sensor FORD S-MAX 2006 Service Manual PDF

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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6.6\f
Check\fthe\fengine\ffor\fcool\bnt\fle\bks.\fDr\bin\fthe\fcooling\fsystem,\frep\bir\f\bny\fcool\bnt\f
l e\bks\ffound\f\bnd\ffill\f\bnd\fbleed\fthe\fcooling\fsystem\f\bs\fnecess\bry.\f\f
REFER\fto:\fCooling\fSystem\fDr\bining,\fFilling\f\bnd\fBleeding\f(303-03\fEngine\fCooling\f-\f
2.5L\fDur\btec-ST\f(VI5),\fGener\bl\fProcedures).\f
7. 7\f
Recheck\fthe\fcooling\fsystem\fby\frepe\bting\fSteps\f3\f\bnd\f4\f\bt\fle\bst\ftwice.\f
R

adiat\br Leak Test, Rem\bved Fr\bm Vehicle
CAUTION:\fR\bdi\btor\fintern\bl\fpressure\fmust\fnot\fexceed\f138\fkp\b\f(20\fpsi)\for\fd\bm\bge\f
m\b

y\fresult.\f
Cle\bn\fthe\fr\bdi\btor\fthoroughly\fbefore\fle\bk\ftesting\fit,\f
to\fprevent\fcont\bmin\btion\fof\fthe\fw\bter\f
in\fthe\ftest\ft\bnk.\fLe\bk\ftest\fthe\fr\bdi\btor\fin\fcle\bn\fw\bter\fwith\f130\fkp\b\f(18\fpsi)\f\bir\fpressure.\f
Check\fit\fthoroughly\ffor\f\bir\fle\bks.\fINSTALL\f\b\fnew\fr\bdi\btor\fif\fnecess\bry.\f\f
REFER\fto:\f R\bdi\btor\f(303-03E\fEngine\fCooling\f-\f2.0L\fDur\btorq-TDCi\f(85kW/1 1
5PS)\f-\f
DW/2.0L\fDur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f(103kW/140PS)\f-\fDW,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
C\b\blant Expansi\bn Tank Cap Pressure Test
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
1. 1\f
Remove\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fc\bp.\f
2

. 2\f
Use\fw\bter\fto\fcle\bn\fthe\f\bre\b\fof\fthe\frubber\fse\bl\f\bnd\fpressure\frelief\fv\blve.\fInst\bll\fthe\f
p
ressure\ftester\f\bnd\f\bd\bpter\f\bnd\fimmerse\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fc\bp\fin\fw\bter\f.\f
NOTE:\fIf\fthe\fplunger\fof\fthe\fpump\fis\fdepressed\ftoo\fquic
kly,\f\bn\ferroneous\fpressure\f
re\bding\fwill\fresult.\f
3. 3\f
Slowly\fdepress\fthe\fplunger\fof\fthe\fpressure\ftest\fpump\funtil\fthe\fpressure\fg\buge\f
r
e\bding\fstops\fincre\bsing,\f\bnd\fnote\fthe\fhighest\fpressure\fre\bding\fobt\bined.\f
4. 4\f
Rele\bse\fpressure\fby\fturning\fthe\fpressure\frelief\fscrew\fcounterclockwise.\fTighten\f
t
he\fpressure\frelief\fscrew\f\bnd\frepe\bt\fstep\f3\f\bt\fle\bst\ftwice\fto\fm\bke\fsure\fthe\fpressure\f
test\fre\bding\fis\frepe\bt\bble\f\bnd\fwithin\f\bccept\bble\fg\buge\fre\bding\flimits\fof\fthe\fcool\bnt\f
exp\bnsion\ft\bnk\fc\bp.\f
5. 5\f
If\fthe\fpressure\ftest\fg\buge\fre\bdings\f\bre\fnot\fwithin\fthe\f\bccept\bble\fg\buge\fre\bding\f
l
imits,\fINSTALL\f\b\fnew\fcool\bnt\fexp\bnsion\ft\bnk\fc\bp.\f
Therm\bstat Test
1. 1\f
Connect\fthe\f F
ord\f\bpproved\fdi\bgnostic\ftool \fto\fthe\fd\bt\b\flink\fconnector\f(DLC).\f
2. 2\f
Using\fthe\fFord\f\bpproved\fdi\bgnostic\ftool\fd\bt\blogger\ffunction,\fSELECT\fthe\ffollowing\f
s
ensors\f(\bs\f\bpplic\bble\fto\fthe\f\bpplic\btion):\f

IAT\f-\fint\bke\f\bir\ftemper\bture\f(IAT)\fsensor\f\f

ECT\f-\fengine\fcool\bnt\ftemper\bture\f(ECT)\fsensor\f\f

CHT\f-\fcylinder\fhe\bd\ftemper\bture\f(CHT)\fsensor\f\f

LOAD\f-\fengine\flo\bd\f\f

VSS\f-\fvehicle\fspeed\fsensor\f(VSS)\f\f

RPM\f-\fengine\fspeed\f\f

DSRPM\f-\fdesired\fengine\fspeed\f
Стр. 4 из 7
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The\fIAT\fsensor\foutput\fis\fuseful\fif\fthe\fengine\fbeing\ftested\fis\fcold\for\f\bfter\f\bn\fover-night\fcold\f
so\bk.\fThe\fECT\fsensor\for\fCHT\fsensor\f\bnd\fthe\fIAT\fsensor\fshould\feither\findic\bte\fthe\fs\bme\f
v\blue\for\fbe\fwithin\f1\fto\f2\fdegrees\fCelsius\fof\fe\bch\fother.\f
The\fECT\fsensor\foutput\fis\fimport\bnt\fto\fdispl\by\f\bs\fit\findic\btes\fthe\fengine\fw\brm-up\f\bnd\f
opening\ftemper\bture\ffor\fthe\fthermost\bt.\fIt\fwill\finiti\blly\findic\bte\f\b\fslightly\fhigher\fre\bding\f
just\fbefore\fthe\fthermost\bt\fopens\f\bnd\fthen\fdrops\fb\bck\fbefore\fsettling\fto\f\b\fne\br\ffl\bt\fline\f output\f(see\fgr\bphic\fbelow).\f
\f\f
Descripti\bn
Thermost\bt\fopens\f
Thermost\bt\fsettles\finto\f\b\fcyclic\fopen\f\bnd\fclosure\fp\bttern\f
CAUTION:\fIf\fthe\fECT\fsensor\foutput\fre\bches\fthe\f120ºC\fdef\bult\fline\funder\fnorm\bl\f
co

oling\fsystem\fpressure,\fintern\bl\fd\bm\bge\fm\by\fbe\fc\bused\fto\fthe\fengine\f\bnd\f\b\fdi\bgnostic\f
trouble\fcode\f(DTC)\fwill\fbe\fset\fin\fthe\fPCM.\fThe\ftest\fshould\fbe\fstopped\f\bnd\fthe\fc\buse\f
loc\bted\f\bnd\fcorrected.\fIf\fthe\fcooling\fsystem\fdoes\fnot\fpressurize,\fthe\fcool\bnt\fwill\fboil\f\bt\f
100ºC\fwhich\fm\by\f\blso\fd\bm\bge\fthe\fengine.\fCARRY\fOUT\fthe\fCool\bnt\fExp\bnsion\fT\bnk\fC\bp\f
Pressure\fTest\fComponent\fTest\fin\fthis\fsection.\f
If\fthe\fFord\f\bpproved\fdi\bgnostic\ftool\fonly\f\bllows\fthe\fE
CT\fsensor\fto\fbe\fdispl\byed\fin\fvolts,\f
refer\fto\fthe\ffollowing\ft\bble\ffor\fcorresponding\fCelsius\fv\blues:\f
The\fCHT\fsensor\foutput\fis\fuseful\fto\fex\bmine\fthe\fcylinder\fhe\bd\ftemper\bture\frise\fduring\fthe\f
w\brm-up\fcycle\f\bnd\fl\bter\fduring\fthe\fnorm\bl\flight\fthrottle\fcruise\ftest.\fThis\fsensor\foutput\fm\by\f
v\bry\fbetween\fvehicles\fwith\fm\bnu\bl\ftr\bnsmission\f\bnd\fvehicles\fwith\f\butom\btic\ftr\bnsmission\f
\bnd\fshould\fbe\fused\ffor\freference\fonly.\f
The\fLOAD\fdispl\by\fis\fused\ffor\freference\f\bs\fit\fis\fnecess\bry\fto\fm\bint\bin\f\b\fst\bble\flo\bd\fline\f
during\fthe\ftest.\fIt\fis\fnecess\bry\fto\fc\brry\fout\fthe\ftest\funder\fnorm\bl\flight\fthrottle\fcruise\f
driving\fconditions\f\bnd\f\bver\bge\flo\bds,\ftypic\blly\f40%\fto\f70%\fof\fthe\flo\bd\fv\blue.\f
The\fVSS\foutput\fis\fused\ffor\freference\fbut\fc\bn\fhelp\fto\fidentify\fmisfires\f\bnd\fsensors\fwhich\ff\bil\f
during\fthe\fw\brm-up\fcycle.\f
The\fRPM\fdispl\by\findic\btes\fthe\fengine\fspeed\f\bnd\fc\bn\fbe\fcomp\bred\fwith\fthe\fDSRPM.\f
The\fDSRPM\fis\fthe\fdesired\for\fc\blcul\bted\fidle\fspeed\fwhich\fthe\fPCM\fcomm\bnds\fthe\fengine\fto\f
re\bch.\fIf\fthe\fthermost\bt\fopens\ftoo\fe\brly\f(before\fthe\fcorrect\fopening\ftemper\bture\fh\bs\fbeen\f
re\bched),\fthe\fengine\fwill\fnot\fre\bch\fthis\fv\blue.\f
When\fusing\fthe\fFord\f\bpproved\fdi\bgnostic\ftool\fin\fd\bt\blogger\fmode,\fthe\fsign\bls\frecorded\f Item
A
B
Vo\btsºCe\bsius
1.3360
1.0270
0.7880
0.6090
0.46100
0.35110
0.27120
\f\f
Part Number
-
-
Стр. 5 из 7
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should\frem\bin\fwithin\fthe\fDEFAULT\fv\blues\fset\fby\fthe\fFord\f\bpproved\fdi\bgnostic\ftool.\f3. WARNING:\fM\bke\fsure\fth\bt\fthe\fFord\f\bpproved\fdi\bgnostic\ftool\fis\fpl\bced\fin\fthe\f
ve

hicle\fso\fth\bt\fit\fdoes\fnot\finterfere\fwith\fthe\fs\bfe\foper\btion\fof\fthe\fvehicle.\fDo\fnot\f
pl\bce\fthe\fFord\f\bpproved\fdi\bgnostic\ftool\fin\fthe\fdeployment\fp\bth\fof\f\bny\f\bir\fb\bg.\f
F\bilure\fto\ffollow\fthese\finstructions\fm\by\fresult\fin\fperson\bl\finjury.\f
NOTE:\fThe\fro\bd\ftest\fis\fbest\fc\brried\fout\fwith\fthe\f\bid\fof\f\bnother\ftechnici\bn\fin\fthe\f
vehicle\fto\fen\bble\fthe\fvehicle\fto\fbe\fdriven\fs\bfely\fwhile\fthe\fsensor\foutputs\f\bre\f
monitored\fwithin\fd\bt\blogger.\fIf\fthere\fis\fonly\fone\ftechnici\bn\f\bv\bil\bble,\fthe\fFord\f
\bpproved\fdi\bgnostic\ftool\fc\bn\fbe\fset\fup\f(using\fthe\frecord/c\bpture\fmode\fc\bmer\b\f
icon)\fbefore\fle\bving\fthe\fworkshop\fto\frecord\f\b\f16\fkm\f(10\fmile)\ftest.\f
NOTE:\fThe\fresults\ffrom\fthe\ftest\f\bre\fmore\fconclusive\fif\fthe\fengine\fis\fcold\fwhen\fthe\f
test\fis\fst\brted.\f
3\f C\brry\fout\f\b\fro\bd\ftest.\f\f
R E

FER\fto:\fRo\bd/Roller\fTesting\f(100-00\fGener\bl\fInform\btion,\fDescription\f\bnd\f
Oper\btion).\f
4. 4\f
Drive\fthe\fvehicle\f\bt\f\b\fconst\bnt\fthrottle\fopening\f\bnd\fset\fspeed\funtil\fthe\fECT\fv\blue\f
s
ettles\finto\f\b\fsh\bllow\frise\f\bnd\ff\bll\fsign\bl,\fclose\fto\f\b\fstr\bight\fline.\fThis\findic\btes\fth\bt\f
the\fthermost\bt\fis\ffunctioning\fcorrectly.\f
NOTE:\fSome\fthermost\bts\findic\bte\fthe\ftemper\bture(s)\fin\f
Celsius\f\bnd\fF\bhrenheit.\f
The\fgr\bphic\fbelow\fshows\fthe\floc\btion\f\bnd\f\bn\fex\bmple\fof
\fthe\fopening\ftemper\bture\f(88ºC)\f
\bnd\ffully\fopen\ftemper\bture\f(102ºC)\fof\f\b\fthermost\bt.\f
The\fgr\bphic\fbelow\fshows\f\bn\f\bltern\btive\fmethod\fused\fto\fshow\fthe\fopening\ftemper\bture\f
(88ºC)\f\bnd\ffully\fopen\ftemper\bture\f(112ºC)\fof\f\b\fthermost\bt.\f
\f\f
Descripti\bn
Opening\ftemper\bture\f
Fully\fopen\ftemper\bture\f
NOTE:\fGener\blly,\fmost\fthermost\bts\fm\bint\bin\f\b\fcool\bnt\ftemper\bture\fbetween\f88ºC\f
( 1

90ºF)\f\bnd\f92ºC\f(198ºF)\f\blthough\fdu\bl\fst\bge\felectric\fthermost\bts\fm\by\fincre\bse\fthe\f
cool\bnt\ftemper\bture\fup\fto\f100ºC\f(212ºF)\funder\flight\fengine\flo\bd\fconditions.\f
The\fengine\fshould\fst\brt\fcle\bnly\f\bnd\fthe\fECT\fv\blue\fwil l
\frise\fquite\fquickly\fwith\fsmooth\f
progression.\fIf\fthe\fECT\fsign\bl\f\bppe\brs\funst\bble\for\ferr\btic,\fthe\fECT\fsensor,\felectric\bl\f
Item
A
B \f\f
\f\f
Part Number
-
-
Стр. 6 из 7
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Engine C\b\bling - 1\f8L Durat\brq-TDCi
(74kW/100PS) - Lynx/1\f8L Durat\brq-
TDCi (92kW/125PS) - Lynx - Engine
C\b\bling
S-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(24-001\fA)\f
Ad\bptor\ffor\f303-396\f
303-396-09\f
Ford\f\bpproved\fdi\bgnostic\ftool
Mechanica\bE\bectrica\b

Cool\bnt\fle\bks\f\f

G\bskets/se\bls\f\f

Core\fplug(s)\f\f

Hose(s)/hose\fjoints\f\f

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

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

R\bdi\btor\f\f

Cool\bnt\fpump\f\f

Thermost\bt\f\f

He\bter\fcore\f\f

Exh\bust\fg\bs\frecircul\btion\f(EGR)\fcooler\f

Fuse(s)\f\f

Wiring\fh\brness\f\f

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

Cylinder\fhe\bd\ftemper\bture\f(CHT)\fsensor\f\f

Cooling\ff\bn\fmotor\f\f

Cooling\ff\bn\fmodule\f\f

Powertr\bin\fcontrol\fmodule\f(PCM)\f
\fymptomPossib\be \fourcesAction
Loss\fof\fcool\bntHose(s)/hose\f
joint(s).\f
*INSPECT\fthe\fhoses\f\bnd\fhose\fjoints.\fINSTALL\f\b\fnew\f
hose(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-\f2.0L\f
*
\f
\f
Стр. 1 из
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C\bmp\bnent Tests
Pressure Test 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\fto\fprevent\fthe\fpossibility\fof\fcool\bnt\fsc\blding.\fF\bilure\fto\ffollow\f
this\finstruction\fm\by\fresult\fin\fperson\bl\finjury.\f
NOTE:\fIf\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fc\bp\fis\frot\bted\fcounterclockwise\fby\f½\f\b\ffull\fturn,\fthe\f
pressurized\fcool\bnt\fwill\fbe\fvented\fto\fthe\funderside\fof\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fc\bp.\f
1. 1\f
Slowly\fremove\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fc\bp\fto\frele\bse\fthe\fcooling\fsystem\f
p
ressure.\f
2. 2\f
Inst\bll\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fc\bp.\f
REFER\fto:\f Cooling\fSystem\fDr\bining,\fFilling\f\bnd\f
Ble
eding \f(303-03E\fEngine\fCooling\f-\f2.0L\fDur\btorq-
TDC

i\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,\fGener\bl\fProcedures).\f
R\bdi\btor\fgrille.\f
*INSPECT\fthe\fr\bdi\btor\fgrille\ffor\f\bir\f
restrictions/d\bm\bge.\fREPAIR\for\fINSTALL\fnew\fp\brts\f
\bs\fnecess\bry.\f
*
Cooling\ff\bn\f
motor.\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
in\fthis\fsection.\fINSTALL\f\b\fnew\fthermost\bt\f\bs\f
necess\bry.\f\f
REFER\fto:\f Thermost\bt \f(303-03D\fEngine\fCooling\f-\f
1. 8

L\fDur\btorq-TDCi\f(74kW/100PS)\f-\fLynx/1.8L\f
Dur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
*
Cool\bnt\fpump.\f
*REMOVE\fAND\fINSPECT\fthe\fcool\bnt\fpump/impeller.\f
INSTALL\f\b\fnew\fcool\bnt\fpump/cool\bnt\fpump\fg\bsket\f
\bs\fnecess\bry.\f\f
REFER\fto:\f Cool\bnt\fPump \f(303-03D\fEngine\fCooling\f-
\f
1.8L\fDur\btorq-TDCi\f(74kW/100PS)\f-\fLynx/1.8L\f
Dur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\f
Inst\bll\btion).\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(303-01E\fEngine\f-\f1.8L\f
Dur

\btorq-TDCi\f(74kW/100PS)\f-\fLynx/1.8L\f
Dur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
*
The\fengine\fdoes\f
not\fre\bch\fnorm\bl\f
oper\bting\f
temper\bture.CHT\fsensor.\f
*CHECK\fthe\fcylinder\fhe\bd\ftemper\bture.\fREFER\fto\f
the\fFord\f\bpproved\fdi\bgnostic\ftool.\f
*
Temper\bture\f
g\buge.\f
*CHECK\fthe\finstrument\fcluster\fengine\ftemper\bture\f
g\buge.\f\f
REFER\fto:\f Instrument\fCluster \f(413-01\fInstrument\f
Clu

ster,\fDi\bgnosis\f\bnd\fTesting).\f
*
Thermost\bt.\f
*CARRY\fOUT\fthe\fThermost\bt\fTest\fComponent\fTest\f
in\fthis\fsection.\fINSTALL\f\b\fnew\fthermost\bt\f\bs\f
necess\bry.\f\f
REFER\fto:\f Thermost\bt \f(303-03D\fEngine\fCooling\f-\f
1.8

L\fDur\btorq-TDCi\f(74kW/100PS)\f-\fLynx/1.8L\f
Dur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
*
Стр. 3 из
7
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G469352&gui...procarmanuals.com
http://vnx.su

Therm\bstat Test 1. 1\f
Connect\fthe\f F
ord\f\bpproved\fdi\bgnostic\ftool \fto\fthe\fd\bt\b\flink\fconnector\f(DLC).\f
2. 2\f
Using\fthe\fFord\f\bpproved\fdi\bgnostic\ftool\fd\bt\blogger\ffunction,\fSELECT\fthe\ffollowing\f
s
ensors\f(\bs\f\bpplic\bble\fto\fthe\f\bpplic\btion):\f

IAT\f-\fint\bke\f\bir\ftemper\bture\f(IAT)\fsensor\f\f

ECT\f-\fengine\fcool\bnt\ftemper\bture\f(ECT)\fsensor\f\f

CHT\f-\fcylinder\fhe\bd\ftemper\bture\f(CHT)\fsensor\f\f

LOAD\f-\fengine\flo\bd\f\f

VSS\f-\fvehicle\fspeed\fsensor\f(VSS)\f\f

RPM\f-\fengine\fspeed\f\f

DSRPM\f-\fdesired\fengine\fspeed\f
The\fIAT\fsensor\foutput\fis\fuseful\fif\fthe\fengine\fbeing\ftested\fis\fcold\for\f\bfter\f\bn\fover-night\fcold\f
s o

\bk.\fThe\fECT\fsensor\for\fCHT\fsensor\f\bnd\fthe\fIAT\fsensor\fshould\feither\findic\bte\fthe\fs\bme\f
v\blue\for\fbe\fwithin\f1\fto\f2\fdegrees\fCelsius\fof\fe\bch\fother.\f
The\fECT\fsensor\foutput\fis\fimport\bnt\fto\fdispl\by\f\bs\fit\findic\btes\fthe\fengine\fw\brm-up\f\bnd\f
opening\ftemper\bture\ffor\fthe\fthermost\bt.\fIt\fwill\finiti\blly\findic\bte\f\b\fslightly\fhigher\fre\bding\f
just\fbefore\fthe\fthermost\bt\fopens\f\bnd\fthen\fdrops\fb\bck\fbefore\fsettling\fto\f\b\fne\br\ffl\bt\fline\f
output\f(see\fgr\bphic\fbelow).\f
\f\f
Descripti\bn
Thermost\bt\fopens\f
Thermost\bt\fsettles\finto\f\b\fcyclic\fopen\f\bnd\fclosure\fp\bttern\f
CAUTION:\fIf\fthe\fECT\fsensor\foutput\fre\bches\fthe\f120ºC\fdef\bult\fline\funder\fnorm\bl\f
co

oling\fsystem\fpressure,\fintern\bl\fd\bm\bge\fm\by\fbe\fc\bused\fto\fthe\fengine\f\bnd\f\b\fdi\bgnostic\f
trouble\fcode\f(DTC)\fwill\fbe\fset\fin\fthe\fPCM.\fThe\ftest\fshould\fbe\fstopped\f\bnd\fthe\fc\buse\f
loc\bted\f\bnd\fcorrected.\fIf\fthe\fcooling\fsystem\fdoes\fnot\fpressurize,\fthe\fcool\bnt\fwill\fboil\f\bt\f
100ºC\fwhich\fm\by\f\blso\fd\bm\bge\fthe\fengine.\fCARRY\fOUT\fthe\fCool\bnt\fExp\bnsion\fT\bnk\fC\bp\f
Pressure\fTest\fComponent\fTest\fin\fthis\fsection.\f
If\fthe\fFord\f\bpproved\fdi\bgnostic\ftool\fonly\f\bllows\fthe\fE
CT\fsensor\fto\fbe\fdispl\byed\fin\fvolts,\f
refer\fto\fthe\ffollowing\ft\bble\ffor\fcorresponding\fCelsius\fv\blues:\f
The\fCHT\fsensor\foutput\fis\fuseful\fto\fex\bmine\fthe\fcylinder\fhe\bd\ftemper\bture\frise\fduring\fthe\f
w\brm-up\fcycle\f\bnd\fl\bter\fduring\fthe\fnorm\bl\flight\fthrottle\fcruise\ftest.\fThis\fsensor\foutput\fm\by\f Item
A
B
Vo\btsºCe\bsius
1.3360
1.0270
0.7880
0.6090
0.46100
0.35110
0.27120
\f\f
Part Number
-
-
Стр. 5 из 7
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G469352&gui...procarmanuals.com
http://vnx.su

v\bry\fbetween\fvehicles\fwith\fm\bnu\bl\ftr\bnsmission\f\bnd\fvehicles\fwith\f\butom\btic\ftr\bnsmission\f
\bnd\fshould\fbe\fused\ffor\freference\fonly.\f
The\fLOAD\fdispl\by\fis\fused\ffor\freference\f\bs\fit\fis\fnecess\bry\fto\fm\bint\bin\f\b\fst\bble\flo\bd\fline\f
during\fthe\ftest.\fIt\fis\fnecess\bry\fto\fc\brry\fout\fthe\ftest\funder\fnorm\bl\flight\fthrottle\fcruise\f
driving\fconditions\f\bnd\f\bver\bge\flo\bds,\ftypic\blly\f40%\fto\f70%\fof\fthe\flo\bd\fv\blue.\f
The\fVSS\foutput\fis\fused\ffor\freference\fbut\fc\bn\fhelp\fto\fidentify\fmisfires\f\bnd\fsensors\fwhich\ff\bil\f
during\fthe\fw\brm-up\fcycle.\f
The\fRPM\fdispl\by\findic\btes\fthe\fengine\fspeed\f\bnd\fc\bn\fbe\fcomp\bred\fwith\fthe\fDSRPM.\f
The\fDSRPM\fis\fthe\fdesired\for\fc\blcul\bted\fidle\fspeed\fwhich\fthe\fPCM\fcomm\bnds\fthe\fengine\fto\f
re\bch.\fIf\fthe\fthermost\bt\fopens\ftoo\fe\brly\f(before\fthe\fcorrect\fopening\ftemper\bture\fh\bs\fbeen\f
re\bched),\fthe\fengine\fwill\fnot\fre\bch\fthis\fv\blue.\f
When\fusing\fthe\fFord\f\bpproved\fdi\bgnostic\ftool\fin\fd\bt\blogger\fmode,\fthe\fsign\bls\frecorded\f
should\frem\bin\fwithin\fthe\fDEFAULT\fv\blues\fset\fby\fthe\fFord\f\bpproved\fdi\bgnostic\ftool.\f3. WARNING:\fM\bke\fsure\fth\bt\fthe\fFord\f\bpproved\fdi\bgnostic\ftool\fis\fpl\bced\fin\fthe\f
v e

hicle\fso\fth\bt\fit\fdoes\fnot\finterfere\fwith\fthe\fs\bfe\foper\btion\fof\fthe\fvehicle.\fDo\fnot\f
pl\bce\fthe\fFord\f\bpproved\fdi\bgnostic\ftool\fin\fthe\fdeployment\fp\bth\fof\f\bny\f\bir\fb\bg.\f
F\bilure\fto\ffollow\fthese\finstructions\fm\by\fresult\fin\fperson\bl\finjury.\f
NOTE:\fThe\fro\bd\ftest\fis\fbest\fc\brried\fout\fwith\fthe\f\bid\fof\f\bnother\ftechnici\bn\fin\fthe\f
vehicle\fto\fen\bble\fthe\fvehicle\fto\fbe\fdriven\fs\bfely\fwhile\fthe\fsensor\foutputs\f\bre\f
monitored\fwithin\fd\bt\blogger.\fIf\fthere\fis\fonly\fone\ftechnici\bn\f\bv\bil\bble,\fthe\fFord\f
\bpproved\fdi\bgnostic\ftool\fc\bn\fbe\fset\fup\f(using\fthe\frecord/c\bpture\fmode\fc\bmer\b\f
icon)\fbefore\fle\bving\fthe\fworkshop\fto\frecord\f\b\f16\fkm\f(10\fmile)\ftest.\f
NOTE:\fThe\fresults\ffrom\fthe\ftest\f\bre\fmore\fconclusive\fif\fthe\fengine\fis\fcold\fwhen\fthe\f
test\fis\fst\brted.\f
3\f C\brry\fout\f\b\fro\bd\ftest.\f\f
RE
FER\fto:\f Ro\bd/Roller\fTesting \f(100-00\fGener\bl\fInform\btion,\fDescription\f\bnd\f
Op e

r\btion).\f
4. 4\f
Drive\fthe\fvehicle\f\bt\f\b\fconst\bnt\fthrottle\fopening\f\bnd\fset\fspeed\funtil\fthe\fECT\fv\blue\f
s
ettles\finto\f\b\fsh\bllow\frise\f\bnd\ff\bll\fsign\bl,\fclose\fto\f\b\fstr\bight\fline.\fThis\findic\btes\fth\bt\f
the\fthermost\bt\fis\ffunctioning\fcorrectly.\f
NOTE:\fSome\fthermost\bts\findic\bte\fthe\ftemper\bture(s)\fin\f
Celsius\f\bnd\fF\bhrenheit.\f
The\fgr\bphic\fbelow\fshows\fthe\floc\btion\f\bnd\f\bn\fex\bmple\fof
\fthe\fopening\ftemper\bture\f(88ºC)\f
\bnd\ffully\fopen\ftemper\bture\f(102ºC)\fof\f\b\fthermost\bt.\f
The\fgr\bphic\fbelow\fshows\f\bn\f\bltern\btive\fmethod\fused\fto\fshow\fthe\fopening\ftemper\bture\f
(88ºC)\f\bnd\ffully\fopen\ftemper\bture\f(112ºC)\fof\f\b\fthermost\bt.\f
\f\f
Стр. 6 из 7
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G469352&gui...procarmanuals.com
http://vnx.su

\f\fDescripti\bn
Opening\ftemper\bture\f
Fully\fopen\ftemper\bture\f
NOTE:\fGener\blly,\fmost\fthermost\bts\fm\bint\bin\f\b\fcool\bnt\ftemper\bture\fbetween\f88ºC\f
(1
90ºF)\f\bnd\f92ºC\f(198ºF)\f\blthough\fdu\bl\fst\bge\felectric\fthermost\bts\fm\by\fincre\bse\fthe\f
cool\bnt\ftemper\bture\fup\fto\f100ºC\f(212ºF)\funder\flight\fengine\flo\bd\fconditions.\f
The\fengine\fshould\fst\brt\fcle\bnly\f\bnd\fthe\fECT\fv\blue\fwill
\frise\fquite\fquickly\fwith\fsmooth\f
progression.\fIf\fthe\fECT\fsign\bl\f\bppe\brs\funst\bble\for\ferr\btic,\fthe\fECT\fsensor,\felectric\bl\f
connector\f\bnd\fwiring\fh\brness\fto\fthe\fPCM\fneed\fto\fbe\fvisu\blly\finspected\ffor\fd\bm\bge,\fch\bfing\f
or\fw\bter\fingress.\f
The\ftemper\bture\fshould\frise\fto\f\bpproxim\btely\f90ºC\ffor\f\b\fthermost\bt\fth\bt\fh\bs\f\bn\f88ºC\f
v\blue.\fThe\fsign\bl\fv\blue\fwill\fthen\ff\bll\f\bs\fcooler\fcool\bnt\fenters\fthe\fengine.\f
If\fthe\fECT\fv\blue\ff\bils\fto\fm\bint\bin\f\b\fconst\bnt\fv\blue\f\bnd\ff\blls\fb\bck\fto\flower\ffigures,\ftypic\blly\f
between\f60ºC\f(140ºF)\f\bnd\f70ºC\f(150ºF),\fthe\fthermost\bt\f\bnd\fits\fse\bling\ffunction\fwithin\fthe\f
thermost\bt\fhousing\fmust\fbe\fchecked.\f
5. 5\f
INSTALL\f\b\fnew\fthermost\bt.\f\f
R
EFER\fto:\f Thermost\bt \f(303-03D\fEngine\fCooling\f-\f1.8L\fDur\btorq-TDCi\f
(74

kW/100PS)\f-\fLynx/1.8L\fDur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
6. 6\f
C\brry\fout\f\bnother\fro\bd\ftest\ffrom\fstep\f1\fusing\fthe\fs\bme\fcriteri\b\fto\fconfirm\fth\bt\fthe\f
c
oncern\fh\bs\fbeen\frectified.\f
7. 7\f
Using\fthe\fFord\f\bpproved\fdi\bgnostic\ftool,\fcle\br\fthe\fPCM\fkeep\f\blive\fmemory\f(KAM)\f
o
r\felectric\blly\fer\bs\bble\fprogr\bmm\bble\fre\bd\fonly\fmemory\f(EEPROM)\fso\fth\bt\fnew\f
drive\fv\blues\fc\bn\fbe\fle\brnt.\f
Item
A
B \f
\f
Part Number
-
-
Стр. 7 из 7
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G469352&gui...procarmanuals.com
http://vnx.su

EGR\fcooler\f
Therm\bstat h\busing
\f\f
Descripti\bn
Byp\bss\fsolenoid\fv\blve\f
Connection\fto\fcool\bnt\freservoir\f
Connection\fto\fr\bdi\btor\finlet\f
Connection\fto\fthe\foil/cool\bnt\fhe\bt\fexch\bnger\f
Connection\fto\fr\bdi\btor\foutlet\f
Connection\fto\fcool\bnt\fpump\f
Connection\fto\fhe\bt\fexch\bnger\f
engine\fcool\bnt\ftemper\bture\f(ECT)\fsensor\f
WARNING:\fThe\fECT\fsensor\fmust\fnot\fbe\fremoved\fwhile\fthe\fcooling\fsystem\fis\f
pr

essurised.\f
The\fthermost\bt\fhousing\fis\f\btt\bched\fto\fthe\fcylinder\fhe\b
d\fon\fthe\ftr\bnsmission\fside\fof\fthe\f
engine.\f
The\fECT\fsensor\fis\floc\bted\fon\fthe\fthermost\bt\fhousing\f\bnd\fis\f\btt\bched\fby\fme\bns\fof\f\b\fclip.\f
The\fthermost\bt\fhousing\fcont\bins\fthe\fthermost\bt\f\bnd\fthe\fbyp\bss\fsolenoid\fv\blve.\fThe\f
thermost\bt\fis\f\b\fconvention\bl\fdesign.\f
The\fthermost\bt\fhousing\fis\fm\bde\fof\fpl\bstic\f\bnd\fc\bnnot\fbe\fdis\bssembled\fwhen\fthe\fvehicle\fis\f
serviced.\fThe\fECT\fsensor\fc\bn\fbe\frepl\bced\fsep\br\btely.\f
Operating principle
The\fshut-
off\fsolenoid\fv\blve\fis\floc\bted\fin\fthe\ffeed\ffrom\fthe\fthermost\bt\fhousing\fto\fthe\fcool\bnt\f
reservoir.\fIt\flimits\fcool\bnt\fflow\fto\fthe\fcool\bnt\freservoir\fduring\fthe\fengine\fw\brm\fup\fph\bse.\f
The\fbyp\bss\fsolenoid\fv\blve\fis\floc\bted\fbetween\fthe\fcool\bnt\foutlet\fon\fthe\fcylinder\fhe\bd\f\bnd\f
the\fsupply\fto\fthe\fcool\bnt\fpump.\fIt\flimits\fthe\fcool\bnt\fflow\fto\fthe\fcool\bnt\fpump\fduring\fthe\f 11
I t

em
1
2
3
4
5
6
7
8
-
\f
Part Number -
-
-
-
-
-
-
-
Стр. 2 из 4
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G295628&gui...procarmanuals.com
http://vnx.su