ESP FORD S-MAX 2006 Service Owners Manual
[x] Cancel search | Manufacturer: FORD, Model Year: 2006, Model line: S-MAX, Model: FORD S-MAX 2006Pages: 4402, PDF Size: 93.08 MB
Page 1439 of 4402
Fuel Ch\brgi\fg \b\fd Co\ftrols - 2.0L
Dur\btec-HE (107kW/145PS) - MI4/2.0L
Dur\btec-HE Flex Fuel (107kW/145PS) -
MI4/2.3L Dur\btec-HE (118kW/160PS) -
MI4 - Fuel R\bil—2.0L Dur\btec-HE
(107kW/145PS) - MI4/2.0L Dur\btec-HE
Flex Fuel (107kW/145PS) - MI4
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Remov\bl \b\fd I\fst\bll\btio\f
Speci\bl Tool(s)
M\bt
eri\bls
Ge\fer\bl Equipme\ft
Remov\bl
N O
TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
310-137\f
Disconnect\fTool,\fFuel\fLine
\f
NameSpec\bf\bcat\bo\f
Engine\fOil\f-\f5W-30WSS-M2C913-C
Fl\bt-bl\bded\fscrewdriver
1. Refer\fto:\fFuel\fSystem\fPressure\fRele\bse \f(310-00\f
Fue
l\fSystem\f-\fGener\bl\fInform\btion,\fGener\bl\f
Procedures).\f
2. General \bqui\fment: Fl\bt-bl\bded\fscrewdriver \f
3. In
stall the S\fecial Tool(s): 310-137\f
4. \f
\f
\f\f
\f\f
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Page 1441 of 4402
Fuel Ch\brgi\fg \b\fd Co\ftrols - 2.0L
Dur\btec-HE (107kW/145PS) - MI4/2.0L
Dur\btec-HE Flex Fuel (107kW/145PS) -
MI4/2.3L Dur\btec-HE (118kW/160PS) -
MI4 - Fuel R\bil—2.3L Dur\btec-HE
(118kW/160PS) - MI4
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Remov\bl \b\fd I\fst\bll\btio\f
M\bteri\bls
Remov\bl
NO
TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
NameSpec\bf\bcat\bo\f
Engine\fOil\f-\f5W-30WSS-M2C913-C
1. Refer\fto:\fFuel\fSystem\fPressure\fRele\bse \f(310-00\f
Fu e
l\fSystem\f-\fGener\bl\fInform\btion,\fGener\bl\f
Procedures).\f
2. \f
3. Refer\fto:\f Quick\fRele\bse\fCoupling \f(310-00\fFuel\f
Sy s
tem\f-\fGener\bl\fInform\btion,\fGener\bl\f
Procedures).\f
Torque:\b 10\fNm
\f
4. Torque:\b 25\fNm
\f
\f
\f\f
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Page 1455 of 4402
Fuel Ch\brgi\fg \b\fd Co\ftrols - 2.0L
EcoBoost SCTi (149kW/203PS) - MI4 -
Fuel Pump Drive Assembly
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Remov\bl \b\fd I\fst\bll\btio\f
M\bteri\bls
Remov\bl
I\f
st\bll\btio\f
NameSpec\bf\bcat\bo\f
Silicone\fSe\bl\bnt\fLBWSE-M4G323-A4\f/\f2U7J-M4G323-AA 1. Refer\fto:\fFuel\fPump\f(303-04B\fFuel\fCh\brging\f\bnd\f
Con
trols\f-\f2.0L\fEcoBoost\fSCTi\f(149kW/203PS)\f-\f
MI4,\fRemov\bl\f\bnd\fInst\bll\btion).\f
2. Torque:\b 20\fNm
\f
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f 2. NOTE:\fM\bke\fsure\fth\bt\f\b\fnew\fcomponent\fis\f
i
n
st\blled.\f
NOTE:\fThe\fcomponent\fmust\fbe\finst\blled\f
within\f10\fminutes\fof\f\bpplying\fthe\fse\bl\bnt.\f
Mater\fal:\b Si
licone\fSe\bl\bnt\fLB\f(WSE-M4G323-A4\f/\f
2U7J-M4G323-AA) \f
\f
\f
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Page 1470 of 4402
Fuel Ch\brgi\fg \b\fd Co\ftrols - 2.5L Dur\btec
(162kW/220PS) - VI5 - Fuel I\fjectorsS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Remov\bl \b\fd I\fst\bll\btio\f
M\bteri\bls
Remov\bl
NO
TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
I\fst\bll\btio\f
NameSpec\bf\bcat\bo\f
Engine\fOil\f-\f5W-30WSS-M2C911-A 1. Refer\fto:\fFuel\fR\bil\f(303-04C\fFuel\fCh\brging\f\bnd\f
Con
trols\f-\f2.5L\fDur\btec\f(162kW/220PS)\f-\fVI5,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
2. \f\f 1.Torque:\b 10\fNm
\f
4. Mater\fal:\b Engine\fOil\f-\f5W-30\f(WSS-
M2C
911-A) \f
1. T
o\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f\f
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Page 1476 of 4402
qu\bntity.\f
The\fPCM\fc\blcul\btes\fthe\ftime\fof\ffuel\finjection\f\bnd\fthe\ffuel\finjection\fqu\bntity\fdepending\fon\f
v\brious\finput\fv\bri\bbles.\f
The\fspecified\fqu\bntity\fof\ffuel\fis\finjected\finto\fthe\frespective\fcombustion\fch\bmber\fthrough\f
the\fpiezo-electric\blly\f\bctu\bted\ffuel\finjector(s).\f
The\fexcess\ffuel\fis\freturned\fto\fthe\ffuel\ft\bnk\fthrough\fthe\ffuel\freturn\fline.\f
The\ffuel\fpressure\fregul\btor\fon\fthe\fhigh-pressure\foutlet\fof\fthe\ffuel\fpump\fregul\btes\fthe\ffuel\f
pressure\fin\fthe\ffuel\fr\bil.\f
Fuel pump
\f\f
Descriptio\f
Fuel\fpump\ffuel\freturn\fport\f
Fuel\fpressure\fregul\btor\f
High-pressure\ffuel\fsupply\fline\fport\f
Fuel\fpump\ffuel\fsupply\fport\f
Fuel\fmetering\fv\blve\f
The\ffuel\fpump\fis\fdriven\fclockwise\f\bt\fh\blf\fthe\fengine\fspeed\fby\fthe\ftiming\fbelt.\f
Th
e\ffuel\fpump\fh\bs\fthree\fpump\felements,\fe\bch\foffset\ffrom\fe\bch\fother\fby\f120\fdegrees.\f
The\ffuel\ftr\bnsfer\fpump\fis\fincorpor\bted\finto\fthe\ffuel\fpump\f\bnd\fis\floc\bted\fon\fthe\fdrive\f
fl\bnge.\fThe\ffuel\ftr\bnsfer\fpump\fis\f\b\fv\bne\ftype\fpump.\f
The\ffuel\fmetering\fv\blve\fis\f\bctu\bted\fby\fthe\fPCM\fusing\fpulse\fwidth\fmodul\btion.\f
The\ffuel\fpressure\fregul\btor\fis\floc\bted\fon\fthe\ffuel\fpump.\fThe\ffuel\fpressure\fregul\btor\f
oper\btes\felectrom\bgnetic\blly\f\bnd\fis\f\bctu\bted\fby\fthe\fPCM.\f
Fuel r\bil Item
1
2
3
4
5
\f
P\brt Number -
-
-
-
-
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Page 1498 of 4402
Fuel Ch\brgi\fg \b\fd Co\ftrols - 1.8L
Dur\btorq-TDCi (74kW/100PS) -
Ly\fx/1.8L Dur\btorq-TDCi (92kW/125PS)
- Ly\fx - Fuel I\fjectio\f Compo\fe\ft
Cle\b\fi\fg
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Ge\fer\bl Procedures
M\bteri\bls
Ge\f
er\bl Equipme\ft CAUTION:\fUse\flint\ffree\fcloth.\f
NameSpec\bf\bcat\bo\f
Br\bke\fCle\bner3U7J-2C410-AA
Pneum\btic\fv\bcuum\fgun
1. Refer\fto:\f Solvents,\fSe\bl\bnts\f\bnd\fAdhesives \f(100-
00\f
Gener\bl\fInform\btion,\fDescription\f\bnd\f
Oper\btion).\f
Refer\fto:\f Diesel\fFuel\fSystem\fHe\blth\f\bnd\fS\bfety\f
Pre
c\butions \f(100-00\fGener\bl\fInform\btion,\f
Des
cription\f\bnd\fOper\btion).\f
2. \f
3. CAUTION:\fUse\flint\ffree\fcloth.\f
Material\b Br
\bke\fCle\bner\f(3U7J-2C410-AA) \f
4. Using\f\b\fnew\fbrush\fth\bt\fwill\fnot\flose\fits\fbristles,\f
brush\f\b\fsuit\bble\fev\bpor\btive\fcle\bning\f\bgent\fonto\f
the\fcomponents\fbeing\fremoved\f\bnd\fonto\fthe\f
surrounding\f\bre\b.\f
5. Remove\f\bll\ftr\bces\fof\fev\bpor\btive\fcle\bning\f\bgent\f
\f
\f
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Page 1509 of 4402
Fuel Ch\brgi\fg \b\fd Co\ftrols - 1.8L
Dur\btorq-TDCi (74kW/100PS) -
Ly\fx/1.8L Dur\btorq-TDCi (92kW/125PS)
- Ly\fx - Fuel Pump
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Remov\bl \b\fd I\fst\bll\btio\f
Speci\bl Tool(s)
M\bt
eri\bls
Remov\bl
WA R
NINGS:\f
M\bk
e\fsure\fth\bt\fthe\ffuel\fpressure\fh\bs\fdropped\fto\fzero\f\bnd\fth\bt\fthe\ffuel\ftemper\bture\f
is\f\bt\f\bmbient\ftemper\bture.\f
W\bit\ffor\f\b\fminimum\fof\f1\fminute\f\bfter\fthe\fengine\fh\bs\fstopped\fbefore\fcommencing\f
\bny\frep\bir\fto\fthe\ffuel\finjection\fsystem.\f
205-072\f
Univers\bl\fFl\bnge\fHolding\fWrench\f
303-249\f
Remover,\fCr\bnksh\bft\fTiming\fPulley
\f
NameSpec\bf\bcat\bo\f
Silicone\fSe\bl\bnt\fLBWSE-M4G323-A4\f/\f2U7J-M4G323-AA
Thre\bd\fLocking\fMSWSK-M2G349-A7\f/\f2U7J-M2G349-AA
1. Refer\fto:\f Diesel\fFuel\fSystem\fHe\blth\f\bnd\fS\bfety\f
Pre
c\butions \f(100-00\fGener\bl\fInform\btion,\f
Des
cription\f\bnd\fOper\btion).\f
2. Remove\fthe\ftiming\fbelt.\f
Refer\fto:\f Timing\fBelt \f(303-01E\fEngine\f-\f1.8L\f
Du r
\btorq-TDCi\f(74kW/100PS)\f-\fLynx/1.8L\f
Dur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
3. CAUTION:\fUse\flint\ffree\fcloth.\f
Protect\fthe\fgener\btor\fto\fprevent\fcont\bmin\btion.\f\f
4. Cle\bn\fthe\ffuel\fpump,\ffuel\fr\bil,\fhigh-pressure\ffuel\f supply\fline\f\bnd\fsurrounding\f\bre\bs.\f
Refer\fto:\f Fuel\fInjection\fComponent\fCle\bning\f
(30
3-04D\fFuel\fCh\brging\f\bnd\fControls\f-\f1.8L\f
Dur\btorq-TDCi\f(74kW/100PS)\f-\fLynx/1.8L\f
Dur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\fGener\bl\f
Procedures).\f
5. CAUTIONS:\f
M\b
ke\fsure\fth\bt\fthe\ffuel\fline\frem\bins\fin\f
cont\bct\f\bt\fboth\fends\funtil\fboth\funions\fnuts\f
h\bve\fbeen\funscrewed\f\bnd\fthe\f\bre\b\f\bround\f
the\fjoints\fthoroughly\fcle\bned.\f
\f
\f
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Page 1516 of 4402
engine.\f
Within\fthe\ffuel\fpump\fis\f\bn\fintegr\bl\ffuel\ftr\bnsfer\fpump\fwhich\fdelivers\fthe\ffuel\ffrom\fthe\ffuel\f
t\bnk\fto\fthe\ffuel\fpump.\f
A\ffuel\fmetering\fv\blve\fis\floc\bted\fin\fthe\ffeed\fport\fto\fthe\fhigh-pressure\fch\bmber\fof\fthe\ffuel\f
pump.\fThe\ffuel\fmetering\fv\blve\fv\bries\fthe\fqu\bntity\fof\ffuel\fsupplied\fto\fthe\ffuel\fpump\f
elements,\fin\f\bccord\bnce\fwith\fdriving\fconditions.\f
At\fhigh-pressure,\fthe\ffuel\fis\fsent\fto\fthe\ffuel\fr\bil\f\bnd\fthen\fto\fthe\ffuel\finjectors\fre\bdy\ffor\ffuel\f
injection.\fDepending\fon\fengine\foper\bting\fconditions,\fthe\ffuel\finjection\fpressure\fv\bries\f
between\f\bpproxim\btely.\f350\fb\br\f\bnd\f1650\fb\br.\f
Fuel\fpressure\fis\fme\bsured\fusing\f\b\fFRP\fsensor\fon\fthe\ffuel\fr\bil.\fThe\fFRP\fsensor\fconverts\fthe\f
fuel\fsystem\fpressure\finto\f\b\fvolt\bge\fsign\bl.\fThis\fvolt\bge\fsign\bl\f\bcts\f\bs\f\bn\finput\fsign\bl\fto\fthe\f
powertr\bin\fcontrol\fmodule\f(PCM)\ffor\fc\blcul\btion\fof\fthe\fcorrect\ffuel\finjection\fqu\bntity.\f
The\fPCM\fc\blcul\btes\fthe\ftime\fof\ffuel\finjection\f\bnd\fthe\ffuel\finjection\fqu\bntity\fdepending\fon\f
v\brious\finput\fv\bri\bbles.\f
The\fspecified\fqu\bntity\fof\ffuel\fis\finjected\finto\fthe\frespective\fcombustion\fch\bmber\fthrough\f
the\fpiezo-electric\blly\f\bctu\bted\ffuel\finjectors.\fIn\fdoing\fso,\f\b\fpre-injection\f\bnd\f\b\fm\bin\f
injection\foccur\fe\bch\ftime.\f
The\fexcess\ffuel\fis\freturned\fto\fthe\ffuel\ft\bnk\fthrough\fthe\ffuel\freturn\fline.\f
The\ffuel\fpressure\fregul\btor\fon\fthe\fhigh-pressure\foutlet\fof\fthe\ffuel\fpump\fregul\btes\fthe\ffuel\f
pressure\f\bnd\fthereby\f\blso\fthe\fpressure\fwithin\fthe\ffuel\fr\bil.\f
Fuel pump
\f\f
Descriptio\f
High-pressure\foutlet\funion\f
Fuel\fpump\ffuel\fsupply\funion\f
Fuel\fmetering\fv\blve\f
Fuel\freturn\funion\f
Fuel\fpressure\fregul\btor\f
The\ffuel\fpump\fis\f\btt\bched\fto\fthe\fcylinder\fhe\bd\fon\fthe\ftr\bnsmission\fside\f\bnd\fis\fdriven\f
d i
rectly\fby\fthe\fexh\bust\fc\bmsh\bft\fthrough\f\b\fdrive\ffl\bnge.\f
Item
1
2
3
4
5
\f
P\brt Number -
-
-
-
-
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Page 1538 of 4402
![FORD S-MAX 2006 Service Owners Manual Fuel Ch\brgi\fg \b\fd Co\ftrols - 2.0L
Dur\btorq-TDCi (85kW/115PS) - DW/2.0L
Dur\btorq-TDCi (100kW/136PS) -
DW/2.0L Dur\btorq-TDCi (103kW/140PS)
- DW, Emissio\f Requireme\fts: St\bge IV -
Fuel I\](/img/11/56999/w960_56999-1537.png "FORD S-MAX 2006 Service Owners Manual Fuel Ch\brgi\fg \b\fd Co\ftrols - 2.0L
Dur\btorq-TDCi (85kW/115PS) - DW/2.0L
Dur\btorq-TDCi (100kW/136PS) -
DW/2.0L Dur\btorq-TDCi (103kW/140PS)
- DW, Emissio\f Requireme\fts: St\bge IV -
Fuel I\")
Fuel Ch\brgi\fg \b\fd Co\ftrols - 2.0L
Dur\btorq-TDCi (85kW/115PS) - DW/2.0L
Dur\btorq-TDCi (100kW/136PS) -
DW/2.0L Dur\btorq-TDCi (103kW/140PS)
- DW, Emissio\f Requireme\fts: St\bge IV -
Fuel I\fjectio\f Compo\fe\ft Cle\b\fi\fg
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Ge\fer\bl Procedures
M\bteri\bls
Ge\f
er\bl Equipme\ft CAUTION:\fUse\flint\ffree\fcloth.\f
NameSpec\bf\bcat\bo\f
Br\bke\fCle\bner3U7J-2C410-AA
Pneum\btic\fv\bcuum\fgun
1. Refer\fto:\f Solvents,\fSe\bl\bnts\f\bnd\fAdhesives \f(100-
00\f
Gener\bl\fInform\btion,\fDescription\f\bnd\f
Oper\btion).\f
Refer\fto:\f Diesel\fFuel\fSystem\fHe\blth\f\bnd\fS\bfety\f
Pre
c\butions \f(100-00\fGener\bl\fInform\btion,\f
Des
cription\f\bnd\fOper\btion).\f
2. \f
3. CAUTION:\fUse\flint\ffree\fcloth.\f
Material\b Br
\bke\fCle\bner\f(3U7J-2C410-AA) \f
4. Using\f\b\fnew\fbrush\fth\bt\fwill\fnot\flose\fits\fbristles,\f
brush\f\b\fsuit\bble\fev\bpor\btive\fcle\bning\f\bgent\fonto\f
the\fcomponents\fbeing\fremoved\f\bnd\fonto\fthe\f
surrounding\f\bre\b.\f
\f
\f
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Page 1563 of 4402
Fuel Ch\brgi\fg \b\fd Co\ftrols -
Turboch\brger - 2.0L EcoBoost SCTi
(149kW/203PS) - MI4 - Turboch\brger -
Overview
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Descriptio\f \b\fd Oper\btio\f
Cooli\fg \b\fd lubric\btio\f
Th
e\fTC\f(turboch\brger) \fis\fcooled\fby\fthe\fengine\fcool\bnt\f\bnd\foil\fcircuit.\fThe\f
engine\foil\fcircuit\f
\blso\flubric\btes\fthe\fturbine\fbe\brings.\f
Closed-loop co\ftrol
The\f TC\fis\fcontrolled\fon\fthe\fexh\bust\fside\fby\fthe\fw\bsteg\bte\fc o
ntrol\fv\blve\f\bnd\fon\fthe\fch\brge\f
\bir\fside\fby\fthe\fturboch\brger\fbyp\bss\fv\blve.\fThis\fdouble\fcontrol\fis\frequired\fin\forder\fto\f
\bchieve\foptim\bl\fturboch\brging\f\bnd\foptim\bl\fresponse\funder\f\bll\foper\bting\fconditions.\f
The\fw\bsteg\bte\fcontrol\fv\blve\fis\fclosed\fwhen\fde-energised.\fThe\fentire\fincoming\fflow\fof\f
exh\bust\fg\bs\fflows\fthrough\fthe\fexh\bust\fturbine\f\bnd\fdrives\fit.\fAs\fsoon\f\bs\fthe\fm\bximum\f
permissible\fch\brge\fpressure\fis\fexceeded,\fthe\fw\bsteg\bte\fcontrol\fv\blve\fopens\f\bnd\fguides\f
p\brt\fof\fthe\fflow\fof\fexh\bust\fg\bs\finto\fthe\fexh\bust\fsystem.\f
The\frecircul\bted\f\bir\fv\blve\fensures\fshort-term\f\bdjustments\fto\fthe\fch\brge\fpressure\fon\fthe\f
ch\brge\f\bir\fside.\fSudden\fclosing\fof\fthe\fthrottle\fpl\bte\fc\buses\fb\bckpressure\fin\fthe\fint\bke\ftr\bct\f
between\fthe\fthrottle\fpl\bte\f\bnd\fcompressor\fwheel.\fThis\fresults\fin\fsh\brp\fbr\bking\fof\fthe\f
compressor\fwheel\f\bnd\fthereby\fthe\fturbine\fsh\bft.\fWhen\fthe\fvehicle\fis\f\bcceler\bted\f\bg\bin,\fthis\f
results\fin\f\b\fsignific\bnt\floss\fof\fch\brge\fpressure\for\fpower\f(turbo-hole).\fThe\frecircul\bted\f\bir\f
v\blve\fprevents\fthis\fb\bckpressure\fby\fopening\fthe\fbyp\bss.\fThe\fbyp\bss\fguides\fthe\fch\brge\f
pressure\fb\bck\fto\fthe\fint\bke\fside\fof\fthe\fcompressor.\fThe\fturbine\fspeed\frem\bins\fconst\bnt.\f
The\frecircul\bted\f\bir\fv\blve\fis\fcontrolled\fby\f\b\fv\bcuum\fline.\fThis\fv\bcuum\fline\fis\fconnected\fto\f
the\fint\bke\fm\bnifold\fbetween\fthe\fengine\f\bnd\fthe\fthrottle\fpl\bte.\fWhen\fthe\fthrottle\fpl\bte\fis\f
suddenly\fclosed,\f\bn\fincre\bsed\fv\bcuum\foccurs\fin\fthe\fint\bke\fm\bnifold.\fThis\fc\buses\fthe\f
recircul\bted\f\bir\fv\blve\fto\fopen\fthe\fbyp\bss.\f
Rep\bir \b\fd m\bi\fte\f\b\fce i\fstructio\fs
Oil retur\f tube: If\fthe\fTC\fis\fremoved,\f\b\fnew\f TC\foil\freturn\ftube\fmust\fbe\ffitted\fduring\f
in s
t\bll\btion.\f
Turboch\brger: The\fTC\f\bnd\fthe\fexh\bust\fm\bnifold\f\bre\fone\funit\f\bnd\fmust\fnot\fbe
\fsep\br\bted\f
from\fe\bch\fother.\fIn\fthe\fevent\fof\fd\bm\bge,\fthe\fentire\funit\fmust\fbe\frepl\bced.\f
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