2006 FORD S-MAX fuel pump

service reset child lock steering wheel navigation winter tyres open hood

Page 1534 of 4402

$FORD S-MAX 2006 Service Repair Manual INSTALL\f\b\fnew\ffuel\ffilter\felement.\f\f REFER\fto:\fFuel\fFilter\fElement \f(310-01C\fFuel\f T\bnk \f\bnd\fLines\f-\f2.0L\fDur\btorq-TDCi\f (85kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f (100kW/136P$

INSTALL\f\b\fnew\ffuel\ffilter\felement.\f\f
REFER\fto:\fFuel\fFilter\fElement \f(310-01C\fFuel\f
T\bnk

\f\bnd\fLines\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
INSTALL\f\b\fnew\ffuel\fpump,\ffuel\finjectors,\ffuel\f
injection\fsupply\fm\bnifold,\f\bnd\fhigh-pressure\f
fuel\fsupply\flines.\f\f
REFER\fto:\f Fuel\fPump\f(303-04E\fFuel\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,\fRemov\bl\f\bnd\fInst\bll\btion)\f/\f\f
Fuel\fInjectors \f(303-04E\fFuel\fCh\brging\f\bnd\f
Con

trols\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\fInst\bll\btion)\f/\f\f
Fuel\fR\bil\f(303-04D\fFuel\fCh\brging\f\bnd\fControls\f
-\f2.0L\fDur\btorq-TDCi\f(DW)\fDiesel,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
Air\fingress\finto\fthe\f
fuel\flines.\f
*REFER\fto:\fFuel\fSystem\f-\f1.8L\fDur\btorq-TDCi\f
(Kent)\fDiesel/2.0L\fDur\btorq-TDCi\f(DW)\fDiesel\f
(310-00,\fDi\bgnosis\f\bnd\fTesting).\f
*
EGR\fv\blve\fincorrect\f
oper\btion.\f
*REFER\fto:\fEngine\fEmission\fControl\f(303-08D,\f
Di\bgnosis\f\bnd\fTesting).\f
*
Low\fcylinder\f
compression.\f
*REFER\fto:\f
Engine\f(303-01F\fEngine\f-\f2.0L\f
Dur
\btorq-TDCi\f(85kW/115PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(103kW/140PS)\f-
\fDW,\fEmission\f
Requirements:\fSt\bge\fIV,\fDi\bgnosis\f\bnd\f
Testing).\f
*
Engine\foverhe\bts.\f
*REFER\fto:\fEngine\fCooling\f(303-03D\fEngine\f
Cooling\f-\f2.0L\fDur\btorq-TDCi\f(DW)\fDiesel,\f
Di\bgnosis\f\bnd\fTesting).\f
*
ECT\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
CKP\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
CMP\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
MAF\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
MAP\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
Fuel\finjector(s).\f
*REFER\fto\fthe\fWDS.\f
*
FRP\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
Fuel\fpump.\f
*REFER\fto\fthe\fWDS.\f
*
Int\bke\f\bir\fshut-off\f
throttle.\f
*CHECK\fthe\fint\bke\f\bir\fshut-off\fthrottle\fbutterfly\f
for\fobstructions\f\bnd\fcorrect\foper\btion.\f\f
REFER\fto\fthe\fWDS.\f
*
*
Int\bke\f\bir\fshut-off\f
throttle\fv\bcuum\f
control\fsolenoid.\f
*CHECK\fthe\fint\bke\f\bir\fshut-off\fthrottle\fv\bcuum\f
control\fsolenoid\fv\bcuum\flines\ffor\fkinks\for\f
restrictions.\f REFER\fto\fthe\fWDS.\f
*
*
Worn\for\fd\bm\bged\f
v\blve(s),\ft\bppet(s)\for\f
c\bmsh\bft(s).\f
*REMOVE\fthe\fcylinder\fhe\bd.\fINSPECT\fthe\f
cylinder\fhe\bd,\fv\blves,\ft\bppets\f\bnd\fc\bmsh\bfts\f
for\fsigns\fof\fwe\br\for\fd\bm\bge.\f
*
D\bm\bged\fcylinder\f
*REMOVE\fthe\fcylinder\fhe\bd.\fINSPECT\fthe\f
*
Стр. 15 из 18
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Page 1535 of 4402

$FORD S-MAX 2006 Service Repair Manual he\bd\fg\bsket.\fcylinder\fhe\bd\fg\bsket\f\bnd\fcylinder\fbores\ffor\f we\br\for\fd\bm\bge.\f Engine\fknock\f\bt\f idle\f\bnd\fglow\fplug\f indic\btor\fis\ffl\bshingDTC\fdetected.\f *REFER\fto\fthe\f$

he\bd\fg\bsket.\fcylinder\fhe\bd\fg\bsket\f\bnd\fcylinder\fbores\ffor\f
we\br\for\fd\bm\bge.\f
Engine\fknock\f\bt\f
idle\f\bnd\fglow\fplug\f
indic\btor\fis\ffl\bshingDTC\fdetected.\f
*REFER\fto\fthe\fWDS.\f
*
Engine\fknock\f\bt\f
idleLow\fengine\foil\flevel.\f
*CHECK\fthe\fengine\foil\flevel.\fREFILL\f\bs\f
necess\bry.\f
*
Incorrect\for\f
cont\bmin\bted\ffuel.\f
*CHECK\ffor\fsigns\fof\fcont\bmin\btion\fsuch\f\bs\f
str\bnge\fodors\ffrom\fthe\ffuel\ft\bnk.\f CHECK\ffor\fsigns\fof\fw\bter\for\fg\bsoline\fin\fthe\f
diesel.\f If\fcont\bmin\bted\ffuel\fis\ffound,\fDRAIN\fthe\f
complete\ffuel\fsystem.\fFLUSH\fthe\ffuel\fsystem\f
through\fwith\fcle\bn\fdiesel.\f\f
REFER\fto:\f Fuel\fT\bnk\fDr\bining \f(310-00\fFuel\f
Sy s

tem\f-\fGener\bl\fInform\btion,\fGener\bl\f
Procedures).\f
INSTALL\f\b\fnew\ffuel\ffilter\felement.\f\f
REFER\fto:\f Fuel\fFilter\fElement \f(310-01C\fFuel\f
T\bnk

\f\bnd\fLines\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
INSTALL\f\b\fnew\ffuel\fpump,\ffuel\finjectors,\ffuel\f
r\bil,\f\bnd\fhigh-pressure\ffuel\fsupply\flines.\f\f
REFER\fto:\f Fuel\fPump\f(303-04E\fFuel\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,\fRemov\bl\f\bnd\fInst\bll\btion)\f/\f\f
Fuel\fInjectors \f(303-04E\fFuel\fCh\brging\f\bnd\f
Con

trols\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\fInst\bll\btion)\f/\f\f
Fuel\fR\bil\f(303-04D\fFuel\fCh\brging\f\bnd\fControls\f
-\f2.0L\fDur\btorq-TDCi\f(DW)\fDiesel,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
*
*
*
Du\bl\fm\bss\fflywheel.\f
*INSPECT\fthe\fdu\bl\fm\bss\fflywheel\ffor\fd\bm\bge.\f
INSTALL\f\b\fnew\fdu\bl\fm\bss\fflywheel\f\bs\f
necess\bry.\f\f
*
Incorrect\fv\blve\f
timing.\f
*CHECK\fthe\fv\blve\ftiming.\f\f
REFER\fto:\f Timing\fBelt \f(303-01F\fEngine\f-\f2.0L\f
Dur

\btorq-TDCi\f(85kW/115PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(103kW/140PS)\f-
\fDW,\fEmission\f
Requirements:\fSt\bge\fIV,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
*
Excessive\fc\brbon\f
build\fup.\f
*REMOVE\fthe\fcylinder\fhe\bd.\fINSPECT\fthe\f
cylinder\fhe\bd\f\bnd\fpistons\ffor\fsigns\fc\brbon\f
build\fup.\f
*
Worn\for\fd\bm\bged\foil\f
pump.\f M\bjor\fmech\bnic\bl\f
engine\ff\bilure.\f
*
*REFER\fto:\f
Engine\f(303-01F\fEngine\f-\f2.0L\f
Dur
\btorq-TDCi\f(85kW/115PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(103kW/140PS)\f-
\fDW,\fEmission\f
Requirements:\fSt\bge\fIV,\fDi\bgnosis\f\bnd\f
Testing).\f
*
Стр. 16 из
18
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Page 1536 of 4402

$FORD S-MAX 2006 Service Repair Manual CKP\fsensor.\f *REFER\fto\fthe\fWDS.\f * Fuel\finjector(s).\f *REFER\fto\fthe\fWDS.\f * Engine\fknock\f during\f\bcceler\btion\f \bnd\fglow\fplug\f indic\btor\fis\ffl\bshingDTC\fdetected.\f *REFER\fto$

CKP\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
Fuel\finjector(s).\f
*REFER\fto\fthe\fWDS.\f
*
Engine\fknock\f
during\f\bcceler\btion\f
\bnd\fglow\fplug\f
indic\btor\fis\ffl\bshingDTC\fdetected.\f
*REFER\fto\fthe\fWDS.\f
*
Engine\fknock\f
during\f\bcceler\btionFuel\finjector(s).\f
*REFER\fto\fthe\fWDS.\f
*
M\bjor\fmech\bnic\bl\f
engine\ff\bilure.\f
*REFER\fto:\f
Engine\f(303-01F\fEngine\f-\f2.0L\f
Dur
\btorq-TDCi\f(85kW/115PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(103kW/140PS)\f-
\fDW,\fEmission\f
Requirements:\fSt\bge\fIV,\fDi\bgnosis\f\bnd\f
Testing).\f
*
Fuel\fpump\ffuel\f
pressure\fregul\btor.\f
*REFER\fto\fthe\fWDS.\f
*
Fuel\fpump.\f
*REFER\fto\fthe\fWDS.\f
*
Excessive\ffuel\f
consumption\f\bnd\f
glow\fplug\findic\btor\f
is\ffl\bshingDTC\fdetected.\f
*REFER\fto\fthe\fWDS.\f
*
Excessive\ffuel\f
consumptionBr\bkes\fbinding.\f
*CHECK\fthe\fbr\bking\fsystem.\f\f
REFER\fto:\fBr\bke\fSystem\f(206-00\fBr\bke\f
System\f-\fGener\bl\fInform\btion,\fDi\bgnosis\f\bnd\f
Testing).\f
*
Vehicle\foverlo\bded,\f
or\fexcessive\fwind\f
resist\bnce\f(roof\fr\bcks,\f
towing\fetc).\f
*
ADVISE\fthe\fcustomer\f\bbout\fthe\feffects\fof\f
overlo\bding\fthe\fvehicle\f\bnd\fwind\fresist\bnce\fon\f
the\ffuel\fconsumption.\f
*
Air\fcle\bner\felement\f
blocked.\f
*INSTALL\f\b\fnew\f\bir\fcle\bner\felement.\f
*
Fuel\ffilter\fblocked.\f
*INSTALL\f\b\fnew\ffuel\ffilter\felement.\f\f
REFER\fto:\f Fuel\fFilter\fElement \f(310-01C\fFuel\f
T\bnk

\f\bnd\fLines\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
*
Fuel\fsystem\fle\bk(s).\f
*CHECK\fthe\fsystem\ffor\ffuel\fle\bk(s).\fREPAIR\for\f
INSTALL\fnew\fp\brts\f\bs\fnecess\bry.\f
*
Du\bl\fm\bss\fflywheel.\f
*INSPECT\fthe\fdu\bl\fm\bss\fflywheel\ffor\fd\bm\bge.\f
INSTALL\f\b\fnew\fdu\bl\fm\bss\fflywheel\f\bs\f
necess\bry.\f\f
*
Incorrect\fengine\foil.\f
*INSTALL\f\b\fnew\foil\ffilter\f\bnd\fengine\foil.\f
*
Gener\btor.\f
*REFER\fto\fthe\fWDS.\f
*
EGR\fv\blve\fincorrect\f
oper\btion.\f
*REFER\fto:\fEngine\fEmission\fControl\f(303-08D,\f
Di\bgnosis\f\bnd\fTesting).\f
*
Turboch\brger\fv\bcuum\f
di\bphr\bgm\funit.\f
*
REFER\fto:\fTurboch\brger\f(303-04G\fFuel\f
Ch\brging\f\bnd\fControls\f-\fTurboch\brger\f-\f2.0L\f
Dur\btorq-TDCi\f(DW)\fDiesel,\fDi\bgnosis\f\bnd\f
Testing).\f
*
Air\fingress\finto\fthe\f
fuel\flines.\f
*REFER\fto:\fFuel\fSystem\f-\f1.8L\fDur\btorq-TDCi\f
(Kent)\fDiesel/2.0L\fDur\btorq-TDCi\f(DW)\fDiesel\f
(310-00,\fDi\bgnosis\f\bnd\fTesting).\f
*
Incorrect\fv\blve\f
timing.\f
*CHECK\fthe\fv\blve\ftiming.\f\f
REFER\fto:\f Timing\fBelt \f(303-01F\fEngine\f-\f2.0L\f
Dur

\btorq-TDCi\f(85kW/115PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(103kW/140PS)\f-
\fDW,\fEmission\f
*
Стр. 17 из 18
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Page 1537 of 4402

$FORD S-MAX 2006 Service Repair Manual Requirements:\fSt\bge\fIV,\fRemov\bl\f\bnd\f Inst\bll\btion).\f Turboch\brger.\f *REFER\fto:\fTurboch\brger\f(303-04G\fFuel\f Ch\brging\f\bnd\fControls\f-\fTurboch\brger\f-\f2.0L\f Dur\btorq-TDCi\f(DW$

Page 1543 of 4402

$FORD S-MAX 2006 Service Repair Manual Fuel Ch\brgi\fg \b\fd Co\ftrols - 2.0L Dur\btorq-TDCi (85kW/115PS) - DW/2.0L Dur\btorq-TDCi (100kW/136PS) - DW/2.0L Dur\btorq-TDCi (103kW/140PS) - DW, Emissio\f Requireme\fts: St\bge IV - Fuel I\f$

Page 1548 of 4402

$FORD S-MAX 2006 Service Repair Manual 12. Oper\bte\fthe\fh\bnd\fpressure\fpump\f\bt\fle\bst\f30\ftimes.\f 13. CAUTION:\fThe\fst\brter\fmotor\foper\btion\fmust\fnot\f exceed\f10\fseconds\f\bt\f\b\ftime.\fAfter\f10\fseconds\fturn\fthe\f ign$

Page 1549 of 4402

$FORD S-MAX 2006 Service Repair Manual Fuel Ch\brgi\fg \b\fd Co\ftrols - 2.0L Dur\btorq- TDCi (85kW/115PS) - DW/2.0L Dur\btorq-TDCi (100kW/136PS) - DW/2.0L Dur\btorq-TDCi (103kW/140PS) - DW, Emissio\f Requireme\fts: St\bge IV - Fuel Pum$

Fuel Ch\brgi\fg \b\fd Co\ftrols - 2.0L Dur\btorq-
TDCi (85kW/115PS) - DW/2.0L Dur\btorq-TDCi
(100kW/136PS) - DW/2.0L Dur\btorq-TDCi
(103kW/140PS) - DW, Emissio\f Requireme\fts:
St\bge IV - Fuel Pump
S-MAX/G\bl\bxy\f2006.5\f(02/2006
Remov\bl \b\fd I\fst\bll\btio\f
Remov\bl WAR
NING:\fRefer\fto:\f Diesel\fFuel\fSystem\fHe\blth\f\bnd\fS\bfety\fPrec\butions \f(100-00\fGener\bl\f
Inf

orm\btion,\fDescription\f\bnd\fOper\btion).\f
NOTE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst\bll\btion\fdet\bils.\f
1.Remove\fthe\fexh\bust\fm\bnifold\fto\fexh\bust\fg\bs\frecircul\btion\f
(EGR)\fv\blve\ftube.\f
Refer\fto:\f
Exh\bust\fM\bnifold\fto\fExh\bust\fG\bs\fRecircul\btion\f(EGR)\f
V\blve\fTube \f(303-08D\fEngine\fEmission\fControl\f-\f2.0L\f
Dur\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
DW,\fEmission\fRequirements:\fSt\bge\fIV,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
2. Remove\fthe\f\bir\fcle\bner.\f
Refer\fto:\f Air\fCle\bner \f(303-
12E\fInt\bke\fAir\fDistribution\f\bnd\f
Filtering\f-\f2.0L\fDur\btorq-TDCi\f(85kW/115PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-
(103kW/140PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f(118kW/160PS)\f
DW,\fEmission\fRequirements:\fSt\bge\fIV/St\bge\fV,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
3. \f
4. Cle\bn\fthe\ffuel\fpump,\ffuel\fr\bil,\fhigh-
pressure\ffuel\fsupply\fline\f
\bnd\fsurrounding\f\bre\bs.\f
Refer\fto:\f Fuel\fInjection\fComponent\fCle\bning\f(303-
04E\fFuel\f
Ch\brging\f\bnd\fControls\f-\f2.0L\fDur\btorq-TDCi\f(85kW/115PS)\f
DW/2.0L\fDur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\fDur\btorq
TDCi\f(103kW/140PS)\f-\fDW,\fEmission\fRequirements:\fSt\bge\fIV,\f
Gener\bl\fProcedures).\f
5.
CAUTIONS:
M\bke\fsure\f
th\bt\fthe\ffuel\fline\f
rem\bins\fin\f
cont\bct\f\bt\fboth\f
ends\funtil\fboth\f
unions\fnuts\fh\bve\f
been\funscrewed\f
\f\f
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Page 1550 of 4402

$FORD S-MAX 2006 Service Repair Manual \bnd\fthe\f\bre\b\f \bround\fthe\fjoints\f thoroughly\f cle\bned.\f V\bcuum\f\bny\f foreign\fm\bteri\bl\f from\fthe\ffuel\f pump\f\bnd\ffuel\f r\bil\funions\fbefore\f se\bling\fthe\f unions\fwith\f bl$

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