FORD S-MAX 2006 Service Repair Manual

Is\fthe\fresist\bnce\fless\fth\bn\f1\fohm?\f
Yes\bINSTALL\f\b\fnew\fst\brter\frel\by.\fTEST\fthe\fsystem\ffor\f
norm\bl\foper\btion.\f
No\b For\fvehicles\fwith\f1.8L\fDur\btorq\fTDCi\f(Kent)\fDiesel\f
\bnd\f2.0L\fDur\btorq\fTDCi\f(DW)\fDiesel,\f GO\fto\fA4.\f\f
Fo r

\fvehicles\fwith\f2.0L\fDur\btec\fHE\f(MI4),\f GO\fto\fA5.\f\f
For

\fvehicles\fwith\f2.5L\fDur\btec\fST\f(VI5),\f GO\fto\fA6.\f\f
A4:\bCHECK\bCIRCUIT\bCDC12A\b(YE)\bFOR\bCONTINUITY
Ignition\fswitch\fin\fposition\f0.\f1\b
Disconnect\fPCM\fC1E108-K.\f2\b
Me\bsure\fthe\fresist\bnce\fbetween\fthe\fBJB\fst\brter\frel\by\f
R1\fconnector\fpin\f2,\fcircuit\fCDC12A\f(YE)\f\bnd\fthe\fPCM\f
C1E108-K\fpin\fK2,\fcircuit\fCDC12A\f(YE),\fh\brness\fside.\f
3\b
Is\fthe\fresist\bnce\fless\fth\bn\f1\fohm?\f
Yes\b
Using\fthe\fWDS,\fCHECK\ffor\fcurrent\fDTCs.\fCORRECT\f
\bll\fDTCs.\fTEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\fIf\f
the\fconcern\fpersists,\fINSTALL\f\b\fnew\fPCM.\fTEST\fthe\f
system\ffor\fnorm\bl\foper\btion.\f
No\b REPAIR\fthe\fcircuit.\fTEST\fthe\fsystem\ffor\fnorm\bl\f
oper\btion.\fIf\fthe\fconcern\fpersists,\fINSTALL\f\b\fnew\f
BJB.\fTEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
A5:\bCHECK\bCIRCUIT\bCDC12A\b(YE)\bFOR\bCONTINUITY
Ignition\fswitch\fin\fposition\f0.\f1\b
Disconnect\fPCM\fC1E104-E.\f2\b
Me\bsure\fthe\fresist\bnce\fbetween\fthe\fBJB\fst\brter\frel\by\f
R1\fconnector\fpin\f2,\fcircuit\fCDC12A\f\bnd\fthe\fPCM\f
C1E104-E\fpin\fL2,\fcircuit\fCDC12A\f(YE),\fh\brness\fside.\f
3\b
Is\fthe\fresist\bnce\fless\fth\bn\f1\fohm?\f
Yes\b Using\fthe\fWDS,\fCHECK\ffor\fcurrent\fDTCs.\fCORRECT\f
\f\f
\f\f
\f\f
Стр. 4 из
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\bll\fDTCs.\fTEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\fIf\f
the\fconcern\fpersists,\fINSTALL\f\b\fnew\fPCM.\fTEST\fthe\f
system\ffor\fnorm\bl\foper\btion.\f
No\b
REPAIR\fthe\fcircuit.\fTEST\fthe\fsystem\ffor\fnorm\bl\f
oper\btion.\fIf\fthe\fconcern\fpersists,\fINSTALL\f\b\fnew\f
BJB.\fTEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
A6:\bCHECK\bCIRCUIT\bCDC35G\b(BU/WH)\bFOR\bCONTINUITY
Ignition\fswitch\fin\fposition\f0.\f1\b
Disconnect\fPCM\fC1E108-B.\f2\b
Me\bsure\fthe\fresist\bnce\fbetween\fthe\fBJB\fst\brter\frel\by\f
R1\fconnector\fpin\f1,\fcircuit\fCDC35G\f(BU/WH),\f
h\brness\fside\f\bnd\fthe\fPCM\fC1E108-B\fpin\f17,\fcircuit\f
CDC35G\f(BU/WH),\fh\brness\fside.\f
3\b
Is\fthe\fresist\bnce\fless\fth\bn\f1\fohm?\f
Yes\b GO\fto\fA7.\f\f
No\b
R

EPAIR\fcircuit\fCDC35G\f(BU/WH).\fTEST\fthe\fsystem\f
for\fnorm\bl\foper\btion.\fIf\fthe\fconcern\fpersists,\f
INSTALL\f\b\fnew\fBJB.\fTEST\fthe\fsystem\ffor\fnorm\bl\f
oper\btion.\f
A7:\bCHECK\bCIRCUIT\bCDC12A\b(YE)\bFOR\bCONTINUITY
Disconnect\fBJB\fC1E108-B.\f1\b
Me\bsure\fthe\fresist\bnce\fbetween\fthe\fBJB\fst\brter\frel\by\f
R1\fconnector\fpin\f2,\fcircuit\fCDC12A\f(YE),\fh\brness\f
side\f\bnd\fthe\fPCM\fC1E108-B\fpin\f9,\fcircuit\fCDC12A\f
(YE),\fh\brness\fside.\f
2\b
Is\fthe\fresist\bnce\fless\fth\bn\f1\fohm?\f
Yes\b Using\fthe\fWDS,\fCHECK\ffor\fcurrent\fDTC's.\fCORRECT\f
\bll\fDTC's.\fTEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\fIf\f
the\fconcern\fpersists,\fINSTALL\f\b\fnew\fPCM.\fTEST\fthe\f
system\ffor\fnorm\bl\foper\btion.\f
No\b
REPAIR\fcircuit\fCDC12A\f(YE).\fTEST\fthe\fsystem\ffor\f
norm\bl\foper\btion.\fIf\fthe\fconcern\fpersists,\fINSTALL\f\b\f
new\fBJB.\fTEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
PINPOINT\bTEST\bB\b:\bTHE\bENGINE\bDOES\bNOT\bCRANK\bBUT\bTHE\bRELAY\bCLICKS\b
TE\fT CONDITION\fDETAIL\f/RE\fULT\f/ACTION\f
B1:\bCHECK\bCIRCUIT\bCDC35B\b(GN/RD)\bFOR\bVOLTAGE
Ignition\fswitch\fin\fposition\fIII.\f1\b
Me\bsure\fthe\fvolt\bge\fbetween\fthe\fst\brter\fmotor\f
solenoid\fC1DC35-B-1\fcircuit\fCDC35B\f(GN/RD),\f
component\fside\f\bnd\fground.\f2\b
\f\f
\f\f
Стр. 5 из 8
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Is\fthe\fvolt\bge\fgre\bter\fth\bn\f10\fvolts?\f
Yes\bGO\fto\fB2.\f\f
No \b
GO

\fto\fB3.\f\f
B2:\bCHECK\bCIRCUIT\bSBF01A\b(RD)\bFOR\bVOLTAGE\bDROP
Ignition\fswitch\fin\fposition\fIII.\f1\b
Me\bsure\fthe\fvolt\bge\fbetween\fst\brter\fmotor\f
solenoid\fC1DC35-A-1\fcircuit\fSBF01A\f(RD),\f
component\fside\f\bnd\fthe\fb\bttery\fpositive\ftermin\bl.\f2\b
Is\fthe\fvolt\bge\fless\fth\bn\f2\fvolts?\f
Yes\b CLEAN\f\bnd\fTIGHTEN\f\bll\fb\bttery\fpositive\fc\bble\f
connections.\fTEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
If\fthe\fconcern\fpersists,\fINSTALL\f\b\fnew\fst\brter\f
motor.\f\f
REFER\fto:\f St\brter\fMotor \f(303-06A\fSt\brting\fSystem\f
-\f 2

.0L\fDur\btec-HE\f(107kW/145PS)\f-\fMI4/2.0L\f
Dur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4/2.3L\f
Dur\btec-HE\f(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\f
Inst\bll\btion)\f/\f\f
St\brter\fMotor\f(303-06B\fSt\brting\fSystem\f-\f2.5L\f
Dur\btec-ST\f(VI5),\fRemov\bl\f\bnd\fInst\bll\btion)\f/\f\f
St\brter\fMotor\f(303-06C\fSt\brting\fSystem\f-\f1.8L\f
Dur\btorq-TDCi\f(Kent)\fDiesel,\fRemov\bl\f\bnd\f
Inst\bll\btion)\f/\f\f
St\brter\fMotor\f(303-06D\fSt\brting\fSystem\f-\f2.0L\f
Dur\btorq-TDCi\f(DW)\fDiesel,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
No\b CLEAN\f\bnd\fTIGHTEN\f\bll\fb\bttery\fpositive\fc\bbles\f
connections.\fTEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
If\fthe\fconcern\fpersists,\fINSTALL\f\b\fnew\fb\bttery\fto\f
st\brter\fmotor\fsolenoid\fc\bble.\fTEST\fthe\fsystem\ffor\f
norm\bl\foper\btion.\f
B3:\bCHECK\bTHE\bSTARTER\bRELAY\bCONTACT\bCIRCUIT\bFOR\bVOLTAGE
Disconnect\fSt\brter\fRel\by\fR1.\f1\b
Me\bsure\fthe\fvolt\bge\fbetween\fthe\fBJB\fst\brter\frel\by\f
R1\fconnector\fpin\f3\f\bnd\fground.\f2\b
\f\f
\f\f
Стр. 6 из 8
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Is\fthe\fvolt\bge\fgre\bter\fth\bn\f10\fvolts?\f
Yes\bGO\fto\fB4.\f\f
No\b I

NSTALL\f\b\fnew\fBJB.\fTEST\fthe\fsystem\ffor\fnorm\bl\f
oper\btion.\f
B4:\bCHECK\bCIRCUIT\bCDC35\b(BU/WH)\bFOR\bCONTINUITY
Ignition\fswitch\fin\fposition\f0.\f1\b
Me\bsure\fthe\fresist\bnce\fbetween\fthe\fBJB\fst\brter\f
rel\by\fR1\fconnector\fpin\f5\f\bnd\fthe\fst\brter\fmotor\f
solenoid\fC1DC35-B\fpin\f1,\fcircuit\fCDC35B\f(BU/WH).\f2\b
Is\fthe\fresist\bnce\fless\fth\bn\f1\fohm?\f
Yes\b INSTALL\f\b\fnew\fst\brter\frel\by.\fTEST\fthe\fsystem\ffor\f
norm\bl\foper\btion.\fIf\fthe\fconcern\fpersists,\fINSTALL\f
\b\fnew\fBJB.\fTEST\fthe\fsystem\ffor\fcorrect\foper\btion.\f
No\b REPAIR\fcircuit\fCDC35A\f(BU/WH)\for\fcircuit\fCDC35B\f
(BU/WH)\f\bs\fnecess\bry.\fTEST\fthe\fsystem\ffor\fcorrect\f
oper\btion.\f
PINPOINT\bTEST\bC\b:\bTHE\bENGINE\bCRANKS\bSLOWLY\b
TE\fT CONDITION\fDETAIL\f/RE\fULT\f/ACTION\f
C1:\bCHECK\bTHE\bBATTERY\bVOLTAGE\bAND\bCONDITION
CHECK\fthe\fb\bttery\fusing\f\b\fb\bttery\ftester.\f1\b
Is\fthe\fb\bttery\fvolt\bge\f\bnd\fcondition\fOK?\f
Yes\bGO\fto\fC2 .\f\f
No\b
C

HARGE\for\finst\bll\f\b\fnew\fb\bttery\f\bs\frequired.\f
CHECK\fthe\fch\brging\fsystem\fusing\fWDS.\fTEST\fthe\f
system\ffor\fnorm\bl\foper\btion.\f
C2:\bCHECK\bCIRCUIT\bSBF01A\b(RD)\bFOR\bVOLTAGE\bDROP
Ignition\fswitch\fin\fposition\fIII.\f1\b
Me\bsure\fthe\fvolt\bge\fbetween\fst\brter\fmotor\f
solenoid\fC1DC35-A-1\fcircuit\fSBF01A\f(RD),\f
component\fside\f\bnd\fthe\fb\bttery\fpositive\ftermin\bl.\f2\b
\f\f
\f\f
Стр. 7 из 8
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Is\fthe\fvolt\bge\fless\fth\bn\f2\fvolts?\f
Yes\bGO\fto\fC3 .\f\f
No \b
C

LEAN\f\bnd\fTIGHTEN\f\bll\fb\bttery\fpositive\fc\bbles\f
connections.\fTEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
If\fthe\fconcern\fpersists,\fINSTALL\f\b\fnew\fb\bttery\fto\f
st\brter\fmotor\fsolenoid\fc\bble.\fTEST\fthe\fsystem\ffor\f
norm\bl\foper\btion.\f
C3:\bCHECK\bFOR\bGROUND\bCONNECTION
Ignition\fswitch\fin\fposition\fIII.\f1\b
Me\bsure\fthe\fvolt\bge\fbetween\fthe\fst\brter\fmotor\f
housing\f\bnd\fthe\fb\bttery\fneg\btive\ftermin\bl.\f2\b
Is\fthe\fvolt\bge\fless\fth\bn\f2\fvolts?\f
Yes\b INSTALL\f\b\fnew\fst\brter\fmotor.\f\f
REFER\fto:\f St\brter\fMotor \f(303-06A\fSt\brting\fSystem\f
-\f 2

.0L\fDur\btec-HE\f(107kW/145PS)\f-\fMI4/2.0L\f
Dur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4/2.3L\f
Dur\btec-HE\f(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\f
Inst\bll\btion)\f/\f\f
St\brter\fMotor\f(303-06B\fSt\brting\fSystem\f-\f2.5L\f
Dur\btec-ST\f(VI5),\fRemov\bl\f\bnd\fInst\bll\btion)\f/\f\f
St\brter\fMotor\f(303-06C\fSt\brting\fSystem\f-\f1.8L\f
Dur\btorq-TDCi\f(Kent)\fDiesel,\fRemov\bl\f\bnd\f
Inst\bll\btion)\f/\f\f
St\brter\fMotor\f(303-06D\fSt\brting\fSystem\f-\f2.0L\f
Dur\btorq-TDCi\f(DW)\fDiesel,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
No\b
CLEAN\f\bnd\fTIGHTEN\f\bll\fb\bttery\fneg\btive\fc\bble\f
connections\f\bnd\fst\brter\fmotor\fmountings.\fTEST\fthe\f
system\ffor\fnorm\bl\foper\btion.\fIf\fthe\fconcern\f
persists,\fINSTALL\f\b\fnew\fb\bttery\fneg\btive\fc\bble.\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
\f\f
\f\f
Стр. 8 из
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Starting\bSyste\f\b-\b2.0L\bDuratec-HE\b
(107kW/145PS)\b-\bMI4/2.0L\bDuratec-HE\b
Flex\bFuel\b(107kW/145PS)\b-\bMI4/2.3L\b
Duratec-HE\b(118kW/160PS)\b-\bMI4\b-\b
Starter\bMotor
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Re\foval\band\bInstallation\b
Re\foval\b
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
1. Disconnect\fthe\fb\bttery\fground\fc\bble.\f
Re
fer\fto:\f B\bttery\fDisconnect\f\bnd\fConnect\f(414-
01 \f

B\bttery,\fMounting\f\bnd\fC\bbles,\fGener\bl\f
Procedures).\f
2. R\bise\f\bnd\fsupport\fthe\fvehicle.\f
Refer\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des

cription\f\bnd\fOper\btion).\f
3. \f
4. \f\f 1.Torque:\b 6\fNm
\f
2. Torque:\b 12\fNm
\f
3. Torque:\b 20\fNm
\f
5. \f\f 1.Torque:\b 40\fNm
\f
2. Retighten\fthe\fbolts.\f
Torque:\b 40\fNm
\f
6. Disc\brd\fthe\fst\brter\fmotor\fg\bsket.\f
\f\f
\f\f
\f\f
Стр. 1 из
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Installation\b1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f
\f
Стр. 2 из 2
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Starting\bSyste\f\b-\b2.0L\bDuratec-HE\b
(107kW/145PS)\b-\bMI4/2.0L\bDuratec-HE\b
Flex\bFuel\b(107kW/145PS)\b-\bMI4/2.3L\b
Duratec-HE\b(118kW/160PS)\b-\bMI4\b-\bStart\b
Inhibit\bSwitch
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Re\foval\band\bInstallation\b
Re\foval\b
CA
UTION:\fM\bke\fsure\fth\bt\fthe\fclutch\fped\bl\frem\bins\fin\fth
e\frest\fposition.\f
Installation\b CAUTION:\fM\bke\fsure\fth\bt\fthe\fclutch\fped\bl\frem\bins\fin\ft h
e\frest\fposition.\f
1. \f
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f\f
Стр. 1 из
1
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Starting\bSyste\f\b-\b2.0L\bEcoBoost\bSCTi\b
(149kW/203PS)\b-\bMI4\b-\bStarter\bMotorS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Re\foval\band\bInstallation\b
Re\foval\b
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
1. Refer\fto:\f B\bt
tery\fDisconnect\f\bnd\fConnect\f(414-
01\f
B\bttery,\fMounting\f\bnd\fC\bbles,\fGener\bl\f
Procedures).\f
2. \f
3. \f
4. Refer\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
De s

cription\f\bnd\fOper\btion).\f
5. Torque:\b 12\fNm
\f
6. Torque:\b 12\fNm
\f
\f\f
\f
\f
Стр. 1 из
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Installation\b7.
Torque:\b
1
\f48\fNm
\f
2\f12\fNm
\f
3\f10\fNm
\f
8. NOTE:\fM\bke\fsure\fth\bt\f\b\fnew\fcomponent\fis\f
in

st\blled.\f
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f
\f
\f\f
\f\f
Стр. 2 из 2
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