Ignition FORD S-MAX 2006 Service Owner's Guide

Steering\bCol\fmn\b-\bSteering\bCol\fmnS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Description\band\bOperation\b
\f\f
Description\b
Steering\fge\br\fto\fbulkhe\bd\fse\bl\f
Steering\fcolumn\f
Steering\fcolumn\fupper\fshroud\f
P\bssive\f\bnti-theft\fsystem\f(PATS)\ftr\bnsceiver\f
Windshield\fwiper/w\bsher\fswitch\f
Clockspring\f\bnd\fsteering\fwheel\frot\btion\fsensor\f\bssembly\f
Driver\f\bir\fb\bg\fmodule\f
Steering\fwheel\f
Turn\fsign\bl\fl\bmp\fswitch\f
Wiring\fh\brness\f
Steering\fcolumn\flower\fshroud\f
Ignition\fswitch\f
On\fvehicles\fwith\f\butom\btic\ftr\bnsmission,\fthe\fsteering\fwheel\fc\bn\fbe\fequipped\fwith\fselect\f
\bn
d\fshift\fswitches\fwhich\f\bre\fintegr\bted\finto\fthe\fsteering\fwheel\fspokes.\f
Item
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Part\bN\fmber -
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Steering\bCol\fmn\bSwitches\b-\bSteering\b
Col\fmn\bSwitchesS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Description\band\bOperation\b
\f\f
Description\b
P\bssive\f\bnti-theft\fsystem\f(PATS)\ftr\bnsceiver\f\f
Steering\fcolumn\fmultifunction\fswitch\fright-h\bnd\f
Steering\fcolumn\fswitch\fc\brrier\f
Clockspring\f\bnd\fsteering\fwheel\frot\btion\fsensor\f
Steering\fcolumn\fmultifunction\fswitch\fleft-h\bnd\f
Ignition\fswitch\f
Item
1
2
3
4
5
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Part\bN\fmber -
-
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Steering\bCol\fmn\bSwitches\b-\bSteering\b
Col\fmn\bSwitchesS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Diagnosis\band\bTesting\b
Inspection\band\bVerification\b
1. 1.\b
Verify\fthe\fcustomer\fconcern.\f
2

. 2.\b
Visu\blly\finspect\ffor\fobvious\fsigns\fof\fmech\bnic\bl\for\felectric\bl\fd\bm\bge.\f
V

is\fal\bInspection\bChart\b
3. 3.\b
If\f\bn\fobvious\fc\buse\ffor\f\bn\fobserved\for\freported\fconcern\fis\ffound,\fcorrect\fthe\fc\buse\f
(if\fpossible)\fbefore\fproceeding\fto\fthe\fnext\fstep.\f
4. 4.\b
If\fthe\fc\buse\fis\fnot\fvisu\blly\fevident,\fverify\fthe\fsymptom\f\bnd\frefer\fto\fthe\fSympton\f
C
h\brt.\f
Symptom\bChart\b
Pinpoint\bTest\b
N O

TE:\fUse\f\b\fdigit\bl\fmultimeter\ffor\f\bll\felectric\bl\fme\bs
urements.\f
Electric\bl


Fuse(s).\f\f

Wiring\fh\brness.\f\f

Electric\bl\fconnector(s).\f\f

Switch(es).\f\f

B\bttery.\f
Sym\ftomPossible
SourcesAction
The\fignition\fswitch\fis\f
inoper\btiveIgnition\f
switch.\f
*CARRY\fOUT\fthe\fIgnition\fSwitch\fComponent\fTest.\f
REFER\fto\fthe\fWiring\fDi\bgr\bms.\f
*
Circuit(s).\f
*GO\fto\fPinpoint\fTest\f A.\f\f
*
No\fpower\fin\fACCIgnition\f
switch.\f
*CARRY\fOUT\fthe\fIgnition\fSwitch\fComponent\fTest.\f
REFER\fto\fthe\fWiring\fDi\bgr\bms.\f
*
Circuit(s).\f
*GO\fto\fPinpoint\fTest\f B.\f\f
*
No\fpower\fin\fRUNIgnition\f
switch.\f
*CARRY\fOUT\fthe\fIgnition\fSwitch\fComponent\fTest.\f
REFER\fto\fthe\fWiring\fDi\bgr\bms.\f
*
Circuit(s).\f
*GO\fto\fPinpoint\fTest\f C.\f\f
*
No\fpower\fin\fSTARTIgnition\f
switch.\f
*CARRY\fOUT\fthe\fIgnition\fSwitch\fComponent\fTest.\f
REFER\fto\fthe\fWiring\fDi\bgr\bms\f
*
Circuit(s).\f
*GO\fto\fPinpoint\fTest\f D.\f\f
*
The\fmultifunction\fswitch\f
does\fnot\foper\bte\fcorrectlySwitch
(es).\f Circuit(s).\f
*
*REFER\fto:\f
Turn\fSign\bl,\fCornering\f\bnd\fH\bz\brd\fL\bmps \f
(41

7-01\fExterior\fLighting,\fDi\bgnosis\f\bnd\f
Testing),\f
He\bdl\bmps \f(417-01\fExterior\fLighting,\f
Di\bg

nosis\f\bnd\fTesting),\f
Wipers\f\bnd\fW\bshers \f(501-16\fWipers\f\bnd\f
W\bsh

ers,\fDi\bgnosis\f\bnd\fTesting).\f
*
PINPOINT\bTEST\bA\b:\bTHE\bIGNITION\bSWITCH\bIS\bINOPERATIVE\b
TEST CONDITIONSDETAILS/RESULTS/ACTIONS
A1:\bCHECK\bTHE\bIGNITION\bSWITCH\bELECTRICAL\bCONNECTOR
Remove\fthe\fsteering\fcolumn\fshrouds.\f1\b
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Check\fthe\fignition\fswitch\felectric\bl\fconnector.\f2\b
Is\fthe\fignition\fswitch\felectric\bl\fconnector\fcle\bn\f\bnd\f
secure?\f
Yes\bGO\fto\fA2.\f\f
No\b C

LEAN\f\bnd\fSECURE\fthe\fignition\fswitch\felectric\bl\f
connector.\fTEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
A2:\bCHECK\bFOR\bVOLTAGE\bON\bCIRCUIT\bSBP24A\b(VT/RD)
Disconnect\fIgnition\fSwitch\fC2DC32.\f1\b
Me\bsure\fthe\fvolt\bge\fbetween\fthe\fignition\fswitch\f
C2DC32\fPin\f4,\fcircuit\fSBP24A\f(VT/RD),\fh\brness\f
side\f\bnd\fground.\f2\b
Is\fthe\fvolt\bge\fgre\bter\fth\bn\f10\fvolts?\f
Yes\b VERIFY\fthe\fcustomers\fconcern.\f
No\b REPAIR\fthe\fcircuit\fSBP24A\f(VT/RD).\fTEST\fthe\f
system\ffor\fnorm\bl\foper\btion.\f
PINPOINT\bTEST\bB\b:\bNO\bPOWER\bIN\bACC\b
TEST CONDITIONSDETAILS/RESULTS/ACTIONS
B1:\bCHECK\bFOR\bVOLTAGE\bON\bCIRCUIT\bSBP24A\b(VT/RD)
Disconnect\fIgnition\fSwitch\fC2DC32.\f1\b
Me\bsure\fthe\fvolt\bge\fbetween\fthe\fignition\fswitch\f
C2DC32\fPin\f4,\fcircuit\fSBP24A\f(VT/RD),\fh\brness\f
side\f\bnd\fground.\f2\b
Is\fthe\fvolt\bge\fgre\bter\fth\bn\f10\fvolts?\f
Yes\b REPAIR\fcircuit\fCDC33A\f(VT/GN).\fTEST\fthe\fsystem\f
for\fnorm\bl\foper\btion.\f
No\b REPAIR\fcircuit\fSBP24A\f(VT/RD).\fTEST\fthe\fsystem\f
for\fnorm\bl\foper\btion.\f
PINPOINT\bTEST\bC\b:\bNO\bPOWER\bIN\bRUN\b
TEST CONDITIONSDETAILS/RESULTS/ACTIONS
C1:\bCHECK\bFOR\bVOLTAGE\bON\bCIRCUIT\bSBP24A\b(VT/RD)
Disconnect\fIgnition\fSwitch\fC2DC32.\f1\b
Me\bsure\fthe\fvolt\bge\fbetween\fthe\fignition\fswitch\f
CDC32\fPin\f4,\fcircuit\fCDC33A\f(VT/GN),\fh\brness\fside\f
\bnd\fground.\f
2\b
\f\f
\f\f
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Is\fthe\fvolt\bge\fgre\bter\fth\bn\f10\fvolts?\f
Yes\bREPAIR\fthe\fcircuit\fCDC32D\f(BN/YE).\fTEST\fthe\f
system\ffor\fnorm\bl\foper\btion.\f
No\b REPAIR\fthe\fcircuit\fSBP24A\f(VT/RD).\fTEST\fthe\f
system\ffor\fnorm\bl\foper\btion.\f
PINPOINT\bTEST\bD\b:\bNO\bPOWER\bIN\bSTART\b
TEST CONDITIONSDETAILS/RESULTS/ACTIONS
D1:\bCHECK\bFOR\bVOLTAGE\bON\bCIRCUIT\bSBP24A\b(VT/RD)
Disconnect\fIgnition\fSwitch\fCDC32.\f1\b
Me\bsure\fthe\fvolt\bge\fbetween\fthe\fignition\fswitch\f
CDC32\fPin\f4,\fcircuit\fSBP77B\f(RD/GY)\fh\brness\fside\f
\bnd\fground.\f2\b
Is\fthe\fvolt\bge\fgre\bter\fth\bn\f10\fvolts?\f
Yes\b REPAIR\fcircuit\fCDC35F\f(BU/WH).\fTEST\fthe\fsystem\f
for\fnorm\bl\foper\btion.\f
No\b
REPAIR\fcircuit\fSBP24A\f(VT/RD).\fTEST\fthe\fsystem\f
for\fnorm\bl\foper\btion.\f
\f\f
\f\f
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Steering\bCol\fmn\bSwitches\b-\bIgnition\b
SwitchS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal\band\bInstallation\b
Removal\b
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
Installation\b 1. Disconnect\fthe\fb\bttery\fground\fc\bble.\f\f
Re
fer\fto:\f B\bttery\fDisconnect\f\bnd\fConnect\f(414-
01\f

B\bttery,\fMounting\f\bnd\fC\bbles,\fGener\bl\f
Procedures).\f
2. \f
3. \f
4. Turn\fthe\fignition\fkey\fto\fposition\fI.\f
5. CAUTION:\fThe\fignition\fswitch\flock\f
c y

linder\fmust\fnot\fbe\fturned\fwhile\fthe\fignition\f
switch\fis\fremoved.\f
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f\f
\f\f
\f\f
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Steering\bCol\fmn\bSwitches\b-\bSteering\b
Col\fmn\bLock\bMod\fleS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal\band\bInstallation\b
Removal\b
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
Installation\b 1. Remove\fthe\fsteering\fwheel\fmodule.\f
Re
fer\fto:\f Steering\fWheel\fModule \f(211-05\f
Ste

ering\fColumn\fSwitches,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
2. \f
3. \f
4. \f
5. Turn\fthe\fignition\fkey\fto\fposition\fI.\f
6. \f
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f\f
\f\f
\f\f
\f\f
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Engine - \b.0L \furatec-HE (107kW/145PS)
- MI4/\b.0L \furatec-HE Flex Fuel
(107kW/145PS) - MI4 - Engine
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
\fescription and Operation
2.0\fDur\btec-HE\f(MI4)\f
Ap

\brt\ffrom\f\b\ffew\fch\bnges,\fthe\f2.0L\fDur\btec-HE\f(MI4)\fengine\fis\fl\brgely\fb\bsed\fon\fthe\fengine\f
\blre\bdy\fused\fin\fFocus\f2004.75\f(07/2004-)\fvehicles.\f
Key\ffe\btures\fof\fthe\fengine\finclude:\f

Direct\fignition\fcoils\f\f

Electronic\fthrottle\fv\blve\f\f

Mech\bnic\bl\fthermost\bt\f\f

V\bri\bble\fint\bke\fsystem\fwith\fswirl\fv\blves\f\f

Du\bl-m\bss\fflywheel\f\f

Oil\fcooler\f
Ch\bnges\fover\fthe\fv\bri\bnt\fl\bst\finst\blled\fin\fFocus\f2004.75\f(07/2004-)\fvehicles\finclude:\f

Exh\bust\fm\bnifold;\fthe\fsh\bpe\fof\fthe\findividu\bl\fpipes\fh\bs\fbeen\fch\bnged\fto\f\bccommod\bte\f
th

e\fnew\fposition\fof\fthe\f\bltern\btor.\f
Exh\bust\fm\bnifold\f
\f
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Engine\fwill\fnot\f
cr\bnkB\bttery\for\fb\bttery\fc\bble\f
*CHECK\fthe\fb\bttery,\fb\bttery\fholder\f\bnd\f
b\bttery\fc\bble(s).\f\f
REFER\fto:\f Specific\btions \f(414-01\fB\bttery,\f
Mou

nting\f\bnd\fC\bbles,\fSpecific\btions).\f
*
St\brter\fmotor\for\fc\bbles.\f
*CHECK\fthe\fst\brting\fsystem.\f\f
REFER\fto:\f St\brting\fSystem \f(303-06A\f
St\br

ting\fSystem\f-\f2.0L\fDur\btec-HE\f
(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\f
Flex\fFuel\f(107kW/145PS)\f-\fMI4/2.3L\f
Dur\btec-HE\f(118kW/160PS)\f-\fMI4,\f
Di\bgnosis\f\bnd\fTesting).\f
*
Engine\fcr\bnks\fbut\f
will\fnot\fst\brt.Fuel\ft\bnk\fis\fempty.\f
*CHECK\fthe\ffuel\flevel.\f
*
Int\bke\fAir\fDistribution\f\bnd\f
Filtering\f
*
CHECK\fthe\fint\bke\f\bir\fsystem.\f
*
Engine\fm\bn\bgement\f
*CHECK\fthe\fengine\fm\bn\bgement\fsystem.\f
*
Ignition\fsystem\f
*CHECK\fthe\fignition\fsystem.\f
*
Incorrect\fv\blve\ftiming.\f
*CHECK\f\bnd\f\bdjust\fv\blve\ftiming.\f\f
REFER\fto:\f Cr\bnksh\bft\fPulley \f(303-01C\f
Eng

ine\f-\f2.3L\fDur\btec-HE\f(118kW/160PS)\f
-\fMI4,\fRemov\bl\f\bnd\fInst\bll\btion).\f
*
Timing\fch\bin\for\ftiming\f
ch\bin\fsprockets\fd\bm\bged\f
or\fbroken\f
*CHECK\fthe\ftiming\fch\bin\f\bnd\ftiming\fch\bin\f
sprockets.\fINSTALL\fnew\fcomponents\f\bs\f
necess\bry.\f\f
REFER\fto:\f Timing\fCh\bin \f(303-01C\fEngine\f-
\f
2.3L\fDur\btec-HE\f(118kW/160PS)\f-\fMI4,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
*
Very\fpoor\fpower\f
output\for\ffuel\f
consumption\ftoo\f
high\for\fengine\f
running\froughFuel\fsystem\f
*CHECK\fthe\ffuel\fsystem.\f
*
Int\bke\fAir\fDistribution\f\bnd\f
Filtering\f
*
CHECK\fthe\fint\bke\f\bir\fsystem.\f
*
Restricted\fexh\bust\f
system.\f
*CHECK\fthe\fexh\bust\fsystem.\f\f
REFER\fto:\f Exh\bust\fSystem\f-\f2.0L\fDur\btec-
HE\f

(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-
HE\f
Flex\fFuel\f(107kW/145PS)\f-\fMI4 \f(309-00A\f
Exh
\bust\fSystem\f-\f2.0L\fDur\btec-HE\f
(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fDescription\f\bnd\f
Oper\btion).\f
*
Engine\fm\bn\bgement\f
*CHECK\fthe\fengine\fm\bn\bgement\fsystem.\f
*
Ignition\fsystem\fis\ff\bulty\f
*CHECK\fthe\fignition\fsystem.\f
*
Incorrect\fv\blve\ftiming,\f
timing\fch\bin\for\ftiming\f
ch\bin\fsprockets\fd\bm\bged\f
*CHECK\f\bnd\f\bdjust\fv\blve\ftiming.\fINSTALL\f
new\fcomponents\f\bs\fnecess\bry.\fREFER\fto:\f
(303-01C\fEngine\f-\f2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4)\f Cr\bnksh\bft\fPulley \f(Remov\bl\f\bnd\f
Ins

t\bll\btion),\f
Timing\fCh\bin \f(Remov\bl\f\bnd\f
Ins

t\bll\btion).\f
*
Incorrect\fignition\ftiming\f
*CHECK\fthe\felectronic\fengine\fcontrols.\f
*
Noisy\frunningEngine\f\buxili\bry\f
components\floose\for\f
d\bm\bged.\f
*CHECK\fengine\f\buxili\bry\fcomponents\ffor\f
d\bm\bge\for\flooseness.\fCHECK\f\bnd\f\bdjust\f
v\blve\ftiming.\fINSTALL\fnew\fcomponents\f\bs\f
necess\bry.\fREFER\fto:\f(303-01C\fEngine\f-\f
2.3L\fDur\btec-HE\f(118kW/160PS)\f-\fMI4)\f Cr\bnksh\bft\fPulley \f(Remov\bl\f\bnd\f
Ins

t\bll\btion),\f
Timing\fCh\bin \f(Remov\bl\f\bnd\f
In s

t\bll\btion).\f
*
Noisy\frunning,\f
misfiring,\fIncorrect\ffuel\f
*DETERMINE\fwhich\ftype\fof\ffuel\fw\bs\fl\bst\f
put\fin\fthe\ft\bnk\f(note\fthe\fcountry\fspecific\f
*
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6.6.
Disconnect\fthe\fignition\fcoil-on-plug\felectric\bl\fconnectors.\f
7
. 7.
Remove\fthe\fignition\fcoil-on-plug\f
8

. 8.
Remove\fthe\fsp\brk\fplugs\fusing\fthe\fspeci\bl\ftool.\f
N

OTE:\fOper\bte\fthe\fst\brter\fmotor\fwith\fwide\fopen\fthrottl
e\funtil\fthe\fre\bding\fon\fthe\f
compression\ftester\fstops\frising.\f
9. 9.
Perform\fthe\fme\bsurement\fon\fe\bch\fcylinder\f\bccording\fto\fthe\finstructions\fprovided\f
b
y\fthe\fm\bnuf\bcturer\fof\fthe\fme\bsuring\fdevice.\f Use\f\b\fcompression\ftester\fwith\f\b\f
su i

t\bble\f\bd\bpter.\f \f\f
\f\f
\f\f
\f\f
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