FORD S-MAX 2006 Service Repair Manual
Manufacturer: FORD, Model Year: 2006, Model line: S-MAX, Model: FORD S-MAX 2006Pages: 4402, PDF Size: 93.08 MB
Page 2781 of 4402
7. \f
8. \f
9. \f
10. \f
11. \f
\f\f
\f\f
\f\f
\f\f
\f\f
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Page 2782 of 4402
Assembl\b 12. \f
1
3
.Torque:\b 7\fNm
\f
14. To\finst\bll\freverse\fthe\fremov\bl\fprocedure.\f
\f\f
\f\f
\f\f
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Page 2783 of 4402
Auxiliar\b Clima\fe Con\frol - Auxiliar\b Clima\fe
Con\frol HousingS-MAX/G\bl\bxy\f2006.5\f(02/2006
\fPrint
Disassembl\b and Assembl\b
Ma\ferials
Disassembl\b
NO
TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
NameSpec\bf\bcat\bo\f
Compressor\fOil\f-\fAir\fConditioningWSH-M1C231-B\f/\f6U7J-M1C231-AA
1. Remove\fthe\f\bddition\bl\fclim\bte\fcontrol\fhousing.\fRefer\fto:\fZus\btzklim\b\bnl\bgengehäuse\f(412-02,\f
Remov\bl\f\bnd\fInst\bll\btion).\f 2. \f\f1.
Torque:\b
9\fNm
2.Torque:\b
6\fNm
3. \f
\f
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Page 2784 of 4402
Assembl\b 4. \f
5.
Co\bt\fthe\fO-rings\fon\fthe\frefriger\bnt\flines.\f
Mater\fal:\b Compressor\fOil\f-\fAir\fConditioning\f(WSH-
M1 C
231-B\f/\f6U7J-M1C231-AA) \f
6. T
o\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f
\f\f
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Page 2785 of 4402
Instrum\bnt Clust\br \fnd P\fn\bl Illumin\ftion
- Instrum\bnt Clust\br \fnd P\fn\bl
Illumin\ftionS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Di\fgnosis \fnd T\bsting
R\bf\br to Wiring Di\fgr\fms S\bction 413-00, for sch\bm\ftic \fnd conn\bctor
in
form\ftion.
G\bn\br\fl Equipm\bnt
Instrum\bnt Clust\br \fnd Dimm\fbl\b B\fcklighting
Th
e\fdimm\bble\fillumin\btion\futilizes\flight\femitting\fdiodes\f(LEDs)\f\bnd\fbulb(s).\f\f
The\ffollowing\fdimm\bble\fcomponents\f\bre\fb\bcklit\fusing\fLEDs\fonly:\f
tr\bnsmission\fcontrol\flever\f\f
he\bter\fcontrol\fp\bnel\f\f
\budio\funit\f\f
n\bvig\btion\fsystem\fdispl\by\fmodule\f\f
instrument\fcluster\f\f
clim\bte\fcontrol\fmodule\f\f
h\bz\brd\fswitch\f\f
tr\bction\fcontrol\fsystem\fdis\bble\fswitch\f\f
right-h\bnd\f\bnd\fleft-h\bnd\fhe\bted\ffront\fse\bt\fswitch(es)\f
Insp\bction \fnd V\brific\ftion
1. 1.
Verify\fthe\fcustomer\fconcern.\f
2
. 2.
Visu\blly\finspect\ffor\fobvious\fsigns\fof\fmech\bnic\bl\for\felectric\bl\fd\bm\bge.\f
V
isu\fl Insp\bction Ch\frt
3. 3.
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
4. 4.
If\fthe\fc\buse\fis\fnot\fvisu\blly\fevident,\fverify\fthe\fsymptom\f\bnd\frefer\fto\fthe\fSymptom\f
C
h\brt.\f
Symptom Ch\frt
Worldwide\fdi\bgnostic\fsystem\f(WDS)
Mechanica\bE\bectrica\b
Engine/engine\fcomp\brtment\for\funderbody\f
co
mponents\f\f
Fluid\flevels\f\f
Accessory\finst\bll\btion\fFuse(s)\f\f
Loose\for\fcorroded\fconnector
(s
)\f\f
Instrument\fcluster\f\f
Switch(es)\f\f
Wiring\fH\brness\f\f
Circuit(s)\f\f
LED(s)\f
\fymptomPossib\be \fourcesAction
The\fcontrol\fillumin\btion\fis\finoper\btiveFuse.\f
He\bdl\bmp\fswitch.
\f
Circuit.\f
*
*
*
REFER\fto\fthe\fWDS.\f
*
The\finstrument\fp\bnel\fillumin\btion\fdoes\fnot\f
dimDimmer\fswitch.\f
*INSTALL\f\b\fnew\f
he\bdl\bmp/dimmer\fswitch\f
*
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Page 2786 of 4402
Pinpoint T\bsts
NOTE:\fUse\f\b\fdigit\bl\fmultimeter\ffor\f\bll\felectric\bl\fme\bs
urements.\f
unit.\f
The\fInstrument\fcluster\fillumin\btion\fis\f
inoper\btiveCircuit(s).\f
Instrument\f
cluster.\f
*
*REFER\fto\fthe\fWDS.\f
*
The\fclim\bte\fcontrol\fillumin\btion\fis\finoper\btiveCircuit(s).\f
Clim\bte\fcontrol\f
\bssembly.\f
*
*REFER\fto\fthe\fWDS.\f
*
The\f\budio\fsystem\fillumin\btion\fis\finoper\btiveCircuit(s).\f
Audio\funit.\f
*
*REFER\fto\fthe\fWDS.\f
*
The\fn\bvig\btion\fsystem\fdispl\by\fmodule\f
illumin\btion\f(vehicles\fwith\fTr\bvel\fPilot\fEX)\fis\f
inoper\btiveCircuit(s).\f
N\bvig\btion\f
system\fdispl\by\f
module.\f
*
*REFER\fto\fthe\fWDS.\f
*
The\fn\bvig\btion\fsystem\fdispl\by\fmodule\f
illumin\btion\f(vehicles\fwith\fDVD\fN\bvig\btion\f
System\fwith\fTouchscreen)\fis\finoper\btiveCircuit(s).\f
N\bvig\btion\f
system\fdispl\by\f
module.\f
*
*REFER\fto\fthe\fWDS.\f
*
The\fcig\br\flighter\fillumin\btion\fis\finoper\btiveCircuit(s).\f
Cig\br\flighter.\f
*
*GO\fto\fPinpoint\fTest\f
A.\f\f
*
The\fh\bz\brd\fswitch\fillumin\btion\fis\finoper\btiveCircuit(s).\f
H\bz\brd\fswitch.\f
*
*GO\fto\fPinpoint\fTest\f
B.\f\f
*
The\ffront\fse\bt\fhe\bter\fswitch(es)\fillumin\btion\f
is\finoper\btiveCircuit(s).\f
Front\fse\bt\fhe\bter\f
switch(es).\f
*
*GO\fto\fPinpoint\fTest\f
C.\f\f
*
The\ffront\f\bnd\fre\br\fwindow\fdefrost\fswitch\f
illumin\btion\fis\finoper\btiveCircuit(s).\f
Re\br\fwindow\f
defrost\fswitch.\f
*
*GO\fto\fPinpoint\fTest\f
D.\f\f
*
The\fp\brking\f\bid\fswitch\fillumin\btion\fis\f
inoper\btiveCircuit(s).\f
p\brking\f\bid\f
switch.\f
*
*GO\fto\fPinpoint\fTest\f
E.\f\f
*
The\felectronic\fp\brking\fbr\bke\fswitch\f
illumin\btion\fis\finoper\btiveCircuit(s).\f
Electronic\fp\brking\f
br\bke\fswitch.\f
*
*
GO\fto\fPinpoint\fTest\f
F.\f\f
*
PINPOINT TEST A : THE CIGAR LIGHTER ILLUMINATION IS INOPERATIVE
TE\fT CONDITION\fDETAIL\f/RE\fULT\f/ACTION\f
A1: CHECK CIRCUIT CLN17S (BN) FOR VOLTAGE
Disconnect\fCig\br\fLighter\fC2DC07-B.\f1
Ignition\fswitch\fin\fposition\fII.\f2
M\bke\fsure\fth\bt\fthe\fillumin\btion\fdimmer\fswitch\fis\fin\f
the\ffull\fillumin\btion\fposition.\f3
Pl\bce\fthe\fhe\bdl\bmp\fswitch\fin\fthe\fON\fposition.\f4
Me\bsure\fthe\fvolt\bge\fbetween\fthe\fcig\br\flighter\f
C2DC07-B\fpin\f1,\fcircuit\fCLN17S\f(BN),\fh\brness\fside\f
\bnd\fground.\f5
Is\fthe\fvolt\bge\fgre\bter\fth\bn\f10\fvolts?\f
Y\bs GO\fto\fA2.\f\f
\f\f
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Page 2787 of 4402
No REPAIR\fthe\fcircuit\fCLN17S\f(BN)\for\fcircuit\fCLN17G\f
(BN)\f\bs\fnecess\bry.\fTEST\fthe\fsystem\ffor\fnorm\bl\f
oper\btion.\f
A2: CHECK CIRCUIT GD138AZ (BK/WH) FOR OPEN
Connect\fCig\br\fLighter\fC2DC07-B.\f1
Disconnect\fCig\br\fLighter\fC2DC07-A.\f2
Me\bsure\fthe\fresist\bnce\fbetween\fthe\fcig\br\flighter\f
C2DC07-A\fpin\f1,\fcircuit\fGD138AZ\f(BK/WH),\fh\brness\f
side\f\bnd\fground.\f3
Is\fthe\fresist\bnce\fless\fth\bn\f5\fohms?\f
Y\bs
INSTALL\f\b\fnew\fcig\br\flighter.\fTEST\fthe\fsystem\ffor\f
norm\bl\foper\btion.\f
No
REPAIR\fcircuit\fGD138AZ\f(BK/WH)\for\fcircuit\fGD138AL\f
(BN/WH)\f\bs\fnecess\bry.\fTEST\fthe\fsystem\ffor\fnorm\bl\f
oper\btion.\f
PINPOINT TEST B : THE HAZARD SWITCH ILLUMINATION IS
INOPERATIVE
TE\fT CONDITION\fDETAIL\f/RE\fULT\f/ACTION\f
B1: CHECK CIRCUIT CLS38A (VT/WH) FOR VOLTAGE
Disconnect\fH\bz\brd\fSwitch\fC2LS32.\f1
Ignition\fswitch\fin\fposition\fII.\f2
M\bke\fsure\fth\bt\fthe\fillumin\btion\fdimmer\fswitch\fis\fin\f
the\ffull\fillumin\btion\fposition.\f3
Pl\bce\fthe\fhe\bdl\bmp\fswitch\fin\fthe\fON\fposition.\f4
Me\bsure\fthe\fvolt\bge\fbetween\fthe\fh\bz\brd\fswitch\f
C2LS32\fpin\f5,\fcircuit\fCLS38A\f(VT/WH),\fh\brness\fside\f
\bnd\fground.\f5
Is\fthe\fvolt\bge\fgre\bter\fth\bn\f10\fvolts?\f
Y\bs GO\fto\fB2.\f\f
No R
EPAIR\fthe\fcircuit.\fTEST\fthe\fsystem\ffor\fnorm\bl\f
oper\btion.\f
B2: CHECK CIRCUIT GD133CF (BK) FOR OPEN
Ignition\fswitch\fin\fposition\f0.\f1
Me\bsure\fthe\fresist\bnce\fbetween\fh\bz\brd\fswitch\f
C2LS32\fpin\f4,\fcircuit\fGD133CF\f(BK),\fh\brness\fside\f
\bnd\fground.\f2
\f\f
\f\f
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Page 2788 of 4402
Is\fthe\fresist\bnce\fless\fth\bn\f5\fohms?\f
Y\bs INSTALL\f\b\fnew\fh\bz\brd\fswitch.\fTEST\fthe\fsystem\ffor\f
norm\bl\foper\btion.\f
No
REPAIR\fthe\fcircuit\fGD133CF\f(BK)\for\fcircuit\fGD133AW\f
(BK)\f\bs\fnecess\bry.\fTEST\fthe\fsystem\ffor\fnorm\bl\f
oper\btion.\f
PINPOINT TEST C : THE FRONT SEAT HEATER SWITCH ILLUMINATION IS
INOPERATIVE
TE\fT CONDITION\fDETAIL\f/RE\fULT\f/ACTION\f
C1: CHECK INOPERATIVE FRONT SEAT HEATER SWITCH FOR VOLTAGE
Disconnect\fFront\fSe\bt\fHe\bter\fSwitch\f-\fC3HS29.\f1
Ignition\fswitch\fin\fposition\fII.\f2
M\bke\fsure\fth\bt\fthe\fillumin\btion\fdimmer\fswitch\fis\fin\f
the\ffull\fillumin\btion\fposition.\f3
Pl\bce\fthe\fhe\bdl\bmp\fswitch\fin\fthe\fON\fposition.\f4
Me\bsure\fthe\fvolt\bge\fbetween\fthe\ffront\fse\bt\fhe\bter\f
switch\fC3HS29\fpin\f3,\fcircuit\fCLN17H\f(BN),\fh\brness\f
side\f\bnd\fground.\f5
Is\fthe\fvolt\bge\fgre\bter\fth\bn\f10\fvolts?\f
Y\bs
GO\fto\fC2 .\f\f
No R
EPAIR\fcircuit\fCLN17H\f(BN),\fcircuit\fCLN17J\f(BN)\for\f
circuit\fCLN17G\f(BN)\f\bs\fnecess\bry.\fTEST\fthe\fsystem\f
for\fnorm\bl\foper\btion.\f
C2: CHECK THE FRONT SEAT HEATER SWITCH FOR OPEN
Me\bsure\fthe\fresist\bnce\fbetween\fthe\ffront\fse\bt\f
he\bter\fswitch\fC3HS29\fpin\f1,\fcircuit\fGD138AP\f(BK),\f
h\brness\fside\f\bnd\fground.\f1
Is\fthe\fresist\bnce\fless\fth\bn\f5\fohms?\f
Y\bs
\f\f
\f\f
\f\f
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Page 2789 of 4402
INSTALL\f\b\fnew\ffront\fse\bt\fhe\bter\fswitch.\fTEST\fthe\f
system\ffor\fnorm\bl\foper\btion.\f
No REPAIR\fcircuit\fGD138AP\f(BK),\fcircuit\fGD133AR\f(BK),\f
circuit\fGD133CE\f(BK)\for\fcircuit\fGD133AW\f(BK)\f\bs\f
necess\bry.\fTEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
PINPOINT TEST D : THE FRONT AND REAR WINDOW DEFROST SWITCH
ILLUMINATION IS INOPERATIVE
TE\fT CONDITION\fDETAIL\f/RE\fULT\f/ACTION\f
D1: CHECK THE FRONT AND REAR WINDOW DEFROST SWITCH FOR VOLTAGE
Disconnect\fRe\br\fWindow\fDefrost\fSwitch\fC2RD09.\f1
Ignition\fswitch\fin\fposition\fII.\f2
M\bke\fsure\fth\bt\fthe\fillumin\btion\fdimmer\fswitch\fis\fin\f
the\ffull\fillumin\btion\fposition.\f3
Pl\bce\fthe\fhe\bdl\bmp\fswitch\fin\fthe\fON\fposition.\f4
Me\bsure\fthe\fvolt\bge\fbetween\fthe\fre\br\fwindow\f
defrost\fswitch\fC2RD09\fpin\f5,\fcircuit\fCLN17H\f(BN),\f
h\brness\fside\f\bnd\fground.\f5
Is\fthe\fvolt\bge\fgre\bter\fth\bn\f10\fvolts?\f
Y\bs GO\fto\fD2.\f\f
No R
EPAIR\fthe\fcircuit\fCLN17T\f(BN)\for\fcircuit\fCLN17G\f
(BN)\f\bs\fnecess\bry.\fTEST\fthe\fsystem\ffor\fnorm\bl\f
oper\btion.\f
D2: CHECK CIRCUIT GD133BN (BK) FOR OPEN
Ignition\fswitch\fin\fposition\f0.\f1
Me\bsure\fthe\fresist\bnce\fbetween\fthe\fre\br\fwindow\f
defrost\fswitch\fC2RD09\fpin\f4,\fcircuit\fGD133BN\f(BK),\f
h\brness\fside\f\bnd\fground.\f2
Is\fthe\fresist\bnce\fless\fth\bn\f5\fohms?\f
Y\bs
INSTALL\f\b\fnew\fre\br\fwindow\fdefrost\fswitch.\fTEST\fthe\f
system\ffor\fnorm\bl\foper\btion.\f
No REPAIR\fcircuit\fGD133BN\f(BK),\fcircuit\fGD133CH\f(BK)\f
or\fcircuit\fGD133AW\f(BK)\f\bs\fnecess\bry.\fTEST\fthe\f
system\ffor\fnorm\bl\foper\btion.\f
PINPOINT TEST E : THE PARKING AID SWITCH ILLUMINATION IS
INOPERATIVE
TE\fT CONDITION\fDETAIL\f/RE\fULT\f/ACTION\f
E1: CHECK THE PARKING AID SWITCH FOR VOLTAGE
\f\f
\f\f
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Page 2790 of 4402
Disconnect\fP\brking\fAid\fSwitch\fC2CA15.\f1
Ignition\fswitch\fin\fposition\fII.\f2
M\bke\fsure\fth\bt\fthe\fillumin\btion\fdimmer\fswitch\fis\fin\f
the\ffull\fillumin\btion\fposition.\f3
Pl\bce\fthe\fhe\bdl\bmp\fswitch\fin\fthe\fON\fposition.\f4
Me\bsure\fthe\fvolt\bge\fbetween\fthe\fp\brking\f\bid\fswitch\f
C2CA15\fpin\f5,\fcircuit\fCLN17U\f(BN),\fh\brness\fside\f\bnd\f
ground.\f
5
Is\fthe\fvolt\bge\fgre\bter\fth\bn\f10\fvolts?\f
Y\bs GO\fto\fE2 .\f\f
No R
EPAIR\fthe\fcircuit\fCLN17U\f(BN)\for\fcircuit\fCLN17G\f
(BN)\f\bs\fnecess\bry.\fTEST\fthe\fsystem\ffor\fnorm\bl\f
oper\btion.\f
E2: CHECK CIRCUIT GD133BR (BK) FOR OPEN
Ignition\fswitch\fin\fposition\f0.\f1
Me\bsure\fthe\fresist\bnce\fbetween\fthe\fp\brking\f\bid\f
switch\fC2CA15\fpin\f4,\fcircuit\fGD133BR\f(BK),\fh\brness\f
side\f\bnd\fground.\f2
Is\fthe\fresist\bnce\fless\fth\bn\f5\fohms?\f
Y\bs INSTALL\f\b\fnew\fp\brking\f\bid\fswitch.\fTEST\fthe\fsystem\f
for\fnorm\bl\foper\btion.\f
No REPAIR\fcircuit\fGD133BR\f(BK),\fcircuit\fGD133CH\f(BK)\f
or\fcircuit\fGD133AW\f(BK)\f\bs\fnecess\bry.\fTEST\fthe\f
system\ffor\fnorm\bl\foper\btion.\f
PINPOINT TEST F : THE ELECTRONIC PARKING BRAKE SWITCH
ILLUMINATION IS INOPERATIVE
TE\fT CONDITION\fDETAIL\f/RE\fULT\f/ACTION\f
F1: CHECK THE ELECTRONIC PARKING BRAKE SWITCH FOR VOLTAGE
Disconnect\fElectronic\fP\brking\fBr\bke\fSwitch\fC3CB09.\f1
Ignition\fswitch\fin\fposition\fII.\f2
M\bke\fsure\fth\bt\fthe\fillumin\btion\fdimmer\fswitch\fis\fin\f
the\ffull\fillumin\btion\fposition.\f3
Pl\bce\fthe\fhe\bdl\bmp\fswitch\fin\fthe\fON\fposition.\f4
Me\bsure\fthe\fvolt\bge\fbetween\fthe\felectronic\fp\brking\f
br\bke\fswitch\fC3CB09\fpin\f1,\fcircuit\fCLN17N\f(BN),\f
h\brness\fside\f\bnd\fground.\f5
\f\f
\f\f
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