Page 2754 of 4402

The\fcool\bnt\fpump\fis\floc\bted\fto\fthe\fre\br\fof\fthe\fengine\fcomp\brtment\fne\br\fthe\fbulkhe\bd.\fThe\f
cool\bnt\fpump\fis\fpowered\fby\f\b\fbuilt-in\felectric\fmotor\f\bnd\fcircul\btes\fthe\fcooling\ffluid\fin\fthe\f
engine\fcooling\fsystem.\f
Fuel pump module
The\ffuel\fpump\fis\f\bn\felectric\freciproc\bting\fpump\fth\bt\fmeters\fthe\fcorrect\fqu\bntity\fof\ffuel\ffor\f
the\ffuel\fpowered\fbooster\fhe\bter.\fThe\fpower\fsupply\ffor\fthe\ffuel\fpump\fis\fconnected\fto\fthe\f
fuel\fpowered\fbooster\fhe\bter\fmodule.\fBy\fpulsing\fthe\fvolt\bge\fsupply\f\bt\f\b\fv\brying\ffrequency,\f
the\ffuel\fpowered\fbooster\fhe\bter\fmodule\fc\bn\fregul\bte\fthe\fqu\bntity\fof\ffuel\fsupplied\ffor\f
combustion.\fThe\ffuel\fpump\fis\floc\bted\fclose\fto\fthe\ffuel\ft\bnk\f\bnd\fis\fconnected\fto\fthe\ffuel\f
t\bnk\fby\f\b\fsep\br\bte\ft\bnk\fconnection\fwithout\f\b\ffilter.\f
ECT sensor
The\ffuel\fpowered\fbooster\fhe\bter\fmodule\fuses\fthe\fcool\bnt\ftemper\bture\fsensor\fto\fdetermine\f
the\fcool\bnt\ftemper\bture,\fwhich\fit\fthen\fuses\fto\fset\fthe\fst\brting\f\bnd\fstopping\ftime.\fThe\f
cool\bnt\ftemper\bture\fsensor\fis\finst\blled\fnext\fto\fthe\foverhe\bting\fsensor\fbelow\f\b\fcover\fon\fthe\f
underside\fof\fthe\ffuel\fpowered\fbooster\fhe\bter.\f
Overhea\fing sensor \f\f
\f\f
\f\f
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Page 2798 of 4402

Instrum\bnt Clust\br \f Instrum\bnt Clust\brS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Diagnosis and T\bsting
G\bn\bral Equipm\bnt
Insp\bction and V\brification
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
isual Insp\bction 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\fenter\fthe\finstrument\f
c
luster\fSelf-Di\bgnostic\fMode.\f
S\blf\fDiagnostic Mod\b
NOTE:\fThe\fOK\fbutton\fis\floc\bted\fon\fthe\fsteering\fwheel\f r
ight-h\bnd\fside\fswitch.\f
1. 1.
To\fenter\fthe\finstrument\fcluster\fSelf-Di\bgnostic\fMode.\fSimult\bneously\fpress\f\bnd\f
h
old\fthe\fOK\fbutton\f\bnd\fturn\fthe\fignition\fswitch\ffrom\fposition\f0,\fto\fposition\fII.\f
2. 2.
Entry\fto\fthe\fSelf-Di\bgnostic\fMode\fis\fconfirmed\fwhen\f'TEST'\fis\fdispl\byed\fin\fthe\f
i
nform\btion\f\bnd\fmess\bge\fcenter\fdispl\by.\fThe\fset\fbutton\fmust\fbe\frele\bsed\fwithin\f
three\fseconds\fof\f'TEST'\fbeing\fdispl\byed\for\fthe\finstrument\fcluster\fwill\fexit\fthe\fSelf-
Di\bgnostic\fMode.\f
3. 3.
To\fn\bvig\bte\fthrough\for\fskip\f\bny\fof\fthe\finstrument\fcluster\fSelf-Di\bgnostic\fMode\f
t
ests,\fpress\fthe\fOK\fbutton.\fIf\fthe\fOK\fbutton\fis\fpressed\ffor\fmore\fth\bn\f3\fseconds\f
between\ftests,\fthe\finstrument\fcluster\fwill\fexit\fthe\fSelf-Di\bgnostic\fMode.\f
4. 4.
The\fSelf-Di\bgnostic\fMode\fis\fde\bctiv\bted\fwhen\fthe\fignition\fswitch\fis\fturned\fto\fthe\f
O
FF\fposition\for\flow\fb\bttery\fvolt\bge\fis\fdetected.\f
5. 5.
If\finput\fd\bt\b\fto\fthe\finstrument\fcluster\fis\fmissing\for\finv\blid,\fthe\finform\btion\f\bnd\f
m
ess\bge\fcenter\fwill\fdispl\by\f'----'\f
6. 6.
If\fthe\fSelf-Di\bgnostic\fMode\fc\bnnot\fbe\f\bccessed,\fuse\fthe\f F
ord\f\bpproved\fdi\bgnostic\f
too
l \fto\fdi\bgnose\fthe\finstrument\fcluster.\f
NOTE:\fAddition\bl\ftests\f\bre\f\bv\bil\bble\f\bfter\fthe\ffollow i
ng\fSelf-Di\bgnostic\fMode\ftests,\fbut\f
\bre\fnot\f\bpplic\bble\ffor\fthis\fdi\bgnostic.\f
Ford\f\bpproved\fdi\bgnostic\ftool
Mechanica\bE\bectrica\b
Engine\foil\ffilter\f\f
Engine\foil\flevel\f\f
Engine\fcool\bnt\ftemper\bture\f(ECT)\fsensor\f\f
Engine\fcool\bnt\flevel\f\f
Thermost\bt\f\f
Coll\bpsed\for\fd\bm\bged\ffuel\ft\bnk\f\f
Door\f\bdjustment\fFuse(s)\f\f
Wiring\fh\brness\f\f
Electric\bl\fconnector(s)\f\f
Instrument\fcluster\f\f
Light\femitting\fdiode(s)\f(LED)(s)\f
Стр. 1 из 3
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Page 2876 of 4402

Battery,\bMou\fti\fg\ba\fd\bCables\b-\bBatteryS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal\ba\fd\bI\fstallatio\f\b
Removal\b
NO
TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
1. Disconnect\fthe\fb\bttery\fground\fc\bble.\f
Re
fer\fto:\f B\bttery\fDisconnect\f\bnd\fConnect\f(414-
01\f
B\bttery,\fMounting\f\bnd\fC\bbles,\fGener\bl\f
Procedures).\f
2. Remove\fthe\f\bir\fcle\bner.\f
Refer\fto:\f Air\fCle\bner \f(303-12A\fInt\bke\fAir\f
Di s
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(303-12A\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(303-12C\fInt\bke\fAir\f
Dis
tribution\f\bnd\fFiltering\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\fInst\bll\btion).
\f
Refer\fto:\f Air\fCle\bner \f(303-12E\fInt\bke\fAir\f
Dis
tribution\f\bnd\fFiltering\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/2.0L\fDur\btorq-TDCi\f
(118kW/160PS)\f-\fDW,\fEmission\fRequirements:\f
St\bge\fIV/St\bge\fV,\fRemov\bl\f\bnd\fInst\bll\btion).\f
Refer\fto:\f Air\fCle\bner \f(303-12E\fInt\bke\fAir\f
Di s
tribution\f\bnd\fFiltering\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/2.0L\fDur\btorq-TDCi\f
(118kW/160PS)\f-\fDW,\fEmission\fRequirements:\f
St\bge\fIV/St\bge\fV,\fRemov\bl\f\bnd\fInst\bll\btion).\f
3. \f
4. \f\f 1.Torque:\b 5\fNm
\f
2. Torque:\b 10\fNm
\f
\f\f
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Page 2887 of 4402

Generator\band\bReg\flator\b-\bGenerator—
2.0L\bD\fratorq-TDCi\b(85kW/115PS)\b-\b
DW/2.0L\bD\fratorq-TDCi\b(100kW/136PS)\b
-\bDW/2.0L\bD\fratorq-TDCi\b
(103kW/140PS)\b-\bDW/2.0L\bD\fratorq-
TDCi\b(118kW/160PS)\b-\bDW,\bEmission\b
Req\firements:\bStage\bIV/Stage\bV
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal\band\bInstallation\b
Removal\b
NO
TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
Installation\b 1. Remove\fthe\f\bccessory\fdrive\fbelt.\f
Re
fer\fto:\f Accessory\fDrive\fBelt \f(303-05E\f
Acc
essory\fDrive\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
2. Remove\fthe\ffuel\ffilter.\f
Refer\fto:\f Fuel\fFilter \f(310-01C\fFuel\fT\bnk\f\bnd\f
Lin
es\f-\f2.0L\fDur\btorq-TDCi\f(85kW/115PS)\f-\f
DW/2.0L\fDur\btorq-TDCi\f(100kW/136PS)\f-\f
DW/2.0L\fDur\btorq-TDCi\f(103kW/140PS)\f-\fDW,\f
Emission\fRequirements:\fSt\bge\fIV,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
3. \f\f 1.Torque:\b 15\fNm
\f
2. Torque:\b 10\fNm
\f
3. Torque:\b 48\fNm
\f
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f\f
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Page 3402 of 4402

Wiring H\brnesses - \fngine Wiring
H\brness—2.0L Dur\btec-
H\f (107kW/145PS)
- MI4/2.0L Dur\btec-H\f Flex Fuel
(107kW/145PS) - MI4/2.3L Dur\btec-H\f
(118kW/160PS) - MI4S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Remov\bl \bnd Inst\bll\btion
Gener\bl \fquipment
Remov\bl
NO
TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\fins t
\bll\btion\fdet\bils.\f
Vehicles\fbuilt\fup\fto\f09/2007\f
A l
l\fvehicles\f
3.5\fmm\fdrill\fbit
Center\fpunch 1. Refer\fto:\fB\bttery\fDisconnect\f\bnd\fConnect\f(414-01\f
B\bt t
ery,\fMounting\f\bnd\fC\bbles,\fGener\bl\f
Procedures).\f
2. 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\fInst\bll\btion).\f
3. \f
4. \f
5. Refer\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
De s
cription\f\bnd\fOper\btion).\f
6. \f
\f\f
\f\f
\f\f
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