1.6L FORD S-MAX 2006 Service Repair Manual

Vehicles\fwith\f1.6L\fengine\f
All\fvehicles\f
Vehicles\fwith\f2.5L\fengine\f
Vehicles\fwith\f2.0L\for\fdiesel\fengine\f
10. \f
1
1

. \f
12. \f
13. \f
\f\f
\f\f
\f\f
\f\f
\f\f
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Vehicles\fwith\f1.6L\fengine\f
All\fvehicles\f
14. \f
15

.General\bEquipment:\b Tr\bnsmission\fj\bck\f
16 .

\f
17. WARNING:\fThis\fstep\frequires\fthe\f\bid\fof\f
\b n

other\ftechnici\bn.\f
Lower\fthe\ffront\fsubfr\bme\fto\fg\bin\f\bccess\fto\fthe\f
st
\bbilizer\fb\br\fbolts.\f
18.Remove\fthe\fst\bbilizer\fb\br\fnuts\fon\fboth\fsides.\fDo\fnot\f
remove\fthe\fst\bbilizer\fb\br\fbolts\f\bt\fthis\fst\bge.\f
19.
NOTE:\fNote\fthe\fposition\fof\fe\bch\fcomponent\fbefore\f
remov\bl.\f
\f\f
\f\f
\f\f
\f\f
\f\f
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Vehicles\fwith\f2.5L\fengine\f
Vehicles\fwith\f2.0L\for\fdiesel\fengine\f
Vehicles\fwith\f1.6L\fengine\f
5. \f\f
1.
Insert\fthe\fw\bsher,\fwith\finside\fdi\bmeter\f22\fmm,\f
outside\fdi\bmeter\f44\fmm\f\bnd\fheight\f5\fmm,\finto\f
the\ffront\fsubfr\bme\f\bbove\fthe\f\blignment\fhole.\f
2. Insert\fthe\f\blignment\fpin\fthrough\fthe\ffront\f
subfr\bme\f\blignment\fholes\f\bnd\fthe\fw\bsher.\f
Special\bTool(\f):\b 205-316A\f
3.
Slide\fthe\flocking\fpl\btes\fon\ftop\fof\fthe\fw\bsher\f\bnd\f
into\fthe\fgroove\fof\fthe\fspeci\bl\ftool\f\bnd\ftighten\f
the\f\blignment\fpin\fsleeve.\f
6. Torque:\b \f
150\fNm
\f
90
°\f
St\bge\f1:\f
St\bge\f2:\f
7. \f\f 1.Torque:\b 30\fNm
\f
2. Torque:\b \f
150\fNm
\f
90
°\f
St\bge\f1:\f
St\bge\f2:\f
8. Torque:\b 110\fNm\f
9. Torque:\b 80\fNm
\f
10. Torque:\b 80\fNm
\f
\f\f
\f\f
\f\f
\f\f
\f\f
Стр. 6 из
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All\fvehicles\f
Vehicles\fwith\f1.6L\fengine\f
All\fvehicles\f
11. \f
12

. \f
13.
CAUTION:\fM\bke\fsure\fth\bt\fthe\fexh\bust\fflexible\f
pipe\fis\fnot\fforcibly\fbent.\f
14. CAUTION:\fM\bke\fsure\fth\bt\fthe\fb\bll\fjoint\fb\bll\f
do
es\fnot\frot\bte.\f
On\fboth\fsides.\f
To

rque:\b 70\fNm
\f
15.Special\bTool(\f):\b 307-242,\f308-440\f
\f\f
\f\f
\f\f
\f\f
\f\f
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Does\fthe\fmeter\fdispl\by\fb\bttery\fvolt\bge?\f
Yes GO\fto\fAG10.\f\f
No
C

HECK\f\bnd\fif\fnecess\bry\fRENEW\fthe\fEJB.\fCHECK\f
the\foper\btion\fof\fthe\fsystem.\f
AG10: \bHE\bK THE \bIR\bUIT BETWEEN RELAY E612 AND FUSE F8 FOR OPEN \bIR\bUIT
Ignition\fswitch\fin\fposition\f0.\f1
Me\bsure\fthe\fresist\bnce\fbetween\frel\by\fE612,\f
socket\fC1BB03-A,\fpin\f37,\fcircuit\fCE612J\f
(GY/VT),\fwiring\fh\brness\fside\f\bnd\ffuse\fF8.\f2
Is\f\b\fresist\bnce\fof\fless\fth\bn\f2\fOhms\fregistered?\f
Yes
-\fVehicles\fwith\f\b\f2.0L\fdiesel\fengine: GO\fto\fAG11.\f
\f
-\fVehicles\fwith\f\b\f2.0L\fengine: GO\fto\fAG12.\f\f
-\fV
ehicles\fwith\f\b\f2.5L\fengine: GO\fto\fAG13.\f\f
-\fV

ehicles\fwith\f\b\f1.8L\fdiesel\fengine: GO\fto\fAG14.\f
\f
-\fVehicles\fwith\f\b\f1.6L\fDur\btec-16V\f(Sigm\b)\f
engine:GO\fto\fAG15 .\f\f
-\fV

ehicles\fwith\f\b\f3.0L\fDur\btec-VE\f(VE6)\f
engine: GO\fto\fAG16 .\f\f
-\fV

ehicles\fwith\f\b\f3.0L\fDur\btec-VE\f(VE6)\f
engine: GO\fto\fAG17 .\f\f
No
L

OCATE\f\bnd\fREPAIR\fthe\fbre\bk\fin\fthe\fcircuit\f
between\frel\by\fE612\f\bnd\ffuse\fF8\fusing\fthe\fWiring\f
Di\bgr\bms.\fCHECK\fthe\foper\btion\fof\fthe\fsystem.\f
AG11: \bHE\bK THE \bIR\bUIT BETWEEN RELAY E612 AND THE P\bM FOR \bONTINUITY.
Disconnect\fConnector\fC1E108-D\ffrom\fthe\fPCM.\f1
Me\bsure\fthe\fresist\bnce\fbetween\frel\by\fE612,\f
socket\fC1BB03-
A,\fpin\f9,\fcircuit\fCE302A\f(YE/BU),\f
wiring\fh\brness\fside\f\bnd\fthe\fPCM,\fconnector\f
C1E108-
D,\fpin\fC1,\fcircuit\fCE302A\f(YE/BU),\fwiring\f
h\brness\fside.\f
2
Is\f\b\fresist\bnce\fof\fless\fth\bn\f2\fOhms\fregistered?\f
Yes GO\fto\fAG18.\f\f
No L

OCATE\f\bnd\fREPAIR\fthe\fbre\bk\fin\fthe\fcircuit\f
between\frel\by\fE612\f\bnd\fthe\fPCM\fusing\fthe\f
Wiring\fDi\bgr\bms.\fCHECK\fthe\foper\btion\fof\fthe\f
system.\f
AG12: \bHE\bK THE \bIR\bUIT BETWEEN RELAY E612 AND THE P\bM FOR \bONTINUITY.
Disconnect\fConnector\fC1E104-E\ffrom\fthe\fPCM.\f1
Me\bsure\fthe\fresist\bnce\fbetween\frel\by\fE612,\f
socket\fC1BB03-A,\fpin\f9,\fcircuit\fCE302E\f(YE/BU),\f
wiring\fh\brness\fside\f\bnd\fthe\fPCM,\fconnector\f
C1E104-
E,\fpin\fG1,\fcircuit\fCE302E\f(YE/BU),\fwiring\f
h\brness\fside.\f
2
Is\f\b\fresist\bnce\fof\fless\fth\bn\f2\fOhms\fregistered?\f
Yes GO\fto\fAG18.\f\f
No L

OCATE\f\bnd\fREPAIR\fthe\fbre\bk\fin\fthe\fcircuit\f
between\frel\by\fE612\f\bnd\fthe\fPCM\fusing\fthe\f
Wiring\fDi\bgr\bms.\fCHECK\fthe\foper\btion\fof\fthe\f
system.\f
AG13: \bHE\bK THE \bIR\bUIT BETWEEN RELAY E612 AND THE P\bM FOR \bONTINUITY.
Disconnect\fConnector\fC1E108-B\ffrom\fthe\fPCM.\f1
Стр. 93 из 159
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-\fVehicles\fwith\f\b\f1.6L\fDur\btec-16V\f(Sigm\b)\f
engine:GO\fto\fAG59 .\f\f
-\fV

ehicles\fwith\f\b\f3.0L\fDur\btec-VE\f(VE6)\f
engine: GO\fto\fAG67 .\f\f
-\fV

ehicles\fwith\f\b\f2.2L\fdiesel\fengine: GO\fto\fAG76.\f
\f
No
GO\fto\fAG22.\f\f
AG22: \bHE\bK THE VOLTAGE AT RELAY D\b21
Ignition\fswitch\fin\fposition\f0.\f1
Disconnect\fRel\by\fDC21\ffrom\fsocket\fC1BB01-A.\f2
Me\bsure\fthe\fvolt\bge\fbetween\frel\by\fDC21,\fsocket\f
C1BB01-A,\fpin\f107,\fcircuit\fCDC01A\f(GN/VT),\f
wiring\fh\brness\fside\f\bnd\fground.\f
3
Does\fthe\fmeter\fdispl\by\fb\bttery\fvolt\bge?\f
Yes GO\fto\fAG23.\f\f
No
L

OCATE\f\bnd\fREPAIR\fthe\fbre\bk\fin\fthe\fcircuit\f
between\frel\by\fDC21\f\bnd\fthe\fCJB\fusing\fthe\fWiring\f
Di\bgr\bms.\fCHECK\fthe\foper\btion\fof\fthe\fsystem.\f
AG23: \bHE\bK THE VOLTAGE AT RELAY D\b21
Me\bsure\fthe\fvolt\bge\fbetween\frel\by\fDC21,\fsocket\f
C1BB01-A,\fpin\f104,\fcircuit\fSDC02H\f(RD),\fwiring\f
h\brness\fside\f\bnd\fground.\f
1
Does\fthe\fmeter\fdispl\by\fb\bttery\fvolt\bge?\f
Yes
GO\fto\fAG24.\f\f
No C

HECK\f\bnd\fif\fnecess\bry\fRENEW\fthe\fEJB.\fCHECK\f
the\foper\btion\fof\fthe\fsystem.\f
AG24: \bHE\bK THE \bIR\bUIT BETWEEN RELAY D\b21 AND FUSE F42 FOR OPEN \bIR\bUIT
Me\bsure\fthe\fresist\bnce\fbetween\frel\by\fDC21,\f
socket\fC1BB01-A,\fpin\f105,\fcircuit\fCDC21F\f
(GY/BN),\fwiring\fh\brness\fside\f\bnd\ffuse\fF42.\f1
Is\f\b\fresist\bnce\fof\fless\fth\bn\f2\fOhms\fregistered?\f
Yes GO\fto\fAG25.\f\f
No L

OCATE\f\bnd\fREPAIR\fthe\fbre\bk\fin\fthe\fcircuit\f
between\frel\by\fDC21\f\bnd\ffuse\fF42\fusing\fthe\f
Wiring\fDi\bgr\bms.\fCHECK\fthe\foper\btion\fof\fthe\f
system.\f
AG25: \bHE\bK THE GROUND \bONNE\bTION OF D\b21
Me\bsure\fthe\fresist\bnce\fbetween\fDC21,\fconnector\f
C1BB01-A,\fpin\f106,\fcircuit\fGD120P\f(BK/GN),\f
wiring\fh\brness\fside\f\bnd\fground.\f
1
Is\f\b\fresist\bnce\fof\fless\fth\bn\f2\fOhms\fregistered?\f
Yes
RENEW\frel\by\fE612.\fCHECK\fthe\foper\btion\fof\fthe\f
system.\f
No LOCATE\f\bnd\fRECTIFY\fthe\fbre\bk\fin\fthe\f
corresponding\fcircuit\fbetween\fDC21\f\bnd\fsoldered\f
connection\fSP358\fwith\fthe\f\bid\fof\fthe\fWiring\f
Di\bgr\bms.\fCHECK\fthe\foper\btion\fof\fthe\fsystem.\f
AG26: \bHE\bK THE VOLTAGE AT THE P\bM
Disconnect\fConnector\fC1E108-C\ffrom\fthe\fPCM.\f1
Me\bsure\fthe\fvolt\bge\fbetween\fthe\fPCM,\fconnector\f2
Стр. 96 из 159
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Power\fsteering\fpump\fmodule:\fC1CS04\f

P\brking\fbr\bke\fmodule:\fC4CB01\f

Lights\fcontrol\fmodule\f(LCM):\fC2LF23-A\f

Collision\fw\brning\fmodule:\fC2FM01\f

Steering\fwheel\fmodule:\fC2LS41\f

Shock\f\bbsorber\fcontrol\fmodule:\fC4CD01-B\f

Y\bw\fr\bte\f/\fl\bter\bl\f\bcceler\btion\fsensor:\fC3CA09\f

Tr\bnsmission\fcontrol\funit\f(TCM)\f-
\fvehicles\fwith\f
\butom\btic\ftr\bnsmission:\fC1ET34\f

Generic\fElectronic\fModule\f(GEM):\fC1BP02-C\f
Select\fthe\fvehicle\fwith\fthe\fFord\f\bpproved\f
di\bgnostic\ftool.\f4
Is\fit\fpossible\fto\fest\bblish\fcommunic\btions\fwith\fthe\f
PCM?\f
Yes
The\fcomponent\fl\bst\fdisconnected\fis\fthe\fc\buse\fof\f
the\fconcern;\fCHECK\f\bnd\fif\fnecess\bry\fRENEW\fthe\f
component.\fCHECK\fthe\foper\btion\fof\fthe\fsystem.\f
No -\fIf\fnot\f\bll\fthe\flisted\fcomponents\f\bre\f
disconnected:Key\fin\fOFF\fposition.\fDISCONNECT\f
the\fnext\fcomponent\f(go\fto\ftest\fstep\f3).\f
-\fIf\f\bll\fthe\flisted\fcomponents\f\bre\f
disconnected: GO\fto\fAK9.\f\f
AK9: \bHE\bK THE HS \bAN BUS FOR A SHORT TO VOLTAGE SUPPLY
Ignition\fswitch\fin\fposition\f0.\f1
Disconnect\f-\fVehicles\fwith\f\b\f2.0L\fdiesel\fengine:\f
Connector\fC1E108-D\ffrom\fthe\fPCM.\f2
Disconnect\f-\fVehicles\fwith\f\b\f2.0L\fengine:\f
Connector\fC1E104-E\ffrom\fthe\fPCM.\f3
Disconnect\f-\fVehicles\fwith\f\b\f2.5L\fengine:\f
Connector\fC1E108-B\ffrom\fthe\fPCM.\f4
Disconnect\f-\fVehicles\fwith\f\b\f1.8L\fdiesel\fengine:\f
Connector\fC1E108-K\ffrom\fthe\fPCM.\f5
Disconnect\f-\fVehicles\fwith\f\b\f1.6L\fDur\btec-16V\f
(Sigm\b)\fengine:\fConnector\fC1E104-J\ffrom\fthe\f
PCM.\f6
Disconnect\f-\fVehicles\fwith\f\b\f3.0L\fDur\btec-VE\f
(VE6)\fengine:\fConnector\fC1E109-B\ffrom\fthe\f
PCM.\f7
Disconnect\f-\fVehicles\fwith\f\b\f2.2L\fdiesel\fengine:\f
Connector\fC1E108-H\ffrom\fthe\fPCM.\f8
Ignition\fswitch\fin\fposition\fII.\f9
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Is\f\b\fresist\bnce\fof\fmore\fth\bn\f10,000\fOhm\fme\bsured?\f
Yes GO\fto\fAK12.\f\f
No
L

OCATE\f\bnd\fREPAIR\fthe\fshort\fto\fground\fin\fthe\f
circuit\fbetween\fthe\fPCM\f\bnd\fthe\fDLC\fwith\fthe\f\bid\f
of\fthe\fWiring\fDi\bgr\bms.\fCHECK\fthe\foper\btion\fof\f
the\fsystem.\f
AK12: \bHE\bK THE HS \bAN BUS FOR A SHORT TO GROUND
Me\bsure\fthe\fresist\bnce\fbetween\fthe\fDLC,\f
connector\fC3DB04,\fpin\f14,\fcircuit\fVDB05Z\f(WH),\f
wiring\fh\brness\fside\f\bnd\fground.\f
1
Is\f\b\fresist\bnce\fof\fmore\fth\bn\f10,000\fOhm\fme\bsured?\f
Yes CHECK\fthe\fPCM\f\bnd\fRENEW\fif\fnecess\bry.\fCHECK\f
the\foper\btion\fof\fthe\fsystem.\f
No
LOCATE\f\bnd\fREPAIR\fthe\fshort\fto\fground\fin\fthe\f
circuit\fbetween\fthe\fPCM\f\bnd\fthe\fDLC\fwith\fthe\f\bid\f
of\fthe\fWiring\fDi\bgr\bms.\fCHECK\fthe\foper\btion\fof\f
the\fsystem.\f
AK13: \bHE\bK THE GEM
Disconnect\fConnector\fC1BP02-C\ffrom\fthe\fGEM.\f1
Me\bsure\fthe\fresist\bnce\fbetween\fthe\fDLC,\f
connector\fC3DB04,\fpin\f6,\fcircuit\fVDB04L\f
(WH/BU),\fwiring\fh\brness\fside\f\bnd\fpin\f14,\fcircuit\f
VDB05Z\f(WH),\fwiring\fh\brness\fside.\f2
Is\f\b\fresist\bnce\fof\fbetween\f115\f\bnd\f125\fOhm\f
me\bsured?\f
Yes GO\fto\fAK14.\f\f
No -

\fVehicles\fwith\f\b\f2.0L\fdiesel\fengine: GO\fto\fAK16.\f
\f
-\fVehicles\fwith\f\b\f2.0L\fengine: GO\fto\fAK18.\f\f
-\fV
ehicles\fwith\f\b\f2.5L\fengine: GO\fto\fAK20.\f\f
-\fV

ehicles\fwith\f\b\f1.8L\fdiesel\fengine: GO\fto\fAK22.\f
\f
-\fVehicles\fwith\f\b\f1.6L\fDur\btec-16V\f(Sigm\b)\f
engine:GO\fto\fAK24 .\f\f
-\f V

ehicles\fwith\f\b\f3.0L\fDur\btec-VE\f(VE6)\f
engine: GO\fto\fAK26 .\f\f
\f\f
\f\f
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No -\fIf\fnot\f\bll\fthe\flisted\fcomponents\f\bre\f
disconnected:Key\fin\fOFF\fposition.\fDISCONNECT\f
the\fnext\fcomponent\f(go\fto\ftest\fstep\f3).\f
-\fIf\f\bll\fthe\flisted\fcomponents\f\bre\f
disconnected: GO\fto\fAK31.\f\f
AK31: \bHE\bK THE HS \bAN BUS FOR A SHORT TO VOLTAGE SUPPLY
Ignition\fswitch\fin\fposition\f0.\f1
Disconnect\f-\fVehicles\fwith\f\b\f2.0L\fdiesel\fengine:\f
Connector\fC1E108-D\ffrom\fthe\fPCM.\f2
Disconnect\f-\fVehicles\fwith\f\b\f2.0L\fengine:\f
Connector\fC1E104-E\ffrom\fthe\fPCM.\f3
Disconnect\f-\fVehicles\fwith\f\b\f2.5L\fengine:\f
Connector\fC1E108-B\ffrom\fthe\fPCM.\f4
Disconnect\f-\fVehicles\fwith\f\b\f1.8L\fdiesel\fengine:\f
Connector\fC1E108-K\ffrom\fthe\fPCM.\f5
Disconnect\f-\fVehicles\fwith\f\b\f1.6L\fDur\btec-16V\f
(Sigm\b)\fengine:\fConnector\fC1E104-J\ffrom\fthe\f
PCM.\f6
Disconnect\f-\fVehicles\fwith\f\b\f3.0L\fDur\btec-VE\f
(VE6)\fengine:\fConnector\fC1E109-B\ffrom\fthe\f
PCM.\f7
Disconnect\f-\fVehicles\fwith\f\b\f2.2L\fdiesel\fengine:\f
Connector\fC1E108-H\ffrom\fthe\fPCM.\f8
Ignition\fswitch\fin\fposition\fII.\f9
Me\bsure\fthe\fvolt\bge\fbetween\fthe\fDLC,\fconnector\f
C3DB04,\fpin\f6,\fcircuit\fVDB04L\f(WH/BU),\fwiring\f
h\brness\fside\f\bnd\fground.\f
10
Is\f\b\fvolt\bge\fme\bsured?\f
Yes LOCATE\f\bnd\fREPAIR\fthe\fshort\fto\fvolt\bge\fsupply\f
in\fthe\frelev\bnt\fcircuit\fwith\fthe\f\bid\fof\fthe\fWiring\f
Di\bgr\bms.\fCHECK\fthe\foper\btion\fof\fthe\fsystem.\f
No GO\fto\fAK32.\f\f
AK32: \bHE\bK THE HS \bAN BUS FOR A SHORT TO VOLTAGE SUPPLY
Me\bsure\fthe\fvolt\bge\fbetween\fthe\fDLC,\fconnector\f1
\f\f
\f\f
Стр. 152 из 159
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