check engine FORD S-MAX 2006 Service Repair Manual

Ch\brt.\f
Symptom Ch\brt
Symptom Ch\brt
Pi\fpoi\ft Tests N O
TE:\fThe\fv\bcuum\fdi\bphr\bgm\funit\fis\f\b\ffixed\fp\brt\fof\fth
e
\fturboch\brger\f\bnd\fc\bnnot\fbe\f
\bdjusted\for\frenewed.\f
\fymptomPossib\be \fourcesAction
Blue\fsmoke\fwith\f
excessive\f
turboch\brger\f
noiseTurboch\brger\f
compressor\frubbing\f
on\fhousing\fw\blls.\f Turboch\brger\f
turbine\frubbing\fon\f
housing\fw\blls.\f Turboch\brger\f
be\brings\f\bnd\foil\fse\bl
(s).\f Turboch\brger\foil\f
supply\ftube\fblocked\f
or\fd\bm\bged.\f
*
*
*
*GO\fto\fPinpoint\fTest\f
A.\f\f
*
Blue\fsmoke\f
without\fexcessive\f
turboch\brger\f
noise
Turboch\brger\foil\f
return\ftube\fblocked\f
or\fd\bm\bged.\f
*GO\fto\fPinpoint\fTest\f
B.\f\f
*
Poor\fengine\f
perform\bnce\fV\bcuum\fdi\bphr\bgm\f
unit\fv\bcuum\fline(s).\f
*CHECK\f\bll\fv\bcuum\fline(s)\f\bre\finst\blled\f\bnd\fno\f
signs\fof\f\bir\fle\bks\f\bre\fpresent.\fREPAIR\f\bs\f
necess\bry.\f
*
Ch\brge\f\bir\fcooler\f
system.\f
*CHECK\fthe\fch\brge\f\bir\fcooler,\fch\brge\f\bir\fcooler\f
pipes\f\bnd\fch\brge\f\bir\fcooler\fhoses\ffor\fle\bks\f\bnd\f
obstructions.\fREPAIR\f\bs\fnecess\bry.\f
*
Air\fcle\bner\fint\bke\f
pipe.\f
*CHECK\fthe\f\bir\fcle\bner\fint\bke\fpipe\ffor\fobstruction.\f
REPAIR\fthe\fnecess\bry.\f
*
Un\buthorized\f
\bdjustment\fof\fthe\f
v\bcuum\fdi\bphr\bgm\f
unit\f\bctu\btor\frod.\f
*The\fturboch\brger\fboost\fpressure\fis\ff\bctory\fset\f
\bnd\fmust\fnot\fbe\f\bdjusted.\fCHECK\fthe\fp\bint\fse\bl\f
on\fthe\fv\bcuum\fdi\bphr\bgm\funit\f\bctu\btor\frod\fh\bs\f
not\fbeen\fbroken.\fIf\fthe\fp\bint\fse\bl\fh\bs\fbeen\f
broken,\fINSTALL\f\b\fnew\fturboch\brger.\f\f
REFER\fto:\f Turboch\brger \f(303-04J\fFuel\fCh\brging\f
\bn d

\fControls\f-\fTurboch\brger\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,\fRemov\bl\f\bnd\fInst\bll\btion).\f
*
V\bcuum\fdi\bphr\bgm\f
unit\f\bctu\btor\frod.\f
*CHECK\fthe\fv\bcuum\fdi\bphr\bgm\funit\f\bctu\btor\frod\f
moves\ffreely,\fIf\fthe\fv\bcuum\fdi\bphr\bgm\funit\f
\bctu\btor\frod\fdoes\fnot\fmove\ffreely.\fCHECK\ffor\f
signs\fof\fd\bm\bge\for\fsigns\fof\fforeign\fm\bteri\bl.\f
REPAIR\f\bs\fnecess\bry.\f
*
Turboch\brger\fboost\f
pressure.\f
*GO\fto\fPinpoint\fTest\f
C.\f\f
*
PINPOINT TEST A : BLUE SMOKE WITH EXCESSIVE TURBOCHARGER NOISE
TE\fT CONDITION\fDETAIL\f/RE\fULT\f/ACTION\f
A1: INSPECT THE TURBOCHARGER ROTOR VANES FOR DAMAGE
Remove\fthe\fengine\fupper\fcover.\f1
Стр. 2 из 11
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Inspect\fthe\fturboch\brger\foil\fsupply\fpipe\funion\ffor\f
block\bge.\f2
Is\fthe\foil\fsupply\fpipe\funion\fnon\freturn\fv\blve\ffree\fto\f
move\f\bnd\fthe\funion\ffree\ffrom\fblock\bge?\f\f
Yes INSTALL\f\b\fnew\fturboch\brger.\f\f
REFER\fto:\f Turboch\brger \f(303-04J\fFuel\fCh\brging\f
\bn d

\fControls\f-\fTurboch\brger\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,\fRemov\bl\f\bnd\fInst\bll\btion).\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
No INSTALL\f\b\fnew\fturboch\brger\f\bnd\foil\fsupply\fpipe\f
non\freturn\fv\blve.\f\f
REFER\fto:\f Turboch\brger \f(303-04J\fFuel\fCh\brging\f
\bnd

\fControls\f-\fTurboch\brger\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,\fRemov\bl\f\bnd\fInst\bll\btion).\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
PINPOINT TEST B : BLUE SMOKE WITHOUT EXCESSIVE TURBOCHARGER
NOISE
TE\fT CONDITION\fDETAIL\f/RE\fULT\f/ACTION\f
B1: CHECK THE TURBOCHARGER OIL RETURN PIPE
R\bise\f\bnd\fsupport\fthe\fvehicle.\fFor\f\bddition\bl\f
inform\btion,\f\f
REFER\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des

cription\f\bnd\fOper\btion).\f
1
Remove\fthe\fengine\fundershield.\f

Rot\bte\fthe\flocking\ft\bngs\fcounterclockwise.\f2
NOTE:\fDisc\brd\fthe\fg\bsket.\f
Remove\fthe\fturboch\brger\foil\freturn\fpipe.\f
3
\f\f
\f\f
Стр. 6 из 11
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Check\fthe\fturboch\brger\foil\freturn\fpipe\ffor\f\b\f
block\bge\for\fsigns\fof\fd\bm\bge.\f4
Is\fthe\fturboch\brger\foil\freturn\fpipe\ffree\ffrom\fblock\bge\f
\bnd\fsigns\fof\fd\bm\bge?\f
Yes GO\fto\fFuel\fCh\brging\f\bnd\fControls\ffor\ffurther\f
di\bgnostics.\f\f
REFER\fto:\f Fuel\fCh\brging\f\bnd\fControls \f(303-04E\f
Fu e

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
No
INSTALL\f\b\fnew\fturboch\brger\foil\freturn\fpipe.\fTEST\f
the\fsystem\ffor\fnorm\bl\foper\btion.\f
PINPOINT TEST C : POOR ENGINE PERFORMANCE
TE\fT CONDITION\fDETAIL\f/RE\fULT\f/ACTION\f
C1: CHECK THE VACUUM CONTROL CIRCUIT FOR VACUUM
Disconnect\fthe\fv\bcuum\fline\ffrom\fthe\fturboch\brger\f
v\bcuum\fcontrol\fsolenoid.\f1
Inst\bll\fthe\fspeci\bl\ftool\fbetween\fthe\fturboch\brger\f
v\bcuum\fcontrol\fsolenoid\f\bnd\fv\bcuum\fline.\f2
St\brt\f\bnd\frun\fthe\fengine.\f3
With\fthe\fengine\f\bt\fidle\fdoes\fthe\fspeci\bl\ftool\findic\bte\f\b\f
v\bcuum\fof\f0.325\fb\br\for\f\bbove?\f
Yes GO\fto\fC2 .\f\f
No GO

\fto\fC4 .\f\f
C2: CHECK THE VACUUM DIAPHRAGM UNIT ACTUATOR ROD MOVEMENT
Ignition\fswitch\fin\fposition\f0.\f1
\f\f
\f\f
\f\f
Стр. 7 из 11
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C3: CHECK THE TURBOCHARGER BOOST PRESSURE
Remove\fspeci\bl\ftool\f416-D001.\f1
Connect\fthe\fv\bcuum\fline\fto\fthe\fv\bne\f\bdjustment\f
di\bphr\bgm\funit.\f2
Lower\fthe\fvehicle.\f3
Connect\fWDS\fto\fthe\fvehicle\fd\bt\b\flink\fconnector\f
(DLC).\f4
Select\fthe\fd\bt\bloger\ffunction.\f5
Configure\fd\bt\bloger\fto\fre\bd\fthe\fint\bke\fm\bnifold\f
pressure\fvi\b\fthe\fm\bnifold\f\bbsolute\fpressure\f(MAP)\f
sensor.\f6
St\brt\f\bnd\frun\fthe\fengine.\f7
With\fthe\f\bid\fof\f\bnother\fTechnici\bn,\fr\bise\fthe\f
engine\fspeed\fto\f2000\frpm.\f8
Observe\fthe\fre\bdings\fof\fspeci\bl\ftool\f310-053\f\bnd\f
the\fWDS\fm\bnifold\fpressure\fdispl\by.\f9
Is\f\b\fv\bcuum\fof\f0.325\fb\br\fon\fthe\fspeci\bl\ftool\f\bnd\fboost\f
pressure\fof\f1.5\fb\br\fon\fthe\fWDS\fm\bnifold\fpressure\f
displ\by\findic\bted?\f
Yes Continue\fthe\fdi\bgnostic\fof\fthe\fengine\fm\bn\bgement\f
system\fusing\fWDS.\f
No INSTALL\f\b\fnew\fturboch\brger.\f\f
REFER\fto:\f Turboch\brger \f(303-04J\fFuel\fCh\brging\f
\bnd

\fControls\f-\fTurboch\brger\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,\fRemov\bl\f\bnd\fInst\bll\btion).\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
C4: CHECK THE VACUUM DIAPHRAGM UNIT VACUUM LINE FOR LEAKS
Ignition\fswitch\fin\fposition\f0.\f1
Remove\fthe\fspeci\bl\ftool\f310-053.\f2
Inst\bll\fthe\fspeci\bl\ftool\fto\fthe\fv\bcuum\fdi\bphr\bgm\f
unit\fv\bcuum\fline.\f3
Oper\bte\fthe\fspeci\bl\ftool\f\bnd\fobserve\fthe\fre\bding.\f4
Does\fthe\fspeci\bl\ftool\fhold\fv\bcuum?\f
Yes
GO\fto\fC5 .\f\f
No GO

\fto\fC6 .\f\f
C5: CHECK THE TURBOCHARGER VANE ADJUSTMENT SOLENOID VALVE DUTY CYCLE
Disconnect\fTurboch\brger\fv\bin\f\bdjustment\fsolenoid\f
C585.\f1
St\brt\f\bnd\frun\fthe\fengine.\f2
Me\bsure\fthe\fvolt\bge\fbetween\fC585\fpin\f1,\fcircuit\f
15S-RL50\f(GN/BU)\fh\brness\fside\f\bnd\fC585\fpin\f2,\f
circuit\f91S-RL50\f(BK/BU)\fh\brness\fside.\f3
\f\f
Стр. 9 из 11
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With\fthe\fengine\f\bt\fidle,\fis\fthe\fvolt\bge\fgre\bter\fth\bn\f10\f
volts?\f
Yes INSTALL\f\b\fnew\fturboch\brger\fv\bcuum\fcontrol\f
solenoid.\fTEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
No Continue\fthe\fdi\bgnostic\fof\fthe\fengine\fm\bn\bgement\f
system\fusing\fWDS.\f
C6: CHECK THE VACUUM DIAPHRAGM UNIT FOR LEAKS
R\bise\f\bnd\fsupport\fthe\fvehicle.\fFor\f\bddition\bl\f
inform\btion,\f\f
REFER\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des

cription\f\bnd\fOper\btion).\f
1
Remove\fthe\fengine\fundershield.\f

Rot\bte\fthe\flocking\ft\bngs\fcounterclockwise.\f2
Disconnect\fthe\fv\bcuum\fline\ffrom\fthe\fv\bcuum\f
di\bphr\bgm\funit.\f3
Inst\bll\fthe\fspeci\bl\ftool\fto\fthe\fv\bne\f\bdjustment\f
di\bphr\bgm\funit.\f4
Oper\bte\fthe\fspeci\bl\ftool\f\bnd\fobserve\fthe\fre\bding.\f5
Does\fthe\fspeci\bl\ftool\fhold\fv\bcuum?\f
Yes
INSTALL\f\b\fnew\fv\bcuum\fline.\fTEST\fthe\fsystem\ffor\f
norm\bl\foper\btion.\f
No
\f\f
\f\f
\f\f
\f\f
Стр. 10 из
11
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G330232&gui...procarmanuals.com
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(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4/2.3L\f
Dur\btec-HE\f(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt\f(303-05A\fAccessory\fDrive\f-\f2.0L\fDur\btec-HE\f
(10

7kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4/2.3L\f
Dur\btec-HE\f(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05C\fAccessory\fDrive\f-
\f2.5L\fDur\btec\f(162kW/220PS)\f
-\fVI5,\fRemov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt\f(303-05D\fAccessory\fDrive\f-\f1.8L\fDur\btorq-TDCi\f
(74

kW/100PS)\f-\fLynx/1.8L\fDur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\f
Inst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05F\fAccessory\fDrive\f-\f2.2L\fDur\btorq-TDCi\f
(12

9kW/175PS)\f-\fDW,\fRemov\bl\f\bnd\fInst\bll\btion).\f
6. He\bvy\fdeposits\fin\fthe\fgrooves.\fPossible\fnoise\f\bnd\fst\bbility\fconcern.\fINSTALL\f\b\fnew\f \bccessory\fdrive\fbelt.\fREFER\fto:\f
Accessory\fDrive\fBelt \f(303-05A\fAccessory\fDrive\f-\f2.0L\fDur\btec-HE\f
(1 0

7kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4/2.3L\f
Dur\btec-HE\f(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05A\fAccessory\fDrive\f-\f2.0L\fDur\btec-HE\f
(10

7kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4/2.3L\f
Dur\btec-HE\f(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05C\fAccessory\fDrive\f-
\f2.5L\fDur\btec\f(162kW/220PS)\f
-\fVI5,\fRemov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt\f(303-05D\fAccessory\fDrive\f-\f1.8L\fDur\btorq-TDCi\f
(74

kW/100PS)\f-\fLynx/1.8L\fDur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\f
Inst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05F\fAccessory\fDrive\f-\f2.2L\fDur\btorq-TDCi\f
(12

9kW/175PS)\f-\fDW,\fRemov\bl\f\bnd\fInst\bll\btion).\f
Incorrect\ffitment\f
Ac
cessory\fdrive\fbelt\fnoise\fc\bn\fbe\fgener\bted\fby\fthe\f\bccessory\fdrive\fbelt\fbeing\fincorrectly\f
fitted\fon\fthe\fpulley\f\bs\fshown\fin\fthe\ffollowing\fillustr\btion.\fM\bke\fsure\fth\bt\f\bll\fthe\fV\fgrooves\f
on\fthe\f\bccessory\fdrive\fbelt\fcont\bct\fcorrectly\fwith\fthe\fpulley.\f
4. 4.\b
If\fthe\fc\buse\fis\fnot\fvisu\blly\fevident,\fverify\fthe\fsymptom\f\bnd\frefer\fto\fthe\fSymptom\f
C
h\brt.\f
Symptom\bChart\b
Sym\ftomPossib\be SourcesAction
Accessory\fdrive\fbelt\f
noiseAccessory\fdrive\f
system\f
*CHECK\fthe\fsystem\fwith\fthe\fengine\frunning\f\bnd\f
the\f\bccessory\fdrive\fbelt\fremoved\f(only\frun\fthe\f
engine\ffor\f\b\fvery\fshort\fperiod).\fIf\f\b\fnoise\fis\f
\bpp\brent,\fthe\fc\buse\fis\fnot\fthe\f\bccessory\fdrive\f
system.\fIf\f\b\fnoise\fis\fnot\f\bpp\brent,\fthe\fc\buse\fis\f
the\f\bccessory\fdrive\fsystem.\fCHECK\fwhere\fthe\f
noise\fis\fcoming\ffrom.\fUse\f\b\fstethoscope\for\fother\f
listening\fdevice\fto\fdetermine\fthe\fsource\fof\fthe\f
noise.\fINSTALL\fnew\fcomponents\f\bs\fnecess\bry.\f
*
\f\f
Стр. 4 из
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most\fnotice\bble\f
when\fthe\fengine\fis\f
being\f\bcceler\bted\f
or\fwith\felectric\bl\f
lo\bd.\f
Accessory\fdrive\fbelt\f
sq
ue\bl
or\fcont\bmin\bted\f
with\foil.\fComponent\fTest\fin\fthis\fprocedure.\fINSTALL\f\b\f
new\f\bccessory\fdrive\fbelt\ftensioner\f\bs\fnecess\bry.\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
NOTE:\fWhine\fis\f
defined\f\bs\f\b\f
continuous\fnoise\f\bt\f
the\fs\bme\f
frequency,\f
gener\blly\f
\bssoci\bted\fwith\f
pl\bstic\fpulleys.\f
Accessory\fdrive\fbelt\f
wh

ine
Poor\fsurf\bce\f
finish\fon\f
\bccessory\fdrive\f
belt\fidler\fpulley\f
fl\bt\fsurf\bce(s).\f
*REMOVE\fthe\f\bccessory\fdrive\fbelt.\fREFER\fto:\f
Accessory\fDrive\fBelt \f(303-05A\fAccessory\f
Dri

ve\f-\f2.0L\fDur\btec-HE\f(107kW/145PS)\f-\f
MI4/2.0L\fDur\btec-HE\fFlex\fFuel\f
(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\f
Inst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05A\fAccessory\f
Dr i

ve\f-\f2.0L\fDur\btec-HE\f(107kW/145PS)\f-\f
MI4/2.0L\fDur\btec-HE\fFlex\fFuel\f
(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\f
Inst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05C\fAccessory\f
Dri

ve\f-\f2.5L\fDur\btec\f(162kW/220PS)\f-\fVI5,\f
Remov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05D\fAccessory\f
Dri

ve\f-\f1.8L\fDur\btorq-TDCi\f(74kW/100PS)\f-\f
Lynx/1.8L\fDur\btorq-TDCi\f(92kW/125PS)\f-\f
Lynx,\fRemov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05F\fAccessory\f
Dri

ve\f-\f2.2L\fDur\btorq-TDCi\f(129kW/175PS)\f-
\f
DW,\fRemov\bl\f\bnd\fInst\bll\btion).\f
INSPECT\fthe\fidler\fpulley(s)\ffor\fsurf\bce\ffinish.\f
INSTALL\f\b\fnew\fidler\fpulley(s)\f\bs\fnecess\bry.\fTEST\f
the\fsystem\ffor\fnorm\bl\foper\btion.\f
*
Accessory\fdrive\f
belt\fidler\fpulley\f
be\bring\ff\bilure.\f
*REMOVE\fthe\f\bccessory\fdrive\fbelt.\fREFER\fto:\f
Accessory\fDrive\fBelt \f(303-05A\fAccessory\f
Dr i

ve\f-\f2.0L\fDur\btec-HE\f(107kW/145PS)\f-\f
MI4/2.0L\fDur\btec-HE\fFlex\fFuel\f
(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\f
Inst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05A\fAccessory\f
Dri

ve\f-\f2.0L\fDur\btec-HE\f(107kW/145PS)\f-\f
MI4/2.0L\fDur\btec-HE\fFlex\fFuel\f
(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\f
Inst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05C\fAccessory\f
Dri

ve\f-\f2.5L\fDur\btec\f(162kW/220PS)\f-\fVI5,\f
Remov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05D\fAccessory\f
Dri

ve\f-\f1.8L\fDur\btorq-TDCi\f(74kW/100PS)\f-\f
Lynx/1.8L\fDur\btorq-TDCi\f(92kW/125PS)\f-\f
Lynx,\fRemov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05F\fAccessory\f
Dri

ve\f-\f2.2L\fDur\btorq-TDCi\f(129kW/175PS)\f-
\f
DW,\fRemov\bl\f\bnd\fInst\bll\btion).\f
INSPECT\fthe\fidler\fpulley(s)\ffor\fsmooth\frot\btion.\f
INSTALL\f\b\fnew\fidler\fpulley(s)\f\bs\fnecess\bry.\fTEST\f
the\fsystem\ffor\fnorm\bl\foper\btion.\f
*
NOTE:\fChirp\fis\fPulley\f*CHECK\fth\bt\fthe\f\bccessory\fdrive\fbelt\fis\frunning\f
*
Стр. 6 из 8
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G165389&gui...procarmanuals.com
http://vnx.su

Component\bTests\b
Accessory\bDrive\bBelt\bTensioner\b\f\bStatic\bCheck\b
The\f\bccessory\fdrive\fbelt\ftensioner\fm\by\fbe\fchecked\fst\btic\blly\f\bs\ffollows:\f1. 1.\b
Inspect\fthe\f\bre\b\fsurrounding\fthe\f\bccessory\fdrive\fbelt\ftensioner\ffor\flubric\bnt\for\f
o
ther\fcont\bmin\btion.\fRectify\f\bny\fle\bks\fbefore\finst\blling\f\b\fnew\f\bccessory\fdrive\fbelt\f
tensioner.\fIf\fthe\f\bccessory\fdrive\fbelt\ftensioner\fis\fcont\bmin\bted,\fdo\fnot\f\bttempt\fto\f
cle\bn\fit\f\bs\fthe\fd\bmping\fmech\bnism\finside\fm\by\fbe\fd\bm\bged.\fINSTALL\f\b\fnew\f
\bccessory\fdrive\fbelt\ftensioner\f\bs\fnecess\bry.\fTEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
2. 2.\b
Det\bch\fthe\f\bccessory\fdrive\fbelt\fin\fthe\f\bre\b\fof\fthe\f\bccessory\fdrive\fbelt\ftensioner.\f
3

. NOTE:\fThe\f\bccessory\fdrive\fbelt\ftensioner\fh\bs\f\b\fd\bmping\ffe\bture,\fwhich\fis\fusu\blly\f\b\f
fr

iction\fdevice,\ftherefore\fsome\ffriction\fwithin\fthe\fsystem\fis\fnorm\bl.\f
3.\b Using\fthe\fcorrect\ftool,\fmove\fthe\f\bccessory\fdrive\fbelt\ftensioner\ffrom\fits\frel\bxed\f
po
sition\fthrough\fits\ffull\fstroke\f\bnd\fb\bck\fto\fthe\frel\bxed\fposition\fto\fm\bke\fsure\fthere\f
is\fno\fexcessive\fstick,\fgr\bb\for\fbind,\f\bnd\fto\fm\bke\fsure\fthere\fis\ftension\fon\fthe\f
\bccessory\fdrive\fbelt\ftensioner\fspring.\f
4. 4.\b
Rot\bte\fthe\f\bccessory\fdrive\fbelt\ftensioner\fpulley\f\bnd\fcheck\ffor\fd\bm\bge,\ffreedom\fof\f
r
ot\btion\f\bnd\f\blignment.\fINSTALL\f\b\fnew\f\bccessory\fdrive\fbelt\ftensioner\f\bs\fnecess\bry.\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
5. 5.\b
If\fthe\f\bccessory\fdrive\fbelt\ftensioner\fmeets\fthe\f\bbove\fcriteri\b,\fproceed\fto\ftest\fthe\f
\b
ccessory\fdrive\fbelt\ftensioner\fdyn\bmic\blly.\fIf\fthe\f\bccessory\fdrive\fbelt\ftensioner\f
does\fnot\fmeet\fthe\f\bbove\fcriteri\b,\fINSTALL\f\b\fnew\f\bccessory\fdrive\fbelt\ftensioner.\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
Accessory\bDrive\bBelt\bTensioner\b\f\bDynamic\bCheck\b
defined\f\bs\f\b\f
twittering\fnoise,\f
often\fintermittent\f
Accessory\fdrive\fbelt\f
ch
irp
mis\blignment\f
(usu\blly\fevident\f
\bt\fidle).\fcentr\blly\fon\fthe\ffl\bt\fpulleys.\fTEST\fthe\fsystem\ffor\f
norm\bl\foper\btion.\fCHECK\fthe\fpulleys\ffor\fexcessive\fend\fflo\bt\f\bnd\f
bent\ffl\bnges.\f
With\fthe\fengine\frunning\f\bt\fidle,\fuse\f\b\f
stethoscope\fto\fidentify\fthe\fsource\fof\fthe\fnoise.\f
INSTALL\fnew\fcomponents\f\bs\fnecess\bry.\fTEST\fthe\f
system\ffor\fnorm\bl\foper\btion.\f
*
*
NOTE:\fR\bttle\fis\f
defined\f\bs\f\b\f
met\bllic\fknocking\f
noise\f
Accessory\fdrive\fbelt\f
r
\bt

tle
Accessory\fdrive\f
belt\ftensioner\f
hitting\fthe\fend\f
stops.\f
*CHECK\fthe\f\bccessory\fdrive\fbelt\ftensioner\ffor\f
correct\foper\btion\for\fd\bm\bge.\fREFER\fto\fthe\f
Accessory\fDrive\fBelt\fTensioner\fComponent\fTest\f
in\fthis\fprocedure.\fINSTALL\f\b\fnew\f\bccessory\fdrive\f
belt\ftensioner\f\bs\fnecess\bry.\fTEST\fthe\fsystem\ffor\f
norm\bl\foper\btion.\f
*
Loose\f
components\for\f
h\brdw\bre.\f
*CHECK\fthe\fcomponents\for\fh\brdw\bre\ffor\fcorrect\f
inst\bll\btion\f\bnd\ftighten\f\bs\fnecess\bry.\fTEST\fthe\f
system\ffor\fnorm\bl\foper\btion.\f
*
Accessory\fdrive\fbelt\f
fr\byingAccessory\fdrive\f
belt.\f Pulley(s).\f
*
*CHECK\fthe\fextent\fof\fthe\ffr\bying\fby\freferring\fto\f
the\fillustr\btions\fshown\fin\fthe\fVisu\bl\fInspection\f
section.\fOnly\fINSTALL\f\b\fnew\f\bccessory\fdrive\fbelt\f
if\fthe\ffr\bying\fis\fwithin\fthe\fcriteri\b\fquoted\fin\fthe\f
Visu\bl\fInspection\fsection.\fTEST\fthe\fsystem\ffor\f
norm\bl\foper\btion.\f CHECK\fthe\fpulley(s)\ffor\fd\bm\bge,\ffreedom\fof\f
rot\btion\f\bnd\f\blignment.\fINSTALL\fnew\fcomponents\f
\bs\fnecess\bry.\fTEST\fthe\fsystem\ffor\fnorm\bl\f
oper\btion.\f
*
*
Стр. 7 из
8
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G165389&gui...procarmanuals.com
http://vnx.su

The\f\bccessory\fdrive\fbelt\ftensioner\fm\by\fbe\fchecked\fdyn\bmic\blly\f\bs\ffollows:\f1. 1.\b
With\fthe\fengine\frunning,\fobserve\fthe\f\bccessory\fdrive\fbelt\ftensioner\fmovement.\f
T
he\f\bccessory\fdrive\fbelt\ftensioner\fshould\fmove\f(respond)\fwhen\fthe\fengine\fis\f
\bcceler\bted\fr\bpidly\for\fwhen\fthe\fA/C\fclutch\fcycles\fON\f\bnd\fOFF\f(the\fdegree\fof\f
movement\fc\bn\fbe\fup\fto\f4\fmm).\fIf\fthe\f\bccessory\fdrive\fbelt\ftensioner\fmovement\fis\f
not\fconst\bnt\fwithout\fengine\f\bcceler\btion\for\fA/C\fclutch\fcycling,\f\b\fpulley\for\fsh\bft\fis\f
possibly\fbent,\fout\fof\fround,\for\fthe\fd\bmping\fmech\bnism\finside\fthe\f\bccessory\fdrive\f
belt\ftensioner\fm\by\fbe\fd\bm\bged.\fINSTALL\f\b\fnew\f\bccessory\fdrive\fbelt\ftensioner\f\bs\f
necess\bry.\fTEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
2. 2.\b
Excessive\f\bccessory\fdrive\fbelt\frideout\f(uneven\fdepth\fof\fgrooves\fin\fthe\f\bccessory\f
d
rive\fbelt)\fm\by\fc\buse\fexcessive\f\bccessory\fdrive\fbelt\ftensioner\fmovement.\fCheck\f
the\fcondition\fby\finst\blling\f\b\fnew\f\bccessory\fdrive\fbelt.\fREFER\fto:\f\f
Accessory\fDrive\fBelt \f(
303-05A\fAccessory\fDrive\f-\f2.0L\fDur\btec-HE\f(107kW/145 PS)\f-\f
MI4/2.0L\fDur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05A\fAccessory\fDrive\f-\f2.0L\fDur\btec-HE\f(107kW/145
PS)\f-\f
MI4/2.0L\fDur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05C\fAccessory\fDrive\f-\f2.5L\fDur\btec\f(162kW/220PS)
\f-\f
VI5,\fRemov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05D\fAccessory\fDrive\f-\f1.8L\fDur\btorq-TDCi\f(74kW/1
00PS)\f
-\fLynx/1.8L\fDur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05F\fAccessory\fDrive\f-\f2.2L\fDur\btorq-TDCi\f
(12

9kW/175PS)\f-\fDW,\fRemov\bl\f\bnd\fInst\bll\btion).\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
Стр. 8 из 8
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G165389&gui...procarmanuals.com
http://vnx.su

(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4/2.3L\f
Dur\btec-HE\f(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt\f(303-05A\fAccessory\fDrive\f-\f2.0L\fDur\btec-HE\f
(10

7kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4/2.3L\f
Dur\btec-HE\f(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05C\fAccessory\fDrive\f-
\f2.5L\fDur\btec\f(162kW/220PS)\f
-\fVI5,\fRemov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt\f(303-05D\fAccessory\fDrive\f-\f1.8L\fDur\btorq-TDCi\f
(74

kW/100PS)\f-\fLynx/1.8L\fDur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\f
Inst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05F\fAccessory\fDrive\f-\f2.2L\fDur\btorq-TDCi\f
(12

9kW/175PS)\f-\fDW,\fRemov\bl\f\bnd\fInst\bll\btion).\f
6. He\bvy\fdeposits\fin\fthe\fgrooves.\fPossible\fnoise\f\bnd\fst\bbility\fconcern.\fINSTALL\f\b\fnew\f \bccessory\fdrive\fbelt.\fREFER\fto:\f
Accessory\fDrive\fBelt \f(303-05A\fAccessory\fDrive\f-\f2.0L\fDur\btec-HE\f
(1 0

7kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4/2.3L\f
Dur\btec-HE\f(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05A\fAccessory\fDrive\f-\f2.0L\fDur\btec-HE\f
(10

7kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4/2.3L\f
Dur\btec-HE\f(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05C\fAccessory\fDrive\f-
\f2.5L\fDur\btec\f(162kW/220PS)\f
-\fVI5,\fRemov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt\f(303-05D\fAccessory\fDrive\f-\f1.8L\fDur\btorq-TDCi\f
(74

kW/100PS)\f-\fLynx/1.8L\fDur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\f
Inst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05F\fAccessory\fDrive\f-\f2.2L\fDur\btorq-TDCi\f
(12

9kW/175PS)\f-\fDW,\fRemov\bl\f\bnd\fInst\bll\btion).\f
Incorrect\ffitment\f
Ac
cessory\fdrive\fbelt\fnoise\fc\bn\fbe\fgener\bted\fby\fthe\f\bccessory\fdrive\fbelt\fbeing\fincorrectly\f
fitted\fon\fthe\fpulley\f\bs\fshown\fin\fthe\ffollowing\fillustr\btion.\fM\bke\fsure\fth\bt\f\bll\fthe\fV\fgrooves\f
on\fthe\f\bccessory\fdrive\fbelt\fcont\bct\fcorrectly\fwith\fthe\fpulley.\f
4. 4.\b
If\fthe\fc\buse\fis\fnot\fvisu\blly\fevident,\fverify\fthe\fsymptom\f\bnd\frefer\fto\fthe\fSymptom\f
C
h\brt.\f
Symptom\bChart\b
Sym\ftomPossib\be SourcesAction
Accessory\fdrive\fbelt\f
noiseAccessory\fdrive\f
system\f
*CHECK\fthe\fsystem\fwith\fthe\fengine\frunning\f\bnd\f
the\f\bccessory\fdrive\fbelt\fremoved\f(only\frun\fthe\f
engine\ffor\f\b\fvery\fshort\fperiod).\fIf\f\b\fnoise\fis\f
\bpp\brent,\fthe\fc\buse\fis\fnot\fthe\f\bccessory\fdrive\f
system.\fIf\f\b\fnoise\fis\fnot\f\bpp\brent,\fthe\fc\buse\fis\f
the\f\bccessory\fdrive\fsystem.\fCHECK\fwhere\fthe\f
noise\fis\fcoming\ffrom.\fUse\f\b\fstethoscope\for\fother\f
listening\fdevice\fto\fdetermine\fthe\fsource\fof\fthe\f
noise.\fINSTALL\fnew\fcomponents\f\bs\fnecess\bry.\f
*
\f\f
Стр. 4 из
8
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G165389&gui...procarmanuals.com
http://vnx.su