Ford Fiesta (2011 year). Manual — part 88

Color coding

Different colors or shading can be used to depict
special areas and components.

• 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

replacement section.

• Brown: Third component or the third partial

replacement section.

Movement arrows

Necessary work such as clinching flanges or
moving lugs etc. will be represented by broken
arrows.

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.

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.

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Health and Safety Precautions

General

Appropriate repair methods and their correct
implementation are very important for both vehicle
operating safety and personal safety.

WARNING: There is danger of injury
through:

• High voltage when electrical welding.

– Do not perform welding work in a damp

environment or on a wet substrate. Use
suitable insulation underneath.

• Flammable substances in the welding area.

– Remove flammable substances from the

danger area. Remove the fuel tank and,
where required, those components which
supply fuel.

– Completely remove the battery before

carrying out any welding in that area.

• Welding fumes, which are harmful to health.

– Always ventilate the workplace well and use

an extraction system.

• Welding spatter and UV radiation.

– Wear protective clothing, gloves and welding

mask or welding goggles.

• Pyrotechnic components.

– Disconnect the battery negative clamp and

cover the battery terminal. Remove any
airbag components.

All the regulations governing Health and Safety at
Work must be complied with during body repairs.

Personal protection

Welding gases and grinding dusts can be harmful
to the health. For this reason, make sure that
rooms are well ventilated and work using the
welding fumes extraction system. Sealants,
underbody protection and paint residues must not
be burnt down with an unshielded flame, as this
will produce gases which are damaging to health.
A dedicated extraction system must always be
used when welding or brazing.

When working with substances containing solvents,
good ventilation must be provided, respiratory
protection must be worn and an extraction system
must be used.

Do not weld in damp areas, if necessary use an
insulation mat. Welding and grinding work near the
battery presents the danger of explosion. For this
reason, it must be removed before the work is
started.

Cutting, grinding and alignment work on metal
panels can cause a noise level of 85 to 90 dB (A)
or even more. For this reason, you must always
wear ear defenders.

The various body areas are subject to very high
forces during realignment work. Should any
component suddenly become detached during this
process, there is a very great danger of injury. For
this reason, pulling chains and pulling shackles
must be secured with arrester cables.

NOTE: Work on airbag systems may only be
performed by persons who have a relevant
certificate of competence.

Some special instructions must be followed when
working on airbag systems:

• Always stand to the side of it when removing or

installing an airbag.

• Always store an airbag or an airbag/steering

wheel with the airbag side pointing upwards and
in a safe place.

• Only install the airbag again when the vehicle

is fully repaired and the complete electrical
systems has been tested.

• Take into account the location of air curtains

and shoulder airbags.

Protection of the vehicle

Protect affected areas from weld spatter and dust
during all welding and grinding work on the vehicle.
If metallic dust stays on the vehicle for some time,
there is the likelihood of film rust formation.
Grinding or sanding work produce tiny spots of
damage to the paint surface, which may cause
corrosion.

For this reason, make sure to:

• Use carbon fibre blankets to protect the vehicle

body.

• Use covering film to protect the vehicle body

from sanding dust and metal dust.

• Take appropriate measures to protect the

interior equipment of the vehicle during any
repair work.

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In addition, take into account:

• Remove fuel supply components as necessary.

• Protect working areas which are in danger of

catching fire with a fireproof blanket.

• The welding must not cause components of the

air conditioning system to become heated.

• Removal of any attached components in the

space adjoining the repair area.

• Use covering paper to protect the interior from

grinding dust.

• Create a definite barrier between the work area

and the interior by using a carbon fibre blanket.

Protective equipment

The following protective equipment must always
be used:

• Protective helmet or welding mask.

• Ear defenders and breathing protection.

• Protective gloves and safety boots.

• Welding fume extraction.

Electronic components

Increased use of comfort and safety electronics in
modern motor vehicles also requires the greatest
attention to be paid during body work. Overvoltages
produced during welding and in alignment work
during bodyshell rectification may cause electronic
systems to be damaged. In particular, the safety
instructions for performing welding work on vehicles
with airbag systems must be adhered to.

NOTE: After disconnecting the power supply and
before performing further work, a wait time of up
to 15 minutes must be maintained, depending on
the vehicle. Work on airbag systems may only be
performed by persons who have a relevant
certificate of competence.

Pay attention to the following points:

• Disconnect the battery negative clamp and

cover the battery terminal.

• Disconnect the electrical connector at the airbag

control module.

• If welding is to be performed directly near a

control module, it must be removed beforehand.

• Never connect the negative cable of the welder

near an airbag or a control module.

• Connect the negative cable of the welder close

to the location of the weld.

For additional information, refer to:

Restraint System, Removal and Installation),

Restraint System, Removal and Installation),

Restraint System, Removal and Installation),

Supplemental Restraint System, Removal and
Installation),

and Testing).

Liquefied gas vehicles

Alternative fuel vehicles often require special
handling in the workshop area. Above all, assembly
operations to some extent require particular
knowledge when dealing with the special
technology and the safety regulations.

NOTE: Only fully trained personnel are permitted
to work on alternative fuel vehicles.

These special requirements must be understood
and taken into account in the body shop as well.

CAUTION: Danger of fire and explosion.
The safety instructions must always be
followed when performing service work on
fuel/gas systems. Failure to observe this
instruction can lead to injury.

If the smell of liquefied petroleum gas (LPG) or
compressed natural gas (CNG) is noticed in the
workshop, instruct everyone present as follows:

• No smoking and extinguish all naked flames.

• Shut off all electrical and air powered

equipment.

• Evacuate the area.

• Ventilate the area.

• Contact the fire control authorities.

• Move the vehicle to a dedicated, well ventilated

area.

Alternative fuels require special handling:

• Handle them in a specially dedicated, well

ventilated area, which is only accessible to
authorized persons.

• Identify the designated area with new warning

notices.

• If possible close the main shut-off valve and run

the vehicle on alternative fuel until it switches

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DESCRIPTION AND OPERATION

Side Air Curtain Module

(501-20 Supplemental

Side Air Bag Module

(501-20 Supplemental

Driver Air Bag Module

(501-20 Supplemental

Passenger Air Bag Module

(501-20

Air Bag and Safety Belt Pretensioner

Supplemental Restraint System, Diagnosis

Supplemental Restraint System (SRS)

(501-20

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