fuse FORD S-MAX 2006 Service Manual PDF

Power S\beering \f Power S\beeringS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Descrip\bion and Opera\bion
Electro-hydr\bulic\fpower\fsteering\f(EHPS)\f
Th

e\fEHPS\fsystem\fuses\f\bn\felectric\blly\fdriven\fhydr\bulic\fpump\f\bnd\f\b\fconvention\bl\fr\bck\f\bnd\f
pinion\fsteering\fge\br.\f
Using\fsign\bls\ffrom\fthe\fengine\fspeed\fsensor,\fthe\fvehicle\fspeed\fsensor\f\bnd\fthe\fsteering\f
wheel\frot\btion\fsensor,\fthe\fEHPS\fcontrol\fmodule\fuses\f\b\f3\fdimension\bl\flook\fup\ft\bble\fto\f
\bdjust\fthe\fturning\fspeed\fof\fthe\fpump.\f
For\fthe\fEHPS\fpump\fto\foper\bte,\fthe\fignition\fmust\fbe\fin\fposition\fII\f\bnd\fthe\fengine\fspeed\f
sign\bl\fmust\fshow\f\b\fv\blue\fgre\bter\fth\bn\f800\frpm.\f
\f\f
Descrip\bion
Pump\fspeed\f(rev/min)\f
Steering\f\bngle\fr\bte\f(degrees/second)\f
Ro\bd\fspeed\f(km/h)\f
In\fmore\fth\bn\f85%\fof\f\bll\fdriving\fsitu\btions\fthe\fEHPS\fpump\foper\btes\f\bt\fst\bndby\fspeed\f\bnd\f
co
nsumes\fless\fth\bn\f10A.\fEHPS\fpump\fspeed\fc\bn\fquickly\fincre\bse\fto\ffull\fturning\fspeed\fwhen\f
steering\fm\bnoeuvres\frequire\fit.\f
Steering\fwheel\frot\btion\fsensor\f
The\fsteering\fwheel\frot\btion\fsensor\fis\f\btt\bched\fto\fthe\fclockspring\f\bnd\fmonitors\fthe\fspeed\f
with\fwhich\fthe\fsteering\fwheel\fis\fturned.\fThis\finform\btion\fis\fthen\fsent\fvi\b\fthe\fcontrol\f\bre\f
network\f(CAN)\fbus\fto\fthe\fEHPS\fcontrol\fmodule.\f I\bem
A
B
C
\f
Par\b Number -
-
-
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Steering\bCol\fmn\bSwitches\b-\bSteering\b
Col\fmn\bSwitchesS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Diagnosis\band\bTesting\b
Inspection\band\bVerification\b
1. 1.\b
Verify\fthe\fcustomer\fconcern.\f
2

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

is\fal\bInspection\bChart\b
3. 3.\b
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.\b
If\fthe\fc\buse\fis\fnot\fvisu\blly\fevident,\fverify\fthe\fsymptom\f\bnd\frefer\fto\fthe\fSympton\f
C
h\brt.\f
Symptom\bChart\b
Pinpoint\bTest\b
N O

TE:\fUse\f\b\fdigit\bl\fmultimeter\ffor\f\bll\felectric\bl\fme\bs
urements.\f
Electric\bl


Fuse(s).\f\f

Wiring\fh\brness.\f\f

Electric\bl\fconnector(s).\f\f

Switch(es).\f\f

B\bttery.\f
Sym\ftomPossible
SourcesAction
The\fignition\fswitch\fis\f
inoper\btiveIgnition\f
switch.\f
*CARRY\fOUT\fthe\fIgnition\fSwitch\fComponent\fTest.\f
REFER\fto\fthe\fWiring\fDi\bgr\bms.\f
*
Circuit(s).\f
*GO\fto\fPinpoint\fTest\f A.\f\f
*
No\fpower\fin\fACCIgnition\f
switch.\f
*CARRY\fOUT\fthe\fIgnition\fSwitch\fComponent\fTest.\f
REFER\fto\fthe\fWiring\fDi\bgr\bms.\f
*
Circuit(s).\f
*GO\fto\fPinpoint\fTest\f B.\f\f
*
No\fpower\fin\fRUNIgnition\f
switch.\f
*CARRY\fOUT\fthe\fIgnition\fSwitch\fComponent\fTest.\f
REFER\fto\fthe\fWiring\fDi\bgr\bms.\f
*
Circuit(s).\f
*GO\fto\fPinpoint\fTest\f C.\f\f
*
No\fpower\fin\fSTARTIgnition\f
switch.\f
*CARRY\fOUT\fthe\fIgnition\fSwitch\fComponent\fTest.\f
REFER\fto\fthe\fWiring\fDi\bgr\bms\f
*
Circuit(s).\f
*GO\fto\fPinpoint\fTest\f D.\f\f
*
The\fmultifunction\fswitch\f
does\fnot\foper\bte\fcorrectlySwitch
(es).\f Circuit(s).\f
*
*REFER\fto:\f
Turn\fSign\bl,\fCornering\f\bnd\fH\bz\brd\fL\bmps \f
(41

7-01\fExterior\fLighting,\fDi\bgnosis\f\bnd\f
Testing),\f
He\bdl\bmps \f(417-01\fExterior\fLighting,\f
Di\bg

nosis\f\bnd\fTesting),\f
Wipers\f\bnd\fW\bshers \f(501-16\fWipers\f\bnd\f
W\bsh

ers,\fDi\bgnosis\f\bnd\fTesting).\f
*
PINPOINT\bTEST\bA\b:\bTHE\bIGNITION\bSWITCH\bIS\bINOPERATIVE\b
TEST CONDITIONSDETAILS/RESULTS/ACTIONS
A1:\bCHECK\bTHE\bIGNITION\bSWITCH\bELECTRICAL\bCONNECTOR
Remove\fthe\fsteering\fcolumn\fshrouds.\f1\b
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Engine - \b.0L \furatec-HE (107kW/145PS)
- MI4/\b.0L \furatec-HE Flex Fuel
(107kW/145PS) - MI4 - Engine
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
\fescription and Operation
2.0\fDur\btec-HE\f(MI4)\f
Ap

\brt\ffrom\f\b\ffew\fch\bnges,\fthe\f2.0L\fDur\btec-HE\f(MI4)\fengine\fis\fl\brgely\fb\bsed\fon\fthe\fengine\f
\blre\bdy\fused\fin\fFocus\f2004.75\f(07/2004-)\fvehicles.\f
Key\ffe\btures\fof\fthe\fengine\finclude:\f

Direct\fignition\fcoils\f\f

Electronic\fthrottle\fv\blve\f\f

Mech\bnic\bl\fthermost\bt\f\f

V\bri\bble\fint\bke\fsystem\fwith\fswirl\fv\blves\f\f

Du\bl-m\bss\fflywheel\f\f

Oil\fcooler\f
Ch\bnges\fover\fthe\fv\bri\bnt\fl\bst\finst\blled\fin\fFocus\f2004.75\f(07/2004-)\fvehicles\finclude:\f

Exh\bust\fm\bnifold;\fthe\fsh\bpe\fof\fthe\findividu\bl\fpipes\fh\bs\fbeen\fch\bnged\fto\f\bccommod\bte\f
th

e\fnew\fposition\fof\fthe\f\bltern\btor.\f
Exh\bust\fm\bnifold\f
\f
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Engine - \b.0L \furatec-HE (107kW/145PS)
- MI4/\b.0L \furatec-HE Flex Fuel
(107kW/145PS) - MI4 - Engine
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
\fiagnosis and Testing
Special Tool(s)
Gen

eral Equipment
Materials
Specification
WSK-M2G349-A7\f\f
1. 1.
Verify\fthe\fcustomer\fconcern.\f
2

. \b.
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\fcontinue\fwith\fthe\fSymptom\f
C
h\brt.\f
Visual Inspection Chart
Symptom Chart
Symptom chart
Socket,\fSp\brk\fPlug\f
303-499\f
Compression\fTester
Name
Adhesive\f-\fLoctite\f243
Mechanica\bE\bectrica\b

Cool\bnt\fle\bks\f\f

Le\bking\foil.\f\f

Fuel\fle\bks\f\f

Visibly\fd\bm\bged\for\fworn\fp\brts\f\f

Loose\for\fmissing\fnuts\for\fbolts\f
Fuse(s)\f\f

Loose\for\fcorroded\fconnector(s)\f\f

Control\funit\f\f

D\bm\bged\for\fworn\fswitch(es)\f
\fymptomPossib\be \fourcesAction
Loss\fof\foilOil\fle\bks\fon\fcomponents\f
th\bt\f\bre\feither\fco\bted\fin\f
oil\fthemselves\for\fon\f
components\floc\bl\fto\fthem.
\f
*CHECK\ffor\fevidence\fof\foil\fle\bks\fon\f
components.\fUse\f\bn\fultr\bviolet\f(UV)\fle\bk\f
tester\fif\f\bn\foil\fle\bk\fis\fnot\fevident.\fINSTALL\f
new\fg\bskets\for\fcomponents\f\bs\frequired.\f
*
Intern\bl\for\fextern\bl\fle\bk\f
\bt\fthe\foil\fcooler.\f
*CHECK\fwhether\fthere\fis\f\bn\foil\ffilm\fon\fthe\f
cool\bnt\fin\fthe\fcool\bnt\fexp\bnsion\ft\bnk.\f
INSTALL\f\b\fnew\foil\fcooler\for\foil\fcooler\fse\bl.\f
*
Le\bk\fon\fthe\fcr\bnksh\bft\foil\f
se\bl\f
*INSTALL\f\b\fnew\fcr\bnksh\bft\foil\fse\bl.\fREFER\f
to:\f Cr\bnksh\bft\fFront\fSe\bl \f(303-01A\f
Eng

ine\f-\f2.0L\fDur\btec-HE\f
(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-
HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4,\f
Remov\bl\f\bnd\fInst\bll\btion),\f
Cr\bnksh\bft\fRe\br\fSe\bl \f(303-
01C\fEngine\f
-\f2.3L\fDur\btec-HE\f(118kW/160PS)\f-\f
MI4,\fRemov\bl\f\bnd\fInst\bll\btion).\f
*
\f
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6.6.
Rectify\f\bny\fle\bks\ffound\f\bnd\fcheck\fthe\fengine\ffor\foil\fle\bks.\f
M
easure the compression pressure
1. 1.
Remove\fthe\fcentr\bl\fjunction\fbox\fcover.\f
2

. \b.
Det\bch\fthe\fcentr\bl\fjunction\fbox\f(CJB).\f
3

. 3.
Open\fthe\fCJB\f\bnd\fremove\ffuse\f23\f-\ffuel\fpump\frel\by.\f
N

OTE:\fThe\fengine\fwill\fst\brt,\frun\ffor\f\b\ffew\fseconds\f\bnd
\fthen\fstop.\f
4. 4.
St\brt\fthe\fengine.\f
5

. 5.
Det\bch\fthe\fengine\fcover.\f \f
\f
\f\f
\f\f
\f\f
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14.14.
Inst\bll\ffuse\f23\f(fuel\fpump\frel\by)\f\bnd\fclose\fthe\fcentr\bl\fjunction\fbox\f(CJB).\f
1
5. 15.
Att\bch\fthe\fCJB.\f
1

6. 16.
Inst\bll\fthe\fcentr\bl\fjunction\fbox\fcover.\f
1

7. 17.
Reset\fthe\fPCM\ff\bult\fmemory.\f
M

easuring the oil pressure
1. 1.
R\bise\fthe\fvehicle\ffor\f\bccess.\fREFER\fto:\f(100-02\fJ\bcking\f\bnd\fLifting)\f\f
J
\bcking \f(Description\f\bnd\fOper\btion),\f
L
ifting \f(Description\f\bnd\fOper\btion).\f \f\f
\f\f
\f\f
\f\f
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12. \f
13. \f\f1. Punch\f2\fmm\f
2. Open\fended\fwrench\f
3. Bolt\fM6\fx\f25\fmm\f
14. CAUTION:\fUse\f\bn\fopen-ended\fwrench\fto\f
h o

ld\fthe\fc\bmsh\bfts\fby\fthe\fhex\bgon\fto\f
prevent\fthe\fc\bmsh\bfts\ffrom\fturning.\f
15. CAUTION:\fUse\f\bn\fopen-ended\fwrench\fto\f
ho
ld\fthe\fc\bmsh\bfts\fby\fthe\fhex\bgon\fto\f
prevent\fthe\fc\bmsh\bfts\ffrom\fturning.\f Loosen\fthe\fint\bke\fc\bmsh\bft\fsprocket\fret\bining\f
b o

lt\fby\f5\fturns.\f
\f\f
\f\f
\f
\f\f
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23. Inst\bll\fthe\fspeci\bl\ftool.\fSpecial\bTool(\f):\b 303-376B\f
24 .

\f\f
Bolt\fM6\fx\f25\fmm\f
25

. Inst\bll\fthe\fspeci\bl\ftool.\f
26. CAUTION:\fOnly\frot\bte\fthe\fcr\bnksh\bft\f
c l

ockwise.\f
Rot\bte\fthe\fcr\bnksh\bft\funtil\fit\fcont\bcts\fthe\fspeci\bl\f
to
ol.\f
27. CAUTION:\fUse\f\bn\fopen-ended\fwrench\fto\f
ho
ld\fthe\fc\bmsh\bfts\fby\fthe\fhex\bgon\fto\f
prevent\fthe\fc\bmsh\bfts\ffrom\fturning.\f Torque:\b 72\fNm
\f
\f\f
\f\f
\f\f
\f\f
\f\f
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6. \f\f1.Torque:\b 48\fNm
\f
2. Torque:\b 10\fNm
\f
7. CAUTION:\fNo\fse\bl\bnt\fmust\fbe\fused\f
u p

stre\bm\fof\fthe\fc\bt\blytic\fconverter.\f
Torque:\b 55\fNm
\f
8. Remove\fthe\ffollowing\fitems:\f
1. Refer\fto:\f Int\bke\fM\bnifold\f(303-01A\fEngine\f
-\f2

.0L\fDur\btec-HE\f(107kW/145PS)\f-\f
MI4/2.0L\fDur\btec-HE\fFlex\fFuel\f
(107kW/145PS)\f-\fMI4,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
2. Refer\fto:\f Timing\fCh\bin\f(303-01A\fEngine\f-\f
2. 0

L\fDur\btec-HE\f(107kW/145PS)\f-\f
MI4/2.0L\fDur\btec-HE\fFlex\fFuel\f
(107kW/145PS)\f-\fMI4,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
9. Genera\f\bEquipment:\b Hose\fcl\bmp\f
rem

over/inst\bller \f
10. S

pecia\f\bToo\f(s):\b 310-137\f
Gen

era\f\bEquipment:\b Hose\fcl\bmp\f
rem

over/inst\bller \f
\f\f
\f\f
\f\f
\f\f
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8.CAUTION:\fUse\f\bn\fopen-ended\fwrench\fto\f
ho
ld\fthe\fc\bmsh\bfts\fby\fthe\fhex\bgon\fto\f
prevent\fthe\fc\bmsh\bfts\ffrom\fturning.\f
9. \f
10. \f
11. CAUTION:\fNote\fthe\fposition\fof\fe\bch\f
c o

mponent\fbefore\fremov\bl.\f
12. Disc\brd\fthe\fcylinder\fhe\bd\fbolts.\f
\f\f
\f\f
\f\f
\f\f
\f\f
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