Ford Galaxy / Ford S-MAX. Manual — part 1

General Information - About This Manual

S-MAX/Galaxy 2006.5 (02/2006-)

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Description and Operation

Introduction

This manual covers diagnosis and testing and repair procedures.

It 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.

References to

LH (left-hand)

and

RH (right-hand)

All

LH

and

RH

references to the vehicle are taken from a position sitting in the driver seat

looking forward.

Vehicle

LH

and

RH

definition

Description

LH

RH

All

LH

and

RH

references to the engine are taken from a position at the flywheel looking

towards the crankshaft front pulley.

Powertrain

LH

and

RH

definition

Item

1

2

Part Number

-

-

Description

front

right

rear

left

How to use Repair Procedures

This manual has been written in a format that is designed to meet the needs of technicians
worldwide. It provides general descriptions for accomplishing repair work with tested and
effective techniques.

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.

Item

1

2

3

4

Part Number

-

-

-

-

Trustmark Authoring Standards (TAS) Repair 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.

Reuse of fasteners and seals and gaskets

The following list details the general policy for the reuse of fasteners and seals and gaskets.

Types of self-locking nuts and bolts

NOTE: There are more types of self-locking fasteners available than shown in following
illustration.

Description

Completely coated self-locking bolt

Partially coated self-locking bolt

Self-locking bolt with a locking washer

Self-locking nut with a plastic locking insert

Self-locking nut with thread deformation (3 dents)

Self-locking nut with thread deformation (squeeze of thread to oval
shape)

Self-locking nut with integrated locking ring

All types of seals and gaskets must be discarded and new seals and gaskets installed
unless otherwise stated within the procedure.
Nuts and bolts with a chemical coating for locking and/or sealing and/or antiseize must
be discarded unless the procedure advises to reapply the coating with a specified

Item

1

2

3

4

5

6

7

Part Number

-

-

-

-

-

-

-

material.
Nuts and bolts with a mechanical locking such as thread inserts, thread deformation or
locking washers must be discarded and new nuts and bolts installed unless otherwise
stated within the procedure.
Torque to yield bolts must be discarded and new torque to yield bolts installed unless
otherwise stated within the procedure, recognizable by a tightening torque with more
than one stage together with a torque angle.

Specification data

Specification procedures will only contain technical data that is not already part of a repair
procedure.

Sequence of tasks

If components must be removed or installed in a specific sequence, the sequence will be
identified numerically in a graphic and the corresponding text will be numbered accordingly.

Special Tools, Equipment, Materials and Torque Figures

Special tools will be shown with the tool numbers in the illustration. The special tool
numbers, general equipment, materials and torque figures used for the procedure step will
be shown in the text column.

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 that is touched or affected in a way but remains in the vehicle. It
may be detached, attached, moved, modified, checked, adjusted etc.
Magenta - Electrical connectors and fasteners such as nuts, bolts, clamps and 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 and clips.

Items in the illustration can be transparent or use cutouts to show hidden details.