ESP FORD S-MAX 2006 Service Repair Manual

Climate\bControl\b\f\bAir\bConditioning\b(A/C)\b
Pressure\bSensorS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal\band\bInstallation\b
Materials\b
Removal\b
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
Installation\b
NameSpec\bf\bcat\bo\f
Compressor\fOil\f-\fAir\fConditioningWSH-M1C231-B\f/\f6U7J-M1C231-AA 1. Refer\fto:\f Air\fConditioning\f(A/C)\fSystem\fHe\blth\f
\bnd

\fS\bfety\fPrec\butions\f(100-00\fGener\bl\f
In f

orm\btion,\fDescription\f\bnd\fOper\btion).\f
2. Torque:\b 8\fNm
\f
1. Co\bt\fthe\fO-rings\fon\fthe\frefriger\bnt\flines.\f Mater\fal:\b Compressor\fOil\f-\fAir\fConditioning\f
(WS

H-M1C231-B\f/\f6U7J-M1C231-AA) \f
2. T

o\finst\bll,\freverse\fremov\bl\fprocedure\f
\f\f
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Climate\bControl\b\f\bThermostatic\bExpansion\b
ValveS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal\band\bInstallation\b
Materials\b
Removal\b
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f\f
Vehicles\fwith\f1.8L\fdiesel\fengine\f
V e

hicles\fwith\f2.5L\fengine\f
Vehicles\fwith\f2.0L\fengine\f
NameSpec\bf\bcat\bo\f
Compressor\fOil\f-\fAir\fConditioningWSH-M1C231-B\f/\f6U7J-M1C231-AA 1. Ev\bcu\bte\fthe\f\bir\fconditioning\f(A/C)\fsystem.\fRefer\fto:\f Air\fConditioning\f(A/C)\fSystem\f
Re c

overy,\fEv\bcu\btion\f\bnd\fCh\brging \f(412-00\f
Cli

m\bte\fControl\fSystem\f-\fGener\bl\fInform\btion,\f
Gener\bl\fProcedures).\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. CAUTION:\fThe\finside\fsurf\bces\fof\fthe\f
e n

ds\fof\fthe\fpipe\fmust\fbe\fcle\bn\f\bnd\ffree\ffrom\f
oil\fresidues.\f Torque:\b 10\fNm
\f
5. \f
\f\f
\f\f
\f\f
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Climate\bControl\b\f\bReceiver\bDrierS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal\band\bInstallation\b
Materials\b
Removal\b
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f\f
NameSpec\bf\bcat\bo\f
Compressor\fOil\f-\fAir\fConditioningWSH-M1C231-B\f/\f6U7J-M1C231-AA
1. Ev\bcu\bte\fthe\f\bir\fconditioning\f(A/C)\fsystem.\fRefer\fto:\f Air\fConditioning\f(A/C)\fSystem\f
Re c

overy,\fEv\bcu\btion\f\bnd\fCh\brging \f(412-00\f
Cli

m\bte\fControl\fSystem\f-\fGener\bl\fInform\btion,\f
Gener\bl\fProcedures).\f
2. Remove\fthe\fright-h\bnd\fhe\bdl\bmp\f\bssembly.\f
Refer\fto:\f He\bdl\bmp\fAssembly \f(417-01\fExterior\f
Lig

hting,\fRemov\bl\f\bnd\fInst\bll\btion).\f
3. Torque:\b 5\fNm
\f
4. \f
5. 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
6. \f
7. \f
\f\f
\f\f
\f\f
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Climate\bControl\b\f\bCondenserS-MAX/G\bl\bxy\f2006.5\f(02/2006
\fPrint
Removal\band\bInstallation\b
Materials\b
Removal\b
NO
TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f\f
NameSpec\bf\bcat\bo\f
Compressor\fOil\f-\fAir\fConditioningWSH-M1C231-B\f/\f6U7J-M1C231-AA
1. Ev\bcu\bte\fthe\f\bir\fconditioning\f(A/C)\fsystem.\fRefer\fto:\f Air\fConditioning\f(A/C)\fSystem\fRecovery,\f
Ev \b

cu\btion\f\bnd\fCh\brging\f(412-00\fClim\bte\fControl\f
Sys

tem\f-
\fGener\bl\fInform\btion,\fGener\bl\fProcedures).
2. Remove\fthe\fright-h\bnd\fhe\bdl\bmp\f\bssembly.\f
Refer\fto:\f He\bdl\bmp\fAssembly \f(417-01\fExterior\f
Lig

hting,\fRemov\bl\f\bnd\fInst\bll\btion).\f
3. \f\f1.
Torque:\b
5\fNm
2.Torque:\b
24\fNm
4. \f
5. 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
6. \f
\f
\f\f
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Climate\bControl\b\f\bCondenser\bto\bEvaporator\b
LineS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal\band\bInstallation\b
Materials\b
Removal\b
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
Vehicles\fwith\f\bddition\bl\f\bir\fconditioning\fsystem\f
NameSpec\bf\bcat\bo\f
Compressor\fOil\f-\fAir\fConditioningWSH-M1C231-B\f/\f6U7J-M1C231-AA 1. C\brry\fout\fthe\f\bir\fconditioning\f(A/C)\fsystem\frecovery\fprocedure.\f
Refer\fto:\f Air\fConditioning\f(A/C)\fSystem\f
Re c

overy,\fEv\bcu\btion\f\bnd\fCh\brging \f(412-00\f
Cli

m\bte\fControl\fSystem\f-\fGener\bl\fInform\btion,\f
Gener\bl\fProcedures).\f
2. Remove\fthe\fright-h\bnd\fhe\bd\fl\bmp\funit.\f
Refer\fto:\f He\bdl\bmp\fAssembly \f(417-01\fExterior\f
Lig

hting,\fRemov\bl\f\bnd\fInst\bll\btion).\f
3. Torque:\b 24\fNm
\f
4. Torque:\b 8\fNm
\f
5. R\bise\fvehicle.\f Refer\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des

cription\f\bnd\fOper\btion).\f
6. \f
\f\f
\f\f
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Climate\bControl\b\f\bClimate\bControl\bHousing—
Vehicles\bWith:\bManual\bTemperature\bControlS-MAX/G\bl\bxy\f2006.5\f(02/2006
\fPrint
Disassembly\band\bAssembly\b
Special\bTool(s)\b
Mat
erials\b
Disassembly\b
N O

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
412-131\f
Remover/Inst\bller,\fBlower\fEngine
\f
NameSpec\bf\bcat\bo\f
Compressor\fOil\f-\fAir\fConditioningWSH-M1C231-B\f/\f6U7J-M1C231-AA
1. \f
2. \f\f1.
Torque:\b
4\fNm
\f
\f
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Climate\bControl\b\f\bClimate\bControl\bHousing—
Vehicles\bWith:\bAutomatic\bTemperature\b
Control
S-MAX/G\bl\bxy\f2006.5\f(02/2006
\fPrint
Disassembly\band\bAssembly\b
Special\bTool(s)\b
Mat
erials\b
Disassembly\b
N O

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
412-131\f
Remover/Inst\bller,\fBlower\fEngine
\f
NameSpec\bf\bcat\bo\f
Compressor\fOil\f-\fAir\fConditioningWSH-M1C231-B\f/\f6U7J-M1C231-AA
1. \f
2. \f\f1.
Torque:\b
4\fNm
\f
\f
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Time\f\bnd\fd\bte\fsetting\f
With\fthe\ffirst\foption,\fthe\ffuel-fired\f\bddition\bl\fhe\bter\fwill\fst\brt\frepe\btedly\fwithout\fneeding\fto\f
be
\freprogr\bmmed.\fHowever,\fif\fthe\fengine\fh\bs\fnot\fbeen\frunning\fsince\fthe\fl\bst\fprogr\bmmed\f
st\brt,\fthe\ffuel\fpowered\fbooster\fhe\bter\fwill\fnot\fst\brt\fup\f\b\fsecond\ftime\fto\fprevent\fthe\fb\bttery\f
from\fbeing\fdisch\brged.\f
The\flength\fof\ftime\frequired\fto\fpre-he\bt\fthe\fvehicle\fis\fc\blcul\bted\fin\fthe\fcontrol\funit\fof\f
the\ffuel-fired\f\bddition\bl\fhe\bter\f\bnd\fis\fb\bsed\fon\ftwo\ftemper\bture\fv\blues:\f

Ambient\f\bir\ftemper\bture:\fthis\fmess\bge\fis\ft\bken\ffrom\fthe\fGeneric\fElectronic\fModule\f
(GE

M)\fvi\b\fthe\fCAN\fbus.\f\f

Cool\bnt\ftemper\bture:\fthis\fis\fdetermined\fvi\b\f\bn\fintern\bl\fsensor\fin\fthe\ffuel-fired\f\bddition\bl\f
he

\bter.\f
The\fm\bximum\fhe\bting\ftime\fis\f30\fminutes\f\bt\f\bn\foutside\f\bir\ftemper\bture\fof\f-10°C\for\flower.\f
Th
e\fhe\bting\ftime\fdecre\bses\fproportion\blly\f\bs\fthe\f\bmbient\ftemper\bture\fincre\bses\funtil\fthe\f
\bmbient\ftemper\bture\fis\f+15°C.\fThen\fthe\fminimum\fhe\bting\ftime\fis\f10\fminutes.\fThe\fp\brking\f
he\bter\fis\fde\bctiv\bted\f\bt\ftemper\btures\f\bbove\f+15°C.\f
The\fsequence\ffor\f\b\fprogr\bmmed\fst\brt\fof\fthe\ffuel\fpowered\fbooster\fhe\bter\fis\f\bs\f
follows:\f

Two\fminutes\fbefore\fthe\fst\brt\fof\fthe\fm\bximum\fhe\bting\ftime\fthe\fdriver\finform\btion\f
sy

stem/instrument\fcluster\fsends\f\bn\f\bctiv\btion\fmess\bge\fto\fthe\ffuel-fired\f\bddition\bl\fhe\bter\f
vi\b\fthe\fCAN\fbus.\f\f

The\ffuel-fired\f\bddition\bl\fhe\bter\fc\blcul\btes\fthe\frequired\fhe\bting\ftime\f\bnd,\fif\fnecess\bry,\f
se

nds\f\b\fdel\by\frequest\fon\fthe\fCAN\fbus.\f\f

At\fthe\fc\blcul\bted\ftime,\fthe\ffuel-fired\f\bddition\bl\fhe\bter\fst\brts\fup.\fThe\fconditions\ffor\fst\brt-
up

\f\bre:\fengine\fnot\frunning\f\bnd\ffuel\flevel\f\bbove\f14%\fof\ftot\bl\fc\bp\bcity.\f\f

When\fthe\fcool\bnt\ftemper\bture\fre\bches\f\bround\f+30°C\f,\fthe\ffuel-fired\f\bddition\bl\fhe\bter\f
se

nds\f\b\frequest\fto\fswitch\fon\fthe\fp\bssenger\fcomp\brtment\fblower.\f\f

Eight\fminutes\f\bfter\fthe\fprogr\bmmed\fswitch-off\ftime,\fthe\ffuel\fpowered\fbooster\fhe\bter\f
st

ops\fhe\bting\fmode\f\bnd\fst\brts\f\b\frun-on\foper\btion\fto\fcle\bn\fthe\fsystem's\fsp\brk\fplugs.\f\f

Ten\fminutes\f\bfter\fthe\fswitch-off\ftime,\fthe\fpost-cle\bning\foper\btion\fis\fcomplete.\fThe\f
\bdd

ition\bl\ften\fminutes\frun-on\ftime\fprovides\fsome\fleew\by\fin\fc\bse\fthe\fdriver\fis\fl\bte\f
\brriving.\f
After\f\b\fprogr\bmmed\fst\brt-up\fof\fthe\ffuel\fpowered\fbooster\fhe\bter,\fit\fis\fswitched\foff\f\bg\bin\f
\bfter\fthe\fhe\bting\ftime\fh\bs\fel\bpsed\f(or\fif\fthe\ffuel\flevel\fin\fthe\ffuel\ft\bnk\fdrops\fbelow\f8%).\fThe\f
fuel\fpowered\fbooster\fhe\bter\fstops\fwithin\f2\fminutes\fof\fthe\fengine\fst\brting.\fThis\fle\bves\f
enough\ftime\fto\fcheck\fwhether\fthe\fswitch-on\fconditions\ffor\fboost\fhe\bt\fmode\fh\bve\fbeen\f
met,\fthus\fpreventing\fthe\ffuel\fpowered\fbooster\fhe\bter\ffrom\fh\bving\fto\fswitch\foff\f\bnd\fswitch\f
b\bck\fon\f\bg\bin.\fThe\fhe\bter\fc\bn\fbe\fswitched\foff\fm\bnu\blly\f\bt\f\bny\ftime\ffrom\fthe\fmenu.\f
Whilst\fthe\ffuel-fired\f\bddition\bl\fhe\bter\fis\fin\f\bddition\bl\fhe\bting\fmode\f\bnd/or\fp\brking\fhe\bting\f
mode,\fthe\finstrument\fcluster\freceives\f\b\ffuel\fconsumption\fsign\bl;\fthis\fis\fused\fto\fre-
c\blcul\bte\f
the\fvehicle's\frem\bining\fr\bnge\f\bnd\ffuel\fconsumption\fd\bt\b.\f
Emergenc\b shu\foff
In\fthe\fevent\fof\f\bn\f\bccident\fin\fwhich\fthe\f\birb\bgs\f\bre\fdeployed,\fthe\ffuel\fpowered\fbooster\f
he
\bter\fmodule\freceives\f\b\fmess\bge\fon\fthe\fCAN\fbus\ffrom\fthe\frestr\bints\fcontrol\fmodule\f
(RCM).\fWhen\fthis\fsign\bl\fis\freceived,\fthe\ffuel\fpowered\fbooster\fhe\bter\fsystem\fis\fimmedi\btely\f
de\bctiv\bted\f.\f
The\ffuel\fpowered\fbooster\fhe\bter\fmodule\fde\bctiv\btes\fthe\fsystem\f\bnd\fdoes\fnot\frespond\fto\f
further\fmess\bges\fon\fthe\fCAN\fbus.\fThe\ffuel\fpowered\fbooster\fhe\bter\fmodule\fneeds\fto\fbe\f
\bctiv\bted\fwith\fthe\fdi\bgnostic\funit.\f
Ini\fial opera\fion
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Auxiliar\b Clima\fe Con\frol - Auxiliar\b
Evapora\for Fron\f Ou\fle\f and Inle\f LineS-MAX/G\bl\bxy\f2006.5\f(02/2006
Removal and Ins\falla\fion
Ma\ferials
Removal
NO
TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
Vehicles\fwith\fdiesel\fengine\f
A l

l\fvehicles\f
NameSpec\bf\bcat\bo\f
Compressor\fOil\f-\fAir\fConditioningWSH-M1C231-B\f/\f6U7J-M1C231-AA 1.
C\brry\fout\fthe\f\bir\fconditioning\f(A/C)\fsystem\frecovery\f
procedure.\f
Refer\fto:\f Air\fConditioning\f(A/C)\fSystem\fRecovery,\f
Ev\b

cu\btion\f\bnd\fCh\brging\f(412-
00\fClim\bte\fControl\fSystem\f
-\fGener\bl\fInform\btion,\fGener\bl\fProcedures).\f
2. R\bise\fthe\fvehicle.\f
Refer\fto:\f Lifting\f(100-
02\fJ\bcking\f\bnd\fLifting,\fDescription\f
\bnd\fOper\btion).\f
3. \f
4. \f
5.
CAUTION:\f
M\bke\fsure\f
th\bt\f\bll\f
openings\f\bre\f
se\bled.\f1.
Torque:\b
Nm\f
2.
Torque:\b
Nm\f
\f\f
\f\f
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Auxiliar\b Clima\fe Con\frol - Auxiliar\b
Evapora\for Rear Ou\fle\f and Inle\f LineS-MAX/G\bl\bxy\f2006.5\f(02/2006
Removal and Ins\falla\fion
Ma\ferials
Removal
NO
TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
All\fexcept\fvehicles\fwith\fdiesel\fengine\f
A l

l\fvehicles\f
NameSpec\bf\bcat\bo\f
Compressor\fOil\f-\fAir\fConditioningWSH-M1C231-B\f/\f6U7J-M1C231-AA 1.
C\brry\fout\fthe\f\bir\fconditioning\f(A/C)\fsystem\frecovery\f
procedure.\f
Refer\fto:\f Air\fConditioning\f(A/C)\fSystem\fRecovery,\f
Ev\b

cu\btion\f\bnd\fCh\brging\f(412-
00\fClim\bte\fControl\fSystem\f
-\fGener\bl\fInform\btion,\fGener\bl\fProcedures).\f
2. R\bise\fthe\fvehicle.\f
Refer\fto:\f Lifting\f(100-
02\fJ\bcking\f\bnd\fLifting,\fDescription\f
\bnd\fOper\btion).\f
3. Refer\fto:\f Petrol\f\bnd\fPetrol-
Eth\bnol\fFuel\fSystems\fHe\blth\f
\bnd\fS\bfety\fPrec\butions\f(100-00\fGener\bl\fInform\btion,\f
Description\f\bnd\fOper\btion).\f
4.
CAUTION:\f
M\bke\fsure\f
th\bt\f\bll\f
openings\f\bre\f
se\bled.\fUse\f
new\fbl\bnking\f
c\bps.\f1.
Torque:\b
Nm\f
2.
Torque:\b
Nm\f
5.CAUTION:\f
M\bke\fsure\f
th\bt\f\bll\f
openings\f\bre\f
se\bled.\f
1.
Torque:\b
\f
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