ECU FORD S-MAX 2006 Service Manual PDF

Intake \bir Di\ftribution and Filtering - 2.2L
Duratorq-TDCi (129kW/175PS) - DW -
Intake \bir Di\ftribution and Filtering
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Diagno\fi\f and Te\fting
In\fpection and Verification
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

i\fual In\fpection Chart
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
C
h\brt.\f
Symptom Chart
Mechanica\bE\bectrica\b

Air\fcle\bner\felement\f\f

Air\fcle\bner\fint\bke\fhose\f\f

Air\fcle\bner\foutlet\fhose\f\f

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

Ch\brge\f\bir\fcooler\fint\bke\fhose\f\f

Ch\brge\f\bir\fcooler\foutlet\fhose\f
M\bss\f\bir\fflow\f(MAF)\fsensor\f\f

M\bnifold\f\bbsolute\fpressure\f(MAP)\fsensor\f\f

Electric\bl\fconnector(s)\f
\fymptomPossib\be \fourcesAction
Excessive\f
int\bke\f\bir\f
noiseDet\bched\f\bir\fcle\bner\f
hose(s).\f Det\bched\f
turboch\brger\fhose(s).
\f
Det\bched\fch\brge\f\bir\f
cooler\fhose(s).\f
*
*
*
CHECK\fthe\fhose(s)\ffor\fsecurity\f\bnd\fle\bks\fto\f
\btmosphere.\fINSTALL\fnew\fint\bke\f\bir\fcomponents\f\bs\f
necess\bry.\fTEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
*
Oil\fin\fthe\f\bir\f
int\bke\f
system
Blocked\for\fd\bm\bged\f
positive\fcr\bnkc\bse\f
ventil\btion\f(PCV)\f
v\blve.\f
Blocked\for\fd\bm\bged\f
PCV\fpipe(s)/hose(s).\f Blocked\for\fd\bm\bged\f
cr\bnkc\bse\fvent\foil\f
sep\br\btor.\f
*
*
*REFER\fto:\f
Engine\fEmission\fControl \f(303-08E\fEngine\f
Emi
ssion\fControl\f-\f2.2L\fDur\btorq-
TDCi\f(129kW/175PS)\f
-\fDW,\fDi\bgnosis\f\bnd\fTesting).\f
*
Turboch\brger.\f
*REFER\fto:\f Turboch\brger \f(303-04J\fFuel\fCh\brging\f\bnd\f
Con
trols\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:\fSt\bge\f
IV,\fDi\bgnosis\f\bnd\fTesting).\f
*
W\bter\fin\fthe\f
\bir\fcle\bner
Air\fint\bke\fpipe\fspl\bsh\f
shield.\f
*
CHECK\fthe\f\bir\fint\bke\fpipe\fspl\bsh\fshield\ffor\fcorrect\f
inst\bll\btion\f\bnd\f\blignment.\fREPAIR/INSTALL\fthe\f\bir\f
int\bke\fpipe\fspl\bsh\fshield\f\bs\fnecess\bry.\fTEST\fthe\f
system\ffor\fnorm\bl\foper\btion.\f
*
Blocked\f\bir\fcle\bner\f
dr\bin.\f
*CHECK\fthe\f\bir\fcle\bner\fdr\bin\ffor\fblock\bge.\fTEST\fthe\f
system\ffor\fnorm\bl\foper\btion.\f
*
Engine\fl\bcks\fAir\fcle\bner\felement\f
*INSPECT\fthe\f\bir\fcle\bner\ffor\fsigns\fof\fblock\bge.\fINSTALL\f*
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Electro\bic E\bgi\be \fo\btrols - 2.0L Duratec-
HE (107kW/145PS) - MI4/2.0L Duratec-
HE Flex Fuel (107kW/145PS) - MI4 -
Powertrai\b \fo\btrol Module (P\fM)
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal a\bd I\bstallatio\b
Ge\beral Equipme\bt
Removal
Vehicles\fwith\fPCM\fsecurity\fshield\f
3.5\fmm\fdrill\fbit
Center\fpunch
Ford\fdi\bgnostic\fequipment1.NOTE:\fThis\fstep\fis\fonly\fnecess\bry\fwhen\f
i
n

st\blling\f\b\fnew\fcomponent.\f
Downlo\bd\fthe\fPCM\f\bnd\fthrottle\fbody\fconfigur\btion\f
in
form\btion\finto\fthe\fdi\bgnostic\ftool,\fusing\fthe\f
Progr\bmm\bble\fModules\fInst\bll\btion\froutine.\f\f
General \bqui\fment: Ford\fdi\bgnostic\fequipment \f
2. R

efer\fto:\f B\bttery\fDisconnect\f\bnd\fConnect\f(414-01\f
B\btt

ery,\fMounting\f\bnd\fC\bbles,\fGener\bl\f
Procedures).\f
3. Left-h\bnd\fside\fwheel\f\bnd\ftire.\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
4. \f
5. \f
6. Torque: 3\fNm
\f
\f\f
\f\f
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3
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Vehicles\fwithout\fPCM\fsecurity\fshield\f
I\bstallatio\b Vehicles\fwith\fPCM\fsecurity\fshield\f7.
General
\bqui\fment:
Center\f
punch
\f
Ge n

eral
\bqui\fment:
3.5\fmm\f
drill\fbit \f
8. \f
9

. Torque: 3\fNm
\f
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f\f
\f
\f\f
\f\f
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3
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Electro\bic E\bgi\be \fo\btrols - 2.0L EcoBoost
S\fTi (149kW/203PS) - MI4 - Powertrai\b
\fo\btrol Module (P\fM)
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal a\bd I\bstallatio\b
Ge\beral Equipme\bt
Removal
Vehicles\fwith\fPCM\fsecurity\fshield\f
3.5\fmm\fdrill\fbit
Center\fpunch
Ford\fdi\bgnostic\fequipment1.NOTE:\fThis\fstep\fis\fonly\fnecess\bry\fwhen\f
i
n

st\blling\f\b\fnew\fcomponent.\f
Downlo\bd\fthe\fPCM\f\bnd\fthrottle\fbody\fconfigur\btion\f
in
form\btion\finto\fthe\fdi\bgnostic\ftool,\fusing\fthe\f
Progr\bmm\bble\fModules\fInst\bll\btion\froutine.\f\f
General \bqui\fment: Ford\fdi\bgnostic\fequipment \f
2. R

efer\fto:\f B\bttery\fDisconnect\f\bnd\fConnect\f(414-01\f
B\btt

ery,\fMounting\f\bnd\fC\bbles,\fGener\bl\f
Procedures).\f
3. Left-h\bnd\fside\fwheel\f\bnd\ftire.\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
4. \f
5. \f
6. Torque: 3\fNm
\f
\f\f
\f\f
Стр. 1 из
3
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Vehicles\fwithout\fPCM\fsecurity\fshield\f
I\bstallatio\b Vehicles\fwith\fPCM\fsecurity\fshield\f7.
General
\bqui\fment:
Center\f
punch
\f
Ge n

eral
\bqui\fment:
3.5\fmm\f
drill\fbit \f
8. \f
9

. Torque: 3\fNm
\f
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f\f
\f
\f\f
\f\f
Стр. 2 из
3
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Electro\bic E\bgi\be \fo\btrols - 2.3L Duratec-
HE (118kW/160PS) - MI4 - Powertrai\b
\fo\btrol Module (P\fM)
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal a\bd I\bstallatio\b
Ge\beral Equipme\bt
Removal
Vehicles\fwith\fPCM\fsecurity\fshield\f
3.5\fmm\fdrill\fbit
Center\fpunch
Ford\fdi\bgnostic\fequipment1.NOTE:\fThis\fstep\fis\fonly\fnecess\bry\fwhen\f
i
n

st\blling\f\b\fnew\fcomponent.\f
Downlo\bd\fthe\fPCM\f\bnd\fthrottle\fbody\fconfigur\btion\f
in
form\btion\finto\fthe\fdi\bgnostic\ftool,\fusing\fthe\f
Progr\bmm\bble\fModules\fInst\bll\btion\froutine.\f\f
General \bqui\fment: Ford\fdi\bgnostic\fequipment \f
2. R

efer\fto:\f B\bttery\fDisconnect\f\bnd\fConnect\f(414-01\f
B\btt

ery,\fMounting\f\bnd\fC\bbles,\fGener\bl\f
Procedures).\f
3. Left-h\bnd\fside\fwheel\f\bnd\ftire.\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
4. \f
5. \f
6. Torque: 3\fNm
\f
\f\f
\f\f
Стр. 1 из
3
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Vehicles\fwithout\fPCM\fsecurity\fshield\f
I\bstallatio\b Vehicles\fwith\fPCM\fsecurity\fshield\f7.
General
\bqui\fment:
Center\f
punch
\f
Ge n

eral
\bqui\fment:
3.5\fmm\f
drill\fbit \f
8. \f
9

. Torque: 3\fNm
\f
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f\f
\f
\f\f
\f\f
Стр. 2 из
3
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Electro\bic E\bgi\be \fo\btrols - 2.5L Duratec
(162kW/220PS) - VI5 - Powertrai\b \fo\btrol
Module (P\fM)
S-MAX/G\bl\bxy\f2006.5\f(02/2006
Removal a\bd I\bstallatio\b
Ge\beral Equipme\bt
Removal
NO
TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\fins t
\bll\btion\fdet\bils.\f
Vehicles\fwithout\fPCM\fsecurity\fshield\f
3.5\fmm\fdrill\fbit
Center\fpunch
Ford\fdi\bgnostic\fequipment 1.
NOTE:\fThis\fstep\fis\fonly\fnecess\bry\fwhen\finst\blling\f\b\f
new\fcomponent.\f
Downlo\bd\fthe\fPCM\f\bnd\fthrottle\fbody\fconfigur\btion\f
in
form\btion\finto\fthe\fdi\bgnostic\ftool,\fusing\fthe\f
Progr\bmm\bble\fModules\fInst\bll\btion\froutine.\f\f
General \bqui\fment: Ford\fdi\bgnostic\fequipment \f
2. R

efer\fto:\fB\bttery\fDisconnect\f\bnd\fConnect\f(414-01\f
B\bttery,\fMounting\f\bnd\fC\bbles,\fGener\bl\fProcedures).
\f
3. \f
4. \f
5. \f
6. \f
\f\f
\f\f
\f\f
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3
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Vehicles\fwith\fPCM\fsecurity\fshield\f
I\bstallatio\b 7.
Torque:
7
\fNm\f
8. Refer\fto:\fAir\fCle\bner\f(303-
12\fInt\bke\fAir\fDistribution\f\bnd\f
Filtering\f-\f2.5L\fDur\btec-ST\f(VI5),\fRemov\bl\f\bnd\f
Inst\bll\btion).\f 9. \f\f1.
General
\bqui\fment:
Center\f
punch\f
2.
General
\bqui\fment:
3.5\fmm\f
drill\fbit
10. \f
\f\f
\f\f
\f
\f\f
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3
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Vehicles\fwith\fPCM\fsecurity\fshield\f
All\fvehicles\f
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
2.

Tighten\fthe\fshe\br\fbolt\funtil\fthe\fhe\bd\fis\fshe\bred\foff.\f
\f
3.NOTE:\fThis\fstep\fis\fonly\fnecess\bry\fwhen\finst\blling\f\b\f
new\fcomponent.\f
Uplo\bd\fthe\fPCM\f\bnd\fthrottle\fbody\fconfigur\btion\f
in
form\btion\finto\fthe\fPCM,\fusing\fthe\fProgr\bmm\bble\f
Modules\fInst\bll\btion\froutine.\f
General \bqui\fment: Ford\fdi\bgnostic\fequipment \f
\f\f
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