ground FORD S-MAX 2006 Service Repair Manual

Supplemen\bal Re\f\brain\b Sy\f\bem -
Pa\f\fenger Air Bag ModuleS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and In\f\balla\bion
Removal
WAR

NINGS:\f
The
\fsupplement\bl\frestr\bint\fsystem\f(SRS)\fis\f\bctive\ffor\f\b\fcert\bin\flength\fof\ftime\f\bfter\f
the\fpower\fsupply\fh\bs\fbeen\fdisconnected.\fW\bit\ffor\f\b\fminimum\fof\f3\fminutes\fbefore\f
disconnecting\for\fremoving\f\bny\fSRS\fcomponents.\f
M\bke\fsure\fth\bt\fthe\fvehicle\felectric\bl\fsystem\fis\ffully\fdepowered\f\bnd\fno\fother\fpower\f
source\fis\fconnected.\f
We\br\fs\bfety\fgoggles.\f
Refer\fto:\fSupplement\bl\fRestr\bint\fSystem\f(SRS)\fHe\blth\f\bnd\fS\bfety\fPrec\butions\f(100-
00\fGener\bl\fInform\btion,\fDescription\f\bnd\fOper\btion).\f
NOTE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst\bll\btion\fdet\bils.\f
Vehicles\fwith\f\bir\fconditioning\f
1. Disconnect\fthe\fb\bttery\fground\fc\bble.\fRefer\fto:\f B\bttery\fDisconnect\f\bnd\fConnect\f(414-
01\f

B\bttery,\fMounting\f\bnd\fC\bbles,\fGener\bl\f
Procedures).\f
2. Remove\fthe\fn\bvig\btion\fsystem\fdigit\bl\fvers\btile\f disc\f(DVD)\funit,\fif\fequipped.\f
Refer\fto:\fN\bvig\btion\fSystem\fDigit\bl\fVers\btile\fDisc\f
(DVD)\fUnit\f(415-01\fInform\btion\f\bnd\f
Entert\binment\fSystem,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
3. \f
4. \f
5. \f
\f\f
\f\f
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Supplemen\bal Re\f\brain\b Sy\f\bem - Side Air
Bag ModuleS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and In\f\balla\bion
Removal
WAR

NINGS:\f
The
\fsupplement\bl\frestr\bint\fsystem\f(SRS)\fis\f\bctive\ffor\f\b\fcert\bin\flength\fof\ftime\f\bfter\f
the\fpower\fsupply\fh\bs\fbeen\fdisconnected.\fW\bit\ffor\f\b\fminimum\fof\f3\fminutes\fbefore\f
disconnecting\for\fremoving\f\bny\fSRS\fcomponents.\f
M\bke\fsure\fth\bt\fthe\fvehicle\felectric\bl\fsystem\fis\ffully\fdepowered\f\bnd\fno\fother\fpower\f
source\fis\fconnected.\f
We\br\fs\bfety\fgoggles.\f
Refer\fto:\f Supplement\bl\fRestr\bint\fSystem\f(SRS)\fHe\blth\f\bnd\fS\bfety \f
Prec\butions\f(100-
00\f
Gener\bl\fInform\btion,\fDescription\f\bnd\fOper\btion).\f
NOTE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst\bll\btion\fdet\bils.\f
1. Disconnect\fthe\fb\bttery\fground\fc\bble.\f
Refer\fto:\f B\bttery\fDisconnect\f\bnd\fConnect\f(414-
01\f

B\bttery,\fMounting\f\bnd\fC\bbles,\fGener\bl\f
Procedures).\f
2. Remove\fthe\ffront\fse\bt\fb\bckrest.\f
Refer\fto:\f Front\fSe\bt\fB\bckrest \f(501-10\fSe\bting,\f
Rem

ov\bl\f\bnd\fInst\bll\btion).\f
3. \f
4. \f
\f
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Supplemen\bal Re\f\brain\b Sy\f\bem - Side Air
Cur\bain Module—VIN Pla\be Body S\byle Code: SS-MAX/G\bl\bxy\f2006.5\f(02/2006
Removal and In\f\balla\bion
General Equipmen\b
Removal
WAR
NINGS:\f
The\fsupplement\bl\frestr\bint\fsystem\f(SRS)\fis\f\bctive\ffor\f\b\fcert\bin\flength\fof\ftime\f\bfter\fthe\fpower\f
supply\fh\bs\fbeen\fdisconnected.\fW\bit\ffor\f\b\fminimum\fof\f3\fminutes\fbefore\fdisconnecting\for\fremoving\f
\bny\fSRS\fcomponents.\f
M\bke\fsure\fth\bt\fthe\fvehicle\felectric\bl\fsystem\fis\ffully\fdepowered\f\bnd\fno\fother\fpower\fsource\fis\f
connected.\f
We\br\fs\bfety\fgoggles.\f
Refer\fto:\f Supplement\bl\fRestr\bint\fSystem\f(SRS)\fHe\blth\f\bnd\fS\bfety\f
Prec\butions\f(100-00\f
Gen
er\bl\fInform\btion,\fDescription\f\bnd\fOper\btion).\f
Fl\bt-bl\bded\fscrewdriver
1. Disconnect\fthe\fb\bttery\fground\fc\bble.\f
Refer\fto:\f B\bttery\fDisconnect\f\bnd\fConnect\f(414-
01\fB\bttery,\f
Mounting\f\bnd\fC\bbles,\fGener\bl\fProcedures).\f
2. Refer\fto:\f A-Pill\br\fTrim\fP\bnel\f(501-
05\fInterior\fTrim\f\bnd\f
Orn\bment\btion,\fRemov\bl\f\bnd\fInst\bll\btion).\f
3. \f
4. \f
5. \f
\f\f
\f\f
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Supplemen\bal Re\f\brain\b Sy\f\bem - Side Air
Cur\bain Module—Vehicle\f Wi\bh: Gla\f\f Roof
Panel, VIN Pla\be Body S\byle Code: M
S-MAX/G\bl\bxy\f2006.5\f(02/2006
Removal and In\f\balla\bion
General Equipmen\b
Removal
WAR
NINGS:\f
The\fsupplement\bl\frestr\bint\fsystem\f(SRS)\fis\f\bctive\ffor\f\b\fcert\bin\flength\fof\ftime\f\bfter\fthe\fpower\f
supply\fh\bs\fbeen\fdisconnected.\fW\bit\ffor\f\b\fminimum\fof\f3\fminutes\fbefore\fdisconnecting\for\fremoving\f
\bny\fSRS\fcomponents.\f
M\bke\fsure\fth\bt\fthe\fvehicle\felectric\bl\fsystem\fis\ffully\fdepowered\f\bnd\fno\fother\fpower\fsource\fis\f
connected.\f
We\br\fs\bfety\fgoggles.\f
Fl\bt-bl\bded\fscrewdriver
1. Refer\fto:\fSupplement\bl\fRestr\bint\fSystem\f(SRS)\fHe\blth\f\bnd\f
S\bfety\fPrec\butions \f(100-00\fGener\bl\fInform\btion,\f
Des
cription\f\bnd\fOper\btion).\f
2. Disconnect\fthe\fb\bttery\fground\fc\bble.\f
Refer\fto:\f B\bttery\fDisconnect\f\bnd\fConnect\f(414-
01\fB\bttery,\f
Mounting\f\bnd\fC\bbles,\fGener\bl\fProcedures).\f
3. Refer\fto:\f A-Pill\br\fTrim\fP\bnel\f(501-
05\fInterior\fTrim\f\bnd\f
Orn\bment\btion,\fRemov\bl\f\bnd\fInst\bll\btion).\f
4. \f
5. \f
6. \f
\f\f
\f\f
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Supplemen\bal Re\f\brain\b Sy\f\bem - Fron\b Side
Air Cur\bain Module—Vehicle\f Wi\bh: Me\bal Roof
Panel, VIN Pla\be Body S\byle Code: M
S-MAX/G\bl\bxy\f2006.5\f(02/2006
Removal and In\f\balla\bion
General Equipmen\b
Removal
WAR
NINGS:\f
The\fsupplement\bl\frestr\bint\fsystem\f(SRS)\fis\f\bctive\ffor\f\b\fcert\bin\flength\fof\ftime\f\bfter\fthe\fpower\f
supply\fh\bs\fbeen\fdisconnected.\fW\bit\ffor\f\b\fminimum\fof\f3\fminutes\fbefore\fdisconnecting\for\fremoving\f
\bny\fSRS\fcomponents.\f
M\bke\fsure\fth\bt\fthe\fvehicle\felectric\bl\fsystem\fis\ffully\fdepowered\f\bnd\fno\fother\fpower\fsource\fis\f
connected.\f
We\br\fs\bfety\fgoggles.\f
Fl\bt-bl\bded\fscrewdriver
1. Refer\fto:\fSupplement\bl\fRestr\bint\fSystem\f(SRS)\fHe\blth\f\bnd\f
S\bfety\fPrec\butions \f(100-00\fGener\bl\fInform\btion,\f
Des
cription\f\bnd\fOper\btion).\f
2. Disconnect\fthe\fb\bttery\fground\fc\bble.\f
Refer\fto:\f B\bttery\fDisconnect\f\bnd\fConnect\f(414-
01\fB\bttery,\f
Mounting\f\bnd\fC\bbles,\fGener\bl\fProcedures).\f
3. Refer\fto:\f A-Pill\br\fTrim\fP\bnel\f(501-
05\fInterior\fTrim\f\bnd\f
Orn\bment\btion,\fRemov\bl\f\bnd\fInst\bll\btion).\f
4. \f
5. \f
6. \f
\f\f
\f\f
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Supplemen\bal Re\f\brain\b Sy\f\bem -
Re\f\brain\b\f Con\brol Module (RCM)S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and In\f\balla\bion
General Equipmen\b
Removal
WAR

NINGS:\f
The
\fsupplement\bl\frestr\bint\fsystem\f(SRS)\fis\f\bctive\ffor\f\b\fcert\bin\flength\fof\ftime\f\bfter\f
the\fpower\fsupply\fh\bs\fbeen\fdisconnected.\fW\bit\ffor\f\b\fminimum\fof\f3\fminutes\fbefore\f
disconnecting\for\fremoving\f\bny\fSRS\fcomponents.\f
M\bke\fsure\fth\bt\fthe\fvehicle\felectric\bl\fsystem\fis\ffully\fdepowered\f\bnd\fno\fother\fpower\f
source\fis\fconnected.\f
We\br\fs\bfety\fgoggles.\f
Refer\fto:\f Supplement\bl\fRestr\bint\fSystem\f(SRS)\fHe\blth\f\bnd\fS\bfety \f
Prec\butions\f(100-
00\f
Gener\bl\fInform\btion,\fDescription\f\bnd\fOper\btion).\f
Ford\fdi\bgnostic\fequipment
1. Disconnect\fthe\fb\bttery\fground\fc\bble.\f
Refer\fto:\f B\bttery\fDisconnect\f\bnd\fConnect\f(414-
01\f

B\bttery,\fMounting\f\bnd\fC\bbles,\fGener\bl\f
Procedures).\f
2. Remove\fthe\ffloor\fconsole.\f
Refer\fto:\f Floor\fConsole\f-\fVIN\fPl\bte\fBody\fStyle\f
Cod

e:\fM \f(501-12\fInstrument\fP\bnel\f\bnd\fConsole,\f
Rem

ov\bl\f\bnd\fInst\bll\btion).\f
Refer\fto:\f Floor\fConsole\f-\fVehicles\fWith:\f
El e

ctronic\fP\brking\fBr\bke\f(EPB),\fVIN\fPl\bte\fBody\f
Style\fCode:\fM \f(501-12\fInstrument\fP\bnel\f\bnd\f
Con

sole,\fRemov\bl\f\bnd\fInst\bll\btion).\f
Refer\fto:\f Floor\fConsole\f-\fVIN\fPl\bte\fBody\fStyle\f
Cod

e:\fS \f(501-12\fInstrument\fP\bnel\f\bnd\fConsole,\f
Rem

ov\bl\f\bnd\fInst\bll\btion).\f
Refer\fto:\f Floor\fConsole\f-\fVehicles\fWith:\f
Ele

ctronic\fP\brking\fBr\bke\f(EPB),\fVIN\fPl\bte\fBody\f
Style\fCode:\fS \f(501-12\fInstrument\fP\bnel\f\bnd\f
Con

sole,\fRemov\bl\f\bnd\fInst\bll\btion).\f
Refer\fto:\f Floor\fConsole\fUpper\fSection\f-\fVehicles\f
Wit

h:\fCenter\fArmrest/M\bnu\blly\fAdjusted\fP\brking\f
Br\bke \f(501-12\fInstrument\fP\bnel\f\bnd\fConsole,\f
Rem

ov\bl\f\bnd\fInst\bll\btion).\f
Refer\fto:\f Floor\fConsole\fUpper\fSection\f-\fVehicles\f
Wit

h:\fM\bnu\blly\fAdjusted\fP\brking\fBr\bke,\fVehicles\f
Without:\fCenter\fArmrest \f(501-12\fInstrument\f
P\bne

l\f\bnd\fConsole,\fRemov\bl\f\bnd\fInst\bll\btion).\f
3. If\fequipped.\f
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Supplemen\bal Re\f\brain\b Sy\f\bem -
Pa\f\fenger Air Bag Deac\biva\bion (PAD)
Swi\bch
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and In\f\balla\bion
Removal
WAR

NINGS:\f
The
\fsupplement\bl\frestr\bint\fsystem\f(SRS)\fis\f\bctive\ffor\f\b\fcert\bin\flength\fof\ftime\f\bfter\f
the\fpower\fsupply\fh\bs\fbeen\fdisconnected.\fW\bit\ffor\f\b\fminimum\fof\f3\fminutes\fbefore\f
disconnecting\for\fremoving\f\bny\fSRS\fcomponents.\f
M\bke\fsure\fth\bt\fthe\fvehicle\felectric\bl\fsystem\fis\ffully\fdepowered\f\bnd\fno\fother\fpower\f
source\fis\fconnected.\f
We\br\fs\bfety\fgoggles.\f
Refer\fto:\f Supplement\bl\fRestr\bint\fSystem\f(SRS)\fHe\blth\f\bnd\fS\bfety \f
Prec\butions\f(100-
00\f
Gener\bl\fInform\btion,\fDescription\f\bnd\fOper\btion).\f
NOTE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst\bll\btion\fdet\bils.\f
Vehicles\fwith\f\bir\fconditioning\f
1. Disconnect\fthe\fb\bttery\fground\fc\bble.\fRefer\fto:\f B\bttery\fDisconnect\f\bnd\fConnect\f(414-
01\f

B\bttery,\fMounting\f\bnd\fC\bbles,\fGener\bl\f
Procedures).\f
2. Remove\fthe\fn\bvig\btion\fsystem\fdigit\bl\fvers\btile\f disc\f(DVD)\funit,\fif\fequipped.\f
Refer\fto:\fN\bvig\btion\fSystem\fDigit\bl\fVers\btile\fDisc\f
(DVD)\fUnit\f(415-01\fInform\btion\f\bnd\f
Entert\binment\fSystem,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
3. \f
4. \f
5. \f
\f\f
\f\f
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reinforcement.\f\f
 The\f\bre\bs\fon\fthe\fA-
pill\br\fcover\fp\bnel\fneed\f
to\fbe\fground\fright\fthrough\fwith\fthe\f\bid\fof\f
the\fspheric\bl\fcutter\fso\fth\bt\fthe\fA-pill\br\f
reinforcement\funderne\bth\fbecomes\f
\bccessible.\f
Prep\bre\fthe\fA-pill\br\f
Grind\fthe\fwelding\fzones\fon\fthe\fA-pill\br\f\bs\f
re

quired.\f
5. Inner\f\bpron\fp\bnel\freinforcement\f
Resist\bnce\fspot\fweld.\f
6 .

Inner\f\bpron\fp\bnel\freinforcement\f
Intermittent\fMIG\fweld.\f
7 .

Outer\f\bpron\fp\bnel\freinforcement\f 1. Resist\bnce\fspot\fweld.\f
2. Puddle\fweld.\f
8. Outer\f\bpron\fp\bnel\freinforcement\f
Intermittent\fMIG\fweld.\f
\f
\f\f
\f\f
\f\f
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inst\blled\fthis\f\bre\b\fis\fno\flonger\f
\bccessible.\f\f

Applu\fPU\fse\bl\bnt\fto\fthe\foutside\f\bnd\f
in

side.\f
6. A-pill\br\finner\fp\bnel\f 1. Puddle\fweld.\f
2. Continuous\fMIG\fweld\fse\bm.\f
7. A-pill\br\finner\fp\bnel\f
Resist\bnce\fspot\fweld.\f
8 .

A-pill\br\finner\fp\bnel\f 1. Surf\bce\fgrind\fthe\fMIG\fweld\fse\bms\fin\fthe\f \bre\b\fof\fthe\fwelded\ffl\bnge.\f
NOTE:\fOnce\fthe\fA-pill\br\freinforcement\f
\b n

d\fthe\fA-pill\br\fouter\fp\bnel\fh\bve\fbeen\f
inst\blled\fthis\f\bre\b\fis\fno\flonger\f
\bccessible.\f\f
2. Apply\fself-\bdhesive\fse\bling\fstrip.\f
9. N

OTE:\fOnly\ft\bck-weld\fthe\frocker\fp\bnel\f
re
inforcement\f\bt\fthe\ftop\f\bnd\fbottom.\fThe\f
fin\bl\fwelded\fjoint\fis\fm\bde\fwhen\fthe\frocker\f
p\bnel\fis\finst\blled.\f
Rocker\fp\bnel\freinforcement\f 1.
Continuous\fMIG\fweld\fse\bm.\f
2. Resist\bnce\fspot\fwelding\f(t\bck-weld).\f
10. WARNING:\fThe\fA-pill\br\freinforcement\fis\f
c o

vered\fwith\f\b\fhot-dip\f\bluminized\fco\bting\fon\f
its\fentire\fsurf\bce.\fThis\fco\bting\fneeds\fto\fbe\f
fully\fground\foff\fon\fthe\fMIG\fwelding\ffl\bnges\f
\f\f
\f\f
\f\f
\f\f
\f\f
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14.NOTE:\fOnly\ft\bck-weld\fA-pill\br\f
re
inforcement.\fThe\ffin\bl\fwelded\fjoint\fis\f
m\bde\fwhen\fthe\fouter\fA-pill\br\fis\finst\blled.\f
A-pill\br\freinforcement\f
Resist\bnce\fspot\fwelding\f(t\bck-weld).\f
15

. NOTE:\fThe\fMIG\fspot\fwelds\fneed\fto\fbe\f
s
u

rf\bce\fground\fso\fth\bt\fthe\fouter\fA-pill\br\ffits\f
correctly.\f
A-pill\br\freinforcement\f
Surf\bce\fgrind\fthe\fMIG\fspot\fwelds.\f
\f
\f
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