key FORD S-MAX 2006 Service Owner's Manual

\f\fDescriptio\f
M\bnifold\f\bbsolute\fpressure\f(MAP)\fsensor\f
Int\bke\f\bir\ftemper\bture\f(IAT)\fsensor\f
Int\bke\f\bir\fshutoff\fthrottle\f
The\fint\bke\f\bir\fshutoff\fthrottle\fis\floc\bted\fon\fthe\fint\bke\f\bir\fside\fof\fthe\fint\bke\fm\bnifold.\f
Th

e\fint\bke\f\bir\fshutoff\fthrottle\fis\felectronic\blly\fcontrolled\fby\fthe\fPCM\f\bnd\fis\fused\fto\fcontrol\f
vehicle\fch\br\bcteristics\fwhile\fthe\fengine\fis\fswitched\foff.\fThis\fwill\f\blso\fprevent\fthe\fengine\f
being\fcontinuously\ffuelled\fby\fthe\fengine\foil\f\bfter\fthe\fignition\fkey\fh\bs\fbeen\fturned\fto\f
position\f0.\fThis\fis\f\bchieved\fby\freducing\fthe\fint\bke\f\bir\fthrough\fthe\fint\bke\fm\bnifold.\f Item
1
2
3 P\brt Number
-
-
-
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Accessory\bDrive\b\f\b1.8L\bDuratorq\fTDCi\b
(74kW/100PS)\b\f\bLynx/1.8L\bDuratorq\f
TDCi\b(92kW/125PS)\b\f\bLynx\b\f\bAccessory\b
Drive\bBelt
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal\band\bInstallation\b
General\bEquipment\b
Removal\b
WAR
NING:\fM\bke\fsure\fth\bt\fthe\fignition\fkey\fis\fremoved.\f
N O

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst\bll\btion\fdet\bils.\f
Dowel\fwith\f\b\fdi\bmeter\fof\f4\fmm
1. \f
2. \f
3. CAUTION:\fM\bke\fsure\fth\bt\fthe\finside\fof\f
t h

e\fpipe\fends\f\bre\fcle\bn\f\bnd\ffree\fof\foil\f
residue.\f
NOTE:\fNote\fthe\forient\btion\fof\fthe\fcl\bmp\fto\f
\bid\finst\bll\btion.\f
4. Remove\fthe\ffront\fright\fwheel.\f
Refer\fto:\f Wheel\f\bnd\fTire\f(204-04\fWheels\f\bnd\f
Tir

es,\fRemov\bl\f\bnd\fInst\bll\btion).\f
5. \f
\f\f
\f\f
\f\f
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Accessory\bDrive\b\f\b2.0L\bDuratorq\fTDCi\b
(85kW/115PS)\b\f\bDW/2.0L\bDuratorq\fTDCi\b
(100kW/136PS)\b\f\bDW/2.0L\bDuratorq\fTDCi\b
(103kW/140PS)\b\f\bDW,\bEmission\b
Requirements:\bStage\bIV\b\f\bAccessory\bDrive\bBelt
S-MAX/G\bl\bxy\f2006.5\f(02/2006
Removal\band\bInstallation\b
General\bEquipment\b
Removal\bWAR
NING:\fM\bke\fsure\fth\bt\fthe\fignition\fkey\fis\fremoved.\f
N O

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst\bll\btion\fdet\bils.\f
Installation\b
Dowel\fwith\f\b\fdi\bmeter\fof\f4\fmm
1. \f 2. \f\f2.
General
\bqui\fment:
Dowel\fwith\f
\b\fdi\bmeter\f
of\f4\fmm
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
2. For\f\bccessory\fdrive\fbelt\frouting.\f
Refer\fto:\fAccessory\fDrive\f(303-
05D\fAccessory\fDrive\f
Dur\btorq-TDCi\f(DW)\fDiesel,\fDescription\f\bnd\fOper\btion).
\f\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 - \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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On\fvehicles\fwith\f\buto\fst\brt/stop\ffunction,\finform\btion\fis\frequired\f\bbout\fwhether\f\b\fge\br\fis\f
eng\bged\for\fthe\ftr\bnsmission\fis\fin\fneutr\bl.\fThe\fneutr\bl\fposition\fsensor\fis\floc\bted\fon\fthe\f
tr\bnsmission\fhousing\ffor\fthis\fpurpose.\fThis\fis\fconnected\fto\fthe\fshift\flink\bge\fby\f\bn\f\bddition\bl\f
link\bge\fon\fthe\ftr\bnsmission.\f
The\fneutr\bl\fposition\fsensor\fis\f\b\fH\bll\fsensor\f\bnd\fis\fsupplied\fwith\f5\fVolt\fby\fthe\fPCM.\fThe\f
sign\bl\fvolt\bge\fv\bries\fbetween\f0.5\f\bnd\f5\fVolt\fwhen\foper\bting\fthe\flink\bge\f\bnd\fis\fmonitored\f
by\fthe\fPCM.\f
A\ffixed\fvolt\bge\fv\blue\fis\fstored\fin\fthe\fPCM\ffor\fe\bch\fge\br.\fAll\fv\blues\flying\fbetween\fthose\ffor\f
the\findividu\bl\fge\brs\f\bre\fstored\f\bs\fv\blues\ffor\fthe\fneutr\bl\fposition.\fThe\fPCM\ftherefore\f\blw\bys\f
detects\fwhether\for\fnot\f\b\fge\br\fis\feng\bged.\f
After\frepl\bcing\fthe\fsensor,\fthe\fv\blue\ffrom\fthe\fold\fsensor\fis\freset\fin\fthe\fPCM\fusing\fIDS.\fThe\f
vehicle\fmust\fthen\fbe\fdriven\f\b\fcert\bin\fdist\bnce\fso\fth\bt\fthe\fPCM\fc\bn\fle\brn\fthe\fnew\fv\blues\ffor\f
the\frelev\bnt\fge\brs\f\bnd\fneutr\bl\fpositions.\f
To\fdo\fthis,\fthe\fvehicle\fmust\fbe\fdriven\f\b\ftot\bl\fof\f5\ftimes\ffor\f10\fseconds\fe\bch,\f\bltern\btely\fin\f
3rd\f\bnd\f4th\fge\br\fwith\flow\f\bcceler\btion.\f
NOTE:\fIf\f\b\ff\bult\foccurs\fon\fthe\fneutr\bl\fposition\fsensor
\fwhen\fthe\fengine\fis\fst\btion\bry,\fthe\f
vehicle\fc\bn\fstill\fbe\fst\brted\fwith\fthe\fignition\fkey.\fIn\fthis\fc\bse,\f\b\fcorresponding\fDTC\fis\fset\f
in\fthe\fPCM.\f

no\fsign\bl\f\f

defective\fsign\bl\f
\f
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Fuel Ta\bk a\bd L\f\bes - 1.8L Duratorq-TDC\f
(74kW/100PS) - Ly\bx/1.8L Duratorq-
TDC\f (92kW/125PS) - Ly\bx - Fuel F\flter
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal a\bd I\bstallat\fo\b
Spec\fal Tool(s)
Ge\b

eral Equ\fpme\bt
Removal
CA

UTION:\fM\bke\fsure\fth\bt\fthe\fignition\fkey\fis\fremoved.\f
310-110A\f
H\bnd\fPressure\fPump\fwith\fAd\bpter\fKit
\f
Fluid\fcont\biner 1. Refer\fto:\fDiesel\fFuel\fSystem\fHe\blth\f\bnd\fS\bfety\f
Pre

c\butions \f(100-00\fGener\bl\fInform\btion,\f
Des

cription\f\bnd\fOper\btion).\f
2. \f
3. \f
4. Cle\bn\fthe\ffuel\ffilter,\ffuel\fsupply\flines\f\bnd\f surrounding\f\bre\bs.\f
Refer\fto:\f Fuel\fInjection\fComponent\fCle\bning\f
(3 0

3-04D\fFuel\fCh\brging\f\bnd\fControls\f-\f1.8L\f
Dur\btorq-TDCi\f(74kW/100PS)\f-\fLynx/1.8L\f
Dur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\fGener\bl\f
Procedures).\f
5. CAUTION:\fM\bke\fsure\fth\bt\f\bll\fopenings\f
\f
\f\f
\f\f
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Fuel Ta\bk a\bd L\f\bes - 1.8L Duratorq-TDC\f
(74kW/100PS) - Ly\bx/1.8L Duratorq-
TDC\f (92kW/125PS) - Ly\bx - Fuel F\flter
Eleme\bt
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal a\bd I\bstallat\fo\b
Spec\fal Tool(s)
Ge\b

eral Equ\fpme\bt
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
310-110A\f
H\bnd\fPressure\fPump\fwith\fAd\bpter\fKit
\f
Fluid\fcont\biner
1. Refer\fto:\fDiesel\fFuel\fSystem\fHe\blth\f\bnd\fS\bfety\f
Pre

c\butions \f(100-00\fGener\bl\fInform\btion,\f
Des

cription\f\bnd\fOper\btion).\f
2. \f
3. \f
4. Dr\bin\fthe\ffuel\ffilter.\f
General \bqui\fment: Fluid\fcont\biner\f
\f
\f\f
\f\f
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Fuel Ta\bk a\bd L\f\bes - 2.0L Duratorq-TDC\f
(85kW/115PS) - DW/2.0L Duratorq-TDC\f
(100kW/136PS) - DW/2.0L Duratorq-
TDC\f (103kW/140PS) - DW, Em\fss\fo\b
Requ\freme\bts: Stage IV - Fuel F\flter
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal a\bd I\bstallat\fo\b
Spec\fal Tool(s)
Ge\b

eral Equ\fpme\bt
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
310-110A\f
H\bnd\fPressure\fPump\fwith\fAd\bpter\fKit
\f
Fluid\fcont\biner
1. Refer\fto:\fDiesel\fFuel\fSystem\fHe\blth\f\bnd\fS\bfety\f
Pre

c\butions \f(100-00\fGener\bl\fInform\btion,\f
Des

cription\f\bnd\fOper\btion).\f
2. \f
3. \f
4. CAUTION:\fUse\flint\ffree\fcloth.\f
Protect\fthe\fgener\btor\fto\fprevent\fcont\bmin\btion.\f\f
5. Using\f\b\fsuit\bble\flength\fof\ffuel\fresist\bnt\ftube,\f dr\bin\fthe\ffuel\ffilter.\f
General \bqui\fment: Fluid\fcont\biner\f
\f
\f\f
\f\f
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Fuel Ta\bk a\bd L\f\bes - 2.0L Duratorq-TDC\f
(85kW/115PS) - DW/2.0L Duratorq-TDC\f
(100kW/136PS) - DW/2.0L Duratorq-
TDC\f (103kW/140PS) - DW, Em\fss\fo\b
Requ\freme\bts: Stage IV - Fuel F\flter
Eleme\bt
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal a\bd I\bstallat\fo\b
Spec\fal Tool(s)
Ge\b

eral Equ\fpme\bt
Removal WAR

NING:\fRefer\fto:\f Diesel\fFuel\fSystem\fHe\blth\f\bnd\fS\bfety\fPrec\butions \f(100-00\f
Gen

er\bl\fInform\btion,\fDescription\f\bnd\fOper\btion).\f
CAUTION:\fM\bke\fsure\fth\bt\fthe\fignition\fkey\fis\fremoved.\f
NOTE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst\bll\btion\fdet\bils.\f
310-110A\f
H\bnd\fPressure\fPump\fwith\fAd\bpter\fKit
\f
Fluid\fcont\biner
1. \f
2. \f
3. CAUTION:\fUse\flint\ffree\fcloth.\f
Protect\fthe\fgener\btor\fto\fprevent\fcont\bmin\btion.\f\f
4. Using\f\b\fsuit\bble\flength\fof\ffuel\fresist\bnt\ftube,\f dr\bin\fthe\ffuel\ffilter.\f
\f
\f\f
\f\f
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NOTE:\fNOTE:\fOn\fvehicles\fequipped\fwith\f\b\fDVD\fn\bvig\btion\fsystem\fwith\ftouchscreen,\f
interrog\btion\fof\fthe\ff\bult\fmemory\fis\fonly\fpossible\fusing\fthe\fFord\f\bpproved\fdi\bgnostic\ftool.\f
The\fclim\bte\fcontrol\fsystem\ffe\btures\f\b\fself-di\bgnosis\ff
unction\fwhich\fc\bn\fdetect\f\bnd\fstore\f
both\fcurrent\fperm\bnent\ff\bults\f\bs\fwell\f\bs\fintermittent\ff\bults\fwhich\fh\bve\foccurred\fduring\f
norm\bl\foper\btion\fof\fthe\fvehicle.\fIt\fis\f\blso\fpossible\fto\fre\bd\fout\fthese\ff\bults\fvi\b\fthe\fdispl\by\fof\f
the\fEATC\fmodule.\fTo\fre\bd\fout\fthe\ff\bult\fmemory,\fthe\fignition\fkey\fmust\fbe\fturned\fto\fthe\f
"ON"\fposition\f\bnd\fthe\fb\bttery\fvolt\bge\fmust\fbe\fbetween\f9\fV\f\bnd\f16\fV.\f
Activ\btion\fof\fself-di\bgnosis\f
At\fthe\fcontrol\fp\bnel\ffor\fthe\fclim\bte\fcontrol\fsystem,\fPRESS\fthe\f"OFF"\f\bnd\f"FOOTWELL"\f
buttons\fsimult\bneously\ffor\f exactly\f2\fseconds,\fthen\fPRESS\f"AUTO"\fwithin\f1.5\fseconds.\fThe\f
self-di\bgnosis\fwhich\fthen\fst\brts\fl\bsts\f\b\ffew\fseconds.\fAn\f\bnim\bted\fdispl\by\f\bppe\brs\fin\fthe\f
EATC\fdispl\by\fduring\fthis\ftime.\fAny\ff\bults\ffound\f\bre\fdispl\byed\fon\fboth\fdispl\bys\fof\fthe\fEATC\f
in\fthe\fform\fof\ftrouble\fcodes.\f
Ex\bmple:\fLeft-h\bnd\fdispl\by\findic\btes\f"908",\fright-h\bnd\fdispl\by\findic\btes\f"100"\f-\ftrouble\f
code\fre\bd\fout\f908100\f=\fCircuit\fof\fleft-h\bnd\ftemper\bture\fcontrol\ffl\bp\f\bctu\btor\ff\bulty.\f
The\ffollowing\ft\bble\fgives\finform\btion\fon\fthe\fpossible\fSelf-test\fcodes\f/\fDTCs\f\bnd\ftheir\f
corresponding\fme\bnings.\fBy\fPRESSING\fthe\f"DEFROST"\fbutton,\fthe\ff\bult\fmemory\fis\fcle\bred\f
\bnd\fdi\bgnosis\fmode\fis\fended.\fTo\fend\fthe\fdi\bgnostic\fmode\fwithout\fcle\bring\fthe\fDTCs,\f
PRESS\f\bny\fother\fEATC\fbutton.\f
Re\bding\fout\fof\fstored\ff\bults\f
At\fthe\fcontrol\fp\bnel\ffor\fthe\fclim\bte\fcontrol\fsystem,\fPRESS\fthe\f"OFF"\f\bnd\f"FOOTWELL"\f
buttons\fsimult\bneously\ffor\f exactly\f2\fseconds,\fthen\fPRESS\f"HEAD\fAREA"\fwithin\f1.5\f
seconds.\fAny\fstored\ff\bults\f\bre\fshown\fon\fthe\fEATC\fdispl\by\f\bnd\fshould\fbe\fnoted\ffor\fs\bfety\f
re\bsons.\fBy\fPRESSING\fthe\f"DEFROST"\fbutton,\fthe\ff\bult\fmemory\fis\fcle\bred\f\bnd\fdi\bgnosis\f
mode\fis\fended.\fTo\fend\fthe\fdi\bgnostic\fmode\fwithout\fcle\bring\fthe\fDTCs,\fPRESS\f\bny\fother\f
EATC\fbutton.\f
Re\bding\fout\fthe\fsoftw\bre\fversion\f
At\fthe\fcontrol\fp\bnel\ffor\fthe\fclim\bte\fcontrol\fsystem,\fPRESS\fthe\f"OFF"\f\bnd\f"FOOTWELL"\f
buttons\fsimult\bneously\ffor\f exactly\f2\fseconds,\fthen\fPRESS\f"A/C"\fwithin\f1.5\fseconds.\fThe\f
softw\bre\fversion\fis\fshown\fon\fthe\fEATC\fdispl\by.\fThe\foutput\fmode\fc\bn\fbe\fexited\fby\f
PRESSING\f\bny\foper\bting\fbutton\fof\fthe\fEATC.\f
Trouble\bcode\btable\b-\bvehicles\bwith\belectronic\bautomatic\btemperature\bcontrol\b
(EATC)\b
Trouble\bcode\btable,\belectronic\bautomatic\btemperature\bcontrol\b(EATC)\b\b
\fau\bt code -
diagnostic unit
DTCDescriptionAction
908100B108100Circuit\fof\fleft-h\bnd\f
temper\bture\fcontrol\ffl\bp\f
\bctu\btor\ff\bultyGO\fto\fPinpoint\fTest\f I.\f
908200B108200Circuit\fof\fright-h\bnd\f
temper\bture\fcontrol\ffl\bp\f
\bctu\btor\ff\bultyGO\fto\fPinpoint\fTest\fH.\f
908300B108300F\bult\fin\fthe\fcircuit\fof\fthe\f\bir\f
recircul\btion\ffl\bp\f\bctu\btorGO\fto\fPinpoint\fTest\fD.\f
908600B108600F\bult\fin\fcircuit\fof\f\bctu\btor\ffor\f
\bir\fdistribution\ffl\bpGO\fto\fPinpoint\fTest\fG.\f
90B300B10B300F\bult\fin\fcircuit\fof\fcenter\fvents\f
\bir\foutlet\ftemper\bture\fsensor
GO\fto\fPinpoint\fTest\fJ.\f
90B400B10B400F\bult\fin\fcircuit\fof\fright-h\bnd\f
footwell\f\bir\foutlet\f
temper\bture\fsensorGO\fto\fPinpoint\fTest\fK.\f
90B500B10B500F\bult\fin\fcircuit\fof\fleft-h\bnd\fGO\fto\fPinpoint\fTest\fL.\f
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