Ford Fiesta Model Introduction Training For Approved Motor Body Repairers
Page content transcription
If your browser does not render page correctly, please read the page content below
The all-new Ford Fiesta is the first small car segment application of the company’s kinetic design philosophy first introduced with the iosis and iosis X concept cars and builds on the premium feel of latest production models like the new Mondeo and Focus. Each new Ford has been created in a new interpretation of this form language, translating the trademark bold graphic elements and proportions to create a family of distinctive models. The result is a new Fiesta that joins a family of vehicles immediately identifiable as new generation Fords, yet with distinctive character to appeal to their target audiences. All-new Fiesta asserts its own air of confidence, stylishness and individuality.
Contents Overview 4 New Technical Specifications 8 Body 16 Supplemental Restraint System 41 This self-study programme highlights the design and function of new vehicle models, new automotive components or new technologies. The self-study programme is not a repair manual! All values given are intended as a guideline only. For maintenance and repair work, always refer to the current technical literature. REFERENCE! NOTE! Copyright © 2009 Ford Motor Company of Southern Africa.
Overview Kinetic Design Energy in Motion The new Fiesta marks a new era in Ford design, a step into the future. The Fiesta embodies the spirit of Ford’s new Kinetic Design movement, which translates into energy in motion. It is bold and independent. It is distinctive and emotional. It is athletic and muscular. Even when standing still it looks poised, ready to strike at any moment. The new Fiesta is also the first major product of Ford’s global product revitalisation strategy process. Foxy Eyes The bold new cat-eye headlamps add even more visual intrigue. It invites you closer, hinting at a stirring personality behind those daring eyes. It is sexy, sultry and captivating. The Shout The large sporty front grille proudly announces the strong new face of Ford. It is constantly shouting and proclaiming your existence boldly to the world. Perfected to suit a lifestyle that demands both fashion and practicality. Why whisper when you can shout? Ready to Pounce The Fiesta imparts a highly dynamic stance and controlled tension. Every line conveys a sense of agile muscularity, the look of energy in motion. The Silver Lining A touch of class is added with the silver character line which accentuates the higher belt-line and window profile. A simple expression that underlines your presence. 4 Copyright © 2009 Ford Motor Company of Southern Africa.
Overview 1.6TDCi Engine 1.4 Sigma & 1.6 Ti-VCT Engine 1.4-litre Sigma engine & 1.6 Ti-VCT engine The new 1.6 Ti-VCT engine (88kW @ 6000 rpm and 149Nm @ 4250 rpm) is class-leading, getting you to 100km/h in sub 10-second time while returning a fuel consumption of just 5.9l/100km, with CO2 emissions of 139g/km. The 1.4l engine boldly offers 71kW @ 5750 rpm and 125Nm @ 4500 rpm, with CO2 emissions of 138g/km. 1.6TDCi engine The 1.6 turbo diesel engine has been refined and improved, offering a satisfying 66kW @ 4000 rpm and 200Nm/1500 rpm with CO2 emissions of only 110g/km. ENGINE 1.4 1.6 1.6 TDCi Types 1.4L 1.6L 1.6L Capacity (cc) 1388 1596 1560 Bore and stroke 76 x 76.5 79 x 81.4 75 x 88.3 (mm) Compression Ratio 11.0 : 1 11.0 : 1 18.0 : 1 Power (kW) @ rpm 71 @ 5750 88 @ 6000 66 @ 4000 Torque (Nm) @ rpm 125 @ 4500 149 @ 4250 200 @ 1500 CO2 emissions 138 139 110 Turbo Diesel Com- Fuel system Multipoint injection Multipoint injection mon Rail injection Copyright © 2009 Ford Motor Company of Southern Africa. 5
Overview Fiesta Ambiente 1.4l, 1.6l and 1.6TDCi Engine 5-door Hatch 5-speed iB5 Manual Transmission Overview The new Ford Fiesta is the car for now. A revolutionary style icon; it redefines what a small hatch should be. The New Fiesta demonstrates that small cars can be styling and sophisticated and yet stay true to Fiesta's traditional strengths of practicality, value for money, agility and safety. Key Features • Dual Airbags • Standard Air conditioner with pollen filter • Twin chamber Halogen Reflector headlights • Manual central locking • Cap less fuel filler neck with misfuel inhibit (petrol and diesel) Fiesta Trend 1.4l and 1.6l 5-door Hatch 5-speed iB5 Manual Transmission Overview Confident Driving The real beauty of the new Fiesta is that it is as easy to maintain as it is to drive. Engineered and built in Germany you experience the build quality, attention to detail and innate reliability every time you get behind the wheel. The new Fiesta offers great fuel economy which means more money in your wallet, and that means less to worry about at the end of the day. Key Features • Standard air conditioner with pollen filter • Radio/CD with MP3 compatibility • Immobiliser • Power steering • Remote Central locking with 2 flip keys • 15" alloy wheels • ABS/EBD • Dual airbags • Power mirrors • Power windows • Bluetooth vehicle interface and voice control 6 Copyright © 2009 Ford Motor Company of Southern Africa.
Overview Fiesta Titanium 1.4l and 1.6l 5-door Hatch & 3-door hatch 5-speed iB5 Manual Transmission Overview The Choice is Yours The new Fiesta is available in 3 door and 5 door body styles, powered by the refined and improved 1.6 turbo diesel, 1.4 petrol engine and a new 1.6 petrol engine. Both petrol engines were engineered to offer great power and fuel efficiency and still be environmentally friendly. All engines feature a new slick 5- speed gearbox. So whether you prefer a torquey diesel engine or an enthusiastic petrol engine, there’s a Fiesta for you. Key Features • Standard air conditioner with pollen filter • Radio/CD with 6 speakers • USB jack • Power steering • Central locking • 16" alloy wheels • ABS/EBD • 2 airbags • Power mirrors • Power windows • Leather steering wheel & Halogen Projector Headlamps Copyright © 2009 Ford Motor Company of Southern Africa. 7
Technical Specifications Dimensions 2489mm 3950mm 1428mm 1474mm 1973mm 8 Copyright © 2009 Ford Motor Company of Southern Africa.
Technical Specifications New Technical features Chassis • Front axle: McPherson struts • Rear axle: Twist-beam axle • Electric power steering Fuel System Cap less fuel tank filler pipe Electrics • Air conditioning (manual or with EATC (Electronic Automatic Temperature Control)) • Central module configuration • Audio system with separate multifunction display and advanced menu navigation Body • Two body versions (3-door and 5-door) • A- and B-pillar reinforcement made from ultra high-strength boron steel • Power windows with pinch protection (driver side only) DLC (Data Link Connector) installation position The DLC is located beneath the light switch behind the instrument panel. The DLC can be accessed by opening the storage compartment on the driver side. Copyright © 2009 Ford Motor Company of Southern Africa. 9
Technical Specifications Front Suspension General A newly developed McPherson front suspension with L-shaped lower arms is used. The lower arm bushes have been enlarged compared with the previous model. This further improves front axle rigidity. The shock absorbers are gas shock absorbers. 1 Stabilizer bar link 5 Subframe 2 Stabilizer bar 6 Lower arm 3 Suspension unit 7 Subframe attachment point 4 Shock absorber unit Rear Suspension General Characteristics of rear axle: • Twist-beam axle (torsionally rigid axle) • Single-pipe gas shock absorbers with stable damping performance for optimum handling • Axle suspension uses large rubber bushes for optimum ride comfort. Function If compression takes place on both wheels evenly (for example when a load is placed on the vehicle), the whole axle unit swivels evenly in the rubber-metal bearings. If only one wheel is compressed, the cross-beam twists (undergoes torsion) and acts as a stabilizer. 10 Copyright © 2009 Ford Motor Company of Southern Africa.
Technical Specifications 1 Shock absorber 3 Twist-beam rear axle Twist-beam rear axle receiver bearing 2 Spring 4 This minimises track and toe changes Front Wheel Sensor The ABS sensor rings are built into the seals in the front wheel bearings. The wheel sensors are joined to the main wiring harness using a separate connecting cable. Copyright © 2009 Ford Motor Company of Southern Africa. 11
Technical Specifications Power Steering 1 Steering gear 6 Electric power steering motor 2 Steering column 7 Joint shaft Universal joint 3 Steering shaft 8 Comments: Part of transfershaft assembly 4 Steering column height and length adjustment 9 Tyre-rod 5 PSC (Power steering control) module General This vehicle employs electric power steering. The electric power steering is integrated into the steering column. As soon as the steering wheel is moved, an electric motor (electric power steering motor) assists the steering movement. The rotary motion of the motor is transferred directly to the steering shaft using a worm gear. The hydraulic power steering pump is therefore no longer required. Advantage: The electric power steering is only active when a steering movement occurs. This decreases the load on the engine and therefore reduces the fuel consumption. The electric power steering consists of the following main components: • Electric power steering motor, • Reduction gear, • Steering torque sensor, • PSC module. 12 Copyright © 2009 Ford Motor Company of Southern Africa.
Technical Specifications Overview of operation When a steering movement occurs, it is detected by the steering torque sensor. The signal from the steering torque sensor is used by the module to calculate the power of the steering assistance. The module drives the motor with the corresponding current. The rotary movement of the motor is transferred directly to the steering shaft through a worm wheel. A Joint shaft D Steering column B Reduction gearset E PSC module Torsional shaft with driving toothed wheel and C steering torque sensor F Electric power steering motor Copyright © 2009 Ford Motor Company of Southern Africa. 13
Technical Specifications Fuel System Capless fuel tank filler pipe NOTE: The locking unit in the fuel tank filler pipe is available as an individual spare part. The conventional fuel tank filler cap is dispensed with for this vehicle. A spring-loaded locking flap closes off the upper end of the fuel tank filler pipe in place of the filler cap. The fuel tank closing flap underneath seals off the fuel system to the outside. In its rest state, the locking flap lies on a flange worked into the fuel pump nozzle guide (cannot be seen in the illustration). When the fuel pump nozzle is introduced, the locking pin is pushed downwards. The fuel pump nozzle guide is now pressed against the compression spring force by the shape of the fuel pump nozzle. The action of pressing away the fuel pump nozzle guide in the direction of the compression spring releases the locking flap and the fuel pump nozzle is admitted. The diameter of the fuel pump nozzle is decisive here. The fuel pump nozzle guide is constructed in such a way that only a fuel pump nozzle of the correct size can release the locking mechanism. As the fuel pump nozzle is introduced further, the spring-loaded tank closing flap is opened. Advantage: • Incorrect refuelling of diesel vehicles with the fuel-pump nozzle at the service station (petrol instead of diesel) is no longer possible. • There is no dirtying of the hands from screwing off the fuel tank filler cap. Instructions on refuelling from a reserve fuel can: There is a funnel in the vehicle for refuelling from a reserve fuel can (applies to both diesel and petrol vehicles). The diameter of the funnel is matched to the type of engine in the vehicle (diesel or petrol). NOTE: Always insert the funnel until it reaches the stop. Otherwise there is the danger that the tank closing flap may not be fully open. 14 Copyright © 2009 Ford Motor Company of Southern Africa.
Technical Specifications NOTE: The locking unit in the fuel tank filler pipe is available as an individual spare part. 1 Compression spring 4 Locking pin 2 Guide-fuel pump nozzle 5 Fuel tank closing flap 3 Locking flap Copyright © 2009 Ford Motor Company of Southern Africa. 15
Body Jacking and Lifting WARNING: Always position the vehicle on a hard level surface. If the vehicle must be jacked up on a soft surface use load spreading blocks under the jack. Always chock the wheel diagonally opposite the jacking point. Failure to follow these instructions may result in personal injury. CAUTION: It is important that only the correct jacking and support locations are used at all times. NOTE: When using the vehicle jack, refer to the owner guide for correct operating instructions. 16 Copyright © 2009 Ford Motor Company of Southern Africa.
Body Body Construction General Two design principles have prevailed in body design. The body design can either be an integral body-frame or a frame with all attached superstructures. Mixed versions are also possible, with the design significantly increasing the stability of the frame. In all versions, the passenger cell must be preserved in the event of an accident. To this end, the front and rear ends are designed so that they absorb the energy of the impact via crumple zones. The use of modern design and manufacturing methods, and the use of body panels whose reshaping and strength properties have been finely balanced, mean that despite the requirements can be met. Integral body-frame The integral body-frame is completed with ancillary components, such as doors, hood, bumpers and other components. The advantages of this are: • Maximum passive safety due to the stable passenger cell. • Defined deformation behavior at the front and rear. • High torsional rigidity and high flexural strength. • Weight reduction. • Economical manufacturing technology. The safety of the driver and passengers is paramount for every body design. There are two key safety aspects in the body: • Safety body cell. • Crumple zone. Copyright © 2009 Ford Motor Company of Southern Africa. 17
Body The safety body cell is characterized by the following design features: • Stable pillars, door sills and door profiles. • Integrated side impact protection in the doors. • The doors are designed to open in the event of extreme deformation. Deformation behavior Different materials and design features lead to staged deformation of the front and rear of the vehicle in an accident. The passenger cell remains undamaged, and the driver and passenger are not shut in. 1 Bolted sheet metal crash element 2 Front side member 3 Rear side member The bolted crash element is made of high-strength steel. Built-in pre-determined folding points prevent damage to the cross member during gentle impacts. The use of bolts means that this can be quickly and cheaply replaced. Side members can be manufactured from panels of different thicknesses. These are joined together through laser welding. These panels are called tailored blanks. NOTE: Follow model-specific instructions when repairing tailored blanks. The rear of the vehicle, like the front of the vehicle, has structures which protect the passenger cell through staged deformation in the event of an accident. The design layouts, however, are adapted to the requirements of the rear area. 18 Copyright © 2009 Ford Motor Company of Southern Africa.
Body A- and B-Pillar Reinforcement 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. Replacing B-Pillar Outer Panel Drill out the 13 spot wields at the lower section of the panel and cut on the lower section in the designated areas. Copyright © 2009 Ford Motor Company of Southern Africa. 19
Body Cut the top section of the panel 100mm below the inside of the door frame and drill out the 43 spot wields. Set the heat gun to 170 Degrees Celsius and apply heat to the lower section of the panel to loosen the bonder. The outer panel can now be removed and the section can cleaned and prepared. 20 Copyright © 2009 Ford Motor Company of Southern Africa.
Body Cut the replacement panel to size to allow for butt joints. Apply bonder to the lower section of the B-Pillar. Remember not to apply bonder in areas where wielding takes place. Fit the replacement panel and spot wield in the 43 designated areas. Copyright © 2009 Ford Motor Company of Southern Africa. 21
Body Join the panel at the joints with full seam wields using MIG welding equipment and spot wield the lower section. 22 Copyright © 2009 Ford Motor Company of Southern Africa.
Body Exterior Trim 1 Trim strip-rear side window (5-door) 7 Trim strip-door window (3-door) 2 Roof strip 8 Rocker panel moulding 3 Trim strip-rear door window 9 Tailgate lettering 4 Windshield strip 10 Tailgate emblem 5 Trim strip-front door window 11 Trim strip-tailgate 6 Trim strip-rear side window (3-door) 12 Variant sign-tailgate System Operation Depending on the way in which they are attached, the components can either be reused or need to be replaced. Components which are attached with adhesive tape should be detached with a plastic wedge. Component Description Windshield strip Depending on the way in which they are attached, the components can either be reused or need to be replaced. Components which are attached with adhesive tape should be detached with a plastic wedge. Copyright © 2009 Ford Motor Company of Southern Africa. 23
Body Windshield strip (continued) Roof strip The trim strip is glued. A new trim strip will need to be replaced after the old one has been removed. 24 Copyright © 2009 Ford Motor Company of Southern Africa.
Body Trim strip-front door window (5-door) The trim strip is a push-fit. The trim strip can be reused after it has been removed. Trim strip-door window (3-door) The trim strip is a push-fit. The trim strip can be reused after it has been removed. Copyright © 2009 Ford Motor Company of Southern Africa. 25
Body Trim strip-rear side window (5-door) The trim strip is a push-fit. The trim strip can be reused after it has been removed. Trim strip-rear door window (5-door) The strip is secured with adhesive tape. A new trim strip will need to be fitted after the old one has been removed. 26 Copyright © 2009 Ford Motor Company of Southern Africa.
Body Trim strip-rear side window (3-door) The strip is secured with adhesive tape. A new trim strip will need to be fitted after the old one has been removed. Rocker panel moulding Copyright © 2009 Ford Motor Company of Southern Africa. 27
Body Rocker panel moulding (continued) On each side the rocker panel moulding consists of: - Front end cap - Jacking point cover (front) - Jacking point cover (rear) The moulding is retained with clips, securing strips and adhesive tape. The trim strip can be reused after it has been removed. Tailgate lettering The lettering is retained with adhesive tape. A new one will need to be fitted after the old one has been removed. Tailgate emblem The lettering is retained with adhesive tape. A new one will need to be fitted after the old one has been removed. 28 Copyright © 2009 Ford Motor Company of Southern Africa.
Body Tailgate emblem (continued) Trim strip-tailgate The trim strip is a push-fit. It can be re-used after removal. Copyright © 2009 Ford Motor Company of Southern Africa. 29
Body Tailgate variant sign The sign is secured with adhesive tape. A new one will need to be fitted after the old one has been removed. Headlamps and Bumpers Headlamps 1 High beam headlamp 3 Side lamp 2 Turn signal indicator 4 Low-beams 30 Copyright © 2009 Ford Motor Company of Southern Africa.
Body Headlamps (continued) The following types of headlamp are used: • Conventional headlamps with free-form reflectors and • Projector headlamps. Conventional incandescent bulbs are fitted as the light source. Incandescent bulbs for dipped and main beam: • Dipped beam: H7 • Main beam: H1 Projector headlamps Projector headlamps have the following advantages compared with conventional headlamp systems: • Greater range and optimum radiance, • More even distribution of the light beam. Removing and Installing Headlamps Top View Side View A A B D C B C Removing Remove the plug connector (D) from the rear of the headlamp. Loosen and remove the 3x screws pictured A, B & C Installing Installation is done in the reverse order. Copyright © 2009 Ford Motor Company of Southern Africa. 31
Body Bumpers 1 Front bumper 4 Rear bumper 2 Fog lights 5 Rear fog lamp 3 Air deflector 6 Cover, bumper The bumpers are painted in the body colour as standard for all vehicle variants. The replacements bumper cover is only available in grey. Removing and Installing Front bumpers To remove the front bumper cover both front headlamps need to be removed (Refer: removing and installing front headlamps p.26) A B C D 32 Copyright © 2009 Ford Motor Company of Southern Africa.
Body Removing and Installing Front bumpers (continued) Once headlamps have been removed loosen 4x Screws A and B on both sides of the vehicle. Loosen screws C and D as well. For vehicles with parking aid. Loosen clips A and B and lift coolant reservoir (C) out of its position. Disconnect X2 plug connector. Detach 5x cable ties from vehicle body. B A C Copyright © 2009 Ford Motor Company of Southern Africa. 33
Body Removing and Installing Front bumpers (continued) For all vehicles. Remove 4x screws from both left and right fender linings. Removing fog lamps if equipped. (Both sides) A Disconnect plug connector (A) from fog lamps. 34 Copyright © 2009 Ford Motor Company of Southern Africa.
Body Removing fog lamps (continued) A B Loosen screws A and B. Lift X4 retaining clips and remove fog lamp from the rear. Removing and Installing Front bumpers (continued) A A B B Two people will be needed to slide the bumper cover forward off the alignment pins (A) and to release the retaining clip (B) at the bottom of the bumper cover. Copyright © 2009 Ford Motor Company of Southern Africa. 35
Body Removing front bumper grills. Lift the four retaining clips (A) on the upper grill and pull it out in the forward direction. A A A A Release the X18 retaining clips on the lower grill and pull it out in the forward direction. Installing Installation is done in the reverse order. 36 Copyright © 2009 Ford Motor Company of Southern Africa.
Body Removing and Installing Rear bumper Remove rear mud flaps on both sides if equipped. Loosen screws A and B and remove plastic deflector. A B Copyright © 2009 Ford Motor Company of Southern Africa. 37
Body For vehicles with parking aid: Remove plug connector A A For all Vehicles: Remove plug connector (A) from rear fog lamp and loosen screws B. B B A B B B B A B B 38 Copyright © 2009 Ford Motor Company of Southern Africa.
Body Two people will be needed to slide the bumper cover up and forward off the alignment pins. 3-Door Model: A 5mm drill bit will be needed to drill out the plastic wields A. Loosen 4X screws B from rear fog lamp and unclip X12 plastic retaining clips to remove lower bumper skin. B B A A Copyright © 2009 Ford Motor Company of Southern Africa. 39
Body 5-Door Model: Loosen 4X screws A from rear fog lamp and unclip X12 plastic retaining clips to remove lower bumper skin. Installing Installation is done in the reverse order. 40 Copyright © 2009 Ford Motor Company of Southern Africa.
Restraint System Supplemental Restraint System Safety precautions when working on airbag General: • Testing, removing, installing and repair work may only be performed by qualified personnel. • Never perform tests with a test lamp, voltmeter or ohmmeter. • Pyrotechnic components may only be tested while installed, using suitable vehicle diagnostic, testing and information systems. • Before handling pyrotechnic components of the restraint system (such as to unplug the connector), the person concerned must “discharge static”, for instance by briefly grasping hold of the door striker plate. • Always disconnect power supply when working on pyrotechnic components of the restraint system. • One minute is necessary after disconnecting the battery to allow for the RCM backup power to become depleted. • The battery must be connected with the ignition SWITCHED ON. If pyrotechnic components of the restraint system are inexpertly repaired, this may result in unwanted triggering after connecting the battery. There must not be anyone in the vehicle while you are connecting the battery. • Pyrotechnic components must never be opened or repaired. Always use new parts. • Pyrotechnic components which have been dropped onto a hard surface or which show signs of damage must not be used. • Pyrotechnic components of the restraint system must be installed immediately after being removed from their packaging. • If the work is interrupted, pyrotechnic components must be placed back into the packaging. • Pyrotechnic components of the restraint system must not be left lying unattended. • Always “wash hands” after handling pyrotechnic components of the restraint system which have been triggered. • When connecting pyrotechnic components of the restraint system, there should be no-one in the vehicle other than the person performing the work. • Storage and transport must be in accordance with the statutory regulations of the countries in question. • Pyrotechnic components must never be treated with grease, cleaning agents or similar. • Pyrotechnic components must not be exposed to temperatures higher than 100 °C even for brief periods of time. Copyright © 2009 Ford Motor Company of Southern Africa. 41
Restraint System Airbags • Following removal, airbag units must be stored with cushioned side facing upwards. • Always renew airbag unit if fabric is contaminated by oil, grease, paint, solvent or similar. • There is no specified interval for renewing airbag units. Always keep to the following sequence when renewing airbag units: 1. Remove the old airbag unit and set it down with the cushioned side facing upwards. 2. Remove the new airbag unit from the transportation container and set it down with the cushioned side facing upwards. 3. Immediately place old airbag unit in transportation container. 4. Install new airbag unit in vehicle. Side airbag • We recommend using genuine seat covers (same as original equipment). • It is NOT permissible to use seat covers or protective covers which have not been approved for use on Ford seats with side airbags. • The backrest foam fill is not to be cut away in the area of the side airbag. • When installing, make sure seam is straight in area of side airbag. • All upholstery clips (metal and plastic clips) must be renewed. • We recommend using only genuine upholstery clips (same as original equipment). • When installing, all new upholstery clips must be fitted in the same positions as the original ones. • For safety reasons, the cover should always be renewed if it is damaged (tears, burn marks, etc.) in the area of the side airbag, as otherwise the side airbag will not inflate properly. • The backrest cover in the area of the side airbag is never to be repaired (on account of special thread and precisely defined seam). • Always replace the backrest padding after the side airbags have been triggered. • All damaged components must be replaced after an accident. The original airbag unit can still be used if no signs of damage are found. • If side airbag units are renewed, remove sticker with airbag number from new side airbag unit and stick it over old sticker on seat pan. • Never pierce cover in area of airbag and sensor mat with upholstery needle or similar pointed objects. 42 Copyright © 2009 Ford Motor Company of Southern Africa.
Restraint System Belt pretensioner in the retractor • Always replace mechanically damaged (dented, cracked) belt pretensioner units. • Never point the open end of a belt pretensioner at another person. • When connecting belt pretensioner unit, all mechanical parts (including those of the three-point seat belt) must be properly anchored. Disposal of pyrotechnic units • Pyrotechnic components (e.g. belt pretensioners, belt force limiters, airbag units) that have not been triggered must be disposed of in original packaging and in accordance with national regulations. Please contact the Importer (or appropriate distribution centre) should you require more information. • Pyrotechnic components ignited in an accident can be disposed of together with commercial refuse. Copyright © 2009 Ford Motor Company of Southern Africa. 43
Restraint System Overview General Three different versions are available: Version 1 comprises the following components: • Single-stage driver airbag, • Single-stage passenger airbag, • Driver and passenger belt pretension in the retractor, • Front crash sensor, • Driver and passenger safety belt buckle switch, • Passenger seat occupancy sensor, • RCM (restraint control module). Version 2 comprises the following components: 1. Components of version 1, 2. Driver and passenger side airbag (upper body and head), 3. Driver and passenger crash sensor, 4. Knee airbag. Version 3 comprises the following components: • Components of version 1, • Driver and passenger side airbag (upper body), • Driver and passenger crash sensor, • Knee airbag, • Driver and passenger head airbag. Module number Description 3- and 5-door model with driver and pas- 8V51-14B321-Ax senger airbag 5-door model with driver and passenger 8V51-14B321-Bx airbag, side airbag (upper body and head) and knee airbag 5-door model with driver and passenger 8V51-14B321-Cx airbag, side airbag (upper body), knee airbag and head airbags 3-door model with driver and passenger 8V51-14B321-Ex airbag, side airbag (upper body and head) and knee airbag 3-door model with driver and passenger 8V51-14B321-Fx airbag, side airbag (upper body), knee airbag and head airbags 44 Copyright © 2009 Ford Motor Company of Southern Africa.
Restraint System Component Location Safety belt buckle switch driver and passenger 1 Front impact sensor 8 side Head airbag driver and passenger side 2 Front passenger airbag 9 (optional) PAD (passenger airbag deactivation) switch Belt pretensioner in the retractor driver and pas- 3 (optional) 10 senger side 4 Seat occupant sensor passenger side only 11 PAD indicator light (optional) 5 Side airbag driver and passenger side (optional) 12 Driver airbag Crash sensor driver and passenger side 6 (optional) 13 Knee airbag (optional) Instrument cluster with airbag indicator light and 7 RCM (restraint control module) 14 safety belt warning light Copyright © 2009 Ford Motor Company of Southern Africa. 45
Restraint System System operation and Component description Control diagram Airbag indicator light and safety belt warning 1 light in instrument cluster 9 PAD indicator light 2 Driver airbag 10 RCM (restraint control module) 3 Front passenger airbag 11 PAD deactivator switch Driver and passenger belt pretensioner in the 4 retractor 12 Seat occupancy sensor (passenger only) 5 Driver and passenger side airbag 13 Safety belt buckle switch (front only) 6 Knee airbag 14 Crash sensor (front only)) 7 Driver and passenger head airbag 15 Front impact sensor 8 PCM (power control module) 46 Copyright © 2009 Ford Motor Company of Southern Africa.
Restraint System System Operation When the ignition is switched on, the RCM performs a self-diagnostic. All components of the safety system, apart from the driver and passenger safety belt buckle switches and the seat occupancy sensor, are checked. If a fault is detected, the airbag indicator light is activated for 8 seconds after the ignition is switched on. The first 8 seconds of the ignition cycle always follow the same pattern: on for the first 3.2 seconds, the off for 4.8 seconds. Only after these 8 seconds can the airbag indicator light be used as a fault indicator. Triggering of the airbags and belt pretensioners is dependent on the impact speed and the impact angle. In the normal situation the signal to the PCM is linked to a triggering of airbags. However, in the event of a side-on collision with Version 1 (no side airbags), the signal is likewise sent to the PCM, even though no airbags have been triggered. The same applies in the event of a collision from behind: no airbags triggered, but a signal is sent to the PCM. Due to this signal the PCM interrupts the fuel supply to the engine so that the engine switches off. The RCM must be renewed after the airbag has been triggered. When the RCM is replaced, the module must be configured with IDS (Integrated Diagnostic System). Safety Belt Warning Indicator The safety belt warning light is controlled by the RCM via the HS-Can (controller area network) data bus. The following signals are evaluated by the module for control purposes: • Driver safety belt buckle switch, • Passenger safety belt buckle switch, • Passenger seat occupancy sensor, • Vehicle speed signal via the HS-Can data bus. Driver side function When the ignition is switched on, the RCM checks by means of the safety belt buckle switch to see whether the driver side safety belt is fastened. If a road speed of approx. 25km/h has been reached and the safety belt is not fastened, the safety belt warning lamp lights up and an audible signal is sounded. Copyright © 2009 Ford Motor Company of Southern Africa. 47
Restraint System Passenger side function When the ignition is switched on, the module checks whether the passenger seat is occupied by a person and whether this person is wearing a safety belt. The seat occupancy sensor and the safety belt buckle switch pass this information to the RCM. If a road speed of approx. 25km/h has been reached and the passenger is not wearing a safety belt, the safety belt warning lamp lights up and an audible signal is sounded. Deactivation/activation of the safety belt warning light The safety belt warning light can be permanently deactivated. To do this: • Turn the ignition switch to position “ll”, • Within a period of 60 seconds, slowly close and reopen the safety belt buckle nine times, then leave it open. • The safety belt warning light flashes three times to confirm the status change. Component Description Seat occupancy sensor The seat belt occupancy sensor consists of several sensor cells and is integrated into the foam structure of the passenger seat. It recognizes whether a person is sitting in the passenger seat. The sensor is used in vehicles which have a safety belt warning light. It does not disable the passenger airbag. The seat occupancy sensor is integrated into the seat cushion and is not available as an individual part. 48 Copyright © 2009 Ford Motor Company of Southern Africa.
Restraint System Belt pretensioner in the retractor 1 Electrical connector 2 Ignition unit The belt pretensioner is integrated into the retractor and installed on the driver and passenger sides. On the outside of the safety belt retractor there is a metal tube, at the upper end of which a pyrotechnic igniter is located. It is connected with the metal tube via joining connector. Side airbag Two different side airbags are installed depending on the equipment version. In vehicles without a head airbag, there is a side airbag which protects the area of the upper body and head. In vehicles with a head airbag, there is a side airbag which protects the area of the upper body. Knee airbag The knee airbag is installed in the instrument panel, below the steering wheel. In the event of a head-on collision, it protects the knee and leg area and prevents the driver from slipping down under the safety belt. Copyright © 2009 Ford Motor Company of Southern Africa. 49
Restraint System PAD deactivator switch Pad deactivatorswitch indicator light 1 PAD deactivator switch 2 switch unit The PAD deactivator switch can be fitted as an option on all versions. This feature is prepared at the factory and must be completed by the authorized dealer. A kit consisting of a deactivator switch (lock switch) and a switch panel with integrated PAD indicator light is obtainable for this purpose. The deactivator switch is installed in the glove box. The switch panel with integrated PAD indicator light is fitted underneath the air conditioning control unit. After the components are installed, the RCM must be programmed with IDS. The driver can operate the PAD deactivator switch with the vehicle key to deactivate the passenger airbag. When the passenger airbag is deactivated, the PAD indicator light comes on. 50 Copyright © 2009 Ford Motor Company of Southern Africa.
Notes: Copyright © 2009 Ford Motor Company of Southern Africa. 51
You can also read
NEXT SLIDES ... Cancel