check engine FORD S-MAX 2006 Service Repair Manual

No -\fIf\fnot\f\bll\fthe\flisted\fcomponents\f\bre\f
disconnected:Key\fin\fOFF\fposition.\fDISCONNECT\f
the\fnext\fcomponent\f(go\fto\ftest\fstep\f3).\f
-\fIf\f\bll\fthe\flisted\fcomponents\f\bre\f
disconnected: GO\fto\fAK31.\f\f
AK31: \bHE\bK THE HS \bAN BUS FOR A SHORT TO VOLTAGE SUPPLY
Ignition\fswitch\fin\fposition\f0.\f1
Disconnect\f-\fVehicles\fwith\f\b\f2.0L\fdiesel\fengine:\f
Connector\fC1E108-D\ffrom\fthe\fPCM.\f2
Disconnect\f-\fVehicles\fwith\f\b\f2.0L\fengine:\f
Connector\fC1E104-E\ffrom\fthe\fPCM.\f3
Disconnect\f-\fVehicles\fwith\f\b\f2.5L\fengine:\f
Connector\fC1E108-B\ffrom\fthe\fPCM.\f4
Disconnect\f-\fVehicles\fwith\f\b\f1.8L\fdiesel\fengine:\f
Connector\fC1E108-K\ffrom\fthe\fPCM.\f5
Disconnect\f-\fVehicles\fwith\f\b\f1.6L\fDur\btec-16V\f
(Sigm\b)\fengine:\fConnector\fC1E104-J\ffrom\fthe\f
PCM.\f6
Disconnect\f-\fVehicles\fwith\f\b\f3.0L\fDur\btec-VE\f
(VE6)\fengine:\fConnector\fC1E109-B\ffrom\fthe\f
PCM.\f7
Disconnect\f-\fVehicles\fwith\f\b\f2.2L\fdiesel\fengine:\f
Connector\fC1E108-H\ffrom\fthe\fPCM.\f8
Ignition\fswitch\fin\fposition\fII.\f9
Me\bsure\fthe\fvolt\bge\fbetween\fthe\fDLC,\fconnector\f
C3DB04,\fpin\f6,\fcircuit\fVDB04L\f(WH/BU),\fwiring\f
h\brness\fside\f\bnd\fground.\f
10
Is\f\b\fvolt\bge\fme\bsured?\f
Yes LOCATE\f\bnd\fREPAIR\fthe\fshort\fto\fvolt\bge\fsupply\f
in\fthe\frelev\bnt\fcircuit\fwith\fthe\f\bid\fof\fthe\fWiring\f
Di\bgr\bms.\fCHECK\fthe\foper\btion\fof\fthe\fsystem.\f
No GO\fto\fAK32.\f\f
AK32: \bHE\bK THE HS \bAN BUS FOR A SHORT TO VOLTAGE SUPPLY
Me\bsure\fthe\fvolt\bge\fbetween\fthe\fDLC,\fconnector\f1
\f\f
\f\f
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Module \bonfi\furation - Module
\bonfi\furationS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
General Procedures
1. The\fvehicles\futilize\f\b\fnew\fform\fof\fmodule\fcon
figur\btion\fc\blled\f"centr\bl\fmodule\f
configur\btion".\fHere,\f\bll\fof\fthe\fnecess\bry\f
configur\btion\fp\br\bmeters\f\bre\fstored\fin\fthe\f
generic\felectronic\fmodule\f(GEM)\f\bt\fthe\ff\bctory,\f
\bnd\ffrom\fthere\fthey\f\bre\ftr\bnsmitted\fvi\b\fthe\fCAN\f
bus\fnetwork\fto\fthe\findividu\bl\fmodules.\fThe\f
Worldwide\fDi\bgnostic\fSystem\f(WDS)\fnow\f
includes\f\b\fnew\froutine\ffor\frepl\bcing\for\f
subsequently\fch\bnging\fthe\fconfigur\btion\fd\bt\b.\f
This\fnew\froutine\fis\fused\fto\fperform\fthe\fcentr\bl\f
module\fconfigur\btion.\fHowever,\fin\fthis\fc\bse\fthe\f
d\bt\b\f\bre\fno\flonger\fre\bd\finto\fWDS\flike\fbefore\f-\f
inste\bd,\fthey\f\bre\ftr\bnsmitted\fby\fthe\fGEM\fto\fthe\f
relev\bnt\fmodule.\fWDS\fis\fonly\fused\fto\finiti\bte\f\bnd\f
monitor\fthe\fprocess.\fFor\fs\bfety\fre\bsons\f\bll\fof\fthe\f
configur\btion\fd\bt\b\fwhich\f\bre\fs\bved\fin\fthe\fGEM\f
\bre\f\blso\fb\bcked\fup\fin\fthe\finstrument\fcluster.\fIf\f
the\fGEM\fthen\fneeds\fto\fbe\frepl\bced,\fthis\fme\bns\f
th\bt\fthe\frequired\fconfigur\btion\fd\bt\b\fc\bn\fbe\fre\bd\f
out\ffrom\fthe\finstrument\fcluster\fwith\fthe\f\bid\fof\f
WDS\f\bnd\fthen\ftr\bnsferred\fto\fthe\fnew\fGEM.\fThe\f
GEM\fchecks\fthe\fconfigur\btion\fd\bt\b\ffor\f
consistency\f\bnd\fstores\f\b\fWDS\ftrouble\fcode\f
(DTC)\fin\fthe\fevent\fof\f\b\ff\bult.\fIn\fthe\fevent\fof\f\b\f
f\bult\fthe\ffunction\blity\fof\f\b\fp\brticul\br\fmodule\fm\by\f
be\frestricted.\fWhen\finst\blling\f\b\fnew\fGEM,\fboth\f
the\fkey\ffor\fthe\fr\bdio\fremote\fcontrol\f\bnd\ffor\fPATS\f
must\fbe\fre-progr\bmmed\f(\blso\fsee\fthe\f
description\f"Module\fControlled\fFunctions").\fThe\f
procedure\ffor\fthis\fis\fthe\fs\bme\f\bs\ffor\fcurrent\f
vehicles.\f
2. NOTE:\fEnsure\fth\bt\fthe\fmost\fup-to-d\bte\f
s
o

ftw\bre\fversion\fis\finst\blled\fin\fWDS.\f
NOTE:\fIn\fthe\fc\bse\fof\fengine\frunning\f
concerns,\fmodule-reprogr\bmming\fof\fthe\fPCM\f
m\by\fbe\frequired.\fTo\fdo\fthis,\f\b\frevised\f
softw\bre\fversion\fis\ftr\bnsferred\fto\fthe\fPCM\fvi\b\f
the\fGEM\fusing\fWDS.\f
In\fWDS,\fselect\f"Centr\bl\fmodule\fconfigur\btion"\f
fr
om\fthe\ftool\fbox\f\bnd\ffollow\fthe\finstructions.\f
3. NOTE:\fFollowing\finst\bll\btion\fof\f\b\fwheel/tire\f
co

mbin\btion,\ffor\fwhich\fthe\ftire-tre\bd\f
circumference\fdoes\fnot\fcorrespond\fto\fth\bt\fof\f
st\bnd\brd\ftires,\fthe\ftire\fsize\fmust\fbe\fch\bnged\f
in\fthe\fGEM\fusing\fWDS.\f
In\fWDS,\fselect\fthe\f"Centr\bl\fmodule\f
co
nfigur\btion"\ffrom\fthe\ftool\fbox\f\bnd\fthen\fthe\f
"Progr\bmm\bble\fp\br\bmeters"\fsubmenu\f\bnd\fenter\f
the\fcorresponding\ftire\fsize\funder\fthe\f"tire\fsize"\f
menu\fitem.\f
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Anti-Th\bft - P\fssiv\b - Anti-Th\bft - P\fssiv\bS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
D\bscription \fnd Op\br\ftion
Compon\bnt loc\ftion
\f\f
D\bscription
P\bssive\f\bnti-theft\f(PATS)\ftr\bnsponder\f
PATS\ftr\bnsceiver\f
Op\br\ftion
PAT
S\f
The\fPATS\fis\f\b\fp\bssive\fsystem\fdesigned\fto\fincre\bse\fthe\f\bnti-theft\fsecurity\fof\fthe\fvehicle.\f
The\fdriver\fdoes\fnot\fneed\fto\f\bctively\fdo\f\bnything\fto\fprotect\fthe\fvehicle.\fThe\fPATS\fis\f
\bctiv\bted\f\butom\btic\blly\f\bfter\fthe\fignition\fis\fswitched\foff.\f
The\fPATS\fsystem\fuses\fspeci\blly\fencoded\fkeys.\f
If\f\b\fv\blid\fkey\fis\finserted\finto\fthe\fignition\flock\fcylinder\f\bnd\fturned\fto\fposition\fII,\fthe\fcode\f
from\fthe\fPATS\ftr\bnsponder\fis\freceived\fby\fthe\fPATS\ftr\bnsceiver.\fThe\fcode\fis\fthen\fsent\fto\f
the\fp\bssenger\fjunction\fbox\f(PJB)\fwhich\fchecks\fth\bt\f\b\fcorrect\fkey\fh\bs\fbeen\finserted\f\bnd\f
communic\btes\fwith\fthe\fpowertr\bin\fcontrol\fmodule\f(PCM)\fto\fen\bble\fthe\fengine\fto\fst\brt.\f
If\fthe\fcode\freceived\fby\fthe\fPATS\ftr\bnsceiver\fdoes\fnot\f\bgree\fwith\f\bny\fof\fthe\fcodes\f
progr\bmmed\fto\fthe\fvehicle,\for\fif\ferrors\foccur\fin\fthe\fPATS,\fthe\fengine\fc\bnnot\fbe\fst\brted.\f\f It\bm
1
2
\f
P\frt Numb\br -
-
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Front En\b Bo\by P\fnels - Cowl P\fnel GrilleS-MAX/G\bl\bxy\f2006.5\f(02/2006
\fPrint
Remov\fl \fn\b Inst\fll\ftion
Gener\fl Equipment
Remov\fl
NO
TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
Inst\fll\ftion
Two\fleg\fpuller 1.General
\bqui\fment:
Two\fleg\f
puller \f
To r

que:
22\f
Nm\f
1. CAUTIONS:\f
Th
e\fengine\fmust\fbe\fin\fthe\fp\brk\fposition.\f\f
The\fcomponent\fmust\fbe\f\bligned\fwith\fthe\f
inst\bll\btion\fm\brkings.\f
To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
2. Check\fthe\f\bngle\fof\fthe\fwiper\f\brms\fto\fthe\f windscreen.\f
Refer\fto:\f Wiper\fBl\bde\fAngle\fAdjustment \f(501-16\f
Wip

ers\f\bnd\fW\bshers,\fGener\bl\fProcedures).\f
\f
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Component Tests
Heate\f Rea\b Win\fow G\bi\f Wi\be Test 1. 1.
Using\f\b\fbright\fl\bmp\finside\fthe\fvehicle,\fvisu\blly\finspect\fthe\fgrid\fwire\ffrom\fthe\f
o
utside.\fA\fbroken\fgrid\fconductor\fline\fwill\f\bppe\br\f\bs\f\b\fbrown\fspot.\f
2. 2.
Run\fthe\fengine\f\bt\fidle.\fSet\fthe\fhe\bted\fre\br\fwindow\fswitch\f\bnd\flights\fto\fON.\fThe\f
h
e\bted\fre\br\fwindow\findic\btor\flight\fshould\fillumin\bte.\f
3. 3.
Wo rking\finside\fthe\fvehicle\fwith\f\b\fmultimeter,\fcont\bct\fthe\fbro\bd\fred/brown\fstrips\f
o
n\fthe\fhe\bted\fre\br\fwindow\fpositive\fle\bd\fto\fb\bttery\fside\f\bnd\fneg\btive\fle\bd\fto\fground\f
side.\fThe\fmeter\fshould\fre\bd\f10-13\fvolts.\fA\flower\fvolt\bge\fre\bding\findic\btes\f\b\floose\f
he\bted\fre\br\fwindow\fground\fwire\fconnection\f\bt\fthe\fhe\bted\fre\br\fwindow\fground\fwire\f
Yes REPAIR\fcircuit\fCBB34B\f(VT/BN)\for\fcircuit\fCBB35A\f
(YE/GY).\fTEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
No
GO\fto\fE3 .\f\f
E3: CHECK FOR CONTINUITY BETWEEN THE HEATED REAR WINDOW RELAY AND
GROUND
Ignition\fswitch\fin\fposition\f0.\f1
Disconnect\fHe\bted\fRe\br\fWindow\fRel\by\fRA2.\f2
Me\bsure\fthe\fresist\bnce\fbetween\fthe\fhe\bted\fre\br\f
window\frel\by\fRA2\fpin\f2,\fcircuit\fCRD02A\f(BN/BU),\f
h\brness\fside\f\bnd\fground.\f3
Is\fthe\fresist\bnce\fless\fth\bn\f5\fohms?\f
Yes REPAIR\fcircuit\fCRD02A\f(BN/BU).\fTEST\fthe\fsystem\f
for\fnorm\bl\foper\btion.\f
No GO\fto\fE4 .\f\f
E4: CHECK THE HEATED REAR WINDOW RELAY CIRCUIT FOR A SHORT TO POWER
Ignition\fswitch\fin\fposition\fII.\f1
Me\bsure\fthe\fvolt\bge\fbetween\fthe\fhe\bted\fre\br\f
window\frel\by\fRA2\fpin\f5,\fcircuit\fCRD06B\f(BN/YE),\f
h\brness\fside\f\bnd\fground.\f2
Is\fthe\fvolt\bge\fgre\bter\fth\bn\f10\fvolts?\f
Yes REPAIR\fcircuit\fCRD06B\f(BN/YE).\fTEST\fthe\fsystem\f
for\fnorm\bl\foper\btion.\f
No VERIFY\fthe\fcustomer\fconcern.\f
\f\f
\f\f
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Wipers \bnd W\bshers \f Wipers \bnd
W\bshersS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Di\bgnosis \bnd Testing
Gener\bl Equipment
Inspection \bnd 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
V

isu\bl Inspection Ch\brt
3. 3.
If\f\bn\fobvious\fc\buse\ffor\f\bn\fobserved\for\freported\fconcern\fis\ffound,\fcorrect\fthe\fc\buse\f
(if\fpossible)\fbefore\fproceeding\fto\fthe\fnext\fstep.\f
4. 4.
If\fthe\fc\buse\fis\fnot\fvisu\blly\fevident,\frefer\fto\fthe\f F
ord\f\bpproved\fdi\bgnostic\ftool.\f
Ford\f\bpproved\fdi\bgnostic\ftool
Mechanica\bE\bectrica\b\fsystems


Wiper\fbl\bde(s)\f\f

Wiper\f\brm\fpivot\fsh\bft\f\f

W\bsher\ffluid\freservoir\f\f

Hose(s)\f\f

W\bsher\fnozzles\f\f

Check\fthe\fwiper\fbl\bdes\ffor\fresidue-free\fwiping\fin\fthe\f
vi

cinity\fof\fthe\fr\bin\fsensor.\f\f

Check\fthe\f\bdhesive\fp\bd\fbetween\fthe\fr\bin\fsensor\f\bnd\fthe\f
wi

ndshield\ffor\ftr\bpped\f\bir.\f\f

Cle\bn\fw\bx\fresidues\ffrom\fthe\fwindshield\fin\fthe\fvicinity\fof\f
th

e\fr\bin\fsensor.\f\f


Check\fthe\fwindshield\ffor\fd\bm\bge/cr\bcks\fin\fthe\fvicinity\fof\f
the\fr\bin\fsensor.\f\f

Check\fth\bt\fthe\fr\bin\fsensor\fret\bining\ffr\bme\fis\fcorrectly\f
\btt

\bched\fto\fthe\fwindshield.\f

Fuse(s)\f\f

Connector\f\f

Wiring\fh\brness(es)\f\f

W\bsher\fpump\fmotor\f\f

He\bdl\bmp\fw\bsher\fpump\f
\f

Front/re\br\fwindow\fwiper\f
mo
tor(s)\f\f

W\bsh/wipe\fswitch\f\f

Centr\bl\fjunction\fbox\f
(C

JB)\f\f

Re\br\fjunction\fbox\f(RJB)\f\f

Engine\fjunction\fbox\f
(E

JB)\f
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Wipers \bnd W\bshers \f Wiper P\brk Position
AdjustmentS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Gener\bl Procedures
Gener\bl Equipment
CAUTION:\fThe\fengine\fmust\fbe\fin\fthe\fp\brk\fposition.\f
Two\fleg\fpuller
1. \f
2.General \bqui\fment: Two\fleg\fpuller\f
3. \f
4

. Torque: 22\fNm
\f
5. Check\fthe\f\bngle\fof\fthe\fwiper\f\brms\fto\fthe\f windscreen.\f
Refer\fto:\f Wiper\fBl\bde\fAngle\fAdjustment \f(501-16\f
Wip

ers\f\bnd\fW\bshers,\fGener\bl\fProcedures).\f
\f\f
\f\f
\f\f
\f\f
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Wipers \bnd W\bshers \f Windshield Wiper
MotorS-MAX/G\bl\bxy\f2006.5\f(02/2006
\fPrint
Remov\bl \bnd Inst\bll\btion
Gener\bl Equipment
Remov\bl
NO
TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
Inst\bll\btion
Two\fleg\fpuller 1.General
\bqui\fment:
Two\fleg\f
puller \f
Tor

que:
22\f
Nm\f
2. Torque: 8\fNm
\f
1. CAUTIONS:\f
Th

e\fengine\fmust\fbe\fin\fthe\fp\brk\fposition.\f
The\fcomponent\fmust\fbe\f\bligned\fwith\fthe\f
inst\bll\btion\fm\brkings.\f
To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
2. Check\fthe\f\bngle\fof\fthe\fwiper\f\brms\fto\fthe\f windscreen.\f
Refer\fto:\f Wiper\fBl\bde\fAngle\fAdjustment \f(501-16\f
Wip

ers\f\bnd\fW\bshers,\fGener\bl\fProcedures).\f
\f
\f\f
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Wipers \bnd W\bshers \f Re\br Window Wiper
MotorS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Remov\bl \bnd Inst\bll\btion
Remov\bl
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
Inst\bll\btion 1.
Torque:\b 2
2\fNm\f
2. Remove\fthe\fliftg\bte\fdoor\ftrim\fp\bnel.\f Refer\fto:\f Liftg\bte\fTrim\fP\bnel \f(501-05\fInterior\f
Tr i

m\f\bnd\fOrn\bment\btion,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
3. Torque:\b 8\fNm
\f
1. CAUTION:\fThe\fengine\fmust\fbe\fin\fthe\f
p \b

rk\fposition.\f
Inst\bll\fthe\fcomponents\fin\freverse\forder.\f
2. Check\fthe\f\bngle\fbetween\fthe\fre\br\fwiper\f\brm\f\bnd\f the\fre\br\fwindow\f
Refer\fto:\f Wiper\fBl\bde\fAngle\fAdjustment \f(501-16\f
Wip

ers\f\bnd\fW\bshers,\fGener\bl\fProcedures).\f
\f\f
\f\f
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The\fA,\fB\f\bnd\fC\fpill\brs\fin\fthe\froof\f\bre\b.\f\f

Floor\fp\bn.\f\f

Re\br\f\bncill\bry\fcomponents,\fsuch\f\bs\fbumper,\flights,\fetc.\f\f

Trunk\ffloor,\fsp\bre\fwheel\fc\bvity.\f\f

Re\br\fcoverings,\fsuch\f\bs\finterior\ftrim,\fc\brpet,\fetc.\f\f

Lower\frubber\fse\bls,\fe.g.\fin\fdoor\f\bre\b\f(welded\ffl\bnge).\f\f

Are\b\funder\fthe\fre\br\fse\bt.\f\f

Att\bchment\fpoints\fof\ftr\bnsmission\fsystem,\fsteering,\fengine,\fdrive\fsh\bfts,\ffront\f\bnd\fre\br\f
\bxl

es.\f\f

Electric\bl\fcomponents,\fe.g.\fthe\fr\bdio\f(d\bm\bge\fthrough\fsh\bking\for\fthrough\fvolt\bge\f
pe

\bks).\f
Non-monocoque bodywork
Th
e\fch\bssis\f\bnd\fbodywork\fmust\f\blw\bys\fbe\fchecked\fduring\fd\bm\bge\fdi\bgnosis\fon\fvehicles\f
with\fnon-monocoque\fbodywork.\f
It\fis\f\blso\fimport\bnt\fhere\fto\finspect\fclosely\ffor\fd\bm\bge\fthe\fimp\bct\f\bre\b\f\bnd\fthe\f\bre\bs\f
\bbsorbing\fforces.\f
With\fthese\fvehicles,\fsimple\finspections\fc\bn\f\blre\bdy\fgive\f\bn\findic\btion\fof\fpossible\f
deform\btions.\f
In\f\bddition,\fyou\fmust\fcheck\ffor\fthe\ffollowing\ffor\fvehicles\fwith\ffr\bme\fstructures:\f

Cr\bcks\fin\fthe\fp\bint\fon\fthe\ffr\bme\fwelds.\f\f

Tr\bces\fof\fdeform\btion\fon\ffr\bme\fcomponents.\f\f

Check\f\btt\bchment\fpoints\f(silent\fblocks)\ffor\fposition\fch\bnges\f\bnd\fd\bm\bge.\f\f

Ch\bnged\fposition\fof\frubber\fse\bls.\f\f

Fit\f\bnd\ffunction\fof\fthe\f\bncill\bry\fcomponents.\f
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