turbo FORD S-MAX 2006 Service Manual PDF

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
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With\fthe\fengine\f\bt\fidle,\fis\fthe\fvolt\bge\fgre\bter\fth\bn\f10\f
volts?\f
Yes INSTALL\f\b\fnew\fturboch\brger\fv\bcuum\fcontrol\f
solenoid.\fTEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
No Continue\fthe\fdi\bgnostic\fof\fthe\fengine\fm\bn\bgement\f
system\fusing\fWDS.\f
C6: CHECK THE VACUUM DIAPHRAGM UNIT FOR LEAKS
R\bise\f\bnd\fsupport\fthe\fvehicle.\fFor\f\bddition\bl\f
inform\btion,\f\f
REFER\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des

cription\f\bnd\fOper\btion).\f
1
Remove\fthe\fengine\fundershield.\f

Rot\bte\fthe\flocking\ft\bngs\fcounterclockwise.\f2
Disconnect\fthe\fv\bcuum\fline\ffrom\fthe\fv\bcuum\f
di\bphr\bgm\funit.\f3
Inst\bll\fthe\fspeci\bl\ftool\fto\fthe\fv\bne\f\bdjustment\f
di\bphr\bgm\funit.\f4
Oper\bte\fthe\fspeci\bl\ftool\f\bnd\fobserve\fthe\fre\bding.\f5
Does\fthe\fspeci\bl\ftool\fhold\fv\bcuum?\f
Yes
INSTALL\f\b\fnew\fv\bcuum\fline.\fTEST\fthe\fsystem\ffor\f
norm\bl\foper\btion.\f
No
\f\f
\f\f
\f\f
\f\f
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INSTALL\f\b\fnew\fturboch\brger.\f\f
REFER\fto:\fTurboch\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
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Fuel Ch\brgi\fg \b\fd Co\ftrols -
Turboch\brger - 2.0L Dur\btorq-TDCi
(85kW/115PS) - DW/2.0L Dur\btorq-TDCi
(100kW/136PS) - DW/2.0L Dur\btorq-
TDCi (103kW/140PS) - DW, Emissio\f
Requireme\fts: St\bge IV - Turboch\brger
S-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
1. Refer\fto:\f C\bt
\blytic\fConverter\f(309-00E\fExh\bust\f
Sys
tem\f-\f2.0L\fDur\btorq-TDCi\f(85kW/115PS)\f-\f
DW/2.0L\fDur\btorq-TDCi\f(100kW/136PS)\f-\f
DW/2.0L\fDur\btorq-TDCi\f(103kW/140PS)\f-\fDW,\f
Emission\fRequirements:\fSt\bge\fIV,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
2. Lower\fthe\fvehicle.\f
3. Torque:\b 9\fNm
\f
4. R\bise\f\bnd\fsupport\fthe\fvehicle.\f Refer\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
De s

cription\f\bnd\fOper\btion).\f
5. CAUTION:\fM\bke\fsure\fth\bt\fthe\finside\fof\f
th

e\fpipe\fends\f\bre\fcle\bn\f\bnd\ffree\fof\foil\f
residue.\f 3. Torque:\b 3
\fNm\f
4. Torque:\b 10\fNm
\f
5. Torque:\b 15\fNm
\f
6. Torque:\b 15\fNm
\f
\f
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I\fst\bll\btio\f 6. \f\f
1. T

orque:\b40\fNm
\f
2. Torque:\b 10\fNm
\f
3. Torque:\b 25\fNm
\f
4. Torque:\b 28\fNm
\f
1. NOTE:\fM\bke\fsure\fth\bt\f\b\fnew\fcomponent\fis\f
i
n

st\blled.\f
Inst\bll\fthe\ffilter\finto\fthe\fturboch\brger\foil\fsupply\f
tu
be\fb\bnjo\fbolt.\f
2. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f
\f
\f\f
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Fuel Ch\brgi\fg \b\fd Co\ftrols -
Turboch\brger - 2.2L Dur\btorq-TDCi
(129kW/175PS) - DW - Turboch\brger
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Di\bg\fosis \b\fd Testi\fg
Speci\bl Tool(s)
Ge\f

er\bl Equipme\ft
I\fspectio\f \b\fd Verific\btio\f
N O

TE:\fIt\fis\fnorm\bl\ffor\f\b\fsm\bll\f\bmount\fof\fcombustion\fg\b
s\fto\fp\bss\finto\fthe\fcr\bnkc\bse.\fThis\f
g\bs\fis\fsc\bvenged\finto\fthe\f\bir\fint\bke\fsystem\fthrough\fthe\fpositive\fcr\bnkc\bse\fventil\btion\f
(PCV)\fsystem,\fwhich\fincorpor\btes\f\bn\foil\fsep\br\btor.\fSome\fengine\foil,\fin\fthe\fform\fof\f\b\f
v\bpor\fis\fc\brried\finto\fthe\f\bir\fint\bke\fsystem\fwith\fthe\fblow-by\fg\bses\f(this\fengine\foil\f\blso\f
contributes\fto\fv\blve\fse\bt\fdur\bbility).\fThis\fme\bns\fth\bt\foil\fwill\fcollect\finside\fthe\f\bir\fint\bke\f
components\f\bnd\fthe\fturboch\brger.\fThis\fis\fnot\f\bn\findic\btion\fth\bt\fthe\fturboch\brger\foil\fse\bl\f
h\bs\ff\biled.\fThe\fturboch\brger\foil\fse\bl\fwill\fnot\ff\bil\funless\fthe\fbe\brings\ff\bil\ffirst,\fwhich\fwill\f
c\buse\fthe\fturboch\brger\fto\fbecome\fnoisy\for\fseize.\fDo\fnot\finst\bll\f\b\fnew\fturboch\brger\fdue\f
to\foil\finside\fthe\fturboch\brger\for\fthe\f\bir\fint\bke\fcomponents.\fIf\f\b\fle\bk\fis\fdetected\fin\fthe\foil\f
supply\for\freturn\ftubes\for\fconnections,\floc\bte\f\bnd\frectify\fthe\fsource.\fDo\fnot\finst\bll\f\b\fnew\f
turboch\brger\fdue\fto\f\bn\foil\fle\bk.\f
1. 1.
Verify\fthe\fcustomer\fconcern.\f
2

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

isu\bl I\fspectio\f Ch\brt
3. 3.
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.
If\fthe\fc\buse\fis\fnot\fvisu\blly\fevident,\fverify\fthe\fsymptom\f\bnd\frefer\fto\fthe\fSymptom\f
H\bnd\fV\bcuum/Pressure\fPump\f
416\f-\fD001\f(23\f-\f036A)\f
Fuel\fPressure\fG\buge\f
310-053\f(23-046)\f
Worldwide\fDi\bgnostic\fSystem\f(WDS)\f(418-
F224)
Mechanica\bE\bectrica\b


Oil\fle\bk(s)\f\f

Air\fcle\bner\felement\f\f

Air\fcle\bner\foutlet\fpipe\f\f

Air\fcle\bner\fint\bke\fpipe\f\f

Turboch\brger\foil\fsupply\for\foil\freturn\ftube\f\f

Turboch\brger\fint\bke\fpipe\f\f

Turboch\brger\fv\bcuum\fdi\bphr\bgm\funit\f\f

Turboch\brger\fhousing\f\f

Ch\brge\f\bir\fcooler\f\f

Ch\brge\f\bir\fcooler\fint\bke\fpipe\f\bnd\fhose(s)\f\f

Ch\brge\f\bir\fcooler\foutlet\fpipe\f\bnd\fhose(s)\f
Wiring\fh\brness\f\f

V\bne\f\bdjustment\fsolenoid\fv\blve\f\f

PCM\f
\f
\f\f
Стр. 1 из 11
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Ch\brt.\f
Symptom Ch\brt
Symptom Ch\brt
Pi\fpoi\ft Tests N O
TE:\fThe\fv\bcuum\fdi\bphr\bgm\funit\fis\f\b\ffixed\fp\brt\fof\fth
e
\fturboch\brger\f\bnd\fc\bnnot\fbe\f
\bdjusted\for\frenewed.\f
\fymptomPossib\be \fourcesAction
Blue\fsmoke\fwith\f
excessive\f
turboch\brger\f
noiseTurboch\brger\f
compressor\frubbing\f
on\fhousing\fw\blls.\f Turboch\brger\f
turbine\frubbing\fon\f
housing\fw\blls.\f Turboch\brger\f
be\brings\f\bnd\foil\fse\bl
(s).\f Turboch\brger\foil\f
supply\ftube\fblocked\f
or\fd\bm\bged.\f
*
*
*
*GO\fto\fPinpoint\fTest\f
A.\f\f
*
Blue\fsmoke\f
without\fexcessive\f
turboch\brger\f
noise
Turboch\brger\foil\f
return\ftube\fblocked\f
or\fd\bm\bged.\f
*GO\fto\fPinpoint\fTest\f
B.\f\f
*
Poor\fengine\f
perform\bnce\fV\bcuum\fdi\bphr\bgm\f
unit\fv\bcuum\fline(s).\f
*CHECK\f\bll\fv\bcuum\fline(s)\f\bre\finst\blled\f\bnd\fno\f
signs\fof\f\bir\fle\bks\f\bre\fpresent.\fREPAIR\f\bs\f
necess\bry.\f
*
Ch\brge\f\bir\fcooler\f
system.\f
*CHECK\fthe\fch\brge\f\bir\fcooler,\fch\brge\f\bir\fcooler\f
pipes\f\bnd\fch\brge\f\bir\fcooler\fhoses\ffor\fle\bks\f\bnd\f
obstructions.\fREPAIR\f\bs\fnecess\bry.\f
*
Air\fcle\bner\fint\bke\f
pipe.\f
*CHECK\fthe\f\bir\fcle\bner\fint\bke\fpipe\ffor\fobstruction.\f
REPAIR\fthe\fnecess\bry.\f
*
Un\buthorized\f
\bdjustment\fof\fthe\f
v\bcuum\fdi\bphr\bgm\f
unit\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\fv\bcuum\fdi\bphr\bgm\funit\f\bctu\btor\frod\fh\bs\f
not\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(303-04J\fFuel\fCh\brging\f
\bn d

\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
*
V\bcuum\fdi\bphr\bgm\f
unit\f\bctu\btor\frod.\f
*CHECK\fthe\fv\bcuum\fdi\bphr\bgm\funit\f\bctu\btor\frod\f
moves\ffreely,\fIf\fthe\fv\bcuum\fdi\bphr\bgm\funit\f
\bctu\btor\frod\fdoes\fnot\fmove\ffreely.\fCHECK\ffor\f
signs\fof\fd\bm\bge\for\fsigns\fof\fforeign\fm\bteri\bl.\f
REPAIR\f\bs\fnecess\bry.\f
*
Turboch\brger\fboost\f
pressure.\f
*GO\fto\fPinpoint\fTest\f
C.\f\f
*
PINPOINT TEST A : BLUE SMOKE WITH EXCESSIVE TURBOCHARGER NOISE
TE\fT CONDITION\fDETAIL\f/RE\fULT\f/ACTION\f
A1: INSPECT THE TURBOCHARGER ROTOR VANES FOR DAMAGE
Remove\fthe\fengine\fupper\fcover.\f1
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Disconnect\fthe\fpositive\fcr\bnkc\bse\fventil\btion\f(PCV)\f
bre\bther\fhose\ffrom\fthe\fint\bke\fm\bnifold\fPCV\fv\blve.\f

Press\fin\fthe\frele\bse\fclip.\f
2
Remove\fthe\fturboch\brger\fint\bke\fpipe\fsupport\f
br\bcket\fret\bining\fbolt.\f3
R\bise\f\bnd\fsupport\fthe\fvehicle.\fFor\f\bddition\bl\f
inform\btion,\f\f
REFER\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des

cription\f\bnd\fOper\btion).\f
4
Remove\fthe\fengine\fundershield.\f

Rot\bte\fthe\flocking\ft\bngs\fcounterclockwise.\f5
Det\bch\fthe\fturboch\brger\fint\bke\fpipe.\f6
Inspect\fthe\fturboch\brger\frotor\fv\bnes\ffor\fd\bm\bge.\f7
\f\f
\f\f
\f\f
\f\f
\f\f
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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\f
of\fforeign\fm\bteri\bl.\f1
Are\fthere\f\bny\fsigns\fof\fforeign\fm\bteri\bl?\f
Yes CLEAN\fthe\fint\bke\f\bir\fsystem\fcomponents.\fINSTALL\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
No GO\fto\fA4.\f\f
A3: CHECK THE TURBOCHARGER BEARINGS FOR EXCESSIVE MOVEMENT
NOTE:\fA\fsm\bll\f\bmount\fof\fmovement\fin\fthe\fbe\brings\fis\fnorm\bl.\f
M\bke\fsure\fthe\fturboch\brger\frotor\fspins\ffreely\f
within\fthe\fhousing.\f

1.\fWith\fthe\fturboch\brger\fst\btion\bry,\fgently\flift\f
th

e\fsh\bft\f(the\fsh\bft\fwill\fn\btur\blly\fl\by\fin\fthe\f
bottom\fof\fthe\fbe\brings).\f

2.\fM\bke\fsure\fthe\frotor\fspins\ffreely\fwithin\fthe\f
ho

using.\f
1
Does\fthe\frotor\fspin\ffreely\fwithin\fthe\fhousing\fwith\fno\f
excessive\fmovement?\f
Yes GO\fto\fA4.\f\f
No I

NSTALL\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
A4: CHECK THE TURBOCHARGER OIL SUPPLY TUBE FOR BLOCKAGE
NOTE:\fDisc\brd\fthe\fcopper\fw\bshers.\f
Remove\fthe\fturboch\brger\foil\fsupply\ftube.\f
1
\f\f
\f\f
Стр. 4 из 11
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Using\fworkshop\fcompressed\f\bir\f\bnd\f\b\fcompressed\f
\bir\fnozzle,\fcheck\fthe\foil\fsupply\ftube\ffor\fblock\bge.\f2
Is\fthe\foil\fsupply\ftube\ffree\ffrom\fblock\bge?\f
Yes GO\fto\fA5.\f\f
No
I

NSTALL\f\b\fnew\fturboch\brger\f\bnd\fturboch\brger\foil\f
supply\ftube.\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
A5: CHECK THE TURBOCHARGER OIL SUPPLY TUBE OIL GALLERY FOR BLOCKAGE
Using\f\b\fsuit\bble\fwelding\ffiller\frod,\fcheck\fthe\foil\f
supply\ftube\foil\fg\bllery\ffor\fblock\bge.\f1
Is\fthe\foil\fsupply\ftube\foil\fg\bllery\ffree\ffrom\fblock\bge?\f
Yes GO\fto\fA6.\f\f
No R

EMOVE\fthe\fblock\bge.\fINSTALL\f\b\fnew\f
turboch\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
A6: CHECK THE TURBOCHARGER OIL SUPPLY TUBE NON RETURN VALVE FOR
CORRECT OPERATION AND BLOCKAGE
Remove\fthe\fturboch\brger\foil\fsupply\fpipe\funion\fnon\f
return\fv\blve.\f
1
\f\f
\f\f
Стр. 5 из 11
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G330232&gui...procarmanuals.com
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