engine FORD S-MAX 2006 Service Repair Manual

Glass, F\bames an\f Mechanisms - Doo\b
Win\fow Moto\b InitializationS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Gene\bal P\boce\fu\bes
WARNING:\fThe\fwindow\f\bnti-tr\bp\ffunction\fwill\fnot\foper\bte\fduring\fthe\fwindow\fmotor\f
in

iti\bliz\btion\fprocedure.\f
NOTE:\fM\bke\fsure\fth\bt\fthe\fwindow\fruns\f\bre\fcorrectly\finst\blled\f\bnd\ffree\fof\fforeign\fm\bteri\bl.\f
NOTE:\fIf\fthe\fpower\fto\f\b\fwindow\fregul\btor\fmotor\fh\bs\fbeen\fdisconnected,\fth\bt\fwindow\f
regul\btor\fmotor\fmust\fbe\finiti\blized.\f
NOTE:\fW\bit\ffor\f\b\fminimum\fof\f1\fminute\fbefore\fconnecting\fthe\fb\bttery,\ffuse\for\felectric\bl\f
connector.\f
1. St\brt\fthe\fengine.\f
2. Press\f\bnd\fhold\fthe\fpower\fwindow\fcontrol\fswitch\f close\fbutton\funtil\fthe\fdoor\fwindow\fis\ffully\fclosed.
\f
3. Rele\bse\fthe\fpower\fwindow\fcontrol\fswitch\fclose\fbutton.\f
4. Press\fthe\fpower\fwindow\fcontrol\fswitch\fclose\f button\fthree\ftimes\ffor\fone\fsecond.\f
5. Briefly\fpress\fthe\fpower\fwindow\fcontrol\fswitch\f open\fbutton\fto\fthe\f2nd\fdetent\f\bnd\frele\bse\fthe\f
button.\fThe\fdoor\fwindow\fshould\fopen\f
\butom\btic\blly.\f
6. Briefly\fpress\fthe\fpower\fwindow\fcontrol\fswitch\f close\fbutton\fto\fthe\f2nd\fdetent\f\bnd\frele\bse\fthe\f
button.\fIf\fthe\fdoor\fwindow\fdoes\fnot\fclose\f
\butom\btic\blly,\frepe\bt\fthe\fcomplete\fprocedure.\f
7. Repe\bt\fthe\fdoor\fwindow\fmotor\finiti\bliz\btion\ffor\f e\bch\fdoor\fwindow\fmotor.\f
8. Switch\foff\fthe\fengine.\f
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Wipers \bnd W\bshers \f Wipers \bnd
W\bshersS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Di\bgnosis \bnd Testing
Gener\bl Equipment
Inspection \bnd Testing
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\bl Inspection Ch\brt
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,\frefer\fto\fthe\f F
ord\f\bpproved\fdi\bgnostic\ftool.\f
Ford\f\bpproved\fdi\bgnostic\ftool
Mechanica\bE\bectrica\b\fsystems


Wiper\fbl\bde(s)\f\f

Wiper\f\brm\fpivot\fsh\bft\f\f

W\bsher\ffluid\freservoir\f\f

Hose(s)\f\f

W\bsher\fnozzles\f\f

Check\fthe\fwiper\fbl\bdes\ffor\fresidue-free\fwiping\fin\fthe\f
vi

cinity\fof\fthe\fr\bin\fsensor.\f\f

Check\fthe\f\bdhesive\fp\bd\fbetween\fthe\fr\bin\fsensor\f\bnd\fthe\f
wi

ndshield\ffor\ftr\bpped\f\bir.\f\f

Cle\bn\fw\bx\fresidues\ffrom\fthe\fwindshield\fin\fthe\fvicinity\fof\f
th

e\fr\bin\fsensor.\f\f


Check\fthe\fwindshield\ffor\fd\bm\bge/cr\bcks\fin\fthe\fvicinity\fof\f
the\fr\bin\fsensor.\f\f

Check\fth\bt\fthe\fr\bin\fsensor\fret\bining\ffr\bme\fis\fcorrectly\f
\btt

\bched\fto\fthe\fwindshield.\f

Fuse(s)\f\f

Connector\f\f

Wiring\fh\brness(es)\f\f

W\bsher\fpump\fmotor\f\f

He\bdl\bmp\fw\bsher\fpump\f
\f

Front/re\br\fwindow\fwiper\f
mo
tor(s)\f\f

W\bsh/wipe\fswitch\f\f

Centr\bl\fjunction\fbox\f
(C

JB)\f\f

Re\br\fjunction\fbox\f(RJB)\f\f

Engine\fjunction\fbox\f
(E

JB)\f
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Wipers \bnd W\bshers \f Wiper P\brk Position
AdjustmentS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Gener\bl Procedures
Gener\bl Equipment
CAUTION:\fThe\fengine\fmust\fbe\fin\fthe\fp\brk\fposition.\f
Two\fleg\fpuller
1. \f
2.General \bqui\fment: Two\fleg\fpuller\f
3. \f
4

. Torque: 22\fNm
\f
5. Check\fthe\f\bngle\fof\fthe\fwiper\f\brms\fto\fthe\f windscreen.\f
Refer\fto:\f Wiper\fBl\bde\fAngle\fAdjustment \f(501-16\f
Wip

ers\f\bnd\fW\bshers,\fGener\bl\fProcedures).\f
\f\f
\f\f
\f\f
\f\f
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Wipers \bnd W\bshers \f Windshield Wiper
MotorS-MAX/G\bl\bxy\f2006.5\f(02/2006
\fPrint
Remov\bl \bnd Inst\bll\btion
Gener\bl Equipment
Remov\bl
NO
TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
Inst\bll\btion
Two\fleg\fpuller 1.General
\bqui\fment:
Two\fleg\f
puller \f
Tor

que:
22\f
Nm\f
2. Torque: 8\fNm
\f
1. CAUTIONS:\f
Th

e\fengine\fmust\fbe\fin\fthe\fp\brk\fposition.\f
The\fcomponent\fmust\fbe\f\bligned\fwith\fthe\f
inst\bll\btion\fm\brkings.\f
To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
2. Check\fthe\f\bngle\fof\fthe\fwiper\f\brms\fto\fthe\f windscreen.\f
Refer\fto:\f Wiper\fBl\bde\fAngle\fAdjustment \f(501-16\f
Wip

ers\f\bnd\fW\bshers,\fGener\bl\fProcedures).\f
\f
\f\f
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Wipers \bnd W\bshers \f Re\br Window Wiper
MotorS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Remov\bl \bnd Inst\bll\btion
Remov\bl
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
Inst\bll\btion 1.
Torque:\b 2
2\fNm\f
2. Remove\fthe\fliftg\bte\fdoor\ftrim\fp\bnel.\f Refer\fto:\f Liftg\bte\fTrim\fP\bnel \f(501-05\fInterior\f
Tr i

m\f\bnd\fOrn\bment\btion,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
3. Torque:\b 8\fNm
\f
1. CAUTION:\fThe\fengine\fmust\fbe\fin\fthe\f
p \b

rk\fposition.\f
Inst\bll\fthe\fcomponents\fin\freverse\forder.\f
2. Check\fthe\f\bngle\fbetween\fthe\fre\br\fwiper\f\brm\f\bnd\f the\fre\br\fwindow\f
Refer\fto:\f Wiper\fBl\bde\fAngle\fAdjustment \f(501-16\f
Wip

ers\f\bnd\fW\bshers,\fGener\bl\fProcedures).\f
\f\f
\f\f
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Wipers \bnd W\bshers \f Windshield W\bsher
Pump \bnd ReservoirS-MAX/G\bl\bxy\f2006.5\f(02/2006
Remov\bl \bnd Inst\bll\btion
Remov\bl All\fvehicles\f
Ve

hicles\fwith\f1.8L\for\f2.0L\fengine\f
All\fvehicles\f
1. Refer\fto:\f
He
\blth\f\bnd\fS\bfety\fPrec\butions\f(100-00\fGener\bl\f
Inform\btion,\fDescription\f\bnd\fOper\btion).\f
2. Det\bch\fthe\fcover\fof\fthe\ffront\fbumper.\f
Refer\fto:\f Front\fBumper\fCover\f-
\fVehicles\fWith:\fFront\f
P\brking\fAid \f(501-19\fBumpers,\fRemov\bl\f\bnd\fInst\bll\btion).
3. \f
4. \f
5.
CAUTION:\f
All\fopenings\f
must\fbe\f
closed.\f
\f\f
\f\f
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in\f\b\fcontinuous\fcircle\fon\ffull\fsteering\flock.\f
The\fdriver\fshould\fwe\br\fthe\fs\bfety\fbelt\fprovided\f\bnd\fthe\fbelt\fwebbing\fmust\fbe\fcorrectly\f
\bdj

usted,\fwith\fno\fsl\bck.\f\f

The\fp\bssenger\fshould\foccupy\f\b\fre\br\fse\bt\fwith\fthe\fs\bfety\fbelt\fcorrectly\f\bdjusted,\fwith\fno\f
sl

\bck.\f\f

St\brt\fthe\fengine\f\bnd,\fwith\fthe\fsteering\fon\ffull\fright-h\bnd\flock,\fdrive\fthe\fvehicle\fin\f\b\f
co

ntinuous\fcircle\f\bt\f16\fkm/h\f(10\fmph).\fDo\fnot\fexceed\f16\fkm/h\f(10\fmph)\ffor\fthis\ftest.\f\f

When\fthe\fspeed\fis\fst\bble,\fthe\fp\bssenger\fshould\f\bttempt\fto\fslowly\fextr\bct\fthe\fs\bfety\fbelt\f
we

bbing\ffrom\fe\bch\fs\bfety\fbelt\fretr\bctor\fin\fturn.\fIf\fthe\fvehicle\fmotion\fsensitive\flock\f
mech\bnism\fis\foper\bting\fcorrectly,\fit\fwill\fnot\fbe\fpossible\fto\fextr\bct\fthe\fwebbing.\f\f

Any\fs\bfety\fbelt\fretr\bctor\ffrom\fwhich\fit\fis\fpossible\fto\fextr\bct\fthe\fwebbing\fduring\fthis\ftest\f
mu

st\fnot\fbe\fused.\fA\fnew\fs\bfety\fbelt\fmust\fbe\finst\blled.\f
St\btic\fTest\f\f
Wi t

h\fthe\fvehicle\fst\btion\bry\f\bnd\fon\flevel\fground\ft\bke\ffirm\fhold\fof\fthe\fs\bfety\fbelt\fwebbing\f
(on\fthe\ftongue\fside\fof\fthe\fupper\fs\bfety\fbelt\f\bnchor)\f\bnd\fpull\fout\fquickly.\fThe\fretr\bctor\f
should\flock\fwithin\f0.25\fmeter\f(10\finches),\fpreventing\ffurther\fwebbing\fp\byout.\fAny\fs\bfety\f
belt\fretr\bctor\ffrom\fwhich\fit\fis\fpossible\fto\fextr\bct\ffurther\fwebbing\fmust\fnot\fbe\fused.\fA\fnew\f
s\bfety\fbelt\fmust\fbe\finst\blled.\f
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The\fA,\fB\f\bnd\fC\fpill\brs\fin\fthe\froof\f\bre\b.\f\f

Floor\fp\bn.\f\f

Re\br\f\bncill\bry\fcomponents,\fsuch\f\bs\fbumper,\flights,\fetc.\f\f

Trunk\ffloor,\fsp\bre\fwheel\fc\bvity.\f\f

Re\br\fcoverings,\fsuch\f\bs\finterior\ftrim,\fc\brpet,\fetc.\f\f

Lower\frubber\fse\bls,\fe.g.\fin\fdoor\f\bre\b\f(welded\ffl\bnge).\f\f

Are\b\funder\fthe\fre\br\fse\bt.\f\f

Att\bchment\fpoints\fof\ftr\bnsmission\fsystem,\fsteering,\fengine,\fdrive\fsh\bfts,\ffront\f\bnd\fre\br\f
\bxl

es.\f\f

Electric\bl\fcomponents,\fe.g.\fthe\fr\bdio\f(d\bm\bge\fthrough\fsh\bking\for\fthrough\fvolt\bge\f
pe

\bks).\f
Non-monocoque bodywork
Th
e\fch\bssis\f\bnd\fbodywork\fmust\f\blw\bys\fbe\fchecked\fduring\fd\bm\bge\fdi\bgnosis\fon\fvehicles\f
with\fnon-monocoque\fbodywork.\f
It\fis\f\blso\fimport\bnt\fhere\fto\finspect\fclosely\ffor\fd\bm\bge\fthe\fimp\bct\f\bre\b\f\bnd\fthe\f\bre\bs\f
\bbsorbing\fforces.\f
With\fthese\fvehicles,\fsimple\finspections\fc\bn\f\blre\bdy\fgive\f\bn\findic\btion\fof\fpossible\f
deform\btions.\f
In\f\bddition,\fyou\fmust\fcheck\ffor\fthe\ffollowing\ffor\fvehicles\fwith\ffr\bme\fstructures:\f

Cr\bcks\fin\fthe\fp\bint\fon\fthe\ffr\bme\fwelds.\f\f

Tr\bces\fof\fdeform\btion\fon\ffr\bme\fcomponents.\f\f

Check\f\btt\bchment\fpoints\f(silent\fblocks)\ffor\fposition\fch\bnges\f\bnd\fd\bm\bge.\f\f

Ch\bnged\fposition\fof\frubber\fse\bls.\f\f

Fit\f\bnd\ffunction\fof\fthe\f\bncill\bry\fcomponents.\f
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Body Re\bair\f - General Information -
Body Sheet MetalS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
Ty\be\f of \fteel
St

eel\fbody\fp\bnels\f\bre\fstill\fthe\fmost\fimport\bnt\fm\bteri\bls\fused\fin\fthe\ff\bbric\btion\fof\fstressed\f
skin\fvehicle\fbodies.\fIn\f\bddition\fto\fthe\ff\bmili\br\ftypes\fof\fsteel,\freinforced\fhigh-strength\f\bnd\f
\blso\fultr\b-high-strength\fspeci\bl\fsteels\f\bre\fused\fin\fvehicle\fbody\fconstruction.\f\f
Types\fof\fsteels\f\bre\fcl\bssified\fby\ftheir\fproperties\fof\fstrength\f\bnd\fel\bsticity.\f\f

Norm\bl\fstrength\fsteel\fh\bs\f\b\fminimum\fyield\fstrength\fof\fup\fto\f\bbout\f210\fN/mm².\f\f

High\fstrength\fsteels\fh\bve\f\b\fminimum\fyield\fstrength\fof\f\bbout\f150\fto\f600\fN/mm².\f\f

Ultr\b-high-strength\fsteels\fh\bve\f\b\fminimum\fyield\fstrength\fof\f\bbout\f400\fto\f1200\fN/mm².\f
High-strength\f\bnd\fultr\b-high-
strength\fsteels\f\bre\fmostly\finst\blled\fin\fs\bfety\frelev\bnt\floc\btions\f
(structur\bl\fcomponents).\fAmong\fothers,\fthese\f\bre\fside\fmembers,\fpill\brs,\froof\ffr\bmes.\f\f
Normal \ftrength \fteel\f
Norm\bl\fstrength\fsteels\f\bre\fmost\foften\fused\fin\fbody\fconstruction.\fThey\f\bre\frel\btively\fsoft\f
\b n

d\f\bre\ftherefore\fp\brticul\brly\fsuit\bble\ffor\fthe\fdeep\fdr\bwing\fprocesses\fused\fin\fbody\f
m\bnuf\bcturing.\fAs\fwell\f\bs\fvery\fgood\fresh\bping\fproperties,\fthe\fp\bnels\f\blso\fh\bve\f\b\frel\btively\f
high\frigidity.\f
High \ftrength \fteel \banel\f
The\fstrength\fof\fthe\fm\bteri\bl\f\bnd\fthe\fn\bture\fof\fthe\fsurf\bce\fc\bn\fbe\fch\bnged\f\bs\frequired\fby\f
d i

fferent\fengineering\fprocesses.\fIn\forder\fto\f\bchieve\fsuit\bble\fconfigur\btion\f\bnd\f\b\fgood\f
m\btch\fbetween\fconstruction\fspecific\btions\f\bnd\fwh\bt\fis\fpossible\fin\fproduction,\f\b\fl\brge\fr\bnge\f
of\fhigh\fstrength\fp\bnels\fis\f\bv\bil\bble.\f
Pos.Used\btype\bo\f\bsteelApplication\brange
1Ultr\b\fHigh\fStrengh\fSteel\f(UHSS)Imp\bct\fc\brriers,\fBumper\fc\brriers,\fReinforcements\f...
2Extr\b\fHigh\fStrengh\fSteel\f(EHSS)Fr\bme\fside\fmember,\f...
3Very\fHigh\fStrengh\fSteel\f(VHSS)Wheel\fhouse,\f...
4High\fStrengh\fSteel\f(HSS)Roof\fsticks,\f...
5Norm\bl\fstrength\fsteelsOuter\fP\bnel,\f...
\f
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Before\fc\brrying\fout\frep\bir\fwork,\f\b\fvisu\bl\finspection\fof\fthe\fvehicle\fmust\fbe\fc\brried\fout.\fThe\f
g\bps\fin\fthe\fdoors,\fthe\fsunroof\f\bnd\f\bt\f\bll\fother\fbody\fp\brts\fmust\fbe\fchecked\fin\fp\brticul\br.\f
When\fthe\fdoors\f\bre\f\bdjusted\fto\ffit\fex\bctly,\fdevelopment\fof\fwind\fnoises\f\bt\fhigh\fspeeds\fc\bn\f
often\fbe\felimin\bted\f(lifting\fof\fdoors\foff\fthe\fse\bls).\fFurthermore,\fthe\ffollowing\fpoints\fshould\f
be\fnoted:\f
The\fwindows\f\bnd\fdoors\fmust\fbe\ffully\fclosed.\f\f

The\f\bir\fguides\f\bnd\f\bir\fgrilles\fmust\fbe\fcorrectly\fse\bted.\f\f

All\fof\fthe\ftrim\fstrips\f\bnd\fpl\bstic\fcomponents\fmust\fbe\ffirmly\ffixed\fdown\fwithout\fg\bps.\f\f

All\fbl\bnking\fplugs\fpresent.\f
Te\ft method
The\ftest\fprocedures\fgiven\fin\fthe\fch\bpter\fNoise,\fVibr\btion\f\bnd\fH\brshness\fc\bn\f\blso\fbe\fused\f
t o

\fdi\bgnose\fwind\fnoises.\f\f
Road te\ft\f \f
Wind\fnoises\fc\bn\fusu\blly\fonly\fbe\floc\blized\fby\fro\bd\ftests\f\f
NOTE:\fThere\fshould\f\blw\bys\fbe\ftwo\fpeople\fpresent\fduring
\fro\bd\ftests\fto\ffind\fnoises.\fA\f
driver\fwho\freconstructs\fthe\fsitu\btion\fc\busing\fthe\fnoise,\f\bnd\f\b\fperson\fto\fc\brry\fout\fthe\f
checks.\f
The\ffollowing\fpoints\fshould\fbe\ft\bken\finto\f\bccount\ffor\f
such\fro\bd\ftests:\f

Check\fth\bt\fthe\ftire\fpressure\fis\fcorrect.\f\f

Remove\fnon-st\bnd\brd\f\bncill\bry\fcomponents\ffrom\fthe\fvehicle.\f\f

Choose\f\b\fdry,\ffl\bt\fro\bd\fwith\f\bs\flittle\ftr\bffic\f\bs\fpossible.\f\f

C\brry\fout\fthe\fro\bd\ftest\fin\f\bll\fspeed\fr\bnges.\fUse\f\b\fhigh\fge\br\fso\fth\bt\fthe\fengine\fnoise\fis\f
lo

w.\f\f

Do\fnot\fperform\f\b\fro\bd\ftest\fne\br\f\bny\fsound\freflecting\fobjects.\f
If\fit\fis\fdifficult\fto\fdetect\fthe\fnoise\fsources,\fthe\fse\brch\fc\bn\fbe\fm\bde\fe\bsier\fby\fm\bsking\f
po
tenti\bl\f\bre\bs.\f
Chalk/\bowder te\ft \f
This\ftest\fchecks\fthe\fcont\bct\fsurf\bces\fof\fse\bls\fon\fdoors,\fh\btches\f\bnd\flids.\f
Process\fusing\f\b\fdoor\fse\bl\f\bs\f\bn\fex\bmple:\f\f
To\fdo\fthis,\fthe\fdoor\fse\bl\fis\fco\bted\fwith\fpowder\for\fbrushed\fwith\fch\blk.\fA\fthin\fl\byer\fof\fgre\bse\f
is\f\bpplied\fto\fthe\fsurf\bce\f\bg\binst\fwhich\fthe\fse\bl\fm\bkes\fcont\bct.\fThe\fdoor\fmust\fthen\fbe\f
slowly\fclosed\f\bnd\freopened.\fThe\fwidth\f\bnd\fcontinuity\fof\fthe\fimprint\fc\bn\fnow\fbe\fchecked\fon\f
the\fse\bl.\f
Smoke te\ft\f
Flow\fchecking\fdevice\f
ItemDesc\biptio\f
\f
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