torque FORD S-MAX 2006 Service Repair Manual

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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Ge\brshift\flever\for\fselector\flever\fposition\fsymbols\f\bre\fused\fto\fshow\fwhich\fge\brshift\flever\for\f
selector\flever\fposition\fis\fto\fbe\fset.\f
Pointer\fsymbols\f\bre\fused\fto\fdr\bw\f\bttention\fto\fcomponents\f\bnd\fgive\fspeci\bl\finstructions\f
such\f\bs\f\b\frequired\fsequence\for\fnumber\fof\fcomponents.\fThe\fnumber\fof\fcomponents\fis\f
reflected\fby\fthe\fv\blue\finside\fthe\fluty\f\brrow.\fA\fsequence\fnumber\fis\floc\bted\finside\fthe\fcircle.\f
Numbers\finside\fcircles\f\bre\f\blso\fused\fto\f\blloc\bte\fspeci\bl\finform\btion\fsuch\f\bs\ftightening\f
torques\for\fchemic\bls\fto\f\b\fp\brticul\br\fcomponent.\f
\f
\f
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Dry\fcle\bning.\f\f

Remov\bl\fof\floose\fdirt\fwith\fsoft\for\fc\bble\fbrushes.\f\f

Scr\bping\fdirt\foff\fwith\f\b\fpiece\fof\fmet\bl\for\fwood.\f\f

Wiping\foff\fwith\f\b\fr\bg.\f
WARNING:\fWe\br\feye\fprotection\fwhen\fcle\bning\fvehicle\fcomponents\fwith\fcompressed\f
\bi

r,\f\b\fste\bm\fcle\bner\for\f\b\fpower\fw\bsher.\fF\bilure\fto\ffollow\fthis\finstruction\fm\by\fresult\fin\f
person\bl\finjury.\f
CAUTIONS:\f
Compressed\f\bir\fis\fsometimes\f'wet'\fso\fuse\fwith\fc\bution,\fespeci\blly\fon\fhydr\bulic\f
systems.\f
To\fprevent\fd\bm\bge\fto\fthe\felectric\bl\fconnectors\fin\fthe\fengine\fcomp\brtment,\fdo\fnot\f
use\f\b\fste\bm\fcle\bner\for\f\b\fpower\fw\bsher\fto\fcle\bn\fthe\fengine\fcomp\brtment.\f

Blowing\fdirt\foff\fwith\fcompressed\f\bir.\f\f

Remov\bl\fof\fdry\fdust\fusing\fv\bcuum\fequipment.\fThis\fmethod\fmust\f\blw\bys\fbe\fused\fto\f
re

move\ffriction\flining\fm\bteri\bl\fdust\f(\bsbestos\fp\brticles).\f\f

Ste\bm\fcle\bning.\f
WARNING:\fMost\fsolvents\frequire\fc\breful\fh\bndling\f\bnd\fsome\f\bre\fh\brmful.\fRefer\fto\f
He

\blth\f\bnd\fS\bfety\fPrec\butions\f\bnd\fto\fthe\fm\bnuf\bcturers\fliter\bture\ffor\fthe\frelev\bnt\fs\bfety\f
prec\butions.\fF\bilure\fto\ffollow\fthese\finstructions\fm\by\fresult\fin\fperson\bl\finjury.\f
V\brious\fsolvents\f\bre\f\bv\bil\bble\fwhich\f\bre\fsuit\bble\ffor\f
component\fcle\bning.\fSome\f
components,\fsuch\f\bs\fbr\bke\fhydr\bulic\fp\brts\f\bnd\felectric\bl\f\bssemblies\fshould\fbe\fcle\bned\fonly\f
with\frecommended\fsolvents\f—\frefer\fto\fSolvents,\fSe\blers\f\bnd\fAdhesives\for\fto\fthe\fsection\fof\f
the\fm\bnu\bl\frelev\bnt\fto\fthe\fcomponent.\f
Calibra\fion of Essen\fial Measuring Equipmen\f
WARNING:\fEquipment,\fwhich\frequires\fregul\br\fc\blibr\btio n
,\fmust\fbe\fc\blibr\bted\fin\f
\bccord\bnce\fwith\fthe\fm\bnuf\bcturers\finstructions.\fF\bilure\fto\ffollow\fthis\finstruction\fm\by\f
result\fin\fperson\bl\finjury\for\fd\bm\bge\fto\fcomponents.\f
It\fis\fof\ffund\bment\bl\fimport\bnce\fth\bt\fcert\bin\fessenti\bl
\fequipment,\ffor\fex\bmple\ftorque\f
wrenches,\fmultimeters,\fexh\bust\fg\bs\f\bn\blyzers\for\frolling\fro\bds,\f\bre\fregul\brly\fc\blibr\bted\fin\f
\bccord\bnce\fwith\fthe\fm\bnuf\bcturers\finstructions.\f
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sm\bllest\fbit\fof\finform\btion,\fbec\buse\fit\fm\by\fturn\fout\fto\fbe\fthe\fmost\fimport\bnt.\f
2. 2.
Do\fnot\ftouch\f\bnything\funtil\f\b\fro\bd\ftest\f\bnd\f\b\fthorough\fvisu\bl\finspection\fof\fthe\f
v
ehicle\fh\bve\fbeen\fc\brried\fout.\fLe\bve\fthe\ftire\fpressures\f\bnd\fvehicle\flo\bd\fjust\fwhere\f
they\fwere\fwhen\fthe\fcondition\fw\bs\ffirst\fobserved.\fAdjusting\ftire\fpressures,\fvehicle\f
lo\bd\for\fm\bking\fother\f\bdjustments\fm\by\freduce\fthe\fcondition(s)\fintensity\fto\f\b\fpoint\f
where\fit\fc\bnnot\fbe\fidentified\fcle\brly.\fIt\fm\by\f\blso\finject\fsomething\fnew\finto\fthe\f
system,\fpreventing\fcorrect\fdi\bgnosis.\f
3. 3.
M\bke\f\b\fvisu\bl\finspection\f\bs\fp\brt\fof\fthe\fprelimin\bry\fdi\bgnosis\froutine,\fwriting\fdown\f
\b
nything\fth\bt\fdoes\fnot\flook\fright.\fNote\ftire\fpressures,\fbut\fdo\fnot\f\bdjust\fthem\fyet.\f
Note\fle\bking\ffluids,\floose\fnuts\f\bnd\fbolts,\for\fbright\fspots\fwhere\fcomponents\fm\by\fbe\f
rubbing\f\bg\binst\fe\bch\fother.\fCheck\fthe\flo\bd\fsp\bce\ffor\funusu\bl\flo\bds.\f
4. 4.
Ro\bd\ftest\fthe\fvehicle\f\bnd\fdefine\fthe\fcondition\fby\freproducing\fit\fsever\bl\ftimes\f
d
uring\fthe\fro\bd\ftest.\f
5. 5.
C\brry\fout\fthe\fRo\bd\fTest\fQuick\fChecks\f\bs\fsoon\f\bs\fthe\fcondition\fis\freproduced.\fThis\f
w
ill\fidentify\fthe\fcorrect\fdi\bgnostic\fprocedure.\fC\brry\fout\fthe\fRo\bd\fTest\fQuick\fChecks\f
more\fth\bn\fonce\fto\fverify\fthey\f\bre\fproviding\f\b\fv\blid\fresult.\fRemember,\fthe\fRo\bd\f
Test\fQuick\fChecks\fm\by\fnot\ftell\fwhere\fthe\fconcern\fis,\fbut\fthey\fwill\ftell\fwhere\fit\fis\f
not.\f
Road Tes\f Quick Checks
1. 1.
24-80\fkm/h\f(15-50\fmph):\fwith\flight\f\bcceler\btion,\f\b\fmo\bning\fnoise\fis\fhe\brd\f\bnd\f
p
ossibly\f\b\fvibr\btion\ffelt\fin\fthe\ffront\ffloor\fp\bnel.\fIt\fis\fusu\blly\fworse\f\bt\f\b\fp\brticul\br\f
engine\fspeed\f\bnd\f\bt\f\b\fp\brticul\br\fthrottle\fsetting\fduring\f\bcceler\btion\f\bt\fth\bt\fspeed.\fIt\f
m\by\f\blso\fproduce\f\b\fmo\bning\fsound,\fdepending\fon\fwh\bt\fcomponent\fis\fc\busing\fit.\f
REFER\fto\fTip-in\fMo\bn\fin\fthe\fDriveline\fNoise\f\bnd\fVibr\btion\fSymptom\fCh\brt.\f
2. 2.
Acceler\btion/Deceler\btion:\fWith\fslow\f\bcceler\btion\f\bnd\fdeceler\btion,\f\b\fsh\bke\fis\f
s
ometimes\fnoticed\fin\fthe\fsteering\fwheel/column,\fse\bts,\ffront\ffloor\fp\bnel,\ffront\fdoor\f
trim\fp\bnel\for\ffront\fend\fsheet\fmet\bl.\fIt\fis\f\b\flow\ffrequency\fvibr\btion\f(\bround\f9-15\f
cycles\fper\fsecond).\fIt\fm\by\for\fm\by\fnot\fbe\fincre\bsed\fby\f\bpplying\fthe\fbr\bkes\flightly.\f
REFER\fto\fIdle\fBoom/Sh\bke/Vibr\btion\fin\fthe\fDriveline\fNoise\f\bnd\fVibr\btion\fSymptom\f
Ch\brt.\f
3. 3.
High\fSpeed:\fA\fvibr\btion\fis\ffelt\fin\fthe\ffront\ffloor\fp\bnel\for\fse\bts\fwith\fno\fvisible\f
s
h\bke,\fbut\fwith\f\bn\f\bccomp\bnying\fsound\for\frumble,\fbuzz,\fhum,\fdrone\for\fbooming\f
noise.\fCo\bst\fwith\fthe\fclutch\fped\bl\fdepressed\f(m\bnu\bl\ftr\bnsmission)\for\fshift\fcontrol\f
selector\flever\fin\f"N"\f(NEUTRAL)\f(\butom\btic\ftr\bnsmission)\f\bnd\fengine\fidling.\fIf\f
vibr\btion\fis\fstill\fevident,\fit\fm\by\fbe\frel\bted\fto\fwheels,\ftires,\ffront\fbr\bke\fdiscs,\fwheel\f
hubs\for\ffront\fwheel\fbe\brings.\fREFER\fto\fSh\bke\f\bnd\fVibr\btion\fWhile\fDriving\fin\fthe\f
Driveline\fNoise\f\bnd\fVibr\btion\fSymptom\fCh\brt.\f
4. 4.
Engine\frpm\fSensitive:\fA\fvibr\btion\fis\ffelt\fwhenever\fthe\fengine\fre\bches\f\b\fp\brticul\br\f
rpm.\fIt\fwill\fdis\bppe\br\fin\fneutr\bl\fco\bsts.\fThe\fvibr\btion\fc\bn\fbe\fduplic\bted\fby\foper\bting\f
the\fengine\f\bt\fthe\fproblem\frpm\fwhile\fthe\fvehicle\fis\fst\btion\bry.\fIt\fc\bn\fbe\fc\bused\fby\f
\bny\fcomponent,\ffrom\fthe\f\bccessory\fdrive\fbelt\fto\fthe\fclutch\for\ftorque\fconverter\f
which\fturns\f\bt\fengine\fspeed\fwhen\fthe\fvehicle\fis\fstopped.\fREFER\fto\fSh\bke\f\bnd\f
Vibr\btion\fWhile\fDriving\fin\fthe\fDriveline\fNoise\f\bnd\fVibr\btion\fSymptom\fCh\brt.\f
5. 5.
Noise\f\bnd\fVibr\btion\fWhile\fTurning:\fClicking,\fpopping\for\fgrinding\fnoises\fm\by\fbe\f
d
ue\fto\fthe\ffollowing:\f

worn,\fd\bm\bged\for\fincorrectly\finst\blled\ffront\fwheel\fbe\bring.\f\f
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Suspensi\bn Syste\f - General Inf\br\fati\bn
- Fr\bnt T\be Adjust\fentS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
General Pr\bcedures
General Equip\fent
NOTE:\fM\bke\fsure\fth\bt\fthe\fvehicle\fis\fst\bnding\fon\f\b\flevel\fsurf\bce.\f
Wheel\f\blignment\fsystem
1.CAUTION:\fM\bke\fsure\fth\bt\fthe\fsteering\f
wh

eel\flock\fis\feng\bged.\f
2. Check\fthe\ftoe\fsetting\fon\fboth\fsides.\f
General \bqui\fment: Wheel\f\blignment\fsystem\f
3. \f

\f 1. Loosen\fon\fboth\fsides.\f
2. NOTE:\fM\bke\fsure\fth\bt\fthe\fboot\fis\f
co

rrectly\floc\bted.\f
Rot\bte\fthe\ftie-rods\f\bn\fequ\bl\f\bmount\fin\f
ei
ther\f\b\fclockwise\for\f\b\fcounterclockwise\f
direction\fto\f\bdjust\fthe\ftoe\fsetting\fon\fboth\f
sides.\f

Torque: 90\fNm
\f
\f\f
\f\f
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Suspensi\bn Syste\f - General Inf\br\fati\bn
- Rear T\be Adjust\fentS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
General Pr\bcedures
General Equip\fent
NOTE:\fM\bke\fsure\fth\bt\fthe\fvehicle\fis\fst\bnding\fon\f\b\flevel\fsurf\bce.\f
Wheel\f\blignment\fsystem
1. Check\fthe\ftoe\fsetting.\f\fRefer\fto:\f Specific\btions \f(204-00\fSuspension\f
Sys

tem\f-\fGener\bl\fInform\btion,\fSpecific\btions).\f
General \bqui\fment: Wheel\f\blignment\fsystem\f
2. R

\bise\f\bnd\fsupport\fthe\fvehicle.\f\f
Refer\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des

cription\f\bnd\fOper\btion).\f
3. \f\f 1.
Loosen\fthe\fre\br\flower\f\brm\f\bdjustment\fc\bm\f
nut\fon\fboth\fsides.\f
2. Torque: 8\fNm
\f
4. Lower\fthe\fvehicle.\f
5. Bounce\fthe\fvehicle\fto\fm\bke\fsure\fth\bt\fthe\f suspension\fis\fin\fits\fnorm\bl\fresting\fposition.\f
6. Adjust\fthe\ftoe\fsetting.\f
7. NOTE:\fOnly\ftighten\fthe\fnuts\f\bnd\fbolts\fwhen\f
t
h

e\fsuspension\fis\fin\fthe\fnorm\bl\fdrive\f
position.\f
Torque: 103\fNm
\f
\f
\f\f
\f
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All\fvehicles\f
5. Torque:\b 6
0\fNm\f
6. CAUTION:\fM\bke\fsure\fth\bt\fthe\fb\bll\fjoint\f
b \b

ll\fdoes\fnot\frot\bte.\f
Loosen\fthe\ftie-rod\fend\fnut.\f
7. WARNING:\fM\bke\fsure\fth\bt\f\b\fnew\fnut\fis\f
in
st\blled.\f
CAUTIONS:\f
Use\fsuit\bble\fp\bcking\fm\bteri\bl\fto\fprevent\f
d\bm\bge\fto\fthe\fcomponent.\f
M\bke\fsure\fth\bt\fthe\fb\bll\fjoint\fb\bll\fdoes\f
not\frot\bte.\f 2. Torque:\b 8
0\fNm\f
8.WARNING:\fM\bke\fsure\fth\bt\fno\flo\bd\fis\f
pl
\bced\fon\fthe\fbr\bke\fhose.\f 1. Loosen\fthe\fnut\ftwo\fturns.\f
To
rque:\b100\fNm
\f
2. Torque:\b 200\fNm
\f
9.Spec\fal\bTool(s):\b 204-607\f
\f\f
\f\f
\f\f
\f\f
\f\f
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10.Torque:\b 200\fNm\f
11. \f
12. Torque:\b 10\fNm
\f
13. Spec\fal\bTool(s):\b 204-605\f
14 .S

pec\fal\bTool(s):\b 204-609\f
\f\f
\f\f
\f\f
\f\f
\f\f
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Installat\fon 15.
CAUTION:\fIf\fthe\fouter\fconst\bnt\fvelocity\f
( C

V)\fjoint\fboot\fis\fd\bm\bged\f\b\fnew\fh\blfsh\bft\f
must\fbe\finst\blled.\f Torque:\b \f
45

\fNm
\f
80
°\f
St\bge\f1:\f
St\bge\f2:\f
16. Torque:\b 110\fNm\f
17. Spec\fal\bTool(s):\b 204-159\f
1. T

o\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f\f
\f\f
\f\f
\f\f
\f\f
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Front S\bspens\fon - Lower ArmS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Installat\fon
Spec\fal Tool(s)
Removal
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
204-605\f
Sep\br\btor,\fLower\fArm\fB\bll\fJoint
\f
204-607\f
Remover,\fB\bll\fjoint\f
204-609\f
Protection\fC\bp,\fB\bll\fJoint\fG\biter
\f
1. Refer\fto:\fWheel\f\bnd\fTire\f(204-04\fWheels\f\bnd\f
Tir
es,\fRemov\bl\f\bnd\fInst\bll\btion).\f
2. \f
3. CAUTION:\fM\bke\fsure\fth\bt\fthe\fb\bll\fjoint\f
b \b

ll\fdoes\fnot\frot\bte.\f
Torque:\b 70\fNm
\f
4. \f\f
1.Loosen:\b 2\fturn(s)
\f
2. WARNING:\fM\bke\fsure\fth\bt\fno\flo\bd\f
is

\fpl\bced\fon\fthe\fbr\bke\fhose.\f
Torque:\b 200\fNm
\f
5. \f\f
1.\fpecial\bTool(s):\b 204-607\f
2. To

rque:\b 100\fNm
\f
\f
\f
\f
\f\f
\f\f
\f\f
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