check engine FORD S-MAX 2006 Service Repair Manual
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Page 1667 of 4402
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
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Page 1672 of 4402
(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
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Page 1674 of 4402
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
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Page 1675 of 4402
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
*
*
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Page 1676 of 4402
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
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Page 1679 of 4402
not\fcr\bnk\f\bnd\fthe\f
rel\by\fdoes\fnot\fclickTesting).\f
Circuit(s)\f
St\brter\f
rel\by\f Ignition\f
switch\f
PCM\f
BJB\f
*
*
*
*
*GO\fto\fPinpoint\fTest\f
A.\f\f
*
PATS\f*REFER\fto:\fAnti-Theft\f-\fP\bssive\f(419-01B,\fDi\bgnosis\f\bnd\f
Testing).\f
*
The\fengine\fdoes\f
not\fcr\bnk\fbut\fthe\f
rel\by\fclicksB\bttery\f
*REFER\fto:\fCh\brging\fSystem\f(414-00,\fDi\bgnosis\f\bnd\f
Testing).\f
*
Circuit(s)\f
St\brter\f
rel\by\f
St\brter\f
motor\f
*
*
*GO\fto\fPinpoint\fTest\f
B.\f\f
*
The\fengine\fcr\bnks\f
slowlyB\bttery\f
*REFER\fto:\fCh\brging\fSystem\f(414-00,\fDi\bgnosis\f\bnd\f
Testing).\f
*
B\bttery\f
c\bble\f St\brter\f
motor\f
*
*GO\fto\fPinpoint\fTest\f
C.\f\f
*
Unusu\bl\fst\brter\f
motor\fnoiseSt\brter\f
motor\f
*INSPECT\fthe\fst\brter\fmotor\ffor\f\blignment\for\fcr\bcked\f
c\bsing.\fM\bke\fsure\fthe\fmounting\fbolts\f\bre\ftightened.\fIf\f
necess\bry,\fINSTALL\f\b\fnew\fst\brter\fmotor.\f\f
REFER\fto:\f St\brter\fMotor \f(303-06A\fSt\brting\fSystem\f-\f2.0L\f
Dur
\btec-HE\f(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\f
Fuel\f(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\fInst\bll\btion)\f/\f\f
St\brter\fMotor\f(303-06B\fSt\brting\fSystem\f-\f2.5L\fDur\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\fDur\btorq-
TDCi\f(Kent)\fDiesel,\fRemov\bl\f\bnd\fInst\bll\btion)\f/\f\f
St\brter\fMotor\f(303-06D\fSt\brting\fSystem\f-\f2.0L\fDur\btorq-
TDCi\f(DW)\fDiesel,\fRemov\bl\f\bnd\fInst\bll\btion).\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
*
Flywheel\f
ring\fge\br\f
*CHECK\fthe\fflywheel\fring\fge\br.\fINSTALL\f\b\fnew\fflywheel\f
ring\fge\br\f\bs\fnecess\bry.\f
*
The\fst\brter\fmotor\f
spins\fbut\fthe\f
engine\fdoes\fnot\f
cr\bnkSt\brter\f
motor\f
*REMOVE\fthe\fst\brter\fmotor.\fINSPECT\fthe\fst\brter\fmotor\f
ge\br\ffor\fd\bm\bge.\fINSTALL\f\b\fnew\fst\brter\fmotor\f\bs\f
necess\bry.\f\f
REFER\fto:\f St\brter\fMotor \f(303-06A\fSt\brting\fSystem\f-\f2.0L\f
Dur
\btec-HE\f(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\f
Fuel\f(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\fInst\bll\btion)\f/\f\f
St\brter\fMotor\f(303-06B\fSt\brting\fSystem\f-\f2.5L\fDur\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\fDur\btorq-
TDCi\f(Kent)\fDiesel,\fRemov\bl\f\bnd\fInst\bll\btion)\f/\f\f
St\brter\fMotor\f(303-06D\fSt\brting\fSystem\f-\f2.0L\fDur\btorq-
TDCi\f(DW)\fDiesel,\fRemov\bl\f\bnd\fInst\bll\btion).\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
*
Flywheel\f
ring\fge\br\f
*INSPECT\fthe\fflywheel\fring\fge\br\ffor\fmissing\fteeth.\fCHECK\f
the\fst\brter\fmotor\ffor\fcorrect\fmounting.\fIf\fthe\fconcern\f
persists,\fINSTALL\f\b\fnew\fst\brter\fmotor.\f\f
REFER\fto:\f St\brter\fMotor \f(303-06A\fSt\brting\fSystem\f-\f2.0L\f
Du r
\btec-HE\f(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\f
Fuel\f(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
*
Стр. 2 из
8
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G510212&gui...procarmanuals.com
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Page 1680 of 4402
Pinpoint\bTests\b
NOTE:\fUse\f\b\fdigit\bl\fmultimeter\ffor\f\bll\felectric\bl\fme\bs
urements.\f
(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\fInst\bll\btion)\f/\f\f
St\brter\fMotor\f(303-06B\fSt\brting\fSystem\f-\f2.5L\fDur\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\fDur\btorq-
TDCi\f(Kent)\fDiesel,\fRemov\bl\f\bnd\fInst\bll\btion)\f/\f\f
St\brter\fMotor\f(303-06D\fSt\brting\fSystem\f-\f2.0L\fDur\btorq-
TDCi\f(DW)\fDiesel,\fRemov\bl\f\bnd\fInst\bll\btion).\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
PINPOINT\bTEST\bA\b:\bTHE\bENGINE\bDOES\bNOT\bCRANK\bAND\bTHE\bRELAY\bDOES\b
NOT\bCLICK\b
TE\fT CONDITION\fDETAIL\f/RE\fULT\f/ACTION\f
A1:\bCHECK\bTHE\bSTARTER\bRELAY\bCOIL\bFOR\bVOLTAGE
Disconnect\fSt\brter\fRel\by\fR1.\f1\b
Ignition\fswitch\fin\fposition\fIII.\f2\b
Me\bsure\fthe\fvolt\bge\fbetween\fthe\fBJB\fst\brter\frel\by\f
R1\fconnector\fpin\f1,\fcircuit\fCDC35D\f(BU/WH),\f
h\brness\fside\f\bnd\fground.\f3\b
Is\fthe\fvolt\bge\fgre\bter\fth\bn\f10\fvolts?\f
Yes\b GO\fto\fA3.\f\f
No\b GO
\fto\fA2.\f\f
A2:\bCHECK\bCIRCUIT\bCDC35D\b(BU/WH)\bAND\bCDC35F\b(BU/WH)\bFOR\bCONTINUITY
Ignition\fswitch\fin\fposition\f0.\f1\b
Disconnect\fIgnition\fSwitch\fC2DC32.\f2\b
Me\bsure\fthe\fresist\bnce\fbetween\fthe\fBJB\fst\brter\frel\by\f
R1\fconnector\fpin\f1,\fcircuit\fCDC35D\f(BU/WH),\f
h\brness\fside\f\bnd\fthe\fignition\fswitch\fC2DC32\fpin\f7,\f
circuit\fCDC35F\f(BU/WH),\fh\brness\fside.\f
3\b
Is\fthe\fresist\bnce\fless\fth\bn\f1\fohm?\f
Yes\b INSTALL\f\b\fnew\fignition\fswitch.\fTEST\fthe\fsystem\ffor\f
correct\foper\btion.\f
No\b REPAIR\fcircuit\fCDC35D\f(BU/WH)\for\fcircuit\fCDC35F\f
(BU/WH)\f\bs\fnecess\bry.\fTEST\fthe\fsystem\ffor\fnorm\bl\f
oper\btion.\f
A3:\bCHECK\bTHE\bSTARTER\bRELAY\bCOIL\bFOR\bGROUND
Me\bsure\fthe\fresist\bnce\fbetween\fthe\fBJB\fst\brter\frel\by\f
R1\fconnector\fpin\f2,\fcircuit\fCDC12A\f(YE),\f\bnd\f
ground.\f
1\b
\f\f
\f\f
Стр. 3 из 8
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G510212&gui...procarmanuals.com
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Page 1682 of 4402
\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
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G510212&gui...procarmanuals.com
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Page 1684 of 4402
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
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G510212&gui...procarmanuals.com
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Page 1693 of 4402
St\brter\f
rel\by\f Ignition\f
switch\f
PCM\f
BJB\f
*
*
*
*
PATS\f*REFER\fto:\fAnti-Theft\f-\fP\bssive\f(419-01B,\fDi\bgnosis\f\bnd\f
Testing).\f
*
The\fengine\fdoes\f
not\fcr\bnk\fbut\fthe\f
rel\by\fclicksB\bttery\f
*REFER\fto:\fCh\brging\fSystem\f(414-00,\fDi\bgnosis\f\bnd\f
Testing).\f
*
Circuit(s)\f
St\brter\f
rel\by\f
St\brter\f
motor\f
*
*
*GO\fto\fPinpoint\fTest\f
B.\f\f
*
The\fengine\fcr\bnks\f
slowlyB\bttery\f
*REFER\fto:\fCh\brging\fSystem\f(414-00,\fDi\bgnosis\f\bnd\f
Testing).\f
*
B\bttery\f
c\bble\f St\brter\f
motor\f
*
*GO\fto\fPinpoint\fTest\f
C.\f\f
*
Unusu\bl\fst\brter\f
motor\fnoiseSt\brter\f
motor\f
*INSPECT\fthe\fst\brter\fmotor\ffor\f\blignment\for\fcr\bcked\f
c\bsing.\fM\bke\fsure\fthe\fmounting\fbolts\f\bre\ftightened.\fIf\f
necess\bry,\fINSTALL\f\b\fnew\fst\brter\fmotor.\f\f
REFER\fto:\f St\brter\fMotor \f(303-06A\fSt\brting\fSystem\f-\f2.0L\f
Dur
\btec-HE\f(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\f
Fuel\f(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\fInst\bll\btion)\f/\f\f
St\brter\fMotor\f(303-06B\fSt\brting\fSystem\f-\f2.5L\fDur\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\fDur\btorq-
TDCi\f(Kent)\fDiesel,\fRemov\bl\f\bnd\fInst\bll\btion)\f/\f\f
St\brter\fMotor\f(303-06D\fSt\brting\fSystem\f-\f2.0L\fDur\btorq-
TDCi\f(DW)\fDiesel,\fRemov\bl\f\bnd\fInst\bll\btion).\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
*
Flywheel\f
ring\fge\br\f
*CHECK\fthe\fflywheel\fring\fge\br.\fINSTALL\f\b\fnew\fflywheel\f
ring\fge\br\f\bs\fnecess\bry.\f
*
The\fst\brter\fmotor\f
spins\fbut\fthe\f
engine\fdoes\fnot\f
cr\bnkSt\brter\f
motor\f
*REMOVE\fthe\fst\brter\fmotor.\fINSPECT\fthe\fst\brter\fmotor\f
ge\br\ffor\fd\bm\bge.\fINSTALL\f\b\fnew\fst\brter\fmotor\f\bs\f
necess\bry.\f\f
REFER\fto:\f St\brter\fMotor \f(303-06A\fSt\brting\fSystem\f-\f2.0L\f
Dur
\btec-HE\f(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\f
Fuel\f(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\fInst\bll\btion)\f/\f\f
St\brter\fMotor\f(303-06B\fSt\brting\fSystem\f-\f2.5L\fDur\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\fDur\btorq-
TDCi\f(Kent)\fDiesel,\fRemov\bl\f\bnd\fInst\bll\btion)\f/\f\f
St\brter\fMotor\f(303-06D\fSt\brting\fSystem\f-\f2.0L\fDur\btorq-
TDCi\f(DW)\fDiesel,\fRemov\bl\f\bnd\fInst\bll\btion).\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
*
Flywheel\f
ring\fge\br\f
*INSPECT\fthe\fflywheel\fring\fge\br\ffor\fmissing\fteeth.\fCHECK\f
the\fst\brter\fmotor\ffor\fcorrect\fmounting.\fIf\fthe\fconcern\f
persists,\fINSTALL\f\b\fnew\fst\brter\fmotor.\f\f
REFER\fto:\f St\brter\fMotor \f(303-06A\fSt\brting\fSystem\f-\f2.0L\f
Du r
\btec-HE\f(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\f
Fuel\f(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\fInst\bll\btion)\f/\f\f
St\brter\fMotor\f(303-06B\fSt\brting\fSystem\f-\f2.5L\fDur\btec-
ST\f
*
Стр. 2 из 8
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G510212&gui...procarmanuals.com
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