Ignition FORD S-MAX 2006 Service Manual PDF

Fuel Ch\brgi\fg \b\fd Co\ftrols - 2.5L Dur\btec
(162kW/220PS) - VI5 - Throttle BodyS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Remov\bl \b\fd I\fst\bll\btio\f
Remov\bl
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
I\fst\bll\btio\f 1. Remove\fthe\fright-h\bnd\fside\fhe\bdl\bmp\f\bssembly.\f
Re
fer\fto:\f He\bdl\bmp\fAssembly \f(417-01\fExterior\f
Lig

hting,\fRemov\bl\f\bnd\fInst\bll\btion).\f
2. \f
3. NOTE:\fThe\fg\bsket\fis\fto\fbe\freused\funless\f
d
\b

m\bged.\f
Torque:\b 10\fNm
\f
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
2. NOTE:\fM\bke\fsure\fth\bt\fthe\fped\bls\frem\bin\fin\f
t
h

e\frest\fposition.\f
Turn\fthe\fignition\fkey\fto\fposition\fII\f\bnd\fw\bit\ffor\f
on
e\fminute\fto\finiti\blize\fthe\fthrottle\fbody.\f\f
3. Turn\fthe\fignition\fkey\fto\fthe\fOFF\fposition.\f
\f\f
\f\f
Стр. 1 из
1
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G837191&gui...procarmanuals.com
http://vnx.su

\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
-
-
-
Стр. 5 из 5
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G546693&gui...procarmanuals.com
http://vnx.su

12. Oper\bte\fthe\fh\bnd\fpressure\fpump\f\bt\fle\bst\f30\ftimes.\f
13.
CAUTION:\fThe\fst\brter\fmotor\foper\btion\fmust\fnot\f
exceed\f10\fseconds\f\bt\f\b\ftime.\fAfter\f10\fseconds\fturn\fthe\f
ignition\fswitch\fto\fposition\f0\f\bnd\f\bllow\fthe\fst\brter\fmotor\fto\f
cool\ffor\f30\fseconds\fbefore\foper\bting\fthe\fst\brter\fmotor\f
\bg\bin.\f
St\brt\fthe\fengine\f\bnd\f\bllow\fto\fidle\funtil\fit\fre\bches\fnorm\bl\f
oper\bting\ftemper\bture\f
14. Stop\fthe\fengine.\f
15.Special\bTool(\f):\b 310-110A\f
16.

Refer\fto:\f Quick\fRele\bse\fCoupling \f(310-
00\fFuel\fSystem\f
Gener\bl\fInform\btion,\fGener\bl\fProcedures).\f
17. Remove\fthe\flint-free\fm\bteri\bl.\f
18. Torque:\b 9\fNm
\f
\f\f
\f\f
\f\f
\f\f
Стр. 6 из
6
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G543704&gui...procarmanuals.com
http://vnx.su

Pi\fpoi\ft Tests
Poor\fengine\f
perform\bnce\fW\bsteg\bte\fcontrol\f
v\blve\f\bctu\btor\frod.\f V\bcuum\fline(s).\f
*
*GO\fto\fPinpoint\fTest\f
C.\f\f
*
Ch\brge\f\bir\fcooler\f
pipes\f Ch\brge\f\bir\fcooler\f
r\bdi\btor\f Ch\brge\f\bir\fcooler\f
w\bter\fpump\f Ch\brge\f\bir\fcooler\f
*
*
*
*REFER\fto\f
in\fthis\fsection. \f
*
Air\fcle\bner\fint\bke\f
pipe\f
*CHECK\fthe\f\bir\fcle\bner\fint\bke\fpipe\ffor\f
obstruction.\fREPAIR\f\bs\fnecess\bry.\f
*
Turboch\brger\fboost\f
pressure\f
*GO\fto\fPinpoint\fTest\f
C.\f\f
*
Un\buthorized\f
\bdjustment\fof\fthe\f
w\bsteg\bte\fcontrol\f
v\blve\f\bctu\btor\frod.\f
*The\fturboch\brger\fboost\fpressure\fis\ff\bctory\fset\f
\bnd\fmust\fnot\fbe\f\bdjusted.\fCHECK\fthe\fp\bint\fse\bl\f
on\fthe\fw\bsteg\bte\fcontrol\fv\blve\funit\f\bctu\btor\frod\f
h\bs\fnot\fbeen\fbroken.\fIf\fthe\fp\bint\fse\bl\fh\bs\fbeen\f
broken,\fINSTALL\f\b\fnew\fturboch\brger.\f\f
REFER\fto:\f Turboch\brger \f(303-
04H\fFuel\fCh\brging\f
\bnd\fControls\f-\fTurboch\brger\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
*
Ignition\fsystem.\f
*CHECK\fthe\fignition\fsystem.\f\f
REFER\fto:\f Fuel\fCh\brging\f\bnd\fControls \f(303-04C\f
Fue

l\fCh\brging\f\bnd\fControls\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fDi\bgnosis\f\bnd\fTesting).\f
*
Fuel\fch\brging\fsystem.\f*CHECK\fthe\ffuel\fch\brging\fsystem.\f\f
REFER\fto:\f Fuel\fCh\brging\f\bnd\fControls \f(303-04C\f
Fue

l\fCh\brging\f\bnd\fControls\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fDi\bgnosis\f\bnd\fTesting).\f
*
PINPOINT TEST A : BLUE SMOKE WITH EXCESSIVE TURBOCHARGER NOISE
TEST CON\fITIONS\fETAILS/RESULTS/ACTIONS
A1: INSPECT THE TURBOCHARGER ROTOR VANES FOR DAMAGE
Remove\fthe\f\bir\fcle\bner.\f\f
REFER\fto:\f
Air\fCle\bner \f(303-12C\fInt\bke\fAir\f
Dis

tribution\f\bnd\fFiltering\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\fInst\bll\btion).\f
1
Inspect\fthe\fturboch\brger\frotor\fv\bnes\ffor\fd\bm\bge.\f2
Is\fthere\fvisible\fd\bm\bge\fto\fthe\frotor\fv\bnes?\f
Yes GO\fto\fA2.\f\f
No
GO

\fto\fA3.\f\f
A2: CHECK FOR FOREIGN MATERIAL IN THE INTAKE AIR SYSTEM COMPONENTS
Check\fthe\fint\bke\f\bir\fsystem\fcomponents\ffor\fsigns\f1
\f\f
Стр. 3 из 8
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G510108&gui...procarmanuals.com
http://vnx.su

Check\fthe\fturboch\brger\foil\freturn\fpipe\ffor\f\b\f
block\bge\for\fsigns\fof\fd\bm\bge.\f4
Is\fthe\fturboch\brger\foil\freturn\fpipe\ffree\ffrom\fblock\bge\f
\bnd\fsigns\fof\fd\bm\bge?\f
Yes GO\fto\fFuel\fCh\brging\f\bnd\fControls\ffor\ffurther\f
di\bgnostics.\f\f
REFER\fto:\f Fuel\fCh\brging\f\bnd\fControls \f(303-04E\f
Fu e

l\fCh\brging\f\bnd\fControls\f-\f2.0L\fDur\btorq-TDCi\f
(85kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(103kW/140PS)\f-\fDW,\fEmission\fRequirements:\f
St\bge\fIV,\fDi\bgnosis\f\bnd\fTesting).\f
No
INSTALL\f\b\fnew\fturboch\brger\foil\freturn\fpipe.\fTEST\f
the\fsystem\ffor\fnorm\bl\foper\btion.\f
PINPOINT TEST C : POOR ENGINE PERFORMANCE
TE\fT CONDITION\fDETAIL\f/RE\fULT\f/ACTION\f
C1: CHECK THE VACUUM CONTROL CIRCUIT FOR VACUUM
Disconnect\fthe\fv\bcuum\fline\ffrom\fthe\fturboch\brger\f
v\bcuum\fcontrol\fsolenoid.\f1
Inst\bll\fthe\fspeci\bl\ftool\fbetween\fthe\fturboch\brger\f
v\bcuum\fcontrol\fsolenoid\f\bnd\fv\bcuum\fline.\f2
St\brt\f\bnd\frun\fthe\fengine.\f3
With\fthe\fengine\f\bt\fidle\fdoes\fthe\fspeci\bl\ftool\findic\bte\f\b\f
v\bcuum\fof\f0.325\fb\br\for\f\bbove?\f
Yes GO\fto\fC2 .\f\f
No GO

\fto\fC4 .\f\f
C2: CHECK THE VACUUM DIAPHRAGM UNIT ACTUATOR ROD MOVEMENT
Ignition\fswitch\fin\fposition\f0.\f1
\f\f
\f\f
\f\f
Стр. 7 из 11
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G330232&gui...procarmanuals.com
http://vnx.su

C3: CHECK THE TURBOCHARGER BOOST PRESSURE
Remove\fspeci\bl\ftool\f416-D001.\f1
Connect\fthe\fv\bcuum\fline\fto\fthe\fv\bne\f\bdjustment\f
di\bphr\bgm\funit.\f2
Lower\fthe\fvehicle.\f3
Connect\fWDS\fto\fthe\fvehicle\fd\bt\b\flink\fconnector\f
(DLC).\f4
Select\fthe\fd\bt\bloger\ffunction.\f5
Configure\fd\bt\bloger\fto\fre\bd\fthe\fint\bke\fm\bnifold\f
pressure\fvi\b\fthe\fm\bnifold\f\bbsolute\fpressure\f(MAP)\f
sensor.\f6
St\brt\f\bnd\frun\fthe\fengine.\f7
With\fthe\f\bid\fof\f\bnother\fTechnici\bn,\fr\bise\fthe\f
engine\fspeed\fto\f2000\frpm.\f8
Observe\fthe\fre\bdings\fof\fspeci\bl\ftool\f310-053\f\bnd\f
the\fWDS\fm\bnifold\fpressure\fdispl\by.\f9
Is\f\b\fv\bcuum\fof\f0.325\fb\br\fon\fthe\fspeci\bl\ftool\f\bnd\fboost\f
pressure\fof\f1.5\fb\br\fon\fthe\fWDS\fm\bnifold\fpressure\f
displ\by\findic\bted?\f
Yes Continue\fthe\fdi\bgnostic\fof\fthe\fengine\fm\bn\bgement\f
system\fusing\fWDS.\f
No INSTALL\f\b\fnew\fturboch\brger.\f\f
REFER\fto:\f Turboch\brger \f(303-04J\fFuel\fCh\brging\f
\bnd

\fControls\f-\fTurboch\brger\f-\f2.0L\fDur\btorq-TDCi\f
(85kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(103kW/140PS)\f-\fDW,\fEmission\fRequirements:\f
St\bge\fIV,\fRemov\bl\f\bnd\fInst\bll\btion).\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
C4: CHECK THE VACUUM DIAPHRAGM UNIT VACUUM LINE FOR LEAKS
Ignition\fswitch\fin\fposition\f0.\f1
Remove\fthe\fspeci\bl\ftool\f310-053.\f2
Inst\bll\fthe\fspeci\bl\ftool\fto\fthe\fv\bcuum\fdi\bphr\bgm\f
unit\fv\bcuum\fline.\f3
Oper\bte\fthe\fspeci\bl\ftool\f\bnd\fobserve\fthe\fre\bding.\f4
Does\fthe\fspeci\bl\ftool\fhold\fv\bcuum?\f
Yes
GO\fto\fC5 .\f\f
No GO

\fto\fC6 .\f\f
C5: CHECK THE TURBOCHARGER VANE ADJUSTMENT SOLENOID VALVE DUTY CYCLE
Disconnect\fTurboch\brger\fv\bin\f\bdjustment\fsolenoid\f
C585.\f1
St\brt\f\bnd\frun\fthe\fengine.\f2
Me\bsure\fthe\fvolt\bge\fbetween\fC585\fpin\f1,\fcircuit\f
15S-RL50\f(GN/BU)\fh\brness\fside\f\bnd\fC585\fpin\f2,\f
circuit\f91S-RL50\f(BK/BU)\fh\brness\fside.\f3
\f\f
Стр. 9 из 11
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G330232&gui...procarmanuals.com
http://vnx.su

Check\fthe\fturboch\brger\foil\freturn\fpipe\ffor\f\b\f
block\bge\for\fsigns\fof\fd\bm\bge.\f4
Is\fthe\fturboch\brger\foil\freturn\fpipe\ffree\ffrom\fblock\bge\f
\bnd\fsigns\fof\fd\bm\bge?\f
Yes GO\fto\fFuel\fCh\brging\f\bnd\fControls\ffor\ffurther\f
di\bgnostics.\f\f
REFER\fto:\f Fuel\fCh\brging\f\bnd\fControls \f(303-04E\f
Fu e

l\fCh\brging\f\bnd\fControls\f-\f2.0L\fDur\btorq-TDCi\f
(85kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(103kW/140PS)\f-\fDW,\fEmission\fRequirements:\f
St\bge\fIV,\fDi\bgnosis\f\bnd\fTesting).\f
No
INSTALL\f\b\fnew\fturboch\brger\foil\freturn\fpipe.\fTEST\f
the\fsystem\ffor\fnorm\bl\foper\btion.\f
PINPOINT TEST C : POOR ENGINE PERFORMANCE
TE\fT CONDITION\fDETAIL\f/RE\fULT\f/ACTION\f
C1: CHECK THE VACUUM CONTROL CIRCUIT FOR VACUUM
Disconnect\fthe\fv\bcuum\fline\ffrom\fthe\fturboch\brger\f
v\bcuum\fcontrol\fsolenoid.\f1
Inst\bll\fthe\fspeci\bl\ftool\fbetween\fthe\fturboch\brger\f
v\bcuum\fcontrol\fsolenoid\f\bnd\fv\bcuum\fline.\f2
St\brt\f\bnd\frun\fthe\fengine.\f3
With\fthe\fengine\f\bt\fidle\fdoes\fthe\fspeci\bl\ftool\findic\bte\f\b\f
v\bcuum\fof\f0.325\fb\br\for\f\bbove?\f
Yes GO\fto\fC2 .\f\f
No GO

\fto\fC4 .\f\f
C2: CHECK THE VACUUM DIAPHRAGM UNIT ACTUATOR ROD MOVEMENT
Ignition\fswitch\fin\fposition\f0.\f1
\f\f
\f\f
\f\f
Стр. 7 из 11
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G330232&gui...procarmanuals.com
http://vnx.su

C3: CHECK THE TURBOCHARGER BOOST PRESSURE
Remove\fspeci\bl\ftool\f416-D001.\f1
Connect\fthe\fv\bcuum\fline\fto\fthe\fv\bne\f\bdjustment\f
di\bphr\bgm\funit.\f2
Lower\fthe\fvehicle.\f3
Connect\fWDS\fto\fthe\fvehicle\fd\bt\b\flink\fconnector\f
(DLC).\f4
Select\fthe\fd\bt\bloger\ffunction.\f5
Configure\fd\bt\bloger\fto\fre\bd\fthe\fint\bke\fm\bnifold\f
pressure\fvi\b\fthe\fm\bnifold\f\bbsolute\fpressure\f(MAP)\f
sensor.\f6
St\brt\f\bnd\frun\fthe\fengine.\f7
With\fthe\f\bid\fof\f\bnother\fTechnici\bn,\fr\bise\fthe\f
engine\fspeed\fto\f2000\frpm.\f8
Observe\fthe\fre\bdings\fof\fspeci\bl\ftool\f310-053\f\bnd\f
the\fWDS\fm\bnifold\fpressure\fdispl\by.\f9
Is\f\b\fv\bcuum\fof\f0.325\fb\br\fon\fthe\fspeci\bl\ftool\f\bnd\fboost\f
pressure\fof\f1.5\fb\br\fon\fthe\fWDS\fm\bnifold\fpressure\f
displ\by\findic\bted?\f
Yes Continue\fthe\fdi\bgnostic\fof\fthe\fengine\fm\bn\bgement\f
system\fusing\fWDS.\f
No INSTALL\f\b\fnew\fturboch\brger.\f\f
REFER\fto:\f Turboch\brger \f(303-04J\fFuel\fCh\brging\f
\bnd

\fControls\f-\fTurboch\brger\f-\f2.0L\fDur\btorq-TDCi\f
(85kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(103kW/140PS)\f-\fDW,\fEmission\fRequirements:\f
St\bge\fIV,\fRemov\bl\f\bnd\fInst\bll\btion).\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
C4: CHECK THE VACUUM DIAPHRAGM UNIT VACUUM LINE FOR LEAKS
Ignition\fswitch\fin\fposition\f0.\f1
Remove\fthe\fspeci\bl\ftool\f310-053.\f2
Inst\bll\fthe\fspeci\bl\ftool\fto\fthe\fv\bcuum\fdi\bphr\bgm\f
unit\fv\bcuum\fline.\f3
Oper\bte\fthe\fspeci\bl\ftool\f\bnd\fobserve\fthe\fre\bding.\f4
Does\fthe\fspeci\bl\ftool\fhold\fv\bcuum?\f
Yes
GO\fto\fC5 .\f\f
No GO

\fto\fC6 .\f\f
C5: CHECK THE TURBOCHARGER VANE ADJUSTMENT SOLENOID VALVE DUTY CYCLE
Disconnect\fTurboch\brger\fv\bin\f\bdjustment\fsolenoid\f
C585.\f1
St\brt\f\bnd\frun\fthe\fengine.\f2
Me\bsure\fthe\fvolt\bge\fbetween\fC585\fpin\f1,\fcircuit\f
15S-RL50\f(GN/BU)\fh\brness\fside\f\bnd\fC585\fpin\f2,\f
circuit\f91S-RL50\f(BK/BU)\fh\brness\fside.\f3
\f\f
Стр. 9 из 11
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G330232&gui...procarmanuals.com
http://vnx.su

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
Стр. 1 из
2
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G543729&gui...procarmanuals.com
http://vnx.su

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
Стр. 1 из 1
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G543732&gui...procarmanuals.com
http://vnx.su