Repairs,
2011 Fiesta 08/2010 G1133568en

501-28-1 Roof Sheet Metal Repairs 501-28-1
.
SECTION 501-28 Roof Sheet Metal Repairs

CONTENTS PAGE

Roof Panel.......................................................................................................................... 501-28-2
2011 Fiesta 08/2010

Roof Panel
General Equipment
Materials
Hot Air Gun
Name Specification
Spot weld drill Bit
Removal
1. • Front and Rear Door
• Refer to: Windshield Glass (501-11 Glass,
Frames and Mechanisms, Removal and
Installation).
• Refer to: Headliner - 5-Door (501-05 Interior
Installation).
• A- B- and C-Pillar Trim
Installation).
and Installation).
Refer to: C-Pillar Trim Panel - 5-Door (501-05
and Installation).
• Refer to: Rear Window Glass (501-11 Glass,
Installation).
2011 Fiesta 08/2010 G1133573en

E112723
E112724
2011 Fiesta 08/2010 G1133573en

4. • General Equipment: Hot Air Gun
170
E112725
Installation
2. NOTE: Sealer or adhesive must be applied with
1. NOTE: Before resistance spot welding of body a minimum height of 20 mm.
panels with a total panel thickness of 3 mm and Refer to: Sealer, Underbody Protection Material
greater, the manufacturer's welding equipment and Adhesives (501-25 Body Repairs -
instructions and sub-section 501-25 must be General Information, Description and
followed. Operation).
Authoring Template 3. • Material: Windshield Adhesive Kit
(WSS-M11P57-A5)
2011 Fiesta 08/2010 G1133573en

E112726

mm and greater!
E112727
2011 Fiesta 08/2010 G1133573en

5. • Resistance spot weld - Panel thickness 3 mm and greater!
E112728

• Refer to: Windshield Glass (501-11 Glass,
Installation).
• Refer to: Headliner - 5-Door (501-05 Interior
Installation).
Installation).
and Installation).
and Installation).
• Refer to: Rear Window Glass (501-11 Glass,
Installation).
2011 Fiesta 08/2010 G1133573en

501-29-1 Side Panel Sheet Metal Repairs 501-29-1
.
SECTION 501-29 Side Panel Sheet Metal Repairs

CONTENTS PAGE

A-Pillar Outer Panel............................................................................................................ 501-29-2
A-Pillar Assembly................................................................................................................ 501-29-9
Rocker Panel — 4-Door..................................................................................................... 501-29-13
Rocker Panel — 5-Door..................................................................................................... 501-29-19
Rocker Panel Inner Reinforcement.................................................................................... 501-29-25
B-Pillar and Reinforcement — 4-Door................................................................................ 501-29-29
B-Pillar and Reinforcement — 5-Door................................................................................ 501-29-40
B-Pillar Outer Panel — 4-Door........................................................................................... 501-29-51
B-Pillar Outer Panel — 5-Door........................................................................................... 501-29-56
2011 Fiesta 08/2010

A-Pillar Outer Panel

General Equipment
Materials
Air Body Saw
Name Specification
Hot Air Gun
Metal Inert Gas (MIG) Welding Equipment
General Equipment
Resistance Spotwelding Equipment
6 mm Drill Bit
Spot weld drill Bit
Removal
1. Refer to: Tools and Equipment for Body Repairs

2. • Windshield
Refer to: Windshield Glass (501-11 Glass,
Installation).
• Front Door
Refer to: Front Door Alignment (501-03 Body
Closures, General Procedures).
• Door Hinges
• Weatherstrip
• A-pillar Trim
Installation).
• Rocker Panel Trim
• Driver or passenger seat
Refer to: Front Seat (501-10 Seating,
• Refer to: Fender Apron Panel Reinforcement
• Reposition the carpeting and the wiring
harness away from the working area.
2011 Fiesta 08/2010 G1183564en

E114692
E114693
2011 Fiesta 08/2010 G1183564en

E114694
170
E114695
Installation instructions and sub-section 501-25 must be

followed.
2011 Fiesta 08/2010 G1183564en

2. NOTE: Sealer or adhesive must not be applied 3. • General Equipment: 6 mm Drill Bit
afterwards.
and Adhesives (501-25 Body Repairs - 6 mm
Operation).
E115189
4. • Material: Windshield Adhesive Kit

(WSS-M11P57-A5)
2011 Fiesta 08/2010 G1183564en

E115190
5. • General Equipment: Resistance Spotwelding

Equipment
E115191
2011 Fiesta 08/2010 G1183564en

6. • General Equipment: Resistance Spotwelding Equipment
E115192

Welding Equipment
E115338
2011 Fiesta 08/2010 G1183564en

8. • Windshield
Installation).
• Front Door
• Door Hinges
• Weatherstrip
• A-pillar Trim
Installation).
2011 Fiesta 08/2010 G1183564en

A-Pillar Assembly
General Equipment
Materials
Hot Air Gun
Name Specification
General Equipment
Spot weld drill Bit
6 mm Drill Bit
Removal
2011 Fiesta 08/2010 G1133576en

2. • Refer to: A-Pillar Outer Panel (501-29 Side
Panel Sheet Metal Repairs, Removal and
Installation).
• Windshield
Installation).
• Front Door
• Door Hinges
• Weatherstrip
• A-pillar Trim
Installation).
Removal and Installation). E115406
Removal and Installation). 4. • General Equipment: Hot Air Gun
170
E115407
2011 Fiesta 08/2010 G1133576en

Installation 4. • Material: Windshield Adhesive Kit
(WSS-M11P57-A5)
followed.
afterwards.
Operation).
3. • General Equipment: 6 mm Drill Bit
E115409
6 mm
E115408
2011 Fiesta 08/2010 G1133576en

5. • General Equipment: Resistance Spotwelding 6. • General Equipment: Metal Inert Gas (MIG)
Equipment Welding Equipment
E115410 E115411
7. • Refer to: A-Pillar Outer Panel (501-29 Side

Installation).
• Windshield
Installation).
• Front Door
• Door Hinges
• Weatherstrip
• A-pillar Trim
Installation).
2011 Fiesta 08/2010 G1133576en

Rocker Panel — 4-Door

General Equipment
Materials
Hot Air Gun
Name Specification
General Equipment
Spot weld drill Bit
Air Body Saw
Removal
1. • Door Hinges
• Front and Rear Door
• Front Wheel Arch Trim
• Rear Wheel Arch Trim
Installation).
and Installation).
and Installation).
• Refer to: Front Seat (501-10 Seating,
Refer to: Rear Seat Cushion (501-10 Seating,
Refer to: Rear Seat Backrest (501-10
2011 Fiesta 08/2010 G1133586en

460 mm
25 mm 35 mm
E112744
E112745
2011 Fiesta 08/2010 G1133586en

170
E112746
170
E112747
2011 Fiesta 08/2010 G1133586en

Installation 2. NOTE: Sealer or adhesive must not be applied
1. NOTE: Before resistance spot welding of body sealed needs to be thoroughly sealed
panels with a total panel thickness of 3 mm and afterwards.
followed.
Refer to: Tools and Equipment for Body Repairs Operation).
(501-25 Body Repairs - General Information, 3. • Material: Windshield Adhesive Kit
Description and Operation). (WSS-M11P57-A5)
E112748

Welding Equipment
2011 Fiesta 08/2010 G1133586en

E112749
5. • General Equipment: Resistance Spotwelding 6.

Equipment
E112789
E112788
2011 Fiesta 08/2010 G1133586en

7. • Door Hinges
Installation).
and Installation).
and Installation).
2011 Fiesta 08/2010 G1133586en

Rocker Panel — 5-Door

General Equipment
Materials
Hot Air Gun
Name Specification
General Equipment
Spot weld drill Bit
Air Body Saw
Removal
• Door Hinges
• Refer to: A-Pillar Trim Panel (501-05 Interior
Installation).
and Installation).
and Installation).
2011 Fiesta 08/2010 G1133587en

460 mm
25 mm 35 mm
E108797
E108798
2011 Fiesta 08/2010 G1133587en

170
E108799
170
E108800
2011 Fiesta 08/2010 G1133587en

followed.
(501-25 Body Repairs - General Information, 3. • Material: Windshield Adhesive Kit
Description and Operation). (WSS-M11P57-A5)
E108801

Welding Equipment
2011 Fiesta 08/2010 G1133587en

E108802

Equipment
E108803
2011 Fiesta 08/2010 G1133587en

6.
E108804

• Door Hinges
• Refer to: A-Pillar Trim Panel (501-05 Interior
Installation).
and Installation).
and Installation).
2011 Fiesta 08/2010 G1133587en

Rocker Panel Inner Reinforcement

Air Body Saw Resistance Spotwelding Equipment
Removal

2. • Refer to: A-Pillar Assembly (501-29 Side
Installation).
• Refer to: A-Pillar Outer Panel (501-29 Side
Installation).
• Rocker Panel
• Door Hinges
Installation).
and Installation).
and Installation).
2011 Fiesta 08/2010 G1183451en

E115412
E115413
Installation
1. NOTE: Before resistance spot welding of body in welding zones. Areas which were bonded or
panels with a total panel thickness of 3 mm and sealed needs to be thoroughly sealed
greater, the manufacturer's welding equipment afterwards.
instructions and sub-section 501-25 must be Refer to: Sealer, Underbody Protection Material
followed. and Adhesives (501-25 Body Repairs -
Refer to: Tools and Equipment for Body Repairs General Information, Description and
(501-25 Body Repairs - General Information, Operation).
Description and Operation). 3. • General Equipment: Resistance Spotwelding
Equipment
2011 Fiesta 08/2010 G1183451en

E115414

Welding Equipment
E115415
2011 Fiesta 08/2010 G1183451en

5. • Refer to: A-Pillar Assembly (501-29 Side
Installation).
• Refer to: A-Pillar Outer Panel (501-29 Side
Installation).
• Rocker Panel
• Door Hinges
Installation).
and Installation).
and Installation).
2011 Fiesta 08/2010 G1183451en

B-Pillar and Reinforcement — 4-Door

General Equipment
Materials
Hot Air Gun
Name Specification
General Equipment
Spot weld drill Bit
Air Body Saw
Removal
NOTE: Equipment: • Due to its strength, the B-pillar reinforcement
Measurement and alignment angle system can not always be worked on with
conventional body tools.
1. WARNING: High-strength steel (Usibor • Additional preparations are required for MIG
1500) puddle welding.
• A suitably powerful resistance spot welding
device with inverter technology must be
used for this repair. Observe the
manufacturer's welding equipment
instructions and sub-section 501-25. 2. • Rocker Panel Trim
• The B-pillar reinforcement is made of Refer to: Front Seat (501-10 Seating,
high-strength steel plate (Usibor 1500). Removal and Installation).
• A partial replacement of the B-pillar Refer to: Rear Seat Cushion (501-10 Seating,
reinforcement is not permissible. The Removal and Installation).
required continuous MIG weld seam in the Refer to: Rear Seat Backrest (501-10
area of the cut causes structural changes Seating, Removal and Installation).
which result in significant loss of strength in Refer to: B-Pillar Trim Panel - 5-Door (501-05
the B-pillar reinforcement. Interior Trim and Ornamentation, Removal
and Installation).
2011 Fiesta 08/2010 G1133589en

E113404

E113405
2011 Fiesta 08/2010 G1133589en

170
E113406
E113407
2011 Fiesta 08/2010 G1133589en

50 mm
220 mm
E113408

E113409
2011 Fiesta 08/2010 G1133589en

E113410
E113411
Installation sealed needs to be thoroughly sealed

afterwards.
Operation).
followed.
2011 Fiesta 08/2010 G1133589en

3. • • The holes need to be pre-milled with a 4. • WARNING: The B-pillar reinforcement
spherical cutter with a small diameter. is covered with a hot-dip aluminized
Afterwards these holes are then milled out coating on its entire surface. This
to the required diameter with a spindle coating needs to be fully ground off
milling cutter. This method is essential in on the welding flanges on the front
order to ensure that the material in the and rear using a fibre grinding disc.
edge area of the milled holes is not Any contamination due to parts of
weakened. the coating in the welding bath will
Equipment: Spherical cutter weaken the welded joint.
• Equipment: spindle milling cutter
E113413
E113412
2011 Fiesta 08/2010 G1133589en

5. • WARNING: The A-pillar reinforcement 7. • General Equipment: Metal Inert Gas (MIG)
is covered with a hot-dip aluminized Welding Equipment
coating on its entire surface. This
coating needs to be fully ground off
on the welding flanges on the front
using a fibre grinding disc. Any
contamination due to parts of the
coating in the welding bath will
weaken the welded joint.
E113414

mm and greater!
General Equipment: Resistance Spotwelding
Equipment
E113416
E113415
2011 Fiesta 08/2010 G1133589en

8. • Material: Windshield Adhesive Kit 9. • Puddle weld 2 panel layer.
(WSS-M11P57-A5) General Equipment: Metal Inert Gas (MIG)
Welding Equipment
E113417
E113418
2011 Fiesta 08/2010 G1133589en

10. • Puddle weld 3 panel layer. General Equipment: Metal Inert Gas (MIG)
Welding Equipment
E113419

mm and greater!
Equipment
2011 Fiesta 08/2010 G1133589en

E113420

Welding Equipment
E113421
2011 Fiesta 08/2010 G1133589en

13. • General Equipment: Resistance Spotwelding General Equipment: Metal Inert Gas (MIG)
E113422
14. • Rocker Panel Trim

and Installation).
2011 Fiesta 08/2010 G1133589en

B-Pillar and Reinforcement — 5-Door

General Equipment
Materials
Hot Air Gun
Name Specification
General Equipment
Spot weld drill Bit
Air Body Saw
Removal
NOTE: Equipment: • Due to its strength, the B-pillar reinforcement
Measurement and alignment angle system can not always be worked on with
conventional body tools.
1. WARNING: High-strength steel (Usibor • Additional preparations are required for MIG
1500) puddle welding.
• A suitably powerful resistance spot welding
device with inverter technology must be
used for this repair. Observe the
manufacturer's welding equipment
instructions and sub-section 501-25. 2. • Rocker Panel Trim
• The B-pillar reinforcement is made of Refer to: B-Pillar Trim Panel - 5-Door (501-05
high-strength steel plate (Usibor 1500). Interior Trim and Ornamentation, Removal
• A partial replacement of the B-pillar and Installation).
reinforcement is not permissible. The Refer to: Front Seat (501-10 Seating,
required continuous MIG weld seam in the Removal and Installation).
area of the cut causes structural changes Refer to: Rear Seat Cushion (501-10 Seating,
which result in significant loss of strength in Removal and Installation).
the B-pillar reinforcement. Refer to: Rear Seat Backrest (501-10
2011 Fiesta 08/2010 G1133590en

E111858

E111970
2011 Fiesta 08/2010 G1133590en

170
E111971
E111972
2011 Fiesta 08/2010 G1133590en

50 mm
220 mm
E111973

E111974
2011 Fiesta 08/2010 G1133590en

E111975
E111976

afterwards.
Operation).
followed.
2011 Fiesta 08/2010 G1133590en

3. • • The holes need to be pre-milled with a 4. • WARNING: The B-pillar reinforcement
spherical cutter with a small diameter. is covered with a hot-dip aluminized
Afterwards these holes are then milled out coating on its entire surface. This
to the required diameter with a spindle coating needs to be fully ground off
milling cutter. This method is essential in on the welding flanges on the front
order to ensure that the material in the and rear using a fibre grinding disc.
edge area of the milled holes is not Any contamination due to parts of
weakened. the coating in the welding bath will
Equipment: Spherical cutter weaken the welded joint.
• Equipment: spindle milling cutter
E112005
E111977
2011 Fiesta 08/2010 G1133590en

5. • WARNING: The A-pillar reinforcement 7. • General Equipment: Metal Inert Gas (MIG)
is covered with a hot-dip aluminized Welding Equipment
coating on its entire surface. This
coating needs to be fully ground off
on the welding flanges on the front
using a fibre grinding disc. Any
contamination due to parts of the
coating in the welding bath will
weaken the welded joint.
E112006

mm and greater!
Equipment
E111979
E111978
2011 Fiesta 08/2010 G1133590en

8. • Material: Windshield Adhesive Kit 9. • Puddle weld 2 panel layer.
(WSS-M11P57-A5) General Equipment: Metal Inert Gas (MIG)
Welding Equipment
E111980
E111981
2011 Fiesta 08/2010 G1133590en

10. • Puddle weld 3 panel layer. General Equipment: Metal Inert Gas (MIG)
Welding Equipment
E111982

mm and greater!
Equipment
2011 Fiesta 08/2010 G1133590en

E111983

Welding Equipment
E111984
2011 Fiesta 08/2010 G1133590en

E111865

and Installation).
2011 Fiesta 08/2010 G1133590en

B-Pillar Outer Panel — 4-Door

General Equipment
Materials
Air Body Saw
Name Specification
Hot Air Gun
Spot weld drill Bit
Removal
and Installation).
E112821

2011 Fiesta 08/2010 G1133593en

100 mm
E112822
170
E112823
2011 Fiesta 08/2010 G1133593en

(WSS-M11P57-A5)
followed.
afterwards.
Operation).
E112824
4.
2011 Fiesta 08/2010 G1133593en

E112825

Welding Equipment
E112826
2011 Fiesta 08/2010 G1133593en

E112827

and Installation).
2011 Fiesta 08/2010 G1133593en

B-Pillar Outer Panel — 5-Door

General Equipment
Materials
Air Body Saw
Name Specification
Hot Air Gun
Spot weld drill Bit
Removal
and Installation).
E111858

2011 Fiesta 08/2010 G1133594en

100 mm
E111859
170
E111860
2011 Fiesta 08/2010 G1133594en

(WSS-M11P57-A5)
followed.
afterwards.
Operation).
E111862
4.
2011 Fiesta 08/2010 G1133594en

E111863

Welding Equipment
E111864
2011 Fiesta 08/2010 G1133594en

E111865

and Installation).
2011 Fiesta 08/2010 G1133594en

501-30-1 Rear End Sheet Metal Repairs 501-30-1
.
SECTION 501-30 Rear End Sheet Metal Repairs

CONTENTS PAGE

Quarter Panel LH — 4-Door............................................................................................... 501-30-2
Quarter Panel LH — 5-Door............................................................................................... 501-30-15
Water Drain Panel.............................................................................................................. 501-30-23
Water Drain Panel — 4-Door.............................................................................................. 501-30-29
Water Drain Panel Reinforcement...................................................................................... 501-30-32
Rear Wheelhouse Outer — 4-Door.................................................................................... 501-30-38
Rear Wheelhouse Outer — 5-Door.................................................................................... 501-30-43
Inner Quarter Panel and Wheelhouse — 4-Door............................................................... 501-30-48
Inner Quarter Panel and Wheelhouse — 5-Door............................................................... 501-30-56
Back Panel and Reinforcement — 4-Door......................................................................... 501-30-63
Back Panel and Reinforcement — 5-Door......................................................................... 501-30-67
Rear Lamp Mounting Panel — 4-Door............................................................................... 501-30-76
Rear Floor Panel................................................................................................................. 501-30-81
Rear Side Member Section................................................................................................ 501-30-90
Quarter Panel LH — 4-Door

General Equipment
Materials
Air Body Saw
Name Specification
Hot Air Gun
General Equipment
6 mm Drill Bit
Spot weld drill Bit
Removal
1. • Liftgate
• Rear Lamp
• Tank Filler Flap and Tank Filler
• Refer to: Liftgate Trim Panel (501-05 Interior
Installation).
Refer to: Rear Bumper Cover - 4-Door
(501-19 Bumpers, Removal and
Installation).
Refer to: Rear Quarter Trim Panel (501-05
and Installation).
and Installation).
Refer to: Loadspace Trim Panel - 4-Door
(501-05 Interior Trim and Ornamentation,
2. • Partial Replacement - Quarter Panel - Cut
Line Options
2011 Fiesta 08/2010 G1133600en

450 mm
E113588

80 mm
E113589
2011 Fiesta 08/2010 G1133600en

E113590
2011 Fiesta 08/2010 G1133600en

5. • Equipment: Spherical cutter 6. • General Equipment: Spot weld drill Bit
E113591
E113592
2011 Fiesta 08/2010 G1133600en

7. • Equipment: Spherical cutter 8. • General Equipment: Air Body Saw
E113593
E113594
2011 Fiesta 08/2010 G1133600en

170
E113595
Installation
followed.
afterwards.
Operation).
2011 Fiesta 08/2010 G1133600en

3. • General Equipment: 6 mm Drill Bit 4. • General Equipment: 6 mm Drill Bit
6 mm 6 mm
E113729 E113730
2011 Fiesta 08/2010 G1133600en

5. • General Equipment: Resistance Spotwelding 6. • Material: Windshield Adhesive Kit
Equipment (WSS-M11P57-A5)
E113731
E113732
2011 Fiesta 08/2010 G1133600en

E113733

Equipment
2011 Fiesta 08/2010 G1133600en

E113734
2011 Fiesta 08/2010 G1133600en

9. • General Equipment: Metal Inert Gas (MIG) 10. • General Equipment: Resistance Spotwelding
Welding Equipment Equipment
E113735
E113736
2011 Fiesta 08/2010 G1133600en

Welding Equipment
E113737
E113738
2011 Fiesta 08/2010 G1133600en

13.
E113739
14. • Liftgate
• Rear Lamp
Installation).
Installation).
and Installation).
and Installation).
2011 Fiesta 08/2010 G1133600en

Quarter Panel LH — 5-Door

General Equipment
Materials
Air Body Saw
Name Specification
Hot Air Gun
General Equipment
6 mm Drill Bit
Spot weld drill Bit
Removal
1. • Liftgate
• Rear Lamp
• Refer to: Rear Bumper Cover (501-19
and Installation).
and Installation).
2. • Partial Replacement - Quarter Panel - Cut
Line Options
2011 Fiesta 08/2010 G1080221en

450 mm
E112277

80 mm
E112128
2011 Fiesta 08/2010 G1080221en

4. • General Equipment: Spot weld drill Bit 5. • General Equipment: Air Body Saw
E112129
E112130
2011 Fiesta 08/2010 G1080221en

170
E112131
Installation 3. • General Equipment: 6 mm Drill Bit

followed.
afterwards.
and Adhesives (501-25 Body Repairs - 6 mm
E112132
Operation).
4. • Material: Windshield Adhesive Kit

(WSS-M11P57-A5)
2011 Fiesta 08/2010 G1080221en

E112133

Equipment
E112134

Welding Equipment
2011 Fiesta 08/2010 G1080221en

E112135
2011 Fiesta 08/2010 G1080221en

Welding Equipment
E112136
E112137
2011 Fiesta 08/2010 G1080221en

9.
E112138
10. • Liftgate
• Rear Lamp
• Rear Bumper
Refer to: Rear Bumper Cover (501-19
and Installation).
2011 Fiesta 08/2010 G1080221en

Water Drain Panel

Air Body Saw Metal Inert Gas (MIG) Welding Equipment
Locking Pliers Spot weld drill Bit
Removal
1. • Liftgate 3. • General Equipment: Air Body Saw
• Rear Bumper General Equipment: Spot weld drill Bit
and Installation).
Refer to: Quarter Panel LH - 5-Door (501-30
Rear End Sheet Metal Repairs, Removal
and Installation).
E111746
2011 Fiesta 08/2010 G1080222en

E111747
E111748
2011 Fiesta 08/2010 G1080222en

Installation 4. • General Equipment: Locking Pliers

followed.
afterwards.
Operation).
3. • General Equipment: Locking Pliers
E111750
5.
6 mm
E111749
2011 Fiesta 08/2010 G1080222en

E111751

Welding Equipment
E111752
2011 Fiesta 08/2010 G1080222en

E111753
8. • Puddle weld 3 panel layer.

Welding Equipment
2011 Fiesta 08/2010 G1080222en

E111754
9. • Puddle weld 3 panel layer. 10. • Liftgate

• Rear Bumper
Welding Equipment Refer to: Rear Bumper Cover (501-19
and Installation).
and Installation).
E111755 harness away from the working area.
2011 Fiesta 08/2010 G1080222en

Water Drain Panel — 4-Door

Metal Inert Gas (MIG) Welding Equipment Resistance Spotwelding Equipment
Spot weld drill Bit
Removal
1. • Liftgate 3. • General Equipment: Spot weld drill Bit
• Rear Bumper
and Installation).
and Installation).
Installation).
E114268
E113752
E113753
Installation
2011 Fiesta 08/2010 G1133610en

instructions and sub-section 501-25 must be 5. • General Equipment: Resistance Spotwelding
followed. Equipment
afterwards.
Operation).
6 mm E114269

Welding Equipment
E113754

Equipment
E113756
E113755
2011 Fiesta 08/2010 G1133610en

7. • Liftgate
• Rear Bumper
and Installation).
and Installation).
Installation).
2011 Fiesta 08/2010 G1133610en

Water Drain Panel Reinforcement

Locking Pliers Spot weld drill Bit
Removal
1. • Refer to: Back Panel and Reinforcement -
5-Door (501-30 Rear End Sheet Metal
Repairs, Removal and Installation).
Refer to: Water Drain Panel (501-30 Rear
Installation).
and Installation).
E111764
3.
2011 Fiesta 08/2010 G1080223en

E111763
2011 Fiesta 08/2010 G1080223en

4. • CAUTION: Do not cut into Inner Installation
Quarter Panel!
followed.
afterwards.
Operation).
3. • Resistance spot weld.
General Equipment: Locking Pliers
E111762
2011 Fiesta 08/2010 G1080223en

E111765

mm and greater!
General Equipment: Locking Pliers
2011 Fiesta 08/2010 G1080223en

E111766
2011 Fiesta 08/2010 G1080223en

5. • Resistance spot weld. 6. • General Equipment: Metal Inert Gas (MIG)
General Equipment: Locking Pliers Welding Equipment
E111768
E111767
7. • Refer to: Back Panel and Reinforcement -

Installation).
and Installation).
2011 Fiesta 08/2010 G1080223en

Rear Wheelhouse Outer — 4-Door

Removal
1. • Refer to: Quarter Panel LH - 4-Door (501-30
and Installation).
E113773
2011 Fiesta 08/2010 G1133601en

3. • General Equipment: Air Body Saw 4. • General Equipment: Air Body Saw
E112343
12
mm
E112344

followed.
2011 Fiesta 08/2010 G1133601en

2. NOTE: Sealer or adhesive must not be applied 3. • Equipment: 10 mm drill bit
afterwards.
Operation).
10 mm
E112345
E112346

Equipment
2011 Fiesta 08/2010 G1133601en

E112347

Welding Equipment
E112348
2011 Fiesta 08/2010 G1133601en

7. • General Equipment: Resistance Spotwelding 9. • General Equipment: Resistance Spotwelding
Equipment Equipment
E112349 E112351
8. • General Equipment: Metal Inert Gas (MIG) 10. • Refer to: Quarter Panel LH - 4-Door (501-30
Welding Equipment Rear End Sheet Metal Repairs, Removal
and Installation).
E112350
2011 Fiesta 08/2010 G1133601en

Rear Wheelhouse Outer — 5-Door

Removal
and Installation).
E112342
2011 Fiesta 08/2010 G1080225en

3. • General Equipment: Air Body Saw 4. • General Equipment: Air Body Saw
E112343
12
mm
E112344

followed.
2011 Fiesta 08/2010 G1080225en

2. NOTE: Sealer or adhesive must not be applied 3. • Equipment: 10 mm drill bit
afterwards.
Operation).
10 mm
E112345
E112346

Equipment
2011 Fiesta 08/2010 G1080225en

E112347

Welding Equipment
E112348
2011 Fiesta 08/2010 G1080225en

Equipment Equipment
E112349 E112351
8. • General Equipment: Metal Inert Gas (MIG) 10. • Refer to: Quarter Panel LH - 5-Door (501-30
Welding Equipment Rear End Sheet Metal Repairs, Removal
and Installation).
E112350
2011 Fiesta 08/2010 G1080225en

Inner Quarter Panel and Wheelhouse — 4-Door

Hot Air Gun Resistance Spotwelding Equipment
Measurement and Alignment Angle System Spot weld drill Bit
Removal
1. • Refer to: Quarter Panel LH - 4-Door (501-30 3. • General Equipment: Spot weld drill Bit
and Installation).
Refer to: Water Drain Panel - 4-Door (501-30
and Installation).
General Equipment: Measurement and
Alignment Angle System
E113740
2011 Fiesta 08/2010 G1133603en

E113741
E113742
2011 Fiesta 08/2010 G1133603en

5. • General Equipment: Spot weld drill Bit 6. • Do not cut in panel below.
50 mm
E113743
E113744
2011 Fiesta 08/2010 G1133603en

170
E113745
Installation
followed.
afterwards.
Operation).
2011 Fiesta 08/2010 G1133603en

3. • Continuous MIG weld seam on C-Pillar. 4. • General Equipment: Resistance Spotwelding
General Equipment: Metal Inert Gas (MIG) Equipment
Welding Equipment
E113747
E113746
2011 Fiesta 08/2010 G1133603en

5. • General Equipment: Resistance Spotwelding 6. • Continuous MIG weld seam on C/D-Pillar.
Equipment General Equipment: Metal Inert Gas (MIG)
Welding Equipment
E113748
E113749

mm and greater!
Equipment
2011 Fiesta 08/2010 G1133603en

E113750
2011 Fiesta 08/2010 G1133603en

Equipment
E113751

and Installation).
Refer to: Water Drain Panel - 4-Door (501-30
and Installation).
2011 Fiesta 08/2010 G1133603en

Inner Quarter Panel and Wheelhouse — 5-Door

Hot Air Gun Resistance Spotwelding Equipment
Removal
1. • Refer to: Quarter Panel LH - 5-Door (501-30 3. • General Equipment: Spot weld drill Bit
and Installation).
Installation).
General Equipment: Measurement and
E112424
2011 Fiesta 08/2010 G1133604en

E112425
4. • Cut all panel layers.

E112426
2011 Fiesta 08/2010 G1133604en

5. • Do not cut in panel below.
E112427
170
E112428
7. • Do not cut in panel below.

2011 Fiesta 08/2010 G1133604en

30 mm
E112429

afterwards.
Operation).
followed.
3. • Continuous MIG weld seam on C-Pillar.
(501-25 Body Repairs - General Information, General Equipment: Metal Inert Gas (MIG)
Description and Operation). Welding Equipment
• Puddle weld.
Welding Equipment
2011 Fiesta 08/2010 G1133604en

E112430

Equipment
E112431
2011 Fiesta 08/2010 G1133604en

5. • General Equipment: Resistance Spotwelding Equipment
E112432

mm and greater!
Equipment
E112433
7. • Continuous MIG weld seam on C-/D-Pillar.

Welding Equipment
2011 Fiesta 08/2010 G1133604en

E112434

Equipment
E112435

and Installation).
Installation).
2011 Fiesta 08/2010 G1133604en

Back Panel and Reinforcement — 4-Door

Resistance Spotwelding Equipment Spot weld drill Bit
Removal
1. • Liftgate
• Rear Bumper
Installation).
• Refer to: C-Pillar Trim Panel - 4-Door (501-05
and Installation).
E113766
2011 Fiesta 08/2010 G1133612en

E113767
4. • General Equipment: Spot weld drill Bit 5. • General Equipment: Spot weld drill Bit
E113768
2011 Fiesta 08/2010 G1133612en

E113769
Installation
1. NOTE: Before resistance spot welding of body in welding zones. Areas which were bonded or
panels with a total panel thickness of 3 mm and sealed needs to be thoroughly sealed
greater, the manufacturer's welding equipment afterwards.
instructions and sub-section 501-25 must be Refer to: Sealer, Underbody Protection Material
followed. and Adhesives (501-25 Body Repairs -
Refer to: Tools and Equipment for Body Repairs General Information, Description and
(501-25 Body Repairs - General Information, Operation).
Description and Operation). 3. • General Equipment: Resistance Spotwelding
Equipment
E113770

Equipment
2011 Fiesta 08/2010 G1133612en

E113771

Equipment
E113772
6. • Liftgate
• Rear Bumper
Installation).
• Refer to: C-Pillar Trim Panel - 4-Door (501-05
and Installation).
2011 Fiesta 08/2010 G1133612en

Back Panel and Reinforcement — 5-Door

Spot weld drill Bit
Removal
1. • Liftgate
• Rear Bumper
• Refer to: Loadspace Trim Panel - 5-Door
and Installation).
E108815
2011 Fiesta 08/2010 G1133613en

E108816
E108817
2011 Fiesta 08/2010 G1133613en

E108818
E108819
2011 Fiesta 08/2010 G1133613en

E108820
8.
E108821
2011 Fiesta 08/2010 G1133613en

followed.
(501-25 Body Repairs - General Information, 3. • General Equipment: 6 mm Drill Bit
6 mm
E108826
4. • CAUTION: 4 Panel puddle weld! Fit

in both replacement panels exactly
and drill holes for puddle welding.
General Equipment: 6 mm Drill Bit
2011 Fiesta 08/2010 G1133613en

6 mm
6 mm
E108827
5.
E108822
2011 Fiesta 08/2010 G1133613en

E108823
7.
2011 Fiesta 08/2010 G1133613en

E108824

Welding Equipment
E108825
2011 Fiesta 08/2010 G1133613en

9. • Liftgate
• Rear Bumper
• Refer to: Loadspace Trim Panel - 5-Door
and Installation).
2011 Fiesta 08/2010 G1133613en

Rear Lamp Mounting Panel — 4-Door

6 mm Drill Bit Resistance Spotwelding Equipment
Removal
• Rear Bumper
Installation).
Refer to: Back Panel and Reinforcement -
E113758
E113757
2011 Fiesta 08/2010 G1133614en

4. • General Equipment: Spot weld drill Bit 5. • General Equipment: Spot weld drill Bit
E113759 E113760
Installation
followed.
afterwards.
Operation).
2011 Fiesta 08/2010 G1133614en

3. • General Equipment: 6 mm Drill Bit 4. • General Equipment: Resistance Spotwelding
Equipment
6 mm
E113761
E113762
2011 Fiesta 08/2010 G1133614en

Equipment Equipment
Welding Equipment
E113763
E113764
2011 Fiesta 08/2010 G1133614en

Equipment
Welding Equipment
E113765
8. • Liftgate
• Rear Bumper
Installation).
2011 Fiesta 08/2010 G1133614en

Rear Floor Panel

Removal
1. • Liftgate
• Rear Door
• Rear Lamp
• Rear Bumper
• Rear Seat Cushion
• Rear Bumper Cover
Installation).
and Installation).
and Installation).
and Installation).
• General Equipment: Measurement and
2. • NOTE: Cut out inner part for better access.
2011 Fiesta 08/2010 G1209232en

E116033
E116034
4. • NOTE: Left side shown. Operate similar at

right side.
2011 Fiesta 08/2010 G1209232en

E116035

right side.
E116036
2011 Fiesta 08/2010 G1209232en

E116037

afterwards.
Operation).
followed.
3. • NOTE: Cut out the small part to adjust the
Refer to: Tools and Equipment for Body Repairs spare part.
Description and Operation). General Equipment: 6 mm Drill Bit
2011 Fiesta 08/2010 G1209232en

6 mm
E116038

Welding Equipment
E116039

Equipment
Welding Equipment
2011 Fiesta 08/2010 G1209232en

E116040

Equipment
E116082

right side.
Equipment
2011 Fiesta 08/2010 G1209232en

E116083

right side.
Welding Equipment
E116084

Welding Equipment
2011 Fiesta 08/2010 G1209232en

E116085
2011 Fiesta 08/2010 G1209232en

10. •Liftgate
•Rear Door
•Rear Lamp
•Rear Bumper
•Rocker Panel Trim
•Rear Seat Cushion
•Rear Bumper Cover
•Rear Wheel Arch Trim
•Refer to: Liftgate Trim Panel (501-05 Interior
Installation).
and Installation).
and Installation).
and Installation).
• General Equipment: Measurement and
2011 Fiesta 08/2010 G1209232en

Rear Side Member Section

Removal
2011 Fiesta 08/2010 G1209233en

• Rear Lamp
• Rear Bumper
Installation).
and Installation).
2. • General Equipment: Air Body Saw E115417
E115416
2011 Fiesta 08/2010 G1209233en

4. • General Equipment: Air Body Saw 3. • General Equipment: Metal Inert Gas (MIG)
Welding Equipment
E115418
E115419
Installation
followed.
afterwards.
Operation).
2011 Fiesta 08/2010 G1209233en

4. • General Equipment: Resistance Spotwelding 5. • General Equipment: Metal Inert Gas (MIG)
E115420 E115421
6. • Liftgate
• Rear Lamp
• Rear Bumper
Installation).
and Installation).
2011 Fiesta 08/2010 G1209233en

501-36-1 Paint - General Information 501-36-1
.
SECTION 501-36 Paint - General Information

CONTENTS PAGE
PAGE 1 OF 2
Description and Usage of Paint Literature.......................................................................... 501-36-3
Symbols.............................................................................................................................. 501-36-4
General............................................................................................................................... 501-36-4
Hazardous materials designations..................................................................................... 501-36-4
Instructions on measures to be taken for personal protection............................................ 501-36-6
Icons................................................................................................................................... 501-36-6
Health and Safety Precautions........................................................................................... 501-36-9
General instructions for the paint shop and handling paint materials................................. 501-36-9
Personal protection............................................................................................................. 501-36-9
Environmental Regulations................................................................................................. 501-36-11
Waste disposal in the repair paint shop.............................................................................. 501-36-11
The new VOC (Volatile Organic Compounds) solvent regulation ...................................... 501-36-11
Factory Paint Application.................................................................................................... 501-36-12
General fundamentals of paint technology......................................................................... 501-36-12
Painting process and corrosion protection......................................................................... 501-36-12
The structure of an original paint finish .............................................................................. 501-36-13
Colored fillers applied in production................................................................................... 501-36-13
Paintwork Defects and Damage......................................................................................... 501-36-14
Diagnosis and Damage Assessment.................................................................................. 501-36-14
Paint damage guide............................................................................................................ 501-36-14
Paint damage caused by environmental factors................................................................ 501-36-14
Mechanical damage........................................................................................................... 501-36-18
Damage due to corrosion................................................................................................... 501-36-18
Damage caused by faults in treatment............................................................................... 501-36-18
Tools and Equipment for Paint Repairs.............................................................................. 501-36-28
General work equipment.................................................................................................... 501-36-28
Filler and spray guns.......................................................................................................... 501-36-28
Hand and machine sanding tools....................................................................................... 501-36-30
Polishing and finishing tools............................................................................................... 501-36-33
Infrared drying technology.................................................................................................. 501-36-33
Air dryers............................................................................................................................ 501-36-33
Paint mixing system............................................................................................................ 501-36-34
Painting cabin..................................................................................................................... 501-36-34
Refinishing Materials.......................................................................................................... 501-36-35
Stopper materials............................................................................................................... 501-36-35
Primers............................................................................................................................... 501-36-36
HS primer filler and HS tinted filler..................................................................................... 501-36-37
Paint................................................................................................................................... 501-36-37
Additional Materials............................................................................................................ 501-36-39
Adhesive sealants.............................................................................................................. 501-36-39
Underbody protection......................................................................................................... 501-36-39
Paint additives ................................................................................................................... 501-36-40
Additive materials............................................................................................................... 501-36-42
Paint Repairs...................................................................................................................... 501-36-43
2011 Fiesta 08/2010

. PAGE 2 OF 2
General information............................................................................................................ 501-36-43
Pre-treatment of the surface .............................................................................................. 501-36-43
Top coat application............................................................................................................ 501-36-45
Repair stages for repair painting........................................................................................ 501-36-46
Polish.................................................................................................................................. 501-36-47
Aids..................................................................................................................................... 501-36-48
Painting Plastic Parts.......................................................................................................... 501-36-49
General............................................................................................................................... 501-36-49
Plastic groups..................................................................................................................... 501-36-49
Painting new components.................................................................................................. 501-36-50
Unknown primer................................................................................................................. 501-36-50
Paint faults on plastic substrates........................................................................................ 501-36-51
Spot Repairs....................................................................................................................... 501-36-52
General............................................................................................................................... 501-36-52
Repair process................................................................................................................... 501-36-53
Dirt inclusions..................................................................................................................... 501-36-54
Corrosion Prevention.......................................................................................................... 501-36-56
General............................................................................................................................... 501-36-56
Operations after painting.................................................................................................... 501-36-56
Definition of the degree of rust........................................................................................... 501-36-56
Color Identification and Chromatics.................................................................................... 501-36-58
Basic color theory............................................................................................................... 501-36-58
Metallic and pearl pigments................................................................................................ 501-36-59
Color codes and their determination on Ford vehicles ...................................................... 501-36-60
Matching tinted filler to the color code ............................................................................... 501-36-63
Tips and Tricks.................................................................................................................... 501-36-64
Comparing paint structures................................................................................................ 501-36-64
Etching substrate................................................................................................................ 501-36-64
Masking the vehicle............................................................................................................ 501-36-64
Color shade problems........................................................................................................ 501-36-66
Isopropanol and water........................................................................................................ 501-36-66
Temperature reduction spray.............................................................................................. 501-36-66
Paint plane.......................................................................................................................... 501-36-66
Shading.............................................................................................................................. 501-36-66
Sanding marks.................................................................................................................... 501-36-67
Improving touch-up work.................................................................................................... 501-36-67
2011 Fiesta 08/2010

Description and Usage of Paint Literature

Vehicle paints are subject to severe demands NOTE: The Ford Service Organization organizes
caused by external influences. Moisture, air-borne basic and more in-depth training on much of the
deposits in the form of various chemicals and UV content of this paint manual. As well as the
light constantly affect a paint surface. Furthermore, practical part of the training, a further component
mechanical damage occurs through grit, stones is the Student Information document, which offers
and sand. Bird droppings, insect residues, pollen supplementary information in the form of a
and tree sap also attack the paint surface. brochure.
The present literature not only informs the specialist During all work it must always be ensured that
about current repair painting techniques, but also personal safety and the operational capability of
provides tips and instructions on modern and the vehicle are not threatened by the choice of
economical repair processes. methods, tools and components.
High quality bodywork paints require the use of the The information given in the diagrams in the
most modern technologies and regular updating chapter "Paint Damage" is provided by the repair
of the technician's knowledge of painting paint manufacturer.
techniques, because of the constantly new
developments in paint technology.
Information about different materials is listed under
Specification.
Furthermore, information on the fundamental
principles of repair painting and paint materials is
provided in several chapters. The safety
instructions indicate the possible health hazards
and other sources of danger. There are also notes
about tools and materials as well as on basic
painting methods.
In the model specific repair instructions, only the
most important repair steps or special features are
referred to. Detailed information on the generally
applicable painting procedures is given in this paint
manual.
Direct supply of repair paints by Ford has been
discontinued. There is however an agreement with
many paint manufacturers, which ensures fast and
problem-free supply to the dealer undertakings.
Paint suppliers:
• DuPont
• Glasurit
• PPG
• Sikkens
• Spies Hecker
• Standox
When using painting materials, it should be taken
into account that the manufacturers have exactly
matched their products between each other. In
order to avoid quality defects, difficulties in working
and losses in corrosion protection, these may not
be substituted with other products.
2011 Fiesta 08/2010 G468088en

Symbols
General NOTE: This caption is used when attention needs
to be drawn to special or extra information.
Various symbols, signs, instructions and
illustrations are used in this literature. Warnings When reading this handbook, you will come across
and cautions have different meanings and require the points WARNING, CAUTION AND NOTE.
different ways of proceeding. Diagrammatic These instructions are always given immediately
representations are provided with instructional before the corresponding job steps.
signs for improved clarity. These are briefly
explained below: Hazardous materials designations
WARNING: This caption is used when
failure to follow instructions exactly or Many accidents occur because of ignorance. In
failure to follow them at all may result in a the area of personal health protection, it is
hazard to persons or in persons being particularly important to clearly emphasize sources
injured. of danger and their effects on human organs.
CAUTION: This caption is used when Only with knowledge of hazardous material
incorrectly following the test procedures designations can it be certain that the necessary
or instructions or failure to follow them at precautions are taken when handling substances
all could lead to damage to the vehicle or which are harmful to health.
components. NOTE: Pay attention to the manufacturer's data
on the containers and given in the Safety Data
Sheet.
2011 Fiesta 08/2010 G468089en

Hazardous material symbols

1 Very poisonous, T+ (extremely toxic), 6 Explosive
small quantities can be fatal. 7 Highly flammable, F+ (extremely
2 Poisonous, T (toxic), causes serious flammable), already flammable at
damage to health temperatures below 0° C.
3 Corrosive, C (corrosive), destroys living 8 Flammable, F (flammable), forms a
tissue. flammable mixture with air.
4 Harmful to health, Xn (noxious). 9 Oxidizing, O (oxidizing), reacts with
combustible substances.
5 Irritant, Xi (irritant), can cause
inflammation. As well as the danger symbols, there is more
comprehensive manufacturer's information to be
2011 Fiesta 08/2010 G468089en

found on the containers and in the Safety Data agreed a standard symbolic language. Language
Sheets, and you must pay attention to this independent representations in the form of icons
information. provide handling instructions which are
supplemented with quantity or time information.
Instructions on measures to be taken Pretreatment
for personal protection.
As well as the information about sources of danger,
there are mandatory instructions which draw your
attention to the personal protection measures to
be taken.
Mandatory symbol
Item Description
1 Clean
2 Sand
Mix
Item Description
1 Breathing protection must be worn
2 Eye protection must be worn
3 Ear protection must be worn
4 Protective gloves must be worn
5 Protective footwear must be worn
Icons
Item Description
So that the necessary information for optimal
handling is clear, unambiguous and can be quickly 1 2 component mixture
understood, the leading paint manufacturers have 2 3 component mixture
2011 Fiesta 08/2010 G468089en

Item Description Dry
3 Use a measuring rod

4 Addition of hardener
5 Addition of additives
Process
Item Description
1 Ventilate
2 Drying time
3 Drying time with infra-red dryer
Further processing
Item Description
1 Flow-beaker spray gun
2 Suction-beaker spray gun
3 Spray passes
4 Filler
5 Coat
6 Underbody protection spray gun
Item Description
1 Hand abrade (wet)
2 Hand abrade (dry)
3 Eccentric sander (wet)
4 Eccentric sander (dry)
2011 Fiesta 08/2010 G468089en

Item Description
5 Oscillating sander (wet)
6 Oscillating sander (dry)
Store
Item Description
1 Protect from moisture
2 Store in a frost-free environment
3 Store in a cool place
4 Close the container
Other
Item Description
1 Stir by hand
2 Stir using a mixing machine
3 Polish
4 Roll
2011 Fiesta 08/2010 G468089en

Health and Safety Precautions

General instructions for the paint shop eyes or on the skin can cause bodily harm.
and handling paint materials When working with solvents, always use
suitable means of protection.
Hazardous areas in repair paint shops:
• Danger from fires, explosions and hot surfaces.
• Dangers to health and safety from the effects
of harmful substances because of their
absorption through the skin and/or inhalation.
• Dangers caused by electricity, compressed air,
power tools and noise.
WARNING: During painting work there is
an increased danger of fire or explosion.
Prevent any sparks being created. Fire,
naked lights and smoking are forbidden.
Measures:
• Wear protective footwear made from anti-static
material.
• Only use tools made of wood, brass or copper
to clean stands and extraction ducts. Do not use
tools made of steel.
Only fill or decant paint materials in a specially
marked area.
As well as these general instructions on the
dangers in repair paint shops, all national and
international regulations must be observed:
• Health and Safety at Work Act
• Ordinance on Hazardous Substances Item Description
• Technical Rules for Hazardous Substances 1 Protective hood with fresh air supply
• Regulations for the Prevention of Industrial
2 Protective clothing
Accidents
• EU Directive on Hazardous Substances, 3 Protective gloves
98/24/EU 4 Protective footwear
• EU Directive on Noise, 2003/10/EU
• EU Directive on Volatile Organic Compounds
(VOC), 1999/13/EU, 2001/81/EU, 2004/42/EU Breathing protection
• Safety instructions of equipment and tool
manufacturers During painting work and in the preparations for
painting, gases, vapors, mists or dusts can appear
in dangerous concentrations in the areas where
Personal protection fellow employees breath.
Besides the body and limbs, several organs vital For short periods of work or minimal concentrations
to life are in very particular danger. Because of hazardous substances, breathing protection
damage is mostly irreparable, special attention and devices with a combination filter are suitable as
comprehensive protection are necessary. breathing protection equipment.
WARNING: Solvents cause damage to the

health through inhalation. Splashes in the
2011 Fiesta 08/2010 G468090en

The protective clothing must be changed at the
proper intervals. Items of clothing which are
contaminated with coating materials can easily
catch fire.
When selecting protective clothing, it must be taken
into account that cloth containing a high proportion
of easily melted plastic thread considerably
increases the degree of burns injury (melted plastic
on the skin!). This must also be taken into account
in the choice of underwear.
For areas of skin which are not covered by
protective clothing, suitable skin protection, skin
Item Description cleaning and skin care agents must be used.
1 Activated charcoal filter

2 Coarse filter Eye protection
For higher concentrations of harmful substances, Working with portable hand sanding machines on
breathing protection devices which are independent which the tools move unguarded, at speed and
of the local atmosphere are suitable. with power is fundamentally dangerous.
In these types of isolation systems, a compressed Goggles must be worn not only when sanding, but
air hose carries natural air from the compressor also when working with paints and their additives.
line into the protective mask. During supply, the These contain substances which are harmful to
air undergoes pressure reduction, water removal, the eyes. Damage ranging from irritation of the
fine filtration and usually warming to natural breath cornea to incurable illnesses are possible.
temperature. The protective goggles must be inert toward
WARNING: Vapor or spray mist containing splashes of solvent, and fully enclose the areas at
isocyanate as a paint base or hardener can the side of the eyes on both sides. The best
cause toxic respiratory disease (conditions protection during spray painting is offered by full
similar to asthma) leading to permanent mask respirators or helmet respirators with a
damage, even when inhaled in the lowest built-in visor.
concentrations.
Filter masks with wadding, sponge or colloid filters Ear protection
and also paper masks are all unsuitable for working
with coating materials because they do not stop Noise disturbance in repair paint shops caused by
solvent vapors. various sources is particularly high. Sanding and
The instructions for use provided by the compressed air machines, paint cabin extractor
manufacturer must be observed when working with fans (compressors) and extractor ducts in the work
breathing protection equipment. rooms are the causes of the high levels of noise.
WARNING: Avoid damage to your hearing!
Wear ear protection.
Skin protection
Suitable ear protection is offered by ear plugs or
Spray painters who are subject to considerable ear defenders.
exposure to coating materials must wear suitable
protective work clothing (flame-proof and
anti-static).
NOTE: Also, when working with water based
materials, comprehensive skin protection must be
worn, because these materials are very easily
absorbed through the skin.
2011 Fiesta 08/2010 G468090en

Environmental Regulations
Waste disposal in the repair paint shop
The new VOC (Volatile Organic
More than ever before, since the introduction of Compounds) solvent regulation
EU directives, rigorous attention is paid to the
avoidance of waste materials and to recycling in Keeping the air clean protects the environment and
repair paint shops. In this respect, repair paint the population from the heath-damaging effects of
shops must take into account and comply with the air pollutants.
following requirements:
In certain atmospheric conditions, volatile organic
• Separate waste according to its recycling and compounds contribute to summer smog.
disposal methods.
NOTE: For comprehensive information, please
• Produce evidence for the correct transport and refer to the European VOC Directive, 1999/13/EU.
disposal of waste. Furthermore, the effective national regulations must
NOTE: The organization of disposal in the plant be complied with.
must comply with the requirements of the Waste The European VOC (Volatile Organic Compounds)
Avoidance and Management Act: The avoidance Directive has controlled the limits for such
and recycling of waste must always take priority. compounds since August 2001. It applies to
However, despite all measures which may be production coating companies and those which
taken, waste cannot be completely avoided. undertake repair painting of private and commercial
vehicles.
NOTE: Waste which is not allowed in household
rubbish, and which can no longer be utilized, must Not least because of the VOC legislation, modern,
be disposed of as special waste. low solvent and solvent-free lacquers and paints
are finding greatly increased distribution across
Paint residues containing solvent, application
industry and the trade. Up to the year 2007,
residues, sanding dust, waste containing peroxides,
emissions from painting work will drop by at least
solvents, soiled cleaning cloths and paint slurry all
40%.
count as special waste. Each of these must be
collected in a separate, sealed and suitably labeled At the same time, the paint manufacturers
metal container and properly disposed of using a guarantee for example that they will produce a
specialist company. ready-to-spray product consisting of base paint +
hardener + thinners, with a permitted VOC level.
Careful separation allows some waste to be
usefully re-used. A company in business today can conform with the
stipulated requirements by introducing water-based
• Empty metal containers can be sent for scrap
paints and using the other necessary products from
instead of being disposed of as waste.
the relevant paint manufacturers.
• Contaminated cleaning thinners can be
separated by distillation. For more detailed information, please refer to the
EU VOC Directive.
• Packing material and masking paper can be
added to the recycled paper collection.
Residues which cannot be used must be correctly
disposed of.
All remaining waste must be treated as commercial
waste and disposed of according to the local
regulations.
2011 Fiesta 08/2010 G468091en

Factory Paint Application

General fundamentals of paint • Clean and de-grease
technology – In the first step, the bare bodywork is initially
dipped in a cleaning bath and cleaned with
Paint is a pigment-containing liquid which a degreasing solution.
undergoes chemical and/or physical processes • Phosphatising
after it has been applied to a surface, so changing
into a solid film covering. – The cleaned bodywork is dipped in a bath
containing various phosphate salt solutions.
Repair paint consists of binder, pigments, filler and This creates a crystalline metal-phosphate
solvent. layer which offers the optimal prepared
NOTE: Organic solvent is being replaced by surface and also corrosion protection.
solvent based on water. • CDP base
Constituents of paint – The cataphoretic dip paint (CDP) base acts
as a further corrosion protection layer.
• Binder
– In this process the bodywork is completely
– Mostly semi-fluid resins which bind together
immersed in a bath consisting of a paint and
the other components of the paint when it
electrolyte solution.
dries.
– By application of an electric voltage, an
– Makes the paint durable.
electric field is created.
– Ensures good surface coverage.
– Positively charged paint particles settle on
• Pigments the negatively charged bodywork and form
– Fine, colored powders, which give color to a protective layer up to 20 µm thick.
the paint. – Next the bodywork is placed in a dryer, where
– Cover the components below (covering the CDP base is hardened at 180°C.
power). • Sealing, stone-chip protection
• Additives – Edges, seams and but joints are sealer with
– Additives give the paint special properties. a sealing compound.
– e.g. flow improver, softener, drying – Vulnerable areas are coated with stone-chip
accelerator, thickener. protection.
• Solvent • Filler
– Thins the paint and allows it to flow more – Filler protects the body panels from stone
freely. impacts. Furthermore, any unevenness of
– Evaporates during drying. the metal surface is flattened out, in order to
create the most homogenous and fault-free
undersurface possible.
Painting process and corrosion – Once the filler is dry, it serves as the base
protection. on which paint is applied.
In production, painting consists of individual steps • Top coat
which are optimally matched to each other. – The top coat is applied as a single layer or
two layers of paint.
Bodywork consists almost entirely of steel panels
which have been pre-coated with zinc. The zinc – When working with two layer paint, in the first
layer is between 5-10 µm thick and acts as the first job step the initial colored base paint is
corrosion protection layer of the steel panel. applied. In the second job step, a clear
lacquer is applied, giving the base paint shine
Production sequence: and hardness.
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The structure of an original paint finish Not every exterior paint has its own matching filler.
It is more that the tones of the filler are color
During construction of the original paint, a total compatible, i.e. they have similar intensity to the
surface thickness of between 120 and 130 µm is top coat.
achieved. The thicknesses of the layers may vary During repair painting the filler color tones must be
however, because they are greater for horizontal used according to the manufacturer's instructions.
surfaces than vertical ones.
Paint layers
Item Description
1 Steel panel
2 Phosphate layer 2.9 g/m², corresponding
to 2 µm.
3 Cathodic dip paint 30-35 µm
4 Filler 30-35 µm
5 Base paint 15-20 µm
6 Clear varnish 55 µm
Colored fillers applied in production

Filler which gives color is used in production. Its
use makes the base paint and clear varnish
unnecessary on certain vehicle interior surfaces
(engine, doors).
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Paintwork Defects and Damage

Diagnosis and Damage Assessment • pH paper.
• Measurement of the thickness using FE / NFE
Paint concerns, regardless of their causes, are part coating thickness meters for ferrous (FE) and
of the everyday work in the paint shop. Correct non-ferrous metals and non-magnetic steel
damage assessment and determination of the (NFE) - magnetic process on steel panels, eddy
cause are preconditions for a professional current process on non-metals.
resolution of a paint concern.
A test method where the traces of testing can be
Paint concerns can still occur through a variety of easily removed again is the finger nail test. With
causes, despite improved paint materials and new suitable experience the existing hardness of the
spray methods. paint can be determined.
NOTE: A first appraisal of the paint damage should Test methods where the paint is partially destroyed
be done before cleaning. External factors such as are:
rust, droppings, incorrect or insufficient paint care
can then be more easily detected. • Pencil hardness test.
• Adhesion test using adhesive tape.
Diagnosis is best done in daylight but not in direct
sunlight. Exact evaluation can also be done under • Lattice cut test process to check the strength of
artificial light from special luminescent lamps. adhesion.
Under certain circumstances these test methods
are not enough for a certain diagnosis. In this case,
Paint damage guide paint diagnosis under laboratory conditions must
be performed.
The most important paint damage concerns which
make a paint repair necessary are:
• Damage from biological paint contamination Measuring and testing equipment for
such as bird or insect droppings, tree resin and painted surfaces
aphids.
• Chemical paint damage caused by industrial Coating thickness measuring devices
contaminants such as smoke, fuel, acids, oils. Magnifying glass
• Mechanical damage caused by stone impact
pH paper (together with water)
during operation, scratches in the car wash and
parking. Suitable photographic equipment with macro lens
• Damage caused by faults in treatment. Shine measuring equipment
Application defects such as paint runs or orange
peel.
• Dirt inclusions in the paint layer, e.g. caused by Paint damage caused by environmental
dust in top coat or textile lint. factors
• Damage due to corrosion. • Bee droppings
Before repair of such paint concerns, exact • Bird droppings
diagnosis must be performed to determine the • Insects
cause exactly. On the spot diagnoses using simple
aids and processes are often enough. • Tree resin and sap
• Aphid secretions
Diagnosis without disturbing the paint is done by:
• Tar spots
• Optical inspection without visual aids, under
suitable light conditions from a suitable angle • Cement, plaster and slaked lime
and correct distance. • Rust film/deposits from industrial fallout
• Optical inspection with the help of a magnifying • Battery acid
glass. • Brake fluid
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In all the cases of paint damage described
below, if the damage is irreversible a new paint
finish must be applied.
Paint damage cause by bee droppings
Bee droppings can be recognized on a paint

surface through its yellow or brown color and
sausage or drop-like shape with a diameter of 3-4
mm.
Cause/damage pattern:
• In combination with heat and high air humidity, Repair of damage:
bee droppings leave discolorations and cause
paint decomposition. • If the damage is light, perform a polishing repair.
• The paint can be destroyed down to the filler.
Paint damage caused by insects
At insect impact locations on the hood, roof and

bumper, small etched or etched through paint
marks with partially visible spots of filler.
• The top coat layer is destroyed in a short time
by surface swelling and etching.
• Colliding insects stick to the paint surface. In
combination with moisture and heat, because
of the resulting acids the insect bodies sink into
the paint top coat.
Repair of damage: • The corrosion is G, C, U or O shaped and is
• If the damage is light, perform a polishing repair. only a few millimeters thick.
Paint damage caused by bird droppings
Bird dropping damage appears most often as matt,

etched topcoat areas of various sizes. If left on the
vehicle for a long time, crack formation and etching
down to the filler will occur.
• Bird droppings are particularly harmful in
combination with heat and moisture. The urea
(white part) has a very high salt content and is
very aggressive.
Repair of damage:
• The intensity of the damage varies depending
on the type, quantity, contact time and extent. • Wash the vehicle, treat the affected area with
insect remover. Clean the paint surface several
• Cracks, etching, marks up to dissolution of the times.
top coat are the results.
• Protect with hard wax.
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Paint damage caused by tree resin or sap
Small yellow-brown marks or drops on the

horizontal parts of the vehicle. The drops melt in
sunlight. Resin damage only occurs in the warm
summer months.
• Because of their chemical composition, tree
resins combine with or adhere very well to paint
top coats and cause them to swell. The higher
the temperature, the more intensive is the
chemical bonding between the resin and the
paint topcoat surface. Repair of damage:
• Remove the excrement as soon as possible.
• Small single matt locations without etching can
be repaired using a polishing repair.
Paint damage caused by tar spots
Yellow or dark marks.

• Firmly stuck spots of tar which lead to
discoloration of the surface. In some cases
penetration through the clear lacquer into the
Repair of damage: top coat.
• Soak several times using a cloth saturated with
a petrol & paraffin mixture.
NOTE: After successful cleaning the top coat must
be preserved.
• Swellings can be removed by warming.
Paint damage from aphid secretions
Small, round, matt marks about 1 mm diameter

and etching with small islands down to the filler.
Fresh aphid excrement looks like small drops of
honey. Repair of damage:
Cause/damage pattern: • Clean the paint surface with tar remover and
• Aphids produce a mixture of starch, leaf acid polish.
and sugar from sap in leaves. Under the effects
of warming and moisture this can turn into
alcohol. Paint damage caused by cement, plaster
• The round shape of the damage and the island and slaked lime
of intact paint are typical.
Damage appears as whitish matt marks on the top
coat.
• Corrosive alkaline compounds interacting with
moisture.
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NOTE: Never try to remove the particles of
industrial fallout by polishing or rubbing!
• Use cleaning dough.
Damage caused by battery acid.
Splashes of battery acid caused by carelessly

topping up the battery.
WARNING: Batteries contain sulphuric
acid. When working near the battery, or
where there is battery acid on the vehicle
Repair of damage: body, protect the skin and eyes from
• Wash immediately if the contamination is fresh. contact with the acid. If battery acid
contacts the skin or enters the eyes, flush
• If the contamination has dried on, dissolve and the affected area immediately with water
neutralise it with vinegar, then thoroughly wash (flush for at least 15 minutes) and call a
off with water and rinse. doctor without delay. If acid is swallowed,
• Rectify mild damage using a polishing repair. call a doctor immediately. Failure to follow
these instructions may result in personal
injury.
Rust film/deposits from industrial fallout
NOTE: High temperatures accelerate the attack
Small round marks, about 1 mm in size, in all on the top coat. At 50°C the top coat layer breaks
shades from black, grey, blue to reddish, on the down after about 15 minutes!
horizontal surfaces of the vehicle. Cause/damage pattern:
Cause/damage pattern: • Etching of the paint layer to decomposition of
• Deposits from oil fired systems and industrial the paint finish.
plant, especially at high humidities and inversion
weather conditions, cause damage to the paint
top coat.
• As the activity time increases so called rust
halos form. They spread as long as the deposits
corrode.
• Industrial fallout containing iron will no longer
be removable after a few days!
Repair of damage:
• Flush the acid splashes with plenty of water and
neutralize with car washing liquid.
• If the contact time of the acid was short, perform
a polishing repair.
Paint damage caused by brake fluid.

Repair of damage:
Careless handling of brake fluid. The glycols
• Remove the dust using an industrial fallout contained in the fluid cause swellings.
remover and thoroughly wash.
• Polish the paint surface.
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Cause/damage pattern: Repair of damage:
• The temperature and contact time are critical. • Sand or blast out.
Splashes lead to loss of shine and lightening of • Use anti-corrosion primer.
color.
• Apply top coat.
Damage due to corrosion
Blistering/rusting below
Air or water filled blister-shaped raised areas in the

paint film.
• Overpainting corroded steel panel.
• Condensation in the spray air.
Repair of damage: • Sanding water not dried out or salt crystal
residues.
• Flush immediately with plenty of water.
• Road chippings and road winter grit containing
• The swellings can often be made to recede
salt.
completely by treatment with the radiant heater
or in the paint drying oven at max. 60°C for
about 1 hour.
Mechanical damage
Stone impact damage or mechanical

damage
Mechanical damage caused by impact of stones

or other hard objects and extending down to the
metal panel lead very quickly to corrosion and
rusting under the paint on the adjoining surface. Repair of damage:
Cause/damage pattern: • Sand the affected area of damage or the body
• Paint damage caused from the outside, down component and re-create the paint finish.
to filler, primer or metal panel. • More severe and larger areas of rusting below
must be repaired using the corresponding repair
painting, Repair Level III or IV.
Damage caused by faults in treatment

• Craters
• Paint boils
• Adhesion defects
• Adhesion defects - clear lacquer
• Sanding scores
• Formation of stripes
• Peeling/blistering on plastic parts
• Blistering on polyester material
• Peroxide marks in metallic paints
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• Crack formation Repair of damage:
• Shrinking back/zone edge marks • Sand paint surface, clean with silicone remover
• Blistering and apply one thin spray pass. Let it begin to
dry well, then apply several thin and dry sprayed
• Etching
passes.
• Paint wrinkles/puckering
• Cloud formation
• Spots/metallics Paint boils
• Metamerism/color deviations
Small, hard, closed or burst blisters in the paint top
• Washing out coat. They appear locally in groups or spread
• Loss of gloss individually across the whole surface. Sanding
• Covering ability/areas of thin paint opens up a larger cavity, under which the primer
• Flow problems/orange peel can often be seen.
• Dirt embedded in metallic base paint Cause/damage pattern:
• Dirt embedded in top coat • Paint applied in layers which were too thick.
• Water marks • Specified flash-off and drying times between
• Paint runs coats were not adhered to.
• Swirl marks • Specified working viscosity and spray pressure
were not adhered to.
• Use of unsuitable hardener and thinner
Craters materials. (Solvent combinations in paint system
not optimally matched).
Crater-like single or extensively occurring • Poor booth conditions.
depressions with raised edges, in top coat or the
intermediate layers.
• Substrate not adequately cleaned with silicone
remover.
• Spray air contaminated by oil residues and
water accumulations.
• Filter ceiling not adequate for requirements.
• Use of polishes, cleaning agents or sprays (e.g.
interior sprays) containing silicone.
• Oil, wax, grease, silicone containing residues.
• Working clothes contaminated by materials
containing silicone. Repair of damage:
• Single boil blisters can be removed using
polishing.
• After thorough drying, sand the top coat at the
affected areas, clean with silicone remover and
re-paint. Fill any fine pores still present with
2-component acrylic filler.
• On larger areas of damaged topcoat, sand
completely away and apply new paint finish.
Adhesion defects
Whole coating detached from substrate or

individual layers one from another. Sometimes
2011 Fiesta 08/2010 G468093en

adhesion defects can only be noticed after an
external influence such as stone impact.
• Substrate not adequately prepared (rust, grease,
moisture, sanding, cleaning).
• Unsuitable material used.
• Drying times, flash-off times too short.
• Base paint not sprayed wet-in-wet, instead the
intermediate drying times were too long.
• Failure to intermediate sand.
• Condensation formed because of temperature
fluctuations. Repair of damage:
• Unprofessional preparation (especially on • Refinish sanding and recreate the paint finish.
plastics).
• Overheated CDP/intermediate filler.
Sanding scores
Single or wide area clusters of scoring or sanding

marks, often with raised edges. Noticeable on
metallic paints as light-dark stripes.
• Stopper sanded too coarsely.
• Filler sanded too coarsely.
• Filler not thoroughly dried bfore sanding.
• Old paint sanded too coarsely.
• Soft elastic substrates, e.g. TPA base, treated
with thinners which was too aggressive and
Repair of damage: therefore etched.
• Sand out the damage and recreate the paint • Top coat applied too thinly.
finish. Create the paint finish strictly in
accordance with the general technical
information.
Adhesion defects in clear lacquer.
Clear lacquer detched from base paint.

• Base paint layer too thick.
• Intermediate and final flash-off times of base
paint too long.
• Incorrect mixture ratio clear lacquer/hardner. Repair of damage:
• If the damage pattern is minimal, after the top
coat has dried fine sand the paint surface and
refurbish by polishing.
• If the damage is great or on metallic paints, sand
the paint surface or substrates and if necessary
remove them, then cover the bare metal and
re-paint.
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Formation of stripes
Differing, stripe shaped color/effect formations in

dark/light areas of a metallic paint finish.
• Spray gun (nozzle) not perfect.
• Incorrect spray pressure.
• Thinners not suitable.
• Incorrect spray viscosity.
• Flash-off time too short.
• Unsuitable working temperature.
Repair of damage:
• Sand away faulty paint coats and re-apply paint
finish.
• In extreme cases use a new part.
Blistering on polyester material
Color shade differences or marks in paintwork

subsequently applied to previously unpainted
plastic material.
Repair of damage: • Plastic material is not suitable for painting.
• Apply base paint evenly. • Incorrect bonding agent.
• Repair spray gun. • Paint used not solvent resistant.
• After clear lacquer has thoroughly dried, sand Repair of damage:
surface and paint again. • Repaint using suitable materials.
• Install unpainted new part (after consulting
customer).
Peeling/blistering on plastic parts
Paint adhesion insufficient between top coat and

filler and/or primer layer. It often happens that the
Peroxide marks in metallic paints
whole of the paint finish detaches from the plastic.
After longer period of drying, abnormal marks
Cause/damage pattern: where the color shade varies.
• Plastic item not cleaned sufficiently, not or Cause/damage pattern:
inadequately tempered.
• Too much hardener added to polyester stopper
• Unsuitable cleaning agent used. (over 3% can cause this damage pattern).
• Unsuitable materials used. • Polyester stopper not well enough mixed.
• Moisture.
• Paint finish underbaked or overbaked.
• Poor or lack of intermediate sanding.
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Shrinking back/zone edge marks
Lifting or dropping in of edge zones (edges which

accentuate themselves in the top coat), flow
problems and loss of shine in top coat.
• Old paintwork not rubbed down to a seamless
transition.
• Stopper and filler on a viscoplastic base primer.
• Filler sanded and overpainted when not
thoroughly hard.
• Previous materials overworked too early,
Repair of damage: substrate not sufficiently hardened.
• Sand, fill with polyester or epoxide filler and • Primer applied in layers which were too thick,
re-paint. and not dried for long enough.
• Sanding paper too coarse.
Crack formation • Top coat thinned too much.
Cracks of different lengths and depths running in

all directions.
• Layers too thick.
• Painted several times.
• Temperature fluctuations.
• Mechanical effects e.g. distortions.
• Substrate not thoroughly hardened.
• Old paint not completely dried out.
• No or insufficient hardener added.
• 2-component materials used on nitro or TPA. Repair of damage:
• After hardening off the top coat, fine sand the
surface and polish up, apply filler if necessary
and paint once more.
Blistering
Small, spot-like, air-filled or water-filled blister

shaped high-spots in the paint construction. Their
dimensions can range from pin-head to pin-point
size in a closed paint film. Arrangement and
accumulation very variable. In the advanced
stages, circular flaking of the paint from the
Repair of damage: substrate. These are neither boils nor corrosion.
• Sand away layers until sound substrate is Cause/damage pattern:
reached and create new paint finish (prime, fill, • Moisture absorption by substrate.
apply topcoat).
• Insufficient drying of the substrate after wet
sanding (especially on polyester material).
• Humidity too high before painting; condensation
formation because of temperature fluctuations.
• Pores/sink holes in substrate not sanded out.
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• Polyester material not covered. Paint wrinkles/puckering
• Sweat from hands.
Lifting/puckering of the paint surface.
• Salts and minerals in sanding water.
• Spray air contaminated. Cause/damage pattern:
• First paint not hardened through or can be
etched.
• Areas of clear lacquer which were sanded
through to base paint have not been not isolated
with filler, or with unsuitable filler.
• Unsuitable substrate (e.g. spray can painting
with TPA or nitro).
• Use of unsuitable primer, paint and thinner
materials.
• Paint systems not matched to each other.
• In wet-in-wet process, specified flash-off times
not adhered to.
Repair of damage: • Synthetic resin top coat (alkyd resin) worked
• Sand away damage, matt sand remainder of over too soon.
surface, clean with silicone remover, fill and
re-paint.
Etching
The base paint is etched by the clear lacquer. This

causes the aluminum pigments to change their
alignments. The color of the etched base paint
seems more grey than that of normal base paint.
Result is that the surface structure of the clear
lacquer becomes increasingly more matt.
Repair of damage:
• Base painted too wet.
• After thorough drying, completely remove the
• No intermediate flash-off time.
top coat together with the attacked substrate at
• Layers too thick. the affected areas and re-create a new paint
finish.
• Before applying top coat, rub down the complete
surface.
Cloud formation
Differing, blotchy color/effect formations in

dark/light areas of a metallic paint finish.
• Spray gun, spray nozzle, spray pressure not
perfect.
Repair of damage: • Varying spray viscosity, spraying method,
• Sand and re-paint. flash-off times, spray booth temperature.
• Thinners not suitable.
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• Use of paints with pigmentation which was not
compatible with the standard, e.g. a green can
be formulated from yellow and blue, or directly
from green.
• Use of an unsuitable mixed or ready made paint
to re-tone.
Repair of damage:
• Droplet method before clear lacquer application.
• After clear lacquer has thoroughly dried, sand
surface and re-paint.
Spots
Repair of damage:
Points rising up from the paint film.
• Repaint using the correct paint.
• Metallic base paint sprayed too dry, so that the
metal particles could not incorporate into the Washing out
paint. The clear lacquer could not cover these
vertical standing particles because the spray air On paint which has been newly applied but not yet
was too hot or the booth temperature was too dried, the interaction of surface tension and very
high. different specific gravities of the different pigments
can lead to swirl-like turbulence which results in
separation of the pigments.
• Layer too thick, paint not stirred enough.
Repair of damage:
• After the paint surface has dried, lightly sand it
with grade P800 sanding paper, clean with
silicone remover and re-apply clear lacquer.
Repair of damage:
Metamerism/color deviations • Sand and re-paint.
Noticeable when identical color shades undergo a

change of hue as the light source changes Loss of gloss
(daylight/artificial light). Different pigment
composition between original and repair paint. Milky, dreary tarnishing of the paint with more or
less even loss of gloss.
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Cause/damage pattern: Repair of damage:
• Cold with low air humidity. • Sand surface and recreate the paint finish.
• Heat with high air humidity.
• Substrate can be etched.
Flow problems/orange peel
• Hardener fault or wrong hardener used.
• Paint thinned too much. Surface structure bumpy, grained. The surface is
• Proportion of pigment too high because of poor similar to the peel of an orange.
stirring. Cause/damage pattern:
• Not optimum drying. • Paint viscosity too high.
• Use of fast evaporating, highly volatile thinners.
• Booth temperature too high.
• Spray gun distance too great, too little material
applied.
• Nozzle too large.
• Incorrect spray pressure.
Repair of damage:
• After drying, remove the matt effect by polishing.
If unsuccessful, rub down complete area and
paint again.
Covering ability/areas of thin paint

Repair of damage:
Different color shades in the surface. The minimum • Small surfaces: fine sand and polish.
layer thickness is not achieved here. The effects
range from local minor shade variations through • Sand out the surface and recreate the paint
mottled spray zones to completely missing top coat. finish.
• No correct, uniform substrate (effect paint). Dirt embedded in metallic base paint.
• On three-layer systems, wrong filler.
Inclusions of contamination in metallic base paint,
• Insufficient top coat application.
of different sizes and shapes (grains or lint).
• Dust was not properly removed from the surface
to be painted.
• Paint material not sieved.
• Function of the painting facilities not optimum.
• Filter contaminated.
• Wearing unsuitable clothing.
Repair of damage:
• Sand and repaint.
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Dirt embedded in top coat
Inclusions of contamination in top coat or under

paint layers, of different sizes and shapes (grains
or lint). Optical adverse effect.
• Dust was not properly removed from the surface
to be painted.
• Paint material not sieved.
• Function of the painting facilities not optimum.
• Filter contaminated.
• Wearing unsuitable clothing. Repair of damage:
• Rub down only slight marks with sanding paper
grade P1000 - P1200 and then polish.
• For heavy marking, sand the surface matt, clean
with silicone remover and repaint.
Paint runs
Wave-like paint run tracks in top coat or in an

intermediate layer on vertical surfaces. Mostly in
the area of swage lines, seams or openings (there
they are paint runs, otherwise curtains).
Repair of damage: Cause/damage pattern:
• Single inclusions: after thorough hardening, • Uneven paint application.
sand out using 1200 - 1500 grade paper and • The specified viscosity was not complied with.
repolish using a suitable silicone-free sanding • Use of unsuitable thinner materials.
or painting paste.
• Air, material or room temperature too low.
• Large area contamination: sand and repaint.
• Layers too thick.
• Spray gun (nozzle) not perfect.
Water marks
Ring shaped marks appearing on the paint surface.

• Evaporation of water droplets on freshly painted
and not yet fully hardened paint finishes (mostly
only found on horizontal surfaces).
• Layer too thick.
• Drying time too short.
• Hardening faults or hardener no longer useable.
• Use of unsuitable thinners.
Repair of damage:
• After thorough drying, sand unevenness flat, if
necessary leave to dry afterwards.
• Small areas of damage can be equalised using
the paint plane, then sand, polish or repaint.
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Swirl marks
Three dimensional appearance in the paint surface

in the form of smears or blotches. This effect is
intensified in direct sunlight.
• Polishing using polishing machine on paint
which has not yet hardened throughout.
• Polishing intervals too long or none at all.
• Pressure too high while polishing.
• Incorrect polishing material or polishing tool.
Repair of damage:
• Allow the paint to harden completely and then
polish.
• If the damage is irreversible, rub down and apply
new clear lacquer.
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Tools and Equipment for Paint Repairs

General work equipment
Principle of operation
In the repair paint shop there is a range of painting
tools which make the work of the painter easier
and improve the quality of the repair paintwork.
Among these are small tools which are used for
the following work:
• Measuring beakers to measure and mix
various paint materials.
• Measuring rods with which the required
combination amounts of paint and primer filler
are gauged and mixed.
• Viscosity measuring beaker with a calibrated
opening of 4mm, used to set the correct paint
viscosity.
• Paint filter/paint sieve for filtering foreign Item Description
bodies out of mixed paint or primer. Care must
1 Air supply
be taken that the correct filter is used for each
paint. 2 Paint supply
• Color sample plates onto which the mixed 3 Nozzle needle
paint is applied, and the shade is then compared
to that of the vehicle. Other aids which should Because of the construction design and with the
help the painter to find the correct shade are aid of compressed air, a spray-ready paint mixture
color sample cards and color panels, which is dragged out of the container to the nozzle by the
are offered by many paint manufacturers. venturi effect, and is applied to the surface being
• Dust bonding cloths which are impregnated worked.
with a tacky resin and which pick up dust When the trigger of the spray gun is pressed to the
particles particularly well. A surface to be first pressure point, only the compressed air
painted must be cleaned with a dust binding passage opens. If the trigger is pressed further,
cloth immediately before paint is applied. the nozzle needle displaces and the air stream
• Compressed air guns are used to remove drags paint with it at high speed. This produces a
sanding residues and to dry sanded surfaces. spray mist consisting of micro-droplets of paint.
Filler and spray guns

NOTE: Regular maintenance, cleaning after use
and careful handling of all individual parts of the
spray gun are essential for a high-quality paint
finish.
The spray gun is the most important implement in
the paint shop. Application of paint using the spray
gun can produce a layer with absolutely constant
thickness and a smooth paint surface.
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Types of spray gun HVLP spray guns
Item Description
1 Suction-beaker spray gun
2 Flow-beaker spray gun
In the flow-beaker spray gun, the paint container
is mounted above the spray gun. On the
suction-beaker spray gun, it is below.
Furthermore, spray guns are categorized by their
air pressure requirement into high and low pressure
guns.
High pressure guns have the disadvantage that
they exhibit high consumption of energy and
materials. The spray pressure they require is Item Description
between 1 - 6 bar.
1 Quantity control
Because of the high air pressure and the large
amount of air needed, the result is a powerful paint 2 Working pressure control
mist formation (paint transfer rate approx. 35%). 3 Spray pattern control
Current practice is mainly to work with reduced The high volume low pressure (HVLP) spray gun
mist spray systems (RP and HVLP systems). is a high performance spray gun which forms a
Reduced pressure (RP) guns are optimized high soft, fine and homogenous spray pattern. The
pressure guns which have an input pressure at the atomization pressure at the air cap is 0.7 bar when
gun of approx. 2.5 bar and an atomization pressure the input pressure at the gun is 2.0 bar.
at the air cap of 1 - 2 bar. In practice this spray The low atomization pressure of 0.7 bar together
technology is preferred for spraying clear lacquer with greatly reduced spray mist provide high
because of the finer atomization. material ejection. The low nozzle internal pressure
Low pressure guns have the advantage that they minimizes rebound of the paint droplets from the
exhibit minimal paint mist formation and because object and thus the proportion of overspray.
of this the paint transfer rate rises to approx. 65%. This spray technology has a very high application
The spray pressure required in this case is between efficiency. By matching the size of the nozzle, the
1 - 5 bar. Nozzle sizes from 1 - 2.2 mm can be HVLP spray gun can be used for all repair painting
used. materials.
HVLP spray guns are often used in practice for the
application of water based paints.
Mini spray guns are often used for small, localized
touching-up work. Use of HVLP spray technology
and nozzle sizes of 0.3 - 1.2 mm permits very fine
2011 Fiesta 08/2010 G468095en

work, so that the area of the repair can be kept as Paint preparation system (PPS)
small as possible.
In order to ensure that a spray gun operates
efficiently for a long time, careful cleaning is
absolutely vital after use.
NOTE: During cleaning you must distinguish
between water based and solvent based materials.
Cleaning by hand:
• Empty the paint beaker immediately after use.
• Flush the gun with cleaner.
• Clean it inside and outside with a brush.
• Dismantle the gun to clean it thoroughly.
• Clean the air cap using a suitable brush.
• Use nozzle cleaning needles to clean bores and
nozzles.
A spray gun washing machine is recommended if
the painting work is highly intensive.
New types of paint processing systems are
replacing the conventional mixing beaker, filter and
spray gun flow beaker. This reduces the amount
of solvent required for cleaning and the amount of
routine waste which remains.
Item Description
1 Beaker
2 Color bag
With this system, which is suitable for both suction
and flow beaker spray guns, only one beaker is
required for mixing and painting.
A bag is inserted in the beaker, in which paint can
be mixed, processed and stored after use or
completely disposed of.
The small quantity of paint remaining in the gun is
removed using a minimum quantity of solvent from
the pipette bottle.
The amount of cleaner used is reduced because
only the spray gun needs to be cleaned.
Hand and machine sanding tools

Sanding is used to prepare a surface for application
of a paint layer, enabling it to adhere well. Sanding
materials have a great influence on the quality of
a repair paint finish. The correct sanding medium
must therefore be chosen for every material.
2011 Fiesta 08/2010 G468095en

During sanding, material is mechanically removed Silicon carbide has a very high degree of hardness,
from a surface. but is more brittle than carborundum. When silicon
In the paint shop, carborundum or silicon carbide carbide is used, the mineral grains break. New long
abrasive on a substrate of paper or cloth are the and pointed profiles are formed.
most common sanding materials used. Use of the correct sanding paper depends on the
Carborundum is a very hard mineral consisting application, the substrates and the tools used. The
mostly of aluminum oxide. During use carborundum following table can be used as a guideline, but the
becomes blunt and wears away. recommendations of the supplier of the auxiliary
materials and additive materials must be followed.
Application Working area Grade Sanding system

Body work, corrosion Equalizing paint system to P150 Orbital sander, dry
damage transition
Hand sanding, dry
Stopper Rough sand P80 - P150 Orbital sander, dry
Fine sand P240 - P320 Orbital sander, dry
Hand sanding, dry
Spray stopper Rough sand P120 - P180 Orbital sander, dry
Fine sand P240 - P320 Orbital sander, dry
Hand sanding, dry
Filler sanding work Filler fine sand P400 - P500 Orbital sander, dry
P800 - P1200 Hand sand, wet
Top coat Old paint P400 - P500 Orbital sand, dry
P800 - P1200 Hand sand, wet
Touch-up paint surfaces P1000 - P2000 Hand sand, wet
Paint damage Sanding out faults P2000 - P3000 Hand sand, wet
Soft Pads are recommended for manual refinishing

of contours, curves and difficult to reach areas. On
a Soft Pad the abrasive is found on a coarse
structured fleece. Because of this, it is very flexible,
does not kink and does not slip in the hand. This
enables a fine and even finish to be achieved.
Item Description
1 Extraction bores
2 Connection for extraction equipment
Notes on working with sanding tools:
2011 Fiesta 08/2010 G468095en

• Tools with a rigid backing pad do not adjust to • Advantage:
fit the surface. They are used for flat surfaces. – Ideal for heavy sanding work.
• Tools with a flexible backing pad are used for – Fast and aggressive sanding possible.
fine sanding of a surface because they adjust
• Disadvantage:
to the shape of the surface.
– Large amount of heat developed.
• Build up an even working pressure over the
sanding surface. – Difficulty sanding flat surfaces.
• Keep the sanding paper tight on the tool (use • Application:
self-gripping systems). – Removal of old paint layers.
• Align the extraction holes in the sanding paper – Preparation of panel for stopper.
with the holes in the tool. – Removal of rust.
• Guide the tool flat over the surface to be worked.
Do not tilt it.
Oscillating sander
Hand sanding can be carried out dry but also wet.
Wet and dry paper with particle size P 80 to P 1200 On these machines the sanding paper oscillates.
is used for this in the paint field. The backing pad is rectangular.
• Advantage:
Ways of sanding – Large sanding surface.
– Ideal for large and flat surfaces.
Sanding tools are driven either by electricity or
compressed air. • Disadvantage:
– Hardly useable on rounded surfaces.
– Flexible backing pad not possible.
– Vibrations because of the poor support of the
backing pad.
• Application:
– Sanding of polyester stopper.
– Sanding processes on flat surfaces.
Orbital sander
On these machines the sanding paper turns and

oscillates.
Item Description
• Advantage:
1 Sanding machine – Easy to handle and good sanding power.
2 Polishing machine – Minimal heat development.
3 Orbital sander • Disadvantage:
– Not suitable for sanding stopper on flat
The disadvantage of electrically driven machines surfaces.
is that their own weight is high compared with
pneumatic systems. They also become warm – Smooth guidance important, otherwise
during work. They do not however need any special sanding marks will occur.
operating equipment for their energy supply. • Application:
Sanding machines are categorized by their type of – Sanding of paint layers.
sanding movement. – Well suited for final preparation of a primer.
NOTE: Comply with the manufacturer's
recommendations when setting the orbital sander.
Rotational sanders
On these machines the sanding paper turns.
2011 Fiesta 08/2010 G468095en

On the orbital sander, stroke settings of approx. 3 • The drying process occurs from the inside to
mm for fine sanding work and approx. 5 - 7 mm for the outside.
coarse sanding work have been established. • The drying time is shorter than for warm air
systems.
Polishing and finishing tools • Because the infrared dryer consists of several
cassettes which can be switched on
The term polishing in the context of paint repairs independently, the drying area can be optimally
means the elimination of paint flaws and high shine controlled.
polishing of neighboring parts. Independent of the manufacturer's instructions,
During polishing the fine sanded surface is returned pay attention to the following:
to a high shine using a special abrasive polish. • Flash-off time of the paint before switching on
Before the actual polishing, all flaws in the paint the infrared dryer.
surface must be removed and the following working • Distance between the infrared dryer and the
procedures must be adhered to: surface.
• Thoroughly clean the vehicle. • Duration of the irradiation.
• Remove spray mist from all surfaces. The most common use of the infrared dryer is to
• Sand out and polish particle inclusions. dry stopper and primers. The wait time between
• Sand down paint runs and polish them out. the job steps is shortened without having to use
the painting/drying cabin.
• Examine the exactness of the color match in
daylight. The painting/drying cabin can then be used
• Remove masking edges. exclusively for application and drying of topcoat.
• Remove sanding water, sanding dust and polish There are two types of infrared dryer:
residues. • Infrared dryer with short wavelength radiation.
After the polishing process the results must be • Infrared dryer with medium wavelength
tested using a special test spray. radiation.
As an indication, the following drying times are
Infrared drying technology listed for some materials (at 80 cm distance):
NOTE: Observe the material manufacturer's and
The drying process in a painting/drying cabin supplier's specifications.
occurs through heat conductance (convection).
When an infrared dryer is used, the drying process • Polyester stopper 2 minutes.
is through heat radiation. • Spray stopper 2 to 7 minutes.
• Water based primer-filler 7 to 9 minutes.
• Primer 3 to 8 minutes.
• Top coat 7 to 10 minutes.
Air dryers
The air dryer is suitable in places where drying
needs to be done, but without great outlay
(painting/drying cabin or infrared dryer).
The infrared rays penetrate the air and the paint

layer without warming them. Because the infrared
rays are reflected from the steel panel, the paint
coat is warmed from the inside outwards.
Advantages of infrared drying:
2011 Fiesta 08/2010 G468095en

The filters should have a dust-removal grade of
not less than 99.8% and must always be kept
clean.
It is especially important that the air supply does
not cause strong air currents in the painting cabin.
If not, the following problems could occur:
• Paint contamination cause by paint mist, which
persists in air eddies and gradually falls on the
fresh paintwork.
• Flow problems in the paint because of the high
speed of the air, causing the paint to thicken
very quickly on the surface.
NOTE: Air from the compressor is often too cold • Loss of gloss and wrinkle formation because
for effective drying. the surface dries too fast.
Air dryers use the venturi effect to blow the warm • Painter disturbance while working.
ambient air over the paint surface in a gentle air
flow. In modern paint cabins the air supply is provided
from the complete surface of the ceiling. The air
speed should be 0.3 m/sec (measured in the
Paint mixing system unrestricted cross-section of the spray cabin). At
the same time, the air in the cabin should change
Because of the many different color variants, it is about 350 times per hour.
now seldom possible to store all color shades as
Air extraction is best achieved through extraction
ready-made mixtures.
channels in the floor of the painting cabin.
For this reason, vehicle manufacturers make the
NOTE: Refer to the manufacturer's specifications
mixture proportions of their paints available as color
for the operating instructions, safety instructions
codes. The required color shade can be obtained
and notes on the maintenance of a paint cabin.
from the paint mixing system using this color code.
Smooth walls in the paint cabin should prevent
All the color components are combined according
dust deposits. Regular cleaning is necessary
to their proportions by weight using a precise
however.
computer scales to produce a finished color shade.
Special easily washed adhesive-bonding paint can
be applied to the walls to protect the cabin from
Painting cabin paint mist.
The air requirement in a painting cabin is large.
The outside air which is drawn in must be passed
through filtering and warming equipment. This
particularly applies during colder times of the year
and especially for combined types of building where
the painting cabin is also used as a drying cabin.
It is primarily used to keep the air free of dust. At
the same time, explosive solvent-air mixture
concentrations are prevented
NOTE: Vacuum will lead to contamination of the
newly applied paint. The outside air flows through
door gaps, wall joints and other openings and as
it does so, brings dust deposits with it.
The air supply quantity depends on the size of the
painting space and the quantity of extracted air.
Enough air must be supplied to cause positive
pressure in the painting space. An air extraction :
air supply ratio of about 1 : 1.05 is sufficient.
2011 Fiesta 08/2010 G468095en

Refinishing Materials
The manufacturer's instructions must always be used for very uneven areas and surfaces and
be followed when dealing with all materials! fine stopper or spray stopper should be applied
The information given in the following text is data afterwards.
which is independent of the manufacturer, and it
should only be used as an indication. Application 2-component polyester
coarse stopper
Stopper materials Use Rough equalization of
unevenness
• 1-component nitro-combination stopper Hardener quantity approx. 3 - 5%
• 2-component polyester stopper
Working time approx. 4 - 6 minutes
• 2-component plastic stopper
Drying 20°C approx. 12 minutes
Use suitable primer to protect from corrosion areas
which have been sanded bare before applying Short wavelength infrared
stopper. approx. 4 minutes
Medium wavelength
1-component nitro-combination stopper infrared approx. 5 - 10
minutes
Nitro-combination stopper has mostly been Sanding tool Eccentric, sanding disk
superseded by 2-component polyester stopper. by hand
Fast drying fine stopper for the smoothing of Grade P80 - P150
irregularities.
The working properties of 1-component Application 2-component polyester
nitro-combination stopper can be improved by the fine stopper
addition of nitro thinners.
Use Equalization of uneven-
Drying time increases with thickness of the layer. ness
Application 1-component nitro- Hardener quantity approx. 3 - 5%

combination stopper Working time approx. 4 - 6 minutes
Layer thickness Max. 80 µm Drying 20°C approx. 12 minutes
Drying time up to 2 hours at 20°C Short wavelength infrared
Sand P240 - P400 approx. 4 minutes
Medium wavelength
infrared approx. 5 - 10
2-component polyester general stopper minutes
Sanding tool Eccentric, sanding disk
CAUTIONS:
by hand
Do not exceed the quantity of hardener
specified by the manufacturer, excess Grade P80 - P240
peroxide can cause staining of the paint
top coat. Application 2-component polyester
glass fiber stopper
Mix the stopper base and the hardener well
to avoid a marble-like effect. Use Equalization of uneven-
ness; blending in of
Check that the manufacturer permits use on the vehicle extensions; repair
substrate to which it will be applied. of GRP components
2-component polyester stopper is available in
Hardener quantity approx. 3 - 5%
coarse and fine grades. The coarse stopper can
2011 Fiesta 08/2010 G468096en

Application 2-component polyester Application 2-component plastic
glass fiber stopper stopper for flexible
thermoplastic
Working time approx. 4 - 6 minutes
60°C approx. 15 min
Drying 20°C approx. 12 minutes
(Short wavelength
Short wavelength infrared
infrared approx. 8
approx. 4 minutes
minutes)*
Medium wavelength
(Medium wavelength
infrared approx. 8-10
minutes
minutes)*
by hand
by hand
Grade P80 - P150
Grade P80 - P150; fine sand -
P280
2-component polyester fine stopper should always
be applied after 2-component polyester glass fiber
*Infrared drying may adversely affect adhesion,
stopper.
therefore check the manufacturer's
instructions.
Application 2-component polyester
spray stopper Plastic stopper has a very great tendency to shrink
back, so that the edge of the stopper repair
becomes visible.
ness
Plastic stoppers are flexible and universally
Hardener quantity approx. 3 - 5% applicable on all types of plastic (except for pure
Working time approx. 25 - 30 minutes PE and PP, these are plastics which cannot be
painted). The manufacturer's instructions must be
Layer thickness 200 µm or 4 - 8 spray very exactly followed in order that no adhesion
passes problems occur. A special plastic etch primer is
Drying 20°C approx. 3 hours specified for some materials.
approx. 10 minutes Primers
Medium wavelength
infrared approx. 15 - 20 Application 1-component primer
minutes Use Isolation of bare sanded
Sanding tool Eccentric, sanding disk areas.
by hand Spray gun HVLP 1.3 mm
Grade P80 - P150; fine sand - Spray pressure 2.0 bar
P280
Drying 20°C approx. 15 - 20
minutes
Application 2-component plastic
stopper for flexible 60°C approx. 10 min
thermoplastic
Coat application Wet on wet, no interme-
Use Equalization of scratches diate sanding
or unevenness
Hardener quantity approx. 3 - 5% Application 2-component primer
Working time approx. 25 - 30 minutes Use Corrosion protection and

bonding agent (steel
Drying 20°C approx. 15 - 30 sheet, zinc coated steel
minutes sheet, aluminum)
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Application 2-component primer Application HS primer filler and HS
tinted filler
Spray gun HVLP 1.3 mm
(Medium wavelength
Spray pressure 2.0 bar
infrared approx. 10-15
Drying 20°C approx. 15 - 20 minutes)*
minutes
Coat application Wet on wet, no interme-
60°C approx. 10 min diate sanding
Coat application Wet on wet, no interme- *In order to avoid boiling out, drying should be
diate sanding performed slowly.
HS primer filler and HS tinted filler Paint

Note: The base and the clear lacquer must be matched
• Primer filler is available as 1-component and to one another.
2-component water based and solvent based
forms. Application Water based paint
• 1-component products are only suitable for Use Two layer metallic effect
isolation of sanded through bare areas and new paint and Uni-paint
painting. finishes
• Water based products are also used for the Spray viscosity At 20°C 18 - 20 s
skinning of thermoplastics and substrates which
are sensitive to solvents. Spray gun HVLP 1.2 - 1.3 mm
• Tinted fillers can be individually matched to the Spray pressure 2.0 bar
top coat color and therefore find uses in effect
paints and paints with poor covering power. Layer thickness 15 - 20 µm
• Use dry sand or wet sand filler according to Drying 20°C approx. 2.5 hours
application in order to avoid unnecessary
sanding work. 60°C approx. 25 min
• On critical substrates the use of epoxy resin Short wavelength infrared
base filler is recommended in order to avoid approx. 8 minutes
adhesion problems. Medium wavelength
Application HS primer filler and HS minutes
tinted filler
Coat application Wet on wet
ness, edge zones, Ventilation time approx. 5 minutes
sanding scores
The base paint must be dried matt before the clear
Spray gun HVLP 1.6 - 1.9 mm lacquer is applied.
Application 2-component HS clear
Layer thickness 50 - 70 µm to 150 µm lacquer
possible
Use Gloss providing
Drying 20°C approx. 2.5 hours protective coat for base
(60°C approx. 25 min)* coat substrate
(Short wavelength Spray viscosity At 20°C 18 - 20 s
infrared approx. 8 Spray gun HVLP 1.2 - 1.3 mm
minutes)*
Layer thickness 50 - 70 µm
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Application 2-component HS clear
lacquer
Drying 20°C approx. 10 hours
approx. 8 minutes
Medium wavelength
minutes
Application 2K HS Uni top coat

Use Color and gloss providing
paint layer
Spray viscosity At 20°C 20 - 22 s
Spray gun HVLP 1.2 - 1.3 mm
Spray pressure 2.0 bar - 3.0 bar
Drying 20°C approx. 8 hours
approx. 8 minutes
Medium wavelength
infrared approx. 10 -15
minutes
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Additional Materials
The manufacturer's instructions must always
be followed when dealing with any materials!
The information given in the following text is data
Underbody protection based on solvent
which is independent of the manufacturer, and it
Application:
should only used as an indication.
• Underbody protection for visible areas.
Properties:
Adhesive sealants
• Can be over-painted, also with 2-component
Adhesive sealants are permanently elastic, paint.
long-lived, can be painted and accept filler. • Can be colored with a proportion of up to 40%
paint.
Application: Sealing of visible and normal seams.
Note:
Can be over-painted with 2-component paint,
primer and fillers after having dried throughout. • Contamination can be removed using cleaner
and thinner.
Contamination can be removed using cleaner and
thinner.
Water based underbody protection
1-component PUR adhesive sealant Can be over-painted with water based paint.
Note: Can be colored with water based paint.
• Hardens using oxygen from the air. For that Contamination can be removed using water.
reason, it must only be stripped after it has
completely dried through. Application Water based underbody
protection
Use Underbody protection
2-component MS polymer adhesive sealant for visible areas
2-component MS polymer adhesive sealant is free Spray viscosity ready to use
of isocyanate, solvent and silicones and can be
Spray gun Suction beaker HVLP
spot-welded.
gun 3 - 4 mm
Spray pressure 4 - 6 bar
MS polymer adhesive sealant
Can be over painted with water-based paints. Drying approx. 6 hours at 20°C
Suitable for spraying and brushing to obtain a approx. 45 - 60 minutes
composition true to the original. at 60°C
MS polymer adhesive sealant is free of isocyanate, Short wavelength infrared
solvent and silicones and can be spot-welded. approx. 8 minutes
Medium wavelength
Underbody protection infrared approx. 10 - 15
minutes
Underbody protection products are immune to
abrasion, permanently elastic, adhere well and are Application Water based underbody
suitable for a true to original texture. protection
Use Isolation primer for
peroxide marks, bloomed
old paintwork and thermo-
plastics.
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Application Water based underbody Application Drying accelerator
protection
Spray viscosity Thin as necessary with
distilled water
Spray gun HVLP gun 1.9 mm
Drying approx. 6 hours at 20°C
Spray pressure 2.0 - 3.0 bar
approx. 25 minutes at
60°C
approx. 30 minutes at approx. 8 minutes
60°C
Medium wavelength
Short wavelength infrared infrared approx. 10 - 15
approx. 8 minutes minutes
Medium wavelength Cannot be used in all paints, read the
infrared approx. 10 - 15 manufacturer's instructions.
minutes
Particularly suitable for partial painting.
Paint additives Application Elastifier additive in

primer material
Application Sanding test color Use Elastifies the complete
Use To test sanding results paint structure on
plastics.
Addition Up to 25%
Layer thickness Spray drifted
Spray pressure 2.0 - 3.0 bar
Application Fixer additive Layer thickness 50 µm
Use Converts solid top coat Drying approx. 4 hours at 20°C
into two layer solid; multi-
color painting
60°C
Spray viscosity 18 - 20 secs at 20°C
Spray gun HVLP 1.2 - 1.3 mm approx. 8 minutes
Spray pressure 2.0 - 3.0 bar Medium wavelength
Layer thickness max. 30 µm
minutes
Coat application Wet on wet
Ventilation time approx. 15 - 30 minutes Application Elastifier additive in top
coat
Maintain maximum layer thickness without fail. Use Elastifies the complete
Must always next be overpainted with clear lacquer. paint structure on
plastics.
Application Drying accelerator Addition Up to 25%
Use Accelerates drying with Spray gun HVLP 1.7 - 1.9 mm
only minimal reduction in
working life Spray pressure 2.0 - 3.0 bar
Working life approx. 5 hours at 20°C Layer thickness 50 - 60 µm
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Application Elastifier additive in top Application Matting additive in clear
coat lacquer
Drying approx. 16 hours at 20°C Semi-gloss addition Up to 25% in the paint
without hardener and
thinner
60°C
Silk gloss addition Up to 35% in the paint
approx. 8 minutes
thinner
Medium wavelength
Silk matt addition Up to 45% in the paint
minutes
thinner
Application Matting additive in solid Spray gun HVLP 1.2 - 1.3 mm
paint Spray pressure 2.0 - 3.0 bar
Use Elastifies the complete Layer thickness 50 - 70 µm
paint structure on
plastics. Drying approx. 8 hours at 20°C
Semi-gloss addition Up to 25% in the paint approx. 30 minutes at
without hardener and 60°C
thinner
Note:
Silk gloss addition Up to 35% in the paint
• When mixing, first put in the matting additive,
then the hardener and thinners.
thinner
• Stir immediately after adding the matting
Silk matt addition Up to 45% in the paint additive.
without hardener and • Do not store after addition of the matting
thinner additive, storage will change the degree of
Spray gun HVLP 1.2 - 1.3 mm gloss.
Spray pressure 2.0 - 3.0 bar • Also suitable for use on plastics without addition
of elastifier additive.
Application Matting paste
Use Matts, elasticizes and
gives structure to solid
60°C
paint and clear lacquer
Short wavelength infrared during painting of
approx. 8 minutes bumpers or hard plastic.
Medium wavelength Addition 1:1 or 2:1 depending on
infrared approx. 10 - 15 manufacturer in solid
minutes paint without hardener or
thinners.
CAUTION: Do not dry using infrared.
Application Matting additive in clear Spray pressure 2.0 - 3.0 bar

lacquer Layer thickness 50 - 70 µm
Use Elastifies the complete Drying approx. 6 - 10 hours at
paint structure on 20°C
plastics.
60°C
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Application Matting paste Polishing materials.
Short wavelength infrared Polishing means microfine sanding. For this
approx. 8 minutes reason, polishes must only contain abrasives, and
Medium wavelength no silicones.
infrared approx. 10 - 15 During polishing repair, a good shine is achieved
minutes through the step-by-step use of polishes, starting
with a highly abrasive polish and ending with a
Note: polish having very slight abrasive action.
• The paint must not be filtered. Polishes are available in graduations from coarse
to fine.
Application Anti-silicone additive
Use Prevents silicone craters
Abrasives
Addition 2% to maximum 5%
Please refer to the "Tools" chapter for information
Note: on abrasives.
• Only add away from the paint cabin and
immediately remove contaminated cloths.
• If anti-silicone additive is used in the first coat,
then it must be used in the following coats, and
in at least the same proportions.
Additive materials
Variety of adhesive tapes
For profile, fine and large area masking work.

Properties:
• Withstands heat.
• Withstands water-based paint.
• Accepts paint.
• Easily removed without leaving adhesive
residues.
Masking film.
For masking of large areas on vehicles.

Properties:
• Accepts 2-component and water-based paints.
• Withstands heat.
• Withstands water spray and condensation.
• Withstands solvent.
• Easily cut.
• Environmentally friendly and can be recycled.
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Paint Repairs
General information Clean the area of the damage
There is a great difference between painting in

production and repair painting.
In production, only the bodyshell is painted, it has
no trim, upholstery or assemblies. Because of this,
other paints, tools and processing techniques can
be used.
In contrast to that used in production, paint used
in the workshop must dry at low temperatures.
Plastics and the vehicle electronics must not be
subjected to temperatures greater than 70°C.
The painting process in the case of repair work
consists of two phases: Clean the damaged surface thoroughly, to allow
the extent of the damage to be seen. Use silicone
• Pre-treatment of the surface for corrosion
remover to produce a grease-free surface.
protection and the smoothing of irregularities.
• Top coat application. NOTE: The treated surface must be rubbed with
a clean dry cloth before the solvent evaporates,
The precondition for a professional paint finish on otherwise there will be no cleaning effect.
a vehicle is the permanently maintained cleanliness
of work spaces, tools and equipment, Effective de-greasing is important not only before
the application of paint, but also before all sanding
Original materials must be worked according to the stages, for two reasons:
manufacturer's instructions, so that no problems
arise in the processing nor during drying. • During sanding of grease contaminated
surfaces, globules may form with the sanding
The room temperature must be 20 - 25°C and the dust. Sanding marks will occur and the sanding
humidity must be low. Temperatures which are too medium quickly becomes unuseable.
low or too high can lead to porosity, poor flow and
• Oil and grease are embedded by the action of
boiling. High humidity leads to paint damage such
the abrasive particles, and are then very difficult
as tarnishing of the paint film (matt film), adhesion
to remove.
problems and craters.
Establish the area of damage and the repair
stages. In doing so, establish how much
Pre-treatment of the surface disassembly work must be undertaken. Perform a
color test at this stage.
Perfect preparation of the subsurface is the
precondition for a brilliant paintwork result. Faults Mask off the area of the repair ready for
in the preliminary stages delay completion and preparatory work.
cause unnecessary extra work. The working steps
Sand out the damage location
described here demonstrate how important it is to
follow these instructions step by step.
NOTE: Thorough cleaning of the vehicle and
especially of the area being repaired is particularly
important because of the danger of contamination
of the paint.
2011 Fiesta 08/2010 G506672en

When sanding, produce smooth transitions from NOTE: Avoid sanding through to the bare metal.
the painted area to the bare metal. Points which are sanded through must be retreated
Use an eccentric sander and P80 or P120 abrasive with primer filler.
sheets. Finish off sanding with P150 or P180. The Stopper application
remaining adhering sanding dust must be
completely removed.
Cleaning, de-greasing
Pre-sand the hardened stopper using an eccentric

sander and P80 dry, then final-sand using P120 -
P140 dry. Clean the sanded surface using silicone
Use silicone remover to thoroughly clean the remover.
surface in order to remove grease residues, sweat Apply 2-component stopper to the filled surface.
from the hands and other contamination. The stopper compound must only be applied thinly.
NOTE: Use a solvent test to establish whether the NOTE: Use of a testing powder is recommended
old paint can be etched. Apply 2-component so that the sanding process can be more easily
thinners to the damaged area using a clean cloth checked.
and rub lightly for about 1 minute. If the
subsurfaces can be etched away, special Apply filler
pre-treatment is necessary. See "Tips and Tricks"
Apply primer filler
Filler can now be applied to the dried repair area.

Choose the correctly toned filler according to the
manufacturer's instructions.
Before applying stopper, apply primer to the
NOTE: Alternatively, filler with the correct tone can
sanded and bare surface.
be mixed with the aid of colour matching cards.
Allow the primer to dry and then lightly sand by
hand using P220 - P400 dry.
NOTE: Most stopper can be applied directly to bare
metal. But application of a primer filler provides
better corrosion protection.
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Sand the filler. mixture proportions, layer thickness, viscosity,
drying time etc.
First of all the work area is carefully masked ready
for paint application. The correct adhesive materials
and techniques must be used so that no hard
transitions and edges are created during painting.
NOTE: The chapter "Tips and Tricks" gives
in-depth information on masking work.
Thoroughly check the surface once more and
rub-off with a dust-bonding cloth.
NOTE: Once more check the paint material and
that the spray gun is correctly adjusted before
The working area is expanded by applying new applying the paint.
masking. This makes it possible to even out the
transition from the damage area to the vehicle Paint application
paintwork.
NOTE: The primer filler must be carefully sanded.
Faults in the primer filler layer will be visible in the
top coat.
The sanding process consists of two stages.
Coarse sanding levels out the surface of the filler
primer. Fine sanding ensures the necessary
surface structure which allows the top coat to
adhere well and cover sanding marks.
Sand the filler using the eccentric sander and P400
- P500 used dry. Clean the sanded filler finished
surface using silicone remover. The base paint is applied in two or three steps.
The painted area is matted using a fine matting First of all only the repair area is painted with the
sponge, and then thoroughly cleaned. first paint application.
Surface ready for paint Flash off
The surface which has been repaired and then Allow the paint application to flash off until the
prepared according to the manufacturer's surface has a matt appearance. So that the
instructions is now ready for basic paint application. transition to the original paint is optimally created,
the next paint application is applied to a wider area.
Top coat application After the base paint has dried for the specified time,
the clear lacquer is applied. Next the transitions to
It is important for a good paint result that the the original paintwork are treated with fade-out
recommended process data is adhered to, i.e.
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remover. This removes the spray mist and forms The following faults are included:
an ideal paint surface. • Loss of gloss.
• Sanding scores.
Repair stages for repair painting • Heavy paint runs.
• Large dust and dirt inclusions.
The required time and material data is divided into
four painting levels for calculations concerning The scope of the work is as follows:
repair painting. Proceed according to these • Sand the surface.
divisions for every calculation. • Sand out paint damage and faults.
Level 1 - Painting of new components • Treatment of small areas which have been
sanded through.
On new components, all inner surfaces, seams • Masking work (when painting an installed
and edges which will no longer be seen after component).
assembly must be primed and pre-painted.
• Apply top coat according to the painting process
NOTE: The cathodic dip primer must not be sanded (one or several coat process).
away. Cleaning with silicone remover or light • Dry the top coat and perform finishing work.
sanding of the primer is all that is required.
Job steps: Level III - Repair painting with stopper applied to up
to 50% of the surface.
• Wash off, prime and pre-paint inner surfaces,
seams and edges which cannot be reached at If in addition to painting, work with stopper
all or only partly after the component is installed. application must be performed, then the repair
• Sand new component with P280 - P320 or a levels III or IV must be used.
fine sanding pad. In repair level III, apart from painting the complete
• Clean subsurface with silicone remover. bodywork surface, partial stopper work is carried
• Carry out masking work (when painting an out on up to 50% of the surface to be painted. The
installed component). necessary primer and filler work are also included.
• Apply one spray run of filler, dry. The following damage must be rectified in this level:
• Sand the filler. P1200 wet or P500 dry. • Slight panel unevenness.
• Clean filler application with silicone remover. • Damage due to corrosion.
Then the prepared surface can be painted with • Dented body surfaces.
solid or 2-component paint. • Weld locations.
If the new part has mild transport damage, this • Deep scores or scratches.
must be rectified beforehand. The scope of the work is as follows:
To do so, add the following steps: • Fine sand pre-treated bodywork surfaces (e.g.
• Grind out the scratch. lead-loaded areas).
• Finely sand the surrounding surfaces. • Sand out existing damage.
• Use a steel cleaning agent to thoroughly clean • Perform all necessary masking operations on
and then rub dry. the vehicle.
• Apply corrosion protection primer to the bare • Apply primer.
areas. • Partial stopper application on up to 50% of the
surface to be painted (two to a maximum of
Level II - Top surface painting (color tone matching) three stopper applications).
Complete bodywork surfaces which are to be • Fill the repair area.
painted without the need to apply stopper belong • Apply stone chip protection (when present in
to this group. In addition, surfaces with faults in the production).
top coat surface which cannot be removed by • Apply top coat according to the painting process
polishing. (one or several coat process).
• Dry the top coat and perform finishing work.
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Level IV - Repair painting with stopper applied to A small eccentric sander can be used for more
more than 50% of the surface. extensive working areas. When doing so, first of
all put the eccentric sander in place and then switch
In repair level IV, apart from painting the complete
it on, so that the danger of sanding through on
bodywork surface, partial stopper work is carried
edge is reduced.
out on more than 50% of the surface to be painted.
The necessary primer and filler work are also Finally polish the sanded area to a high gloss with
included. suitable polish. To this end the various
manufacturers recommend materials and process
The following damage must be rectified in this level:
techniques which are specially suited to their
• Damage due to hail. products.
• More extensive stone chip damage.
NOTE: The polishing is to be done in the same
• Extensively dented body panels. way as that used to remove swirl marks.
• Sectional repairs with large weld seams.
• Surfaces with severe corrosion damage. Polish
The scope of the work is different to level III

because of the partial application of stopper to
more than 50% of the area to be painted. In
addition, more extensive sanding work is usually
required.
Polish
In order to achieve faultless quality, it is sometimes
necessary afterwards to polish a newly painted
surface.
Even after the most careful painting, it sometimes NOTE: Before using the nap sponge for the first
happens that dirt inclusions and paint runs occur time and after any long pauses in working, dampen
in work with top coat or clear lacquer. Before the nap sponge with polish.
polishing, such paint faults must be removed with
Job steps:
the sanding cylinder ("Finiball") and hand sanding
or eccentric sander in a wet sanding process. • Clean and degrease the area to be polished
using silicone remover.
Sanding cylinder • Apply the polish to the polishing disc and spread
it.
• Place the polishing machine down flat on the
area to be polished and before switching it on,
gently distribute the polish over the underlying
surface.
• Polish out the location for 10 - 15 seconds with
the edge, working with a criss-cross motion.
• Subsequently polish the location for about 10
seconds with the machine laid down flat.
• Wash off and clean the polished location using
the professional polishing cloth and then clean
the polished surface.
The special sanding compound -1- (sanding bloom) • It is absolutely vital to carry out a visual check
for the sanding cylinder is self-adhering and after finishing the polishing procedure. If any
available in grades from P1000 to P2500. swirl marks are not completely removed by the
• P1000 - P1500 for pre-sanding of runs and large first polishing procedure, then process must be
imperfections in the paint. repeated.
• P1500 - P3000 for subsequent sanding of runs
and sanding out of dust inclusions.
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Aids
Cleaning putty
Cleaning putty allows deposits on the paint surface
to be removed easily and gently. The following
paint faults can be removed using cleaning putty:
• Metal deposits and iron dust.
• Paint or color mist.
• Tree resin and tar.
• Insect residues.
The surface to be worked must be thoroughly
cleaned before the cleaning putty can be applied.
Then the surface is sprayed with soapy water. Now
the cleaning putty can be slid over the surface until
all unevenness is removed.
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Painting Plastic Parts

General Elastomers
Although these days plastics can be produced in Elastomers are characterized by high elasticity
all colors and with a matt or gloss surface, painting over a wide temperature range. They have
is often necessary. properties like rubber or a sponge and after
compression or distension they return to their
NOTE: Manufacturer's limitations concerning the original state.
feasibility of painting certain components must
always be observed. Types of plastic
Reasons in favor of applying paint to plastic are: The plastics used in the automotive area:
• Individual coloring, matching the body paint. • ABS - Acrylonitrile butadiene styrene (polymer)
• More gloss and color brilliance through painting. • PA - Polyamide
• Removal of production imperfections. • PC - Polycarbonate
• Protection from atmospheric exposure. • PE - Polyethylene
Nowadays painting plastic presents no problems • PP - Polypropylene
because the materials are known and matched to • PP/EPDM - Polypropylene/ethylene propylene
the paint. In order that the painter can use the diene copolymer
correct painting materials, the type of plastic must • PC/PBT - Polycarbonate/Polybutylene
first be correctly determined. terephthalate
To allow this, plastics are marked on the rear in • PBT/PC - Polybutylene
accordance with the recommendations of the terephthalate/Polycarbonate
Association of Vehicle Manufacturers. • PUR - Polyurethane
Once the type of plastic is determined it is an easy • GRP - Glass reinforced plastic
matter to assign special paint recommendations,
matched to that particular plastic. Unmarked NOTE: PE and PP are plastics which cannot be
plastics require knowledge of materials so that a painted, or can only be painted using special
correct choice of paint materials can be made and techniques.
the component can be reliably painted. As well as the pure plastics, so-called 'blends' are
also used. This means combinations of different
plastics. If we were dealing with metals they would
Plastic groups be called alloys.
Thermoplastics Plastic identification
When warmed these undergo a reversible Normally the identifier is marked on the plastic
transformation into a plastic deformable state and components used in vehicle construction.
once cooled they maintain their shape. They
consist of string-like (linear) or only slightly One method to determine the plastic group is the
branched molecular chains. sanding test. In this a place is chosen which will
not be visible later, and the finger belt sander is
Thermosets used to sand the plastic.
Thermosets are hard and have the form of a The plastic group can be determined using the
close-meshed network in all directions. They do pattern left by the sanding and the dust:
not undergo plastic deformation, are especially • Thermosets produce a white dust.
resistant to chemicals, are difficult to swell and are
• Thermoplastics smear and do not produce dust.
insoluble. At normal temperatures they are hard to
brittle. At first the material does not undergo any The plastic group can be determined by a sound
change when heated, but when it reaches a critical test:
point, the thermoset is totally destroyed.
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• Degree of hardness - the higher-pitched the • Afterwards clean with antistatic cleaner or
sound, the harder the plastic. antistatic cloths.
• Elasticity - the more muffled the sound, the • Apply the bonding agent.
higher the elasticity of the plastic. • Apply elastic filler. After it has dried, sand and
clean.
Cleaning plastic
• Apply one coat Uni-paint with elasticizer
Plastic components are manufactured using additive. For two layer painting the elasticizer
complicated moulds and presses or other highly additive is in the clear lacquer.
engineered tools, mostly using an injection
moulding process or reactive injection moulding NOTE: Follow the paint manufacturer's guidelines
process. during all work.
In order to be able to remove the component from Work process for thermosets:
a particular tool, a separating agent is used, which • As a rule, thermosets can be handled in the
in some cases adheres very strongly to the plastic. same way as normal body components.
This separating agent on the plastic components Work process for PUR soft foam:
must be completely removed before any surface • The work process is the same as for
coating is applied. thermoplastic.
Warm storage (tempering) before actual cleaning • Instead of using bonding agent, a filler wash is
brings the following advantages: applied to close the pores of the PUR soft foam.
• The separating agent sweats out of the plastic. The primer which has been applied to a primed
• Tensions in the plastic are released. new component can vary greatly. If no
manufacturer's data is available, the composition
• Air inclusions can be recognized and removed.
and suitability for further working must be tested.
Intensively clean the item several times using a
Painted components with an already ascertained
pad and fresh cleaning agent.
and intact paint coat present no problems for
NOTE: A single wipe, even with cleaning agent, is possible repainting. After sanding and careful
not usually sufficient in most cases. Clean textured cleaning with plastic cleaner or thinners, painting
components with the aid of a soft brush. can be done directly.
After cleaning, it is absolutely vital that cleaning
agent absorbed by the plastic should be expelled Unknown primer
by tempering again. If the ventilation is good and
the room temperature is about 20°C the solvent When dealing with unknown substrates it is
can be evaporated away by overnight storage. important to carry out an adhesion test on the
existing paint before any repainting is attempted.
Painting new components First of all a mechanical test must be carried out,
for instance using a lattice cut and tear-off band.
It is absolutely vital that the substrate of an If the adhesion of the old paint is not acceptable,
unpainted new component is free of separating it must be mechanically removed and new paint
agent. Paint can only be applied directly to very finish applied.
few plastics. The plastic must first be identified If the adhesion is acceptable, then an etch test is
exactly and then worked with a repair system which performed using 2-component thinners. If no
is matched to the type of plastic. In most cases a etching can be detected in this test, application of
plastic etch primer must be applied as adhesion the the paint finish can be started directly.
base to all plastics which can be painted. Otherwise the old paint must be removed and a
NOTE: Plastics have a tendency to become new paint finish created.
electrostatically charged. This can easily cause With the help of universal or special plastic primers
contamination during painting. Special antistatic and with only a few materials complementary to
cleaning cloths prevent electrostatic charging. those previously present anyway, the painter can
Work process for thermoplastics: now apply a long-lasting paint finish to all popular
vehicle attachments made of plastic.
• Thoroughly clean the surface.
• Temper the plastic.
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Paint faults on plastic substrates Paint damage caused by blisters, craters,
sink holes
NOTE: Paint faults are fully described in the
chapter Paint Defects and Damage. Cause/damage pattern:
The most common paint faults which can occur • Painting on PUR plastic which was not painted
when painting plastic components and the methods in production.
of repair are briefly described. • Surface of the plastic material too porous.
• Flash-off time not adhered to.
• Drying temperature too high.
Discoloration
• Moisture in plastic material.
Cause/damage pattern: • Layers too thick.
• Plastic material is not suitable for painting. Repair of damage:
• Incorrect bonding agent. • Clean the damaged area, sand, re-isolate and
• Paint used not solvent resistant. paint.
Repair of damage: • Remove the paint layers and re-paint.
• Repaint using suitable materials.
• Install a new unpainted component. Crack formation
Softening • Overexpansion of painted PUR plastic
components.
• Use of unsuitable paint materials.
• Substrate not carefully cleaned.
• Paint materials not suited to each other or
• Air humidity too high or working temperature
incorrect mixture ratio.
too low.
• Drying time incorrect (too short). Repair of damage:
• Materials for substrate not correctly matched to • It is not possible to repair overexpanded PUR
each other or not mixed correctly. plastic components.
• On other plastics, sand away damaged layers,
Repair of damage:
isolate and repaint.
• Dry out, sand, re-isolate and paint.
finish.
Paint damage caused by detachment, poor

adhesion
• Insufficient paint adhesion between top coat
and filler. The whole of the paint finish detaches
from the plastic.
• Plastic not cleaned sufficiently, not or
inadequately tempered.
• Unsuitable cleaning agent or materials used.
• Poor or lack of intermediate sanding.
• Paint finish underbaked or overbaked.
Repair of damage:
finish.
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Spot Repairs
General application may cause tear-off edges to appear in
clear lacquer. Only certain application areas are
In general, partial surface painting at a point is recommended.
called a spot repair. Using this technique, minor NOTE: The final decision on whether to spot repair
paint damage can be resolved economically and or paint the component must be made by an expert.
to time.
Application areas:
• 2-layer paint.
Advantage of this method • Depending on the damage zone, paint damage
up to a diameter of 3.5 cm or a length of 10 cm.
Because this application remains confined to the
area of the damage, it is often unnecessary to • Scratches.
remove components or color match against • Clear lacquer application up to an area of DIN
neighboring components. The material used is very A4 max.
much reduced because only a part of the repair • Smaller areas which are optically broken up by
area is coated. other components such as trim strip, tail lights,
swage lines and edges.
• Boundary zones and edge areas of larger
Practical application areas components.
Only occasionally can satisfactory results be The best application areas have proven to be
achieved in the centre of larger surfaces and/or on optical break lines such as corners, narrow
difficult colors. In addition, unprofessional surfaces, fenders and wheel arches.
Because of their locations, the violet colored areas the rest of the areas are not suitable for spot
are the most suitable for spot repair painting. The repairs.
turquoise areas are only marginally suitable and
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Repair process Sand out
Perfect preparation of the subsurface is the

precondition for a brilliant paintwork result. Faults
in the preliminary stages delay completion and
cause unnecessary extra work. The working steps
described here demonstrate how important it is to
follow these instructions step by step.
Illustration of damage
Sand out the damaged location using P180 - P320.

Only small sanding blocks and small sanding
machines must be used, so that the area of the
repair remains as small as possible.
Sanding is completed by rubbing down the
surrounding surface with a fine sanding pad or
P1000 paper. Remove sanding residues and clean
the repair area with silicone remover. The
A typical case for spot repair is a small stone chip peripheral zone must then be masked for
on the fender. application of the filler.
NOTE: The size of the repair area must be kept
Cleaning as small as possible (maximum size DIN A4).
Filling
First of all the component is thoroughly cleaned

using silicone remover and refurbished using
abrading and polishing paste. This re-creates the The filler layer is applied in stages. First of all, filler
original degree of shine and ensures exact color is only applied to the location which has been
matching on the touch-up surface. sanded away. After a wait time for flashing off, the
second coat is applied so that it spreads over onto
the existing paintwork.
The filler must be dried according to the instructions
of the material supplier.
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Rubbing down Dry
The repair location is now rubbed down with P400 Now dry the clear lacquer according to the
- P500 and the bordering surface with P2000 - manufacturer's instructions using an infrared gun.
P4000. Remove sanding residues and clean the
repair area with silicone remover. Polish
Paint
Polish the component using a polisher and polish

and check the polished area for any swirl marks
Before painting, clean the area for the final time which may be present. Polish away any swirl marks
using a dust-bonding cloth. Then apply the basic which are present.
paint in thin layers using a spray gun until enough
coverage is achieved.
Dirt inclusions
After drying, apply clear lacquer in 1 or 2 coats
(depending on product). In doing so, spray so that Sand out
only the newly applied basic paint is completely
covered. Finally a touch-up thinners is sprayed
over the edge of the clear lacquer to dissolve the
clear lacquer spray mist.
Minor damage can be removed with a small

sanding machine or preferably with an eccentric
sander with P1500 - P2000. Very fine spray mist
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can be removed using P2000 - P4000 paper and
a larger eccentric sander.
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Corrosion Prevention
General such as sodium chloride used as road salt
accelerate the corrosion process.
Although corrosion protection measures and • Mechanical damage such as stone chips and
painting processes in production have reached a scratches which penetrate through to the steel
very high technical standard and will be panel.
continuously developed further, in the long term • Lack of care by the vehicle owner of the painted
corrosion on a vehicle cannot be totally avoided. and corrosion proofed surfaces or areas on the
Further demands are therefore made of the paint vehicle.
specialist besides his knowledge of normal
repainting of vehicles which have been repaired • Unfavorable weather or environmental
after an accident, in addition specialist knowledge conditions, as may occur in areas with high
is required for assessing and rectifying damage humidity, high salt content in the air or serious
due to corrosion. air pollution due to aggressive gases and dusts.
During repair painting, take care over the In the case of mechanical damage, formation of
maintenance and re-creation of the corrosion rust can often be seen, beginning to spread into
protection applied in production, in view of the the painted surface from a point (stone chip) or
long-term warranty on Ford vehicles. Only those from a line (scratch). If these faults are not
repair materials which are approved by Ford may professionally rectified in good time, the result is
be used for body repair work and repair painting. rusting through from the outside to the inside.
Rusting penetration from the inside to the outside
For detailed information on corrosion protection occurs when for instance the cavity protection was
measures during body repairs, please refer to inadequate.
chapter 501-25.
Furthermore, information on corrosion protection Operations after painting
measures is repeated in individual chapters of the
paint manual. NOTE: The manufacturer's instructions must be
In particular, pay attention that the layer followed when working with the various corrosion
thicknesses specified in production are maintained. protection materials.
The complete system of solid one-layer on • After painting, treat all cavities in the repair area
galvanized steel panels must equal at least 90 µm with cavity protection wax. In doing so, pay
and the total system of two-layer on galvanized particular attention to the weld seams. In
steel panels must equal at least 105 µm. dead-end applications with a panel insert, the
It is important that sealing operations, as far as cavity protection wax must be applied so that it
they are necessary, should be undertaken after also reaches the area of the panel insert.
the application of the paint to specification, in order • Seals which were applied in production and not
to ensure the best corrosion protection. All over painted must be reapplied. Seals protect
components which form hollow cavities such as vulnerable parts of the bodywork, keep moisture
pillars, rails, side components etc. must be away, reduce wind and road noise and dampen
provided with a coating of cavity protection wax. vibrations.
Causes of corrosion • Apply transparent wax.
Corrosion of steel is an electrochemical process

during which the steel combines with oxygen. The Definition of the degree of rust
following factors lead to corrosion:
In workshop practice, in order to be able to carry
• Acidic compounds contained in the air, such as out a consistent and objective evaluation of the
carbonic acid and sulphur dioxide, combined scope of the damage, a degree of rust on the scale
with oxygen from the air and/or water. Salts of 1 to 5 is determined by the DIN 53 210 standard.
The main criterion here is the extent to which rust
exists under the paint structure. It is determined in
millimeters (mm).
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Underlying rust grade: R1 < 1 mm
Corrosion starting with up to 1 mm of rust
underlying (in the form of a spot or a line).
The damage can be rectified by cleaning the
defective location and mechanically removing the
underlying rust. For a small extent, apply a primer
using a brush and allow it to dry. Touch-up the
location with a paint pen or provide a new paint
coating.
Underlying rust grade R2 < 1 - 2 mm

Advanced corrosion with up to 2 mm underlying
rust.
Rectifying the damage:
• Clean the defective location.
• Remove the underlying rust mechanically down
to the paintwork carrier.
• Apply 1-component filler and then 2-component
"Vario" filler.
• Provide the damage location with new paint coat
on visible outer surfaces. Only locally touch-up
areas which are not optically conspicuous.

More advanced corrosion with up to 4 mm
underlying rust. The damage must be rectified in
the same way as for R2. A permanent cure of this
type of damage pattern is still just possible

Notably advanced corrosion with up to 5 mm
underlying rust. The damage must be rectified in
the same way as for R2. If it is found that for whole
areas this is only possible with a great deal of work,
or is not possible at all, then a new component
must be used.
Underlying rust grade R5 > 5 mm

Extreme corrosion, with more than 5mm underlying
rust (panels, flanges or load-bearing components
partially rusted or rusted through).
Such damage can no longer be repaired because
in many cases the constructional strength of the
component can no longer be produced. The risk
in making a repair is too great. Install a new
component and paint it.
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Color Identification and Chromatics

Basic color theory in) and other components are reflected (sent on).
The components which are reflected produce the
In order to achieve optically perfect painting results specific color impression.
it is vital to understand the physical principles of
the origin of color impression.
Color
Color itself is a sensory perception.

This perception arises through the combined effect
of the following components:
• Light (sunlight or artificial light irradiates the
object).
• Surface of the object (reflection from the object
of certain constituent parts of the light).
The colors as we see them are the result of a
• Eye (perception of the reflections from the combination of reflected colors from the spectrum.
object). Physically speaking, these are electromagnetic
waves with different wavelengths (and
frequencies). The healthy human eye can
recognize wavelengths between 0.36 µm (violet)
and 0.78 µm (red).
If all the perceptible wavelengths of the spectrum
impinge on the human eye at the same time, the
impression of white light is produced.
Additive and subtractive color mixing
Because the sensory impression of color is

produced by all three of these components, it is
dependent on the type, quality and function of the
individual components. Practical examples make
this clear:
• If a particular article is subjected to artificial light,
then it gives a different impression of color to
that which it gives in sunlight.
• An object with uniform color but different surface
textures appears to have different colors
(grained or ungrained dashboard).
Additive color mixing is the combination of light
• A person with perception disorder
from different sources to give white. Different
(colorblindness) cannot recognize certain colors
intensities of the additive primary colors red, green
or distinguish between them e.g. red-green
and blue allow millions of different colors to be
weakness).
represented (RGB colors).
In turn the type of color is determined by the light
Additive color mixing is always therefore used when
absorption ability of an object. Light shines with all
light should enter the eye directly (without reflection
color components (spectral colors) onto an object,
off an object). Such as in the case of computer
certain components of the light are absorbed (taken
monitors or overhead beamers.
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In addition, black and/or white may be necessary
to produce a particular color shade.
• White makes the color shade lighter.
• Black makes the color shade darker.
• With black and white the color shade becomes
more dreary or greyer.
Metamerism
Metamerism is the name of the effect which occurs

when two colors appear identical in a particular
Subtractive color mixing means mixing the primary light (e.g. artificial light), but the colors appear
colors cyan, magenta and yellow to form a desired different under another light source (e.g. daylight).
color (CMY colors). The cause is the fact that the human brain, aided
Subtractive color mixing is used when light should by the eyes, does not evaluate the wavelength,
enter the eye of an observer after reflection from instead it evaluates the spectral intensity of the
an object. Such as happens with painting or in reflected light.
printing. It is for this reason that color matching in practice
must only ever be performed in daylight, or under
special artificial light which is based on daylight.
Oswald color circle
Metallic and pearl pigments
Colored paints achieve their color effect by the
addition of pigments. Pigments are colored, solid,
very fine organic and inorganic particles which are
insoluble in the binding material.
Metallic pigments
Aluminum platelets are added as pigment to form

metallic paint.
The Oswald color circle is based on subtractive

color mixing, and enables the behavior of paints
when they are mixed together to be represented.
Colors lying opposite each other are
complementary colors and should not be mixed
together as this will produce a dull (i.e. grey) shade.
If green is added to red, the red becomes greyer,
not greener.
Color shades which are side by side are partner
colors and produce a mixed color shade. For
instance, mixing red and blue produces a pure
violet.
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Pearl pigments
The basis of pearl pigments is formed by mica,

which is metallized with a silver or gold layer.
Depending on the angles of light and observation,
the mica platelets reflect different proportions of
light. Because of this, the color of the paint appears
to the observer to change.
Pearl pigments produce a colored and light-dark
reflected light effect.
Color codes and their determination on

Depending on the size and shape of the aluminum Ford vehicles
platelets, different metallic effects can be achieved:
• Cornflake aluminum (1) causes very strong It is necessary to determine the correct color shade
dispersion because of rough edges, low of the original paintwork in order to perform a
brilliance, very low flop and produces grey-silver professional and perfect paint repair.
shades. The original paint color shade can be found by:
• Dollar aluminum (2) causes hardly any • Inspection of the vehicle type plate with the color
dispersion because of the smooth surface, high code stamped on it.
brilliance, produces very light, almost white – Later design
silver shades.
– Earlier design
With metallic paints however, only a light-dark light • Color shade catalog or color shade system of
reflection effect occurs. the manufacturer.
Colored metallic paints are produced by the extra • The bare bodyshell plate with color designation.
addition of color pigments to the metallic paint.
Type plate
Type plate - location on Ford vehicles:

• Right-hand B-pillar - door rebate
• Left-hand B-pillar - door rebate
• Hood lock panel
• Left-hand vertical edge of inner front wing
• Right-hand vertical edge of inner front wing
• Right-hand engine compartment side member
• Left-hand bulkhead
• Right-hand bulkhead
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• Luggage compartment interior
• Inner rear panel - luggage compartment
On the newer type plates, the color code is given

in the left-hand column, at the penultimate position.
The type plate gives the color code in the last row.
Color shade catalog or color shade system

of the repair paint manufacturer.
The repair paint manufacturers offer a variety of

possible systems for the determining the production
color shade of motor vehicles. There are electronic
systems, color card systems and manuals for the
determination of color shades.
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Most repair paint manufacturers use the following Comparison of the results of both methods
systems: increases the certainty of using the correct original
• A tabular system based on the following color shade and its formulation.
parameters: Additional certainty can be achieved during color
– Color code shade determination by making a color sample
– Make plate. Here it is however important to apply the
complete paint structure with base paint and clear
– Model
lacquer onto a sample plate (1) in order to carry
– Build year out a color shade and color coverage test.
– Color or color name
– Ancillary codes
• A system with color cards based on the following
parameters:
– Make
– Color shade
– Build year
The color shade comparison is done by comparing

the vehicle paintwork with the sample plate (1).
The color coverage test is possible by using the
black test stripe (2): If the test stripe (2) is still
visible after test painting of the sample plate (1),
the coverage is not good enough.
By using this determination of the original color
shade, the formulation and information on any very
slight fine adjustments which may be necessary
can be established.
Bare bodyshell plate
The bare bodyshell plate is located:

• On the hood lock panel.
• Near the type plate.
The color name is stamped on in the last row.
Because of the many parameters used, in a tabular

system the color shade can also be determined by
the lack of a parameter.
When using the color cards, emphasis is placed
on matching of the original color shade with the
color shade samples. For this reason this method
is very helpful when the other parameters are not
available.
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Matching tinted filler to the color code
NOTE: Color samples must always be made from
the same materials as the subsequent repair
painting. Perform color shade matching in the fully
hardened state, in natural light or under suitable
artificial light.
Various tinted fillers are used during factory
painting. In order to achieve the exact color shade
of the factory applied paint, attention should be
paid that the correctly matched fillers are used.
The repair paint manufacturers offer suitable

precolored primers. The use of filler color cards
allows the matching color shade to be determined.
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Tips and Tricks

Comparing paint structures
Masking the vehicle
It may happen that an area remains visible,
especially when the area of the repair is small. The Masking and covering work are among the most
reason for this is the structural variation in the paint important preparations required to achieve a high
surface at the repair location compared with the quality paint finish. Paint application onto
original paint finish. The original paint finish has a neighboring components, paint mist and sharp
slight orange peel effect while the repair areas is paint transitions are quality faults. For this reason
extremely smooth. it is extremely important to take special care and
This effect can be reduced by fine sanding using to use suitable masking materials.
P3000 of the area around the repair location and NOTE: When water based paints are used, all
then polishing. materials must be stable towards water.
Plan the masking work:
Etching substrate • Determine the sequence of masking work.
Sometimes after masking film has been applied,
If the substrate can be etched during the solvent it is difficult or impossible to reach certain areas.
test, suitable preparation must be done.
• Prepare the masking material.
Job steps: • Start with small difficult areas.
NOTE: Follow the manufacturer specific Pay special attention to the areas of profiled seals,
instructions. edges, openings and paint transitions.
• Sand the damaged area extensively using an
eccentric sander and P80 or P120 abrasive
sheets. Finish off sanding with P150 or P180. Masking tape
• Remove the sanding dust and clean the area
of the damage using silicone remover. Masking tape is available in various widths for
special application areas. In practice however, a
• Apply polyester stopper to the bare panel and wide tape has proved best for almost all areas,
to the damaged area. also taking into account the time required for
• Sand the dried polyester stopper to an even masking work.
surface using P80 - P150. Finish sanding using
P180 - P240. If required apply more stopper, NOTE: Use of differing masking materials is often
again only on the bare panel. much more time-consuming.
• Wet sand the residual old paint finish using Advantages
P600 - P800. Transitions with P400 - P600. • Good coverage. Narrower tapes must often be
Clean with silicone remover. applied in several layers.
• Prime bare metal areas with acid primer. • More resistant to tearing.
• After the acid primer has been left exposed to • Wide tapes can be applied deep into joints and
the air for the correct evaporation time, apply therefore protect from paint mist and
2-component primer filler in thin layers over the contamination.
complete repair area, leaving enough air • Removal is often easier.
exposure time in between coats.
• After the filler has dried, sand wet with P800 or
sand dry with P400. Sanded through areas must Masking film
be covered again with 2-component Nonstop
filler primer. Transparent plastic film has become accepted as
a practical method to mask large areas of a whole
Another possible method of preventing etching of
vehicle. It can quickly and easily be applied to the
the substrate is to use waterbased primer and filler
vehicle from the roll.
materials.
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NOTE: Only mask the vehicle when it is dry. Edges/openings
Moisture under the film can lead to matt paint in
the drying process. Smooth paint transitions can be produced by
positioning adhesive tapes.
Using masking film
• Clean the vehicle before masking it. NOTE: Pull the adhesive tapes away immediately
after the paint has been applied and check the
• Pull the film over the vehicle. Because of the
paint transitions.
static charge, the film lies on the vehicle like a
second skin.
• Cut out the repair area using the film knife and
then mask it.
Other ways of masking a vehicle are:
• Masking using masking paper.
• Painting cloth (mostly used during filling work).
Profiled seals
If it is not possible to remove a profiled seal, then

it must be masked in such a way that no edges
can form due to paint accumulation. Item Description
To do this, the seal is lifted slightly and masked. 1 Vehicle edge
The following techniques are possible:
2 Adhesive surface
3 Masking paper
Possible variations
• At edges apply one strip of masking tape half
on the area not to be painted and mask using
a second strip.
• On surfaces, two masking strips can be
attached, each affixed by half their adhesive
surface. The adhesive strip which arises is then
applied with one half on the edge of the area to
be painted. The other half is aligned and fixed
in addition in the curves.
Item Description • Affix masking paper on one side over the area
to be painted. Double back the masking paper
1 Masking tape with plastic strips and secure it.
2 Sealing lip • Affix round profiled foam at the edge of the area
to be painted using masking tape.
3 Sandpaper with masking tape
Foam strips are suitable for affixing to openings
• Laying a string or cord under the seal. Suitable such as door gaps.
for soft and elastic seal lips.
• Special masking tape with plastic strips for hard
seal lips.
• Instead of using plastic strips, fine sandpaper
cut into strips can be inserted and secured using
normal masking tape.
• If the seal can be easily displaced, normal
masking tape can also be used.
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applied to the surface. The transition area is then
alternately sprayed and polished until a perfect
transition surface is achieved.
Paint faults on soft plastic components where
elasticizer additive has been used in painting must
be wet sanded using grade P2000 - P2500 paper.
In doing this the sanding location and the
surroundings are sprayed with temperature
reduction spray and the paint faults sanded out by
hand. Afterwards the location is polished as
described above.
NOTE: Choose a suitable profile diameter. A profile

which is too thick will protrude from the opening, Paint plane
one which is too thin will leave a gap.
Dirt inclusions and paint runs can be removed with
Clean the door opening well and affix the matching the sanding cylinder ("Finiball") and hand sanding
shape. or eccentric sander in a wet sanding process.
Another practical tool for removal of paint faults
Color shade problems which lie proud of the surface is the paint plane.
NOTE: Guide the tool carefully with the minimum
If a vehicle color shade is taken from a vehicle on of force. It must not tilt, otherwise more serious
a hot summer day and the mixed color applied, damage may easily be caused.
this may cause color shade problems. Some colors
change so much at higher temperatures that it can
lead to an incorrect result. Red color shades are
particularly prone to this shade behavior.
This means that color determination should always
be done on the bodywork when it is at about the
same temperature as the later working temperature
will be. The best temperature of the item is between
15° and 25° C.
Isopropanol and water

Painted surfaces are very easily cleaned using a
mixture of 70% water and 30% isopropanol (can This tool allows paint faults to be carefully removed
be obtained through a laboratory supplies specialist in shavings. Afterwards the surface must be
or a pharmacist). polished using suitable materials.
Temperature reduction spray Shading
If finishing work must be performed on touched-up Even when all the rules, steps and corresponding
surfaces and newly painted plastic parts, problems instructions have been followed concerning
may arise. The paint and the transitions are not possible shades, it may happen that the mixed
yet fully hardened. color shade does not exactly match the vehicle
color.
NOTE: When working with the polishing machine,
make certain that each operating run lasts no In these cases, shading must be done. Because
longer than about 5 - 10 seconds, in order to there is no fixed formula for this, experience and
prevent the paint becoming warm. a trained eye are important. Some rules must be
followed for shading.
Even so, in order to be able to polish over
transitions, temperature reduction spray must be NOTE: Self-made color sample plates of the
current colors are very helpful for determining the
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color shade. Refer to the chapter Color
Determination and Color Theory.
• When shading, if possible only use the paint
mixture that is also allotted in the color shade
formula.
• Observe the rules concerning contrary colors
(complementary colors) and partner colors
according to the Oswald color circle.
• Complementary colors are not recommended
during shading because they mutually inhibit
and lead to muddy mixtures.
Sanding marks
In certain circumstances, the recommended
sanding methods up to now are no longer suitable
for light metallic color shades. Wet sanding with
grade P1200 paper or a grey sanding pad can
cause sanding scratches which can become very
visible under certain lights.
In order to achieve an excellent paint result on
difficult color shades, follow these working rules:
• Sand filler as before, rub down area to be
painted with 3M ultra fine matting sponge and
3M matting gel.
painted with soaked 3M wet sand paper P1500
- P2000.
painted with 3M 260 L P1000 eccentric
(Interface Pad).
Improving touch-up work

During application of special effect base paints,
the effect particles align themselves exactly parallel
to the surface in the paint layer while it is still liquid.
This means a particular thickness of the paint layer
is required.
Because during painting the layer thickness in the
transition zones reduces from normal to zero, the
effect particles can no longer align themselves.
This leads to lighter, darker or cloudy zones.
If 1-component clear lacquer is sprayed before the
base coat, this effect is prevented. An optically
perfect transition will result.
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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

Front Subframe................................................................................................................... 502-00-2
Front Subframe
Special Tool(s) General Equipment
204-605-01 Transmission Jack
Adapter for 204-605
E73707
Removal
contain installation details. Refer to: Wheel and Tire (204-04 Wheels and
1. Refer to: Health and Safety Precautions (100-00 Tires, Removal and Installation).
General Information, Description and 5. WARNING: Make sure that a new bolt is
Operation). installed.
2. CAUTION: Make sure that the steering On both sides.
wheel lock is engaged. Torque: 48 Nm
NOTE: Make sure that the road wheels are in
E102188
E99259 6. On both sides.

Special Tool(s): 204-605-01
3. WARNING: Make sure that a new bolt is
installed.
Torque: 26 Nm
204-605
E102189
7. CAUTION: Make sure that the ball joint

E66155 ball does not rotate.
2011 Fiesta 08/2010 G1062441en

On both sides. 10. Torque: 57 Nm
Torque: 51 Nm
E102255
E102235
11.
8. CAUTION: Make sure that the ball joint
ball does not rotate.
On both sides.
Torque: 80 Nm
E102256
12. Torque: 52 Nm
E99197
9. On both sides.
E102258
211-020
E99198
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13. General Equipment: Transmission Jack 14. 1. Torque: 63 Nm
2. Torque: 140 Nm
2
E99060
E103374

Torque: 90 Nm
E103301
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Torque: 55 Nm
E99063
17. WARNING: Make sure that new bolts are

installed.
NOTE: This step is only necessary when
Torque: 101 Nm
E103376
Installation
2. Refer to: Front Toe Adjustment (204-00
Suspension System - General Information,
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502-00- 6 Jacking and Lifting 502-00- 6
Jacking and Lifting – Component Location

NOTE: Only the specified jacking points may be
used for jacking up and supporting the vehicle.
E101825
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502-00-7 General Information 502-00-7
Supplemental Restraint System (SRS) Health and Safety

Precautions
WARNINGS: If permenantly disabling or enabling the
Only qualified technicians are allowed to passenger air bag a new seat belt for
work on pyrotechnic components. vehicles without or with a passenger air
bag must be installed.
INHALED: Exposure to pyrotechnic residue
may cause low blood pressure, severe Undeployed pyrotechnic components must
headache, irritation of mucous membranes, not be deployed in the vehicle.
fainting, shortness of breath or rapid pulse. Pyrotechnic components must be deployed
Move a victim to fresh air. Seek immediate following local regulations.
medical attention.
Check thoroughly that no loose objects
EYE CONTACT: Exposure to unburned can be spread during the deployment of
pyrotechnic residue may cause irritation, pyrotechnic components.
burning and etching of the eyes. Flush
immediately with plenty of cold running Pyrotechnic components must be
water for at least 15 minutes. Seek transported following local regulations.
immediate medical attention. Never carry out any electrical measurement
EYE CONTACT: Exposure to burned on disconnected, undeployed pyrotechnic
pyrotechnic residue may cause irritation, components.
burning and etching of the eyes. Flush Pyrotechnic components must not be
immediately with diluted boric acid disassembled.
solution. Seek immediate medical
attention. Pyrotechnic components are not
interchangeable between vehicles.
SKIN CONTACT: Unburned pyrotechnic
residue may be rapidly absorbed through Always carry a live air bag module away
the skin in toxic quantities. Wash from the body with the air bag or trim cover
immediately with plenty of soap and water. pointing upwards.
Seek medical attention. Live air bag modules must be placed in a
SKIN CONTACT: Burned pyrotechnic suitable cage when removed from the
residue may be rapidly absorbed through vehicle. The air bag or trim cover must be
the skin in toxic quantities. Wash with facing upwards.
plenty of water. Do not use soap. Seek Do not install a rearward facing child safety
medical attention. seat to the passenger seat with an
SWALLOWED: Unburned pyrotechnic activated passenger air bag.
residue is extremely toxic. If conscious
CAUTIONS:
drink plenty of water then induce vomiting.
Seek immediate medical attention. If Pyrotechnic components must not be
unconscious, or in convulsions do not subjected to temperatures higher than
attempt to induce vomiting or give 110°C.
anything by mouth. Seek immediate Never install aftermarket accessories to
medical attention. the vehicle on or adjacent to the
SWALLOWED: Burned pyrotechnic residue supplemental restraint system module.
is extremely toxic. Drink plenty of water
and seek immediate medical attention.
The deployment key must only be
accessible to authorized personnel.
Make sure that the deployment key remains
removed from the deployment equipment
except during deployment.
2011 Fiesta 08/2010 G548998en

502-00- 8 Wheels and Tires 502-00- 8
Wheel and Tire
Removal
CAUTIONS: NOTE: Only tighten the nuts finger tight at this
Do not use heat to loosen a seized wheel stage.
nut.
Do not use power tools on locking wheel
nuts.
1. Loosen: 360°
x4
x4 E102026
2. Lower the vehicle.

3. Tighten the wheel nuts in the sequence shown.
E102024
Torque: 103 Nm

1
3.
3 4
x4 E102025
E102026
Installation
1. WARNING: Make sure that the mating
faces are clean and free of corrosion
and foreign material
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502-00-9 Multifunction Electronic Modules 502-00- 9
Generic Electronic Module (GEM)

General Equipment • Heated rear window
Ford diagnostic equipment • Heated windscreen (if fitted)
An acoustic signal sounds and the turn signal
lamps flash to indicate receipt of each input signal
Principles of Operation by the generic electronic module.
A diagnosis of the generic electronic module (GEM) Output signals
can be performed with the Ford diagnostic
equipment. Furthermore, an integrated service SWITCH the wiper switch to the "Intermittent"
mode enables testing of the input and output position to test the output signals. PRESS the
signals without the need for further tools. To enable heated rear window switch activates or deactivates
activation of service mode: the output signals in the following order:
• Switch off the ignition, a. Windshield wipers (a signal sounds and the
direction indicator lamps flash when the "Park"
• Switch off all other electrical consumers,
position is reached)
• Apply the handbrake,
b. Heated rear window
• Shift to neutral
c. Interior light(s) (the interior light switch must be
• Close the doors. in the "ON" position)
Activating the service mode d. Rear window wiper
e. heated windshield (if fitted, is only activated
Proceed as follows to activate the service mode:
when engine is running)
• OPERATE the switch of the heated rear window
If the heated rear window switch is operated again,
and HOLD IT THERE
the sequence restarts with point 'a' and the
• Turn on the ignition. functions are activated again in this order.
• RELEASE the switch of the heated rear window
Ending the service mode
• PRESS the heated rear window switch 8 times
within 6 seconds The GEM automatically ends service mode 20
A signal sounds and the turn signal lamps flash to seconds after the last input. However, service
indicate that service mode has been successfully mode can be manually ended at any time by
activated. proceeding as follows:
• OPERATE the switch of the heated rear window
Input signals and HOLD IT THERE
SWITCH the wiper switch to the "Off" position to • SWITCH OFF the ignition
test the input signals. The following is a list of the • RELEASE the switch of the heated rear window
signals to be tested, in no particular order:
3 signals sound and the turn signal lamps illuminate
• Turn signals (right, left, hazard warning lights) to indicate that service mode has ended.
• "Lights on" warning (terminal 58)
• Windshield wiper (intermittent wipe)
• Windshield washer system
• Rear window wiper 1. VERIFY customer concern.
• Rear window washer system 2. Visually CHECK for any obvious mechanical or
• Doors/tailgate open/closed electrical damage.
• Central locking NOTE: Make sure that the wiring harness electrical
• Hood open/closed (in vehicles equipped with connector is correctly and securely connected.
an anti-theft alarm system) Visual Inspection
• Front fog switch (if fitted)
Electrical
• Rear fog switch
Fuses
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502-00-10 Battery, Mounting and Cables 502-00-10
GENERAL PROCEDURES
Battery Disconnect and Connect

8. When the engine reaches normal operating
Disconnection temperature, increase the engine speed to 1200
WARNING: The supplemental restraint rpm and maintain for approximately 2 minutes.
system (SRS) is active for a certain length
of time after the power supply has been 9. Drive the vehicle for approximately five
disconnected. Wait for a minimum of 3 miles/eight kilometers of varied driving.
minutes before disconnecting or removing
any SRS components.
1. Refer to: Battery and Battery Charging Health
and Safety Precautions (100-00 General
Information, Description and Operation).
2. Obtain and record the audio unit keycode and
preset radio frequencies.
3.
E107686
Connect
4. Torque: 15 Nm
E107686
5. Enter the audio unit keycode and preset radio

frequencies.
6. Reset the clock to the correct time.
7. Start and run the engine at idle for three
minutes.
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502-00-11 Climate Control System - General Information 502-00- 11
GENERAL PROCEDURES
Air Conditioning (A/C) System Recovery, Evacuation and Charging

General Equipment 3. 1. Low-pressure connection
Air Conditioning Service Unit 2. High-pressure connection
Automatic Calibration Halogen Leak Detector

Electronic Leak Detector 1
Refrigerant Identification Equipment
UV Leak Detector
1. Refer to: Air Conditioning (A/C) System Health

and Safety Precautions (100-00 General
Information, Description and Operation).
2. CAUTION: The refrigerant analyzer must
be used before recovery, otherwise the
refrigerant center may become
contaminated. Contaminated refrigerant
must be disposed of as hazardous
2
waste. Always follow the manufacturer's
instructions when using the refrigerant
center and the refrigerant analyzer.
Unscrew and remove the protective caps from
the A/C charging connections.
General Equipment: Air Conditioning Service
Unit
General Equipment: Refrigerant Identification
Equipment E104869
4. Connect the service unit lines to the filling

connection of the air conditioning system.
VFE0031288
5. Drain the air conditioning system via the

low-pressure port in accordance with the service
unit manufacturer instructions.
6. CAUTION: Make sure that the specified
amount of refrigerant oil is added.
NOTE: This step is only required when installing
a new component.
2011 Fiesta 08/2010 G1030188en

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FOREWORD

No part of this publication may be reproduced, stored in a data processing

Body and Paint

SECTION 501-00 Body System - General Information

DESCRIPTION AND OPERATION

A- and B-pillar reinforcement

The A- and B-pillar reinforcement is made of the

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2011 Fiesta 08/2010 G1071723en

Item Description Item Description

At introduction, a removable towbar is made

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SECTION 501-02 Front End Body Panels

REMOVAL AND INSTALLATION

Cowl Panel Grille

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Fender Splash Shield

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SECTION 501-03 Body Closures

Front Door Alignment

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7. On front passenger's side:

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2011 Fiesta 08/2010 G1155351en

2011 Fiesta 08/2010 G1155351en

11. On driver's side:

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12. On front passenger's side:

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2011 Fiesta 08/2010 G1155351en

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Rear Door Alignment

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20. 1. Loosen: 1 turn(s)

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Inspection 25. Torque: 20 Nm

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33. Check the area for paintwork damage and repair

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2011 Fiesta 08/2010 G1208539en

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42. On both sides.

43. Check the area for paintwork damage and repair

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2011 Fiesta 08/2010 G1208539en

Adjustment 48. Loosen: 1 turn(s)

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59. Loosen: 1 turn(s)

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62. On both sides. 64.

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SECTION 501-05 Interior Trim and Ornamentation

REMOVAL AND INSTALLATION

A-Pillar Trim Panel