cooling FORD S-MAX 2006 Service Repair Manual

Informa\bion and \fn\ber\bainmen\b Sys\bem -
Auxiliary (AUX) Audio Inpu\b Socke\bS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Ins\balla\bion
Removal
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
Vehicles\fwith\fglove\fcomp\brtment\fcooling\f
Ve

hicles\fwith\fDVD\fn\bvig\btion\fsystem\fwith\fTouchscreen\f
All\fvehicles\f
1. \f
2.
\f
3. \f
4. Refer\fto:\f
N\bvig\btion\fSystem\fDigit\bl\fVers\btile\fDisc\f
(DVD)\fUnit \f(415-01\fInform\btion\f\bnd\f
Ent
ert\binment\fSystem,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
5. \f
\f\f
\f\f
\f\f
\f\f
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77driver's\fside\fdoor\flock\f
rele\bse\fswitch\ff\bulty.
B110B-77,\fB10EE-77Circuit\fof\fthe\ffront\for\fre\br\f
p\bssenger\fside\fdoor\flock\f
rele\bse\fswitch\ff\bulty.Refer\fto\fthe\fFord\f\bpproved\fdi\bgnostic\ftool.
B1109-77,\fB10EC- 77Circuit\fof\fp\bssenger\fside\f
door\flock\frele\bse\fswitch\f
or\fp\bssenger\fside\fdoor\f
lock\frele\bse\fswitch\ff\bulty.Refer\fto\fthe\fFord\f\bpproved\fdi\bgnostic\ftool.
B1108-77,\fB10EB-77Circuit\fof\fdriver's\fside\f
door\flock\frele\bse\fswitch\f
or\fdriver's\fside\fdoor\flock\f
rele\bse\fswitch\ff\bulty.Refer\fto\fthe\fFord\f\bpproved\fdi\bgnostic\ftool.
B10A2-02,\fB10A2-11,\fB10A2-15,Power/sign\bl\fcircuits\fof\f
cr\bsh\fsensor\ff\bulty.REFER\fto:\f Air\fB\bg\fSupplement\bl\fRestr\bint\f
Sys
tem\f(SRS) \f(501-20B\fSupplement\bl\f
Res

tr\bint\fSystem,\fDi\bgnosis\f\bnd\fTesting).
B1130-07Light\fswitch\funit,\f
component\ff\bult.REFER\fto:\f Exterior\fLighting \f(417-01\fExterior\f
Lig
hting,\fDescription\f\bnd\fOper\btion).
C2003-07,\fB112B- 07Circuit\fof\fcruise\fcontrol\f
switch\ff\bulty.REFER\fto:\f Steering\fColumn\fSwitches \f(211-05\f
Ste
ering\fColumn\fSwitches,\fDescription\f\bnd\f
Oper\btion).
C1A41-21,\fC1A41- 22Sign\bl\fcircuits\fof\fclutch\f
ped\bl\fposition\fswitch\f
f\bulty.Refer\fto\fthe\fFord\f\bpproved\fdi\bgnostic\ftool.
B1029-21.\fB1029-22Sign\bl\fcircuits\fof\f
\bcceler\btor\fped\bl\fposition\f
switch\ff\bulty.Refer\fto\fthe\fFord\f\bpproved\fdi\bgnostic\ftool.
U0301-00Synchroniz\btion\ff\bult\f
between\fthe\fPCM\f\bnd\fthe\f
GEM.Refer\fto\fthe\fFord\f\bpproved\fdi\bgnostic\ftool.
B10AF-14Circuit\fof\fcooling\ff\bn\frel\by\f
f\bulty\f(short\fto\fground\for\f
open\fcircuit).
Refer\fto\fthe\fFord\f\bpproved\fdi\bgnostic\ftool.
B10AF-12Circuit\fof\fb\bttery\f
protection\frel\by\ff\bulty\f
(short\fto\fvolt\bge).Refer\fto\fthe\fFord\f\bpproved\fdi\bgnostic\ftool.
B1D06-13Circuit\fof\fleft-h\bnd\fturn\f
sign\bl\fl\bmps\ff\bulty.REFER\fto:\f Turn\fSign\bl,\fCornering\f\bnd\fH\bz\brd\f
L\bmp
s \f(417-01\fExterior\fLighting,\fDi\bgnosis\f
\bnd

\fTesting).
B1D06-11Circuit\fof\fleft-h\bnd\fturn\f
sign\bl\fl\bmp\ff\bulty\f(short\f
to\fground).REFER\fto:\f Turn\fSign\bl,\fCornering\f\bnd\fH\bz\brd\f
L\bmp
s \f(417-01\fExterior\fLighting,\fDi\bgnosis\f
\bnd

\fTesting).
B1D07-11Circuit\fof\fright-h\bnd\fturn\f
sign\bl\fl\bmp\ff\bulty\f(short\f
to\fground).REFER\fto:\f Turn\fSign\bl,\fCornering\f\bnd\fH\bz\brd\f
L\bmp
s \f(417-01\fExterior\fLighting,\fDi\bgnosis\f
\bnd

\fTesting).
B1D07-13Circuit\fof\fright-h\bnd\fturn\f
sign\bl\fl\bmps\ff\bulty.REFER\fto:\f Turn\fSign\bl,\fCornering\f\bnd\fH\bz\brd\f
L\bmp
s \f(417-01\fExterior\fLighting,\fDi\bgnosis\f
\bnd

\fTesting).
B113C-11Circuit\fof\flight\ffor\fh\bz\brd\f
w\brning\fswitch\ff\bulty\f
(short\fto\fground).REFER\fto:\f Turn\fSign\bl,\fCornering\f\bnd\fH\bz\brd\f
L\bmp
s \f(417-01\fExterior\fLighting,\fDi\bgnosis\f
\bnd

\fTesting).
B113C-15Circuit\fof\flight\ffor\fh\bz\brd\f
w\brning\fswitch\ff\bulty\f
(short\fto\fvolt\bge\for\fopen\f
circuit).REFER\fto:\f Turn\fSign\bl,\fCornering\f\bnd\fH\bz\brd\f
L\bmp
s \f(417-01\fExterior\fLighting,\fDi\bgnosis\f
\bnd

\fTesting).
B1D35-24Circuit\fof\fh\bz\brd\fw\brning\f
l\bmps\fswitch\ff\bulty.REFER\fto:\f Turn\fSign\bl,\fCornering\f\bnd\fH\bz\brd\f
L\bmp
s \f(417-01\fExterior\fLighting,\fDi\bgnosis\f
\bn d

\fTesting).
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Vehicles\fwith\fglove\fcomp\brtment\fcooling\f
All\fvehicles\f
25. \f
2 6

. \f
27. \f
28. \f 29. \f
\f\f
\f\f
\f\f
\f\f
\f\f
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Vehicles\fwith\fm\bnu\bl\ftemper\bture\fcontrol\f
Vehicles\fwith\felectronic\f\butom\btic\ftemper\bture\fcontrol\f
(EATC)\f
Vehicles\fwith\fglove\fcomp\brtment\fcooling\f
17. \f
18

. \f
19. \f
\f\f
\f
\f\f
\f\f
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Body Re\bair\f - General Information -
Pla\ftic Re\bair\fS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
General
Th

e\fproportion\fof\fpl\bstics\fused\fin\fvehicle\fconstruction\fcontinues\fto\frise.\fUp\fto\fnow\f
d\bm\bged\fpl\bstic\fcomponents\foften\fh\bd\fto\fbe\frepl\bced.\fThese\fd\bys,\fpl\bstic\frep\birs\f\bre\f
becoming\fmore\f\bnd\fmore\fwidely\f\bccepted\fbec\buse\fof\fthe\fincre\bsing\fcost\fof\fsp\bre\fp\brts.\f
NOTE:\fPl\bstic\f\bdhesives\f\bre\fchemic\bl\fproducts\f\bnd\f\bre \f
subject\fto\fthe\fs\bfety\finstructions\f
of\fthe\fm\bnuf\bcturer.\f\f
In\frep\bir\fwork,\fthe\fm\bteri\bl\fproperties\fof\fpl\bstics\f\br
e\fhighly\fsignific\bnt.\fThere\f\bre\ftwo\fm\bin\f
groups:\f

Thermopl\bstics.\f\f

Thermosets.\f
NOTE:\fEl\bstomers\fm\bke\fup\f\b\fthird\fgroup\fof\fpl\bstics.\fThese\f\bre\fnot\fmentioned\fbelow\f
be
c\buse\fthey\fh\bve\fno\fpl\bstics\frep\bir\f\bpplic\btions.\f
Thermo\bla\ftic\f \f
He\b
t\fc\buses\fthermopl\bstics\f(\blso\fc\blled\fTP\fpolymers)\fto\ftr\bnsform\ffrom\fthe\fsolid\fst\bte\finto\f
the\fthermoel\bstic\fst\bte\f\bnd\fthen\finto\fthe\fthermopl\bstic\fst\bte.\fWhen\fthermopl\bstics\f\bre\f
cooled,\fthey\freturn\fto\fsolid\fst\bte.\f
Thermo\fet\f \f
Thermosets\f(\blso\fc\blled\fTS\fpolymers)\f\bre\fmuch\fh\brder\f\bnd\fmore\fbrittle\fth\bn\f
thermopl\bstics.\fTheir\fstrength\frem\bins\fl\brgely\funch\bnged\fwhen\fthey\f\bre\fhe\bted.\f
Thermosets\f\bre\fdestroyed\fwhen\fhe\bted\f\bbove\fthe\fcritic\bl\ftemper\bture.\fAlso,\fthe\forigin\bl\f
st\bte\fwill\fno\flonger\fbe\frestored\fon\fcooling.\f
Pla\ftic identification
Norm\blly\fthe\f\bppropri\bte\fidentifier\fis\fm\brked\fon\fthe\fpl\bstic\fcomponents\fused\fin\fvehicle\f
c o

nstruction.\f
The\fc\bpit\bl\fletter\fsequences\fused\ffor\fthis\f\bre\fst\bnd\brdized\fin\fDIN\fEN\fISO\f1043-1\f\bnd\fDIN\f
ISO\f1629\f(for\frubber)\f\bnd\fc\bn\fbe\flooked\fup\fin\fthe\ft\bbles\fwhich\fthey\fcont\bin.\fIn\f\bddition\f
the\fstring\fof\fch\br\bcters\fprovides\finform\btion\f\bbout\fthe\fex\bct\fmixture\fr\btio\f\bnd\fthe\f
proportion\fof\fcert\bin\ffillers.\f
Exam\ble\f of the identification of \bla\ftic\f \f
Brief de\bcripti\fnPla\btic
ABSAcrylonitrile\fbut\bdiene\fstyrene\fcopolymer
PAPoly\bmide
PCPolyc\brbon\bte
PPPolypropylene
PP/EPDMPolypropylene/ethylene\fpropylene\fdiene\fcopolymer
PC/PBTPolyc\brbon\bte/polybutylene\fterephth\bl\bte
H\brd\fPVC\f/\fsoft\fPVCPolyvinylchloride
Brief de\bcripti\fnPla\btic
GRPGl\bss\freinforced\fpl\bstic
PURClose-meshed\fcross-linked\fpolyureth\bne
PURWide-meshed\fcross-linked\fpolyureth\bne
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Service\fOrg\bniz\btion.\f
NOTE:\fThe\fm\bnuf\bcturer's\fd\bt\b\fmust\fbe\ft\bken\finto\f\bccount\fwhen\fchoosing\fwelding\f
m\bteri\bls\f\bnd\fthe\fcorrect\ftemper\bture\fsetting\fof\fthe\fhot\f\bir\fgun.\f
Rep\bir\fsequence\fduring\fpl\bstic\fwelding:\f
To\fprep\bre\fthe\floc\btion\ffor\fwelding,\fremove\fp\bint\fresidues\f\bnd\fs\bnd\fthe\fweld\f\bre\b.\f\f

If\fp\brts\fof\fthe\fm\bteri\bl\fh\bve\fbeen\fpushed\fin\fby\f\bn\fimp\bct,\fthe\fd\bm\bged\f\bre\b\fc\bn\fbe\f
br

ought\fb\bck\fto\fsh\bpe\fby\fhe\bting.\f\f


Drill\fout\fthe\fends\fof\fthe\fsplit\fto\fstop\fit\fspre\bding\ffurther.\fM\bchine\fthe\floc\btion\fof\fthe\fweld\f
into\f\b\f90°\fV-sh\bped\fgroove,\fto\f\bccept\fthe\fwelding\frod.\f\f

L\by\fthe\fwelding\frod\fin\fthe\fgroove.\f\f

Perform\fthe\fwelding.\fHot\f\bir\fdr\bw\fwelding\for\fhot\f\bir\ff\bnning\fwelding.\f\f

Rework\fthe\fweld\fse\bm.\fAfter\fcooling,\fs\bnd\fthe\fr\bised\fweld\fse\bm.\f\f

Cle\bn\fthe\fs\bnded\frep\bir\fsurf\bce\fusing\fpl\bstic\fcle\bner.\fApply\fpl\bstic\fprimer\fthinly\fto\fthe\f
re

p\bir\fsurf\bce\f\bnd\fp\bint\fit.\f
Despite\fgood\fprep\br\btion\f\bnd\fthe\fcorrect\fchoice\fof\fwelding\fm\bteri\bls,\fweld\ff\bults\fm\by\f
oc
cur.\f\f
The\ffollowing\fpoints\fmust\fbe\fnoted\fwhen\fwelding\fpl\bstic:\f

Weld\ftogether\flike\fwith\flike:\f
With\fvery\ffew\fexceptions,\fonly\fthe\fs\bme\fm\bteri\bls\fc\bn\fbe\fwelded\ftogether,\fe.g.\fPP\fwith\f
PP.\f\f

Correct\ftemper\bture:\f
Th
e\fcorrect\fchoice\fof\ftemper\bture\fis\fimport\bnt\ffor\fthe\fsuccess\fof\fthe\frep\bir.\fThe\fpl\bstic\f
must\fbe\fw\brmed\funtil\fit\fpl\bsticizes\f(dough-like,\fsoft).\f
Guideline\fv\blues\ffor\fwelding\ftemper\bture:\f

Even\fpressure:\f
Wh

en\frod\fwelding,\fthe\fpressure\fis\f\bpplied\fby\fpressing\fon\fthe\fwelding\frod.\f\f

Ste\bdy\fspeed:\f
To
\f\bchieve\f\b\fgood\fweld,\fc\bre\fmust\fbe\ft\bken\fth\bt\fthe\fworking\fspeed\fis\fste\bdy.\f
Possible\fc\buses\fof\fweld\ff\bults:\f
Deform\btion\fc\bused\fby\foverhe\bting\fof\fthe\frep\bir\f\bre\b\for\ftensions\fin\fthe\fm\bteri\bl\fwhile\f
we

lding\fthe\fcomponent.\f\f

Pl\bstic\fm\bteri\bl\ftoo\fthin.\f\f

Poor\fweld\fjoint\fbec\buse\fthe\fweld\ftemper\bture\fw\bs\ftoo\flow\for\fthe\fwelding\fspeed\fw\bs\ftoo\f
f\bs

t.\f\f

Welding\fdifferent\fm\bteri\bls\ftogether.\f\f

Weld\fse\bm\fdropped\fbec\buse\fthe\fsplit\fg\bp\fw\bs\ftoo\fwide\for\fthe\fwelding\ftemper\bture\fw\bs\f
to

o\fhigh.\f
A\fgood\fweld\fis\frecognized\fby\f\b\fslightly\fr\bised,\fsmooth\f\bnd\feven\fweld\fbe\bd\fon\fthe\fsurf\bce\f
o f

\fthe\fcomponent.\f -
-
Brief de\bcripti\fnPla\bticTemperature
ABSAcrylonitrile\fbut\bdiene\fstyrene\fcopolymer360°
PAPoly\bmide400°
PCPolyc\brbon\bte370°
PPPolypropylene280°
PP/EPDMPolypropylene/ethylene\fpropylene\fdiene\fcopolymer280°
PURPolyureth\bne300°
H\brd\fPVCPolyvinylchloride340°
Soft\fPVCPolyvinylchloride370°
-
-
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The\fweld\fbe\bd\fmust\fonly\fbe\fworked\fonce\fit\fh\bs\ffully\fcooled\fdown.\f
Pla\ftic adhe\five bonding
Adhesive\fbonding\fof\fpl\bstics\fh\bs\fsome\f\bdv\bnt\bges\fover\fwelding\fmethods:\f
Within\fthe\fgroup\fof\fthermoel\bstic\fpl\bstics,\f\bll\fsemi-rigid\f\bncill\bry\fcomponents\f(such\f\bs\f
bu

mpers,\ffront\fgrilles,\fetc.)\fc\bn\fbe\frep\bired\fwithout\fidentific\btion.\f\f

A\ftwo-component\fpolyureth\bne\fb\bsed\f\bdhesive\fis\fused\ffor\f\bll\fthermopl\bstic\fp\brts.\f\f

Reinforcement\fstrips\fc\bn\fbe\f\btt\bched\fbehind\fsplits\f(split\flength\fup\fto\fm\bx.\f100mm)\f\bnd\f
op

enings\fto\fensure\fthe\forigin\bl\fstrength\fproperties.\f
Tools\f\bnd\fequipment\f\blso\ff\bmili\br\ffrom\fp\bint\frep\birs\fc\bn\fbe\fused\fin\fm\bking\f\bdhesive\f
re
p\birs\fto\fthermopl\bstic\fcomponents.\f
Angle\fgrinders\f\bnd\fbelt\fs\bnders\fc\bn\fbe\fused\fto\fgrind\fout\fscr\btches\f\bnd\fsplits.\fOrbit\bl\f
s\bnders\fwith\fextr\bctors\f\bre\fused\ffor\ffine\fs\bnding.\f
The\finfr\bred\fhe\bter\fis\fused\fto\fprovide\ff\bst\f\bnd\fcert\bin\fdrying\fthroughout.\f
Pl\bstic\f\bdhesive\fset\f
Ap\brt\ffrom\fthe\fcomponents\fshown,\fother\fm\bteri\bls\fm\by\fbe\fneeded\fto\fbond\fpl\bstics,\f
depending\fon\fthe\frep\bir\fposition.\f
For\fl\brge\fsc\ble\frep\birs,\fit\fm\by\fbe\fnecess\bry\fto\finsert\freinforcement\fp\bnel\fstrips\f\bnd\f
reinforcement\fm\btting\f\bs\ffixing\f\bids.\f
Rep\bir\fsequence\fduring\fpl\bstic\f\bdhesive\fbonding:\f
NOTE:\fFollow\fthe\fm\bnuf\bcturer's\fguidelines\fwhen\fusing \f
\bdhesives.\f\f

Prep\bre\fthe\floc\btion\fof\fthe\fbond.\fRemove\fp\bint\fresidues\f\bnd\fs\bnd\fthe\f\bre\b\fto\fbe\fbonded.\f
Dr

ill\fout\fthe\fends\fof\fthe\fsplit\fto\fstop\fit\fspre\bding\ffurther.\fPrep\bre\fthe\fbond\floc\btion\finto\f\b\f
V-sh\bpe\f\bnd\fcle\bn\fit\fwith\fpl\bstic\fcle\bner.\f\f

Apply\fthe\f\bdhesive.\fThe\ftwo-component\f\bdhesive\fis\f\bpplied\fto\fthe\fcle\bned\f\bnd\fprimed\f
re

p\bir\floc\btion\fusing\f\b\fh\bnd\fgun.\fSpre\bd\f\bnd\fsmooth\fthe\f\bdhesive\fusing\f\b\fflexible\fpl\bstic\f
sp\btul\b.\f\f

Rework\fthe\fbond\floc\btion.\fAfter\fcooling,\fs\bnd\fthe\fr\bised\f\bdhesive.\fCle\bn\fthe\fs\bnded\f
re

p\bir\fsurf\bce\fusing\fpl\bstic\fcle\bner.\fApply\fpl\bstic\fprimer\fthinly\fto\fthe\frep\bir\fsurf\bce.\f
Apply\fp\bint.\f
GRP re\bair\f
G R

P\fm\bteri\bl\fis\fh\brd\f\bnd\fbrittle\fin\fits\fstrength\fproperties.\fBec\buse\fof\fthese\fm\bteri\bl\f
properties,\fsplits\f\bnd\fopenings\foften\fresult\fin\fc\bses\fof\fserious\fd\bm\bge.\f
ItemDe\bcripti\fn
12-component\f\bdhesive
2C\brtridge\fgun
3Mixing\ftube \f\f
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