2006 FORD S-MAX Service Repair Manual

coolant capacity relay reset infotainment system emergency towing air suspension fold seats

Page 1521 of 4402

$FORD S-MAX 2006 Service Repair Manual \f\fDescriptio\f Fuel\fr\bil\f Fuel\fr\bil\fpressure\f(FRP)\fsensor\f The\ffuel\fr\bil\ffunction\fis\fto\fsupply\f\b\freservoir\fof\ffuel\fto\f\bll\ffour\ffuel\finjectors\fwith\fno\f v\b ri\btions\f$

Page 1522 of 4402

$FORD S-MAX 2006 Service Repair Manual flow\fch\br\bcteristics\finto\fone\fof\fthree\fgr\bdes.\fThe\fgr\bde\fis\fprinted\fon\fthe\ftop\fof\fthe\ffuel\f injector\f\bnd\fc\bn\fbe\fthe\fnumber\f4,\f5,\for\f6.\fAll\ffour\ffuel\finjectors\fmust$

flow\fch\br\bcteristics\finto\fone\fof\fthree\fgr\bdes.\fThe\fgr\bde\fis\fprinted\fon\fthe\ftop\fof\fthe\ffuel\f
injector\f\bnd\fc\bn\fbe\fthe\fnumber\f4,\f5,\for\f6.\fAll\ffour\ffuel\finjectors\fmust\fbe\fof\f\b\fm\btching\f
gr\bde\ffor\f\bny\fone\fengine\f\bpplic\btion.\fThe\fgr\bde\fv\blue\fis\fused\fby\fthe\fPCM\fto\f\bdjust\fthe\ffuel\f
injector\finjection\fsign\bl\fto\f\bchieve\foptimum\fefficiency.\fThe\ffuel\finjectors\f\bre\fdesigned\fto\f
\bllow\f\b\fqu\bntity\fof\ffuel\fto\freturn\fto\fthe\ffuel\ft\bnk.\fThe\freturned\ffuel\fis\fdeveloped\fduring\fthe\f
opening\fcycle\fof\fthe\ffuel\finjector\fcontrol\fv\blve.\fThis\freturned\ffuel\fis\fused\fto\flubric\bte\fthe\f
fuel\finjector\fmoving\fcomponents\f\bnd\fis\fessenti\bl\fto\fthe\foper\btion\fof\fthe\ffuel\finjector.\fThis\f
lubric\bting\ffuel\fis\freturned\fto\fthe\ffuel\ft\bnk\fthrough\fthe\ffuel\finjector\ffuel\freturn\fline.\fOnly\fby\f
\bccur\bte\fme\bsurement,\f\bt\fprecise\fengine\fconditions,\fc\bn\fthe\fvolumes\fof\ffuel\ffrom\fthe\ffuel\f
injector\ffuel\freturn\fbe\fused\fto\fdi\bgnose\fconcerns\fwith\fthe\ffuel\fch\brging\fcontrol\fsystem.\f\f
Fuel Temper\bture Se\fsor
\f\f
Descriptio\f
Fuel\finjector\ffuel\freturn\fline\f
Fuel\fpump\ffuel\freturn\fline\f
Fuel\ftemper\bture\fsensor\fto\ffuel\ft\bnk\ffuel\freturn\fline\f
Fuel\ftemper\bture\fsensor\f
The\ffuel\ftemper\bture\fsensor\fis\ffitted\finto\fthe\ffuel\fpump\fto\ffuel\ft\bnk\ffuel\freturn\fline.\fThe\f
temper\bture\fsensor\fmonitors\fthe\ftemper\bture\fof\fthe\ffuel\freturning\fto\fthe\ffuel\ft\bnk\ffrom\fthe\f
fuel\fpump\f\bnd\fthe\ffuel\finjectors.\fThe\ffuel\ftemper\bture\fsensor\fhousing\f\bcts\f\bs\f\b\fventuri.\f
The\fventuri\f\bssists\fwith\fthe\ffuel\freturn\ffrom\fthe\ffuel\finjectors\fby\fcre\bting\f\b\fpressure\f
reduction\fin\fthe\ffuel\finjector\ffuel\freturn\fline.\f\f
I\fspectio\f \b\fd Verific\btio\f
WARNINGS:\f
REF

ER\fto:\fDiesel\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
This\fprocedure\finvolves\ffuel\fh\bndling.\fBe\fprep\bred\ffor\ffuel\fspill\bge\f\bt\f\bll\ftimes.\f
F\bilure\fto\ffollow\fthis\finstruction\fm\by\fresult\fin\fperson\bl\finjury.\f
CAUTION:\fDiesel\ffuel\finjection\fequipment\fis\fm\bnuf\bctured\fto\fvery\fprecise\ftoler\bnces\f
\bnd\ffine\fcle\br\bnces.\fIt\fis\ftherefore\fessenti\bl\fth\bt\f\bbsolute\fcle\bnliness\fis\fobserved\fwhen\f
working\fwith\fthese\fcomponents.\fAlw\bys\ffit\fbl\bnking\fplugs\fto\f\bny\fopen\forifices\for\flines.\f
NOTE:\fAs\fwell\f\bs\fc\brrying\fout\fits\fnorm\bl\ffunction\fthe\fglow\fplug\findic\btor\f\blso\f\bcts\f\bs\f\bn\f
engine\fcheck\fl\bmp\fwhich\fwill\ffl\bsh\fcontinuously\fwhen\f\b\fh\brd\fdi\bgnostic\ftrouble\fcode\f
(DTC)\fis\fdetected\fby\fthe\fpowertr\bin\fcontrol\fmodule\f(PCM).\fSoft\fDTCs\f\bre\f\blso\fstored\fby\f
the\fPCM\fbut\fwill\fonly\fbe\fknown\fif\fthe\fsystem\fis\fchecked\ffor\fDTCs\fusing\fthe\fWDS.\f
NOTE:\fIf\f\b\fDTC\fis\fdetected,\f\bll\fDTCs\fmust\fbe\fcle\bred\f\bfter\fthe\fconcern\fis\frectified.\fF\bilure\f
to\fcle\br\f\bll\fDTCs\fm\by\fc\buse\fdrive\bbility\fconcerns.\f
NOTE:\fIf\fthe\ffuel\flevel\fin\fthe\ffuel\ft\bnk\fdrops\fbelow\f\bpproxim\btely\ffour\fliters,\frough\f
running\fwill\foccur.\fThis\fis\fto\fsign\bl\fto\fthe\fdriver\fth\bt\fthe\fvehicle\frequires\frefuelling\fin\f
order\fto\fprevent\fthe\ffuel\fsystem\ffrom\frunning\fdry.\f
1. 1.
Verify\fthe\fcustomer\fconcern.\f
I

tem
1
2
3
4
\f\f
P\brt Number -
-
-
-
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Page 1523 of 4402

$FORD S-MAX 2006 Service Repair Manual 2.2. Visu\blly\finspect\ffor\fobvious\fsigns\fof\fmech\bnic\bl\for\felectric\bl\fd\bm\bge.\f V isu\bl I\fspectio\f Ch\brt 3. 3. If\f\bn\fobvious\fc\buse\ffor\f\bn\fobserved\for\freported\fconcern\f$

2.2.
Visu\blly\finspect\ffor\fobvious\fsigns\fof\fmech\bnic\bl\for\felectric\bl\fd\bm\bge.\f
V
isu\bl I\fspectio\f Ch\brt
3. 3.
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.
If\fthe\fc\buse\fis\fnot\fvisu\blly\fevident,\fverify\fthe\fsymptom\f\bnd\frefer\fto\fthe\fWDS\fto\f
r
etrieve\fthe\fdi\bgnostic\ftrouble\fcodes\f(DTCs).\f
5. 5.
If\fno\fDTCs\frel\bted\fto\fthe\fconcern\f\bre\fretrieved,\fproceed\fto\fthe\fSymptom\fCh\brt\fto\f
c
ontinue\fdi\bgnostics.\f
Symptom Ch\brt
Mechanica\bE\bectrica\b
Fuel\fle\bk(s)Fuse(s)
Fuel\ffilterRel\by(s)
Air\fcle\bner\felementWiring\fh\brness
V\bcuum\fline(s)/v\bcuum\fconnectionsElectric\bl\fconnector(s)
Hose(s)/hose\fconnectionsSensor(s)
Tube(s)/tube\fconnections
Cont\bmin\bted\ffuel
Fuel\fsupply\fline(s)
Fuel\freturn\fline(s)
High-pressure\ffuel\fsupply\fline(s)
Fuel\finjectors
Fuel\fr\bil
Fuel\fpump
\fymptomPossib\be \fourcesAction
Engine\fdoes\fnot\f
cr\bnk\f\bnd\fp\bssive\f
\bnti-theft\fsystem\f
(PATS)\fLED\fis\f
fl\bshingPATS\fsystem\ff\bult\f
detected.\f
*REFER\fto:\f
Anti-Theft\f-\fP\bssive \f(419-01B\fAnti-
The
ft\f-\fP\bssive,\fDi\bgnosis\f\bnd\fTesting).\f
*
Engine\fdoes\fnot\f
cr\bnk\f\bnd\fglow\f
plug\findic\btor\fis\f
fl\bshingDTC\fdetected.\f
*REFER\fto\fthe\fWDS.\f
*
Engine\fdoes\fnot\f
cr\bnkSt\brting\fsystem.\f
*REFER\fto:\f St\brting\fSystem \f(303-06E\fSt\brting\f
Sys
tem\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,\fDi\bgnosis\f
\bnd\fTesting).\f
*
Engine\fcr\bnks\fbut\f
does\fnot\fst\brt\f\bnd\f
glow\fplug\findic\btor\f
is\ffl\bshingDTC\fdetected.\f
*REFER\fto\fthe\fWDS.\f
*
Engine\fcr\bnks\fbut\f
does\fnot\fst\brtLow\ffuel\ft\bnk\ffuel\f
level.\f
*CHECK\fthe\ffuel\ft\bnk\ffuel\flevel\fis\fgre\bter\fth\bn\f
four\fliters.\fIf\fthe\ffuel\ft\bnk\ffuel\flevel\fis\fless\fthen\f
four\fliters,\fFILL\fwith\ffuel.\f
*
Fuel\ffilter\fblocked.\f
*INSTALL\f\b\fnew\ffuel\ffilter.\f\f
REFER\fto:\f Fuel\fFilter\f(310-01C\fFuel\fT\bnk\f\bnd\f
Lin

es\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
*
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Page 1524 of 4402

$FORD S-MAX 2006 Service Repair Manual Emission\fRequirements:\fSt\bge\fIV,\fRemov\bl\f \bnd\fInst\bll\btion).\f Fuel\flines\fd\bm\bged\for\f blocked.\f * REFER\fto:\f Fuel\fSystem\f-\f1.8L\fDur\btorq-TDCi\f (Ly nx)\fDiesel/2.0L\fDur\btorq$

Emission\fRequirements:\fSt\bge\fIV,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
Fuel\flines\fd\bm\bged\for\f
blocked.\f
*
REFER\fto:\f
Fuel\fSystem\f-\f1.8L\fDur\btorq-TDCi\f
(Ly
nx)\fDiesel/2.0L\fDur\btorq-TDCi\f(DW)\fDiesel \f
(31

0-00\fFuel\fSystem\f-\fGener\bl\fInform\btion,\f
Di\bgnosis\f\bnd\fTesting).\f
*
Air\fingress\finto\fthe\f
fuel\flines.\f
*REFER\fto:\f
Fuel\fSystem\f-\f1.8L\fDur\btorq-TDCi\f
(Ly
nx)\fDiesel/2.0L\fDur\btorq-TDCi\f(DW)\fDiesel \f
(31

0-00\fFuel\fSystem\f-\fGener\bl\fInform\btion,\f
Di\bgnosis\f\bnd\fTesting).\f
*
Glow\fplugs.\f
*REFER\fto\fthe\fWDS.\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
Du r

\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
*
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
*
Cr\bnksh\bft\fposition\f
(CKP)\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
C\bmsh\bft\fposition\f
(CMP)\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
Engine\fcool\bnt\f
temper\bture\f(ECT)\f
sensor.\f
*REFER\fto\fthe\fWDS.\f
*
PCM.\f*REFER\fto\fthe\fWDS.\f
*
FRP\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
Fuel\fpump\ffuel\f
pressure\fregul\btor.\f
*REFER\fto\fthe\fWDS.\f
*
Fuel\fpump.\f
*REFER\fto\fthe\fWDS.\f
*
Fuel\finjector(s).\f
*REFER\fto\fthe\fWDS.\f
*
Poor\fst\brting\f\bnd\f
glow\fplug\findic\btor\f
is\ffl\bshingDTC\fdetected.\f
*REFER\fto\fthe\fWDS.\f
*
Poor\fst\brtingLow\ffuel\ft\bnk\ffuel\f
level.\f
*CHECK\fthe\ffuel\ft\bnk\ffuel\flevel\fis\fgre\bter\fth\bn\f
four\fliters.\fIf\fthe\ffuel\ft\bnk\ffuel\flevel\fis\fless\fthen\f
four\fliters,\fFILL\fwith\ffuel.\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
*
Air\fcle\bner\felement\f
blocked.\f
*INSTALL\f\b\fnew\f\bir\fcle\bner\felement.\f\f
*
Glow\fplugs.\f
*REFER\fto\fthe\fWDS.\f
*
Fuel\fsystem\fle\bk.\f
*CHECK\fthe\fsystem\ffor\ffuel\fle\bk(s).\fREPAIR\fthe\f
system\f\bs\fnecess\bry.\f
*
Air\fingress\finto\fthe\f
fuel\flines.\f
*REFER\fto:\f
Fuel\fSystem\f-\f1.8L\fDur\btorq-TDCi\f
(Ly
nx)\fDiesel/2.0L\fDur\btorq-TDCi\f(DW)\fDiesel \f
(31

0-00\fFuel\fSystem\f-\fGener\bl\fInform\btion,\f
*
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Page 1525 of 4402

$FORD S-MAX 2006 Service Repair Manual Di\bgnosis\f\bnd\fTesting).\f Fuel\fsystem\f restriction.\f *REFER\fto:\f Fuel\fSystem\f-\f1.8L\fDur\btorq-TDCi\f (Ly nx)\fDiesel/2.0L\fDur\btorq-TDCi\f(DW)\fDiesel \f (31 0-00\fFuel\fSystem\f-\fGene$

Di\bgnosis\f\bnd\fTesting).\f
Fuel\fsystem\f
restriction.\f
*REFER\fto:\f
Fuel\fSystem\f-\f1.8L\fDur\btorq-TDCi\f
(Ly
nx)\fDiesel/2.0L\fDur\btorq-TDCi\f(DW)\fDiesel \f
(31

0-00\fFuel\fSystem\f-\fGener\bl\fInform\btion,\f
Di\bgnosis\f\bnd\fTesting).\f
*
Incorrect\fengine\foil.\f
*INSTALL\f\b\fnew\fengine\foil\ffilter\f\bnd\fengine\foil.\f
*
C\bt\blytic\fconverter\f
blocked.\f
*REMOVE\f\bnd\fvisu\blly\fINSPECT\fthe\fc\bt\blytic\f
converter\ffor\fd\bm\bge.\fINSTALL\f\b\fnew\fc\bt\blytic\f
converter\f\bs\fnecess\bry.\f\f
REFER\fto:\f
C\bt\blytic\fConverter \f(309-00E\f
Exh

\bust\fSystem\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
*
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
*
CKP\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
ECT\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
Fuel\ftemper\bture\f
sensor.\f
*REFER\fto\fthe\fWDS.\f
*
M\bss\f\bir\fflow\f(MAF)\f
sensor.\f
*REFER\fto\fthe\fWDS.\f
*
M\bnifold\f\bbsolute\f
pressure\f(MAP)\f
sensor.\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\ffuel\f
pressure\fregul\btor.\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\fsut-off\fthrottle\ffor\f
obstructions\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
*
*
Engine\fst\brts\fbut\f
immedi\btely\fstops\f
\bnd\fglow\fplug\f
indic\btor\fis\ffl\bshingDTC\fdetected.\f
*REFER\fto\fthe\fWDS.\f
*
Engine\fst\brts\fbut\f
immedi\btely\fstopsAir\fcle\bner\felement\f
blocked.\f
*INSTALL\f\b\fnew\f\bir\fcle\bner\felement.\f
*
Air\fingress\finto\fthe\f
fuel\flines.\f
*REFER\fto:\f
Fuel\fSystem\f-\f1.8L\fDur\btorq-TDCi\f
(Ly
nx)\fDiesel/2.0L\fDur\btorq-TDCi\f(DW)\fDiesel \f
(31

0-00\fFuel\fSystem\f-\fGener\bl\fInform\btion,\f
Di\bgnosis\f\bnd\fTesting).\f
*
PCM\frel\by.\f
*CARRY\fOUT\f\b\frel\by\fcomponent\ftest.\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
*
CKP\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
CMP\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
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Page 1526 of 4402

$FORD S-MAX 2006 Service Repair Manual ECT\fsensor.\f *REFER\fto\fthe\fWDS.\f * PCM.\f*REFER\fto\fthe\fWDS.\f * Fuel\fpump\ffuel\f pressure\fregul\btor.\f *REFER\fto\fthe\fWDS.\f * Int\bke\f\bir\fshut-off\f throttle.\f *CHECK\fthe\fint\bke$

ECT\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
PCM.\f*REFER\fto\fthe\fWDS.\f
*
Fuel\fpump\ffuel\f
pressure\fregul\btor.\f
*REFER\fto\fthe\fWDS.\f
*
Int\bke\f\bir\fshut-off\f
throttle.\f
*CHECK\fthe\fint\bke\f\bir\fshut-off\fthrottle\ffor\f
obstructions\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
*
*
Poor\fidling\f\bnd\f
glow\fplug\findic\btor\f
is\ffl\bshingDTC\fdetected.\f
*REFER\fto\fthe\fWDS.\f
*
Poor\fidlingLow\ffuel\ft\bnk\ffuel\f
level.\f
*CHECK\fthe\ffuel\ft\bnk\ffuel\flevel\fis\fgre\bter\fth\bn\f
four\fliters.\fIf\fthe\ffuel\ft\bnk\ffuel\flevel\fis\fless\fthen\f
four\fliters,\fFILL\fwith\ffuel.\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
*
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
*
*
*
Стр. 7 из
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Page 1527 of 4402

$FORD S-MAX 2006 Service Repair Manual \bnd\fInst\bll\btion).\f Air\fingress\finto\fthe\f fuel\flines.\f *REFER\fto:\f Fuel\fSystem\f-\f1.8L\fDur\btorq-TDCi\f (Ly nx)\fDiesel/2.0L\fDur\btorq-TDCi\f(DW)\fDiesel \f (31 0-00\fFuel\fSystem\f-$

\bnd\fInst\bll\btion).\f
Air\fingress\finto\fthe\f
fuel\flines.\f
*REFER\fto:\f
Fuel\fSystem\f-\f1.8L\fDur\btorq-TDCi\f
(Ly
nx)\fDiesel/2.0L\fDur\btorq-TDCi\f(DW)\fDiesel \f
(31

0-00\fFuel\fSystem\f-\fGener\bl\fInform\btion,\f
Di\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
*
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
*
Fuel\finjector(s).\f
*REFER\fto\fthe\fWDS.\f
*
MAF\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
MAP\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
CKP\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
FRP\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
Fuel\fpump\ffuel\f
pressure\fregul\btor.\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
*
*
Engine\fstumbling\f
\bnd\fglow\fplug\f
indic\btor\fis\ffl\bshingDTC\fdetected.\f
*REFER\fto\fthe\fWDS.\f
*
Engine\fstumblingLow\ffuel\flevel.\f
*CHECK\fthe\ffuel\ft\bnk\flevel\fis\fgre\bter\fth\bn\ffour\f
litres.\fIf\fthe\ffuel\ft\bnk\flevel\fis\fless\fth\bn\ffour\f
litres,\fFILL\fwith\ffuel.\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
*
Acceler\btor\fped\bl\f
position\f(APP)\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
*
Engine\fl\bcks\fpower\f
\bnd\fglow\fplug\f
indic\btor\fis\ffl\bshingDTC\fdetected.\f
*REFER\fto\fthe\fWDS.\f
*
Engine\fl\bcks\fpowerBr\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\bs\f
necess\bry.\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
*
Стр. 8 из
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Page 1528 of 4402

$FORD S-MAX 2006 Service Repair Manual (103kW/140PS)\f-\fDW,\fEmission\fRequirements:\f St\bge\fIV,\fRemov\bl\f\bnd\fInst\bll\btion).\f Kinked\for\frestricted\f fuel\flines.\f *REFER\fto:\fSpring\fLock\fCouplings\f(310-00,\f Gener\bl\fProc$

(103kW/140PS)\f-\fDW,\fEmission\fRequirements:\f
St\bge\fIV,\fRemov\bl\f\bnd\fInst\bll\btion).\f
Kinked\for\frestricted\f
fuel\flines.\f
*REFER\fto:\fSpring\fLock\fCouplings\f(310-00,\f
Gener\bl\fProcedures).\f
*
Air\fingress\finto\fthe\f
fuel\flines.\f
*REFER\fto:\fSpring\fLock\fCouplings\f(310-00,\f
Gener\bl\fProcedures).\f
*
Turboch\brger.\f
Turboch\brger\fv\bcuum\f
di\bphr\bgm\funit.\f
*
*
INSPECT\fthe\fv\bcuum\fline(s)\ffor\fvisible\fsigns\fof\f
d\bm\bge\for\fblock\bge.\fCLEAN,\fREPAIR\for\f
INSTALL\fnew\fp\brts\f\bs\fnecess\bry.\f\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
*
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
*
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
*
C\bt\blytic\fconverter\f
blocked.\f
*REMOVE\f\bnd\fvisu\blly\fINSPECT\fthe\fc\bt\blytic\f
converter\ffor\fd\bm\bge.\fINSTALL\f\b\fnew\fc\bt\blytic\f
converter\f\bs\fnecess\bry.\f\f
REFER\fto:\f
C\bt\blytic\fConverter \f(309-00E\f
Exh

\bust\fSystem\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
*
EGR\fv\blve\fincorrect\f
oper\btion.\f
*REFER\fto:\fEngine\fEmission\fControl\f(303-08D,\f
Di\bgnosis\f\bnd\fTesting).\f
*
Ch\brge\f\bir\fcooler\f
blocked\for\fcr\bcked.\f Ch\brge\f\bir\fcooler\f
pipes\fsplit\for\fcr\bcked.\f
Ch\brge\f\bir\fcooler\fpipe\f
ret\bining\fclips\fmissing\f
or\floose.\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
*
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
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\bn k

\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
*
*
*
Стр. 9 из
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jack points fuel ad blue lug pattern gas type clock