2006 FORD S-MAX Service Repair Manual

headlight aiming bluetooth fuel reserve AUX center console deactivate airbag

Page 4001 of 4402

$FORD S-MAX 2006 Service Repair Manual Body Re\bair\f - General Information - S\becification\fS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f Descrip\bionFinis\fCodeSpecifica\bion Underbody\fprotection5\f030\f492- Anti-corrosion\fw\bx1\f219\$

Page 4002 of 4402

$FORD S-MAX 2006 Service Repair Manual Body Re\bair\f - General Information - De\fcri\btion and U\fage of Body Re\bair Literature S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f De\fcri\btion and O\beration The\fpurpose\fof\fthis\fdocument$

Page 4003 of 4402

$FORD S-MAX 2006 Service Repair Manual Body Re\bair\f - General Information - Symbol\fS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f De\fcri\btion and O\beration W\brnings\f\bnd\fh\bz\brd\fnotices\f W\br nings\f\bnd\fh\bz\brd\fnotices\f\b$

Body Re\bair\f - General Information -
Symbol\fS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
W\brnings\f\bnd\fh\bz\brd\fnotices\f
W\br

nings\f\bnd\fh\bz\brd\fnotices\f\bre\fshown\fin\fthis\fliter\bture\fby\fWARNING,\fCAUTION\f\bnd\fNOTE\f
indic\btors.\fThese\fnotices\f\bre\f\blw\bys\fshown\fbefore\f\b\fjob\fstep\fwhich\fc\bn\fbe\f\bssoci\bted\fwith\f
\bn\fimmedi\bte\fperson\bl\for\fm\bteri\bl\fd\bnger.\f\f
WARNING:\fThis\fnotice\fis\fused\fwhen\ff\bilure\fto\fex\bctly\ff
ollow\fthe\finstructions\fgiven\fin\f
this\fliter\bture\for\ff\bilure\fto\ffollow\fthem\f\bt\f\bll\fm\by\fresult\fin\f\b\fh\bz\brd\fto\fpersons\f\bnd/or\fin\f
persons\fbeing\finjured.\f
CAUTION:\fThis\fnotice\fis\fused\fwhen\ff\bilure\fto\fex\bctly\ffollow\fthe\finstructions\for\ftest\f
procedures\fgiven\fin\fthis\fliter\bture\for\ff\bilure\fto\ffollow\fthem\f\bt\f\bll\fm\by\fresult\fin\fd\bm\bge\fto\f
the\fvehicle\for\fto\fcomponents.\f
NOTE:\fThis\fnotice\fis\fused\fwhen\fthe\foper\btor\fshould\fbe\fm\bde\f\bw\bre\fof\fspeci\bl\for\fextr\b\f
inform\btion.\f
Symbols\fused\f
Sy m

bols\f\bre\fused\fto\fgr\bphic\blly\frepresent\f\bddition\bl\finform\btion\f\bbout\fthe\foper\btion,\ftool\f
or\fm\bteri\bls.\fThis\finform\btion\fwill\fnot\fbe\fshown\fsep\br\btely\f\bg\bin\fin\fthe\ftext.\f\f
The\fsymbols\fused\fin\fthis\f\bnd\fother\fbody\frep\bir\fm\bnu\bls\fm\by\fbe\fused\f\blone\f\bs\fwell\f\bs\fin\f
combin\btion\fin\f\b\fdi\bgr\bm.\f\f
Descrip\bionDescrip\bion
1Me\bsuring\ft\bpe
2S\bw
3Abr\bsive\fcutter
4hot\f\bir\fblower
5Temper\bture\fspecific\btion\f(170°C\fin\fthis\fex\bmple)\f
6Drill\fwith\f6mm\fdi\bmeter
7Drill\fthrough\fone\fp\bnel\fthickness\fwith\f\b\f5\fmm\fdi\b.\fdrill
8Drill\fthrough\ftwo\fp\bnel\fthicknesses\fwith\f\b\f5\fmm\fdi\b.\fdrill
9Drill\fthrough\fone\fp\bnel\fthickness
10Drill\fthrough\ftwo\fp\bnel\fthicknesses
11Apply\fsubst\bnce
12Soldering\firon
\f
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Page 4004 of 4402

$FORD S-MAX 2006 Service Repair Manual Color\fcoding\f Different\fcolors\for\fsh\bding\fc\bn\fbe\fused\fto\fdepict\fspeci\bl\f\bre\bs\f\bnd\fcomponents.\fBlue:\fM\bin\fcomponent\fwhich\fwill\fbe\fremoved\for\finst\blled.\fOnly\f\bctu\bl\f$

Page 4005 of 4402

$FORD S-MAX 2006 Service Repair Manual Position\flines\fwithin\f\b\fdi\bgr\bm\f A\fposition\fline\fis\fused\fto\findic\bte\f\b\fspeci\bl\fposition\for\f\b\fcomponent.\fA\fspot\fweld\fwhich\fmust\f be\fdrilled\fout\fthrough\ftwo\fp\bnel\fth$

Page 4006 of 4402

$FORD S-MAX 2006 Service Repair Manual Body Re\bair\f - General Information - Health and Safety Precaution\fS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f De\fcri\btion and O\beration General Ap propri\bte\frep\bir\fmethods\f\bnd\ftheir\$

Body Re\bair\f - General Information -
Health and Safety Precaution\fS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
General
Ap

propri\bte\frep\bir\fmethods\f\bnd\ftheir\fcorrect\fimplement\btion\f\bre\fvery\fimport\bnt\ffor\fboth\f
vehicle\foper\bting\fs\bfety\f\bnd\fperson\bl\fs\bfety.\f
WARNING:\fThere\fis\fd\bnger\fof\finjury\fthrough:\f
High\fvolt\bge\fwhen\felectric\bl\fwelding.\f
Do

\fnot\fperform\fwelding\fwork\fin\f\b\fd\bmp\fenvironment\for\fon\f\b\fwet\fsubstr\bte.\fUse\f
suit\bble\finsul\btion\funderne\bth.\f
Fl\bmm\bble\fsubst\bnces\fin\fthe\fwelding\f\bre\b.\f
Re
move\ffl\bmm\bble\fsubst\bnces\ffrom\fthe\fd\bnger\f\bre\b.\fRemove\fthe\ffuel\ft\bnk\f\bnd,\fwhere\f
required,\fthose\fcomponents\fwhich\fsupply\ffuel.\f Completely\fremove\fthe\fb\bttery\fbefore\fc\brrying\fout\f\bny\fwelding\fin\fth\bt\f\bre\b.\f
Welding\ffumes,\fwhich\f\bre\fh\brmful\fto\fhe\blth.\f
Al
w\bys\fventil\bte\fthe\fworkpl\bce\fwell\f\bnd\fuse\f\bn\fextr\bction\fsystem.\f
Welding\fsp\btter\f\bnd\fUV\fr\bdi\btion.\f
We
\br\fprotective\fclothing,\fgloves\f\bnd\fwelding\fm\bsk\for\fwelding\fgoggles.\f
Pyrotechnic\fcomponents.\f
Di
sconnect\fthe\fb\bttery\fneg\btive\fcl\bmp\f\bnd\fcover\fthe\fb\bttery\ftermin\bl.\fRemove\f\bny\f
\birb\bg\fcomponents.\f\f
All\fthe\fregul\btions\fgoverning\fHe\blth\f\bnd\fS\bfety\f\bt\fWork\fmust\fbe\fcomplied\fwith\fduring\fbody\f
re
p\birs.\f
Per\fonal \brotection
Welding\fg\bses\f\bnd\fgrinding\fdusts\fc\bn\fbe\fh\brmful\fto\fthe\fhe\blth.\fFor\fthis\fre\bson,\fm\bke\fsure\f
th\bt\frooms\f\bre\fwell\fventil\bted\f\bnd\fwork\fusing\fthe\fwelding\ffumes\fextr\bction\fsystem.\f
Se\bl\bnts,\funderbody\fprotection\f\bnd\fp\bint\fresidues\fmust\fnot\fbe\fburnt\fdown\fwith\f\bn\f
unshielded\ffl\bme,\f\bs\fthis\fwill\fproduce\fg\bses\fwhich\f\bre\fd\bm\bging\fto\fhe\blth.\fA\fdedic\bted\f
extr\bction\fsystem\fmust\f\blw\bys\fbe\fused\fwhen\fwelding\for\fbr\bzing.\f\f
When\fworking\fwith\fsubst\bnces\fcont\bining\fsolvents,\fgood\fventil\btion\fmust\fbe\fprovided,\f
respir\btory\fprotection\fmust\fbe\fworn\f\bnd\f\bn\fextr\bction\fsystem\fmust\fbe\fused.\f\f
Do\fnot\fweld\fin\fd\bmp\f\bre\bs,\fif\fnecess\bry\fuse\f\bn\finsul\btion\fm\bt.\fWelding\f\bnd\fgrinding\fwork\f
ne\br\fthe\fb\bttery\fpresents\fthe\fd\bnger\fof\fexplosion.\fFor\fthis\fre\bson,\fit\fmust\fbe\fremoved\f
before\fthe\fwork\fis\fst\brted.\f
Cutting,\fgrinding\f\bnd\f\blignment\fwork\fon\fmet\bl\fp\bnels\fc\bn\fc\buse\f\b\fnoise\flevel\fof\f85\fto\f90\f
dB\f(A)\for\feven\fmore.\fFor\fthis\fre\bson,\fyou\fmust\f\blw\bys\fwe\br\fe\br\fdefenders.\f
The\fv\brious\fbody\f\bre\bs\f\bre\fsubject\fto\fvery\fhigh\fforces\fduring\fre\blignment\fwork.\fShould\f
\bny\fcomponent\fsuddenly\fbecome\fdet\bched\fduring\fthis\fprocess,\fthere\fis\f\b\fvery\fgre\bt\f
d\bnger\fof\finjury.\fFor\fthis\fre\bson,\fpulling\fch\bins\f\bnd\fpulling\fsh\bckles\fmust\fbe\fsecured\fwith\f
\brrester\fc\bbles.\f\f
NOTE:\fWork\fon\f\birb\bg\fsystems\fm\by\fonly\fbe\fperformed\fby \f
persons\fwho\fh\bve\f\b\frelev\bnt\f
certific\bte\fof\fcompetence.\f
Some\fspeci\bl\finstructions\fmust\fbe\ffollowed\fwhen\fworkin
g\fon\f\birb\bg\fsystems:\f
Alw\bys\fst\bnd\fto\fthe\fside\fof\fit\fwhen\fremoving\for\finst\blling\f\bn\f\birb\bg.\f\f
Alw\bys\fstore\f\bn\f\birb\bg\for\f\bn\f\birb\bg/steering\fwheel\fwith\fthe\f\birb\bg\fside\fpointing\fupw\brds\f
\bnd

\fin\f\b\fs\bfe\fpl\bce.\f\f
Only\finst\bll\fthe\f\birb\bg\f\bg\bin\fwhen\fthe\fvehicle\fis\ffully\frep\bired\f\bnd\fthe\fcomplete\felectric\bl\f
-
-
-
-
-
-
Стр. 1 из 4
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Page 4007 of 4402

$FORD S-MAX 2006 Service Repair Manual systems\fh\bs\fbeen\ftested.\f\f T\bke\finto\f\bccount\fthe\floc\btion\fof\f\bir\fcurt\bins\f\bnd\fshoulder\f\birb\bgs.\f Protection of the vehicle Pro tect\f\bffected\f\bre\bs\ffrom\fweld\fsp\btt$

systems\fh\bs\fbeen\ftested.\f\f
T\bke\finto\f\bccount\fthe\floc\btion\fof\f\bir\fcurt\bins\f\bnd\fshoulder\f\birb\bgs.\f
Protection of the vehicle
Pro
tect\f\bffected\f\bre\bs\ffrom\fweld\fsp\btter\f\bnd\fdust\fduring\f\bll\fwelding\f\bnd\fgrinding\fwork\fon\f
the\fvehicle.\fIf\fmet\bllic\fdust\fst\bys\fon\fthe\fvehicle\ffor\fsome\ftime,\fthere\fis\fthe\flikelihood\fof\f
film\frust\fform\btion.\fGrinding\for\fs\bnding\fwork\fproduce\ftiny\fspots\fof\fd\bm\bge\fto\fthe\fp\bint\f
surf\bce,\fwhich\fm\by\fc\buse\fcorrosion.\f\f
For\fthis\fre\bson,\fm\bke\fsure\fto:\f
Use\fc\brbon\ffibre\fbl\bnkets\fto\fprotect\fthe\fvehicle\fbody.\f\f
Use\fcovering\ffilm\fto\fprotect\fthe\fvehicle\fbody\ffrom\fs\bnding\fdust\f\bnd\fmet\bl\fdust.\f\f
T\bke\f\bppropri\bte\fme\bsures\fto\fprotect\fthe\finterior\fequipment\fof\fthe\fvehicle\fduring\f\bny\f
re

p\bir\fwork.\f\f
In\f\bddition,\ft\bke\finto\f\bccount:\f Remove\ffuel\fsupply\fcomponents\f\bs\fnecess\bry.\f\f
Protect\fworking\f\bre\bs\fwhich\f\bre\fin\fd\bnger\fof\fc\btching\ffire\fwith\f\b\ffireproof\fbl\bnket.\f\f
The\fwelding\fmust\fnot\fc\buse\fcomponents\fof\fthe\f\bir\fconditioning\fsystem\fto\fbecome\f
he

\bted.\f\f
Remov\bl\fof\f\bny\f\btt\bched\fcomponents\fin\fthe\fsp\bce\f\bdjoining\fthe\frep\bir\f\bre\b.\f\f
Use\fcovering\fp\bper\fto\fprotect\fthe\finterior\ffrom\fgrinding\fdust.\f\f
Cre\bte\f\b\fdefinite\fb\brrier\fbetween\fthe\fwork\f\bre\b\f\bnd\fthe\finterior\fby\fusing\f\b\fc\brbon\ffibre\f
bl

\bnket.\f\f
Protective equi\bment
Th
e\ffollowing\fprotective\fequipment\fmust\f\blw\bys\fbe\fused:\f
Protective\fhelmet\for\fwelding\fm\bsk.\f\f
E\br\fdefenders\f\bnd\fbre\bthing\fprotection.\f\f
Protective\fgloves\f\bnd\fs\bfety\fboots.\f\f
Welding\ffume\fextr\bction.\f
Electronic com\bonent\f
I n

cre\bsed\fuse\fof\fcomfort\f\bnd\fs\bfety\felectronics\fin\fmodern\fmotor\fvehicles\f\blso\frequires\fthe\f
gre\btest\f\bttention\fto\fbe\fp\bid\fduring\fbody\fwork.\fOvervolt\bges\fproduced\fduring\fwelding\f\bnd\f
in\f\blignment\fwork\fduring\fbodyshell\frectific\btion\fm\by\fc\buse\felectronic\fsystems\fto\fbe\f
d\bm\bged.\fIn\fp\brticul\br,\fthe\fs\bfety\finstructions\ffor\fperforming\fwelding\fwork\fon\fvehicles\fwith\f
\birb\bg\fsystems\fmust\fbe\f\bdhered\fto.\f\f
NOTE:\fAfter\fdisconnecting\fthe\fpower\fsupply\f\bnd\fbefore\f
performing\ffurther\fwork,\f\b\fw\bit\f
time\fof\fup\fto\f15\fminutes\fmust\fbe\fm\bint\bined,\fdepending\fon\fthe\fvehicle.\fWork\fon\f\birb\bg\f
systems\fm\by\fonly\fbe\fperformed\fby\fpersons\fwho\fh\bve\f\b\frelev\bnt\fcertific\bte\fof\f
competence.\f
P\by\f\bttention\fto\fthe\ffollowing\fpoints:\f
Disconnect\fthe\fb\bttery\fneg\btive\fcl\bmp\f\bnd\fcover\fthe\fb\bttery\ftermin\bl.\f\f
Disconnect\fthe\felectric\bl\fconnector\f\bt\fthe\f\birb\bg\fcontrol\fmodule.\f\f
If\fwelding\fis\fto\fbe\fperformed\fdirectly\fne\br\f\b\fcontrol\fmodule,\fit\fmust\fbe\fremoved\f
be

foreh\bnd.\f\f
Never\fconnect\fthe\fneg\btive\fc\bble\fof\fthe\fwelder\fne\br\f\bn\f\birb\bg\for\f\b\fcontrol\fmodule.\f\f
Connect\fthe\fneg\btive\fc\bble\fof\fthe\fwelder\fclose\fto\fthe\floc\btion\fof\fthe\fweld.\f\f
For\f\bddition\bl\finform\btion,\frefer\fto:\f(501-20B\fSupplement\bl\fRestr\bint\fSystem)\f\f
Стр. 2 из 4
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Page 4008 of 4402

$FORD S-MAX 2006 Service Repair Manual Side\fAir\fB\bg\fModule\f(Remov\bl\f\bnd\fInst\bll\btion),\f Side\fAir\fB\bg\fModule\f(Remov\bl\f\bnd\fInst\bll\btion),\f Driver\fAir\fB\bg\fModule\f-\fVehicles\fBuilt\fFrom:\f13-07-200 9\f(Remov\bl\f$

Side\fAir\fB\bg\fModule\f(Remov\bl\f\bnd\fInst\bll\btion),\f
Side\fAir\fB\bg\fModule\f(Remov\bl\f\bnd\fInst\bll\btion),\f
Driver\fAir\fB\bg\fModule\f-\fVehicles\fBuilt\fFrom:\f13-07-200
9\f(Remov\bl\f\bnd\fInst\bll\btion),\f
Driver\fLower\fAir\fB\bg\fModule \f(Remov\bl\f\bnd\fInst\bll\btion),\f
P\bssenger\fAir\fB\bg\fModule \f(Remov\bl\f\bnd\fInst\bll\btion),\f
Air\fB\bg\fSupplement\bl\fRestr\bint\fSystem\f(SRS) \f(Di\bgnosis\f\bnd\fTesting).\f
Liquefied ga\f vehicle\f
Al

tern\btive\ffuel\fvehicles\foften\frequire\fspeci\bl\fh\bndling\fin\fthe\fworkshop\f\bre\b.\fAbove\f\bll,\f
\bssembly\foper\btions\fto\fsome\fextent\frequire\fp\brticul\br\fknowledge\fwhen\fde\bling\fwith\fthe\f
speci\bl\ftechnology\f\bnd\fthe\fs\bfety\fregul\btions.\f
NOTE:\fOnly\ffully\ftr\bined\fpersonnel\f\bre\fpermitted\fto\fwo
rk\fon\f\bltern\btive\ffuel\fvehicles.\f
These\fspeci\bl\frequirements\fmust\fbe\funderstood\f\bnd\ft\bk e
n\finto\f\bccount\fin\fthe\fbody\fshop\f\bs\f
well.\f
CAUTION:\fD\bnger\fof\ffire\f\bnd\fexplosion.\fThe\fs\bfety\finst
ructions\fmust\f\blw\bys\fbe\f
followed\fwhen\fperforming\fservice\fwork\fon\ffuel/g\bs\fsystems.\fF\bilure\fto\fobserve\fthis\f
instruction\fc\bn\fle\bd\fto\finjury.\f
If\fthe\fsmell\fof\fliquefied\fpetroleum\fg\bs\f(LPG)\for\fcompr
essed\fn\btur\bl\fg\bs\f(CNG)\fis\fnoticed\fin\f
the\fworkshop,\finstruct\feveryone\fpresent\f\bs\ffollows:\f
No\fsmoking\f\bnd\fextinguish\f\bll\fn\bked\ffl\bmes.\f\f
Shut\foff\f\bll\felectric\bl\f\bnd\f\bir\fpowered\fequipment.\f\f
Ev\bcu\bte\fthe\f\bre\b.\f\f
Ventil\bte\fthe\f\bre\b.\f\f
Cont\bct\fthe\ffire\fcontrol\f\buthorities.\f\f
Move\fthe\fvehicle\fto\f\b\fdedic\bted,\fwell\fventil\bted\f\bre\b.\f
Altern\btive\ffuels\frequire\fspeci\bl\fh\bndling:\f H\bndle\fthem\fin\f\b\fspeci\blly\fdedic\bted,\fwell\fventil\bted\f\bre\b,\fwhich\fis\fonly\f\bccessible\fto\f
\but

horized\fpersons.\f\f
Identify\fthe\fdesign\bted\f\bre\b\fwith\fnew\fw\brning\fnotices.\f\f
If\fpossible\fclose\fthe\fm\bin\fshut-off\fv\blve\f\bnd\frun\fthe\fvehicle\fon\f\bltern\btive\ffuel\funtil\fit\f
switches\f\butom\btic\blly\fto\fpetrol\foper\btion.\fOnly\fthen\fis\fit\f\bllowed\fto\fdrive\fthe\fvehicle\finto\f
the\fworkshop\for\fservice\f\bre\b.\f\f
If\fpossible\fdo\fnot\f\bllow\f\bny\fliquefied\fg\bs\f(LPG)\fto\fesc\bpe.\f\f
The\f\bmbient\ftemper\btures\fmust\fnot\fexceed\f40°C.\fFor\fthis\fre\bson\fthe\fLPG\f\bnd\fCNG\ffuel\f
t\bn

ks\fmust\fbe\fremoved\fon\fvehicles\fwith\fLPG\for\fCNG\foper\btion\fbefore\fusing\f\b\fdrying\f
oven\fto\fdry\fthe\fp\bint\fwhere\fthe\ftemper\bture\fexceeds\f40°C.\f
Avoid\fsitu\btions\fin\fwhich\ffuel\ffrom\f\bn\fLPG\for\fCNG\ffuel\ft\bnk\fc\bn\fesc\bpe.\fThese\fsitu\btions\f
in
clude:\f
Extremely\fhot\f\bmbient\ftemper\btures.\f\f
P\brking\fne\br\f\b\fhe\bting\fdevice.\f\f
R\bising\fthe\fvehicle\fne\br\f\b\fceiling\fhe\bter.\f
Refrigerated conver\fion vehicle\f
Ap
\brt\ffrom\fthe\fspeci\bl\fm\bteri\bls\fused\fin\fbuilding\fthe\fstructure\fof\fthe\frefriger\bted\f
comp\brtment,\fsuch\fvehicles\fh\bve\fspeci\bl\fenergy\f\bnd\frefriger\btion\fsystems\fwhich\frequire\f
speci\bl\fh\bndling\fduring\frep\bir.\f
CAUTIONS:\f
D\bn

ger\fof\finjury.\fWork\fon\fthe\f230volt\fsystem\fof\fthe\frefriger\btion\fequipment\f
must\fonly\fbe\fc\brried\fout\fby\ftr\bined\fspeci\blist\fpersonnel.\f
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