ESP FORD S-MAX 2006 Service Repair Manual

Exhaust\bSyste\f\b-\b2.5L\bDuratec\b
(162kW/220PS)\b-\bVI5\b-\bCatalytic\b
Converter
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Re\foval\band\bInstallation\b
Materials\b
Re\foval\b
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
NameSpec\bf\bcat\bo\f
Gre\bse\fKS-PSSA-M1C9107-A\f/\fYS5J-M1C9107-AA
1. R\bise\f\bnd\fsupport\fthe\fvehicle.\fRefer\fto:\fLifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Description\f\bnd\fOper\btion).\f
2. CAUTION:\fM\bke\fsure\fth\bt\fthe\fexh\bust\f
f l

exible\fpipe\fis\fnot\fforcibly\fbent.\f
3. \f
4. Torque:\b 47\fNm
\f
5. CAUTION:\fJointing\fcompound\fmust\fnot\f
be

\fused\fforw\brd\fof\fthe\fc\bt\blytic\fconverter.\f
NOTE:\fM\bke\fsure\fth\bt\fthe\fexh\bust\fflexible\f
pipe\fis\fnot\ftwisted.\f Co\bt\fthe\fstuds\fwith\fgre\bse.\f
Mat

er\fal:\b Gre\bse\fKS-PS\f(SA-M1C9107-A\f/\fYS5J-
M1 C

9107-AA) \f
To r

que:\b 48\fNm
\f
\f\f
\f\f
\f\f
\f\f
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Exhaust\bSyste\f\b-\b2.5L\bDuratec\b
(162kW/220PS)\b-\bVI5\b-\bExhaust\bFlexible\bPipeS-MAX/G\bl\bxy\f2006.5\f(02/2006
Re\foval\band\bInstallation\b
Materials\b
Re\foval\b
NameSpec\bf\bcat\bo\f
Gre\bse\fKS-PSSA-M1C9107-A\f/\fYS5J-M1C9107-AA1. \f\f3.
Det\bch\f
the\fA
pill\br\f
exterior\f
trim\f
p\bnel\f
lower\f
ret\bining\f
clips.
2. \f
3. \f
4. \f
\f
\f
\f\f
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Exhaust\bSyste\f\b-\b1.8L\bDuratorq-TDCi\b
(74kW/100PS)\b-\bLynx/1.8L\bDuratorq-
TDCi\b(92kW/125PS)\b-\bLynx\b-\bCatalytic\b
Converter
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Re\foval\band\bInstallation\b
Materials\b
Re\foval\b
NameSpec\bf\bcat\bo\f
Gre\bse\fKS-PSSA-M1C9107-A\f/\fYS5J-M1C9107-AA
1. R\bise\f\bnd\fsupport\fthe\fvehicle.\fRefer\fto:\fLifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Description\f\bnd\fOper\btion).\f
2. \f
3. CAUTION:\fM\bke\fsure\fth\bt\fthe\fexh\bust\f
f l

exible\fpipe\fis\fnot\fforcibly\fbent.\f
4. \f
5. CAUTION:\fM\bke\fsure\fth\bt\fthe\fexh\bust\f
fl

exible\fpipe\fis\fnot\ftwisted.\f
\f\f
\f\f
\f\f
\f\f
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Exhaust\bSyste\f\b-\b2.0L\bDuratorq-TDCi\b
(85kW/115PS)\b-\bDW/2.0L\bDuratorq-TDCi\b
(100kW/136PS)\b-\bDW/2.0L\bDuratorq-
TDCi\b(103kW/140PS)\b-\bDW,\bE\fission\b
Require\fents:\bStage\bIV\b-\bCatalytic\b
Converter
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Re\foval\band\bInstallation\b
Materials\b
Re\foval\b
Vehicles\fwith\fdiesel\fp\brticul\bte\ffilter\f
Al

l\fvehicles\f
NameSpec\bf\bcat\bo\f
Gre\bse\fKS-PSSA-M1C9107-A\f/\fYS5J-M1C9107-AA 1. \f
2. Refer\fto:\fAir\fCle\bner\f(303-12D\fInt\bke\fAir\f
Di s

tribution\f\bnd\fFiltering\f-\f1.8L\fDur\btorq-TDCi\f
(74kW/100PS)\f-\fLynx/1.8L\fDur\btorq-TDCi\f
(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\fInst\bll\btion).
\f
3. \f
4. R\bise\f\bnd\fsupport\fthe\fvehicle.\f
Refer\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
De s

cription\f\bnd\fOper\btion).\f
5. \f
6. CAUTION:\fM\bke\fsure\fth\bt\fthe\fexh\bust\f
\f\f
\f\f
\f\f
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Exhaust\bSyste\f\b-\b2.0L\bDuratorq-TDCi\b
(85kW/115PS)\b-\bDW/2.0L\bDuratorq-TDCi\b
(100kW/136PS)\b-\bDW/2.0L\bDuratorq-
TDCi\b(103kW/140PS)\b-\bDW,\bE\fission\b
Require\fents:\bStage\bIV\b-\bDiesel\b
Particulate\bFilter\b(DPF)
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Re\foval\band\bInstallation\b
Materials\b
Gen

eral\bEquip\fent\b
Re\foval\b
N O

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
NameSpec\bf\bcat\bo\f
Gre\bse\fKS-PSSA-M1C9107-A\f/\fYS5J-M1C9107-AA
Ford\fdi\bgnostic\fequipment
1. R\bise\f\bnd\fsupport\fthe\fvehicle.\fRefer\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des

cription\f\bnd\fOper\btion).\f
2. CAUTION:\fM\bke\fsure\fth\bt\fthe\fexh\bust\f
fl

exible\fpipe\fis\fnot\fforcibly\fbent.\f
3. \f
4. \f
5. CAUTION:\fM\bke\fsure\fth\bt\fthe\fexh\bust\f
f l

exible\fpipe\fis\fnot\fforcibly\fbent.\f
Co\bt\fthe\fstuds\fwith\fgre\bse.\f
\f\f
\f\f
\f\f
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Exhaust\bSyste\f\b-\b2.2L\bDuratorq-TDCi\b
(129kW/175PS)\b-\bDW\b-\bCatalytic\b
Converter
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Re\foval\band\bInstallation\b
Materials\b
Re\foval\b
NameSpec\bf\bcat\bo\f
Gre\bse\fKS-PSSA-M1C9107-A\f/\fYS5J-M1C9107-AA
1. \f
2. \f
3. R\bise\f\bnd\fsupport\fthe\fvehicle.\fRefer\fto:\f J\bcking\f(100-02\fJ\bcking\f\bnd\fLifting,\f
De s

cription\f\bnd\fOper\btion).\f
Refer\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des

cription\f\bnd\fOper\btion).\f
4. \f
5. CAUTION:\fM\bke\fsure\fth\bt\fthe\fexh\bust\f
fl

exible\fpipe\fis\fnot\fforcibly\fbent.\f
\f\f
\f\f
\f\f
\f\f
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Exhaust\bSyste\f\b-\b2.2L\bDuratorq-TDCi\b
(129kW/175PS)\b-\bDW\b-\bDiesel\bParticulate\b
Filter\b(DPF)
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Re\foval\band\bInstallation\b
Materials\b
Gen

eral\bEquip\fent\b
Re\foval\b
N O

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
NameSpec\bf\bcat\bo\f
Gre\bse\fKS-PSSA-M1C9107-A\f/\fYS5J-M1C9107-AA
Ford\fdi\bgnostic\fequipment
1. R\bise\f\bnd\fsupport\fthe\fvehicle.\fRefer\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
De s

cription\f\bnd\fOper\btion).\f
2. CAUTION:\fM\bke\fsure\fth\bt\fthe\fexh\bust\f
fl

exible\fpipe\fis\fnot\fforcibly\fbent.\f
3. \f
4. \f
5. CAUTION:\fM\bke\fsure\fth\bt\fthe\fexh\bust\f
f l

exible\fpipe\fis\fnot\fforcibly\fbent.\f
Co\bt\fthe\fstuds\fwith\fgre\bse.\f
M at

erial\b Gre\bse\fKS-PS\f(SA-M1C9107-A\f/\fYS5J-
M1 C

9107-AA) \f
Tor

\fue\b 48\fNm
\f
\f\f
\f\f
\f\f
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Fuel Sy\btem - \feneral Information -
Spring Lock Coupling\bS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
\feneral Procedure\b
Special Tool(\b)
Mat

erial\b Di\bconnect
WARNINGS:\f
Re

fer\fto:\f Petrol\f\bnd\fPetrol-Eth\bnol\fFuel\fSystems\fHe\blth\f\bnd\fS\bfe
ty\fPrec\butions\f(100-
00\f
Gener\bl\fInform\btion,\fDescription\f\bnd\fOper\btion).\f
Refer\fto:\f Diesel\fFuel\fSystem\fHe\blth\f\bnd\fS\bfety\fPrec\butions \f(100-00\fGener\bl\f
Inf

orm\btion,\fDescription\f\bnd\fOper\btion).\f
NOTE:\fFuel\fsupply\fline\fconnectors\f\bre\fcolor\fcoded\fwhite.\fFuel\freturn\fline\fconnectors\f\bre\f
color\fcoded\fred.\f
310-040\f
Disconnect\fTool,\fFuel\fLine\f(5/16")\f
310-137\f
Disconnect\fTool,\fFuel\fLine\f
310-D004\f
Disconnect\fTool,\fSpring\fLock\fCoupling\f(3/8"\fyellow)
\f
310-D005\f
Disconnect\fTool,\fSpring\fLock\fCoupling\f(1/2"\fgreen)\f
412-038\f
Disconnect\fTool,\fSpring\fLock\fCoupling\f(5/8"\fbl\bck)\f
412-069\f
Disconnect\fTool,\fSpring\fLock\fCoupling\f(3/4"\fwhite)\f
NameSpec\bf\bcat\bo\f
Engine\fOil\f-\f5W-30WSS-M2C153-G
1. Rele\bse\fthe\ffuel\fsystem\fpressure\f
Refer\fto:\f Fuel\fSystem\fPressure\fRele\bse \f(310-00\f
Fue

l\fSystem\f-\fGener\bl\fInform\btion,\fGener\bl\f
Procedures).\f
2. Special\bTool(\f):\b 310-137\f
\f
\f
\f
\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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Climate\bControl\b\fystem\b-\bGeneral\b
Information\b-\bClimate\bControl\b\fystemS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Diagnosis\band\bTesting\b
Refer\bto\bWiring\bDiagrams\b\fection\b412-00,\bfor\bschematic\band\bconnector\b
in

formation.\b\b
\fpecial\bTool(s)\b
Ge

neral\bEquipment\b
Inspection\band\bTesting\b 1. 1.\b
VERIFY\fthe\fcustomer\fconcern.\f
2

. 2.\b
Visu\blly\fCHECK\ffor\f\bny\fobvious\fmech\bnic\bl\for\felectric\bl\fd\bm\bge.\f
N

OTE:\fEnsure\fcorrect\flocking\fof\fwiring\fh\brness\fconnect
or.\f
Visual\bInspection\b
3. 3.\b
RECTIFY\f\bny\fobvious\fc\buses\ffor\f\b\fconcern\ffound\fduring\fthe\fvisu\bl\finspection\f
b
efore\fperforming\f\bny\ffurther\ftests.\fCHECK\fthe\foper\btion\fof\fthe\fsystem.\f
4. 4.\b
If\fthe\fconcern\fpersists\f\bfter\fthe\fvisu\bl\finspection,\fPERFORM\f\b\ff\bult\fdi\bgnosis\fon\f
t
he\felectronic\fengine\fm\bn\bgement,\fthe\fch\brging\fsystem,\fthe\fgeneric\felectronic\f
module\f(GEM)\f\bnd\fthe\finstrument\fcluster\f(vehicles\fwith\fEATC:\f\blso\fre\bd\fout\fthe\f
f\bult\fmemory\fof\fthe\fEATC)\fwith\fthe\f Ford\f\bpproved\fdi\bgnostic\ftool\f\bnd\fRECTIFY\f\bny\f
dis

pl\byed\ff\bults\fin\f\bccord\bnce\fwith\fthe\fdispl\byed\ff\bult\fdescription.\fCHECK\fthe\f
oper\btion\fof\fthe\fsystem.\f
5. 5.\b
On\f\b\fvehicle\fwithout\fstored\ff\bult(s),\fcontinue\f\bccording\fto\fthe\fSymptom\fCh\brt\f\bnd\f
t
he\fcorresponding\fsymptom.\f
6. 6.\b
Following\fchecking\for\felimin\btion\fof\fthe\ff\bult(s)\f\bnd\f\bfter\fcompletion\fof\foper\btions,\f
the\ff\bult\fmemories\fof\f\bll\fvehicle\fmodules\fmust\fbe\fREAD\fOUT\f\bnd\f\bny\fstored\ff\bults\f
must\fbe\fDELETED.\fREAD\fOUT\f\bll\ff\bult\fmemories\f\bg\bin\ffollowing\f\b\fro\bd\ftest.\f
Fault\bMemory\bInterrogation\bwithout\bthe\bFord\bapproved\bdiagnostic\btool\b-\bvehicles\b
with\belectronic\bautomatic\btemperature\bcontrol\b(EATC)\b
Termin\bl\fProbe\fKit\f
418-S035\f
Digit\bl\fMultimeter\f(comp\btible\fwith\fK-type\f
thermocouple)
Ford\fdi\bgnostic\fequipment
Refriger\bnt\fcenter
Thermometer\f-\fFluke\f80\fPK-8\f(FSE\fnumber\f260\f
4102\f001\f07)
Mechanica\bE\bectrica\b

Refriger\bnt\flines\f\f

Condenser\f\f

Cool\bnt\flevel\f\f

Drive\fbelt\f\f

A/C\fcompressor\f
Fuses\f\f

Wiring\fh\brness\f\f

Connector\f
\f\f
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