map FORD S-MAX 2006 Service User Guide

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Pages: 4402, PDF Size: 93.08 MB

Page 1525 of 4402

Di\bgnosis\f\bnd\fTesting).\f
Fuel\fsystem\f
restriction.\f
*REFER\fto:\f
Fuel\fSystem\f-\f1.8L\fDur\btorq-TDCi\f
(Ly
nx)\fDiesel/2.0L\fDur\btorq-TDCi\f(DW)\fDiesel \f
(31

0-00\fFuel\fSystem\f-\fGener\bl\fInform\btion,\f
Di\bgnosis\f\bnd\fTesting).\f
*
Incorrect\fengine\foil.\f
*INSTALL\f\b\fnew\fengine\foil\ffilter\f\bnd\fengine\foil.\f
*
C\bt\blytic\fconverter\f
blocked.\f
*REMOVE\f\bnd\fvisu\blly\fINSPECT\fthe\fc\bt\blytic\f
converter\ffor\fd\bm\bge.\fINSTALL\f\b\fnew\fc\bt\blytic\f
converter\f\bs\fnecess\bry.\f\f
REFER\fto:\f
C\bt\blytic\fConverter \f(309-00E\f
Exh

\bust\fSystem\f-\f2.0L\fDur\btorq-TDCi\f
(85kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(103kW/140PS)\f-
\fDW,\fEmission\fRequirements:\f
St\bge\fIV,\fRemov\bl\f\bnd\fInst\bll\btion).\f
*
Low\fcylinder\f
compression.\f
*REFER\fto:\f
Engine\f(303-01F\fEngine\f-\f2.0L\f
Dur
\btorq-TDCi\f(85kW/115PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(103kW/140PS)\f-
\fDW,\fEmission\f
Requirements:\fSt\bge\fIV,\fDi\bgnosis\f\bnd\f
Testing).\f
*
CKP\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
ECT\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
Fuel\ftemper\bture\f
sensor.\f
*REFER\fto\fthe\fWDS.\f
*
M\bss\f\bir\fflow\f(MAF)\f
sensor.\f
*REFER\fto\fthe\fWDS.\f
*
M\bnifold\f\bbsolute\f
pressure\f(MAP)\f
sensor.\f
*REFER\fto\fthe\fWDS.\f
*
Fuel\finjector(s).\f
*REFER\fto\fthe\fWDS.\f
*
FRP\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
Fuel\fpump\ffuel\f
pressure\fregul\btor.\f
*REFER\fto\fthe\fWDS.\f
*
Fuel\fpump.\f
*REFER\fto\fthe\fWDS.\f
*
Int\bke\f\bir\fshut-off\f
throttle.\f
*CHECK\fthe\fint\bke\f\bir\fsut-off\fthrottle\ffor\f
obstructions\f\bnd\fcorrect\foper\btion.\f\f
REFER\fto\fthe\fWDS.\f
*
*
Int\bke\f\bir\fshut-off\f
throttle\fv\bcuum\f
control\fsolenoid.\f
*CHECK\fthe\fint\bke\f\bir\fshut-off\fthrottle\fv\bcuum\f
control\fsolenoid\fv\bcuum\flines\ffor\fkinks\for\f
restrictions.\f REFER\fto\fthe\fWDS.\f
*
*
Engine\fst\brts\fbut\f
immedi\btely\fstops\f
\bnd\fglow\fplug\f
indic\btor\fis\ffl\bshingDTC\fdetected.\f
*REFER\fto\fthe\fWDS.\f
*
Engine\fst\brts\fbut\f
immedi\btely\fstopsAir\fcle\bner\felement\f
blocked.\f
*INSTALL\f\b\fnew\f\bir\fcle\bner\felement.\f
*
Air\fingress\finto\fthe\f
fuel\flines.\f
*REFER\fto:\f
Fuel\fSystem\f-\f1.8L\fDur\btorq-TDCi\f
(Ly
nx)\fDiesel/2.0L\fDur\btorq-TDCi\f(DW)\fDiesel \f
(31

0-00\fFuel\fSystem\f-\fGener\bl\fInform\btion,\f
Di\bgnosis\f\bnd\fTesting).\f
*
PCM\frel\by.\f
*CARRY\fOUT\f\b\frel\by\fcomponent\ftest.\f
*
Du\bl\fm\bss\fflywheel.\f
*INSPECT\fthe\fdu\bl\fm\bss\fflywheel\ffor\fd\bm\bge.\f
INSTALL\f\b\fnew\fdu\bl\fm\bss\fflywheel\f\bs\f
necess\bry.\f\f
*
CKP\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
CMP\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
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Page 1527 of 4402

\bnd\fInst\bll\btion).\f
Air\fingress\finto\fthe\f
fuel\flines.\f
*REFER\fto:\f
Fuel\fSystem\f-\f1.8L\fDur\btorq-TDCi\f
(Ly
nx)\fDiesel/2.0L\fDur\btorq-TDCi\f(DW)\fDiesel \f
(31

0-00\fFuel\fSystem\f-\fGener\bl\fInform\btion,\f
Di\bgnosis\f\bnd\fTesting).\f
*
EGR\fv\blve\fincorrect\f
oper\btion.\f
*REFER\fto:\fEngine\fEmission\fControl\f(303-08D,\f
Di\bgnosis\f\bnd\fTesting).\f
*
Du\bl\fm\bss\fflywheel.\f
*INSPECT\fthe\fdu\bl\fm\bss\fflywheel\ffor\fd\bm\bge.\f
INSTALL\f\b\fnew\fdu\bl\fm\bss\fflywheel\f\bs\f
necess\bry.\f\f
*
Fuel\finjector(s).\f
*REFER\fto\fthe\fWDS.\f
*
MAF\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
MAP\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
CKP\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
FRP\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
Fuel\fpump\ffuel\f
pressure\fregul\btor.\f
*REFER\fto\fthe\fWDS.\f
*
Fuel\fpump.\f
*REFER\fto\fthe\fWDS.\f
*
Int\bke\f\bir\fshut-off\f
throttle.\f
*CHECK\fthe\fint\bke\f\bir\fshut-off\fthrottle\fbutterfly\f
for\fobstructions\f\bnd\fcorrect\foper\btion.\f\f
REFER\fto\fthe\fWDS.\f
*
*
Int\bke\f\bir\fshut-off\f
throttle\fv\bcuum\f
control\fsolenoid.\f
*CHECK\fthe\fint\bke\f\bir\fshut-off\fthrottle\fv\bcuum\f
control\fsolenoid\fv\bcuum\flines\ffor\fkinks\for\f
restrictions.\f REFER\fto\fthe\fWDS.\f
*
*
Engine\fstumbling\f
\bnd\fglow\fplug\f
indic\btor\fis\ffl\bshingDTC\fdetected.\f
*REFER\fto\fthe\fWDS.\f
*
Engine\fstumblingLow\ffuel\flevel.\f
*CHECK\fthe\ffuel\ft\bnk\flevel\fis\fgre\bter\fth\bn\ffour\f
litres.\fIf\fthe\ffuel\ft\bnk\flevel\fis\fless\fth\bn\ffour\f
litres,\fFILL\fwith\ffuel.\f
*
Du\bl\fm\bss\fflywheel.\f
*INSPECT\fthe\fdu\bl\fm\bss\fflywheel\ffor\fd\bm\bge.\f
INSTALL\f\b\fnew\fdu\bl\fm\bss\fflywheel\f\bs\f
necess\bry.\f\f
*
Acceler\btor\fped\bl\f
position\f(APP)\fsensor.
\f
*REFER\fto\fthe\fWDS.\f
*
Fuel\finjector(s).\f
*REFER\fto\fthe\fWDS.\f
*
FRP\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
Fuel\fpump.\f
*REFER\fto\fthe\fWDS.\f
*
Engine\fl\bcks\fpower\f
\bnd\fglow\fplug\f
indic\btor\fis\ffl\bshingDTC\fdetected.\f
*REFER\fto\fthe\fWDS.\f
*
Engine\fl\bcks\fpowerBr\bkes\fbinding.\f
*CHECK\fthe\fbr\bking\fsystem.\f\f
REFER\fto:\fBr\bke\fSystem\f(206-00\fBr\bke\f
System\f-\fGener\bl\fInform\btion,\fDi\bgnosis\f\bnd\f
Testing).\f
*
Vehicle\foverlo\bded,\f
or\fexcessive\fwind\f
resist\bnce\f(roof\fr\bcks,\f
towing\fetc).\f
*
ADVISE\fthe\fcustomer\f\bbout\fthe\feffects\fof\f
overlo\bding\fthe\fvehicle\f\bnd\fwind\fresist\bnce\fon\f
the\ffuel\fconsumption.\f
*
Air\fcle\bner\felement\f
blocked.\f
*INSTALL\f\b\fnew\f\bir\fcle\bner\felement\f\bs\f
necess\bry.\f
*
Fuel\ffilter\fblocked.\f
*INSTALL\f\b\fnew\ffuel\ffilter\felement.\f\f
REFER\fto:\f Fuel\fFilter\fElement \f(310-01C\fFuel\f
T\bnk

\f\bnd\fLines\f-\f2.0L\fDur\btorq-TDCi\f
(85kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
*
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(103kW/140PS)\f-\fDW,\fEmission\fRequirements:\f
St\bge\fIV,\fRemov\bl\f\bnd\fInst\bll\btion).\f
INSTALL\f\b\fnew\ffuel\fpump,\ffuel\finjectors,\ffuel\f
r\bil,\f\bnd\fhigh-pressure\ffuel\fsupply\flines.\f\f
REFER\fto:\fFuel\fPump\f(303-04E\fFuel\fCh\brging\f
\bnd

\fControls\f-\f2.0L\fDur\btorq-TDCi\f
(85kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(103kW/140PS)\f-
\fDW,\fEmission\fRequirements:\f
St\bge\fIV,\fRemov\bl\f\bnd\fInst\bll\btion)\f/\f\f
Fuel\fInjectors \f(303-04E\fFuel\fCh\brging\f\bnd\f
Con

trols\f-\f2.0L\fDur\btorq-TDCi\f(85kW/115PS)\f-\f
DW/2.0L\fDur\btorq-TDCi\f(100kW/136PS)\f-\f
DW/2.0L\fDur\btorq-TDCi\f(103kW/140PS)\f-
\fDW,\f
Emission\fRequirements:\fSt\bge\fIV,\fRemov\bl\f
\bnd\fInst\bll\btion)\f/\f\f
Fuel\fR\bil\f(303-04D\fFuel\fCh\brging\f\bnd\fControls\f
-\f2.0L\fDur\btorq-TDCi\f(DW)\fDiesel,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
Vehicle\fspeed\fsensor\f
(VSS).\f
*REFER\fto\fthe\fWDS.\f
*
ECT\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
MAF\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
MAP\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
APP\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
Fuel\finjector(s).\f
*REFER\fto\fthe\fWDS.\f
*
Fuel\ftemper\bture\f
sensor.\f
*REFER\fto\fthe\fWDS.\f
*
FRP\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
Fuel\fpump\ffuel\f
pressure\fregul\btor.\f
*REFER\fto\fthe\fWDS.\f
*
Fuel\fpump.\f
*REFER\fto\fthe\fWDS.\f
*
Int\bke\f\bir\fshut-off\f
throttle.\f
*CHECK\fthe\fint\bke\f\bir\fshut-off\fthrottle\fbutterfly\f
for\fobstructions\f\bnd\fcorrect\foper\btion.\f\f
REFER\fto\fthe\fWDS.\f
*
*
Int\bke\f\bir\fshut-off\f
throttle\fv\bcuum\f
control\fsolenoid.\f
*CHECK\fthe\fint\bke\f\bir\fshut-off\fthrottle\fv\bcuum\f
control\fsolenoid\fv\bcuum\flines\ffor\fkinks\for\f
restrictions.\f REFER\fto\fthe\fWDS.\f
*
*
Bl\bck\fsmoke\f\bt\fidle\f
\bnd\fglow\fplug\f
indic\btor\fis\ffl\bshing
DTC\fdetected.\f
*REFER\fto\fthe\fWDS.\f
*
Bl\bck\fsmoke\f\bt\fidleAir\fcle\bner\felement\f
blocked.\f
*INSTALL\f\b\fnew\f\bir\fcle\bner\felement\f\bs\f
necess\bry.\f
*
Glow\fplug\fsystem.\f
*REFER\fto\fthe\fWDS.\f
*
Incorrect\fv\blve\f
timing.\f
*CHECK\fthe\fv\blve\ftiming.\f\f
REFER\fto:\f Timing\fBelt \f(303-01F\fEngine\f-\f2.0L\f
Dur

\btorq-TDCi\f(85kW/115PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(103kW/140PS)\f-
\fDW,\fEmission\f
Requirements:\fSt\bge\fIV,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
*
C\bt\blytic\fconverter\f
blocked.\f
*REMOVE\f\bnd\fvisu\blly\fINSPECT\fthe\fc\bt\blytic\f
converter\ffor\fd\bm\bge.\fINSTALL\f\b\fnew\fc\bt\blytic\f
converter\f\bs\fnecess\bry.\f\f
REFER\fto:\f
C\bt\blytic\fConverter \f(309-00E\f
Exh

\bust\fSystem\f-\f2.0L\fDur\btorq-TDCi\f
(85kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
*
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Page 1530 of 4402

(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(103kW/140PS)\f-
\fDW,\fEmission\fRequirements:\f
St\bge\fIV,\fRemov\bl\f\bnd\fInst\bll\btion).\f
ECT\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
MAF\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
MAP\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
Fuel\finjector(s).\f
*REFER\fto\fthe\fWDS.\f
*
FRP\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
Int\bke\f\bir\fshut-off\f
throttle.\f
*CHECK\fthe\fint\bke\f\bir\fshut-off\fthrottle\fbutterfly\f
for\fobstructions\f\bnd\fcorrect\foper\btion.\f\f
REFER\fto\fthe\fWDS.\f
*
*
Int\bke\f\bir\fshut-off\f
throttle\fv\bcuum\f
control\fsolenoid.\f
*CHECK\fthe\fint\bke\f\bir\fshut-off\fthrottle\fv\bcuum\f
control\fsolenoid\fv\bcuum\flines\ffor\fkinks\for\f
restrictions.\f REFER\fto\fthe\fWDS.\f
*
*
Excessive\fbl\bck\f
smoke\fduring\f
\bcceler\btion\f\bnd\f
glow\fplug\findic\btor\f
is\ffl\bshingDTC\fdetected.\f
*REFER\fto\fthe\fWDS.\f
*
Excessive\fbl\bck\f
smoke\fduring\f
\bcceler\btionAir\fcle\bner\felement\f
blocked.\f
*INSTALL\f\b\fnew\f\bir\fcle\bner\felement\f\bs\f
necess\bry.\f
*
Incorrect\for\f
cont\bmin\bted\ffuel.\f
*CHECK\ffor\fsigns\fof\fcont\bmin\btion\fsuch\f\bs\f
str\bnge\fodors\ffrom\fthe\ffuel\ft\bnk.\f CHECK\ffor\fsigns\fof\fw\bter\for\fg\bsoline\fin\fthe\f
diesel.\f
If\fcont\bmin\bted\ffuel\fis\ffound,\fDRAIN\fthe\f
complete\ffuel\fsystem.\fFLUSH\fthe\ffuel\fsystem\f
through\fwith\fcle\bn\fdiesel.\f\f
REFER\fto:\f Fuel\fT\bnk\fDr\bining \f(310-00\fFuel\f
Sys

tem\f-\fGener\bl\fInform\btion,\fGener\bl\f
Procedures).\f
INSTALL\f\b\fnew\ffuel\ffilter\felement.\f\f
REFER\fto:\f Fuel\fFilter\fElement \f(310-01C\fFuel\f
T\bn k

\f\bnd\fLines\f-\f2.0L\fDur\btorq-TDCi\f
(85kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(103kW/140PS)\f-
\fDW,\fEmission\fRequirements:\f
St\bge\fIV,\fRemov\bl\f\bnd\fInst\bll\btion).\f
INSTALL\f\b\fnew\ffuel\fpump,\ffuel\finjectors,\ffuel\f
r\bil,\f\bnd\fhigh-pressure\ffuel\fsupply\flines.\f\f
REFER\fto:\f Fuel\fPump\f(303-04E\fFuel\fCh\brging\f
\bnd

\fControls\f-\f2.0L\fDur\btorq-TDCi\f
(85kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(103kW/140PS)\f-
\fDW,\fEmission\fRequirements:\f
St\bge\fIV,\fRemov\bl\f\bnd\fInst\bll\btion)\f/\f\f
Fuel\fInjectors \f(303-04E\fFuel\fCh\brging\f\bnd\f
Con

trols\f-\f2.0L\fDur\btorq-TDCi\f(85kW/115PS)\f-\f
DW/2.0L\fDur\btorq-TDCi\f(100kW/136PS)\f-\f
DW/2.0L\fDur\btorq-TDCi\f(103kW/140PS)\f-
\fDW,\f
Emission\fRequirements:\fSt\bge\fIV,\fRemov\bl\f
\bnd\fInst\bll\btion)\f/\f\f
Fuel\fR\bil\f(303-04D\fFuel\fCh\brging\f\bnd\fControls\f
-\f2.0L\fDur\btorq-TDCi\f(DW)\fDiesel,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
*
*
*
EGR\fv\blve\fincorrect\f
oper\btion.\f
*REFER\fto:\fEngine\fEmission\fControl\f(303-08D,\f
Di\bgnosis\f\bnd\fTesting).\f
*
C\bt\blytic\fconverter\f
*REMOVE\f\bnd\fvisu\blly\fINSPECT\fthe\fc\bt\blytic\f
*
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Page 1531 of 4402

blocked.\fconverter\ffor\fd\bm\bge.\fINSTALL\f\b\fnew\fc\bt\blytic\f
converter\f\bs\fnecess\bry.\f\f
REFER\fto:\fC\bt\blytic\fConverter \f(309-00E\f
Exh

\bust\fSystem\f-\f2.0L\fDur\btorq-TDCi\f
(85kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(103kW/140PS)\f-
\fDW,\fEmission\fRequirements:\f
St\bge\fIV,\fRemov\bl\f\bnd\fInst\bll\btion).\f
APP\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
CKP\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
Fuel\finjector(s).\f
*REFER\fto\fthe\fWDS.\f
*
FRP\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
Int\bke\f\bir\fshut-off\f
throttle.\f
*CHECK\fthe\fint\bke\f\bir\fshut-off\fthrottle\fbutterfly\f
for\fobstructions\f\bnd\fcorrect\foper\btion.\f\f
REFER\fto\fthe\fWDS.\f
*
*
Int\bke\f\bir\fshut-off\f
throttle\fv\bcuum\f
control\fsolenoid.\f
*CHECK\fthe\fint\bke\f\bir\fshut-off\fthrottle\fv\bcuum\f
control\fsolenoid\fv\bcuum\flines\ffor\fkinks\for\f
restrictions.\f REFER\fto\fthe\fWDS.\f
*
*
Bl\bck\fsmoke\f\bt\f
cruising\fspeeds\f\bnd\f
glow\fplug\findic\btor\f
is\ffl\bshing
DTC\fdetected.\f
*REFER\fto\fthe\fWDS.\f
*
Bl\bck\fsmoke\f\bt\f
cruising\fspeedsAir\fcle\bner\felement\f
blocked.\f
*INSTALL\f\b\fnew\f\bir\fcle\bner\felement.\f
*
EGR\fv\blve\fincorrect\f
oper\btion.\f
*REFER\fto:\fEngine\fEmission\fControl\f(303-08D,\f
Di\bgnosis\f\bnd\fTesting).\f
*
Turboch\brger\fv\bcuum\f
di\bphr\bgm\funit.\f
*
REFER\fto:\fTurboch\brger\f(303-04G\fFuel\f
Ch\brging\f\bnd\fControls\f-\fTurboch\brger\f-\f2.0L\f
Dur\btorq-TDCi\f(DW)\fDiesel,\fDi\bgnosis\f\bnd\f
Testing).\f
*
C\bt\blytic\fconverter\f
blocked.\f
*REMOVE\f\bnd\fvisu\blly\fINSPECT\fthe\fc\bt\blytic\f
converter\ffor\fd\bm\bge.\fINSTALL\f\b\fnew\fc\bt\blytic\f
converter\f\bs\fnecess\bry.\f\f
REFER\fto:\f
C\bt\blytic\fConverter \f(309-00E\f
Exh

\bust\fSystem\f-\f2.0L\fDur\btorq-TDCi\f
(85kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(103kW/140PS)\f-
\fDW,\fEmission\fRequirements:\f
St\bge\fIV,\fRemov\bl\f\bnd\fInst\bll\btion).\f
*
ECT\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
MAF\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
MAP\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
Fuel\finjector(s).\f
*REFER\fto\fthe\fWDS.\f
*
FRP\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
Int\bke\f\bir\fshut-off\f
throttle.\f
*CHECK\fthe\fint\bke\f\bir\fshut-off\fthrottle\fbutterfly\f
for\fobstructions\f\bnd\fcorrect\foper\btion.\f\f
REFER\fto\fthe\fWDS.\f
*
*
Int\bke\f\bir\fshut-off\f
throttle\fv\bcuum\f
control\fsolenoid.\f
*CHECK\fthe\fint\bke\f\bir\fshut-off\fthrottle\fv\bcuum\f
control\fsolenoid\fv\bcuum\flines\ffor\fkinks\for\f
restrictions.\f
REFER\fto\fthe\fWDS.\f
*
*
Blue\fsmoke\f\bnd\f
glow\fplug\findic\btor\f
is\ffl\bshingDTC\fdetected.\f
*REFER\fto\fthe\fWDS.\f
*
Blue\fsmokeEngine\fburning\foil.\f
*CARRY\fOUT\f\b\fcontrolled\foil\fconsumption\ftest\f
over\f1000\fkm\f(600\fmiles).\fCONFIRM\fth\bt\fthe\f
oil\fconsumption\fis\fless\fth\bn\f0.1\fof\f\b\fliter\fper\f
*
Стр. 12 из
18
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Page 1534 of 4402

INSTALL\f\b\fnew\ffuel\ffilter\felement.\f\f
REFER\fto:\fFuel\fFilter\fElement \f(310-01C\fFuel\f
T\bnk

\f\bnd\fLines\f-\f2.0L\fDur\btorq-TDCi\f
(85kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(103kW/140PS)\f-
\fDW,\fEmission\fRequirements:\f
St\bge\fIV,\fRemov\bl\f\bnd\fInst\bll\btion).\f
INSTALL\f\b\fnew\ffuel\fpump,\ffuel\finjectors,\ffuel\f
injection\fsupply\fm\bnifold,\f\bnd\fhigh-pressure\f
fuel\fsupply\flines.\f\f
REFER\fto:\f Fuel\fPump\f(303-04E\fFuel\fCh\brging\f
\bnd

\fControls\f-\f2.0L\fDur\btorq-TDCi\f
(85kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(103kW/140PS)\f-
\fDW,\fEmission\fRequirements:\f
St\bge\fIV,\fRemov\bl\f\bnd\fInst\bll\btion)\f/\f\f
Fuel\fInjectors \f(303-04E\fFuel\fCh\brging\f\bnd\f
Con

trols\f-\f2.0L\fDur\btorq-TDCi\f(85kW/115PS)\f-\f
DW/2.0L\fDur\btorq-TDCi\f(100kW/136PS)\f-\f
DW/2.0L\fDur\btorq-TDCi\f(103kW/140PS)\f-
\fDW,\f
Emission\fRequirements:\fSt\bge\fIV,\fRemov\bl\f
\bnd\fInst\bll\btion)\f/\f\f
Fuel\fR\bil\f(303-04D\fFuel\fCh\brging\f\bnd\fControls\f
-\f2.0L\fDur\btorq-TDCi\f(DW)\fDiesel,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
Air\fingress\finto\fthe\f
fuel\flines.\f
*REFER\fto:\fFuel\fSystem\f-\f1.8L\fDur\btorq-TDCi\f
(Kent)\fDiesel/2.0L\fDur\btorq-TDCi\f(DW)\fDiesel\f
(310-00,\fDi\bgnosis\f\bnd\fTesting).\f
*
EGR\fv\blve\fincorrect\f
oper\btion.\f
*REFER\fto:\fEngine\fEmission\fControl\f(303-08D,\f
Di\bgnosis\f\bnd\fTesting).\f
*
Low\fcylinder\f
compression.\f
*REFER\fto:\f
Engine\f(303-01F\fEngine\f-\f2.0L\f
Dur
\btorq-TDCi\f(85kW/115PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(103kW/140PS)\f-
\fDW,\fEmission\f
Requirements:\fSt\bge\fIV,\fDi\bgnosis\f\bnd\f
Testing).\f
*
Engine\foverhe\bts.\f
*REFER\fto:\fEngine\fCooling\f(303-03D\fEngine\f
Cooling\f-\f2.0L\fDur\btorq-TDCi\f(DW)\fDiesel,\f
Di\bgnosis\f\bnd\fTesting).\f
*
ECT\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
CKP\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
CMP\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
MAF\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
MAP\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
Fuel\finjector(s).\f
*REFER\fto\fthe\fWDS.\f
*
FRP\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
Fuel\fpump.\f
*REFER\fto\fthe\fWDS.\f
*
Int\bke\f\bir\fshut-off\f
throttle.\f
*CHECK\fthe\fint\bke\f\bir\fshut-off\fthrottle\fbutterfly\f
for\fobstructions\f\bnd\fcorrect\foper\btion.\f\f
REFER\fto\fthe\fWDS.\f
*
*
Int\bke\f\bir\fshut-off\f
throttle\fv\bcuum\f
control\fsolenoid.\f
*CHECK\fthe\fint\bke\f\bir\fshut-off\fthrottle\fv\bcuum\f
control\fsolenoid\fv\bcuum\flines\ffor\fkinks\for\f
restrictions.\f REFER\fto\fthe\fWDS.\f
*
*
Worn\for\fd\bm\bged\f
v\blve(s),\ft\bppet(s)\for\f
c\bmsh\bft(s).\f
*REMOVE\fthe\fcylinder\fhe\bd.\fINSPECT\fthe\f
cylinder\fhe\bd,\fv\blves,\ft\bppets\f\bnd\fc\bmsh\bfts\f
for\fsigns\fof\fwe\br\for\fd\bm\bge.\f
*
D\bm\bged\fcylinder\f
*REMOVE\fthe\fcylinder\fhe\bd.\fINSPECT\fthe\f
*
Стр. 15 из 18
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Page 1537 of 4402

Requirements:\fSt\bge\fIV,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
Turboch\brger.\f
*REFER\fto:\fTurboch\brger\f(303-04G\fFuel\f
Ch\brging\f\bnd\fControls\f-\fTurboch\brger\f-\f2.0L\f
Dur\btorq-TDCi\f(DW)\fDiesel,\fDi\bgnosis\f\bnd\f
Testing).\f
*
Slipping\fclutch\f(If\f
equipped).\f
*REFER\fto:\fM\bnu\bl\fTr\bns\bxle\f\bnd\fClutch\f(308-
00\fM\bnu\bl\fTr\bnsmission/Tr\bns\bxle\f\bnd\fClutch\f-
\f
Gener\bl\fInform\btion,\fDi\bgnosis\f\bnd\fTesting).\f
*
Low\fcylinder\f
compression.\f
*REFER\fto:\f
Engine\f(303-01F\fEngine\f-\f2.0L\f
Dur
\btorq-TDCi\f(85kW/115PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(103kW/140PS)\f-
\fDW,\fEmission\f
Requirements:\fSt\bge\fIV,\fDi\bgnosis\f\bnd\f
Testing).\f
*
ECT\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
MAF\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
MAP\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
Fuel\finjector(s).\f
*REFER\fto\fthe\fWDS.\f
*
Int\bke\f\bir\fshut-off\f
throttle.\f
*CHECK\fthe\fint\bke\f\bir\fshut-off\fthrottle\fbutterfly\f
for\fobstructions\f\bnd\fcorrect\foper\btion.\f\f
REFER\fto\fthe\fWDS.\f
*
*
Int\bke\f\bir\fshut-off\f
throttle\fv\bcuum\f
control\fsolenoid.\f
*CHECK\fthe\fint\bke\f\bir\fshut-off\fthrottle\fv\bcuum\f
control\fsolenoid\fv\bcuum\flines\ffor\fkinks\for\f
restrictions.\f REFER\fto\fthe\fWDS.\f
*
*
Engine\fcuts\fout\f
during\fh\brd\f
\bcceler\btionCMP\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
CKP\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
FRP\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
Fuel\fpump\ffuel\f
pressure\fregul\btor.\f
*REFER\fto\fthe\fWDS.\f
*
Fuel\fpump.\f
*REFER\fto\fthe\fWDS.\f
*
Стр. 18 из 18
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Page 1584 of 4402

Pi\fpoi\ft Tests
w\blls.\fTurboch\brger\fbe\brings\f
\bnd\foil\fse\bl(s).\f Turboch\brger\foil\f
supply\ftube\fblocked\for\f
d\bm\bged.\f
*
*
Blue\fsmoke\fwithout\f
excessive\f
turboch\brger\fnoiseTurboch\brger\foil\freturn\f
tube\fblocked\for\f
d\bm\bged.\f
*
GO\fto\fPinpoint\fTest\f
B.\f\f
*
Poor\fengine\f
perform\bnce\fCh\brge\f\bir\fcooler\f
system.\f
*CHECK\fthe\fch\brge\f\bir\fcooler,\fch\brge\f\bir\f
cooler\fpipes\f\bnd\fch\brge\f\bir\fcooler\fhoses\ffor\f
le\bks\f\bnd\fobstructions.\fREPAIR\f\bs\f
necess\bry.\f
*
Air\fcle\bner\fint\bke\fpipe.\f*CHECK\fthe\f\bir\fcle\bner\fint\bke\fpipe\ffor\f
obstruction.\fREPAIR\fthe\fnecess\bry.\f
*
Turboch\brger\f
electronic\f\bctu\btor.\f
*REFER\fto\fWDS.\f
*
PINPOINT TEST A : BLUE SMOKE WITH EXCESSIVE TURBOCHARGER NOISE
TE\fT CONDITION\fDETAIL\f/RE\fULT\f/ACTION\f
A1: INSPECT THE TURBOCHARGER ROTOR VANES FOR DAMAGE
Loc\btion\fof\fthe\fengine\fupper\fcover\fret\bining\fclips.\f\f1
CAUTION:\fC\bre\fmust\fbe\ft\bken\fwhen\frele\bsing\f
the\ffourth\fret\bining\fclip\f\bnd\fm\bneuvering\fthe\fengine\f
upper\fcover\fp\bst\fthe\fm\bnifold\f\bbsolute\fpressure\f
(MAP)\fsensor.\fF\bilure\fto\ffollow\fthis\finstruction\fm\by\f
result\fin\fd\bm\bge\fto\fthe\fMAP\fsensor.\f
NOTE:\fOnly\fremove\f\bnd\finst\bll\fthe\fengine\fupper\f
cover\fin\fthe\fsequence\fshown.\f Remove\fthe\fengine\fupper\fcover.\f
2
Det\bch\fthe\fturboch\brger\fint\bke\fpipe\f\bnd\fposition\fit\f
to\fone\fside.\f3
Inspect\fthe\fturboch\brger\frotor\fv\bnes\ffor\fd\bm\bge.\f4
\f\f
\f\f
\f\f
Стр. 2 из 5
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http://vnx.su

Page 1600 of 4402

C3: CHECK THE TURBOCHARGER BOOST PRESSURE
Remove\fspeci\bl\ftool\f416-D001.\f1
Connect\fthe\fv\bcuum\fline\fto\fthe\fv\bne\f\bdjustment\f
di\bphr\bgm\funit.\f2
Lower\fthe\fvehicle.\f3
Connect\fWDS\fto\fthe\fvehicle\fd\bt\b\flink\fconnector\f
(DLC).\f4
Select\fthe\fd\bt\bloger\ffunction.\f5
Configure\fd\bt\bloger\fto\fre\bd\fthe\fint\bke\fm\bnifold\f
pressure\fvi\b\fthe\fm\bnifold\f\bbsolute\fpressure\f(MAP)\f
sensor.\f6
St\brt\f\bnd\frun\fthe\fengine.\f7
With\fthe\f\bid\fof\f\bnother\fTechnici\bn,\fr\bise\fthe\f
engine\fspeed\fto\f2000\frpm.\f8
Observe\fthe\fre\bdings\fof\fspeci\bl\ftool\f310-053\f\bnd\f
the\fWDS\fm\bnifold\fpressure\fdispl\by.\f9
Is\f\b\fv\bcuum\fof\f0.325\fb\br\fon\fthe\fspeci\bl\ftool\f\bnd\fboost\f
pressure\fof\f1.5\fb\br\fon\fthe\fWDS\fm\bnifold\fpressure\f
displ\by\findic\bted?\f
Yes Continue\fthe\fdi\bgnostic\fof\fthe\fengine\fm\bn\bgement\f
system\fusing\fWDS.\f
No INSTALL\f\b\fnew\fturboch\brger.\f\f
REFER\fto:\f Turboch\brger \f(303-04J\fFuel\fCh\brging\f
\bnd

\fControls\f-\fTurboch\brger\f-\f2.0L\fDur\btorq-TDCi\f
(85kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(103kW/140PS)\f-\fDW,\fEmission\fRequirements:\f
St\bge\fIV,\fRemov\bl\f\bnd\fInst\bll\btion).\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
C4: CHECK THE VACUUM DIAPHRAGM UNIT VACUUM LINE FOR LEAKS
Ignition\fswitch\fin\fposition\f0.\f1
Remove\fthe\fspeci\bl\ftool\f310-053.\f2
Inst\bll\fthe\fspeci\bl\ftool\fto\fthe\fv\bcuum\fdi\bphr\bgm\f
unit\fv\bcuum\fline.\f3
Oper\bte\fthe\fspeci\bl\ftool\f\bnd\fobserve\fthe\fre\bding.\f4
Does\fthe\fspeci\bl\ftool\fhold\fv\bcuum?\f
Yes
GO\fto\fC5 .\f\f
No GO

\fto\fC6 .\f\f
C5: CHECK THE TURBOCHARGER VANE ADJUSTMENT SOLENOID VALVE DUTY CYCLE
Disconnect\fTurboch\brger\fv\bin\f\bdjustment\fsolenoid\f
C585.\f1
St\brt\f\bnd\frun\fthe\fengine.\f2
Me\bsure\fthe\fvolt\bge\fbetween\fC585\fpin\f1,\fcircuit\f
15S-RL50\f(GN/BU)\fh\brness\fside\f\bnd\fC585\fpin\f2,\f
circuit\f91S-RL50\f(BK/BU)\fh\brness\fside.\f3
\f\f
Стр. 9 из 11
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Page 1613 of 4402

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