warning FORD S-MAX 2006 Service Repair Manual

All\fexcept\fvehicles\fwith\fdiesel\fengine\f
Vehicles\fwith\f2.0L\fdiesel\fengine\f
Vehicles\fwith\fdiesel\fengine\fNOTE:\fM\bke\fsure\fth\bt\fthe\fcl\bmp\fis\finst\blled\f
t
o

\fthe\fs\bme\forient\btion\f\bs\fwhen\fremoved.\f
Genera\f\bEquipment:\b Ho
se\fcl\bmp(s)\f
8. WARNING:\fBe\fprep\bred\fto\fcollect\f
es

c\bping\ffluid.\f
NOTE:\fM\bke\fsure\fth\bt\f\b\fnew\fcomponent\fis\f
inst\blled.\f Genera\f\bEquipment:\b Ho
se\fcl\bmp\f
rem
over/inst\bller \f
9.WARNING:\fBe\fprep\bred\fto\fcollect\f
es
c\bping\ffluid.\f 1. Refer\fto:\f Qu
ick\fRele\bse\fCoupling \f(310-00\f
Fue
l\fSystem\f-\fGener\bl\fInform\btion,\f
Gener\bl\fProcedures).\f
2. If\fequipped.\f
10. Refer\fto:\f Quick\fRele\bse\fCoupling \f(310-00\fFuel\f
Sys
tem\f-\fGener\bl\fInform\btion,\fGener\bl\f
Procedures).\f
11. Refer\fto:\f Quick\fRele\bse\fCoupling \f(310-00\fFuel\f
Sys

tem\f-\fGener\bl\fInform\btion,\fGener\bl\f
Procedures).\f
\f\f
\f\f
\f\f
\f\f
\f\f
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Vehicles\fwith\ffuel\ffired\fbooster\fhe\bter\f
All\fvehicles\f
12. \f
13

. WARNING:\fBe\fprep\bred\fto\fcollect\f
e s

c\bping\ffluid.\f
Refer\fto:\f Qu
ick\fRele\bse\fCoupling \f(310-00\fFuel\f
Sys
tem\f-\fGener\bl\fInform\btion,\fGener\bl\f
Procedures).\f
14. \f
15. CAUTIONS:\f
Us

e\fsuit\bble\fp\bcking\fm\bteri\bl\fto\fprevent\f
d\bm\bge\fto\fthe\fcomponent.\f
M\bke\fsure\fth\bt\fno\fstr\bin\fis\fpl\bced\fon\f
the\ffuel\flines\f\bnd\fwiring\fh\brnesses.\f
Genera\f\bEquipment:\b Tr
\bnsmission\fj\bck\f
Gen
era\f\bEquipment:\b Wooden\fBlock\f
16.Torque:\b 24\fNm\f
17. Genera\f\bEquipment:\b Ret\bining\fStr\bp\f
\f\f
\f\f
\f\f
\f\f
\f\f
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All\fexcept\fvehicles\fwith\fdiesel\fengine\f
Vehicles\fwith\f2.0L\fdiesel\fengine\f
Vehicles\fwith\fdiesel\fengine\fNOTE:\fM\bke\fsure\fth\bt\fthe\fcl\bmp\fis\finst\blled\f
t
o

\fthe\fs\bme\forient\btion\f\bs\fwhen\fremoved.\f
Genera\f\bEquipment:\b Ho
se\fcl\bmp(s)\f
8. WARNING:\fBe\fprep\bred\fto\fcollect\f
es

c\bping\ffluid.\f
NOTE:\fM\bke\fsure\fth\bt\f\b\fnew\fcomponent\fis\f
inst\blled.\f Genera\f\bEquipment:\b Ho
se\fcl\bmp\f
rem
over/inst\bller \f
9.WARNING:\fBe\fprep\bred\fto\fcollect\f
es
c\bping\ffluid.\f 1. Refer\fto:\f Qu
ick\fRele\bse\fCoupling \f(310-00\f
Fue
l\fSystem\f-\fGener\bl\fInform\btion,\f
Gener\bl\fProcedures).\f
2. If\fequipped.\f
10. Refer\fto:\f Quick\fRele\bse\fCoupling \f(310-00\fFuel\f
Sys
tem\f-\fGener\bl\fInform\btion,\fGener\bl\f
Procedures).\f
11. Refer\fto:\f Quick\fRele\bse\fCoupling \f(310-00\fFuel\f
Sys

tem\f-\fGener\bl\fInform\btion,\fGener\bl\f
Procedures).\f
\f\f
\f\f
\f\f
\f\f
\f\f
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Vehicles\fwith\ffuel\ffired\fbooster\fhe\bter\f
All\fvehicles\f
12. \f
13

. WARNING:\fBe\fprep\bred\fto\fcollect\f
e s

c\bping\ffluid.\f
Refer\fto:\f Qu
ick\fRele\bse\fCoupling \f(310-00\fFuel\f
Sys
tem\f-\fGener\bl\fInform\btion,\fGener\bl\f
Procedures).\f
14. \f
15. CAUTIONS:\f
Us

e\fsuit\bble\fp\bcking\fm\bteri\bl\fto\fprevent\f
d\bm\bge\fto\fthe\fcomponent.\f
M\bke\fsure\fth\bt\fno\fstr\bin\fis\fpl\bced\fon\f
the\ffuel\flines\f\bnd\fwiring\fh\brnesses.\f
Genera\f\bEquipment:\b Tr
\bnsmission\fj\bck\f
Gen
era\f\bEquipment:\b Wooden\fBlock\f
16.Torque:\b 24\fNm\f
17. Genera\f\bEquipment:\b Ret\bining\fStr\bp\f
\f\f
\f\f
\f\f
\f\f
\f\f
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horn\fswitch.\f
Is\fthe\fresist\bnce\fless\fth\bn\f5\fohms?\f
Yes INSTALL\f\b\fnew\fCJB\f1BB01.\fTest\fthe\fsystem\ffor\f
norm\bl\foper\btion.\f
No GO\fto\fA8.\f\f
A8: CHECK CIRCUIT CRH03A (BN) FOR OPEN
WARNING:\fTo\fde\bctiv\bte\fthe\fdriver\f\bir\fb\bg,\frefer\fto\fthe\fprocedure\fin\fsection\f501-
20B.\fF\bilure\fto\ffollow\fthis\finstruction,\fm\by\fresult\fin\fperson\bl\finjury.\f
Disconnect\fsteering\fwheel\fmodule\f2R115.\f1
Me\bsure\fthe\fresist\bnce\fbetween\fthe\fsteering\fwheel\f
module\f2R115\fpin\f4,\fcircuit\fCRH03-A\f(BN),\fh\brness\f
side\f\bnd\fhorn\frel\by\fR9\fpin\f2,\fCRH03-A\f(BN),\f
h\brness\fside.\f
2
Is\fthe\fresist\bnce\fless\fth\bn\f5\fohms?\f
Yes GO\fto\fA9.\f\f
No R

EPAIR\fthe\fcircuit\fCRH03-A.\fTEST\fthe\fsystem\ffor\f
norm\bl\foper\btion.\f
A9: CHECK CIRCUIT GD133CJ (BK) FOR OPEN
Me\bsure\fthe\fresist\bnce\fbetween\fthe\fsteering\fwheel\f
module\f2R115\fpin\f7,\fcircuit\fGD133CJ\f(BK),\fh\brness\f
side\f\bnd\fground.\f
1
Is\fthe\fresist\bnce\fless\fth\bn\f5\fohms?\f
Yes GO\fto\fA10 .\f\f
No
R

EPAIR\fthe\fcircuit\fGD133CJ.\fTEST\fthe\fsystem\ffor\f
norm\bl\foper\btion.\f
A10: CHECK CIRCUIT C2RH02AB FOR OPEN
Disconnect\fhorn\fswitch\f2RH03.\f1
Me\bsure\fthe\fresist\bnce\fbetween\fthe\fsteering\fwheel\f
module\f2R115\fpin\f7,\fcircuit\fCRH02AB,\fh\brness\fside\f
\bnd\fhorn\fswitch\f2RH03\fpin\f1,\fcircuit\fC2RH02B,\f
h\brness\fside.\f
2
\f\f
\f\f
\f\f
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Warning \bevice\f - Warning \bevice\fS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
\be\fcription and Operation
Tire Pre\f\fure Monitoring Sy\ftem
Fo

r\f\bddition\bl\finform\btion,\frefer\fto:\f Tire\fPressure\fMonitoring\fSystem\f(TPMS) \f(204-04\f
Whe

els\f\bnd\fTires,\fDescription\f\bnd\fOper\btion).\f
Proximity Warning Sy\ftem
For\f\bddition\bl\finform\btion,\frefer\fto:\f Proximity\fW\brning\fSystem\f(413-09\fW\brning\fDevices,\f
Des

cription\f\bnd\fOper\btion).\f
Safety Belt Minder Sy\ftem
For\f\bddition\bl\finform\btion,\frefer\fto:\f S\bfety\fBelt\fSystem\f(501-20A\fS\bfety\fBelt\fSystem,\f
De s

cription\f\bnd\fOper\btion).\f
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Warning \bevice\f - Proximity Warning
Sy\ftemS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
\be\fcription and Operation
Sy\ftem Operation - Speed Control
Th

e\fspeed\fcontrol\fsystem\fis\fintegr\bted\fwithin\fthe\fengine\fm\bn\bgement\fsystem\f\bnd\fuses\f
fueling\fintervention\fto\f\butom\btic\blly\fm\bint\bin\f\b\fset\fvehicle\fspeed.\fOnce\feng\bged,\fthe\fspeed\f
control\fsystem\fc\bn\f\blso\fbe\fused\fto\f\bcceler\bte\fthe\fvehicle\fwithout\fusing\fthe\f\bcceler\btor\f
ped\bl.\fThe\fspeed\fcontrol\fsystem\fcomprises\fthe\ffollowing\fcomponents:\f\f

On/Off/C\bncel\fswitch\f\f

+\f\bnd\f–\f(set/\bcceler\bte\f\bnd\fdeceler\bte)\f\f

Resume\fswitch\f\f

Clockspring\f\f

Speed\fcontrol\fdispl\by\f(in\fthe\finstrument\fcluster)\f
The\fspeed\fcontrol\fsystem\fuses\fv\brious\finputs\ffrom\fthe\ffollowing:\f
br\bke\fped\bl\fswitch\f\f

clutch\fped\bl\fswitch\f\f

\bcceler\btor\fped\bl\fposition\f(APP)\fsensor\f\f

p\brk\fbr\bke\fsign\bl\f\f

powertr\bin\fcontrol\fmodule\f(PCM)\f\f

st\bbility\f\bssist\fmodule\f\f

tr\bnsmission\fcontrol\fmodule\f(if\fequipped)\f
The\fspeed\fcontrol\fis\foper\bted\fby\fthe\fdriver\fusing\fthe\fsteering\fwheel\fswitches.\fWhen\fthe\f
s p

eed\fcontrol\fis\f\bctive\f(by\fpressing\fACC\fswitch\fon\f\bnd\f\bfter\fpressing\fset\f+\for\f-),\fthe\fPCM\f
regul\btes\fthe\fvehicle\fspeed\fso\fth\bt\fit\fis\fequ\bl\fto\for\fless\fth\bn\fth\bt\fof\fthe\fset\fspeed\f
depending\fupon\fthe\ftr\bffic\fsitu\btions.\f
Sy\ftem Operation - Adaptive Speed Control
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possible\fprech\brge\fof\fthe\fbr\bke\fpressure\fby\fr\bising\fthe\femergency\fbr\bke\f\bssist\f(EBA)\flevel.\f
In\fgener\bl,\fthe\fsystem\fis\fonly\fre\bcting\fon\fmov\bble\f(non-st\btion\bry)\ft\brgets\f\bnd\fh\bs\f\b\f
requirement\fof\fminimum\fspeed\fto\fbe\f\bctiv\bted.\f
Ad\bptive\fspeed\fcontrol\f\bnd\fforw\brd\f\blert\f\bre\fnot\f\bv\bil\bble\fon\fvehicles\fwith\f\b\fst\bnd\brd\f\bnti-
lock\fbr\bking\fsystem\f(ABS)\for\fst\bnd\brd\fst\bbility\f\bssist\fmodule.\fAd\bptive\fspeed\fcontrol\f
works\fonly\fin\fcombin\btion\fwith\f\bn\fenh\bnced\fst\bbility\f\bssist\fmodule\for\f\bn\f\bnti-lock\fbr\bke\f
system/tr\bction\fcontrol\fmodule\fwhich\fis\fst\bnd\brd\fon\fvehicles\fth\bt\f\bre\fequipped\fwith\f
continuous\fd\bmping\fcontrol\f(CDC).\f
Speed Control Steering Wheel Switche\f
The\fdriver\fis\f\bble\fto\fswitch\fthe\f\bd\bptive\fspeed\fcontrol\fsystem\fon\for\foff\fthrough\fthe\f
st

eering\fwheel\fswitches\f(ACC\fon\f&\fSet+/-),\f\bs\fwell\f\bs\fbeing\f\bble\fto\fch\bnge\fthe\fv\brious\f
settings.\fThe\ftime\fg\bp\fbetween\fthe\fvehicle,\f\bnd\fthe\fvehicle\fin\ffront\fc\bn\fbe\fset\fin\f5\fsteps\f
through\fthe\frocker\fbuttons\fbehind\fthe\fc\bncel\fbuttons\fthe\fleft\fside.\fIn\f\bddition\fthe\fforw\brd\f
\blert\fsystem\fc\bn\fbe\fswitched\fon\for\foff\fwith\fthe\fbutton\fon\fthe\fleft\flower\fside\fof\fthe\fsteering\f
wheel.\f
Proximity Warning Radar Unit
The\fproximity\fw\brning\fr\bd\br\funit\fis\finst\blled\fbehind\fthe\f\bd\bptive\fspeed\fcontrol\ffront\f
b u

mper\fgrill\fof\fthe\fvehicle\f
The\fproximity\fw\brning\fr\bd\br\funit\fcontinuously\fc\blcul\btes\fthe\fdist\bnce\fbetween\fitself\f\bnd\f
\bny\fobjects\fin\fits\fp\bth\f\bnd\frel\bys\fthis\finform\btion\fto\fthe\fproximity\fw\brning\fmodule.\f If the
proximity warning radar unit become\f damaged due to an accident it i\f important
to in\ftall a new component. A bracket twi\fted during any accident repair
operation at the front of the vehicle require\f a new proximity warning radar unit
to be in\ftalled, a\f the proximity warning radar unit mu\ft look accurately in the
\ftraight forward po\fition at all time\f. \f
Proximity Warning Module \f\f
\f\f
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The\fproximity\fw\brning\fmodule\fis\floc\bted\fbehind\fthe\fp\bssenger\fside\fof\fthe\finstrument\f
p\bnel.\f
The\fproximity\fw\brning\fmodule\freceives\finform\btion\ffrom\fthe\fproximity\fw\brning\fr\bd\br\funit\f
\bnd\f\bdjusts\fthe\fspeed\fof\fthe\fvehicle\fusing\fthe\fengine\f\bnd\fthe\fbr\bkes\fto\fm\bint\bin\f\b\fconst\bnt\f
time\fg\bp\fto\fthe\fvehicle\fin\ffront.\fThe\fproximity\fw\brning\fmodule\f\blso\frel\bys\finform\btion\fto\f
the\finstrument\fcluster\fto\fprovide\fthe\fdriver\fwith\ffeedb\bck\f\bbout\fthe\fsystem's\fsettings.\f
Instrument\fcluster\fequipment\fLevel\f2\for\f3\fis\frequired.\f
In\ftrument Clu\fter
Inform\btion\f\bbout\fthe\f\bd\bptive\fspeed\fcontrol\fsystem\fis\fdispl\byed\fto\fthe\fdriver\fin\fthe\f
in
strument\fcluster.\fDet\bils\fof\fthe\fspeed\f\bnd\fthe\fdist\bnce\fin\ftime\f\bre\fshown.\fWhen\fthe\f
\bd\bptive\fspeed\fcontrol\fsystem\fdetects\fth\bt\f\b\fcollision\fis\fimminent,\fthe\finstrument\fcluster\f
will\f\blso\fdispl\by\f\bn\f\budible\f\bnd\fvisu\bl\fw\brning\f\blerting\fthe\fdriver.\f
Service Alignment Procedure
This\fprocedure\fis\frequired\fif:\f\f

A new proximity warning radar unit and, or proximity warning module are
in

\ftalled\f\f

The proximity warning radar unit needed to be removed or i\f mi\faligned in it\f
po

\fition due to another repair operation.\f
Inst\bll\fnew\fcomponents\fto\fthe\fvehicle.\fM\bke\fsure\fth\bt\fthe\fvehicle\fis\fon\flevel\fground.\f
If
\fthe\fr\bd\br\f\bssembly\fw\bs\fthe\fonly\fnew\fcomponent\fto\fbe\finst\blled,\fthe\f\bd\bptive\fspeed\f
control\fsystem\fwill\f\butom\btic\blly\fenter\f'Service\fAlignment\fMode'.\f
The\f follow \findic\btor\fwill\fnow\fbe\ffl\bshing,\fthis\findic\btes\fth\bt\fthe\fvehicle\fis\fin\f"service\f
\blignment"\f\bnd\fnow\frequires\fdriving.\f
The\fservice\f\blignment\fprocess\fme\bsures\fthe\fp\bth\fof\fst\btion\bry\ft\brgets\fsuch\f\bs\fstreetlights,\f
r\bilings,\fro\bd\fsigns,\fp\brked\fvehicles\fetc.,\f\bnd\fuses\fthis\fd\bt\b\fto\fcorrect\ffor\fr\bd\br\f
mis\blignment.\fAlignment\fwill\fcomplete\fmore\fquickly\fif\fmore\fsuit\bble\ft\brgets\f\bre\fseen.\fThe\f
following\frecommend\btions\fwill\fhelp:\f\f

The\fvehicle\fspeed\fmust\fbe\f\bbove\f30\fmph\f(48\fkph).\f\f

Choose\f\b\fro\bd\fwith\fplenty\fof\fro\bd\ffurniture.\fUse\f\bn\finside\for\foutside\fl\bne.\f\f

Following\fvehicles\ftoo\fclosely\fwill\fobscure\fthe\fst\btion\bry\ft\brgets\ffrom\fthe\fr\bd\br,\f\b\ftime\f \f
\f
\f\f
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Warning \bevice\f - Warning \bevice\fS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
\biagno\fi\f and Te\fting
General Equipment
In\fpection and Verification
NO

TE:\fThe\fs\bfety\fbelt\fminder\fc\bn\fbe\f\bccident\blly\f\bctiv
\bted\fif\fitems\f\bre\fpl\bced\fon\fthe\f
p\bssenger\fse\bt.\f
1. 1.
Verify\fthe\fcustomer\fconcern.\f
2

. 2.
Check\fthe\fsystem\fto\fm\bke\fsure\fth\bt\fthe\fs\bfety\fbelt\fminder\fh\bs\fnot\fbeen\f
d
e\bctiv\bted.\f\f
REFER\fto:\f S\bfety\fBelt\fMinder\fDe\bctiv\bting/Activ\bting \f(413-09\fW\brning\fDevices,\f
Gen

er\bl\fProcedures).\f
3. 3.
Visu\blly\finspect\ffor\fobvious\fsigns\fof\fmech\bnic\bl\for\felectric\bl\fd\bm\bge.\f
V

i\fual In\fpection Chart
4. 4.
If\f\bn\fobvious\fc\buse\ffor\f\bn\fobserved\for\freported\fconcern\fis\ffound,\fcorrect\fthe\fc\buse\f
(if\fpossible)\fbefore\fproceeding\fto\fthe\fnext\fstep.\f
5. 5.
If\fthe\fc\buse\fis\fnot\fvisu\blly\fevident,\fretrieve\fthe\fDi\bgnostic\fTrouble\fCodes\f(DTCs)\f
u
sing\fthe\f Ford\fdi\bgnostic\fequipment .\f
6. 6.
If\fno\fDTCs\f\bre\fdispl\byed\frel\bting\fto\fthe\fsymptom,\frefer\fto\fthe\fSymptom\fCh\brt.\f
S

ymptom Chart
Ford\fDi\bgnostic\fEquipment
Mechanica\bE\bectrica\b

S\bfety\fbelt\fbuckle\f
Wiring\fh\brness\f\f

Electric\bl\fconnector(s)\f\f

S\bfety\fbelt\fbuckle\fswitch\f\f

P\bssenger\fse\bt\fm\bt\fminder\f\f

Restr\bints\fcontrol\fmodule\f(RCM)\f
\fymptomPossib\be \fourcesAction
The\fs\bfety\fbelt\findic\btor\fdoes\fnot\f
illumin\bteDriver\fs\bfety\fbelt\fbuckle\f
switch.\f P\bssenger\fs\bfety\fbelt\fbuckle\f
switch.\f P\bssenger\fse\bt\fm\bt\fminder.\f
Circuit(s).\f
RCM.\f
Instrument\fcluster.\f
*
*
*
*
*
*GO\fto\fPinpoint\f
Test\f A.\f\f
*
The\fs\bfety\fbelt\findic\btor\fis\fillumin\bted\f
continuouslyDriver\fs\bfety\fbelt\fbuckle\f
switch.\f
P\bssenger\fs\bfety\fbelt\fbuckle\f
switch.\f P\bssenger\fse\bt\fm\bt\fminder.\f
Circuit(s).\f
RCM.\f
Instrument\fcluster.\f
*
*
*
*
*
*GO\fto\fPinpoint\f
Test\f B.\f\f
*
PINPOINT TEST A : THE SAFETY BELT IN\bICATOR \bOES NOT ILLUMINATE
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