wiring FORD GALAXY 2006 Service Service Manual

In\bpection and Ve\fification 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

i\bual In\bpection Cha\ft
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,\fverify\fthe\fsymptom\f\bnd\frefer\fto\fthe\fDTC\fIndex\f
C
h\brt.\f
5. 5.
If\fno\fDTCs\frel\bted\fto\fthe\fconcern\f\bre\fretrieved,\fproceed\fto\fthe\fSymptom\fCh\brt\fto\f
c
ontinue\fdi\bgnosis.\f
Diagno\btic T\fouble Code (DTC) Index Cha\ft
Symptom Cha\ft
Mechanica\bE\bectrica\b

Exh\bust\fg\bs\frecircul\btion\f(EGR)\fv\blve\f\f

EGR\ftube\f\f

EGR\fcooler\f\f

EGR\ftube\fcl\bmp\f\f

G\bsket\f\f

PCV\fhose\f\f

Cr\bnkc\bse\fvent\foil\fsep\br\btor\f
Electric\bl\fconnector\f\f

Wiring\fh\brness\f
\fTC\fescription
Possib\be
Source
Action
P1412MIL\fillumin\btedEGR\fv\blveREFER\fto\fExcessive\fexh\bust\fbl\bck\fsmoke\fin\f
the\fSymptom\fCh\brt
P0404MIL\fillumin\btedEGR\fv\blveREFER\fto\fExcessive\fexh\bust\fbl\bck\fsmoke\fin\f
the\fSymptom\fCh\brt
P1335Powertr\bin\fw\brning\findic\btor\f illumin\btedEGR\fv\blveREFER\fto\fExcessive\fexh\bust\fbl\bck\fsmoke\fin\f
the\fSymptom\fCh\brt
SymptomPossib\be
SourcesAction
Excessive\f
exh\bust\f
bl\bck\f
smokeEGR\fv\blve.\f
*Using\fthe\fFord\f\bpproved\fdi\bgnostic\ftool,\fCHECK\fthe\fPCM\f
c\blibr\btion.\fIf\fnecess\bry\fUPDATE\fthe\fPCM\fc\blibr\btion\fto\fthe\f
l\btest\flevel.\fUsing\fthe\fFord\f\bpproved\fdi\bgnostic\ftool,\f
TOOLBOX/POWERTRAIN\fSERVICE\fFUNCTIONS/COMPONENT\f
OR\fPARAMETER\fRESET/EGR\fRE-CALIBRATION,\fRESET\fthe\fEGR\f
v\blve.\fC\brry\fout\f\b\fro\bd\ftest,\fif\fthe\fconcern\fpersists\fGO\fto\f
Pinpoint\fTest\f A.\f\f
*
Excessive\f
cr\bnkc\bse\f
pressureBlocked\for\f
d\bm\bged\fPCV\f
hose(s).\f
Blocked\f
cr\bnkc\bse\f
vent\foil\f
sep\br\btor.\f
*
*
GO\fto\fPinpoint\fTest\f
B.\f\f
*
Worn\for\f
d\bm\bged\f
engine\f
components.\f
*REFER\fto:\f
Engine\f(303-01G\fEngine\f-\f2.2L\fDur\btorq-TDCi\f
(12
9kW/175PS)\f-\fDW,\fDi\bgnosis\f\bnd\fTesting).\f
*
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DLC\f(d\bt\b\flink\fconnector)\f
Medium\fspeed\fCAN\f
GEM\f(generic\felectronic\fmodule) \f
PCM\f(powertr\bin\fcontrol\fmodule) \f
injectors\f
HO2S\f(he\bted\foxygen\fsensor)\f
CKP\f(cr\bnksh\bft\fposition)\f
ECT\f(engine\fcool\bnt\ftemper\bture) \f
St\brter\fRel\by\f
Ignition\flock\f
PCM\frel\by\f
B\bttery\f
Instrument\fcluster\f
Fuel\fpump\fdriver\fmodule\f
\fomme\bts:
Of\fwhich\fthe\ffollowing\f\bre\frelev\bnt\fhere:\fFlo\bt\f\brm,\fresistor\fbo\brd\f
Refer\fto:\f Fuel\fT\bnk\f\bnd\fLines\f-\f2.0L\fDur\btec-HE\fFlex\fFuel\f(107kW
/145PS)\f-\fMI4,\fVehicles\f
With:\fEth\bnol\fC\bp\bbility \f(310-01A\fFuel\fT\bnk\f\bnd\fLines\f-\f2.0L\fEcoBoost\fSCTi\f(14
9kW/203PS)\f-\f
MI4/2.0L\fDur\btec-HE\f(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\f
MI4/2.3L\fDur\btec-HE\f(118kW/160PS)\f-\fMI4/2.5L\fDur\btec\f(162kW/220PS)\f-\fVI5,\fDescription\f
\bnd\fOper\btion).\f
Instrument\fcluster\f
System Operatio\b
Fuel type determi\batio\b a\bd adaptatio\b
Th

e\fcruci\bl\ff\bctor\ffor\foptim\bl\f\bd\bpt\btion\fof\fthe\ffuel-\bir\fmixture\fis\fknowledge\fof\fthe\ffuel\f
composition\fin\fthe\ffuel\ft\bnk.\fTo\fdetermine\fthe\feth\bnol\fsh\bre\fin\fthe\ffuel,\fthe\f HO2S\fsign\bl\f
\bnd

\fthe\ffuel\flevel\fsensor\f\bre\fused.\fA\fcorresponding\f\blgorithm\fin\fthe\f PCM\fc\blcul\btes\fthe\ffuel\f
co m

position\ffrom\fthese.\f
The\ffollowing\fprerequisites\fmust\fbe\ffulfilled\ffor\ffuel\ftype\fdetermin\btion:\f

The\ffuel\flevel\fmust\fbe\fincre\bsed\fby\f\bt\fle\bst\f10\fliters\fif\fthe\ffuel\flevel\fsensor\fh\bs\freported\f
th

\bt\fthe\ffuel\ft\bnk\fis\fempty.\f\f

The\ffuel\flevel\fmust\fbe\fincre\bsed\fby\f\bt\fle\bst\f5\fliters\fif\fthe\ffuel\ft\bnk\fis\fp\brti\blly\ffull.\f\f

Approxim\btely\f0.1\fliters\fof\ffuel\fmust\fh\bve\fbeen\fconsumed\fsince\frefueling\f\f

Engine\fm\bn\bgement\fis\fworking\fin\f\b\fclosed\floop\f(L\bmbd\b\fcontrol\fis\f\bctive).\fThis\frequires\f
\bn\f

engine\ftemper\bture\fof\f\bpproxim\btely\f30\fto\f40°C\f\f

The\fengine\flo\bd\fis\fin\fthe\fr\bnge\fbetween\fidling\f\bnd\ffull\flo\bd\f(provided\fno\ffuel\fenrichment\f
is

\fc\brried\fout\fto\fprotect\fthe\fc\bt\blyst)\f\f

No\ferror\fcodes\f\bre\fs\bved\fin\fthe\f PC
M\f
The\ffollowing\fevents\fc\bn\ftrigger\f\b\ffuel\ftype\fdetermin\btion:\f

\b\fsufficient\fincre\bse\fin\fthe\ffuel\flevel\fin\fthe\ffuel\ft\bnk\f\f

\bn\fempty\ffuel\ft\bnk\for\fvery\flow\ffuel\flevel\f\bfter\fprolonged\fst\bndstill\fof\fthe\fvehicle\for\f
st

\brting\fof\fthe\fengine\f\f

progr\bmming\fof\fthe\f PC
M\f
As\fthe\ffuel\flevel\frises,\fthe\fflo\bt\f\brm\fof\fthe\ffuel\flevel\fsensor\frises\f\bnd\fch\bnges\fthe\fsensing\f
p o

sition\fon\fthe\fresist\bnce\ftr\bck\fof\fthe\fresistor\fbo\brd.\fThe\fresistor\fbo\brd\ftr\bnsfers\fthe\f
resulting\fdrop\fin\fvolt\bge\fto\fthe\f GEM\fvi\b\fdirect\fwiring.\fThe\f GEM\fsends\fthis\fv\blue\fto\fthe\f CAN\f
vi \b

\f PCM .\fWhen\fthe\f\bbove\fconditions\ffor\ffuel\ftype\fdetermin\btio
n\fh\bve\fbeen\fmet,\fthe\fPCM\f
2
3
4
5
6
7
8
9
1 0
1

1
12
13
14
15
16
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Electro\bic E\bgi\be \fo\btrols - 1.8L
Duratorq-TD\fi (74kW/100PS) -
Ly\bx/1.8L Duratorq-TD\fi (92kW/125PS)
- Ly\bx - \fyli\bder Head Temperature (\fHT)
Se\bsor
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal a\bd I\bstallatio\b
Removal
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
I\bstallatio\b
NOTE:\fM\bke\fsure\fth\bt\f\b\fnew\fcomponent\fis\finst\blled.\f 1. \f
2.
T

orque:\b 23\fNm
\f
3. CAUTION:\fM\bke\fsure\fth\bt\fno\fstr\bin\fis\f
pl

\bced\fon\fthe\ffuel\flines\f\bnd\fwiring\fh\brnesses.\f
Torque:\b 9\fNm
\f
4. NOTE:\fM\bke\fsure\fth\bt\fthe\fsensor\fhousing\fis\f
cl
e\bn\f\bnd\ffree\fof\fforeign\fm\bteri\bl.\f
Torque:\b 20\fNm
\f
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f\f
\f\f
\f\f
\f\f
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Automati\b Tra\fsmissio\f/Tra\fsaxle -
Vehi\bles With: 6-Speed Automati\b
Tra\fsaxle - AWF21 - Tra\fsmissio\f
I\fter\fal Wiri\fg Har\fess
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal a\fd I\fstallatio\f
Removal
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
1. Refer\fto:\f Tr
\bnsmission\fControl\fModule\f(TCM) \f
(30
7-01\fAutom\btic\fTr\bnsmission/Tr\bns\bxle\f-\f
Vehicles\fWith:\f6-Speed\fAutom\btic\fTr\bns\bxle\f-\f
AWF21,\fRemov\bl\f\bnd\fInst\bll\btion).\f
2. Refer\fto:\f Tr\bnsmission\fFluid\fP\bn \f(307-01\f
Au t

om\btic\fTr\bnsmission/Tr\bns\bxle\f-\fVehicles\f
With:\f6-Speed\fAutom\btic\fTr\bns\bxle\f-\fAWF21,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
3. \f
4. NOTE:\fNote\fthe\fposition\fof\fthe\felectric\bl\f
co

nnectors.\f
5. CAUTION:\fM\bke\fsure\fth\bt\fthe\fwiring\f
h \b

rness\fdoes\fnot\fc\btch.\f
\f\f
\f
\f\f
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Fuel Sy\btem - \feneral Information - Fuel
Sy\btem—2.0L Duratec-HE (MI4)/2.3L
Duratec-HE (MI4)/2.5L Duratec (VI5)
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Diagno\bi\b and Te\bting
\feneral Equipment
In\bpection and Verification
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

i\bual In\bpection Chart
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,\fverify\fthe\fsymptom\f\bnd\frefer\fto\fthe\f F
ord\f
\bpp
roved\fdi\bgnostic\ftool .\f
Ford\f\bpproved\fdi\bgnostic\ftool
Mechanica\bE\bectrica\b


Fuel\flevel\f\f

Fuel\fpump\f\bnd\fsender\funit\f\f

Fuel\fle\bk(s)\f\f

Fuel\fline(s)\f\f

Fuel\ffilter\f\f

Fuel\ft\bnk\f\f

Fuel\ft\bnk\ffiller\fpipe\f\f

Fuel\ft\bnk\ffiller\fc\bp\f
Electric\bl\fconnector(s)\f\f

Wiring\fh\brness\f\f

Fuel\fpump\fmodule\f
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Fuel Sy\btem - \feneral Information - Fuel
Sy\btem—1.8L Duratorq-TDCi (Lynx)
Die\bel/2.0L Duratorq-TDCi (DW) Die\bel
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Diagno\bi\b and Te\bting
Special Tool(\b)
\fen

eral Equipment
In\bpection and Verification 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

i\bual In\bpection Chart
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,\fverify\fthe\fsymptom\f\bnd\frefer\fto\fthe\fSymptom\f
C
h\brt.\f
Symptom Chart
H\bnd\fPressure\fPump\fwith\fAd\bpter\fKit\f
310-110\f
Worldwide\fDi\bgnostic\fSystem\f(WDS)
Mechanica\bE\bectrica\b

Fuel\flevel\f\f

Fuel\fle\bk(s)\f\f

Fuel\fline(s)\f\f

Fuel\ffiller\fc\bp\f\f

Fuel\ffilter\f\f

Fuel\ft\bnk\f\f

Fuel\ft\bnk\fventil\btion\fhose\f\f

Fuel\ft\bnk\ffiller\fhose\f
Wiring\fh\brness\f\f

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

Fuel\flevel\fsensor\f\f
\fymptomPossib\be \fourcesAction
Engine\fcr\bnks\f
but\fdoes\fnot\f
st\brtFuel\fch\brging\f\bnd\f
controls.\f
*Vehicles\fwith\f1.8L\fDur\btorq-TDCi\f(Kent)\fdiesel\f
engine.\f\f
REFER\fto:\f Fuel\fCh\brging\f\bnd\fControls \f(303-04D\f
Fue

l\fCh\brging\f\bnd\fControls\f-\f1.8L\fDur\btorq-TDCi\f
(74kW/100PS)\f-\fLynx/1.8L\fDur\btorq-TDCi\f
(92kW/125PS)\f-\fLynx,\fDi\bgnosis\f\bnd\fTesting).\f
Vehicles\fwith\f2.0L\fDur\btorq-TDCi\f(DW)\fdiesel\f
engine.\f\f
REFER\fto:\f Fuel\fCh\brging\f\bnd\fControls \f(303-04E\f
Fue

l\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,\fDi\bgnosis\f\bnd\fTesting).\f
*
Air\fingress\finto\fthe\f
fuel\flines.\f
*Vehicles\fwith\f1.8L\fDur\btorq-TDCi\f(Kent)\fdiesel\f
engine.\fGO\fto\fPinpoint\fTest\f A.\fVehicles\fwith\f2.0L\f
Dur

\btorq-TDCi\f(DW)\fdiesel\fengine.\fGO\fto\fPinpoint\f
*
\f\f
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Fuel\fpump\fdriver\fmodule\f-\feth\bnol\fvehicle\f
Enc\bpsul\bted\fconnector\f
The\ffuel\fpump\fmodule\ffor\feth\bnol\foper\btion\flooks\fvery\fsimil\br\fto\fthe\ffuel\fpump\fmodule\ffor\f
petrol\fvehicles.\fThe\fdifference\fis\fin\fthe\ffuel\fpump\fconnector.\fThis\fis\fenc\bpsul\bted\fdue\fto\fthe\f
higher\fconductivity\fof\fthe\feth\bnol\fsh\bre.\f
\f\f
Descr\fpt\fo\b
Fuel\flevel\fsensor\f
Resistor\fbo\brd\f
The\fresistor\fbo\brd\fof\fthe\ffuel\flevel\fsensor\fis\fsupplied\fwith\f\bltern\bting\fvolt\bge\finste\bd\fof\f
direct\fvolt\bge.\fThis\fprevents\felectrolysis\f\bnd\fthe\fdeposit\fof\fp\brticles.\fThe\f\bltern\bting\f
volt\bge\fis\fgener\bted\fby\f\b\f DC\f(direct\fcurrent)-AC\f(\bltern\bting\fcurrent) \fconverter.\fThe\fDC-AC
\f
converter\fis\fintegr\bted\fin\fthe\fwiring\fh\brness\for\fthe\f GEM\f(generic\felectronic\fmodule)\f
dep
ending\fon\fthe\fconstruction\fperiod.\fIt\fconverts\fthe\fdirect\fvolt\bge\finto\f\bn\f\bltern\bting\f
volt\bge\fwith\f\b\ffrequency\fof\f170\fHz.\fThe\fcourse\fof\fthe\f\bltern\bting\fvolt\bge\fcorresponds\fto\f\b\f
rect\bngul\br\fimpulse.\f
Both\ffuel\fpump\fdriver\funits\fh\bve\fdifferent\fresist\bnce\ftr\bcks\ffor\fthe\ffuel\flevel\fsensor.\f
Another\fdifference\fis\fth\bt\fthe\ffuel\fpump\fdriver\funit\ffor\feth\bnol\foper\btion\fis\fm\bnuf\bctured\f
from\feth\bnol-resist\bnt\fm\bteri\bls.\f
The\ffuel\flevel\fsensor\fis\fused\fduring\ffuel\ftype\fdetermin\btion.\f\f
Refer\fto:\f Electronic\fEngine\fControls\f-\fVehicles\fWith:\fEth\bnol\fC \b
p\bbility\f(303-14A\fElectronic\f
Eng
ine\fControls\f-\f2.0L\fDur\btec-HE\f(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\fFuel\f
(107kW/145PS)\f-\fMI4,\fDescription\f\bnd\fOper\btion).\f 2
3
I t

em
1
2 \f\f
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Vehicles\fwith\ffuel\ffired\fbooster\fhe\bter\f
All\fvehicles\f
12. \f
13

. WARNING:\fBe\fprep\bred\fto\fcollect\f
e s

c\bping\ffluid.\f
Refer\fto:\f Qu
ick\fRele\bse\fCoupling \f(310-00\fFuel\f
Sys
tem\f-\fGener\bl\fInform\btion,\fGener\bl\f
Procedures).\f
14. \f
15. CAUTIONS:\f
Us

e\fsuit\bble\fp\bcking\fm\bteri\bl\fto\fprevent\f
d\bm\bge\fto\fthe\fcomponent.\f
M\bke\fsure\fth\bt\fno\fstr\bin\fis\fpl\bced\fon\f
the\ffuel\flines\f\bnd\fwiring\fh\brnesses.\f
Genera\f\bEquipment:\b Tr
\bnsmission\fj\bck\f
Gen
era\f\bEquipment:\b Wooden\fBlock\f
16.Torque:\b 24\fNm\f
17. Genera\f\bEquipment:\b Ret\bining\fStr\bp\f
\f\f
\f\f
\f\f
\f\f
\f\f
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Vehicles\fwith\ffuel\ffired\fbooster\fhe\bter\f
All\fvehicles\f
12. \f
13

. WARNING:\fBe\fprep\bred\fto\fcollect\f
e s

c\bping\ffluid.\f
Refer\fto:\f Qu
ick\fRele\bse\fCoupling \f(310-00\fFuel\f
Sys
tem\f-\fGener\bl\fInform\btion,\fGener\bl\f
Procedures).\f
14. \f
15. CAUTIONS:\f
Us

e\fsuit\bble\fp\bcking\fm\bteri\bl\fto\fprevent\f
d\bm\bge\fto\fthe\fcomponent.\f
M\bke\fsure\fth\bt\fno\fstr\bin\fis\fpl\bced\fon\f
the\ffuel\flines\f\bnd\fwiring\fh\brnesses.\f
Genera\f\bEquipment:\b Tr
\bnsmission\fj\bck\f
Gen
era\f\bEquipment:\b Wooden\fBlock\f
16.Torque:\b 24\fNm\f
17. Genera\f\bEquipment:\b Ret\bining\fStr\bp\f
\f\f
\f\f
\f\f
\f\f
\f\f
Стр. 4 из
7
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G544298&gui...procarmanuals.com
http://vnx.su

Vehicles\fwith\ffuel\ffired\fbooster\fhe\bter\f
All\fvehicles\f
12. \f
13

. WARNING:\fBe\fprep\bred\fto\fcollect\f
e s

c\bping\ffluid.\f
Refer\fto:\f Qu
ick\fRele\bse\fCoupling \f(310-00\fFuel\f
Sys
tem\f-\fGener\bl\fInform\btion,\fGener\bl\f
Procedures).\f
14. \f
15. CAUTIONS:\f
Us

e\fsuit\bble\fp\bcking\fm\bteri\bl\fto\fprevent\f
d\bm\bge\fto\fthe\fcomponent.\f
M\bke\fsure\fth\bt\fno\fstr\bin\fis\fpl\bced\fon\f
the\ffuel\flines\f\bnd\fwiring\fh\brnesses.\f
Genera\f\bEquipment:\b Tr
\bnsmission\fj\bck\f
Gen
era\f\bEquipment:\b Wooden\fBlock\f
16.Torque:\b 24\fNm\f
17. Genera\f\bEquipment:\b Ret\bining\fStr\bp\f
\f\f
\f\f
\f\f
\f\f
\f\f
Стр. 4 из
7
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G544298&gui...procarmanuals.com
http://vnx.su