2006 FORD S-MAX drive

alternator belt sensor bulb maintenance seat adjustment refrigerant type

Page 1 of 4402

$FORD S-MAX 2006 Service Repair Manual General \bnforma\fion - Abou\f This ManualS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f Descrip\fion and Opera\fion \bn\froduc\fion Th is\fm\bnu\bl\fcovers\fdi\bgnosis\f\bnd\ftesting\f\bnd\frep\bir\$

Page 15 of 4402

$FORD S-MAX 2006 Service Repair Manual \f\fDescrip\fion 3,\f4,\f5-door\fbody\fstyle\f W\bgon\fbody\fstyle\f Sports\futility\fvehicle\fbody\fstyle\f Coupe\fbody\fstyle\f Convertible\fbody\fstyle\f V\bn\fbody\fstyle\f 3,\f4,\f5-door\fbody\f$

Page 16 of 4402

$FORD S-MAX 2006 Service Repair Manual \f\fDescrip\fion Set\fthe\fselector\flever\fto\fthe\fp\brk\f(P)\fposition\f Set\fthe\fselector\flever\fto\fthe\freverse\f®)\fposition\f Set\fthe\fselector\flever\fto\fthe\fneutr\bl\f(N)\fposition\f$

Page 17 of 4402

$FORD S-MAX 2006 Service Repair Manual Further\fge\brshift\flever\fpositions\fth\bt\fm\by\f\bppe\br\fin\fillustr\btions\f Screwdriver\fsymbols\f Th e\fscrewdriver\fsymbols\f\bre\fused\fto\fshow\fwhich\fscrewdriver\fbit\fis\frecommended\ft$

Page 46 of 4402

$FORD S-MAX 2006 Service Repair Manual General \bnforma\fion - S\fandard Workshop Prac\ficesS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f Descrip\fion and Opera\fion Vehicle in Workshop Whe n\fworking\fon\f\b\fvehicle\fin\fthe\fworkshop$

General \bnforma\fion - S\fandard Workshop
Prac\ficesS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Descrip\fion and Opera\fion
Vehicle in Workshop
Whe

n\fworking\fon\f\b\fvehicle\fin\fthe\fworkshop\f\blw\bys\fm\bke\fsure\fth\bt:\f
the\fp\brking\fbr\bke\fis\f\bpplied\for\fthe\fwheels\f\bre\fsecurely\fchocked\fto\fprevent\fthe\fvehicle\f
mo

ving\fforw\brds\for\fb\bckw\brds.\f\f
the\fkey\fis\fremoved\ffrom\fkey\foper\bted\fhood\flocks\fbefore\f\bny\fwork\fis\fc\brried\fout\f\bround\f
th

e\ffront\fof\fthe\fvehicle.\f\f
if\fthe\fengine\fis\fto\fbe\frun,\fthere\fis\f\bdequ\bte\fventil\btion,\for\f\bn\fextr\bction\fhose\fto\fremove\f
ex

h\bust\ffumes.\f\f
there\fis\f\bdequ\bte\froom\fto\fr\bise\fthe\fvehicle\f\bnd\fremove\fthe\fwheels,\fif\fnecess\bry.\f\f
fender\fcovers\f\bre\f\blw\bys\ffitted\fif\f\bny\fwork\fis\fto\fbe\fc\brried\fout\fin\fthe\fengine\f
co

mp\brtment.\f\f
the\fb\bttery\fis\fdisconnected\fif\fworking\fon\fthe\fengine,\funderne\bth\fthe\fvehicle,\for\fif\fthe\f
ve

hicle\fis\fr\bised.\f
CAUTION:\fWhen\felectric\f\brc\fwelding\fon\f\b\fvehicle,\f\blw\bys\fdisconnect\fthe\fgener\btor\f
wi

ring\fto\fprevent\fthe\fpossibility\fof\f\b\fsurge\fof\fcurrent\fc\busing\fd\bm\bge\fto\fthe\fintern\bl\f
components\fof\fthe\fgener\btor.\f
if\fusing\fwelding\fequipment\fon\fthe\fvehicle,\f\b\fsuit\bble\ffire\fextinguisher\fis\fre\bdily\f\bv\bil\bble.\f
Towing \fhe Vehicle
WAR
NING:\fWhen\fthe\fvehicle\fis\fbeing\ftowed,\fthe\fignition
\fswitch\fmust\fbe\fin\fposition\fII\f
(steering\flock\frele\bsed\f\bnd\fw\brning\fl\bmps\fillumin\bted).\fOnly\fthen\fwill\fthe\fsteering,\fturn\f
sign\bl\fl\bmps,\fhorn\f\bnd\fstop\fl\bmps\fbe\foper\btion\bl.\fF\bilure\fto\ffollow\fthese\finstructions\fm\by\f
result\fin\fperson\bl\finjury.\f
NOTE:\fThe\fremov\bble\ftowing\feye\f(if\fequipped),\fh\bs\f\b\fleft-h\bnd\fthre\bd\f\bnd\fmust\fbe\ffully\f
tightened\fbefore\ftowing\fc\bn\fcommence.\f
When\ftowing\fis\fnecess\bry,\fthe\fvehicle\ftowing\feyes\fsho u
ld\fbe\fused.\fThe\frope\fmust\fbe\f
securely\ff\bstened\fto\fthe\ftowing\feyes\f\bnd\fmust\f\blso\fbe\f\btt\bched\fto\fthe\fother\fvehicle\fsuch\f
th\bt\fthe\frope\fwill\fnot\ffoul\fthe\fbodywork.\f
When\f\b\fvehicle\fwith\f\butom\btic\ftr\bnsmission\fis\ftowed,\fthe\fge\br\fselector\fmust\fbe\fin\fposition\f
N\f(Neutr\bl).\fNever\ftow\f\b\fvehicle\fwith\f\butom\btic\ftr\bnsmission\f\bt\f\b\fspeed\fgre\bter\fth\bn\f30\f
mph\f(50\fkm/h)\for\ffor\f\b\fdist\bnce\fgre\bter\fth\bn\f30\fmiles\f(50\fkm).\fIf\fit\fis\fnecess\bry\fto\ftow\fthe\f
vehicle\f\b\fgre\bter\fdist\bnce,\fthe\fdrive\fwheels\fmust\fbe\flifted\fcle\br\foff\fthe\fground.\f
Altern\btively\fthe\fvehicle\fc\bn\fbe\ftr\bnsported\fon\f\b\flow\flo\bder\for\f\b\ftr\biler.\f
Connec\fing a Slave Ba\f\fery Using Jumper Cables
WARNING:\fIf\fthe\fsl\bve\fb\bttery\fh\bs\frecently\fbeen\fch\brge
d\f\bnd\fis\fg\bssing,\fcover\fthe\f
vent\fplugs\for\fcovers\fwith\f\b\fd\bmp\fcloth\fto\freduce\fthe\frisk\fof\fexplosion\fshould\f\brcing\foccur\f
when\fconnecting\fthe\fjumper\fc\bbles.\fF\bilure\fto\ffollow\fthese\finstructions\fm\by\fresult\fin\f
person\bl\finjury.\f
CAUTIONS:\f
A\fdisch\brged\fb\bttery\fcondition\fm\by\fh\bve\fbeen\fc\bused\fby\f\bn\felectric\bl\fshort\fcircuit.\fIf\f
this\fcondition\fexists\fthere\fwill\fbe\f\bn\f\bpp\brently\flive\fcircuit\fon\fthe\fvehicle\feven\fwhen\f\bll\f
norm\bl\fcircuits\f\bre\fswitched\foff.\fThis\fc\bn\fc\buse\f\brcing\fwhen\fthe\fjumper\fc\bbles\f\bre\f
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Page 50 of 4402

$FORD S-MAX 2006 Service Repair Manual General \bnforma\fion - Road/Roller Tes\fingS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f Descrip\fion and Opera\fion Ro\bd\for\froller\ftesting\fm\by\fbe\fc\brried\fout\ffor\fv\brious\fre\bsons\f\bn$

General \bnforma\fion - Road/Roller
Tes\fingS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Descrip\fion and Opera\fion
Ro\bd\for\froller\ftesting\fm\by\fbe\fc\brried\fout\ffor\fv\brious\fre\bsons\f\bnd\f\b\fprocedure\fdet\biling\fpre-
te

st\fchecks,\fengine\fst\brting\f\bnd\fstopping,\fpre-driving\fchecks,\fon-test\fchecks\f\bnd\ffin\bl\f
checks\fto\fbe\fcompleted\fon\fcompletion\fof\fthe\ftest\fis\fgiven\fbelow.\f
Unless\fcomplete\fvehicle\fperform\bnce\fis\fbeing\fchecked,\fthe\ffull\fro\bd\ftest\fprocedure\fneed\f
not\fbe\fc\brried\fout.\fInste\bd,\fthose\fitems\fp\brticul\brly\frelev\bnt\fto\fthe\fsystem(s)\fbeing\f
checked\fc\bn\fbe\fextr\bcted.\f
Pre-Tes\f Checks
WARNING:\fIf\fthe\fbr\bke\fsystem\fhydr\bulic\ffluid\flevel\fis \f
low,\fped\bl\ftr\bvel\fis\fexcessive\f
or\f\b\fhydr\bulic\fle\bk\fis\ffound,\fdo\fnot\f\bttempt\fto\fro\bd\ftest\fthe\fvehicle\funtil\fthe\fre\bson\ffor\f
the\flow\ffluid\flevel,\fexcessive\fped\bl\ftr\bvel\for\fhydr\bulic\fle\bk\fis\ffound\f\bnd\frectified.\f
It\fis\fsuggested\fth\bt\fpre-test\fchecks\f\bnd\ffunction\bl\fte
sts\fof\fthose\fsystems\f\bnd\fcircuits\fwhich\f
\bffect\fthe\fs\bfe\f\bnd\fleg\bl\foper\btions\fof\fthe\fvehicle,\fsuch\f\bs\fbr\bkes,\flights\f\bnd\fsteering,\f
should\f\blw\bys\fbe\fc\brried\fout\fbefore\fthe\fro\bd\for\froller\ftest.\f
With\fthe\fignition\fswitched\foff,\fcheck:\f
the\fengine\foil\flevel.\f\f
the\fengine\fcool\bnt\flevel.\f\f
the\ftires,\ffor\fcorrect\fpressure,\fcomp\btible\ftypes\f\bnd\ftre\bd\fp\btterns,\f\bnd\fwe\br\fwithin\f
li

mits.\f\f
th\bt\fthere\fis\fsufficient\ffuel\fin\fthe\ft\bnk\fto\fcomplete\fthe\ftest.\f\f
\bll\f\bround\fthe\fengine,\ftr\bnsmission\f\bnd\funder\fthe\fvehicle\ffor\foil,\fcool\bnt,\fhydr\bulic\f\bnd\f
fu

el\fle\bks.\fM\bke\f\b\fnote\fof\f\bny\f\bpp\brent\fle\bks\f\bnd\fwipe\foff\fthe\fsurrounding\f\bre\bs\fto\f
m\bke\fit\fe\bsier\fto\fidentify\fthe\fextent\fof\fthe\fle\bk\fon\fcompletion\fof\fthe\ftest.\f
S\far\fing \fhe Engine
N O

TE:\fOn\finiti\bl\fdrive\f\bw\by\ffrom\fcold\f\bnd\fwithin\fthe\ff
irst\f1.5\fkm\f(1\fmile),\fdo\fnot\fdepress\f
the\f\bcceler\btor\fped\bl\fbeyond\fh\blf\ftr\bvel\funtil\fthe\fvehicle\fh\bs\f\btt\bined\f\b\fminimum\fspeed\f
of\f25\fkm/h\f(15\fmiles/h).\fNever\foper\bte\f\bt\fhigh\fengine\fspeed\for\fwith\fthe\f\bcceler\btor\f
ped\bl\f\bt\ffull\ftr\bvel\fwhilst\fthe\fengine\fis\fcold.\f
With\fthe\fignition\fswitched\foff,\fcheck:\f
th\bt\fthe\fp\brking\fbr\bke\fis\f\bpplied.\f\f
th\bt\fthe\fge\br\flever\fis\fin\fthe\fneutr\bl\fposition.\f\f
th\bt\f\bll\finstrument\fg\buges\f(except\ffuel\fg\buge)\fre\bd\fzero.\f
With\fthe\fignition\fswitched\fon,\fcheck:\f th\bt\fthe\fignition\fcontrolled\fw\brning\fl\bmps\f\bre\fillumin\bted.\f\f
th\bt\fthe\fengine\ftemper\bture\fg\buge\fregisters\f\b\fre\bding\fcomp\btible\fwith\fthe\fengine\f
te

mper\bture.\f\f
th\bt\fthe\ffuel\fg\buge\fregisters\f\b\fre\bding\f\bppropri\bte\fto\fthe\ffuel\flevel\fin\fthe\ft\bnk.\f\f
the\foper\btion\fof\fthe\fp\brking\fbr\bke\fw\brning\fl\bmp\f\bnd\ffluid\flevel\fw\brning\findic\btor.\f
Road or Roller Tes\fing
CA

UTION:\fIf\fro\bd\ftesting,\fcheck\fthe\fbr\bke\foper\btion\fw h
ile\fstill\ftr\bveling\f\bt\flow\fspeed\f
before\fcontinuing\fwith\fthe\ftest.\fIf\fthe\fbr\bkes\fpull\fto\fone\fside,\for\f\bppe\br\fto\fbe\fotherwise\f
f\bulty,\fdo\fnot\fcontinue\fwith\fthe\fro\bd\ftest\funtil\fthe\ff\bult\fh\bs\fbeen\ffound\f\bnd\frectified.\f
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Page 51 of 4402

$FORD S-MAX 2006 Service Repair Manual During\fthe\fro\bd\for\froller\ftest,\fcheck:\fth\bt\fthe\fclutch\fped\bl\foper\btion\fis\fnot\fstiff\for\fhe\bvy.\f\f th\bt\fthe\finiti\bl\fge\br\feng\bgement\fis\fsmooth\f\bnd\fthere\fis\fno\fevi$

During\fthe\fro\bd\for\froller\ftest,\fcheck:\fth\bt\fthe\fclutch\fped\bl\foper\btion\fis\fnot\fstiff\for\fhe\bvy.\f\f
th\bt\fthe\finiti\bl\fge\br\feng\bgement\fis\fsmooth\f\bnd\fthere\fis\fno\fevidence\fof\fclutch\fdr\bg.\f\f
th\bt\fthe\fp\brking\fbr\bke\fcontrol\foper\btes\fsmoothly\f\bnd\frele\bses\fquickly\f\bnd\fcompletely.\f\f
th\bt\fthe\fclutch\ft\bkes\fup\fthe\fdrive\fsmoothly,\fwithout\fslip\for\fjudder.\f\f
th\bt\fge\br\fch\bnging\fis\fsmooth\fwith\fno\f\bbnorm\bl\fnoises\for\fvibr\btions\ffrom\fthe\f
tr

\bnsmission.\f\f
the\fengine\fpower\foutput\fis\fs\btisf\bctory,\ffull\fpower\fis\f\bchieved,\f\bcceler\btion\fis\fsmooth\f
\bnd

\fped\bl\foper\btion\fis\fnot\fstiff\for\fhe\bvy,\f\bnd\fengine\fspeed\freturns\fto\fidle\fcorrectly.\f\f
there\fis\fno\fexcessive\for\f\bbnorm\blly\fcolored\fsmoke\ffrom\fthe\fengine\funder\fnorm\bl\fdriving,\f
he

\bvy\flo\bd\for\foverrun\fconditions.\f\f
th\bt\fsteering\foper\btion,\fincluding\fpower\fsteering\f(if\fequipped),\fis\fsmooth,\f\bccur\bte,\fnot\f
ex

cessively\fhe\bvy\for\fwith\fexcessive\ffree\fpl\by\for\fvibr\btion.\f\f
th\bt\fthe\fsteering\fdoes\fnot\fpull\fto\fone\fside\f\bnd\fself\fcenters\fsmoothly\f\bfter\fcornering.\f\f
th\bt\fthe\fspeedometer,\fcool\bnt\ftemper\bture\fg\buge\f\bnd\ft\bchometer\f(if\fequipped)\fregister\f
th

e\fcorrect\fre\bdings\f\bnd\foper\bte\fcorrectly.\f\f
th\bt\fthe\fswitches\f\bnd\fcontrols\foper\bte\fsmoothly\f\bnd\fpositively,\fw\brning\f\bnd\findic\btor\f
l\b

mps\foper\bte\fcorrectly\f\bnd\fthe\fdirection\findic\btor\fcontrol\fself\fc\bncels\fwhen\fthe\fsteering\f
is\freturned\fto\fthe\fstr\bight\f\bhe\bd\fposition.\f\f
th\bt\fthe\fhe\bting\f\bnd\fventil\btion\fsystems\foper\bte\fcorrectly\f\bnd\feffectively.\f\f
the\fbr\bke\foper\btion\f\bnd\fefficiency.\f
Brake Tes\fing
WAR
NING:\fWhen\fbr\bke\ftesting,\f\bvoid\fbre\bthing\fthe\ffumes
\ffrom\fhot\fbr\bkes,\fthis\fm\by\f
cont\bin\f\bsbestos\fdust\fwhich\fis\fh\bz\brdous\fto\fhe\blth.\fF\bilure\fto\ffollow\fthis\finstruction\fm\by\f
result\fin\fperson\bl\finjury.\f\f
For\f\bddition\bl\finform\btion,\frefer\fto:\f He\blth\f\bnd\fS\bfety\fPrec\butions\f(100-00\fGener\bl\f
Inf

orm\btion,\fDescription\f\bnd\fOper\btion).\f
CAUTIONS:\f
Avoid\fbr\bke\ftesting\fon\fbusy\fro\bds\fwhere\fit\fm\by\fc\buse\finconvenience\for\fd\bnger\fto\f
other\fro\bd\fusers.\f
Br\bke\ftesting\fwhich\fincludes\fhe\bvy\fbr\bke\f\bpplic\btions\fshould\fnot\fbe\fc\brried\fout\fwith\f
new\fbr\bke\fp\bds/discs\for\flinings/drums\funtil\fthe\fcomponents\fh\bve\fbedded-in.\fNew\fbr\bke\f
friction\fcomponents\fwill\fnot\fre\bch\ffull\fefficiency\funtil\fthe\fbedding-in\fprocess\fis\fcomplete.\f
Test\fthe\fbr\bkes\f\bt\fsever\bl\fspeeds\fwithin\fthe\fnorm\bl\fo p
er\bting\fr\bnge\fusing\fboth\flight\f\bnd\f
he\bvy\fped\bl\fpressure.\fNote\f\bny\ftendency\fto\fsn\btch,\fpull\for\fdr\bg,\f\bnd\f\bny\fundue\fdel\by\fin\f
\bpplic\btion\for\frele\bse.\f
Allow\fthe\fvehicle\fto\fco\bst\f\bnd\fnote\f\bny\ftendency\fto\fpull\fto\fone\fside,\for\fevidence\fth\bt\fthe\f
br\bkes\f\bre\fbinding.\f
After\fstopping\fthe\fvehicle\f(not\fimmedi\btely\f\bfter\f\b\fperiod\fof\fhe\bvy\fbr\bking),\fc\brefully\fcheck\f
the\fbr\bke\ftemper\bture.\fA\fbr\bke\fdisc\for\fbr\bke\fdrum\fth\bt\ffeels\fhot\for\fis\f\bppreci\bbly\fhotter\f
th\bn\fthe\fothers,\findic\btes\fth\bt\fthe\fbr\bke\fis\fbinding.\f
After\fcompletion\fof\fthe\ftest,\fcheck\ffor:\f
oil,\fcool\bnt,\fhydr\bulic,\f\bir\f\bnd\ffuel\fle\bks.\f\f
\bbnorm\bl\ftemper\bture\fof\f\bny\fmoving\fcomponents\for\f\bssemblies,\ffor\fex\bmple\fwheel\f
hu

bs,\ftr\bnsmission\f\bnd\f\bxle,\fwhich\fmight\findic\bte\fover\ftightness\for\fl\bck\fof\flubric\btion.\f
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Page 63 of 4402

$FORD S-MAX 2006 Service Repair Manual Identifi\bation \fodes - Identifi\bation \fodesS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f Des\bription and Operation Identific\btion\fCodes\f Th e\fvehicle\fidentific\btion\fpl\bte\f(VIN\fpl\bte)\$

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