drive FORD S-MAX 2006 Service Repair Manual

vehicle\fso\fth\bt\fit\fdoes\fnot\finterfere\fwith\fthe\fs\bfe\foper\btion\fof\fthe\fvehicle.\fDo\fnot\f
pl\bce\fthe\fFord\f\bpproved\fdi\bgnostic\ftool\fin\fthe\fdeployment\fp\bth\fof\f\bny\f\bir\fb\bg.\f
F\bilure\fto\ffollow\fthese\finstructions\fm\by\fresult\fin\fperson\bl\finjury.\f
NOTE:\fThe\fro\bd\ftest\fis\fbest\fc\brried\fout\fwith\fthe\f\bid\fof\f\bnother\ftechnici\bn\fin\fthe\f
vehicle\fto\fen\bble\fthe\fvehicle\fto\fbe\fdriven\fs\bfely\fwhile\fthe\fsensor\foutputs\f\bre\f
monitored\fwithin\fd\bt\blogger.\fIf\fthere\fis\fonly\fone\ftechnici\bn\f\bv\bil\bble,\fthe\fFord\f
\bpproved\fdi\bgnostic\ftool\fc\bn\fbe\fset\fup\f(using\fthe\frecord/c\bpture\fmode\fc\bmer\b\f
icon)\fbefore\fle\bving\fthe\fworkshop\fto\frecord\f\b\f16\fkm\f(10\fmile)\ftest.\f
NOTE:\fThe\fresults\ffrom\fthe\ftest\f\bre\fmore\fconclusive\fif\fthe\fengine\fis\fcold\fwhen\fthe\f
test\fis\fst\brted.\f
3\f C\brry\fout\f\b\fro\bd\ftest.\f\f
RE
FER\fto:\f Ro\bd/Roller\fTesting \f(100-00\fGener\bl\fInform\btion,\fDescription\f\bnd\f
Ope

r\btion).\f
4. 4\f
Drive\fthe\fvehicle\f\bt\f\b\fconst\bnt\fthrottle\fopening\f\bnd\fset\fspeed\funtil\fthe\fECT\fv\blue\f
s
ettles\finto\f\b\fsh\bllow\frise\f\bnd\ff\bll\fsign\bl,\fclose\fto\f\b\fstr\bight\fline.\fThis\findic\btes\fth\bt\f
the\fthermost\bt\fis\ffunctioning\fcorrectly.\f
NOTE:\fSome\fthermost\bts\findic\bte\fthe\ftemper\bture(s)\fin\f
Celsius\f\bnd\fF\bhrenheit.\f
The\fgr\bphic\fbelow\fshows\fthe\floc\btion\f\bnd\f\bn\fex\bmple\fof
\fthe\fopening\ftemper\bture\f(88ºC)\f
\bnd\ffully\fopen\ftemper\bture\f(102ºC)\fof\f\b\fthermost\bt.\f
The\fgr\bphic\fbelow\fshows\f\bn\f\bltern\btive\fmethod\fused\fto\fshow\fthe\fopening\ftemper\bture\f
(88ºC)\f\bnd\ffully\fopen\ftemper\bture\f(112ºC)\fof\f\b\fthermost\bt.\f
\f\f
Descripti\bn
Opening\ftemper\bture\f
Fully\fopen\ftemper\bture\f
NOTE:\fGener\blly,\fmost\fthermost\bts\fm\bint\bin\f\b\fcool\bnt\ftemper\bture\fbetween\f88ºC\f
(1
90ºF)\f\bnd\f92ºC\f(198ºF)\f\blthough\fdu\bl\fst\bge\felectric\fthermost\bts\fm\by\fincre\bse\fthe\f
cool\bnt\ftemper\bture\fup\fto\f100ºC\f(212ºF)\funder\flight\fengine\flo\bd\fconditions.\f
The\fengine\fshould\fst\brt\fcle\bnly\f\bnd\fthe\fECT\fv\blue\fwill
\frise\fquite\fquickly\fwith\fsmooth\f
progression.\fIf\fthe\fECT\fsign\bl\f\bppe\brs\funst\bble\for\ferr\btic,\fthe\fECT\fsensor,\felectric\bl\f
connector\f\bnd\fwiring\fh\brness\fto\fthe\fPCM\fneed\fto\fbe\fvisu\blly\finspected\ffor\fd\bm\bge,\fch\bfing\f
or\fw\bter\fingress.\f
The\ftemper\bture\fshould\frise\fto\f\bpproxim\btely\f90ºC\ffor\f\b\fthermost\bt\fth\bt\fh\bs\f\bn\f88ºC\f
v\blue.\fThe\fsign\bl\fv\blue\fwill\fthen\ff\bll\f\bs\fcooler\fcool\bnt\fenters\fthe\fengine.\f Item
A
B \f\f
\f\f
Part Number
-
-
Стр. 6 из 7
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If\fthe\fECT\fv\blue\ff\bils\fto\fm\bint\bin\f\b\fconst\bnt\fv\blue\f\bnd\ff\blls\fb\bck\fto\flower\ffigures,\ftypic\blly\f
between\f60ºC\f(140ºF)\f\bnd\f70ºC\f(150ºF),\fthe\fthermost\bt\f\bnd\fits\fse\bling\ffunction\fwithin\fthe\f
thermost\bt\fhousing\fmust\fbe\fchecked.\f5. 5\f
INSTALL\f\b\fnew\fthermost\bt.\f\f
R
EFER\fto:\f Thermost\bt \f(303-03E\fEngine\fCooling\f-\f2.0L\fDur\btorq-TDCi\f
(85

kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(103kW/140PS)\f-\fDW,\fRemov\bl\f\bnd\fInst\bll\btion).\f
6. 6\f
C\brry\fout\f\bnother\fro\bd\ftest\ffrom\fstep\f1\fusing\fthe\fs\bme\fcriteri\b\fto\fconfirm\fth\bt\fthe\f
c
oncern\fh\bs\fbeen\frectified.\f
7. 7\f
Using\fthe\fFord\f\bpproved\fdi\bgnostic\ftool,\fcle\br\fthe\fPCM\fkeep\f\blive\fmemory\f(KAM)\f
o
r\felectric\blly\fer\bs\bble\fprogr\bmm\bble\fre\bd\fonly\fmemory\f(EEPROM)\fso\fth\bt\fnew\f
drive\fv\blues\fc\bn\fbe\fle\brnt.\f
Стр. 7 из 7
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F\bilure\fto\ffollow\fthese\finstructions\fm\by\fresult\fin\fperson\bl\finjury.\f
NOTE:\fThe\fro\bd\ftest\fis\fbest\fc\brried\fout\fwith\fthe\f\bid\fof\f\bnother\ftechnici\bn\fin\fthe\f
vehicle\fto\fen\bble\fthe\fvehicle\fto\fbe\fdriven\fs\bfely\fwhile\fthe\fsensor\foutputs\f\bre\f
monitored\fwithin\fd\bt\blogger.\fIf\fthere\fis\fonly\fone\ftechnici\bn\f\bv\bil\bble,\fthe\fFord\f
\bpproved\fdi\bgnostic\ftool\fc\bn\fbe\fset\fup\f(using\fthe\frecord/c\bpture\fmode\fc\bmer\b\f
icon)\fbefore\fle\bving\fthe\fworkshop\fto\frecord\f\b\f16\fkm\f(10\fmile)\ftest.\f
NOTE:\fThe\fresults\ffrom\fthe\ftest\f\bre\fmore\fconclusive\fif\fthe\fengine\fis\fcold\fwhen\fthe\f
test\fis\fst\brted.\f
3\f C\brry\fout\f\b\fro\bd\ftest.\f\f
RE
FER\fto:\f Ro\bd/Roller\fTesting \f(100-00\fGener\bl\fInform\btion,\fDescription\f\bnd\f
Ope

r\btion).\f
4. 4\f
Drive\fthe\fvehicle\f\bt\f\b\fconst\bnt\fthrottle\fopening\f\bnd\fset\fspeed\funtil\fthe\fECT\fv\blue\f
s
ettles\finto\f\b\fsh\bllow\frise\f\bnd\ff\bll\fsign\bl,\fclose\fto\f\b\fstr\bight\fline.\fThis\findic\btes\fth\bt\f
the\fthermost\bt\fis\ffunctioning\fcorrectly.\f
NOTE:\fSome\fthermost\bts\findic\bte\fthe\ftemper\bture(s)\fin\f
Celsius\f\bnd\fF\bhrenheit.\f
The\fgr\bphic\fbelow\fshows\fthe\floc\btion\f\bnd\f\bn\fex\bmple\fof
\fthe\fopening\ftemper\bture\f(88ºC)\f
\bnd\ffully\fopen\ftemper\bture\f(102ºC)\fof\f\b\fthermost\bt.\f
The\fgr\bphic\fbelow\fshows\f\bn\f\bltern\btive\fmethod\fused\fto\fshow\fthe\fopening\ftemper\bture\f
(88ºC)\f\bnd\ffully\fopen\ftemper\bture\f(112ºC)\fof\f\b\fthermost\bt.\f
\f\f
Descripti\bn
Opening\ftemper\bture\f
Fully\fopen\ftemper\bture\f
NOTE:\fGener\blly,\fmost\fthermost\bts\fm\bint\bin\f\b\fcool\bnt\ftemper\bture\fbetween\f88ºC\f
(1
90ºF)\f\bnd\f92ºC\f(198ºF)\f\blthough\fdu\bl\fst\bge\felectric\fthermost\bts\fm\by\fincre\bse\fthe\f
cool\bnt\ftemper\bture\fup\fto\f100ºC\f(212ºF)\funder\flight\fengine\flo\bd\fconditions.\f
The\fengine\fshould\fst\brt\fcle\bnly\f\bnd\fthe\fECT\fv\blue\fwill
\frise\fquite\fquickly\fwith\fsmooth\f
progression.\fIf\fthe\fECT\fsign\bl\f\bppe\brs\funst\bble\for\ferr\btic,\fthe\fECT\fsensor,\felectric\bl\f
connector\f\bnd\fwiring\fh\brness\fto\fthe\fPCM\fneed\fto\fbe\fvisu\blly\finspected\ffor\fd\bm\bge,\fch\bfing\f
or\fw\bter\fingress.\f
The\ftemper\bture\fshould\frise\fto\f\bpproxim\btely\f90ºC\ffor\f\b\fthermost\bt\fth\bt\fh\bs\f\bn\f88ºC\f
v\blue.\fThe\fsign\bl\fv\blue\fwill\fthen\ff\bll\f\bs\fcooler\fcool\bnt\fenters\fthe\fengine.\f
If\fthe\fECT\fv\blue\ff\bils\fto\fm\bint\bin\f\b\fconst\bnt\fv\blue\f\bnd\ff\blls\fb\bck\fto\flower\ffigures,\ftypic\blly\f Item
A
B \f\f
\f\f
Part Number
-
-
Стр. 6 из 7
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between\f60ºC\f(140ºF)\f\bnd\f70ºC\f(150ºF),\fthe\fthermost\bt\f\bnd\fits\fse\bling\ffunction\fwithin\fthe\f
thermost\bt\fhousing\fmust\fbe\fchecked.\f5. 5\f
INSTALL\f\b\fnew\fthermost\bt.\f\f
R
EFER\fto:\f Thermost\bt \f(303-03E\fEngine\fCooling\f-\f2.0L\fDur\btorq-TDCi\f
(85

kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(103kW/140PS)\f-\fDW,\fRemov\bl\f\bnd\fInst\bll\btion).\f
6. 6\f
C\brry\fout\f\bnother\fro\bd\ftest\ffrom\fstep\f1\fusing\fthe\fs\bme\fcriteri\b\fto\fconfirm\fth\bt\fthe\f
c
oncern\fh\bs\fbeen\frectified.\f
7. 7\f
Using\fthe\fFord\f\bpproved\fdi\bgnostic\ftool,\fcle\br\fthe\fPCM\fkeep\f\blive\fmemory\f(KAM)\f
o
r\felectric\blly\fer\bs\bble\fprogr\bmm\bble\fre\bd\fonly\fmemory\f(EEPROM)\fso\fth\bt\fnew\f
drive\fv\blues\fc\bn\fbe\fle\brnt.\f
Стр. 7 из 7
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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
Стр. 1 из 2
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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
Стр. 1 из 1
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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 -
-
-
-
-
Стр. 2 из 4
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\f\fDescriptio\f
Fuel\finjector\ffuel\freturn\fline\f
Fuel\ftemper\bture\fsensor\f
Fuel\fpump\ffuel\freturn\fline\f
Fuel\ft\bnk\ffuel\freturn\fline\funion\f
The\ffuel\ftemper\bture\fsensor\fis\finst\blled\finto\fthe\ffuel\finjector\fto\ffuel\ft\bnk\ffuel\freturn\fline.\f
Th
e\ftemper\bture\fsensor\fmonitors\fthe\ftemper\bture\fof\fthe\ffuel\freturning\fto\fthe\ffuel\ft\bnk\f
from\fthe\ffuel\finjectors\f\bnd\fsends\f\b\fsign\bl\fto\fthe\fPCM.\f\f
I\fspectio\f \b\fd Verific\btio\f
WARNINGS:\f
Do\f

not\fsmoke\for\fc\brry\flighted\ftob\bcco\fof\f\bny\ftype\fwhen\fworking\fon\for\fne\br\f\bny\ffuel\f
rel\bted\fcomponents.\fHighly\ffl\bmm\bble\fmixtures\f\bre\f\blw\bys\fpresent\f\bnd\fm\by\fignite.\f
F\bilure\fto\ffollow\fthese\finstructions\fm\by\fresult\fin\fperson\bl\finjury.\f
This\fprocedure\finvolves\ffuel\fh\bndling.\fBe\fprep\bred\ffor\ffuel\fspill\bge\f\bt\f\bll\ftimes.\f
F\bilure\fto\ffollow\fthis\finstruction\fm\by\fresult\fin\fperson\bl\finjury.\f
CAUTION:\fDiesel\ffuel\finjection\fequipment\fis\fm\bnuf\bctured\fto\fvery\fprecise\ftoler\bnces\f
\bnd\ffine\fcle\br\bnces.\fIt\fis\ftherefore\fessenti\bl\fth\bt\f\bbsolute\fcle\bnliness\fis\fobserved\fwhen\f
working\fwith\fthese\fcomponents.\fAlw\bys\ffit\fbl\bnking\fplugs\fto\f\bny\fopen\forifices\for\flines.\f
NOTE:\fAs\fwell\f\bs\fc\brrying\fout\fits\fnorm\bl\ffunction\fthe\fglow\fplug\findic\btor\f\blso\f\bcts\f\bs\f\bn\f
engine\fcheck\fl\bmp\fwhich\fwill\ffl\bsh\fcontinuously\fwhen\f\b\fh\brd\fdi\bgnostic\ftrouble\fcode\f
(DTC)\fis\fdetected\fby\fthe\fpowertr\bin\fcontrol\fmodule\f(PCM).\fSoft\fDTCs\f\bre\f\blso\fstored\fby\f
the\fPCM\fbut\fwill\fonly\fbe\fknown\fif\fthe\fsystem\fis\fchecked\ffor\fDTCs\fusing\fFord\f\bpproved\f
di\bgnostic\ftool.\f
NOTE:\fIf\f\b\fDTC\fis\fdetected,\f\bll\fDTCs\fmust\fbe\fcle\bred\f\bfter\fthe\fconcern\fis\frectified.\fF\bilure\f
to\fcle\br\f\bll\fDTCs\fm\by\fc\buse\fdrive\bbility\fconcerns.\f
NOTE:\fIf\fthe\ffuel\flevel\fin\fthe\ffuel\ft\bnk\fdrops\fbelow\f\bpproxim\btely\ffour\flitres,\frough\f
running\fwill\foccur.\fThis\fis\fto\fsign\bl\fto\fthe\fdriver\fth\bt\fthe\fvehicle\frequires\frefuelling\fin\f
order\fto\fprevent\fthe\ffuel\fsystem\ffrom\frunning\fdry.\f
1. 1.
Verify\fthe\fcustomer\fconcern.\f
I

tem
1
2
3
4
\f
P\brt Number -
-
-
-
Стр. 5 из 19
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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\fjectors
S-MAX/G\bl\bxy\f2006.5\f(02/2006
Remov\bl \b\fd I\fst\bll\btio\f
Ge\fer\bl Equipme\ft
Remov\bl
Fl\bt-bl\bded\fscrewdriver
Hose\fcl\bmp\fremover/inst\bller
Long\fnose\fpliers1. Refer\fto:\fDiesel\fFuel\fSystem\fHe\blth\f\bnd\fS\bfety\f
Pr e

c\butions \f(100-
00\fGener\bl\fInform\btion,\fDescription\f\bnd\f
Oper\btion).\f
2. \f
3. General \bqui\fment: Hose\fcl\bmp\fremover/inst\bller \f
4. \f
5

. Refer\fto:\f Fuel\fInjection\fComponent\fCle\bning\f(303-
04E\f
Fuel\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\f
Requirements:\fSt\bge\fIV,\fGener\bl\fProcedures).\f
6.
CAUTIONS:
Use\f\bn\f
open-ended\f
wrench\fto\f
\f\f
\f\f
\f\f
Стр. 1 из 5
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I\fst\bll\btio\f
prevent\fthe\f
component\f
from\f
turning.
\f
M\bke\f
sure\fth\bt\f
the\ffuel\fline\f
rem\bins\fin\f
cont\bct\f\bt\f
both\fends\f
until\fboth\f
unions\fnuts\f
h\bve\fbeen\f
unscrewed\f
\bnd\fthe\f
\bre\b\f\bround\f
the\fjoints\f
thoroughly\f
cle\bned.
V\bcuum\f
\bny\fforeign\f
m\bteri\bl\f
from\fthe\f
fuel\fpump\f
\bnd\ffuel\fr\bil\f
unions\f
before\f
se\bling\fthe\f
unions\fwith\f
bl\bnking\f
c\bps.\f
M\bke\f
sure\fth\bt\f\bll\f
openings\f
\bre\fse\bled.\f
Use\fnew\f
bl\bnking\f
c\bps.\f
General
\bqui\fment:
Fl\bt-bl\bded\f
screwdriver
7. \f
\f
\f\f
Стр. 2 из 5
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G543699&gui...procarmanuals.com
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