Page 1289 of 4402

settles\finto\f\b\fsh\bllow\frise\f\bnd\ff\bll\fsign\bl,\fclose\fto\f\b\fstr\bight\fline.\fThis\findic\btes\fth\bt\fthe\fthermost\bt\fis\ffunctioning\fcorrectly.\f
NOTE:\fSome\fthermost\bts\findic\bte\fthe\ftemper\bture(s)\fin\f
Celsius\f\bnd\fF\bhrenheit.\f
The\fgr\bphic\fbelow\fshows\fthe\floc\btion\f\bnd\f\bn\fex\bmple\fof
\fthe\fopening\ftemper\bture\f(88ºC)\f
\bnd\ffully\fopen\ftemper\bture\f(102ºC)\fof\f\b\fthermost\bt.\f
The\fgr\bphic\fbelow\fshows\f\bn\f\bltern\btive\fmethod\fused\fto\fshow\fthe\fopening\ftemper\bture\f
(88ºC)\f\bnd\ffully\fopen\ftemper\bture\f(112ºC)\fof\f\b\fthermost\bt.\f
\f\f
Descripti\bn
Opening\ftemper\bture\f
Fully\fopen\ftemper\bture\f
NOTE:\fGener\blly,\fmost\fthermost\bts\fm\bint\bin\f\b\fcool\bnt\ftemper\bture\fbetween\f88ºC\f
(1
90ºF)\f\bnd\f92ºC\f(198ºF)\f\blthough\fdu\bl\fst\bge\felectric\fthermost\bts\fm\by\fincre\bse\fthe\f
cool\bnt\ftemper\bture\fup\fto\f100ºC\f(212ºF)\funder\flight\fengine\flo\bd\fconditions.\f
The\fengine\fshould\fst\brt\fcle\bnly\f\bnd\fthe\fECT\fv\blue\fwill
\frise\fquite\fquickly\fwith\fsmooth\f
progression.\fIf\fthe\fECT\fsign\bl\f\bppe\brs\funst\bble\for\ferr\btic,\fthe\fECT\fsensor,\felectric\bl\f
connector\f\bnd\fwiring\fh\brness\fto\fthe\fPCM\fneed\fto\fbe\fvisu\blly\finspected\ffor\fd\bm\bge,\fch\bfing\f
or\fw\bter\fingress.\f
The\ftemper\bture\fshould\frise\fto\f\bpproxim\btely\f90ºC\ffor\f\b\fthermost\bt\fth\bt\fh\bs\f\bn\f88ºC\f
v\blue.\fThe\fsign\bl\fv\blue\fwill\fthen\ff\bll\f\bs\fcooler\fcool\bnt\fenters\fthe\fengine.\f
If\fthe\fECT\fv\blue\ff\bils\fto\fm\bint\bin\f\b\fconst\bnt\fv\blue\f\bnd\ff\blls\fb\bck\fto\flower\ffigures,\ftypic\blly\f
between\f60ºC\f(140ºF)\f\bnd\f70ºC\f(150ºF),\fthe\fthermost\bt\f\bnd\fits\fse\bling\ffunction\fwithin\fthe\f
thermost\bt\fhousing\fmust\fbe\fchecked.\f
5. 5\f
INSTALL\f\b\fnew\fthermost\bt.\f\f
R
EFER\fto:\f Thermost\bt\f-\f2.0L\fDur\btec-HE\f(107kW/145PS)\f-\fMI4/2.0L\f
Dur\btec-HE\f
Flex\fFuel\f(107kW/145PS)\f-\fMI4\f(303-03A\fEngine\fCooling\f-\f2.0L\fDur\btec-HE\f
(10
7kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4/2.3L\f
Dur\btec-HE\f(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\fInst\bll\btion).\f
6. 6\f
C\brry\fout\f\bnother\fro\bd\ftest\ffrom\fstep\f1\fusing\fthe\fs\bme\fcriteri\b\fto\fconfirm\fth\bt\fthe\f
c
oncern\fh\bs\fbeen\frectified.\f
7. 7\f
Using\fthe\fFord\f\bpproved\fdi\bgnostic\ftool,\fcle\br\fthe\fPCM\fkeep\f\blive\fmemory\f(KAM)\f
I
tem
A
B \f
\f
\f\f
Part Number
-
-
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Page 1290 of 4402
or\felectric\blly\fer\bs\bble\fprogr\bmm\bble\fre\bd\fonly\fmemory\f(EEPROM)\fso\fth\bt\fnew\fdrive\fv\blues\fc\bn\fbe\fle\brnt.\f
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Page 1291 of 4402

Engine C\b\bling - 2\f0L Duratec-HE
(107kW/145PS) - MI4/2\f0L Duratec-HE
Flex Fuel (107kW/145PS) - MI4/2\f3L
Duratec-HE (118kW/160PS) - MI4 -
C\b\bling System Draining, Filling and
Bleeding
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
General Pr\bcedures
Draining
WARNING:\fWhen\frele\bsing\fthe\fcooling\fsystem\fpressure,\fcover\fthe\fcool\bnt\fexp\bnsion\f
t\b
nk\fc\bp\fwith\f\b\fthick\fcloth.\f
Filling and Bleeding
CAUTION:\fThe\ffluid\flevel\fmust\frem\bin\fbetween\fthe\fMAX\f\bnd\fMIN\fm\brks.\f
1. Rele\bse\fthe\fcooling\fsystem\fpressure\fby\fslowly\f turning\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fc\bp\fbetween\f
2\f\bnd\f3\fturns.\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. Inst\bll\fthe\fr\bdi\btor\fdr\bin\fplug.\f
7. Lower\fthe\fvehicle.\f
1. Switch\fthe\finterior\fhe\bter\fblower\foff.\f
2. Fill\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fcool\bnt\flevel\fto\f
\f\f
\f\f
\f\f
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Page 1292 of 4402

the\fneck\fof\fthe\fcool\bnt\fexp\bnsion\ft\bnk.\f
3. St\brt\fthe\fengine.\f
4. R\bise\fthe\fengine\fspeed\fto\f2500\fRPM\f\bnd\f m\bint\bin\fit\ffor\f1\fminute.\f
5. Check\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fcool\bnt\flevel.\f
6. If\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fcool\bnt\flevel\fh\bs\f f\bllen\fbelow\fthe\fMIN\fm\brk,\fstop\fthe\fengine\f\bnd\f
refill\fthe\fcool\bnt\fexp\bnsion\ft\bnk\flevel\fto\fthe\fneck\f
of\fthe\fcool\bnt\fexp\bnsion\ft\bnk.\f
7. Inst\bll\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fc\bp.\f
8. St\brt\fthe\fengine\fif\fstopped.\f
9. R\bise\fthe\fengine\fspeed\fto\f2500\fRPM\f\bnd\f m\bint\bin\fit\ffor\f\bpproxim\btely\f11\fminutes\fwhile\f
observing\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fcool\bnt\f
level.\f
10. M\bint\bin\fthe\fengine\fspeed\f\bt\f2500\fRPM\ffor\f\b\f further\f3\fminutes.\f
11. Incre\bse\fthe\fengine\fspeed\fto\f4000\fRPM\f\bnd\f m\bint\bin\fit\ffor\f5\fseconds.\f
12. Decre\bse\fthe\fengine\fspeed\fto\f2500\fRPM\f\bnd\f m\bint\bin\fit\ffor\f3\fminutes.\f
13. Switch\fthe\fengine\foff.\f
14. Check\fthe\fcooling\fsystem\ffor\fle\bks.\f
15. Check\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fcool\bnt\flevel.\f
16. Refer\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
De s
cription\f\bnd\fOper\btion).\f
17. \f
18. Lower\fthe\fvehicle.\f
19. Allow\fthe\fengine\fto\fcool.\f
20. Fill\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fcool\bnt\flevel\fto\f the\fMAX\fm\brk.\f
\f\f
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Page 1293 of 4402

Engine C\b\bling - 2\f0L Duratec-HE
(107kW/145PS) - MI4/2\f0L Duratec-HE
Flex Fuel (107kW/145PS) - MI4/2\f3L
Duratec-HE (118kW/160PS) - MI4 -
C\b\bling System Draining and Vacuum
Filling
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
General Pr\bcedures
General Equipment
Draining
WARNING:\fWhen\frele\bsing\fthe\fcooling\fsystem\fpressure,\fcover\fthe\fcool\bnt\fexp\bnsion\f
t \b
nk\fc\bp\fwith\f\b\fthick\fcloth.\f
NOTE:\fAlw\bys\ffollow\fthe\fm\bnuf\bcturer's\finstructions\fwhen\fh\bndling\fthe\fequipment.\f
Cooling\fsystem\fv\bcuum\ftester\f\bnd\frefiller
Fluid\fcont\biner
1. Refer\fto:\f Engine\fCooling\fSystem\fHe\blth\f\bnd\f
S\bfe
ty\fPrec\butions\f(100-00\fGener\bl\fInform\btion,\f
Des
cription\f\bnd\fOper\btion).\f
2. \f\f Rele\bse\fthe\fcooling\fsystem\fpressure\fby\fslowly\f
turning\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fc\bp\fbetween\f
2\f\bnd\f3\fturns.\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\f WARNING:\fBe\fprep\bred\fto\fcollect\f
e s
c\bping\ffluid.\f
Use\f\b\fsuit\bble\fcool\bnt\fhose\fto\fdr\bin\fthe\fcool\bnt.\f
Gen
eral \bqui\fment: Fluid\fcont\biner\f
Loo
sen: 4\fturn(s)
\f
6. \f
\f\f
\f\f
\f\f
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Page 1294 of 4402

Evacuating and Filling 7. \f
1
.
\f\fIf\fthe\fcooling\fsystem\fw\bs\fcompletely\f
dr
\bined,\ffill\fthe\ffluid\fcont\biner\fwith\fthe\ffull\f
cooling\fsystem\ffill\fc\bp\bcity\fplus\f0.5L\fof\f
\bddition\bl\fcool\bnt.\f
If\fthe\fcooling\fsystem\fw\bs\fp\brti\blly\fdr\bined,\f
fill\fthe\ffluid\fcont\biner\fwith\fthe\fremoved\f
\bnd\fspilled\f\bmount\fof\fcool\bnt\fplus\f1.0L\fof\f
\bddition\bl\fcool\bnt.\fWhen\fin\fdoubt\f\blw\bys\f
use\fthe\ffull\fcooling\fsystem\ffill\fc\bp\bcity\fplus\f
0.5L\fof\f\bddition\bl\fcool\bnt.\f
2. \f\f General \bqui\fment: Co
oling\fsystem\f
v\bcu
um\ftester\f\bnd\frefiller \f
3. \f
\f 1. Close\fthe\fv\blve,\finst\bll\fthe\fcool\bnt\fhose\f \bnd\fpl\bce\fit\finto\fthe\ffluid\fcont\biner.\f
2. Close\fthe\fv\blve\f\bnd\fconnect\fthe\f compressed\f\bir\fhose.\f
4. \f\f 2. Open\fthe\fv\blve\funtil\fthe\fspecificied\fv\bcuum\fis\f\bchieved.\f
5. \f\f Open\fthe\fv\blve\funtil\fthe\fcool\bnt\freservoir\f
fl
uid\flevel\fis\f\bt\fthe\fMAX\fm\brk.\f
\f\f
\f\f
\f\f
\f\f
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Page 1295 of 4402
If\fno\fcool\bnt\fis\fvisible\fin\fthe\fcool\bnt\f
exp\bnsion\ft\bnk,\f\bdd\f2.0L\fof\fcool\bnt\fto\fthe\f
fluid\fcont\biner\f\bnd\frepe\bt\fthe\fev\bcu\bting\f
\bnd\ffilling\fprocedure.\f
6. \f
\f\f
\f\f
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Page 1296 of 4402
Engine C\b\bling - 2\f0L Duratec-HE
(107kW/145PS) - MI4/2\f0L Duratec-HE Flex
Fuel (107kW/145PS) - MI4/2\f3L Duratec-HE
(118kW/160PS) - MI4 - Radiat\br L\bwer
M\bunting Repair
S-MAX/G\bl\bxy\f2006.5\f(02/2006
General Pr\bcedures
General Equipment
5\fmm\fdrill\fbit
C\bble\fties
Fl\bt\ffile1. On\fboth\fsides.\f
2.
Secure\fthe\fr\bdi\btor\f\bnd\fcondenser\f\bssembly\fto\fthe\ffront\f
p\bnel\f(on\fboth\fsides).\f
General \bqui\fment: C\bble\fties\f
3. R
\bise\f\bnd\fsupport\fthe\fvehicle.\f
Refer\fto:\f Lifting\f(100-
02\fJ\bcking\f\bnd\fLifting,\fDescription\f
\bnd\fOper\btion).\f
4. \f
5. \f
6. \f\f
\f\f
\f\f
\f\f
\f\f
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