2006 FORD S-MAX check engine

fuel reserve auxiliary battery location refrigerant type buttons service indicator key

Page 1532 of 4402

$FORD S-MAX 2006 Service Repair Manual 1000\fkm\f(600\fmiles).\f\f REFER\fto:\fEngine\f(303-01F\fEngine\f-\f2.0L\f Dur \btorq-TDCi\f(85kW/115PS)\f-\fDW/2.0L\f Dur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\f Dur\btorq-TDCi\f(103kW/140PS)\f- \f$

1000\fkm\f(600\fmiles).\f\f
REFER\fto:\fEngine\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
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
*
*
*
Positive\fcr\bnkc\bse\f
ventil\btion\f(PCV)\f
system.\f
*INSPECT\ffor\fvisible\fsigns\fof\fd\bm\bge\for\f
block\bge.\fCLEAN,\fREPAIR\for\fINSTALL\fnew\f
p\brts\f\bs\fnecess\bry.\f
*
Turboch\brger\foil\f
return\ftube\fblocked\for\f
d\bm\bged.\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
*
Worn\for\fd\bm\bged\f
v\blve\fguide(s),\fpiston\f
ring(s),\fcylinder\fbore
(s),\fcylinder\fhe\bd\for\f
g\bsket.\f
*REMOVE\fthe\fcylinder\fhe\bd.\fINSPECT\fthe\f
cylinder\fhe\bd,\fpistons\f\bnd\fcylinder\fbores\ffor\f
signs\fof\fwe\br\for\fd\bm\bge.\f
*
White\fsmoke\f\bnd\f
glow\fplug\findic\btor\f
is\ffl\bshingDTC\fdetected.\f
*REFER\fto\fthe\fWDS.\f
*
White\fsmokeW\bter\fin\ffuel.\f
*CHECK\ffor\fsigns\fof\fw\bter\fin\fthe\fdiesel.\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
*
*
Стр. 13 из
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Page 1533 of 4402

$FORD S-MAX 2006 Service Repair Manual REFER\fto:\fFuel\fT\bnk\fDr\bining \f(310-00\fFuel\f Sys tem\f-\fGener\bl\fInform\btion,\fGener\bl\f Procedures).\f INSTALL\f\b\fnew\ffuel\ffilter\felement.\f\f REFER\fto:\f Fuel\fFilter\fElement \f(3$

REFER\fto:\fFuel\fT\bnk\fDr\bining \f(310-00\fFuel\f
Sys
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
Fuel\finjector(s).\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
*
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
*
Cool\bnt\fin\fthe\f
combustion\fch\bmber.\f
*CARRY\fOUT\f\b\fcooling\fsystem\fpressure\ftest.\f\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
REMOVE\fthe\fcylinder\fhe\bd.\fINSPECT\fthe\f
cylinder\fhe\bd,\fcylinder\fhe\bd\fg\bsket\f\bnd\f
cylinder\fbores\ffor\fwe\br\for\fd\bm\bge.\f
*
Engine\fmisfire\f\bnd\f
glow\fplug\findic\btor\f
is\ffl\bshingDTC\fdetected.\f
*REFER\fto\fthe\fWDS.\f
*
Engine\fmisfireLow\ffuel\ft\bnk\flevel.\f
*CHECK\fthe\ffuel\ft\bnk\flevel\fis\fgre\bter\fth\bn\ffour\f
liters.\fIf\fthe\ffuel\ft\bnk\flevel\fis\fless\fth\bn\ffour\f
liters,\fFILL\fwith\ffuel.\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
*
*
*
Стр. 14 из
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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
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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 1571 of 4402

$FORD S-MAX 2006 Service Repair Manual Pi\fpoi\ft Tests Poor\fengine\f perform\bnce\fW\bsteg\bte\fcontrol\f v\blve\f\bctu\btor\frod.\f V\bcuum\fline(s).\f * *GO\fto\fPinpoint\fTest\f C.\f\f * Ch\brge\f\bir\fcooler\f pipes\f Ch\brge\f\bir\$

Pi\fpoi\ft Tests
Poor\fengine\f
perform\bnce\fW\bsteg\bte\fcontrol\f
v\blve\f\bctu\btor\frod.\f V\bcuum\fline(s).\f
*
*GO\fto\fPinpoint\fTest\f
C.\f\f
*
Ch\brge\f\bir\fcooler\f
pipes\f Ch\brge\f\bir\fcooler\f
r\bdi\btor\f Ch\brge\f\bir\fcooler\f
w\bter\fpump\f Ch\brge\f\bir\fcooler\f
*
*
*
*REFER\fto\f
in\fthis\fsection. \f
*
Air\fcle\bner\fint\bke\f
pipe\f
*CHECK\fthe\f\bir\fcle\bner\fint\bke\fpipe\ffor\f
obstruction.\fREPAIR\f\bs\fnecess\bry.\f
*
Turboch\brger\fboost\f
pressure\f
*GO\fto\fPinpoint\fTest\f
C.\f\f
*
Un\buthorized\f
\bdjustment\fof\fthe\f
w\bsteg\bte\fcontrol\f
v\blve\f\bctu\btor\frod.\f
*The\fturboch\brger\fboost\fpressure\fis\ff\bctory\fset\f
\bnd\fmust\fnot\fbe\f\bdjusted.\fCHECK\fthe\fp\bint\fse\bl\f
on\fthe\fw\bsteg\bte\fcontrol\fv\blve\funit\f\bctu\btor\frod\f
h\bs\fnot\fbeen\fbroken.\fIf\fthe\fp\bint\fse\bl\fh\bs\fbeen\f
broken,\fINSTALL\f\b\fnew\fturboch\brger.\f\f
REFER\fto:\f Turboch\brger \f(303-
04H\fFuel\fCh\brging\f
\bnd\fControls\f-\fTurboch\brger\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
*
Ignition\fsystem.\f
*CHECK\fthe\fignition\fsystem.\f\f
REFER\fto:\f Fuel\fCh\brging\f\bnd\fControls \f(303-04C\f
Fue

l\fCh\brging\f\bnd\fControls\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fDi\bgnosis\f\bnd\fTesting).\f
*
Fuel\fch\brging\fsystem.\f*CHECK\fthe\ffuel\fch\brging\fsystem.\f\f
REFER\fto:\f Fuel\fCh\brging\f\bnd\fControls \f(303-04C\f
Fue

l\fCh\brging\f\bnd\fControls\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fDi\bgnosis\f\bnd\fTesting).\f
*
PINPOINT TEST A : BLUE SMOKE WITH EXCESSIVE TURBOCHARGER NOISE
TEST CON\fITIONS\fETAILS/RESULTS/ACTIONS
A1: INSPECT THE TURBOCHARGER ROTOR VANES FOR DAMAGE
Remove\fthe\f\bir\fcle\bner.\f\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
1
Inspect\fthe\fturboch\brger\frotor\fv\bnes\ffor\fd\bm\bge.\f2
Is\fthere\fvisible\fd\bm\bge\fto\fthe\frotor\fv\bnes?\f
Yes GO\fto\fA2.\f\f
No
GO

\fto\fA3.\f\f
A2: CHECK FOR FOREIGN MATERIAL IN THE INTAKE AIR SYSTEM COMPONENTS
Check\fthe\fint\bke\f\bir\fsystem\fcomponents\ffor\fsigns\f1
\f\f
Стр. 3 из 8
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Page 1572 of 4402

$FORD S-MAX 2006 Service Repair Manual of\fforeign\fm\bteri\bl.\f Are\fthere\f\bny\fsigns\fof\fforeign\fm\bteri\bl?\f Yes CLEAN\fthe\fint\bke\f\bir\fsystem\fcomponents.\fINSTALL\f \b\fnew\fturboch\brger.\f\f REFER\fto:\f Turboch\brger \f(3$

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