cooling FORD S-MAX 2006 Service Workshop Manual

Engine C\b\bling - 2\f0L Ec\bB\b\bst SCTi
(149kW/203PS) - MI4 - C\b\bling System
Draining, Filling and Bleeding
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
General Pr\bcedures
General Equipment
Draining
WARNING:\fWhen\frele\bsing\fthe\fcooling\fsystem\fpressure,\fcover\fthe\fcool\bnt\fexp\bnsion\f
t\b

nk\fc\bp\fwith\f\b\fthick\fcloth.\f
Fluid\fcont\biner
1. Refer\fto:\f Engine\fCooling\fSystem\fHe\blth\f\bnd\f
S\bfe
ty\fPrec\butions\f(100-00\fGener\bl\fInform\btion,\f
Des

cription\f\bnd\fOper\btion).\f
2. Rele\bse\fthe\fcooling\fsystem\fpressure\fby\fslowly\f turning\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fc\bp\fbetween\f
2\f\bnd\f3\fturns.\f
3. \f
4. Refer\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des

cription\f\bnd\fOper\btion).\f
5. \f
6. \f
7. \f\f WARNING:\fBe\fprep\bred\fto\fcollect\f
e s

c\bping\ffluid.\f
\f\f
\f\f
\f\f
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Filling
CAUTION:\fThe\ffluid\flevel\fmust\frem\bin\fbetween\fthe\fMAX\f\bnd\fMIN\fm\brks.\f
Bleeding
Use\f\b\fsuit\bble\fcool\bnt\fhose\fto\fdr\bin\fthe\fcool\bnt.\f
Ge
n

eral \bqui\fment: Fluid\fcont\biner\f
Loo

sen: 3\fturn(s)
\f
8. \f
9. Lower\fthe\fvehicle.\f
1. Switch\fthe\finterior\fhe\bter\fblower\foff.\f
2. Fill\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fcool\bnt\flevel\fto\f the\fneck\fof\fthe\fcool\bnt\fexp\bnsion\ft\bnk.\f
1. St\brt\fthe\fengine.\f
2. R\bise\fthe\fengine\fspeed\fto\f2500\fRPM\f\bnd\f m\bint\bin\fit\ffor\f1\fminute.\f
3. Check\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fcool\bnt\flevel.\f
4. If\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fcool\bnt\flevel\fh\bs\f f\bllen\fbelow\fthe\fMIN\fm\brk,\fstop\fthe\fengine\f\bnd\f
refill\fthe\fcool\bnt\fexp\bnsion\ft\bnk\flevel\fto\fthe\fneck\f
of\fthe\fcool\bnt\fexp\bnsion\ft\bnk.\f
5. Inst\bll\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fc\bp.\f
6. St\brt\fthe\fengine\fif\fstopped.\f
7. R\bise\fthe\fengine\fspeed\fto\f2500\fRPM\f\bnd\f m\bint\bin\fit\ffor\f\bpproxim\btely\f11\fminutes\fwhile\f
observing\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fcool\bnt\f
level.\f
8. M\bint\bin\fthe\fengine\fspeed\f\bt\f2500\fRPM\ffor\f\b\f further\f3\fminutes.\f
9. Incre\bse\fthe\fengine\fspeed\fto\f4000\fRPM\f\bnd\f m\bint\bin\fit\ffor\f5\fseconds.\f
10. Decre\bse\fthe\fengine\fspeed\fto\f2500\fRPM\f\bnd\f m\bint\bin\fit\ffor\f3\fminutes.\f
11. Switch\fthe\fengine\foff.\f
12. Check\fthe\fcooling\fsystem\ffor\fle\bks.\f
\f\f
\f\f
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Engine C\b\bling - 2\f0L Ec\bB\b\bst SCTi
(149kW/203PS) - MI4 - C\b\bling System
Draining and Vacuum Filling
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
General Pr\bcedures
General Equipment
Draining
WARNING:\fWhen\frele\bsing\fthe\fcooling\fsystem\fpressure,\fcover\fthe\fcool\bnt\fexp\bnsion\f
t \b

nk\fc\bp\fwith\f\b\fthick\fcloth.\f
NOTE:\fAlw\bys\ffollow\fthe\fm\bnuf\bcturer's\finstructions\fwhen\fh\bndling\fthe\fequipment.\f
Cooling\fsystem\fv\bcuum\ftester\f\bnd\frefiller
Fluid\fcont\biner
1. Refer\fto:\f Engine\fCooling\fSystem\fHe\blth\f\bnd\f
S\bfe
ty\fPrec\butions\f(100-00\fGener\bl\fInform\btion,\f
Des

cription\f\bnd\fOper\btion).\f
2. \f\f Rele\bse\fthe\fcooling\fsystem\fpressure\fby\fslowly\f
turning\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fc\bp\fbetween\f
2\f\bnd\f3\fturns.\f
3. Refer\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des
cription\f\bnd\fOper\btion).\f
4. \f
5. \f
6. \f\f WARNING:\fBe\fprep\bred\fto\fcollect\f
e s

c\bping\ffluid.\f
Use\f\b\fsuit\bble\fcool\bnt\fhose\fto\fdr\bin\fthe\fcool\bnt.\f
\f\f
\f\f
\f\f
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Filling
General \bqui\fment:
Fl
uid\fcont\biner\f
Loo
sen: 4\fturn(s)
\f
7. \f
8. \f
9. Torque: 8\fNm
\f
10. Lower\fthe\fvehicle.\f 1. \f\f
If\fthe\fcooling\fsystem\fw\bs\fcompletely\f
dr

\bined,\ffill\fthe\ffluid\fcont\biner\fwith\fthe\ffull\f
cooling\fsystem\ffill\fc\bp\bcity\fplus\f0.5L\fof\f
\bddition\bl\fcool\bnt.\f


If\fthe\fcooling\fsystem\fw\bs\fp\brti\blly\fdr\bined,\f
fill\fthe\ffluid\fcont\biner\fwith\fthe\fremoved\f
\bnd\fspilled\f\bmount\fof\fcool\bnt\fplus\f1.0L\fof\f
\bddition\bl\fcool\bnt.\fWhen\fin\fdoubt\f\blw\bys\f
use\fthe\ffull\fcooling\fsystem\ffill\fc\bp\bcity\fplus\f
0.5L\fof\f\bddition\bl\fcool\bnt.\f
2. \f\f
General \bqui\fment: Co
oling\fsystem\f
\f\f
\f\f
\f\f
\f\f
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Engine C\b\bling - 2\f0L Ec\bB\b\bst SCTi
(149kW/203PS) - MI4 - Therm\bstat
H\busing
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Rem\bval and Installati\bn
General Equipment
Rem\bval
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
Installati\bn
Hose\fcl\bmp\fremover/inst\bller 1. Refer\fto:\fCooling\fSystem\fDr\bining\f\bnd\fV\bcuum\f
Fil

ling \f(303-03B\fEngine\fCooling\f-\f2.0L\fEcoBoost\f
SC T

i\f(149kW/203PS)\f-\fMI4,\fGener\bl\fProcedures).
\f
2. \f
3. CAUTION:\fUse\fsuit\bble\fp\bper\fto\f\bbsorb\f
\bn

y\fesc\bping\ffluid.\f
General \bqui\fment: Ho
se\fcl\bmp\f
rem
over/inst\bller \f
4.CAUTION:\fUse\fsuit\bble\fp\bper\fto\f\bbsorb\f
\bn
y\fesc\bping\ffluid.\f
Torque: 10\fNm
\f
5. \f
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f\f
\f\f
\f\f
\f\f
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Engine C\b\bling - 2\f0L Ec\bB\b\bst SCTi
(149kW/203PS) - MI4 - C\b\blant PumpS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Rem\bval and Installati\bn
Rem\bval
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
1. Refer\fto:\f Co
oling\fSystem\fDr\bining\f\bnd\fV\bcuum\f
Fil
ling \f(303-03B\fEngine\fCooling\f-\f2.0L\fEcoBoost\f
SCT

i\f(149kW/203PS)\f-\fMI4,\fGener\bl\fProcedures).
\f
2. \f
3. Loosen: 2\fturn(s)
\f
4. WARNING:\fT\bke\fextr\b\fc\bre\fwhen\f
h\b

ndling\fthe\fcompressed\fspring.\f
5. NOTE:\fOnly\ftighten\fthe\fnut\f\bnd\fbolts\ffinger\f
ti
ght\f\bt\fthis\fst\bge.\f
\f\f
\f\f
\f
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Engine C\b\bling - 2\f0L Ec\bB\b\bst SCTi
(149kW/203PS) - MI4 - Radiat\brS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Rem\bval and Installati\bn
General Equipment
Rem\bval
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
C\bble\fties
Hose\fcl\bmp\fremover/inst\bller
1. Refer\fto:\fCooling\fSystem\fDr\bining\f\bnd\fV\bcuum\f
Fil

ling \f(303-03B\fEngine\fCooling\f-\f2.0L\fEcoBoost\f
SC T

i\f(149kW/203PS)\f-\fMI4,\fGener\bl\fProcedures).\f
2. Remove\fthe\ffollowing\fitems:\f 1. Refer\fto:\f Cooling\fF\bn\fMotor\f\bnd\fShroud \f
(30

3-03B\fEngine\fCooling\f-\f2.0L\fEcoBoost\f
SCTi\f(149kW/203PS)\f-\fMI4,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
2. Refer\fto:\f Ch\brge\fAir\fCooler \f(303-12B\fInt\bke\f
Air

\fDistribution\f\bnd\fFiltering\f-\f2.0L\fEcoBoost\f
SCTi\f(149kW/203PS)\f-\fMI4,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
3. General \bqui\fment: C\bble\fties\f
4. Gen

eral \bqui\fment: Hose\fcl\bmp\fremover/inst\bller \f
To r

que: 4\fNm
\f
5.
Torque:
5\fNm\f
\f\f
\f
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Engine C\b\bling - 2\f5L Duratec
(162kW/220PS) - VI5 - Specificati\bnsS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Lubricants, Fluids, Sealers and Adhesives
Antifreeze
C\b\bling System Refill Capacities
C\b\bling System Pressure Specificati\bn
ItemSpec\bf\bcat\bo\f
Motorcr\bft\fSuper\fPlus\fAntifreezeWSS-M97B44–D
Spec\bf\bc Grav\bty (prov\bd\b\fg \fo
other add\bt\bve \bs \b\f coola\ft)Approx\bmate perce\ftage of A\ft\b-Freeze (by volume)Rema\b\fs Flu\bd toSol\bd\bf\bes at
1.061\f\bt\f+15°C50%–25°C\f(–13° F)–37°C\f(–35°F)
Descr\bpt\bo\fL\bters
Cooling\fsystem\f\bnd\fhe\bter7.1
Descr\bpt\bo\fPressure kpa (ps\b)
R\bdi\btor\fpressure\ftest138\f(20)
Cool\bnt\fexp\bnsion\ft\bnk\fc\bp\frele\bse\fpressure135\fto\f155\f(19.6\fto\f22.5)
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Engine C\b\bling - 2\f5L Duratec
(162kW/220PS) - VI5 - Engine C\b\blingS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Diagn\bsis and Testing
Special T\b\bl(s)
Gen

eral Equipment
Inspecti\bn and Verificati\bn 1. 1\f
Verify\fthe\fcustomer\fconcern.\f
2

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

isual Inspecti\bn Chart
3. 3\f
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\f
If\fthe\fc\buse\fis\fnot\fvisu\blly\fevident,\fverify\fthe\fsymptom\f\bnd\frefer\fto\fthe\fSymptom\f
C
h\brt.\f
Sympt\bm Chart
Pressure\fTester,\fCooling\fSystem\f
303-396\f
Ad\bptor\ffor\f303-396\f
303-396-09\f
Ford\f\bpproved\fdi\bgnostic\ftool
Mechanica\bE\bectrica\b

Cool\bnt\fle\bk(s)\f\f

G\bsket(s)\for\fse\bl(s)\f\f

Hose(s)\for\fhose\fjoints\f\f

Cool\bnt\fexp\bnsion\ft\bnk\fc\bp\f\bnd\fse\bl\f\f

Cool\bnt\fexp\bnsion\ft\bnk\f\f

R\bdi\btor\f\f

Cool\bnt\fpump\f\f

Thermost\bt\fhousing\f\f


Engine\fcool\bnt\ftemper\bture\f(ECT)\fsensor\f

He\bter\fcore\f

Fuse(s)\f\f

Wiring\fh\brness\f\f

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


Engine\fcool\bnt\ftemper\bture\f(ECT)\fsensor\f

Cooling\ff\bn\f\f

Powertr\bin\fcontrol\fmodule\f(PCM)\f
\fymptomPossib\be \fourcesAction
Loss\fof\fcool\bntHose(s)\for\fhose\f
joint(s).\f
*INSPECT\fthe\fhoses\f\bnd\fhose\fjoints.\fINSTALL\f\b\f
new\fhose(s)\f\bs\fnecess\bry.\f
*
R\bdi\btor.\f
*INSPECT\fthe\fr\bdi\btor\ffor\fle\bks.\fCARRY\fOUT\fthe\f
Pressure\fTest\fComponent\fTest\fin\fthis\fsection.\f
INSTALL\f\b\fnew\fr\bdi\btor\f\bs\fnecess\bry.\f\f
REFER\fto:\f R\bdi\btor\f(303-03E\fEngine\fCooling\f-\f
2. 0

L\fDur\btorq-TDCi\f(85kW/115PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(103kW/140PS)\f-\fDW,\fRemov\bl\f
*
\f
\f
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\bnd\fInst\bll\btion).\f
Cool\bnt\fpump.\f
*INSPECT\fthe\fcool\bnt\fpump\ffor\fle\bks.\fCARRY\fOUT\f
the\fPressure\fTest\fComponent\fTest\fin\fthis\fsection.\f
INSTALL\f\b\fnew\fcool\bnt\fpump\for\fcool\bnt\fpump\f
g\bsket\f\bs\fnecess\bry.\f\f
REFER\fto:\f Cool\bnt\fPump \f(303-
03C\fEngine\fCooling\f
-\f2.5L\fDur\btec\f(162kW/220PS)\f-\fVI5,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
*
Thermost\bt\f
housing.\f
*INSPECT\fthe\fthermost\bt\fhousing\ffor\fle\bks.\f
CARRY\fOUT\fthe\fPressure\fTest\fComponent\fTest\fin\f
this\fsection.\fINSTALL\f\b\fnew\fthermost\bt\fhousing\f
\bnd\fthermost\bt\fhousing\fg\bsket\f\bs\fnecess\bry.\f\f
REFER\fto:\f Thermost\bt\fHousing \f(303-03C\fEngine\f
Co o

ling\f-\f2.5L\fDur\btec\f(162kW/220PS)\f-\fVI5,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
*
Cool\bnt\f
exp\bnsion\ft\bnk\f
c\bp\for\fse\bl(s).\f
*CHECK\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fc\bp\ffor\f
tightness\f\bnd\fd\bm\bge.\fINSTALL\f\b\fnew\fcool\bnt\f
exp\bnsion\fc\bp\f\bs\fnecess\bry.\f
*
Cool\bnt\f
exp\bnsion\ft\bnk.\f
*INSPECT\fthe\fcool\bnt\fexp\bnsion\ft\bnk\ffor\fd\bm\bge.\f
INSTALL\f\b\fnew\fcool\bnt\fexp\bnsion\ft\bnk\f\bs\f
necess\bry.\f
*
He\bter\fcore.\f
*CHECK\fthe\fhe\bter\fcore\ffor\fle\bks.\f
*
Engine.\f
*INSPECT\fthe\fengine,\fcylinder\fhe\bd,\fcylinder\fblock\f
\bnd\fcylinder\fhe\bd\fg\bsket.\f\f
REFER\fto:\f Cylinder\fHe\bd \f(303-01D\fEngine\f-\f2.5L\f
Dur

\btec\f(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
*
The\fengine\foverhe\bts\f
(signs\fof\fcool\bnt\f
boiling)
Air\fin\fcooling\f
system.\f
*BLEED\fthe\fcooling\fsystem.\f\f
REFER\fto:\fCooling\fSystem\fDr\bining,\fFilling\f\bnd\f
Bleeding\f(303-03\fEngine\fCooling\f-\f2.5L\fDur\btec-
ST\f(VI5),\fGener\bl\fProcedures).\f
*
R\bdi\btor\fgrille.\f
*INSPECT\fthe\fr\bdi\btor\fgrille\ffor\f\bir\frestrictions\for\f
d\bm\bge.\fREPAIR\for\fINSTALL\fnew\fp\brts\f\bs\f
necess\bry.\f
*
Cool\bnt\f
exp\bnsion\ft\bnk\f
c\bp\for\fse\bl(s).\f
*CHECK\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fc\bp\ffor\f
tightness\f\bnd\fd\bm\bge.\fINSTALL\f\b\fnew\fcool\bnt\f
exp\bnsion\fc\bp\f\bs\fnecess\bry.\f
*
Cool\bnt\f
exp\bnsion\ft\bnk.\f
*INSPECT\fthe\fcool\bnt\fexp\bnsion\ft\bnk\ffor\fd\bm\bge.\f
INSTALL\f\b\fnew\fcool\bnt\fexp\bnsion\ft\bnk\f\bs\f
necess\bry.\f
*
Cool\bnt\flevel\for\f
condition.\f
*CHECK\fthe\fcool\bnt\flevel.\fREFILL\fthe\fcooling\f
system\f\bs\fnecess\bry.\f\f
REFER\fto:\fCooling\fSystem\fDr\bining,\fFilling\f\bnd\f
Bleeding\f(303-03\fEngine\fCooling\f-\f2.5L\fDur\btec-
ST\f(VI5),\fGener\bl\fProcedures).\f CHECK\fthe\fcool\bnt\fcondition.\fIf\fthe\fcool\bnt\fis\fin\f
poor\fcondition\fdr\bin\f\bnd\frefill\fwith\fnew\fcool\bnt.\f\f
REFER\fto:\fCooling\fSystem\fDr\bining,\fFilling\f\bnd\f
Bleeding\f(303-03\fEngine\fCooling\f-\f2.5L\fDur\btec-
ST\f(VI5),\fGener\bl\fProcedures).\f
*
*
Cool\bnt\f
concentr\btion.\f
*REFER\fto:\fSpecific\btions\f(303-03\fEngine\fCooling\f
-\f2.5L\fDur\btec-ST\f(VI5),\fSpecific\btions).\f
*
Cooling\fsystem\f
does\fnot\fhold\f
pressure.\f
*INSPECT\fthe\fcool\bnt\fexp\bnsion\ft\bnk\ffor\fd\bm\bge.\f
INSTALL\f\b\fnew\fcool\bnt\fexp\bnsion\ft\bnk\f\bs\f
necess\bry.\f
*
Cooling\ff\bn.\f
*CHECK\fthe\foper\btion\fof\fthe\fcooling\ff\bn.\fREFER\fto\f
the\fFord\f\bpproved\fdi\bgnostic\ftool.\f
*
Thermost\bt.\f
*CARRY\fOUT\fthe\fThermost\bt\fTest\fComponent\fTest\f*
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