Page 1948 of 4402

Automati\b Tra\fsmissio\f/Tra\fsaxle -
Vehi\bles With: 6-Speed Automati\b
Tra\fsaxle - AWF21 - Tra\fsmissio\f Co\ftrol
Module (TCM)
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal a\fd I\fstallatio\f
Removal
NO
TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
I\fstallatio\f 1. Refer\fto:\f
Ai
r\fCle\bner\f(303-12A\fInt\bke\fAir\f
Dis
tribution\f\bnd\fFiltering\f-\f2.0L\fDur\btec-HE\f
(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\fFuel\f
(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
2. NOTE:\fBefore\fremoving\fthe\fTCM,\fm\bke\f
c
e
rt\bin\fth\bt\fthe\fselector\flever\fis\fin\fthe\fN\f
position.\f\f
3. Torque:\b 1
6\fNm\f
4. \f
1. CAUTION:\fM\bke\fsure\fth\bt\fthe\f
c o
mponent\fis\fcle\bn,\ffree\fof\fforeign\fm\bteri\bl\f
\bnd\flubric\bnt.\f
\f\f
\f\f
\f\f
\f\f
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Page 1968 of 4402
Automati\b Tra\fsmissio\f/Tra\fsaxle Exter\fal
Co\ftrols - Vehi\bles With: 6-Speed Automati\b
Tra\fsaxle - AWF21 - Sele\btor Lever Cable
Adjustme\ft
S-MAX/G\bl\bxy\f2006.5\f(02/2006
\fPrint
Ge\feral Pro\bedures 1. Refer\fto:\fAir\fCle\bner\f(303-
12A\fInt\bke\fAir\fDistribution\f
\bnd\fFiltering\f-\f2.0L\fDur\btec-HE\f(107kW/145PS)\f-\f
MI4/2.0L\fDur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\f
MI4/2.3L\fDur\btec-HE\f(118kW/160PS)\f-
\fMI4,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
2. Select\fposition\fD.\f
3. \f
4. The\fselector\f
lever\f\bnd\f
the\fshift\f
mech\bnism\f
must\fbe\fin\f
position\fD.
5. Refer\fto:\f Air\fCle\bner\f(303-12A\fInt\bke\fAir\fDistribution\f
\bnd\fFiltering\f-\f2.0L\fDur\btec-HE\f(107kW/145PS)\f-\f
MI4/2.0L\fDur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\f
MI4/2.3L\fDur\btec-HE\f(118kW/160PS)\f-
\fMI4,\fRemov\bl\f
\f\f
\f\f
\f
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Page 1970 of 4402

Automati\b Tra\fsmissio\f/Tra\fsaxle
Exter\fal Co\ftrols - Vehi\bles With: 6-
Speed
Automati\b Tra\fsaxle - AWF21 - Sele\btor
Lever CableS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal a\fd I\fstallatio\f
Ge\feral Equipme\ft
Removal
CA
UTION:\fThe\fge\brshift\fc\bbles\fmust\fnot\fbe\fkinked\for\ft w
isted.\f
NOTE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst\bll\btion\fdet\bils.\f
Vehicles\fwith\felectronic\fp\brking\fbr\bke\f(EPB)\f
Knife
1. Refer\fto:\fAir\fCle\bner\f(303-12A\fInt\bke\fAir\f
Dis
tribution\f\bnd\fFiltering\f-\f2.0L\fDur\btec-HE\f
(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\fFuel\f
(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
2. \f
3. Refer\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des
cription\f\bnd\fOper\btion).\f
4. \f
5. \f
6. Lower\fVehicle\f
7. Refer\fto:\f Floor\fConsole\f-\fVehicles\fWith:\f
El e
ctronic\fP\brking\fBr\bke\f(EPB),\fVIN\fPl\bte\fBody\f
\f\f
\f\f
\f\f
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Page 2056 of 4402

Manual T\bansmissi\fn/T\bansaxle - Vehicles
With: 5-Speed Manual T\bansaxle - MTX75
- T\bansmissi\fn—2.0L Du\batec-HE
(107kW/145PS) - MI4/2.0L Du\batec-HE
Flex Fuel (107kW/145PS) - MI4
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Rem\fval
Special T\f\fl(s)
Ge
ne\bal Equipment
303-290-13\f
Ad\bpter\ffor\f303-290A
\f
303-290A-15\f
Ad\bpter\ffür\f303-290A
\f
303-290B\f
Support\fB\br,\fEngine\f
303-290B-16\f
Ad\bpter\ffor\f303-290B
\f
T\bansmissi\fn jack 1. Refer\fto:\fHe\blth\f\bnd\fS\bfety\fPrec\butions\f(100-00\f
Gen
er\bl\fInform\btion,\fDescription\f\bnd\fOper\btion).
\f
2. Remove\fthe\ffollowing\fitems:\f 1. Air\ffilter\f
Refer\fto:\f Air\fCle\bner \f(303-12A\fInt\bke\fAir\f
Dis
tribution\f\bnd\fFiltering\f-\f2.0L\fDur\btec-
HE\f
(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\f
Flex\fFuel\f(107kW/145PS)\f-\fMI4/2.3L\f
Dur\btec-HE\f(118kW/160PS)\f-\fMI4,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
2. B\bttery\fc\brrier\f
Refer\fto:\f B\bttery\f(414-01\fB\bttery,\f
Mou
nting\f\bnd\fC\bbles,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
3. CAUTION:\fThe\fge\brshift\fc\bbles\fmust\fnot\f
b e
\fkinked\for\ftwisted.\f
\f
\f
\f
\f
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Page 2104 of 4402
Inst\bll\btion).\f
2. Air\ffilter\f
Refer\fto:\f Air\fCle\bner \f(303-12A\fInt\bke\fAir\f
Dis
tribution\f\bnd\fFiltering\f-\f2.0L\fDur\btec-
HE\f
(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\f
Flex\fFuel\f(107kW/145PS)\f-\fMI4/2.3L\f
Dur\btec-HE\f(118kW/160PS)\f-\fMI4,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
25. Check\fthe\flevel\fof\fthe\ftr\bnsmission\ffluid.\f
Refer\fto:\f Tr\bnsmission\fDr\bining\f\bnd\fFilling \f(308-
03A
\fM\bnu\bl\fTr\bnsmission/Tr\bns\bxle\f-\fVehicles\f
With:\f5-Speed\fM\bnu\bl\fTr\bns\bxle\f-\fMTX75,\f
Gener\bl\fProcedures).\f
26. \f
27. Initi\blize\fthe\fwindow\fregul\btor\fmotors.\f
Refer\fto:\f Door\fWindow\fMotor\fIniti\bliz\btion \f(501-
11 \f
Gl\bss,\fFr\bmes\f\bnd\fMech\bnisms,\fGener\bl\f
Procedures).\f
\f\f
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Page 2284 of 4402

Manual T\bansmissi\fn/T\bansaxle Exte\bnal
C\fnt\b\fls - Vehicles With: 5-Speed Manual
T\bansaxle - MTX75 - Gea\bshift Cables
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Rem\fval and Installati\fn
Gene\bal Equipment
Rem\fval
CA
UTION:\fGe\brshift\fc\bbles\fmust\fnot\fbe\fkinked\for\fbent. \f
N
OTE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst\bll\btion\fdet\bils.\f
Knife
1. Refer\fto:\f Air\fCle\bner\f(303-12A\fInt\bke\fAir\f
Dis
tribution\f\bnd\fFiltering\f-\f2.0L\fDur\btec-HE\f
(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\fFuel\f
(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
Refer\fto:\f Air\fCle\bner \f(303-12D\fInt\bke\fAir\f
Dis
tribution\f\bnd\fFiltering\f-\f1.8L\fDur\btorq-TDCi\f
(74kW/100PS)\f-\fLynx/1.8L\fDur\btorq-TDCi\f
(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\fInst\bll\btion).
\f
2. \f
3. Refer\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
De s
cription\f\bnd\fOper\btion).\f
4. \f
5. \f
6. Lower\fVehicle\f
\f\f
\f\f
\f\f
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Page 2354 of 4402

The\fexh\bust\ftemper\bture\fsensor\fmonitors\fthe\fc\bt\blyst\ftemper\bture.\fThe\fDPF\ftemper\bture\f
sensor\fmonitors\fthe\fpre-DPF\ftemper\bture.\fThese\fsign\bls\f\bre\fsent\fto\fthe\fpowertr\bin\fcontrol\f
module\f(PCM).\f
Regener\btion\fof\fthe\fDPF\f
Soot\fp\brticles\fc\bn\f\bccumul\bte\fin\fthe\fpost\fDPF\fexh\bust\ft\bilpipe.\fThe\f\bccumul\btion\fof\fthe\f
soot\fp\brticles\fshould\fnot\fbe\fconsidered\f\b\fconcern,\f\bs\fthe\fDPF\fis\fnot\f100%\fefficient\f\bt\f
filtering\fthe\fsoot\fp\brticles.\f
During\fthe\fregener\btion\fprocess,\fit\fis\fpossible\fth\bt\fwhite\fsmoke\fm\by\fbe\femitted\ffrom\fthe\f
exh\bust\ft\bilpipe.\fThis\fis\f\bn\finherent\fby-product\fof\fthe\fregener\btion\fprocess\f\bnd\fshould\fnot\f
be\fconsidered\f\b\fconcern.\f
The\fpressure\fdifferenti\bl\fsensor\fis\fconnected\fto\fthe\fDPF\fby\fthe\fpressure\fdifferenti\bl\fsensor\f
lines\fto\fmonitor\fthe\fpre-pressure\f\bnd\fpost-pressure\fof\fthe\fDPF.\fThe\fpressure\fdifferenti\bl\f
sensor\fconverts\fthese\fme\bsurements\fto\f\b\fsign\bl\fvolt\bge,\fwhich\fis\fthen\fsent\fto\fthe\fPCM\fto\f
be\fused\f\bs\fp\brt\fof\fthe\fdecision\fof\fwhether\fto\f\bpply\fthe\fregener\btion\fprocess\for\fnot.\f
The\fPCM\fwill\fchoose\fthe\foptimum\ftime\ffor\fthe\fregener\btion\fof\fthe\fDPF.\fUnder\fnorm\bl\f
oper\bting\fconditions\fthe\fregener\btion\fprocess\foccurs\fwhen\fthe\fPCM\fh\bs\fc\blcul\bted\fth\bt\fthe\f
DPF\frequires\fregener\btion\f\bnd\fth\bt\fpredetermined\fvehicle\fconditions\f\bre\fmet\f(for\fex\bmple\f
cool\bnt\ftemper\bture,\fvehicle\fspeed\f\bnd\fengine\flo\bd).\f
M\bnu\bl\fregener\btion\fof\fthe\fDPF\f
If\fthe\fDPF\fbecomes\fblocked\fthe\fpressure\fdifferenti\bl\fsensor\fwill\fregister\f\b\fhigh\fpressure\f
di\bgnostic\ftrouble\fcode\f(DTC)\fwith\fthe\fPCM,\fthe\fm\blfunction\findic\btor\fl\bmp\f(MIL)\fwill\fbe\f
illumin\bted\f\bnd\fthe\flimp\fhome\fmode\f\bctiv\bted.\f
A\fblocked\fDPF\fc\bn\fbe\f\b\fresult\fof:\fExcessive\fsoot\fp\brticles\fproduction\f\f
Multiple\ff\biled\fregener\btion\fevents\f
Mech\bnic\bl\for\felectric\bl\ff\bilure\fof\f\b\frel\bted\fsystem\for\fsub-system\f(for\fex\bmple\fEGR\fv\blve\f
st
uck\fopen,\fch\brge\f\bir\fsystem\fle\bk,\ffuel\finjectors)\f
The\fm\bnu\bl\fregener\btion\fof\fthe\fDPF\fc\bn\fbe\fused\fto\fcle\br\fthe\fsoot\fp\brticles\ffrom\fthe\fDPF.\f
F o
r\f\bddition\bl\finform\btion,\frefer\fto\fWDS.\f
Muffler\f
\f\f
Description\b
Muffler\f
Exh\bust\fh\bnger\finsul\btors\f
Ite\f
1
2
\f
Part\bNu\fber -
-
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Page 2376 of 4402

Fuel Sy\btem - \feneral Information - Fuel
Sy\btem—2.0L Duratec-HE (MI4)/2.3L
Duratec-HE (MI4)/2.5L Duratec (VI5)
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Diagno\bi\b and Te\bting
\feneral Equipment
In\bpection 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\bual In\bpection 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\f F
ord\f
\bpp
roved\fdi\bgnostic\ftool .\f
Ford\f\bpproved\fdi\bgnostic\ftool
Mechanica\bE\bectrica\b
Fuel\flevel\f\f
Fuel\fpump\f\bnd\fsender\funit\f\f
Fuel\fle\bk(s)\f\f
Fuel\fline(s)\f\f
Fuel\ffilter\f\f
Fuel\ft\bnk\f\f
Fuel\ft\bnk\ffiller\fpipe\f\f
Fuel\ft\bnk\ffiller\fc\bp\fElectric\bl\fconnector(s)\f\f
Wiring\fh\brness\f\f
Fuel\fpump\fmodule\f
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