ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

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General Information - About This Manual S-MAX/Galaxy 2006.5 (03/2006-)
Description and Operation


This manual covers diagnosis and testing and repair procedures.

This manual is structured into groups and sections, with specific system sections collected together under their relevant group.

A group covers a specific portion of the vehicle. The manual is divided into five groups, General Information, Chassis, Powertrain, Electrical and Body and Paint. The number of the group is the first number of a section number.

Within Etis, the navigation tree will list the groups. After selecting a group the navigation tree will then list the sections within that group. Each section has a contents list detailing Specifications, Description and Operation, Diagnosis and Testing, General Procedures, Disassembly and Assembly, Removal and Installation.

If components need to be removed or disassembled in sequence, the sequence will be identified numerically in a graphic and the corresponding text will be numbered accordingly.

All left-hand and right-hand references to the vehicle are taken from a position sitting in the driver seat looking forward.

All left-hand and right-hand references to the engine are taken from a position at the flywheel looking towards the front camshaft pulley.

How to Use This Manual - Repair Procedures

This manual has been written in a format that is designed to meet the needs of technicians worldwide. The objective is to use common formats and include similar content in each manual.

This manual provides general descriptions for accomplishing diagnosis and testing and repair work with tested and effective techniques. Following them will help to ensure reliability.

Important Safety Instructions

Appropriate service methods and correct repair procedures are essential for the safe, reliable operation of all motor vehicles as well as the personal safety of the individual carrying out the work.

Anyone who departs from the instructions provided in this manual must first establish that personal safety or vehicle integrity is not compromised by the choice of method, tools or components.

Warnings, Cautions and Notes in This Manual

WARNING:Warnings are used to indicate that failure to follow a procedure correctly may result in personal injury.
CAUTION:Cautions are used to indicate that failure to follow a procedure correctly may result in damage to the vehicle or equipment being used.
NOTE:Notes are used to provide additional essential information required to carry out a complete and satisfactory repair.

Generic warnings or cautions are in their relevant description and operation procedure within section 100-00. If the generic warnings or cautions are required for a procedure, there will be a referral to the appropriate description and operation procedure.

If a warning, caution or note only applies to one step, it is placed at the beginning of the specific step.

Trustmark Authoring Standards (TAS) Removal and Installation Procedures

NOTE:TAS style procedures can be identified by steps that have no accompanying step text and the magenta color of the electrical connectors and fasteners such as nuts, bolts, clamps or clips.

A TAS removal and installation procedure uses a sequence of color illustrations to indicate the order to be followed when removing/disassembling or installing/assembling a component.

Many of the TAS procedures will have the installation information within the removal steps. These procedures will have the following note at the beginning of the procedure:

NOTE:Removal steps in this procedure may contain installation details.

Items such as O-ring seals, gaskets, seals, self-locking nuts and self-locking bolts are to be discarded and new components installed unless otherwise stated within the procedure. Coated nuts or bolts are to be reused, unless damaged or otherwise stated within the procedure.

Specification procedures will only contain technical data that are not allready part of a repair procedure.

TAS Graphics

Colors used in the graphic are as follows:

  • Blue - Component to be removed/installed or disassembled/assembled
  • Green and Brown - Additional components that need to be removed/installed or disassembled/assembled prior to the target component
  • Yellow - Component to be detached, attached or moved only and remains in the vehicle
  • Magenta - Electrical connectors and fasteners such as nuts, bolts, clamps or clips
  • Pale Blue - Special tool(s) and general equipment.

One illustration may have multiple steps assigned to it.

Numbered pointers are used to indicate the number of electrical connectors and fasteners such as nuts, bolts, clamps or clips.

Items in the illustration can be transparent or use cutouts to show hidden detail(s).

TAS Symbols

Symbols are used inside the graphics and in the text area to enhance the information display. The following paragraphs describe the various types and categories of symbols.

Prohibition symbols advise on prohibited actions to either avoid damage or health and safety related risks.

Health and Safety symbols recommend the use of particular protection equipment to avoid or at least reduce the risk or severity of possible injuries.

Warning symbols are used to indicate potential risks resulting from a certain component or area.

Instruction symbols are used to apply sealer, lubricant, weight, tape or cleaning detergent to a component.

Location symbols are used to show the location of a component or system within the vehicle.

Gearshift lever or selector lever position symbols are used to show which gearshift lever or selector lever position is to be set.

Pointer symbols are used to draw the attention to components and give special instructions such as a required sequence or number of components. The number of components is reflected by the value inside the luty arrow. A sequence number is located inside the circle. Numbers inside circles are also used to allocate special information such as tightening torques or chemicals to a particular component.

Movement arrows are used to show three dimensional or rotational movements. These movements can include specific values inside the symbol if required.

Standard tool symbols recommend the use of certain standard tools. These tools can include dimension values if required.

The following graphic illustrates a set of symbols that are used to provide detailed information on where to apply a material.

Measurement symbols provide detailed information on where to carry out a specific measurement. These symbols can include specific values if required.

Special Tools and Torque Figure(s)

Special tools will be shown with the tool number in the illustration. The special tool number(s), general equipment, material(s) and torque figure(s) used for the procedure step will be shown in the text column.

How to Use This Manual - Diagnosis and Testing procedures

Inspection and Verification

Visual Inspection Charts, Symptom Charts and other information charts (such as diagnostic routines) or supplement test procedures with technical specifications will navigate the user to a specific test procedure.

Symptom Chart

The symptom chart indicates symptoms, sources and actions to address a condition.

Pinpoint Tests

For electrical systems, pinpoint test steps are used to identify the source of a concern in a logical, step-by-step manner. Pinpoint tests have two columns: CONDITIONS and DETAILS/RESULTS/ACTIONS.

The CONDITIONS column is used exclusively for graphics and icons (with or without captions) and the DETAILS/RESULTS/ACTIONS column provides direction to another test step or specific corrective actions.

The boxed numbers indicate the order in which the described action is to be carried out.

Component Tests

A component test is used when a component is tested in multiple pinpoint tests, or if a procedure is too complicated to be formatted within a single page of the pinpoint test.


Test graphics show the measurement or test to be carried out in a test step.

A representative tester graphic is used for voltmeters and ohmmeters.

If multiple measurements are made in a single graphic, the test leads are drawn with a solid line until the test lead splits to indicate the multiple measurements, at which point dashed lines are used.

Breakout box type testers are represented by a double circle test pin. Test pins are labeled with the pin number.

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