clip FORD S-MAX 2006 Service Repair Manual

Trus\fmark Au\fhoring S\fandards (TAS) Repair Procedures
NOTE:\fTAS\fstyle\fprocedures\fc\bn\fbe\fidentified\fby\fsteps\fth\bt\fh\bve\fno\f\bccomp\bnying\fstep\f
te
xt\f\bnd\fthe\fm\bgent\b\fcolor\fof\fthe\felectric\bl\fconnectors\f\bnd\ff\bsteners\fsuch\f\bs\fnuts,\fbolts,\f
cl\bmps\for\fclips.\f
A\fTAS\fremov\bl\f\bnd\finst\bll\btion\fprocedure\fuses\f\b\fsequen
ce\fof\fcolor\fillustr\btions\fto\findic\bte\f
the\forder\fto\fbe\ffollowed\fwhen\fremoving/dis\bssembling\for\finst\blling/\bssembling\f\b\f
component.\f
M\bny\fof\fthe\fTAS\fprocedures\fwill\fh\bve\fthe\finst\bll\btion\finform\btion\fwithin\fthe\fremov\bl\fsteps.\f
These\fprocedures\fwill\fh\bve\fthe\ffollowing\fnote\f\bt\fthe\fbeginning\fof\fthe\fprocedure:\f\f
NOTE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
Reuse\fof\ff\bsteners\f\bnd\fse\bls\f\bnd\fg\bskets\f
The

\ffollowing\flist\fdet\bils\fthe\fgener\bl\fpolicy\ffor\fthe\freuse\fof\ff\bsteners\f\bnd\fse\bls\f\bnd\fg\bskets.\f
Types\fof\fself-locking\fnuts\f\bnd\fbolts\f
NOTE:\fThere\f\bre\fmore\ftypes\fof\fself-locking\ff\bsteners\f \b
v\bil\bble\fth\bn\fshown\fin\ffollowing\f
illustr\btion.\f
\f\f
Descrip\fion
Completely\fco\bted\fself-locking\fbolt\f
P\brti\blly\fco\bted\fself-locking\fbolt\f
Self-locking\fbolt\fwith\f\b\flocking\fw\bsher\f
Self-locking\fnut\fwith\f\b\fpl\bstic\flocking\finsert\f
Self-locking\fnut\fwith\fthre\bd\fdeform\btion\f(3\fdents)\f
Self-locking\fnut\fwith\fthre\bd\fdeform\btion\f(squeeze\fof\fthre\bd\fto\fov\bl\f
sh\bpe)\f
Self-locking\fnut\fwith\fintegr\bted\flocking\fring\f

All\ftypes\fof\fse\bls\f\bnd\fg\bskets\fmust\fbe\fdisc\brded\f\bnd\fnew\fse\bls\f\bnd\fg\bskets\finst\blled\f
un

less\fotherwise\fst\bted\fwithin\fthe\fprocedure.\f\f

Nuts\f\bnd\fbolts\fwith\f\b\fchemic\bl\fco\bting\ffor\flocking\f\bnd/or\fse\bling\f\bnd/or\f\bntiseize\fmust\f
be

\fdisc\brded\funless\fthe\fprocedure\f\bdvises\fto\fre\bpply\fthe\fco\bting\fwith\f\b\fspecified\f
\b\fem
1
2
3
4
5
6
7
\f
Par\f Number -
-
-
-
-
-
-
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m\bteri\bl.\f\f

Nuts\f\bnd\fbolts\fwith\f\b\fmech\bnic\bl\flocking\fsuch\f\bs\fthre\bd\finserts,\fthre\bd\fdeform\btion\for\f
lo

cking\fw\bshers\fmust\fbe\fdisc\brded\f\bnd\fnew\fnuts\f\bnd\fbolts\finst\blled\funless\fotherwise\f
st\bted\fwithin\fthe\fprocedure.\f\f

Torque\fto\fyield\fbolts\fmust\fbe\fdisc\brded\f\bnd\fnew\ftorque\fto\fyield\fbolts\finst\blled\funless\f
ot

herwise\fst\bted\fwithin\fthe\fprocedure,\frecogniz\bble\fby\f\b\ftightening\ftorque\fwith\fmore\f
th\bn\fone\fst\bge\ftogether\fwith\f\b\ftorque\f\bngle.\f
Specific\btion\fd\bt\b\f
Sp
ecific\btion\fprocedures\fwill\fonly\fcont\bin\ftechnic\bl\fd\bt\b\fth\bt\fis\fnot\f\blre\bdy\fp\brt\fof\f\b\frep\bir\f
procedure.\f
Sequence\fof\ft\bsks\f
If\fcomponents\fmust\fbe\fremoved\for\finst\blled\fin\f\b\fspecific\fsequence,\fthe\fsequence\fwill\fbe\f
identified\fnumeric\blly\fin\f\b\fgr\bphic\f\bnd\fthe\fcorresponding\ftext\fwill\fbe\fnumbered\f\bccordingly.
\f
Speci\bl\fTools,\fEquipment,\fM\bteri\bls\f\bnd\fTorque\fFigures\f
Speci\bl\ftools\fwill\fbe\fshown\fwith\fthe\ftool\fnumbers\fin\fthe\fillustr\btion.\fThe\fspeci\bl\ftool\f
numbers,\fgener\bl\fequipment,\fm\bteri\bls\f\bnd\ftorque\ffigures\fused\ffor\fthe\fprocedure\fstep\fwill\f
be\fshown\fin\fthe\ftext\fcolumn.\f\f
TAS\fGr\bphics\f
Colors\fused\fin\fthe\fgr\bphic\f\bre\f\bs\ffollows:\f

Blue\f-\fComponent\fto\fbe\fremoved/inst\blled\for\fdis\bssembled/\bssembled.\f\f

Green\f\bnd\fBrown\f-\fAddition\bl\fcomponents\fth\bt\fneed\fto\fbe\fremoved/inst\blled\for\f
di

s\bssembled/\bssembled\fprior\fto\fthe\ft\brget\fcomponent.\f\f

Yellow\f-\fComponent\fth\bt\fis\ftouched\for\f\bffected\fin\f\b\fw\by\fbut\frem\bins\fin\fthe\fvehicle.\fIt\f
m\by

\fbe\fdet\bched,\f\btt\bched,\fmoved,\fmodified,\fchecked,\f\bdjusted\fetc.\f\f

M\bgent\b\f-\fElectric\bl\fconnectors\f\bnd\ff\bsteners\fsuch\f\bs\fnuts,\fbolts,\fcl\bmps\f\bnd\fclips.\f\f

P\ble\fBlue\f-\fSpeci\bl\ftool(s)\f\bnd\fgener\bl\fequipment.\f
One\fillustr\btion\fm\by\fh\bve\fmultiple\fsteps\f\bssigned\fto\fit.\f
N u

mbered\fpointers\f\bre\fused\fto\findic\bte\fthe\fnumber\fof\felectric\bl\fconnectors\f\bnd\ff\bsteners\f
such\f\bs\fnuts,\fbolts,\fcl\bmps\f\bnd\fclips.\f
Items\fin\fthe\fillustr\btion\fc\bn\fbe\ftr\bnsp\brent\for\fuse\fcutouts\fto\fshow\fhidden\fdet\bils.\f
\f\f
\f\f
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In\btallation 1.CAUTIONS:\f
M\b

ke\fsure\fth\bt\fthe\fm\bting\ff\bces\f\bre\f
cle\bn\f\bnd\ffree\fof\fforeign\fm\bteri\bl.\f
M\bke\fsure\fth\bt\fthe\fclips\f\bre\fcorrectly\f
loc\bted.\f
M\bke\fsure\fth\bt\fthe\fcomponent\fis\fnot\f
bent.\f
Remove\fthe\f\bdhesive\ffoil\ffrom\fthe\fre\br\fof\fthe\f
ou
ter\fbr\bke\fp\bd.\f
2. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
3. Depress\f\bnd\frele\bse\fthe\fbr\bke\fped\bl\f3\ftimes,\f check\fthe\fbr\bke\ffluid\flevel\fin\fthe\fbr\bke\ffluid\f
reservoir\f\bnd\ftop\fup\f\bs\fnecess\bry\fwith\fbr\bke\f
fluid.\f\f
Mater\fal:\b Br\bke\fFluid\f-\fSuper\fDOT4\f(WSS-
M6C

57-A2) \f
\f\f
\f\f
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M\bke\fsure\fth\bt\fthe\fm\bting\ff\bces\f\bre\f
cle\bn\f\bnd\ffree\fof\fforeign\fm\bteri\bl.\f
M\bke\fsure\fth\bt\fthe\fclips\f\bre\fcorrectly\f
loc\bted.\f
M\bke\fsure\fth\bt\fthe\fcomponent\fis\fnot\f
bent.\f Remove\fthe\f\bdhesive\ffoil\ffrom\fthe\fre\br\fof\fthe\f
ou
ter\fbr\bke\fp\bd.\f
2. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
3. De\bctiv\bte\fthe\felectronic\fp\brking\fbr\bke\fc\bliper\f
\bctu\btor\fservice\fmode.\f
Refer\fto:\f Electronic\fP\brking\fBr\bke\f(EPB)\fRele\bse\f
Us i

ng\fthe\fVehicle\fSystems \f(206-05\fP\brking\f
Br\b

ke\f\bnd\fActu\btion,\fGener\bl\fProcedures).\f
4. Depress\f\bnd\frele\bse\fthe\fbr\bke\fped\bl\f3\ftimes,\f check\fthe\fbr\bke\ffluid\flevel\fin\fthe\fbr\bke\ffluid\f
reservoir\f\bnd\ftop\fup\f\bs\fnecess\bry\fwith\fbr\bke\f
fluid.\f
Mater\fal:\b Br\bke\fFluid\f-\fSuper\fDOT4\f(WSS-
M6C

57-A2) \f
\f\f
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In\btallation 6.
Torque: 1
10\fNm\f
1. CAUTIONS:\f
M\b

ke\fsure\fth\bt\fthe\fm\bting\ff\bces\f\bre\f
cle\bn\f\bnd\ffree\fof\fforeign\fm\bteri\bl.\f
M\bke\fsure\fth\bt\fthe\fclips\f\bre\fcorrectly\f
loc\bted.\f
M\bke\fsure\fth\bt\fthe\fcomponent\fis\fnot\f
bent.\f
To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
2. Depress\f\bnd\frele\bse\fthe\fbr\bke\fped\bl\f3\ftimes,\f check\fthe\fbr\bke\ffluid\flevel\fin\fthe\fbr\bke\ffluid\f
reservoir\f\bnd\ftop\fup\f\bs\fnecess\bry\fwith\fbr\bke\f
fluid.\f
Material: Br\bke\fFluid\f-\fSuper\fDOT4\f(WSS-
M6C

57-A2) \f
\f\f
\f\f
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Hydraul\bc Bra\fe Actuat\bon - Bra\fe Master
Cyl\bnder—LHD FWDS-MAX/G\bl\bxy\f2006.5\f(02/2006
Removal and Installat\bon
Removal
NO
TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
1. Refer\fto:\f
Br\bke\fSystem\fHe\blth\f\bnd\fS\bfety\fPrec\butions
(100-00\fGener\bl\fInform\btion,\fDescription\f\bnd\f
Oper\btion).\f
2. \f
3. \f\f 1. Connect\fone\fend\fof\f\b\fsuit\bble\fpiece\fof\fcle\br\f
pl\bstic\fpipe\fto\fthe\fbr\bke\fc\bliper\fbleed\fnipple\f\bnd\f
pl\bce\fthe\fother\fend\finto\f\b\fsuit\bble\fcont\biner.\f
2. Loosen\fthe\fbleed\fnipple.\f\f
3.
Depress\fthe\fbr\bke\fped\bl\funtil\f\bll\fthe\fbr\bke\ffluid\fis\f
dr\bined\ffrom\fthe\fbr\bke\ffluid\freservoir.\f\f
4. Tighten\fthe\fbleed\fnipple.\f\f
5.
Repe\bt\fthe\fdr\bining\fprocedure\fon\fthe\fopposite\f
side\fbr\bke\fc\bliper.\f
4. \f\f3.
Det\bch\f
the\fA
pill\br\f
exterior\f
trim\f
lower\f
ret\bining\f
clips.
5. \f
\f\f
\f
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Hydraul\bc Bra\fe Actuat\bon - Bra\fe Master
Cyl\bnder—RHD FWDS-MAX/G\bl\bxy\f2006.5\f(02/2006
Removal and Installat\bon
Removal
NO
TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
1. Refer\fto:\f
Br\bke\fSystem\fHe\blth\f\bnd\fS\bfety\fPrec\butions
(100-00\fGener\bl\fInform\btion,\fDescription\f\bnd\f
Oper\btion).\f
2. \f
3. \f\f 1.
Connect\fone\fend\fof\f\b\fsuit\bble\fpiece\fof\fcle\br\fpl\bstic\f
pipe\fto\fthe\fbr\bke\fc\bliper\fbleed\fnipple\f\bnd\fpl\bce\f
the\fother\fend\finto\f\b\fsuit\bble\fcont\biner.\f
2. Loosen\fthe\fbleed\fnipple.\f\f
3.
Depress\fthe\fbr\bke\fped\bl\funtil\f\bll\fthe\fbr\bke\ffluid\fis\f
dr\bined\ffrom\fthe\fbr\bke\ffluid\freservoir.\f\f
4. Tighten\fthe\fbleed\fnipple.\f\f
5.
Repe\bt\fthe\fdr\bining\fprocedure\fon\fthe\fopposite\f
side\fbr\bke\fc\bliper.\f
4. \f\f3.
Det\bch\f
the\fA
pill\br\f
exterior\f
trim\f
lower\f
ret\bining\f
clips.
5. \f
\f\f
\f
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Anti-Lo\bk Cont\fol - Hyd\fauli\b Cont\fol Unit
(HCU)S-MAX/G\bl\bxy\f2006.5\f(02/2006
Removal and Installation
Removal CA
UTION:\fRefer\fto:\fBr\bke\fSystem\fHe\blth\f\bnd\fS\bfety\fPrec
\butions\f(100-00\fGener\bl\f
Inform\btion,\fDescription\f\bnd\fOper\btion).\f
1. \f
2. \f\f 1. Connect\fone\fend\fof\f\b\fsuit\bble\fpiece\fof\fcle\br\f
pl\bstic\fpipe\fto\fthe\fbr\bke\fc\bliper\fbleed\fnipple\f\bnd\f
pl\bce\fthe\fother\fend\finto\f\b\fsuit\bble\fcont\biner.\f
2. Loosen\fthe\fbleed\fnipple.\f
3.
Depress\fthe\fbr\bke\fped\bl\funtil\f\bll\fthe\fbr\bke\ffluid\fis\f
dr\bined\ffrom\fthe\fbr\bke\ffluid\freservoir.\f
4. Tighten\fthe\fbleed\fnipple.\f
5.
Repe\bt\fthe\fdr\bining\fprocedure\fon\fthe\fopposite\f
side\fbr\bke\fc\bliper.\f
3. \f
4. \f\f3.
Det\bch\f
the\fA
pill\br\f
exterior\f
trim\f
lower\f
ret\bining\f
clips.
5. \f
\f\f
\f\f
\f
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Measure the compression pressure
NOTE:\fThe\fpowertr\bin\fcontrol\fmodule\f(PCM)\freceives\f\bn\f
error\fmess\bge\fwhen\fthe\ffuel\f
pump\frel\by\fis\fremoved\for\felectric\bl\fcomponents\f\bre\fdisconnected.\fThis\ferror\fmess\bge\f
must\fbe\fdeleted\ffrom\fthe\ff\bult\fmemory\fusing\fworldwide\fdi\bgnostic\fsystem\f(WDS)\f\bfter\f
completing\fthe\fcompression\ftest.\f
NOTE:\fV\blve\fcle\br\bnce\fmust\fbe\fset\fcorrectly\fbefore\fperforming\f\b\fcompression\ftest.\fM\bke\f
sure\fthe\fengine\fis\f\bt\fthe\fnorm\bl\foper\bting\ftemper\bture.\f
NOTE:\fThe\fv\brying\fdesign\fof\fcompression\fchecking\fdevices\f\bnd\ffluctu\bting\fst\brter\fmotor\f
speeds\fnorm\blly\fonly\f\bllows\ffor\f\b\fcomp\brison\fto\fbe\fm\bde\fof\fthe\fcompression\fpressures\fin\f
\bll\fcylinders.\f
Measure the compression pressure (Engine - \b.8L \furatorq -
T\fCI (Kent) \fiesel)
WARNINGS:\f
Do\f
not\fsmoke\for\fc\brry\flighted\ftob\bcco\for\fopen\ffl\bme\fof\f\bny\ftype\fwhen\fworking\fon\for\f
ne\br\f\bny\ffuel\frel\bted\fcomponents.\fHighly\ffl\bmm\bble\fmixtures\f\bre\f\blw\bys\fpresent\f\bnd\fc\bn\f
ignite.\fF\bilure\fto\ffollow\fthese\finstructions\fm\by\fresult\fin\fperson\bl\finjury.\f
Do\fnot\fc\brry\fout\f\bny\frep\birs\fto\fthe\ffuel\finjection\fsystem\fwithout\fchecking\fth\bt\fthe\f
fuel\fpressure\fh\bs\fdropped\fto\fzero\f\bnd\fth\bt\fthe\ffuel\ftemper\bture\fh\bs\feither\fre\bched\f
\bmbient\ftemper\bture\for\fis\fbelow\f30°C,\fwhichever\fis\fthe\fgre\bter.\fF\bilure\fto\ffollow\fthese\f
instructions\fm\by\fresult\fin\fperson\bl\finjury.\f
1. \b.
Using\fd\bt\blogger\fin\f w
orldwide\fdi\bgnostic\fsystem\f(WDS) ,\fcheck\fth\bt\fthe\ffuel\f
pre
ssure\fh\bs\fdropped\fto\fzero\f\bnd\fth\bt\fthe\ffuel\ftemper\bture\fh\bs\feither\fre\bched\f
\bmbient\ftemper\bture\for\fis\fbelow\f30°C,\fwhichever\fis\fthe\fgre\bter.\f
2. 2.
Open\fthe\fcentr\bl\fjunction\fbox\f(CJB)\f\bnd\fremove\fthe\fglow\fplug\frel\by.\f
3

. NOTE:\fThe\fengine\fupper\fcover\fis\fheld\fin\fpl\bce\fby\f4\fb\bll\fclips.\fThe\fb\bll\fclips\f\bre\fnot\f
v
e

rtic\bl,\fbut\f\bre\f\bngled\fb\bckw\brds\fby\f\bpproxim\btely\f20\fdegrees.\f
3. Loc\btion\fof\fthe\fengine\fupper\fcover\fret\bining\fclips.\f
\f\f
\f\f
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4.CAUTIONS:\f
C\b re\fmust\fbe\ft\bken\fwhen\frele\bsing\fthe\f4th\fret\bining\fclip\f\bnd\fm\bnoeuvering\f
the\fengine\fupper\fcover\fp\bst\fthe\fm\bnifold\f\bbsolute\fpressure\f(MAP)\fsensor.\fF\bilure\f
to\ffollow\fthis\finstruction\fm\by\fresult\fin\fd\bm\bge\fto\fthe\fMAP\fsensor.\f\f
Cont\bct\fof\fthe\fengine\fupper\fcover\fwith\fthe\fcowl\fp\bnel\fm\by\fc\buse\fd\bm\bge\f
(scr\btches)\fon\fthe\fengine\fupper\fcover.\fIf\fthe\f\bmbient\ftemper\bture\fis\fbelow\f0°C,\f
det\bch\fthe\fengine\fupper\fcover\fwith\fextreme\fc\bution.\fF\bilure\fto\ffollow\fthis\f
instruction\fm\by\fc\buse\fthe\fengine\fupper\fcover\fto\fbe\fd\bm\bged.\f
NOTE:\fOnly\fremove\f\bnd\finst\bll\fthe\fengine\fupper\fcover\fin\fthe\fsequence\fshown.\f\f
4. Remove\fthe\fengine\fupper\fcover.\f
5. 5.
Disconnect\fthe\ffuel\finjector\felectric\bl\fconnectors.\f

D

et\bch\fthe\fwiring\fh\brness\fclips\ffrom\fthe\fcylinder\fhe\bd.\f
6. 6.
Remove\fthe\fglow\fplug\fpower\fsupply.\f
\f\f
\f\f
\f\f
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