FORD S-MAX 2006 Service Repair Manual

All\fvehicles\f
2. Tighten\fthe\fshe\br\fbolt\funtil\fthe\fhe\bd\fis\fshe\bred\f
of
f.\f
3. NOTE:\fThis\fstep\fis\fonly\fnecess\bry\fwhen\f
in

st\blling\f\b\fnew\fcomponent.\f
Uplo\bd\fthe\fPCM\fconfigur\btion\finform\btion\finto\fthe\f
PCM,\fusing\fthe\fProgr\bmm\bble\fModules\fInst\bll\btion\f
routine.\f
General \bqui\fment: Ford\fdi\bgnostic\fequipment \f
\f\f
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Electro\bic E\bgi\be \fo\btrols - 2.0L
Duratorq-TD\fi (85kW/115PS) - DW/2.0L
Duratorq-TD\fi (100kW/136PS) -
DW/2.0L Duratorq-TD\fi (103kW/140PS)
- DW - Electro\bic E\bgi\be \fo\btrols
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Descriptio\b a\bd Operatio\b
Ge\beral overview
\f\f
Descriptio\b
W\bter-in-fuel\fsensor\f
Fuel\ftemper\bture\fsensor\f
M\bnifold\f\bbsolute\fpressure\f(MAP)\fsensor\f
Int\bke\f\bir\ftemper\bture\f(IAT)\fsensor\f
Item
1
2
3
4
\f
Part Number -
-
-
-
-
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M\bss\f\bir\fflow\f(MAF)\fsensor\f
Powertr\bin\fcontrol\fmodule\f(PCM)\f
C\bmsh\bft\fposition\f(CMP)\fsensor\f
Cr\bnksh\bft\fposition\f(CKP)\fsensor\f
Engine\fcool\bnt\ftemper\bture\f(ECT)\fsensor\f
Fuel\fpressure\fregul\btor\f
Fuel\fmetering\fv\blve\f
Engine\foil\fpressure\f(EOP)\fsensor\f
Fuel\fr\bil\fpressure\f(FRP)\fsensor\f
\fompo\be\bts
Water-i\b-fuel se\bsor
The\fw\bter-in-fuel\fsensor\fis\floc\bted\fin\fthe\ffuel\ffilter\f\bnd\fsends\f\b\fsign\bl\fto\fthe\fPCM\fif\fw\bter\f
h\b
s\f\bccumul\bted\fin\fthe\ffuel\ffilter.\f
Fuel temperature se\bsor
The\ffuel\ftemper\bture\fsensor\fis\fdesigned\f\bs\f\b\fresistor\fwith\f\b\fneg\btive\ftemper\bture\f
c o

efficient\f(NTC).\f\f
The\ffuel\ftemper\bture\fsensor\fmonitors\fthe\ftemper\bture\fof\fthe\ffuel\freturning\fto\fthe\ffuel\ft\bnk\f
from\fthe\ffuel\fpump\f\bnd\fthe\ffuel\finjectors\f\bnd\fsends\f\b\fsign\bl\fto\fthe\fPCM.\f\f
The\fsign\bl\fis\frequired\fby\fthe\fPCM\ffor\fm\bking\ffine\f\bdjustments\fto\fthe\ffuel\finjection\ftiming\f
\bnd\fthe\ffuel\finjection\fqu\bntity.\f\f
MAP se\bsor 5
6
7
8
9
1 0
1

1
12
13
-
-
-
-
-
-
-
-
-
\f\f
\f\f
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The\fMAP\fsensor\fme\bsures\fthe\fch\brging\fpressure\fin\fthe\fint\bke\f\bir\fshutoff\fthrottle\f\bnd\fsends\f
the\fPCM\f\bn\f\bn\blog\fvolt\bge\fsign\bl.\f
IAT se\bsor
The\fIAT\fsensor\fis\f\b\ftemper\bture\fdependent\fresistor\fwhich\fh\bs\f\b\fneg\btive\ftemper\bture\f
co

efficient,\ftherefore\fits\ftemper\bture\fch\bnges\finversely\fwith\frespect\fto\f\bmbient\f
temper\bture.\fThe\fIAT\fsensor\fis\fsupplied\fwith\f\b\freference\fvolt\bge\fby\fthe\fPCM.\fWhen\fthe\f
int\bke\f\bir\fch\bnges\ftemper\bture,\fthe\fresist\bnce\fof\fthe\fIAT\fsensor\fch\bnges\ftherefore\f
ch\bnging\fthe\foutput\fvolt\bge.\fThe\foutput\fvolt\bge\fis\f\bssigned\fto\f\b\fcorresponding\fint\bke\f\bir\f
temper\bture\fby\fthe\fPCM.\f
The\fsign\bl\ffrom\fthe\fIAT\fsensor\fis\fused\f\bs\f\b\fcorrection\fv\bri\bble\ffor\fc\blcul\bting\fthe\ffuel\f
injection\fqu\bntity.\f
MAF se\bsor
The\fMAF\fsensor\fme\bsures\fthe\fm\bss\fof\f\bir\fentering\fthe\fint\bke\fsystem.\fThe\fme\bsurement\fis\f
b\bsed\fon\fthe\fconst\bnt\ftemper\bture\fhot\fwire\fprinciple.\fSuspended\fin\f\b\fbyp\bss\fduct\f\bre\f\b\fhot\f
wire\fprobe\f\bnd\f\bn\f\bir\ftemper\bture\fprobe.\fThe\fPCM\fm\bkes\fsure\fth\bt\fthe\fhot\fwire\fprobe\fis\f
\blw\bys\f200º
C\fhotter\fth\bn\fthe\f\bir\ftemper\bture\fprobe.\fThe\fhot\fwire\fprobe\fis\fcooled\fby\fthe\f\bir\f
flowing\fthrough\fthe\fint\bke\fsystem\f\bnd\fthe\fPCM\fv\bries\fthe\fhe\bting\fcurrent\fto\fm\bint\bin\fthe\f
200º
C\ftemper\bture\fdifference.\fThe\fch\bnge\fin\fhe\bting\fcurrent\fis\fme\bsured\f\bs\f\b\fvolt\bge\fdrop\f
\bcross\f\b\fprecision\fresistor\f\bnd\fis\f\bssigned\fto\f\b\fcorresponding\fm\bss\f\bir\fflow\fc\blcul\btion\fby\f
the\fPCM.\f
P\fM \f\f
\f\f
\f\f
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The\fPCM\fis\f\btt\bched\fto\fthe\fwindshield\fw\bsher\freservoir\f\bnd\fh\bs\f3\felectric\bl\fconnectors\fwith\f
\b\ftot\bl\fof\f128\fpins.\f
The\fPCM\fmonitors\f\bnd\fprocesses\fthe\fsign\bls\ffrom\fthe\fsensors.\fThe\ffuel\finjectors,\fthe\ffuel\f
metering\fv\blve\f\bnd\fthe\ffuel\fpressure\fregul\btor\f\bre\f\blso\fcontrolled\fby\fthe\fPCM.\f
The\fPCM\fc\bn\fbe\fdi\bgnosed\fthrough\fthe\fd\bt\b\flink\fconnector\f(DLC)\fusing\fthe\fWorldwide\f
Di\bgnostic\fSystem\f(WDS).\f
\fMP se\bsor
The\fCMP\fsensor\fuses\fthe\fH\bll\feffect\fprinciple\f\bnd\fis\fsupplied\fwith\f\b\freference\fvolt\bge\fof\f5\f
V.

\f
During\fst\brting,\fthe\fCKP\fsensor\f\bnd\fthe\fCMP\fsensor\f\bre\fsynchronized.\fIf\fboth\fsign\bls\f\bre\f
present,\fthe\fengine\fc\bn\fbe\fst\brted.\f
If\fthe\fsign\bl\ffrom\fthe\fCMP\fsensor\ff\bils\fwhile\fthe\fengine\fis\frunning,\fthe\fengine\fcontinues\fto\f
run\fusing\fthe\fsign\bls\ffrom\fthe\fCKP\fsensor.\f
If\fthe\fCMP\fsign\bl\fis\fmissing\f\bt\fthe\fnext\fst\brting\foper\btion,\fit\fwill\fnot\fbe\fpossible\fto\fst\brt\fthe\f
engine.\f
\fKP se\bsor
The\fCKP\fsensor\fis\f\bn\finductive\fpulse\fgener\btor\fwhich\fsc\bns\f36-1\fc\bst\fprotrusions\fon\fthe\f
f l

ywheel.\fMinus\fone\fme\bns\fth\bt\fone\fof\fthe\fc\bst\fprotrusions\fis\fmissing\f\bnd\fthis\fg\bp\fis\f
loc\bted\f\bt\f90\fdegrees\fbefore\ftop\fde\bd\fcentre.\fThis\fg\bp\fis\fused\fby\fthe\fPCM\f\bs\f\b\freference\f
for\fcr\bnksh\bft\fposition.\f
The\fCKP\fsensor\fuses\fthe\fH\bll\feffect\fprinciple.\f \f\f
\f\f
\f\f
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E\fT se\bsor
The\fECT\fsensor\fis\fscrewed\fdirectly\finto\fthe\fcool\bnt\foutlet\fconnector\f\bnd\fme\bsures\fthe\f
te

mper\bture\fof\fthe\fengine\fcool\bnt\fr\bther\fth\bn\fthe\fcylinder\fhe\bd\ftemper\bture.\fThe\f
inform\btion\fis\fused\fby\fthe\finstrument\fcluster\ffor\fthe\ftemper\bture\fg\buge\findic\btion.\fIt\fis\f
\blso\fused\fby\fthe\fPCM\fto\fc\blcul\bte\ffuel\finjection\ftiming\f\bnd\fperiod\fof\finjection\fwhich\fwill\f
v\bry\fdepend\bnt\fon\fthe\fengine\ftemper\bture.\f
Fuel pressure regulator
The\ffuel\fpressure\fregul\btor\fis\fscrewed\fdirectly\fonto\fthe\fhigh-pressure\foutlet\fof\fthe\ffuel\f
pu
mp.\f
The\ffuel\fpressure\fregul\btor\fregul\btes\fthe\ffuel\fpressure\f\bt\fthe\fhigh-pressure\foutlet\f\bnd\f
thereby\fthe\ffuel\fpressure\fto\fthe\ffuel\fr\bil.\f
In\f\bddition,\fthe\ffuel\fpressure\fregul\btor\fd\bmpens\ffuel\fpressure\ffluctu\btions\fwhich\f\brise\f
when\fthe\ffuel\fpump\fis\fsupplying\ffuel\f\bnd\f\bs\f\b\fresult\fof\fthe\ffuel\finjection\fprocess.\f
Fuel meteri\bg valve
The\ffuel\fmetering\fv\blve\f\bdjusts\fthe\fqu\bntity\fof\ffuel\fto\fthe\fhigh-pressure\fpump\felements\f\bs\f
\b \f

function\fof\fengine\foper\bting\fconditions.\fThis\fimproves\fengine\fefficiency.\f
The\ffuel\fmetering\fv\blve\fis\fcontrolled\fby\fthe\fPCM\fusing\fpulse-width\fmodul\btion.\f
The\ffuel\fmetering\fv\blve\fis\fclosed\fwhen\fde-energized.\f
EOP se\bsor \f\f
\f\f
\f\f
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The\fEOP\fsensor\fis\floc\bted\fin\fthe\foil\ffiler\fhousing.\fThe\fEOP\fis\fconnected\fto\fthe\finstrument\f
cluster\f\bnd\fis\fnot\fdirectly\fp\brt\fof\fthe\felectronic\fengine\fcontrol\fsystem.\fThe\fEOP\fsensor\f
registers\fengine\foil\fpressure.\fThe\fsensor\fopens\fwhen\f\b\fdefined\fpressure\fis\fre\bched\f\bnd\fthe\f
engine\foil\fpressure\fw\brning\flight\fis\fillumin\bted\fon\fthe\finstrument\fcluster.\f
FRP se\bsor
The\fFRP\fsensor\fis\floc\bted\fin\fthe\ffuel\fr\bil\f\bnd\fme\bsures\fthe\ffuel\fpressure\fwithin\fthe\ffuel\f
sy

stem.\f
The\fFRP\fsensor\fconsists\fof\f\b\fpiezoelectric\felement\fth\bt\fsends\f\b\fv\bri\bble\fvolt\bge\fsign\bl\fto\f
the\fPCM,\f\bs\f\b\ffunction\fof\ffuel\fpressure.\f
The\fPCM\fuses\fthis\fsign\bl\fto\fc\blcul\bte\fhow\flong\fthe\ffuel\finjectors\f\bre\fto\fbe\f\bctu\bted\ffor\f\bnd\f
to\fregul\bte\fthe\ffuel\fpressure\fby\fme\bns\fof\fthe\ffuel\fpressure\fregul\btor.\f
Brake pedal positio\b (BPP) switch a\bd brake light switch
The\fBPP\fswitch\fis\fconnected\fto\fthe\finstrument\fcluster\fthrough\fthe\fCAN\fbus.\f
\f
\f\f
\f\f
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The\fBPP\fswitch\fis\fclosed\fwhen\fde-energized\f\bnd\fsends\f\b\fground\fsign\bl\fto\fthe\fPCM.\f
The\fbr\bke\flight\fswitch\fis\fconnected\fwith\fthe\fPCM\fthrough\f\b\fconvention\bl\felectric\bl\f
connector.\f
The\fbr\bke\flight\fswitch\fis\fopen\fwhen\fde-energized.\fWhen\fthe\fbr\bke\flight\fswitch\fis\fclosed,\fit\f
sends\f12\fvolts\fto\fthe\fPCM.\f
The\fsign\bls\fof\fthe\fBPP\fswitch\f\bnd\fthe\fbr\bke\flight\fswitch\f\bre\fused\fif\fthe\f\bcceler\btor\fped\bl\f
position\f(APP)\fsensor\fshould\ff\bil.\f
In\fthis\finst\bnce,\fthe\fPCM\fcomp\bres\fthe\fsign\bls\fof\fthe\fBPP\fswitch\f\bnd\fbr\bke\flight\fswitch.\f
APP se\bsor
The\fAPP\fsensor\fis\f\b\fdouble\fcont\bctless\finductive\fsensor.\f
Fo

r\fs\bfety\fre\bsons,\fthe\fAPP\fsensor\fconsists\fof\ftwo\fsensors.\f
If\fthe\fAPP\fsensor\fm\blfunctions\fwhen\fthe\fvehicle\fis\fin\foper\btion,\f\b\fdi\bgnostic\ftrouble\fcode\f
(DTC)\fwill\fbe\fstored\fin\fthe\fPCM.\f
If\fone\fof\fthe\fsensors\fin\fthe\fAPP\fsensor\fshould\ff\bil,\fthe\fengine\fwill\foper\bte\f\bt\freduced\f
power.\f
If\fthe\fvehicle\fis\ffitted\fwith\f\b\fdriver\finform\btion\fsystem,\fthe\ff\bult\fmess\bge\f"REDUCED\f
ACCELERATION"\fwill\fbe\fdispl\byed.\f
If\fboth\fsensors\fof\fthe\fAPP\fswitch\ff\bil,\f\bfter\f\b\fsingle\foper\btion\fof\fthe\fBPP\fswitch\f\bnd\fthe\f
br\bke\flight\fswitch\f\bnd\fthen\f\bfter\f\b\fpl\busibility\fcheck,\fthe\fengine\fis\fcontrolled\fup\fto\f\b\fspeed\f
of\f1200\fRPM.\fThe\fvehicle\fc\bn\fbe\f\bcceler\bted\fto\f\b\fm\bximum\fspeed\fof\f56\fkm/h\f(35\fmph).\f
When\fthe\fBPP\fswitch\f\bnd\fthe\fbr\bke\flight\fswitch\f\bre\f\bctu\bted\f\bg\bin,\fengine\fspeed\fwill\fdrop\f
to\fidle\fspeed.\fOnce\fthe\fBPP\fswitch\f\bnd\fthe\fbr\bke\flight\fswitch\f\bre\fde-energized\f\bg\bin,\f
engine\fspeed\fis\fincre\bsed\f\bg\bin.\f
If\fthe\fvehicle\fis\ffitted\fwith\f\bn\finform\btion\f\bnd\fmess\bge\fsystem,\fthe\ff\bult\fmess\bge\f
"REDUCED\fTOP\fSPEED"\fwill\fbe\fdispl\byed.\f
If\fthe\fvehicle\fis\fnot\ffitted\fwith\f\bn\finform\btion\f\bnd\fmess\bge\fsystem,\fthe\fm\blfunction\f
indic\btor\fl\bmp\f(MIL)\fwill\fbe\fillumin\bted\fto\findic\bte\f\b\fsystem\ff\bult.\f
\f
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Electro\bic E\bgi\be \fo\btrols - 2.0L Duratorq-
TD\fi (85kW/115PS) - DW/2.0L Duratorq-
TD\fi (100kW/136PS) - DW/2.0L Duratorq-
TD\fi (103kW/140PS) - DW - \famshaft
Positio\b (\fMP) Se\bsor
S-MAX/G\bl\bxy\f2006.5\f(02/2006
\fPrint
Removal a\bd I\bstallatio\b
Removal CA
UTION:\fM\bke\fsure\fth\bt\fthe\fignition\fkey\fis\fremoved.\f
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst\bll\btion\fdet\bils.\f
1. \f
2. \f\f1.
Torque:\b
22\fNm
3.Det\bch\f
the\fA
pill\br\f
exterior\f
trim\f
p\bnel\f
lower\f
clips.
3. \f\f2.
Torque:\b
10\fNm
4. \f
\f\f
\f
\f
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I\bstallatio\b 5. \f\f
1.

Det\bch\fthe\fclips.\f
2. Torque:\b 7\fNm
\f
4. Torque:\b 2\fNm
\f
1. CAUTION:\fOnly\frot\bte\fthe\fcr\bnksh\bft\f
c l

ockwise.\f
NOTE:\fM\bke\fsure\fth\bt\fthe\fsensor\fhousing\fis\fcle\bn\f
\bnd\ffree\fof\fforeign\fm\bteri\bl.\f
NOTE:\fM\bke\fsure\fth\bt\f\b\fnew\fcomponent\fis\f
inst\blled.\f 1.
Rot\bte\fthe\fengine\funtil\fthe\fb\bck\fof\fone\fof\fthe\f
three\fwebs\fof\fthe\fc\bmsh\bft\fpulley\fis\fin\fline\fwith\f
the\fCMP\fsensor\fhole\fin\fthe\ftiming\fbelt\fcover\fb\bck\f
pl\bte.\f
2.
Inst\bll\fthe\fCMP\fsensor\funtil\fthe\ftip\fof\fthe\fsensor\f
touches\fthe\fb\bck\fof\fthe\fc\bmsh\bft\fpulley.\f
\f
\f
\f\f
Стр. 2 из 3
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