drive FORD S-MAX 2006 Service Repair Manual

Manual T\bansmissi\fn/T\bansaxle - Vehicles
With: 6-Speed Manual T\bansaxle - M66 -
3\bd-4th Gea\b Output ShaftS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Disassembly and Assembly \ff Subassemblies
Special T\f\fl(s)
Mat

e\bials
Gene\bal Equipment
205-071-01\f
Ad\bpter\ffor\f205-071\f(Thrust\fP\bd)\f
205-295\f
Remover,\fBe\bring\f(M\bin\fTool)\f
308-095\f
Inst\bller,\fInput\fSh\bft\fBe\bring\f
308-112\f
Inst\bller,\fOutput\fDrive\fFl\bnge\fSe\bl
\f
308-196\f
Collet\ffor\f205-295\f
308-605\f
Inst\bller,\fInput\fSh\bft\fSe\bl\f
308-798\f
Inst\bller\fBe\bring\fCup\f
NameSpec\bf\bcat\bo\f
Tr\bnsmission\fOil\f75W\fFEWSS-M2C200-D2\f/\f7U7J-M2C200-BA
Be\bring\fsep\br\btor
Hydr\bulic\fpress
\f
\f
\f
\f
\f
\f
\f
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Mate\bials
Gene\bal Equipment All vehicles
308-789\f
Inst\bller,\fDrivesh\bft\fSe\bl\f
308-796\f
G\buge\f
308-798\f
Inst\bller\fBe\bring\fCup\f
NameSpec\bf\bcat\bo\f
Silicone\fSe\bl\bnt\fDCW9U7J-99J9624-AA
Tr\bnsmission\fOil\f75W\fFEWSS-M2C200-D2\f/\f7U7J-M2C200-BA
Cable ties
H\ft ai\b gun
Ti\be leve\b1.Special\bTool(\f):\b 30
8-798\f
Mate
rial:\b Tr\bnsmission\fOil\f75W\fFE\f(WSS-M2C200-
D2\f/\f7U7J
M2C200-BA) \f
\f
\f
\f
\f
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Fuel Sy\btem - \feneral Information - Quick
Relea\be CouplingS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
\feneral Procedure\b
\feneral Equipment
Di\bconnect
WARNINGS:\f
Re
fer\fto:\f Petrol\f\bnd\fPetrol-Eth\bnol\fFuel\fSystems\fHe\blth\f\bnd\fS\bfe
ty\fPrec\butions\f(100-
00\f
Gener\bl\fInform\btion,\fDescription\f\bnd\fOper\btion).\f
Refer\fto:\f Diesel\fFuel\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
NOTE:\fFuel\fsupply\fline\fconnectors\f\bre\fcolor\fcoded\fwhite.\fFuel\freturn\fline\fconnectors\f\bre\f
color\fcoded\fred.\f
Fl\bt-bl\bded\fscrewdriver
1. Rele\bse\fthe\ffuel\fsystem\fpressure\f
Refer\fto:\f Fuel\fSystem\fPressure\fRele\bse \f(310-00\f
Fue

l\fSystem\f-\fGener\bl\fInform\btion,\fGener\bl\f
Procedures).\f
2. \f
3. \f
4. \f
5. \f
\f\f
\f\f
\f\f
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Connect
6. \f
7
. Ge

neral \bqui\fment: Fl\bt-bl\bded\fscrewdriver \f
1. T

o\fconnect,\freverse\fthe\fdisconnect\fprocedure.\f
\f\f
\f\f
\f\f
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Fuel Sy\btem - \feneral Information - Fuel
Sy\btem Pre\b\bure Check—2.0L Duratec-HE
(107kW/145PS) - MI4/2.0L Duratec-HE
Flex Fuel (107kW/145PS) - MI4/2.3L
Duratec-HE (118kW/160PS) - MI4
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
\feneral Procedure\b
Special Tool(\b)
\fen

eral Equipment WARNING:\fRefer\fto:\f Pet
rol\f\bnd\fPetrol-Eth\bnol\fFuel\fSystems\fHe\blth\f\bnd\fS\bfe ty\f
Prec\butions \f(100-00\fGener\bl\fInform\btion,\fDescription\f\bnd\fOper\btio
n).\f
Vehicles\fwith\f2.0L\fengine\f
310-025\f
Fuel\fPressure\fG\buge\f
310-025-18\f
Test\fHose\ffor\f310-025\f
310-025-19A\f
Test\fHose\ffor\f310-025\f
310-137\f
Disconnect\fTool,\fFuel\fLine
\f
Fl\bt-bl\bded\fscrewdriver
1. Refer\fto:\f Fuel\fSystem\fPressure\fRele\bse \f(310-00\f
Fue
l\fSystem\f-\fGener\bl\fInform\btion,\fGener\bl\f
Procedures).\f
2. General \bqui\fment: Fl\bt-bl\bded\fscrewdriver \f
\f
\f
\f
\f
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Vehicles\fwith\f2.3L\fengine\f
All\fvehicles\f
3.
General \bqui\fment: F
l\bt-bl\bded\fscrewdriver\f
4. S\f
ecial Tool(s): 310-137\f
5. In

stall the S\fecial Tool(s): 310-025,\f310-025-18
,\f
310-025-19A \f
6. In
stall the S\fecial Tool(s): 310-025-18\f
\f\f
\f
\f\f
\f\f
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\f\fDescr\fpt\fo\b
Fuel\ft\bnk\flocking\fring\f
Fuel\fpump\f\bnd\fsender\funit\f
Fuel\ffilter\f
Fuel\fpump\f\bnd\fsender\funit\fse\bl\f\f
Fuel\ft\bnk\flevel\fsensor\fflo\bt\f\bnd\f\brm\f
The\ffuel\fpump\f\bnd\fsender\funit\fis\floc\bted\fin\fthe\ftop\fof\fthe\ffuel\ft\bnk\f\bnd\fret\bined\fby\f\b\fre-
us
\bble\ffuel\ft\bnk\flocking\fring.\fThe\ffuel\fpump\f\bnd\fsender\funit\fse\bl\fmust\fnot\fbe\fre-used\fonce\f
removed\ffrom\fthe\ffuel\ft\bnk.\f
The\ffuel\fpump\f\bnd\fsender\funit\fconsists\fof\f\b\ffuel\fsender,\f\b\ffuel\ffilter\f\bnd\f\b\fhigh\fpressure\f
fuel\fpump\fwith\fpressure\fregul\btor.\fThe\ffuel\ft\bnk\fmodule\ffilter\fh\bs\fbeen\fdesigned\f\bs\f\b\fnon-
service\bble\fitem\f\bnd\fwill\fl\bst\fthe\flifetime\fof\fthe\fvehicle.\fIf\fthe\ffuel\ft\bnk\fmodule\ffuel\ffilter\f
becomes\fblocked\f\b\fnew\ffuel\fpump\f\bnd\fsender\funit\fmust\fbe\finst\blled.\f\f
For\f\bddition\bl\finform\btion,\frefer\fto:\f Fuel\fPump\f\bnd\fSender\fUnit\f(310-01A\fFuel\fT\bnk\f\bnd\f
Li n

es\f-\f2.0L\fEcoBoost\fSCTi\f(149kW/203PS)\f-\fMI4/2.0L\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-\f
MI4/2.5L\fDur\btec\f(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\fInst\bll\btion).\f
The\ffuel\fpump\fis\f\b\fturbine\ftype\fpump\fwhich\fis\f\bn\fintegr\bl\fp\brt\fof\fthe\ffuel\fpump\f\bnd\fsender\f
unit.\fThe\ffuel\ft\bnk\fmodule\ffuel\fsender\fcommunic\btes\fdirectly\fwith\fthe\finstrument\fcluster\f
which\fdrives\fthe\ffuel\fg\buge\finforming\fthe\fdriver\fthe\f\bmount\fof\ffuel\fth\bt\fis\fcurrently\fin\fthe\f
fuel\ft\bnk.\f
CAUTION:\fT\bke\fextr\b\fc\bre\fnot\fto\fd\bm\bge\fthe\ffuel\ft\bnk\f l
evel\fsensor\fflo\bt\f\bnd\f\brm.\f
Item
1
2
3
4
5
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Part Number -
-
-
-
-
\f\f
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Fuel Ta\bk a\bd L\f\bes - 2.0L EcoBoost SCT\f
(149kW/203PS) - MI4/2.0L Duratec-HE
(107kW/145PS) - MI4/2.0L Duratec-HE
Flex Fuel (107kW/145PS) - MI4/2.3L
Duratec-HE (118kW/160PS) - MI4/2.5L
Duratec (162kW/220PS) - VI5 - Fuel Ta\bk
a\bd L\f\bes—2.0L Duratec-HE Flex Fuel
(107kW/145PS) - MI4, Veh\fcles W\fth:
Etha\bol Capab\fl\fty - Overv\few
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Descr\fpt\fo\b a\bd Operat\fo\b
The\ffuel\ft\bnk\f\bnd\ffuel\flines\f\bre\fthe\fs\bme\f\bs\fthose\fin\fvehicles\ffor\fpetrol\foper\btion.\f
Pr

opert\fes of etha\bol E85
CAUTION:\fFuels\fcont\bining\feth\bnol\fh\bve\f\b\fcorrosive\fef f
ect\fon\fother\fm\bteri\bls\fsuch\f\bs\f
pl\bstic,\fp\bint\f\bnd\fmet\bl.\f
Eth\bnol\fE85:\f

is\fdescribed\fby\fthe\fst\bnd\brd\fASTM\fD5798\f(Ed75-Ed85)\f\f

cont\bins\f\bpproxim\btely\f85%\feth\bnol\f\bnd\f15%\fpetrol\fwith\f95\foct\bne\fr\bting\fin\f"summer\f
qu

\blity"\f\f

cont\bins\f\bpproxim\btely\f75%\feth\bnol\f\bnd\f25%\fpetrol\fwith\f95\foct\bne\fr\bting\fin\f"winter\f
qu

\blity"\f\f

h\bs\f\bn\f\bntiknock\fresist\bnce\fof\f\bpprox.\f104\f RO
N\f(rese\brch\foct\bne\fnumber)\f\f

supplies\f\bround\f66%\fof\fthe\fenergy\fcontent\fof\fpetrol\f\f

c\buses\f\bround\f70-80%\fless\fc\brbon\fdioxide\femissions\f\f

the\feth\bnol\fsh\bre\fis\ffree\ffrom\fsulphur\f\bnd\fodors\f\bnd\fcont\bins\fno\fc\brcinogenic\f
co

mpounds\fsuch\f\bs\fbenzene\f
Fuel Ta\bk a\bd L\f\bes
CA
UTION:\fIf\f\bnother\ffuel\ftype\fis\fused\f\bfter\femptying\f t
he\ffuel\ft\bnk,\f\bt\fle\bst\f10\fliters\f
more\fmust\fbe\f\bdded\fin\forder\fto\fst\brt\ffuel\ftype\fdetermin\btion\f\bnd\f\bd\bpt\btion.\f
The\ffuel\ft\bnk\f\bnd\frust-free\ffuel\flines\f\bre\fthe\fs\bme\ffo
r\fpetrol\fvehicles\f\bs\ffor\fvehicles\f
oper\bted\fwith\feth\bnol.\fTo\f\bchieve\fthis,\fthe\fcomponents\foptimized\ffor\feth\bnol\foper\btion\f
h\bve\fbeen\f\bpplied\fto\fthe\fentire\fproduct\fr\bnge.\f
Fuel pump dr\fver module
The\ffuel\fpump\fdriver\fmodule\fmust\fnot\fbe\fdism\bntled\f\bnd\fmust\fbe\frepl\bced\f\bs\f\b\fwhole.\f
The\ffuel\fpump\fdriver\fmodule\fis\fdifferent\ffor\fpetrol\fvehicles\f\bnd\ffor\fvehicles\foper\bted\fwith\f
eth\bnol,\f\bnd\fmust\fnot\fbe\finterch\bnged.\f
\f\f
Descr\fpt\fo\b
Fuel\fpump\fdriver\fmodule\f-\fpetrol\fvehicle\f
Item
1 \f\f
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Fuel\fpump\fdriver\fmodule\f-\feth\bnol\fvehicle\f
Enc\bpsul\bted\fconnector\f
The\ffuel\fpump\fmodule\ffor\feth\bnol\foper\btion\flooks\fvery\fsimil\br\fto\fthe\ffuel\fpump\fmodule\ffor\f
petrol\fvehicles.\fThe\fdifference\fis\fin\fthe\ffuel\fpump\fconnector.\fThis\fis\fenc\bpsul\bted\fdue\fto\fthe\f
higher\fconductivity\fof\fthe\feth\bnol\fsh\bre.\f
\f\f
Descr\fpt\fo\b
Fuel\flevel\fsensor\f
Resistor\fbo\brd\f
The\fresistor\fbo\brd\fof\fthe\ffuel\flevel\fsensor\fis\fsupplied\fwith\f\bltern\bting\fvolt\bge\finste\bd\fof\f
direct\fvolt\bge.\fThis\fprevents\felectrolysis\f\bnd\fthe\fdeposit\fof\fp\brticles.\fThe\f\bltern\bting\f
volt\bge\fis\fgener\bted\fby\f\b\f DC\f(direct\fcurrent)-AC\f(\bltern\bting\fcurrent) \fconverter.\fThe\fDC-AC
\f
converter\fis\fintegr\bted\fin\fthe\fwiring\fh\brness\for\fthe\f GEM\f(generic\felectronic\fmodule)\f
dep
ending\fon\fthe\fconstruction\fperiod.\fIt\fconverts\fthe\fdirect\fvolt\bge\finto\f\bn\f\bltern\bting\f
volt\bge\fwith\f\b\ffrequency\fof\f170\fHz.\fThe\fcourse\fof\fthe\f\bltern\bting\fvolt\bge\fcorresponds\fto\f\b\f
rect\bngul\br\fimpulse.\f
Both\ffuel\fpump\fdriver\funits\fh\bve\fdifferent\fresist\bnce\ftr\bcks\ffor\fthe\ffuel\flevel\fsensor.\f
Another\fdifference\fis\fth\bt\fthe\ffuel\fpump\fdriver\funit\ffor\feth\bnol\foper\btion\fis\fm\bnuf\bctured\f
from\feth\bnol-resist\bnt\fm\bteri\bls.\f
The\ffuel\flevel\fsensor\fis\fused\fduring\ffuel\ftype\fdetermin\btion.\f\f
Refer\fto:\f Electronic\fEngine\fControls\f-\fVehicles\fWith:\fEth\bnol\fC \b
p\bbility\f(303-14A\fElectronic\f
Eng
ine\fControls\f-\f2.0L\fDur\btec-HE\f(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\fFuel\f
(107kW/145PS)\f-\fMI4,\fDescription\f\bnd\fOper\btion).\f 2
3
I t

em
1
2 \f\f
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\f\fDescr\fpt\fo\b
Fuel\ft\bnk\ffiller\fpipe\f
Fuel\ft\bnk\ffiller\fpipe\fc\bp\f
Fill\flimit\fvent\fv\blve\f
Ev\bpor\btive\femission\fc\bnister\f
Ev\bpor\btive\femission\fc\bnister\fdust\ffilter\f
Fuel\ft\bnk\fsupport\fstr\bp(s)\f
Fuel\ft\bnk\fvent\fv\blve(s)\f
Fuel\fpump\fdriver\fmodule\f(FPDM)\f
Fuel\fpump\f\bnd\fsender\funit\f(including\ffuel\ffilter)\f
Fuel\fsupply\fline\f
Ev\bpor\btive\femission\fc\bnister\fto\fev\bpor\btive\femission\fc\bnister\fpurge\f
v\blve\fline\f
Fuel\ft\bnk\f
The\ffuel\ft\bnk\fholds\f\bpproxim\btely\f70\fliters\fof\fus\bble\ffuel\f\bnd\fis\fof\f\b\fpl\bstic\fconstruction.\fIt\f
is
\fret\bined\fto\fthe\fvehicle\fby\fme\bns\fof\ftwo\fsteel\fsupport\fstr\bps,\fthe\ffuel\ft\bnk\fsupports\f
str\bps\f\bre\fsecured\fby\ffour\fret\bining\fbolts\fonto\fthe\funderside\fof\fthe\fvehicle\fch\bssis.\f
Fuel\ft\bnk\fventil\btion\fis\f\bchieved\fby\ftwo\ffuel\ft\bnk\fvent\fv\blves\fventing\fthrough\f\b\ffuel\flimit\f
vent\fv\blve\f\bnd\finto\f\bn\fev\bpor\btive\femission\fc\bnister\fwhich\f\bbsorbs\fthe\ffuel\fv\bpor.\fThe\ffuel\f
t\bnk\fvent\fv\blve\fwill\fprevent\ffuel\floss\ffrom\fthe\ffuel\ft\bnk\fif\fthe\fvehicle\fbecomes\finverted.\f\f Item
1
2
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4
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6
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8
9
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12
\f
Part Number -
-
-
-
-
-
-
-
-
-
-
-
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