2006 FORD S-MAX Service Repair Manual

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Page 1409 of 4402

$FORD S-MAX 2006 Service Repair Manual C\bmp\bnent Tests Pressure Test WARNING:\fWhen\frele\bsing\fthe\fcooling\fsystem\fpressure,\fcover\fthe\fcool\bnt\fexp\bnsion\f t\b nk\fc\bp\fwith\f\b\fthick\fcloth\fto\fprevent\fthe\fpossibility\fo$

C\bmp\bnent Tests
Pressure Test 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\fto\fprevent\fthe\fpossibility\fof\fcool\bnt\fsc\blding.\fF\bilure\fto\ffollow\f
this\finstruction\fm\by\fresult\fin\fperson\bl\finjury.\f
NOTE:\fIf\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fc\bp\fis\frot\bted\fcounterclockwise\fby\f½\f\b\ffull\fturn,\fthe\f
pressurized\fcool\bnt\fwill\fbe\fvented\fto\fthe\funderside\fof\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fc\bp.\f
1. 1\f
Slowly\fremove\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fc\bp\fto\frele\bse\fthe\fcooling\fsystem\f
p
ressure.\f
2. 2\f
Inst\bll\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fc\bp.\f
3

. 3\f
Inst\bll\fthe\fspeci\bl\ftools\f303-396\f\bnd\f303-396-09\fto\fthe\fcool\bnt\fexp\bnsion\ft\bnk.\f
4

. 4\f
Pressurize\fthe\fcooling\fsystem\fto\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fc\bp\frele\bse\fpressure.\f
\f
REFER\fto:\f Specific\btions \f(303-03E\fEngine\fCooling\f-\f2.0L\fDur\btorq-TDCi\f
(85
kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(103kW/140PS)\f-\fDW,\fSpecific\btions).\f
5. 5\f
Observe\fthe\fcooling\fsystem\fpressure\ftester\fg\buge\fre\bding\ffor\f\bpproxim\btely\ftwo\f
m
inutes.\fThe\fpressure\fshould\fnot\fdrop\fduring\fthis\ftime.\fIf\fthe\fcooling\fsystem\fholds\f
pressure,\fINSTALL\f\b\fnew\fcool\bnt\fexp\bnsion\ft\bnk\fc\bp.\fIf\fthe\fcooling\fsystem\fdoes\f
not\fhold\fpressure,\fcheck\fthe\fcooling\fsystem\fthoroughly\ffor\fcool\bnt\fle\bks.\f
6. 6\f
Check\fthe\fcooling\fsystem\fby\frepe\bting\fsteps\f3\f\bnd\f4\f\bt\fle\bst\ftwice.\f
7

. 7\f
If\f\b\fcool\bnt\fle\bk\fc\bnnot\fbe\ffound,\fcheck\fthe\fengine\ffor\fcylinder\fle\bk\bge.\fDr\bin\fthe\f
c
ooling\fsystem.\fRep\bir\f\bny\fcool\bnt\fle\bks\ffound\f\bnd\ffill\f\bnd\fbleed\fthe\fcooling\fsystem\f
\bs\fnecess\bry.\f\f
REFER\fto:\f Cooling\fSystem\fDr\bining,\fFilling\f\bnd\fBleeding \f(303-03E\fEngine\fCooling\f-\f
2. 0

L\fDur\btorq-TDCi\f(85kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f(100kW/136PS)\f-\f
DW/2.0L\fDur\btorq-TDCi\f(103kW/140PS)\f-\fDW,\fGener\bl\fProcedures).\f
\bnd\fcylinder\fhe\bd\fg\bsket.\f\f
REFER\fto:\f Cylinder\fHe\bd \f(303-01F\fEngine\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-\fDW,\fEmission\fRequirements:\f
St\bge\fIV,\fRemov\bl\f\bnd\fInst\bll\btion).\f
The\fengine\fdoes\f
not\fre\bch\fnorm\bl\f
oper\bting\f
temper\bture.ECT\fsensor.\f
*CHECK\fthe\fengine\fcool\bnt\ftemper\bture.\fREFER\fto\f
the\fFord\f\bpproved\fdi\bgnostic\ftool.\f
*
Temper\bture\f
g\buge.\f
*CHECK\fthe\finstrument\fcluster\fengine\ftemper\bture\f
g\buge.\f\f
REFER\fto:\f Instrument\fCluster \f(413-01\fInstrument\f
Cl u

ster,\fDi\bgnosis\f\bnd\fTesting).\f
*
Thermost\bt.\f
*CARRY\fOUT\fthe\fThermost\bt\fTest\fComponent\fTest\f
in\fthis\fsection.\fINSTALL\f\b\fnew\fthermost\bt\f\bs\f
necess\bry.\f\f
REFER\fto:\f Thermost\bt \f(303-03E\fEngine\fCooling\f-\f
2.0

L\fDur\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,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
*
Стр. 3 из
7
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Page 1410 of 4402

$FORD S-MAX 2006 Service Repair Manual Radiat\br Leak Test, Rem\bved Fr\bm Vehicle CAUTION:\fR\bdi\btor\fintern\bl\fpressure\fmust\fnot\fexceed\f130\fkp\b\f(20\fpsi)\for\fd\bm\bge\f m\b y\fresult.\f Cle\bn\fthe\fr\bdi\btor\fthoroughly\fbe$

Radiat\br Leak Test, Rem\bved Fr\bm Vehicle CAUTION:\fR\bdi\btor\fintern\bl\fpressure\fmust\fnot\fexceed\f130\fkp\b\f(20\fpsi)\for\fd\bm\bge\f
m\b

y\fresult.\f
Cle\bn\fthe\fr\bdi\btor\fthoroughly\fbefore\fle\bk\ftesting\fit,\f
to\fprevent\fcont\bmin\btion\fof\fthe\fw\bter\f
in\fthe\ftest\ft\bnk.\fLe\bk\ftest\fthe\fr\bdi\btor\fin\fcle\bn\fw\bter\fwith\f138\fkp\b\f(20\fpsi)\f\bir\fpressure.\f
Check\fit\fthoroughly\ffor\f\bir\fle\bks.\fINSTALL\f\b\fnew\fr\bdi\btor\fif\fnecess\bry.\f\f
REFER\fto:\f R\bdi\btor\f(303-03E\fEngine\fCooling\f-\f2.0L\fDur\btorq-TDCi\f(85kW/11
5PS)\f-\f
DW/2.0L\fDur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f(103kW/140PS)\f-\fDW,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
C\b\blant Expansi\bn Tank Cap Pressure Test
WARNING:\fWhen\frele\bsing\fthe\fcooling\fsystem\fpressure,\fcover\fthe\fexp\bnsion\ft\bnk\f
c \b

p\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
so
\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
Стр. 4 из 7
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Page 1411 of 4402

$FORD S-MAX 2006 Service Repair Manual just\fbefore\fthe\fthermost\bt\fopens\f\bnd\fthen\fdrops\fb\bck\fbefore\fsettling\fto\f\b\fne\br\ffl\bt\fline\foutput\f(see\fgr\bphic\fbelow).\f \f\f Descripti\bn Thermost\bt\fopens\f Thermost\bt\fse$

just\fbefore\fthe\fthermost\bt\fopens\f\bnd\fthen\fdrops\fb\bck\fbefore\fsettling\fto\f\b\fne\br\ffl\bt\fline\foutput\f(see\fgr\bphic\fbelow).\f
\f\f
Descripti\bn
Thermost\bt\fopens\f
Thermost\bt\fsettles\finto\f\b\fcyclic\fopen\f\bnd\fclosure\fp\bttern\f
CAUTION:\fIf\fthe\fECT\fsensor\foutput\fre\bches\fthe\f120ºC\fdef\bult\fline\funder\fnorm\bl\f
co

oling\fsystem\fpressure,\fintern\bl\fd\bm\bge\fm\by\fbe\fc\bused\fto\fthe\fengine\f\bnd\f\b\fdi\bgnostic\f
trouble\fcode\f(DTC)\fwill\fbe\fset\fin\fthe\fPCM.\fThe\ftest\fshould\fbe\fstopped\f\bnd\fthe\fc\buse\f
loc\bted\f\bnd\fcorrected.\fIf\fthe\fcooling\fsystem\fdoes\fnot\fpressurize,\fthe\fcool\bnt\fwill\fboil\f\bt\f
100ºC\fwhich\fm\by\f\blso\fd\bm\bge\fthe\fengine.\fCARRY\fOUT\fthe\fCool\bnt\fExp\bnsion\fT\bnk\fC\bp\f
Pressure\fTest\fComponent\fTest\fin\fthis\fsection.\f
If\fthe\fFord\f\bpproved\fdi\bgnostic\ftool\fonly\f\bllows\fthe\fE
CT\fsensor\fto\fbe\fdispl\byed\fin\fvolts,\f
refer\fto\fthe\ffollowing\ft\bble\ffor\fcorresponding\fCelsius\fv\blues:\f
The\fCHT\fsensor\foutput\fis\fuseful\fto\fex\bmine\fthe\fcylinder\fhe\bd\ftemper\bture\frise\fduring\fthe\f
w\brm-up\fcycle\f\bnd\fl\bter\fduring\fthe\fnorm\bl\flight\fthrottle\fcruise\ftest.\fThis\fsensor\foutput\fm\by\f
v\bry\fbetween\fvehicles\fwith\fm\bnu\bl\ftr\bnsmission\f\bnd\fvehicles\fwith\f\butom\btic\ftr\bnsmission\f
\bnd\fshould\fbe\fused\ffor\freference\fonly.\f
The\fLOAD\fdispl\by\fis\fused\ffor\freference\f\bs\fit\fis\fnecess\bry\fto\fm\bint\bin\f\b\fst\bble\flo\bd\fline\f
during\fthe\ftest.\fIt\fis\fnecess\bry\fto\fc\brry\fout\fthe\ftest\funder\fnorm\bl\flight\fthrottle\fcruise\f
driving\fconditions\f\bnd\f\bver\bge\flo\bds,\ftypic\blly\f40%\fto\f70%\fof\fthe\flo\bd\fv\blue.\f
The\fVSS\foutput\fis\fused\ffor\freference\fbut\fc\bn\fhelp\fto\fidentify\fmisfires\f\bnd\fsensors\fwhich\ff\bil\f
during\fthe\fw\brm-up\fcycle.\f
The\fRPM\fdispl\by\findic\btes\fthe\fengine\fspeed\f\bnd\fc\bn\fbe\fcomp\bred\fwith\fthe\fDSRPM.\f
The\fDSRPM\fis\fthe\fdesired\for\fc\blcul\bted\fidle\fspeed\fwhich\fthe\fPCM\fcomm\bnds\fthe\fengine\fto\f
re\bch.\fIf\fthe\fthermost\bt\fopens\ftoo\fe\brly\f(before\fthe\fcorrect\fopening\ftemper\bture\fh\bs\fbeen\f
re\bched),\fthe\fengine\fwill\fnot\fre\bch\fthis\fv\blue.\f
When\fusing\fthe\fFord\f\bpproved\fdi\bgnostic\ftool\fin\fd\bt\b\flogger\fmode,\fthe\fsign\bls\frecorded\f
should\frem\bin\fwithin\fthe\fDEFAULT\fv\blues\fset\fby\fthe\fFord\f\bpproved\fdi\bgnostic\ftool.\f
3. WARNING:\fM\bke\fsure\fth\bt\fthe\fFord\f\bpproved\fdi\bgnostic\ftool\fis\fpl\bced\fin\fthe\f
v e

hicle\fso\fth\bt\fit\fdoes\fnot\finterfere\fwith\fthe\fs\bfe\foper\btion\fof\fthe\fvehicle.\fDo\fnot\f
pl\bce\fthe\fFord\f\bpproved\fdi\bgnostic\ftool\fin\fthe\fdeployment\fp\bth\fof\f\bny\f\bir\fb\bg.\f
Item
A
B
Vo\btsºCe\bsius
1.3360
1.0270
0.7880
0.6090
0.46100
0.35110
0.27120
\f\f
Part Number -
-
Стр. 5 из 7
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Page 1412 of 4402

$FORD S-MAX 2006 Service Repair Manual F\bilure\fto\ffollow\fthese\finstructions\fm\by\fresult\fin\fperson\bl\finjury.\f NOTE:\fThe\fro\bd\ftest\fis\fbest\fc\brried\fout\fwith\fthe\f\bid\fof\f\bnother\ftechnici\bn\fin\fthe\f vehicle\fto\fe$

F\bilure\fto\ffollow\fthese\finstructions\fm\by\fresult\fin\fperson\bl\finjury.\f
NOTE:\fThe\fro\bd\ftest\fis\fbest\fc\brried\fout\fwith\fthe\f\bid\fof\f\bnother\ftechnici\bn\fin\fthe\f
vehicle\fto\fen\bble\fthe\fvehicle\fto\fbe\fdriven\fs\bfely\fwhile\fthe\fsensor\foutputs\f\bre\f
monitored\fwithin\fd\bt\blogger.\fIf\fthere\fis\fonly\fone\ftechnici\bn\f\bv\bil\bble,\fthe\fFord\f
\bpproved\fdi\bgnostic\ftool\fc\bn\fbe\fset\fup\f(using\fthe\frecord/c\bpture\fmode\fc\bmer\b\f
icon)\fbefore\fle\bving\fthe\fworkshop\fto\frecord\f\b\f16\fkm\f(10\fmile)\ftest.\f
NOTE:\fThe\fresults\ffrom\fthe\ftest\f\bre\fmore\fconclusive\fif\fthe\fengine\fis\fcold\fwhen\fthe\f
test\fis\fst\brted.\f
3\f C\brry\fout\f\b\fro\bd\ftest.\f\f
RE
FER\fto:\f Ro\bd/Roller\fTesting \f(100-00\fGener\bl\fInform\btion,\fDescription\f\bnd\f
Ope

r\btion).\f
4. 4\f
Drive\fthe\fvehicle\f\bt\f\b\fconst\bnt\fthrottle\fopening\f\bnd\fset\fspeed\funtil\fthe\fECT\fv\blue\f
s
ettles\finto\f\b\fsh\bllow\frise\f\bnd\ff\bll\fsign\bl,\fclose\fto\f\b\fstr\bight\fline.\fThis\findic\btes\fth\bt\f
the\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 Item
A
B \f\f
\f\f
Part Number
-
-
Стр. 6 из 7
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Page 1413 of 4402

$FORD S-MAX 2006 Service Repair Manual between\f60ºC\f(140ºF)\f\bnd\f70ºC\f(150ºF),\fthe\fthermost\bt\f\bnd\fits\fse\bling\ffunction\fwithin\fthe\f thermost\bt\fhousing\fmust\fbe\fchecked.\f5. 5\f INSTALL\f\b\fnew\fthermost\bt.\f\f R$

Page 1414 of 4402

$FORD S-MAX 2006 Service Repair Manual Engine C\b\bling - 2\f2L Durat\brq-TDCi (129kW/175PS) - DW - Radiat\br L\bwer M\bunting Repair S-MAX/G\bl\bxy\f2006.5\f(02/2006 General Pr\bcedures General Equipment 5\fmm\fdrill\fbit C\bble\fties$

Page 1415 of 4402

$FORD S-MAX 2006 Service Repair Manual Fl\bt\ffile 2.General \bqui\fment: 5\fmm\fdrill\f bit\f 7. \f 8 . Torque: 25\fNm \f 9. Torque: 8\fNm \f \f \f \f\f Стр. 2 из 3 05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=14$

Page 1416 of 4402

$FORD S-MAX 2006 Service Repair Manual 10. Lower\fthe\fvehicle.\f 11. Remove\fthe\fc\bble\fties\fsecuring\fthe\fr\bdi\btor\f\bnd\fcondenser\f \bssembly.\f 12. On\fboth\fsides.\f \f\f \f\f Стр. 3 из 3 05.01.2013http://127.0.0.1:8888/w$

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check transmission fluid lane assist reset sun roof rear view mirror language manual transmission