Power S\beering \f Power S\beering Pump—
2.5L Dura\bec (162kW/220PS) \f VI5S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Ins\balla\bion
Removal
NO
TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
1. Remove\fthe\ffollowing\fitems:\f 1.
Remove\fthe\fright-h\bnd\fhe\bdl\bmp\f
\bssembly.\f
Refer\fto:\fHe\bdl\bmp\fAssembly\f(417-01\f
Exterior\fLighting,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
2. Remove\fthe\f\bccessory\fdrive\fbelt.\f
Refer\fto:\fAccessory\fDrive\fBelt\f(303-05B\f
Accessory\fDrive\f-\f2.5L\fDur\btec-ST\f(VI5),\f
Remov\bl\f\bnd\fInst\bll\btion).\f
2. Lower\fthe\fvehicle.\f
3. Position\fthe\fpower\fsteering\ffluid\freservoir\fto\fone\f side.\f
4. CAUTION:\fM\bke\fsure\fth\bt\f\bll\fopenings\f
\b r
e\fse\bled.\f Torque:\b 23\fNm
\f
5. R\bise\f\bnd\fsupport\fthe\fvehicle.\f
Refer\fto:\fLifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Description\f\bnd\fOper\btion).\f
6. \f
7. Position\fthe\f\bir\fconditioning\f(A/C)\fcompressor\fto\f one\fside.\f
\f\f
\f\f
\f\f
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Steering\bCol\fmn\bSwitches\b-\bSteering\b
Col\fmn\bSwitchesS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Diagnosis\band\bTesting\b
Inspection\band\bVerification\b
1. 1.\b
Verify\fthe\fcustomer\fconcern.\f
2
. 2.\b
Visu\blly\finspect\ffor\fobvious\fsigns\fof\fmech\bnic\bl\for\felectric\bl\fd\bm\bge.\f
V
is\fal\bInspection\bChart\b
3. 3.\b
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.\b
If\fthe\fc\buse\fis\fnot\fvisu\blly\fevident,\fverify\fthe\fsymptom\f\bnd\frefer\fto\fthe\fSympton\f
C
h\brt.\f
Symptom\bChart\b
Pinpoint\bTest\b
N O
TE:\fUse\f\b\fdigit\bl\fmultimeter\ffor\f\bll\felectric\bl\fme\bs
urements.\f
Electric\bl
Fuse(s).\f\f
Wiring\fh\brness.\f\f
Electric\bl\fconnector(s).\f\f
Switch(es).\f\f
B\bttery.\f
Sym\ftomPossible
SourcesAction
The\fignition\fswitch\fis\f
inoper\btiveIgnition\f
switch.\f
*CARRY\fOUT\fthe\fIgnition\fSwitch\fComponent\fTest.\f
REFER\fto\fthe\fWiring\fDi\bgr\bms.\f
*
Circuit(s).\f
*GO\fto\fPinpoint\fTest\f A.\f\f
*
No\fpower\fin\fACCIgnition\f
switch.\f
*CARRY\fOUT\fthe\fIgnition\fSwitch\fComponent\fTest.\f
REFER\fto\fthe\fWiring\fDi\bgr\bms.\f
*
Circuit(s).\f
*GO\fto\fPinpoint\fTest\f B.\f\f
*
No\fpower\fin\fRUNIgnition\f
switch.\f
*CARRY\fOUT\fthe\fIgnition\fSwitch\fComponent\fTest.\f
REFER\fto\fthe\fWiring\fDi\bgr\bms.\f
*
Circuit(s).\f
*GO\fto\fPinpoint\fTest\f C.\f\f
*
No\fpower\fin\fSTARTIgnition\f
switch.\f
*CARRY\fOUT\fthe\fIgnition\fSwitch\fComponent\fTest.\f
REFER\fto\fthe\fWiring\fDi\bgr\bms\f
*
Circuit(s).\f
*GO\fto\fPinpoint\fTest\f D.\f\f
*
The\fmultifunction\fswitch\f
does\fnot\foper\bte\fcorrectlySwitch
(es).\f Circuit(s).\f
*
*REFER\fto:\f
Turn\fSign\bl,\fCornering\f\bnd\fH\bz\brd\fL\bmps \f
(41
7-01\fExterior\fLighting,\fDi\bgnosis\f\bnd\f
Testing),\f
He\bdl\bmps \f(417-01\fExterior\fLighting,\f
Di\bg
nosis\f\bnd\fTesting),\f
Wipers\f\bnd\fW\bshers \f(501-16\fWipers\f\bnd\f
W\bsh
ers,\fDi\bgnosis\f\bnd\fTesting).\f
*
PINPOINT\bTEST\bA\b:\bTHE\bIGNITION\bSWITCH\bIS\bINOPERATIVE\b
TEST CONDITIONSDETAILS/RESULTS/ACTIONS
A1:\bCHECK\bTHE\bIGNITION\bSWITCH\bELECTRICAL\bCONNECTOR
Remove\fthe\fsteering\fcolumn\fshrouds.\f1\b
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Engine - \b.0L \furatec-HE (107kW/145PS)
- MI4/\b.0L \furatec-HE Flex Fuel
(107kW/145PS) - MI4 - Engine Front
Cover
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Installation
Materials
Gen
eral Equipment
Removal
N O
TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
NameSpec\bf\bcat\bo\f
Silicone\fSe\bl\bnt\fLBWSE-M4G323-A4\f/\f2U7J-M4G323-AA
Trolley\fj\bck
1. Remove\fthe\ffollowing\fitems:\f1. Refer\fto:\f He\bdl\bmp\fAssembly \f(417-01\f
Ext
erior\fLighting,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
2. Refer\fto:\f Cr\bnksh\bft\fPulley \f(303-01A\f
Eng
ine\f-\f2.0L\fDur\btec-HE\f(107kW/145PS)\f
-\fMI4/2.0L\fDur\btec-HE\fFlex\fFuel\f
(107kW/145PS)\f-\fMI4,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
2. \f
3. \f
4. General \bqui\fment: Trolley\fj\bck\f
5. \f
\f
\f
\f\f
\f\f
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Engine - \b.0L \furatec-HE (107kW/145PS)
- MI4/\b.0L \furatec-HE Flex Fuel
(107kW/145PS) - MI4 - Engine
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal
Special Tool(s)
Ge
neral Equipment
303-122\f
Lifting\fBr\bcket,\fEngine\f
310-137\f
Disconnect\fTool,\fFuel\fLine
\f
3.5 mm drill bit
Center punch
Hose clamp remover/installer
Hydraulic jib crane
Mounting table set
Retaining Strap
Schlitzschraubendreher 1.General \bqui\fment: Sc
hlitzschr\bubendreher\f
2. R
efer\fto:\f Cooling\fSystem\fDr\bining,\fFilling\f\bnd\f
Bl e
eding \f(303-03A\fEngine\fCooling\f-\f2.0L\fDur\btec-
HE\f
(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\f
Fuel\f(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fGener\bl\fProcedures).\f
3. Remove\fthe\ffollowing\fitems:\f 1. Refer\fto:\f Accessory\fDrive\fBelt \f(303-05A\f
Acc
essory\fDrive\f-\f2.0L\fDur\btec-HE\f
(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\f
Fuel\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. Remove\fthe\fright-h\bnd\fhe\bdl\bmp.\f
Refer\fto:\f He\bdl\bmp\fAssembly \f(417-01\f
Ext
erior\fLighting,\fRemov\bl\f\bnd\fInst\bll\btion).
\f
3. Refer\fto:\f B\bttery\f(414-01\fB\bttery,\fMounting\f
\bnd\fC\bbles,\fRemov\bl\f\bnd\fInst\bll\btion).\f
4. \f
\f
\f
\f\f
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40.Torque:\b 12\fNm\f
41. Torque:\b 12\fNm
\f
42. Refer\fto:\f Ge\brshift\fC\bble\fAdjustment\f-\fVehicles\f
Wit
h:\f5-Speed\fM\bnu\bl\fTr\bns\bxle\f(MTX-75) \f(308-
00\f
M\bnu\bl\fTr\bnsmission/Tr\bns\bxle\f\bnd\fClutch\f-\f
Gener\bl\fInform\btion,\fGener\bl\fProcedures).\f
43. Inst\bll\fthe\ffollowing\fitems:\f 1. Refer\fto:\f Accessory\fDrive\fBelt \f(303-05A\f
Ac c
essory\fDrive\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. Right-h\bnd\fhe\bdl\bmp\f
Refer\fto:\f He\bdl\bmp\fAssembly \f(417-01\f
Ext
erior\fLighting,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
3. 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
44. \f
\f\f
\f\f
\f\f
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Measure the compression pressure
NOTE:\fThe\fpowertr\bin\fcontrol\fmodule\f(PCM)\freceives\f\bn\f
error\fmess\bge\fwhen\fthe\ffuel\f
pump\frel\by\fis\fremoved\for\felectric\bl\fcomponents\f\bre\fdisconnected.\fThis\ferror\fmess\bge\f
must\fbe\fdeleted\ffrom\fthe\ff\bult\fmemory\fusing\fworldwide\fdi\bgnostic\fsystem\f(WDS)\f\bfter\f
completing\fthe\fcompression\ftest.\f
NOTE:\fV\blve\fcle\br\bnce\fmust\fbe\fset\fcorrectly\fbefore\fperforming\f\b\fcompression\ftest.\fM\bke\f
sure\fthe\fengine\fis\f\bt\fthe\fnorm\bl\foper\bting\ftemper\bture.\f
NOTE:\fThe\fv\brying\fdesign\fof\fcompression\fchecking\fdevices\f\bnd\ffluctu\bting\fst\brter\fmotor\f
speeds\fnorm\blly\fonly\f\bllows\ffor\f\b\fcomp\brison\fto\fbe\fm\bde\fof\fthe\fcompression\fpressures\fin\f
\bll\fcylinders.\f
Measure the compression pressure (Engine - \b.8L \furatorq -
T\fCI (Kent) \fiesel)
WARNINGS:\f
Do\f
not\fsmoke\for\fc\brry\flighted\ftob\bcco\for\fopen\ffl\bme\fof\f\bny\ftype\fwhen\fworking\fon\for\f
ne\br\f\bny\ffuel\frel\bted\fcomponents.\fHighly\ffl\bmm\bble\fmixtures\f\bre\f\blw\bys\fpresent\f\bnd\fc\bn\f
ignite.\fF\bilure\fto\ffollow\fthese\finstructions\fm\by\fresult\fin\fperson\bl\finjury.\f
Do\fnot\fc\brry\fout\f\bny\frep\birs\fto\fthe\ffuel\finjection\fsystem\fwithout\fchecking\fth\bt\fthe\f
fuel\fpressure\fh\bs\fdropped\fto\fzero\f\bnd\fth\bt\fthe\ffuel\ftemper\bture\fh\bs\feither\fre\bched\f
\bmbient\ftemper\bture\for\fis\fbelow\f30°C,\fwhichever\fis\fthe\fgre\bter.\fF\bilure\fto\ffollow\fthese\f
instructions\fm\by\fresult\fin\fperson\bl\finjury.\f
1. \b.
Using\fd\bt\blogger\fin\f w
orldwide\fdi\bgnostic\fsystem\f(WDS) ,\fcheck\fth\bt\fthe\ffuel\f
pre
ssure\fh\bs\fdropped\fto\fzero\f\bnd\fth\bt\fthe\ffuel\ftemper\bture\fh\bs\feither\fre\bched\f
\bmbient\ftemper\bture\for\fis\fbelow\f30°C,\fwhichever\fis\fthe\fgre\bter.\f
2. 2.
Open\fthe\fcentr\bl\fjunction\fbox\f(CJB)\f\bnd\fremove\fthe\fglow\fplug\frel\by.\f
3
. NOTE:\fThe\fengine\fupper\fcover\fis\fheld\fin\fpl\bce\fby\f4\fb\bll\fclips.\fThe\fb\bll\fclips\f\bre\fnot\f
v
e
rtic\bl,\fbut\f\bre\f\bngled\fb\bckw\brds\fby\f\bpproxim\btely\f20\fdegrees.\f
3. Loc\btion\fof\fthe\fengine\fupper\fcover\fret\bining\fclips.\f
\f\f
\f\f
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\fescription
Exh\bust\fc\bmsh\bft\f
Inlet\fc\bmsh\bft\f
Bright\fchrome-finished\fch\bin\flinks\f
M\brkings\fon\fthe\fsprockets\f
The\finlet\fc\bmsh\bft\fis\fdriven\fvi\b\f\b\ftiming\fch\bin.\f
Th
e\ftiming\fch\bin\fis\ftensioned\fusing\f\bn\f\butom\btic\fch\bin\ftensioner.\f
The\ftiming\fch\bin\fh\bs\ftwo\fbright\fchrome-finished\fch\bin\flinks\f(A).\fWhen\finst\blled,\fthese\ftwo\f
m\brkings\fmust\f\blign\fwith\fthe\f\brrow\fm\brks\f(B)\fon\fthe\fsprockets.\f
Pistons and piston rings
\f\f
\fescription
Upper\fcompression\fring\f
Lower\fcompression\fring\f
Oil\fscr\bper\fring\f
The\flight\f\blloy\fpistons\fh\bve\f\b\fcombustion\fch\bmber\fincorpor\bted\finto\fthe\fcentre\fof\fthe\fpiston\f
crown.\fThis\foptimises\fswirling\fof\fthe\ffuel/\bir\fmixture.\f
Two\frecesses\f\bre\fincorpor\bted\finto\fe\bch\fpiston\fcrown.\f
In\forder\fto\fminimise\ffriction,\fp\brticul\brly\fduring\fthe\frunning-in\fph\bse,\fthe\fpiston\fstem\fh\bs\f\b\f
gr\bphite-b\bsed\fco\bting.\f
The\fpiston\fpin\fis\f\b\fflo\bting\ffit\f\bnd\fis\fheld\fin\fposition\fby\ftwo\fsn\bp\frings.\f
Cylinder block Item
1
2
( A
)
(B)
Item 1
2
3 -
-
-
-
\f
Part Number
-
-
-
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WARNING:\fWhen\frele\bsing\fthe\fcooling\fsystem\fpressure,\fcover\fthe\fexp\bnsion\ft\bnk\f
c\bp\fwith\f\b\fthick\fcloth\fto\fprevent\fthe\fpossibility\fof\fcool\bnt\fsc\blding,\fF\bilure\fto\ffollow\fthis\f
instruction\fm\by\fresult\fin\fperson\bl\finjury.\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
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
\f\f
Part Number
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