2006 FORD S-MAX Service Repair Manual

length winter tyres key fob spare wheel brake sensor alternator belt

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$FORD S-MAX 2006 Service Repair Manual reduce\fthe\fmovement\fof\fthis\fm\bss\f\bccordingly\f(e.g.\fbumper\fon\fch\bssis).\f D\bmping\f\bffects\fthe\freson\bnce\fof\f\bn\fobject\for\fsystem.\f I\folation\f In\foscill\btion\ftechnology,\fth$

Page 4098 of 4402

$FORD S-MAX 2006 Service Repair Manual On\fthe\fFocus\f2004.75\f(07/2004-)\fthese\felements\f\bre\floc\bted\fin\fthe\fc\bvities\fof\fthe\fA,\fB\f\bnd\f C\fpill\brs.\fOn\fthe\fest\bte\fversion,\fthey\f\bre\f\blso\floc\bted\fin\fthe\fD\fpill$

On\fthe\fFocus\f2004.75\f(07/2004-)\fthese\felements\f\bre\floc\bted\fin\fthe\fc\bvities\fof\fthe\fA,\fB\f\bnd\f
C\fpill\brs.\fOn\fthe\fest\bte\fversion,\fthey\f\bre\f\blso\floc\bted\fin\fthe\fD\fpill\brs.\f
The\fNVH\fm\bteri\bl\fconsists\fof\f\b\fc\brrier\fpl\bte\fwhich\fh\bs\fcompressed\fisol\btion\fm\bteri\bl\f\bt\fthe\f
edges.\fIn\fthe\fdrying\fsystem\fof\fthe\fp\binting\fequipment\fused\fin\fproduction,\fthe\fbody\fis\f
he\bted\fto\f\bpprox.\f170°\fC.\fAt\fthis\ftemper\bture\fthe\fisol\btion\fm\bteri\bl\fexp\bnds\fto\fse\bl\fthe\f
g\bp\fbetween\fthe\fc\brrier\fpl\bte\f\bnd\fthe\fbodywork.\f
NOTE:\fNVH\felements\fmust\fnot\fbe\fd\bm\bged\fduring\fwork\fon\f
the\fvehicle\fbody.\fNVH\f
elements\fdeformed\fthrough\fimp\bct\fmust\f\blw\bys\fbe\frepl\bced.\fPU\f\bdhesive\fmust\f\blw\bys\f
be\f\bpplied\fto\fthe\fedges\fof\fnew\f\bnd\freused\fNVH\felements\fduring\frep\bir\fwork.\f
For\fthe\fex\bct\finst\bll\btion\fposition\fof\f\bn\fNVH\felement ,
\fple\bse\frefer\fto\fthe\fvehicle-specific\f
rep\bir\finstructions.\f
If\f\bn\fNVH\felement\fis\fto\fbe\freused,\fthe\fbonding\fon\fthe\fbody\fp\bnel\fmust\fbe\fdet\bched.\fTo\fdo\f
this,\fthe\fbody\fp\bnel\fmust\fbe\fhe\bted\fin\fthe\f\bre\b\f\bround\fthe\fNVH\felement.\fThe\fbonding\fc\bn\f
be\fdet\bched\f\bt\f\bpprox.\f170°\fC.\fThe\fd\bm\bged\fp\bnel\fp\brt\fc\bn\fnow\fbe\fc\brefully\fdism\bntled.\f
Before\finst\blling\fthe\fnew\fp\bnel\fp\brt,\f\b\fPU\f\bdhesive\fmust\fbe\f\bpplied\fto\fthe\fcont\bct\f\bre\bs\f
between\fthe\fp\bnel\f\bnd\fthe\fNVH\felement.\f
Test\ftechniques,\fme\bsuring\fdevices\f
The\fshortest\froute\fto\f\bn\f\bccur\bte\fdi\bgnosis\fresults\ffrom:\f
gener\bl\finform\btion\fon\fthe\fproblem\fvehicle\f\bnd\f\b\fcomp\brison\ftest\fwith\f\b\fvehicle\fof\fthe\f
s\bm

e\fconstruction,\fwithout\fNVH\fproblems.\f\f
vehicle\fhistory,\fincluding\frep\bir\fhistory\f\bnd\fus\bge\fp\btterns.\f\f
condition\fhistory,\fespeci\blly\f\bny\frel\btionship\fto\frep\birs\for\fsudden\fch\bnge.\f\f
knowledge\fof\fprob\bble\fc\buses.\f\f
\bpplic\btion\fof\fdi\bgnosis\fprocedures\fin\fwhich\fthe\fvehicle\fis\fsplit\finto\fcorresponding\f\bre\bs.\f
The\fdi\bgnosis\f\bnd\fcorrection\fof\fnoise,\fvibr\btion\f\bnd\fh\brshness\fconcerns\frequires:\f gener\bl\finform\btion\fon\fthe\fproblem\fvehicle\f\bnd\f\b\fcomp\brison\ftest\fwith\f\b\fvehicle\fof\fthe\f
s\bm

e\fconstruction,\fwithout\fNVH\fproblems.\f\f
vehicle\fhistory,\fincluding\frep\bir\fhistory\f\bnd\fus\bge\fp\btterns.\f\f
condition\fhistory,\fespeci\blly\f\bny\frel\btionship\fto\frep\birs\for\fsudden\fch\bnge.\f\f
knowledge\fof\fprob\bble\fc\buses.\f\f
\bpplic\btion\fof\fdi\bgnosis\fprocedures\fin\fwhich\fthe\fvehicle\fis\fsplit\finto\fcorresponding\f\bre\bs.\f
NOTE:\fThe\fdi\bgnosis\fof\fdroning\fproblems\fis\fone\fof\fthe\fmost\fdifficult\ft\bsks\fin\fthe\fNVH\f
\b r

e\b.\fWith\fthe\fexception\fof\finst\blled\fcomponents\funder\fstress,\f\b\fcert\bin\fdi\bgnosis\fof\f
droning\fproblems\f(or\fboom)\fon\fcustomer\fvehicles\fm\bkes\fgre\bt\fdem\bnds\fon\fthe\f
\butomotive\ftechnici\bn.\fThe\fperform\bnce\fof\fme\bsuring\fequipment\f\bnd\ftheir\fpr\bctice-
3A-pill\br\f\bre\b
ItemDesc\biptio\f
1NVH\felement
2PU\f\bdhesive \f\f
Стр. 3 из
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$FORD S-MAX 2006 Service Repair Manual orient\bted\f\bpplic\btion\fc\bn\fonly\fbe\fobt\bined\fthrough\fsuit\bble\finstruction\f(NVH\ftr\bining).\f The\fsuccessful\fuse\fof\fthese\fdevices\frequires\f\b\fgre\bt\fde\bl\fof\fexperience\fon\ft$

orient\bted\f\bpplic\btion\fc\bn\fonly\fbe\fobt\bined\fthrough\fsuit\bble\finstruction\f(NVH\ftr\bining).\f
The\fsuccessful\fuse\fof\fthese\fdevices\frequires\f\b\fgre\bt\fde\bl\fof\fexperience\fon\fthe\fp\brt\fof\fthe\f
user.\f\f
The\fdi\bgnosis\f\bnd\fcorrection\fof\fnoise,\fvibr\btion\f\bnd\fh
\brshness\fconcerns\frequires:\f
\b\fro\bd\for\fsystem\ftest\fto\fdetermine\fthe\fex\bct\fn\bture\fof\fthe\fconcern.\f
An\blysis\fof\fpossible\fc\buses:\f checking\fof\fthe\fc\buse\f\bnd\felimin\btion\fof\fthe\ff\bults\ffound.\f\f
\b\fro\bd\ftest\for\fsystem\ftest\fto\fm\bke\fsure\fthe\fconcern\fh\bs\fbeen\fcorrected\for\fbrought\fb\bck\f
to

\fwithin\f\bn\f\bccept\bble\fr\bnge.\f\f
It\fis\foften\fvery\fdifficult\fto\floc\bte\fnoises\fth\bt\f\bre\f\budible\fin\fthe\fp\bssenger\fcomp\brtment\f
b\bs

ed\fon\fthe\fproblem\fdescription\fprovided\fby\fthe\fcustomer\f\bnd\fthe\fro\bd\ftests\f
performed.\fThe\fdirection\fof\fthe\fnoise\fc\bn\fbe\fdetected\fsubjectively,\fbut\fthe\fsource\fof\fthe\f
noise\fc\bnnot\fbe\ffound.\f
NOTE:\fFor\f\b\fselection\fof\fsimple\ftest\ftools,\fsee\fthe\fwind\fnoises\fsection.\f
El
ectronic NVH te\fter \f
NOTE:\fBefore\fusing\fthe\fNVH\ftester\fin\fthe\fservice,\fthe\f
service\ftechnici\bn\fshould\ft\bke\fp\brt\f
in\f\bn\fNVH\ftr\bining\fcourse\fto\fensure\feffective\fuse\fof\fthis\fdevice\fduring\fthe\fro\bd\ftest.\fA\f
description\fof\fthe\ffunction\f\bnd\f\bpplic\btion\fof\fthe\fNVH\ftester\fis\fenclosed\fwith\fthe\fdevice.\f
The\fme\bsuring\fdevice\fdescribed\fbelow\fis\fused\ffor\fdi\bg n
osis\fof\fthe\fsolid-borne\fsound\f\bnd\f
solid-borne\fsound\ftr\bnsmission\fp\bths.\fThe\fdevice\fis\fp\brticul\brly\fsuit\bble\ffor\fmedium\f\bnd\f
high\ffrequency\fnoise\f\bn\blyses.\fIt\fprincip\blly\fen\bbles\fnoise\fdi\bgnosis\fin\fthe\f\bre\b\fof\fsolid-
borne\fsound\f\bnd\fhelps\fto\fidentify\fsolid-borne\fsound\ftr\bnsmission\froutes.\f\f
In\forder\fto\fobt\bin\f\b\fpositive\fdi\bgnosis\fof\fdroning\fproblems\f(low\ffrequency\fnoises)\f\bnd\ftheir\f
sources,\fyou\fmust\fh\bve\fsufficient\fexperience\fof\fhow\fto\fuse\fthis\fme\bsuring\fdevice.\f
The\fdevice\fworks\f\bccording\fto\fthe\ffollowing\foper\bting\fprinciple:\fAccelerometers\f
(tr\bnsmitters)\f\bre\ffitted\fon\fv\brious\fvehicle\fcomponents\for\fbody\f\bre\bs.\fThe\fsign\bls\frecorded\f
here\fc\bn\fbe\flistened\fto\fone\f\bfter\fthe\fother\fon\fhe\bdphones\for\fspe\bkers\fvi\b\fthe\fdifferent\f
ch\bnnels.\fSimult\bneous\fillustr\btion\fof\fsever\bl\for\f\bll\fme\bsuring\fch\bnnels\f(for\fcomp\brison)\fis\f
only\fpossible\fvisu\blly\fon\fthe\fdispl\by\fof\fthe\fme\bsuring\fdevice.\f
L\byout\f\bnd\foper\btion:\f
The\ftest\fdevice\fh\bs\fsix\fdifferent\fch\bnnels\ffor\fnoise\fdi\bgnosis.\f\f
E\bch\fch\bnnel\fis\fm\brked\fin\fcolor\fon\fthe\ftermin\bl,\fc\bble\f\bnd\ftest\fdevice.\f\f
The\fsolid-borne\fsound\frecorded\fis\ftr\bnsmitted\fto\fthe\ftest\fdevice\for\fthe\fhe\bdphones\fby\f
th

e\fm\bgnetic\f\bccelerometers\f(tr\bnsmitters).\f\f
There\fis\f\bn\f\bmplifier\fon\fthe\ftest\fdevice\fwith\fwhich\fthe\fsign\bl\fstrength\f\bnd\fthe\f
co

rresponding\fch\bnnel\fc\bn\fbe\fset.\f\f
Only\fthe\fnoises\ffrom\f\b\ftr\bnsmitter\f\bre\ftr\bnsferred\fto\fthe\fhe\bdphones.\f\f
All\fconnected\fc\bbles\fc\bn\fbe\fvisu\blly\fillustr\bted\findividu\blly\for\fsimult\bneously\fon\fthe\f
di

spl\by.\f\f
The\ftest\fdevice\fs\bves\fthe\frecorded\fd\bt\b.\f\f
\f
Стр. 4 из 6
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$FORD S-MAX 2006 Service Repair Manual The\frecorded\fd\bt\b\fc\bn\fbe\fimported\fto\f\b\fPC\f\bnd\fev\blu\bted.\f The\fNVH\ftester\fis\fequipped\fin\f\bddition\fwith\fmobile\fm\bgnetic\fsensors\fwhich\f\bre\fp\brticul\brly\f su it\bble\$

The\frecorded\fd\bt\b\fc\bn\fbe\fimported\fto\f\b\fPC\f\bnd\fev\blu\bted.\f
The\fNVH\ftester\fis\fequipped\fin\f\bddition\fwith\fmobile\fm\bgnetic\fsensors\fwhich\f\bre\fp\brticul\brly\f
su
it\bble\ffor\fthe\ffollowing\fnoise\ftests:\f
Intern\bl\fnoises\f\bt\fthe\fd\bshbo\brd\f\f
Engine\fnoise\f\f
Electric\bl\fnoises\f(sp\brking/volt\bge\ftr\bnsmissions)\f\f
Wind\fnoises\f\f
V\bcuum\f-\fle\bks\f
Cha\f\fi\f noi\fe te\fter (cha\f\fi\f ear) \f
Us
ed\fto\fdi\bgnose\fsolid-borne\fsound\f\bnd\fits\ftr\bnsmission\froutes.\fThe\fdevice\fis\fp\brticul\brly\f
suit\bble\ffor\fmedium\f\bnd\fhigh\ffrequency\fnoise\f\bn\blysis\f\bnd\fprincip\blly\fen\bbles\fnoise\f
di\bgnosis\fin\fthe\f\bre\b\fof\fsolid-borne\fsound\f\bnd\fhelps\fto\fidentify\fsolid-borne\fsound\f
tr\bnsmission\froutes.\f
In\forder\fto\fobt\bin\f\b\fpositive\fdi\bgnosis\fof\fdroning\fproblems\f(low\ffrequency\fnoises)\f\bnd\ftheir\f
sources,\fyou\fmust\fh\bve\fsufficient\fexperience\fof\fhow\fto\fuse\fthis\fme\bsuring\fdevice.\f
L\byout\f\bnd\foper\btion:\f
The\ftest\fdevice\fh\bs\fsix\fdifferent\fch\bnnels\ffor\fnoise\fdi\bgnosis.\fThis\fme\bns\fth\bt\fsix\f
microphones\fequipped\fwith\fcl\bmps\fc\bn\fbe\f\btt\bched\fto\fdifferent\fcomponents\fon\fthe\fvehicle.\f
The\femitted\for\ftr\bnsmitted\fsolid-borne\fsound\fwill\fbe\ftr\bnsferred\ffrom\fmicrophone\fto\fthe\f
he\bdphones.\fThere\fis\f\bn\f\bmplifier\fbetween\fthe\fmicrophone\f\bnd\fthe\fhe\bdphones\f\bt\fwhich\f
the\fsign\bl\fstrengths\f\bnd\fthe\fcorresponding\fch\bnnel\fc\bn\fbe\fset.\f
Only\fthe\fnoises\ffrom\fone\fmicrophone\f\bre\ftr\bnsferred\fto\fthe\fhe\bdphones.\fE\bch\fch\bnnel\fis\f
color-coded\fon\fthe\fcl\bmp,\fc\bble\f\bnd\f\bmplifier.\f
NOTE:\fIn\forder\fto\fbe\f\bble\fto\frel\bte\fthe\fpositions\fof\f t
he\fdifferent\fmicrophones\fduring\fthe\f
test\fprocess,\fthey\f\bre\fentered\fin\f\b\fspeci\bl\ftest\fsheet\f\bccording\fto\ftheir\fcolors.\f
Microphones,\fcl\bmps\f\bnd\fc\bbles\fmust\fbe\fc\brefully\frouted\f\bnd\f\btt\bched.\f\f
Te\ft \broce\f\f (exam\ble for tran\fmi\f\fion noi\fe): \f
Att\bch\fmicrophones\fto\fv\brious\fpositions\fon\fthe\ftr\bnsmission\for\fmountings.\fThis\ffirst\f
\bll

ows\fthe\fsource\fof\fthe\fnoise\fto\fbe\fdetermined,\f\bnd\fthen\fthe\fpossible\ftr\bnsfer\froutes.\f\f
A\fro\bd\ftest\fc\bn\fbe\fperformed\f\bfter\f\bll\fthe\fcl\bmps\fh\bve\fbeen\f\btt\bched\fto\fthe\fvehicle\f\bnd\f
\bll

\fthe\fc\bbles\fconnected\fto\fthe\f\bmplifier.\f\f
Firstly,\f\bll\fthe\fch\bnnels\f\bre\fswitched\fthrough\fone\f\bfter\fthe\fother\fin\fneutr\bl,\fto\fcheck\fthe\f
op

er\btion\fof\fthe\fdifferent\fch\bnnels\f\bs\fwell\f\bs\fthe\fnoise\flevel\fin\fneutr\bl.\f\f
During\fthe\fro\bd\ftest,\f\bll\fch\bnnels\f\bre\flistened\fto\fin\fthe\fdifferent\fge\brs,\fengine\fspeeds,\f
ve

hicle\fspeeds\f\bnd\flo\bds.\fThis\fprocedur\bl\fmethod\fpermits\fun\bmbiguous\fdi\bgnosis\fof\fthe\f
c\buse\fof\fthe\fnoise\f\bnd\fthe\froute\fof\fthe\fnoise\funtil\fit\fenters\fthe\fbodywork\fstructure.\f\f
The\fch\br\bcteristics\fof\fthe\fnoise\fwhich\fis\fthe\fc\buse\fof\fthe\fconcern\fshould\fm\btch\fthose\fof\f
th

e\fnoise\fwhich\fis\fhe\brd.\fThis\fme\bns\fcomp\bre\fthe\fsound.\f\f
Depending\fon\fthe\finput\fsign\bl\flevel,\fthere\fm\by\fbe\f\b\fgre\bt\fde\bl\fof\fdifference\fin\fthe\fnoise\f
le

vel\fin\fthe\findividu\bl\fch\bnnels.\f\f
\f
Стр. 5 из 6
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Page 4101 of 4402

$FORD S-MAX 2006 Service Repair Manual Alw\bys\fset\fthe\f\bmplifier\fvolume\fto\fzero\fbefore\fswitching\fto\f\bnother\fch\bnnel.\f\f In\forder\fto\fbe\f\bble\fto\fm\bke\f\bny\fcomp\brisons,\fthe\fvolume\fsettings\fof\fthe\fdifferent\f$

Page 4102 of 4402

$FORD S-MAX 2006 Service Repair Manual Body Re\bair\f - Vehicle S\becific Information and Tolerance Check\f - S\becification\f S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f Anti-corro\fion \brotection for body work DetailPa\bt Nu\fbe\bSp$

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$FORD S-MAX 2006 Service Repair Manual Body Re\bair\f - Vehicle S\becific Information and Tolerance Check\f - Body and Frame S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f De\fcri\btion and O\beration Introduction\f No te\fthe\ffitted\fp$

Body Re\bair\f - Vehicle S\becific
Information and Tolerance Check\f - Body
and Frame
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
Introduction\f
No

te\fthe\ffitted\fposition\fof\fthe\fspeci\bl\fw\bsher.\fIt\fwill\fbe\fb\bsed\fon\fthe\fCD\fpl\btform,\fwhich\f
will\f\blso\fform\fthe\fb\bsis\ffor\ffuture\fmodels.\fTwo\findependent\fvehicle\fv\bri\bnts\f\bre\finiti\blly\f
\bv\bil\bble\fon\fthis\fCD\fpl\btform\f-\fthe\fG\bl\bxy\fwith\fits\fintern\bl\fdesign\btion\fLMV\f(Luxury\f
Multipurpose\fVehicle)\f\bnd\fthe\fS-MAX\fwith\fits\fintern\bl\fdesign\btion\fSAV\f(Sport\fActivity\f
Vehicle).\f
Design\ffe\btures\f
The\fm\bin\fdifferences\fbetween\fthe\fbody\fof\fthe\fS-MAX\f\bnd\fthe\fbody\fof\fthe\fG\bl\bxy\flie\fin\fthe\f
roof\fsection\f\bnd\fin\fthe\fre\br\fend\fof\fthe\fvehicle.\fThe\froof\fof\fthe\fS-
MAX\fis\ffl\btter\fover\bll,\fwhile\f
the\fre\br\fis\fshorter\f\bnd\fmore\fsloped.\fConsequently,\fthere\f\bre\fdifferences\fin\fthe\fsh\bpe\f\bnd\f
size\fof\f\bll\fof\fthe\fgl\bss\fsurf\bces\fof\fthe\fS-MAX\f\bnd\fG\bl\bxy.\f
Vehicle\fv\bri\bnts\f
\f\f
De\fcri\btion
G\bl\bxy\f
S-MAX\f
Cr\bsh\felement\f
At

\fthe\ffront\fof\fthe\fvehicle\fthere\fis\f\b\fsteel\fpl\bte\fcr\bsh\felement\fconnected\fto\fthe\fside\f
member\fby\fthre\bded\fconnections.\fThis\fcr\bsh\felement\fc\bn\f\bbsorb\flight\fimp\bcts\fof\fup\fto\f
\bbout\f15\fkm/hr.\fBec\buse\fof\fthe\fthre\bded\fconnections,\fthe\fcr\bsh\felement\fc\bn\fbe\fch\bnged\f
very\fquickly.\fThe\ffront\fcr\bsh\felement\fis\fidentic\bl\fon\fboth\fvehicle\fv\bri\bnts.\f
NOTE:\fDeformed\fcr\bsh\felements\fmust\fnot\fbe\fstr\bightened
\for\frep\bired.\f
He\bvier\fimp\bcts\fwhich\fc\bn\fno\flonger\fbe\f\bbsorbed\fby\fthe
\fcr\bsh\felement\fmust\fbe\f\bbsorbed\f
by\fthe\fside\fmembers\for\fthe\ffloor\fp\bn\fstructure.\fDepending\fon\fthe\fextent\fof\fthe\fd\bm\bge,\f
the\fside\fmembers\fc\bn\fbe\frepl\bced\fin\fwhole\for\fin\fp\brt\f(see\fsubsection\f501-27).\f
A\fsteel\fcross\fmember\fis\f\blso\finst\blled\f\bt\fthe\fre\br\fof\fthe\fvehicle\fusing\fthre\bded\fconnections.\f
This\fforms\f\b\fconnection\fbetween\fthe\fends\fof\fthe\ftwo\fside\fmembers\f\bnd\ftherefore\f
contributes\fto\f\bn\fincre\bse\fin\fp\bssive\fs\bfety\fin\fthe\fevent\fof\fre\br\fend\fimp\bct.\fThis\fbolted-on\f
crossmember\f\bbsorbs\fthe\fimp\bct\fenergy\fof\fminor\fimp\bcts\f\bnd\fthus\fprevents\fdeform\btion\f
of\fthe\fside\fmembers\f\bnd\ftherefore\fthe\fbody\fstructure.\fMore\fsevere\fimp\bcts\f\bt\fthe\fre\br\f\bre\f
\bbsorbed\fby\fthe\fre\br\fp\bnel,\fthe\freinforcement\fof\fthe\fre\br\fp\bnel,\fthe\fside\fmembers\f\bnd\fthe\f
lugg\bge\fcomp\brtment\ffloor\fp\bnel.\fIt\fis\fpossible\fto\fperform\fp\brti\bl\frepl\bcements\fof\fthe\fside\f
members\f\bnd\fthe\flugg\bge\fcomp\brtment\ffloor\fp\bnel\f(see\fsubsection\f501-30).\f Item
1
2
\f
Part Number -
-
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