2006 FORD S-MAX warning light

navigation system hood open trip computer brake fluid buttons keyless entry

Page 3073 of 4402

$FORD S-MAX 2006 Service Repair Manual wiring\fdi\bgr\bms.\fCHECK\fsystem\foper\btes\fcorrectly\f B3:\bCHECK\bTHE\bCIRCUIT\bBETWEEN\bTHE\bHAZARD\bWARNING\bLIGHTS\bSWITCH\bAND\bTHE\b SMART\bJUNCTION\bBOX\bFOR\bOPEN\bCIRCUIT Ignition\fswitch$

wiring\fdi\bgr\bms.\fCHECK\fsystem\foper\btes\fcorrectly\f
B3:\bCHECK\bTHE\bCIRCUIT\bBETWEEN\bTHE\bHAZARD\bWARNING\bLIGHTS\bSWITCH\bAND\bTHE\b
SMART\bJUNCTION\bBOX\bFOR\bOPEN\bCIRCUIT
Ignition\fswitch\fin\fposition\f0.\f1\b
Disconnect\fSm\brt\fJunction\fBox\ffrom\fconnector\f
C1BP02C.\f2\b
Me\bsure\fthe\fresist\bnce\fbetween\fthe\fh\bz\brd\f
w\brning\flights\fswitch,\fconnector\fC2LS32,\fpin\f6,\f
circuit\fCLS32A\f(BN/YE),\fwiring\fh\brness\fside\f\bnd\f
the\fSm\brt\fJunction\fBox,\fconnector\fC1BP02C,\fpin\f8,\f
circuit\fCLS32A\f(BN/YE),\fwiring\fh\brness\fside.\f
3\b
Is\f\b\fresist\bnce\fof\fless\fth\bn\f2\fOhms\fregistered?\f
Yes\b INSTALL\fA\fNEW\fSm\brt\fJunction\fBox.\fCHECK\f
system\foper\btes\fcorrectly\f
No\b LOCATE\f\bnd\fRECTIFY\fthe\fbre\bk\fin\fthe\fcircuit\f
between\fthe\fh\bz\brd\fw\brning\flights\fswitch\f\bnd\fthe\f
Sm\brt\fJunction\fBox\fwith\fthe\f\bid\fof\fthe\fWiring\f
Di\bgr\bms.\fCHECK\fsystem\foper\btes\fcorrectly\f
PINPOINT\bTEST\bC\b:\bSINGLE\bOR\bMULTIPLE\bTURN\bSIGNAL\bLAMPS\b
INOPERATIVE\b
TEST CONDITIONSDETAILS/RESULTS/ACTIONS
C1:\bDETERMINE\bTHE\bCONDITION\bUNDER\bWHICH\bTHE\bFAULT\bOCCURS
Ignition\fswitch\fin\fposition\fII.\f1\b
CHECK\fthe\fturn\fsign\bl\fl\bmps.\f2\b
SWITCH\fON\fthe\fleft-h\bnd\fturn\fsign\bl.\f3\b
SWITCH\fON\fthe\fright-h\bnd\fturn\fsign\bl.\f4\b
Is\fone\for\fmore\fturn\fsign\bl\fl\bmp\fon\fthe\fleft-h\bnd\fside\f
inoper\btive?\f
Yes\b-\fAll\fturn\fsign\bl\fl\bmps\fon\fleft-h\bnd\fside\f
inoper\btive:\fCHECK\f\bnd\fif\fnecess\bry\fRENEW\fthe\f
steering\fwheel/steering\fcolumn\fswitch.\fCHECK\f
system\foper\btes\fcorrectly\fIf\fthe\fconcern\fpersists:\f
\f
REFER\fto:\f Communic\btions\fNetwork \f(418-00\f
Mod
ule\fCommunic\btions\fNetwork,\fDi\bgnosis\f\bnd\f
Testing).\f
-\fLeft-h\bnd\ffront\fturn\fsign\bl\fl\bmp\fis\finoper\btive:\f
GO\fto\fC2 .\f\f
-\fL

eft-h\bnd\fre\br\fturn\fsign\bl\fl\bmp\fis\finoper\btive:\f
GO\f
to\fC5 .\f\f
-\fI
ntegr\bted\fturn\fsign\bl\fl\bmp\fin\fthe\fleft-h\bnd\f
exterior\fmirror\fis\finoper\btive:\f GO\fto\fC8.\f\f
No\b
-

\fAll\fturn\fsign\bl\fl\bmps\fon\fright-h\bnd\fside\f
inoper\btive:\fCHECK\f\bnd\fif\fnecess\bry\fRENEW\fthe\f
steering\fwheel/steering\fcolumn\fswitch.\fCHECK\f
system\foper\btes\fcorrectly\fIf\fthe\fconcern\fpersists:\f
\f
REFER\fto:\f Communic\btions\fNetwork \f(418-00\f
Mod
ule\fCommunic\btions\fNetwork,\fDi\bgnosis\f\bnd\f
Testing).\f
\f\f
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Page 3087 of 4402

$FORD S-MAX 2006 Service Repair Manual Module\fCommunic\btions\fNetwork,\fDi\bgnosis\f\bnd\f Testing).\f No\b RENEW\fthe\fsteering\fwheel/steering\fcolumn\fmodule\f CHECK\fsystem\foper\btes\fcorrectly\f D3:\bRULE\bOUT\bTHE\bHIGH\bBEAM\bHEA$

Module\fCommunic\btions\fNetwork,\fDi\bgnosis\f\bnd\f
Testing).\f
No\b
RENEW\fthe\fsteering\fwheel/steering\fcolumn\fmodule\f
CHECK\fsystem\foper\btes\fcorrectly\f
D3:\bRULE\bOUT\bTHE\bHIGH\bBEAM\bHEADLAMP\bSWITCH\bHAZARD\bWARNING\bLIGHT\b
SYSTEM\bAS\bTHE\bCAUSE\bOF\bTHE\bFAULT
Ignition\fswitch\fin\fposition\f0.\f1\b
Disconnect\fH\bz\brd\fw\brning\flights\fswitch\ffrom\f
connector\fC2LS32.\f2\b
Ignition\fswitch\fin\fposition\fII.\f3\b
CHECK\fthe\fturn\fsign\bl\fl\bmps.\f4\b
Are\fthe\fturn\fsign\bl\fl\bmps\ffl\bshing\fcontinuously?\f
Yes\b GO\fto\fD4.\f\f
No\b
R

ENEW\fthe\fh\bz\brd\fw\brning\flights\fswitch.\fCHECK\f
system\foper\btes\fcorrectly\f
D4:\bCHECK\bTHE\bCONTROL\bCIRCUIT\bBETWEEN\bTHE\bHAZARD\bWARNING\bLIGHTS\b
SWITCH\bAND\bTHE\bSMART\bJUNCTION\bBOX\bFOR\bSHORT\bTO\bGROUND
Ignition\fswitch\fin\fposition\f0.\f1\b
Disconnect\fSm\brt\fJunction\fBox\ffrom\fconnector\f
C1BP02C.\f2\b
Me\bsure\fthe\fresist\bnce\fbetween\fthe\fh\bz\brd\f
w\brning\flights\fswitch,\fconnector\fC2LS32,\fpin\f6,\f
circuit\fCLS32A\f(BN/YE),\fwiring\fh\brness\fside\f\bnd\f
ground.\f3\b
Is\f\b\fresist\bnce\fof\fmore\fth\bn\f10,000\fOhm\fme\bsured?\f
Yes\b CHECK\fthe\fSm\brt\fJunction\fBox\f\bnd\fRENEW\fit\fif\f
required.\fCHECK\fsystem\foper\btes\fcorrectly\f
No\b LOCATE\f\bnd\fRECTIFY\fthe\fshort\fto\fground\fin\fthe\f
circuits\fbetween\fthe\fh\bz\brd\fw\brning\flights\fswitch\f
\bnd\fthe\fSm\brt\fJunction\fBox\fwith\fthe\f\bid\fof\fthe\f
Wiring\fDi\bgr\bms.\fCHECK\fsystem\foper\btes\fcorrectly
\f
PINPOINT\bTEST\bE\b:\bONE\bOR\bMORE\bTURN\bSIGNAL\bLAMPS\bPERMANENTLY\b
LIT\b
TEST
CONDITIONSDETAILS/RESULTS/ACTIONS
E1:\bDETERMINE\bTHE\bCONDITION\bUNDER\bWHICH\bTHE\bFAULT\bOCCURS
Ignition\fswitch\fin\fposition\fII.\f1\b
CHECK\fthe\fturn\fsign\bl\fl\bmps.\f2\b
Are\fthe\fturn\fsign\bl\fl\bmps\flit\fup\fperm\bnently?\f
Yes\b CHECK\fthe\fSm\brt\fJunction\fBox\f\bnd\fRENEW\fit\fif\frequired.\fCHECK\fsystem\f
oper\btes\fcorrectly\fIf\fthe\fconcern\fpersists:\f\f
REFER\fto:\f Communic\btions\fNetwork \f(418-00\fModule\fCommunic\btions\f
Ne t

work,\fDi\bgnosis\f\bnd\fTesting).\f
No\b \f\f
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Page 3175 of 4402

$FORD S-MAX 2006 Service Repair Manual Exterior\bLighti\fg\b-\bHeadlamp\bBulb— Vehicles\bWith:\bHigh\bI\fte\fsity\bDischarge\b Headlamps S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f Removal\ba\fd\bI\fstallatio\f\b Removal\b WAR NING:\fH$

Page 3486 of 4402

$FORD S-MAX 2006 Service Repair Manual Symptom Chart Pinpoint T\fsts volt\bge\for\fopen\fcircuit). B1D07-11Circuit\fof\fturn\fsign\bl\fl\bmp\f integr\bted\fin\fthe\fright-h\bnd\f exterior\fmirror\ff\bulty\f(short\fto\f ground).REFER\fto:$

Symptom Chart
Pinpoint T\fsts
volt\bge\for\fopen\fcircuit).
B1D07-11Circuit\fof\fturn\fsign\bl\fl\bmp\f
integr\bted\fin\fthe\fright-h\bnd\f
exterior\fmirror\ff\bulty\f(short\fto\f
ground).REFER\fto:\fTurn\fSign\bl,\fCornering\f\bnd\fH\bz\brd\f
L\bmps\f(417-01\fExterior\fLighting,\fDi\bgnosis\f
\bnd
\fTesting).
B1A94-11Circuit\fof\fdriver\fside\fexterior\f
mirror\ff\bulty\f(short\fto\fground).REFER\fto:\f Re\br\fView\fMirrors \f(501-09\fRe\br\f
Vie
w\fMirrors,\fDi\bgnosis\f\bnd\fTesting).
B1A94-15Circuit\fof\fdriver\fside\fexterior\f
mirror\ff\bulty\f(short\fto\fvolt\bge\for\f
open\fcircuit).REFER\fto:\f Re\br\fView\fMirrors \f(501-09\fRe\br\f
Vie
w\fMirrors,\fDi\bgnosis\f\bnd\fTesting).
B1A95-15Circuit\fof\fp\bssenger\fside\fexterior\f
mirror\ff\bulty\f(short\fto\fvolt\bge\for\f
open\fcircuit).REFER\fto:\f Re\br\fView\fMirrors \f(501-09\fRe\br\f
Vie
w\fMirrors,\fDi\bgnosis\f\bnd\fTesting).
B1A95-11Circuit\fof\fp\bssenger\fside\fexterior\f
mirror\ff\bulty\f(short\fto\fground).REFER\fto:\f Re\br\fView\fMirrors \f(501-09\fRe\br\f
Vie
w\fMirrors,\fDi\bgnosis\f\bnd\fTesting).
U3003-62Volt\bge\fsupply\f(termin\bl\f30)\f
f\bulty.GO\fto\fPinpoint\fTest\f A.\f
B1A98-86,\f
B1A98-83,\f
B1A98-87,\f
B1B70-86,\f
B1B70-83,\f
B1B70-87No\fcommunic\btions\fpossible\fvi\b\f
the\fLIN\fbus.REFER\fto:\f Communic\btions\fNetwork \f(418-00\f
Mod
ule\fCommunic\btions\fNetwork,\fDi\bgnosis\f
\bnd\fTesting).
U0010-00No\fcommunic\btions\fpossible\fvi\b\f
the\fMS\fCAN\fbus.REFER\fto:\f Communic\btions\fNetwork \f(418-00\f
Mod
ule\fCommunic\btions\fNetwork,\fDi\bgnosis\f
\bnd\fTesting).
SymptomPo\f\fible
Source\fAction
Driver\fdoor\fmodule\fnot\f
communic\bting\fwith\fthe\fFord\f
di\bgnostic\fequipment.Fuse(s).\f
Circuit(s).\f
Driver's\fdoor\f
module.\f
*
*
*REFER\fto:\f
Communic\btions\fNetwork \f
(41
8-00\fModule\fCommunic\btions\f
Network,\fDi\bgnosis\f\bnd\fTesting).\f
*
P\bssenger\fdoor\fmodule\fnot\f
communic\bting\fwith\fthe\fFord\f
di\bgnostic\fequipment.Fuse(s).\f
Circuit(s).\f
P\bssenger\f
door\fmodule.\f
*
*
*REFER\fto:\f
Communic\btions\fNetwork \f
(41
8-00\fModule\fCommunic\btions\f
Network,\fDi\bgnosis\f\bnd\fTesting).\f
*
Volt\bge\fsupply\f(termin\bl\f30)\f\bt\f
the\fdriver\fdoor\fmodule\ff\bulty.Fuse(s).\f
Circuit(s).\f
Driver\fdoor\f
module.\f
*
*
*GO\fto\fPinpoint\fTest\f
A.\f\f
*
Volt\bge\fsupply\f(termin\bl\f30)\f\bt\f
the\fp\bssenger\fdoor\fmodule\f
f\bulty.Fuse(s).\f
Circuit(s).\f
P\bssenger\f
door\fmodule.\f
*
*
*GO\fto\fPinpoint\fTest\f
B.\f\f
*
PINPOINT TEST A : VOLTAGE SUPPLY (TERMINAL 30) AT THE DRIVER
DOOR MODULE FAULTY.
WARNING:\fThe\fwindow\f\bnti-tr\bp\ffunction\fwill\fnot\foper\bte\fduring\fthe\fwindow\fmotor\f
initi\bliz\btion\fprocedure.\f
NOTE:\fIf\fthe\fpower\fto\f\b\fwindow\fregul\btor\fmotor\fh\bs\fbeen\fdisconnected,\fit\fis\fnecess\bry\f
to\finiti\blize\fth\bt\fwindow\fregul\btor\fmotor.\f\f
TEST CONDITIONSDETAILS/RESULTS/ACTIONS
A1: DETERMINE THE VEHICLE VARIANT.
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Page 4060 of 4402

$FORD S-MAX 2006 Service Repair Manual The\fjoggled\fjoint\fv\bri\bnt\fis\frestricted\fto\fbody\f\bre\bs\fwith\f\b\fgood\fsurf\bce\fcondition\fwithout\f be\bds/sw\bge\flines\for\fprofiles.\fA\fsection\bl\frepl\bcement\fwith\f\b\fjoggled\fj$

The\fjoggled\fjoint\fv\bri\bnt\fis\frestricted\fto\fbody\f\bre\bs\fwith\f\b\fgood\fsurf\bce\fcondition\fwithout\f
be\bds/sw\bge\flines\for\fprofiles.\fA\fsection\bl\frepl\bcement\fwith\f\b\fjoggled\fjoint\fis\fwelded\fusing\f\b\f
continuous\fse\bm.\fThis\fprocedure\fis\fused,\ffor\fex\bmple,\f\bt\fthe\ftr\bnsition\ffrom\fthe\fside\fp\bnel\f
to\fthe\frocker\fp\bnel\f(3-door\fvehicles).\f
When\fcutting\fthe\fnew\fp\brt,\fslight\fme\bsuring\ftoler\bnces\f\bre\fpermitted,\f\bs\fthese\f\bre\fcovered\f
by\fthe\fjoggled\f\bre\b.\f
Prep\br\btion\fof\fthe\fjoint\f\bre\bs\fincludes:\fS\bnding\fthe\fconnection\f\bre\bs\fb\bre\fon\fboth\fsides.\f\f
Remov\bl\fof\fthe\fzinc\fl\byer\fin\fthe\fwelding\f\bre\b.\f\f
Prep\br\btion\fof\f\b\fjoggled\fstrip.\f\f
C\brrying\fout\fwelding\ftests\fon\f\bn\fequiv\blent\fs\bmple\fp\bnel\fbefore\fthe\f\bctu\bl\fwelding,\fif\f
ne

cess\bry.\f\f
Joining\fthe\fnew\f\bnd\fold\fp\bnel\fwith\fcontinuous\fse\bm\fwelding.\f\f
Le\bd\flo\bding\fthe\fweld\fse\bm.\f
Soft \foldering
WAR
NING:\fThe\froof\frep\bir\fm\by\fonly\fbe\fc\brried\fout\fin\fFo
rd-\bpproved\fspeci\bl\f
workshops\f\bnd\fonly\fby\fspeci\blly\ftr\bined\fpersonnel.\f
NOTE:\fThe\froof\fis\fsecured\fto\fthe\fside\fw\blls\fwith\fl\bser\fsoldered\fse\bms\fin\fproduction.\f
When\frep\birs\f\bre\fc\brried\fout,\fthese\fl\bser-soldered\fse\bms\fmust\fbe\frepl\bced\fby\fsoft-
soldered\fse\bms.\f
WARNING:\fPoisonous\fg\bses\f\bnd\fdust\fc\bn\fbe\fproduced\fwhen\fworking\fsolder.\fUse\f\bn\f
extr\bction\funit\f\bnd,\fif\frequired,\f\b\fprotective\fm\bsk.\f
NOTE:\fFord\foffers\fb\bsic\f\bnd\fin-depth\ftr\bining\fon\fthe\ffollowing\ftopics.\f
NOTE:\fAre\bs\ffor\fsoft\fsoldered\fjoints\frequire\fc\breful\fprep\br\btion.\fIt\fis\fextremely\fimport\bnt\f
th\bt\fthe\fjoint\fsurf\bces\f\bre\fex\bctly\f\bligned\f\bnd\fth\bt\f\b\fb\bre\fmet\bl\fjoint\fsurf\bce\fis\fprep\bred.\f
Descrip\bionDescrip\bion
1Body\fp\brt
2Joggled\f\bre\b
3New\fp\bnel
\f
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Page 4282 of 4402

$FORD S-MAX 2006 Service Repair Manual Paint - \beneral \fnformation - Health and Safety PrecautionsS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f Description and Operation \beneral instructions for the paint shop and handling paint materi$

Paint - \beneral \fnformation - Health and
Safety PrecautionsS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Description and Operation
\beneral instructions for the paint shop and handling paint materials
H\b

z\brdous\f\bre\bs\fin\frep\bir\fp\bint\fshops:\f\f
D\bnger\ffrom\ffires,\fexplosions\f\bnd\fhot\fsurf\bces.\f\f
D\bngers\fto\fhe\blth\f\bnd\fs\bfety\ffrom\fthe\feffects\fof\fh\brmful\fsubst\bnces\fbec\buse\fof\ftheir\f
\bbs

orption\fthrough\fthe\fskin\f\bnd/or\finh\bl\btion.\f\f
D\bngers\fc\bused\fby\felectricity,\fcompressed\f\bir,\fpower\ftools\f\bnd\fnoise.\f\f
WARNING:\fDuring\fp\binting\fwork\fthere\fis\f\bn\fincre\bsed\fd\bnger\fof\ffire\for\fexplosion.\f
Pre

vent\f\bny\fsp\brks\fbeing\fcre\bted.\fFire,\fn\bked\flights\f\bnd\fsmoking\f\bre\fforbidden.\f\f
Me\bsures:\f
We\br\fprotective\ffootwe\br\fm\bde\ffrom\f\bnti-st\btic\fm\bteri\bl.\f\f
Only\fuse\ftools\fm\bde\fof\fwood,\fbr\bss\for\fcopper\fto\fcle\bn\fst\bnds\f\bnd\fextr\bction\fducts.\fDo\f
no

t\fuse\ftools\fm\bde\fof\fsteel.\f
Only\ffill\for\fdec\bnt\fp\bint\fm\bteri\bls\fin\f\b\fspeci\blly\fm\brked\f\bre\b.\f\f
A s

\fwell\f\bs\fthese\fgener\bl\finstructions\fon\fthe\fd\bngers\fin\frep\bir\fp\bint\fshops,\f\bll\fn\btion\bl\f\bnd\f
intern\btion\bl\fregul\btions\fmust\fbe\fobserved:\f
He\blth\f\bnd\fS\bfety\f\bt\fWork\fAct\f\f
Ordin\bnce\fon\fH\bz\brdous\fSubst\bnces\f\f
Technic\bl\fRules\ffor\fH\bz\brdous\fSubst\bnces\f\f
Regul\btions\ffor\fthe\fPrevention\fof\fIndustri\bl\fAccidents\f\f
EU\fDirective\fon\fH\bz\brdous\fSubst\bnces,\f98/24/EU\f\f
EU\fDirective\fon\fNoise,\f2003/10/EU\f\f
EU\fDirective\fon\fVol\btile\fOrg\bnic\fCompounds\f(VOC),\f1999/13/EU,\f2001/81/EU,\f
20

04/42/EU\f\f
S\bfety\finstructions\fof\fequipment\f\bnd\ftool\fm\bnuf\bcturers\f
Personal protection
Be
sides\fthe\fbody\f\bnd\flimbs,\fsever\bl\forg\bns\fvit\bl\fto\flife\f\bre\fin\fvery\fp\brticul\br\fd\bnger.\f
Bec\buse\fd\bm\bge\fis\fmostly\firrep\br\bble,\fspeci\bl\f\bttention\f\bnd\fcomprehensive\fprotection\f\bre\f
necess\bry.\f
WARNING:\fSolvents\fc\buse\fd\bm\bge\fto\fthe\fhe\blth\fthrough\f i
nh\bl\btion.\fSpl\bshes\fin\fthe\f
eyes\for\fon\fthe\fskin\fc\bn\fc\buse\fbodily\fh\brm.\fWhen\fworking\fwith\fsolvents,\f\blw\bys\fuse\f
suit\bble\fme\bns\fof\fprotection.\f
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