turbo FORD S-MAX 2006 Service Manual PDF

Inspect\fthe\fturboch\brger\foil\fsupply\fpipe\funion\ffor\f
block\bge.\f2
Is\fthe\foil\fsupply\fpipe\funion\fnon\freturn\fv\blve\ffree\fto\f
move\f\bnd\fthe\funion\ffree\ffrom\fblock\bge?\f\f
Yes INSTALL\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
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
No INSTALL\f\b\fnew\fturboch\brger\f\bnd\foil\fsupply\fpipe\f
non\freturn\fv\blve.\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
PINPOINT TEST B : BLUE SMOKE WITHOUT EXCESSIVE TURBOCHARGER
NOISE
TE\fT CONDITION\fDETAIL\f/RE\fULT\f/ACTION\f
B1: CHECK THE TURBOCHARGER OIL RETURN PIPE
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
NOTE:\fDisc\brd\fthe\fg\bsket.\f
Remove\fthe\fturboch\brger\foil\freturn\fpipe.\f
3
\f\f
\f\f
Стр. 6 из 11
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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
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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
2
Remove\fthe\fengine\fundershield.\f

Rot\bte\fthe\flocking\ft\bngs\fcounterclockwise.\f3
Disconnect\fthe\fv\bcuum\fline\ffrom\fthe\fv\bne\f
\bdjustment\fdi\bphr\bgm\funit.\f4
Inst\bll\fthe\fspeci\bl\ftool\fto\fthe\fv\bne\f\bdjustment\f
di\bphr\bgm\funit.\f5
Oper\bte\fthe\fspeci\bl\ftool\funtil\f\b\fv\bcuum\fof\f35\fKp\b\f
is\f\bchieved.\fMe\bsure\fthe\fdist\bnce\ftr\bvelled\fby\fthe\f
v\bne\f\bdjustment\fdi\bphr\bgm\funit\f\bctu\btor\frod.\f6
Does\fthe\fv\bne\f\bdjustment\fdi\bphr\bgm\funit\f\bctu\btor\frod\f
move\fbetween\f9\f\bnd\f11\fmm?\f
Yes GO\fto\fC3 .\f\f
No C

HECK\ffor\fsigns\fof\fd\bm\bge\for\fsigns\fof\fforeign\f
m\bteri\bl\fin\fthe\fturboch\brger\fv\bnes.\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
\f\f
\f\f
\f\f
\f\f
Стр. 8 из 11
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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
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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
Стр. 10 из
11
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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
Стр. 11 из 11
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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
Remov\bl \b\fd I\fst\bll\btio\f
M\bteri\bls
Remov\bl
NameSpec\bf\bcat\bo\f
Br\bke\fCle\bner3U7J-2C410-AA
1. Refer\fto:\fLifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des

cription\f\bnd\fOper\btion).\f
2. Refer\fto:\f C\bt\blytic\fConverter \f(309-00F\fExh\bust\f
Sy s

tem\f-\f2.2L\fDur\btorq-TDCi\f(129kW/175PS)\f-\f
DW,\fRemov\bl\f\bnd\fInst\bll\btion).\f
Refer\fto:\f Exh\bust\fG\bs\fRecircul\btion\f(EGR)\fCooler \f
(30

3-08E\fEngine\fEmission\fControl\f-\f2.2L\f
Dur\btorq-TDCi\f(129kW/175PS)\f-\fDW,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
3. \f
4. \f
5. \f
\f
\f\f
\f\f
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Engine Emi\b\bion Cont\fol - 2.5L Du\fatec
(162kW/220PS) - VI5 - Engine Emi\b\bion
Cont\fol
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\bc\fiption and Ope\fation
2.5L Du\fatec-ST (VI5)
Engine Emi\b\bion Component\b
\f\f
De\bc\fiption
Int\bke\fm\bnifold\fto\fturboch\brger\fbre\bther\fhose\f
Cr\bnkc\bse\fvent\foil\fsep\br\btor\fto\fv\blve\fcover\fhose\f
Cr\bnkc\bse\fvent\foil\fsep\br\btor\fto\fint\bke\fm\bnifold\fhose\f
Cr\bnkc\bse\fvent\foil\fsep\br\btor\f
Item
1
2
3
4
\f
Pa\ft Numbe\f -
-
-
-
Стр. 1 из 1
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Engine Emi\b\bion Cont\fol - 2.5L Du\fatec
(162kW/220PS) - VI5 - Engine Emi\b\bion
Cont\fol
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Diagno\bi\b and Te\bting
In\bpection and Ve\fification
1. 1.
Verify\fthe\fcustomer\fconcern.\f
2

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

i\bual In\bpection Cha\ft
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 Cha\ft
Mechanica\bE\bectrica\b

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

G\bsket(s)\f\f

Positive\fcr\bnkc\bse\fventil\btion\f(PCV)\fv\blve\f\f

PCV\fcr\bnkc\bse\fvent\foil\fsep\br\btor\f\f

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

Wiring\fh\brness\f\f

Fuse(s)\f\f

Rel\by\f\f

Powert\bin\fcontrol\fmodule\f(PCM)\f
\fymptomPossib\be \fourcesAction
Excessive\f
cr\bnkc\bse\f
pressureBlocked\fPCV\fcr\bnkc\bse\f
vent\foil\fsep\br\btor.\f
Blocked\fPCV\fhose.\f
*
*CLEAN\for\fINSTALL\fnew\fPCV\fcomponents\f\bs\f
necess\bry.\fTEST\fthe\fsystem\ffor\fnorm\bl\f
oper\btion.\f
*
Worn\for\fd\bm\bged\f
engine\fcomponents.\f
*REFER\fto:\fEngine\f(303-01B,\fDi\bgnosis\f\bnd\f
Testing).\f
*
Oil\fin\fthe\f\bir\f
int\bke\fsystemCr\bnkc\bse\fvent\foil\f
sep\br\btor.\f
*CLEAN\for\fINSTALL\f\b\fnew\fcr\bnkc\bse\fvent\foil\f
sep\br\btor.\fTEST\fthe\fsystem\ffor\fnorm\bl\f
oper\btion.\f
*
Turboch\brger\f
*REFER\fto:\fTurboch\brger\f(303-04E,\fDi\bgnosis\f
\bnd\fTesting).\f
*
Worn\for\fd\bm\bged\f
engine\fcomponents.\f
*REFER\fto:\fEngine\f(303-01B,\fDi\bgnosis\f\bnd\f
Testing).\f
*
Стр. 1 из
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Ch\brge\f\bir\fcooler\f
Turboch\brger\f
Ch\brge\f\bir\fcooler\foutlet\fpipe\f
13
14
15
-
-
-
Стр. 2 из 2
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