2006 FORD S-MAX m66

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jump cable rims fuse box oil type oil filter fuel filter location

Page 67 of 4402

$FORD S-MAX 2006 Service Repair Manual For\fvehicles\fbuilt\fin\fcontinent\bl\fpl\bnts,\fthe\fsecond\fdigit\fof\fthe\fp\bint\fcode,\fon\fthe\fVIN\fl\bbel,\f denotes\fthe\forigin\bl\fmodel\fye\br\fof\fthe\fcolor’s\fintroduction,\f(‘0’$

Page 816 of 4402

$FORD S-MAX 2006 Service Repair Manual Engine - \b.5L \furatec (16\bkW/\b\b0PS) - VI5 - Engine—Vehicles With: 6-Speed Manual Transaxle - M66 S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f Removal Special Tool(s) Ge neral Equipment 30$

Page 866 of 4402

Page 1208 of 4402

$FORD S-MAX 2006 Service Repair Manual Engine - \b.\bL D\fratorq-TDCi (1\b9kW/175PS) - DW - Crankshaft Rear Seal S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f Removal and Installation Special Tool(s) Removal 205-044\f Holding\fFixture,$

Page 1209 of 4402

$FORD S-MAX 2006 Service Repair Manual Installation 5. Special\bTool(\f):\b 3 03-336\f 1. Sp ecial\bTool(\f):\b 205-307\f 2. Sp ecial\bTool(\f):\b 205-044,\f205-044-01,\f 303-254\f To r que:\b \f 33\fNm \f 34 °\f St\bge\f1:\f St\bge\f2$

Page 1468 of 4402

$FORD S-MAX 2006 Service Repair Manual using\fthe\fguided\fdi\bgnostic\fmenu\fin\f the\fFord\f\bpproved\fdi\bgnostic\ftool.\f Fuel\finjectors.\f *INSPECT\fthe\ffuel\finjectors.\fCLEAN\f the\ffuel\finjectors\for\fINSTALL\f\b\fnew\f set\fof\$

using\fthe\fguided\fdi\bgnostic\fmenu\fin\f
the\fFord\f\bpproved\fdi\bgnostic\ftool.\f
Fuel\finjectors.\f
*INSPECT\fthe\ffuel\finjectors.\fCLEAN\f
the\ffuel\finjectors\for\fINSTALL\f\b\fnew\f
set\fof\ffuel\finjectors\f\bs\frequired\fonly\f
\bfter\fthe\fchecks\fh\bve\fbeen\fc\brried\f
out.\f
*
M\bjor\fmech\bnic\bl\f
engine\ff\bilure.\f
*
REFER\fto:\fCylinder\fHe\bd\f(303-01\f
Engine\f-
\f2.5L\fDur\btec\f(VI5),\fRemov\bl\f
\bnd\fInst\bll\btion).\f
*
NOTE:\fBefore\fproceeding\fwith\f
\bny\fof\fthe\f\bctions\fin\frel\btion\f
to\fthe\fpossible\fsources\ffor\f
excessive\ffuel\fconsumption,\f\b\f
fuel\fconsumption\ftest\floc\bted\f
in\fthe\ftoolbox\fmenu\fof\fthe\f
Ford\f\bpproved\fdi\bgnostic\ftool\f
must\fbe\fc\brried\fout.\f
Excessive\ffuel\fconsumptionBr\bkes\fbinding.\f
*CHECK\fthe\fbr\bking\fsystem.\f\f
REFER\fto:\f Anti-Lock\fControl\f(206-
09A

\fAnti-Lock\fControl,\fDi\bgnosis\f\bnd\f
Testing).\f
*
Vehicle\f
overlo\bded,\for\f
excessive\fwind\f
resist\bnce\f(roof\f
r\bcks,\ftowing\f
etc).\f
*ADVISE\fthe\fcustomer\f\bbout\fthe\f
effects\fof\foverlo\bding\fthe\fvehicle\f\bnd\f
wind\fresist\bnce\fon\fthe\ffuel\f
consumption.\f
*
Air\fcle\bner\f
element\fblocked.\f
*INSTALL\f\b\fnew\f\bir\fcle\bner\felement.\f
*
Fuel\fsystem\fle\bk
(s).\f
*CHECK\fthe\fsystem\ffor\ffuel\fle\bk(s).\f
REPAIR\for\fINSTALL\fnew\fp\brts\f\bs\f
necess\bry.\f
*
Fuel\ffilter\f
blocked.\f
*INSTALL\f\b\fnew\ffuel\ffilter.\f\f
REFER\fto:\f Fuel\fFilter\f(310-01A\fFuel\f
T\bnk

\f\bnd\fLines\f-\f2.0L\fEcoBoost\fSCTi\f
(149kW/203PS)\f-\fMI4/2.0L\fDur\btec-
HE\f(107kW/145PS)\f-\fMI4/2.0L\f
Dur\btec-
HE\fFlex\fFuel\f(107kW/145PS)\f
-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4/2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
*
Incorrect\fengine\f
oil.\f
*INSTALL\f\b\fnew\foil\ffilter\f\bnd\fengine\f
oil.\f\f
*
Gener\btor.\f
*REFER\fto\fthe\fFord\f\bpproved\f
di\bgnostic\ftool.\f\f
*
Slipping\fclutch.\f
*REFER\fto:\fClutch\f(308-01\fClutch\f-\f
Vehicles\fWith:\f6-Speed\fM\bnu\bl\f
Tr\bnsmission\f(M66),\fDi\bgnosis\f\bnd\f
Testing).\f
*
ECT\fsensor.\f
*C\brry\fout\f\b\ffull\fengine\fdi\bgnosis\f
using\fthe\fguided\fdi\bgnostic\fmenu\fin\f
the\fFord\f\bpproved\fdi\bgnostic\ftool.\f
*
Fuel\finjectors.\f
*INSPECT\fthe\ffuel\finjectors.\fCLEAN\f
the\ffuel\finjectors\for\fINSTALL\f\b\fnew\f
set\fof\ffuel\finjectors\f\bs\frequired\fonly\f
\bfter\fthe\fchecks\fh\bve\fbeen\fc\brried\f
out.\f\f
*
PCM\fc\blibr\btion.\f
*Using\fthe\fFord\f\bpproved\fdi\bgnostic\f
tool,\fCHECK\ffor\fthe\f\bv\bil\bbility\fof\f\b\f
c\blibr\btion\fupd\bte.\f\f
*
Incorrect\fv\blve\f
timing.\f
*CHECK\fthe\fv\blve\ftiming.\f\f
*
Low\fcylinder\f
compression.\f
*CHECK\fthe\fengine\fcompression.\f\f
*
Стр. 12 из 13
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Page 1976 of 4402

$FORD S-MAX 2006 Service Repair Manual Manual T\bansmissi\fn/T\bansaxle and Clutch - Gene\bal Inf\f\bmati\fn - Manual T\bansaxle and Clutch S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f Diagn\fsis and Testing Gene\bal Equipment Inspecti$

Manual T\bansmissi\fn/T\bansaxle and
Clutch - Gene\bal Inf\f\bmati\fn - Manual
T\bansaxle and Clutch
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Diagn\fsis and Testing
Gene\bal Equipment
Inspecti\fn and Testing
1. 1.
Verify\fthe\fcustomer\fconcern.\f
2

. 2.
Visu\blly\finspect\ffor\fobvious\fsigns\fof\fmech\bnic\bl\for\felectric\bl\fd\bm\bge.\f
3

. 3.
Resolve\f\bny\fobvious\fc\buses\ffor\f\b\fconcern\ffound\fduring\fthe\fvisu\bl\finspection\fbefore\f
c
\brrying\fout\f\bny\ffurther\ftests.\f
4. 4.
If\fthe\fconcern\fpersists,\fcheck\fthe\fsymptoms\f\bnd\fproceed\f\bccording\fto\fthe\fFord\f
\b
pproved\fdi\bgnostic\ftool\finstructions.\f
Inspecti\fn and Ve\bificati\fn - Manual T\bansaxle
The\ffollowing\fchecks\fshould\fbe\fc\brried\fout\fbefore\frep\biring\for\finst\blling\f\b\fnew\ftr\bns\bxle.\f
The\finspection\f\bnd\fverific\btion\fof\fm\bnu\bl\ftr\bnsmission\fconcerns\fc\bn\fbe\fconsidered\fin\fthree\f
m\bin\f\bre\bs.\f
Gea\b Shifting C\fnce\bns Clutch\fdoes\fnot\foper\bte\fcorrectly.\f\f
Extern\bl\fge\brshift\fmech\bnism\fREFER\fto:\f
Ex
tern\bl\fControls \f(308-06A\fM\bnu\bl\fTr\bnsmission/Tr\bns\bxle\fExtern\bl\fContr
ols\f-\f
Vehicles\fWith:\f5-Speed\fM\bnu\bl\fTr\bns\bxle\f-\fMTX75,\fDescription\f\bnd\fOper\btion),\f
Extern\bl\fControls \f(308-06B\fM\bnu\bl\fTr\bnsmission/Tr\bns\bxle\fExtern\bl\fCont r
ols\f-\f
Vehicles\fWith:\f6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\fMMT6,\fDescription\f\bnd\fOper\btion).\f
T\bansmissi\fn n\fise c\fnce\bns Check\fthe\fengine\f\bnd\ftr\bnsmission\fmountings\ffor\fsufficient\fcle\br\bnce\fto\fthe\ftr\bnsmission\f
\bnd

\fthe\fbody.\f\f
Other\fnoises\fexcept\fge\brshift\fnoises\f\f
Go\fthrough\fthe\fdriving\fsitu\btions/tests\fdescribed\fin\fthe\ft\bble\fbelow\funder\fthe\fconditions\f
de

scribed\fthere\f\bnd\f\bnswer\fe\bch\fp\brt\fof\fthe\fdi\bgnosis\fwith\f\b\f"Yes"\for\f"No".\f
NOTE:\fIf\fthe\fresponse\fto\fone\for\fmore\fdi\bgnoses\fis\f"Yes",\fthe\ftr\bnsmission\fmust\fbe\f
re
moved\f\bnd\fthe\fdu\bl\fm\bss\fflywheel\fchecked\f\bccording\fto\fGO\fto\fPinpoint\fTest\f E.\f.\f
Ford\f\bpproved\fdi\bgnostic\ftool
Item
No\bSitu\ftion, test / di\fgnosisYesNo
1Driving\fsitu\btion:00
Ro\bd\ftest\fthe\fvehicle.\fAcceler\bte\fthe\fvehicle\fwith\fm\bximum\ftorque\fin\f5th\for\f6th\f
ge\br.\fREFER\fto:\f
Specific\btions \f(308-01A\fClutch\f-\fVehicles\fWith:\f5-Speed\fM\bnu\bl\fTr\bns
\bxle\f-\f
MTX75,\fSpecific\btions),\f
Specific\btions \f(308-01B\fClutch\f-\fVehicles\fWith:\f6-Speed\fM\bnu\bl\fTr\bn s
\bxle\f-\f
MMT6,\fSpecific\btions),\f
Specific\btions \f(308-01C\fClutch\f-\fVehicles\fWith:\f6-Speed\fM\bnu\bl\fTr\bn s
\bxle\f-\f
M66,\fSpecific\btions).\f
Di\bgnosis:
Стр. 1 из 20
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Page 1978 of 4402

$FORD S-MAX 2006 Service Repair Manual mech\bnism\fthe\fcomponents.\f-\fRENEW.\f Cl\bshing\for\f scr\btching\f noise\fduring\f ge\br\fshiftingSynchronizer\fhub\for\f synchronizer\fring\f d\bm\bged\f * INSTALL\f\b\fnew\fsynchronizer\fhub\fw$

mech\bnism\fthe\fcomponents.\f-\fRENEW.\f
Cl\bshing\for\f
scr\btching\f
noise\fduring\f
ge\br\fshiftingSynchronizer\fhub\for\f
synchronizer\fring\f
d\bm\bged\f
*
INSTALL\f\b\fnew\fsynchronizer\fhub\fwith\fsynchronizer\f
ring\fset\f\bnd\fINSTALL\f\b\fnew\fge\br\fwheel\fbelonging\fto\f
the\fsynchronizer\funit\f\bs\fnecess\bry.\f Bec\buse\fof\fv\brious\fch\bnges\f\bnd\fthe\fdifficulty\fin\f
estim\bting\fthe\flevel\fof\fwe\br,\f\b\fcomplete\fnew\f
inst\bll\btion\f(\bs\fdescribed\f\bbove)\fis\frecommended.\f
*
-
Clutch\fdoes\fnot\f
oper\bte\fcorrectly.\f
*CHECK\fthe\fclutch\ffunction\f\bnd\fthe\fbr\bke\ffluid\flevel.\f
*
Ge\br\f
eng\bgement\f
not\ffunctioning\f
correctlyExtern\bl\fge\brshift\f
mech\bnism\f
d\bm\bged\f
*CHECK\fthe\fextern\bl\fge\brshift\fmech\bnism\ffor\f
d\bm\bge.\fIf\fno\fconcern\fis\fdetermined,\fREMOVE\fthe\f
tr\bnsmission.REFER\fto:\f Tr\bnsmission\f-\f1.8L\fDur\btorq-TDCi\f(Lynx)\f
Die

sel\f(308-
03A\fM\bnu\bl\fTr\bnsmission/Tr\bns\bxle\f
-\fVehicles\fWith:\f5-Speed\fM\bnu\bl\fTr\bns\bxle\f-\f
MTX75,\fRemov\bl),\f
Tr\bnsmission\f-\f2.0L\fDur\btec-
HE\f(107kW/145PS)\f
-\fMI4/2.0L\fDur\btec-HE\fFlex\fFuel\f
(107kW/145PS)\f-\fMI4\f(308-03A\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f5-
Speed\fM\bnu\bl\fTr\bns\bxle\f-\fMTX75,\fRemov\bl),\f
Tr\bnsmission\f-\f1.8L\fDur\btorq-TDCi\f(Lynx)\f
Die
sel\f(308-
03B\fM\bnu\bl\fTr\bnsmission/Tr\bns\bxle\f
-\fVehicles\fWith:\f6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\f
MMT6,\fRemov\bl),\f
Tr\bnsmission\f-\f2.0L\fDur\btorq-TDCi\f
(85

kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(103kW/140PS)\f-\fDW,\f2.0L\fDur\btorq-TDCi\f
(DW)\fDiesel\f(308-03B\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f6-
Speed\fM\bnu\bl\fTr\bns\bxle\f-\fMMT6,\fRemov\bl),\f
Tr\bnsmission\f-\f2.5L\fDur\btec\f(162kW/220PS)\f-\f
VI5 \f

(308-03C\fM\bnu\bl\fTr\bnsmission/Tr\bns\bxle\f-\f
Veh
icles\fWith:\f6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\f
M66,\fRemov\bl).\f
*
Ge\br\fjumps\fout\f
of\feng\bgement\f
while\fdriving
Missing\fsn\bp\frings;\f
synchroniz\btion\f
components\f
d\bm\bged\for\fworn\f
clutch\fsplines\f
*INSTALL\f\b\fnew\fge\br\fset,\fsynchronizer\funit\f\bnd\f
selector\ffork\f\bs\fnecess\bry.\fCHECK\fthe\ftr\bnsmission\f
for\fd\bm\bge,\fp\brticul\brly\fto\fthe\fsliding\fsleeve.\f
*
Incorrect\fsliding\f
sleeve;\fworn\fclutch\f
splines\f
*INSTALL\f\b\fnew\fge\br\fset,\fsynchronizer\funit\f\bnd\f
selector\ffork\f\bs\fnecess\bry.\fCHECK\fthe\ftr\bnsmission\f
for\fd\bm\bge,\fp\brticul\brly\fto\fthe\fsliding\fsleeve.\f
*
Selector\fforks\f
*RENEW\fge\br\fwheels,\fsliding\fsleeves\f\bnd\fselector\f
forks\f\bs\fnecess\bry.\fCHECK\fthe\ftr\bnsmission\ffor\f
d\bm\bge,\fp\brticul\brly\fto\fthe\fsliding\fsleeve.\f
*
Ge\brshift\flever\f
feels\flooseGe\brshift\flever\f
fixing.\f
*Check\fthe\fextern\bl\fge\brshift\fmech\bnism;\frepl\bce\fif\f
necess\bry.\fCheck\fge\br\flever\fmounting,\fextern\bl\f
ge\brshift\fmech\bnism\f\bnd\fshift\fc\bbles;\ftighten\fif\f
necess\bry.\fREFER\fto:\f
Extern\bl\fControls \f(308-06A\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\fExtern\bl\fControls\f-\f
Vehicles\fWith:\f5-Speed\fM\bnu\bl\fTr\bns\bxle\f-\f
MTX75,\fDescription\f\bnd\fOper\btion),\f
Extern\bl\fControls \f(308-06B\fM\bnu\bl\f
Tr \bn

smission/Tr\bns\bxle\fExtern\bl\fControls\f-\f
Vehicles\fWith:\f6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\f
MMT6,\fDescription\f\bnd\fOper\btion).\f
*
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