2006 FORD S-MAX Service Repair Manual

load capacity jack points fuel boot parking sensors headlights

Page 1569 of 4402

$FORD S-MAX 2006 Service Repair Manual Fuel Ch\brgi\fg \b\fd Co\ftrols - Turboch\brger - 2.5L Dur\btec (162kW/220PS) - VI5 - Turboch\brger S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f Di\bg\fosis \b\fd Testi\fg Speci\bl Tool(s) Ge\f e$

Fuel Ch\brgi\fg \b\fd Co\ftrols -
Turboch\brger - 2.5L Dur\btec
(162kW/220PS) - VI5 - Turboch\brger
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Di\bg\fosis \b\fd Testi\fg
Speci\bl Tool(s)
Ge\f

er\bl Equipme\ft
Pri\fciples of Oper\btio\f
T h

e\fturboch\brger\fis\fgoverned\fby\f\b\fw\bsteg\bte\fcontrol\fv\blve.\fThe\fw\bsteg\bte\fcontrol\fv\blve\f
redirects\fsome\fof\fthe\fexh\bust\fg\bs\fp\bst\fthe\fturbine\f\bnd\ftherefore\f\bcts\f\bs\f\b\fgovernor.\fThe\f
w\bsteg\bte\fcontrol\fv\blve\fis\fpreset\fduring\fm\bnuf\bcture\f\bnd\fmust\fnot\fbe\ft\bmpered\fwith.\f
The\fint\bke\f\bir\fsystem\fis\ffitted\fwith\f\b\fturboch\brger\fpressure\frele\bse\fv\blve.\fThis\fvents\fthe\f
int\bke\f\bir\fsystem\fwhen\fthe\fthrottle\fis\fclosed\f\bnd\frecircul\btes\fthe\f\bir\fb\bck\finto\fthe\fint\bke\f\bir\f
system.\fIt\f\blso\frele\bses\fpressure\fon\fthe\fturboch\brger\fwhich\fwill\freduce\fturbo\fl\bg\f\bnd\fwill\f
improve\f\bcceler\btion\f\bnd\fincre\bse\fengine\fperform\bnce.\f
The\fturboch\brger\fis\fequipped\fwith\f\b\fboost\fcontrol\fsystem.\fThe\fpowertr\bin\fcontrol\fmodule\f
(PCM)\fdetects\f1st\for\f2nd\fge\br\fusing\fthe\fengine\fspeed\f\bnd\fvehicle\fspeed\fsign\bls.\fThis\f
inform\btion\fis\fthen\fused\fto\f\bdjust\fthe\fpressures\f\bpplied\fto\fthe\fw\bsteg\bte\fcontrol\fv\blve\f
\bllowing\fit\fto\fopen\f\bt\f\b\flower\fboost\fpressure.\fThis\fprevents\fthe\fturboch\brger\fdeveloping\f
m\bximum\fboost\fin\f1st\f\bnd\f2nd\fge\brs.\f
I\fspectio\f \b\fd Verific\btio\f
NOTE:\fIt\fis\fnorm\bl\ffor\f\b\fsm\bll\f\bmount\fof\fcombustion\fg \b
s\fto\fp\bss\finto\fthe\fcr\bnkc\bse.\fThis\f
g\bs\fis\fsc\bvenged\finto\fthe\f\bir\fint\bke\fsystem\fthrough\fthe\fpositive\fcr\bnkc\bse\fventil\btion\f
(PCV)\fsystem,\fwhich\fincorpor\btes\f\bn\fcr\bnkc\bse\fvent\foil\fsep\br\btor.\fSome\fengine\foil,\fin\fthe\f
form\fof\f\b\fv\bpor\fis\fc\brried\finto\fthe\f\bir\fint\bke\fsystem\fwith\fthe\fblow-by\fg\bses\f(this\fengine\f
oil\f\blso\fcontributes\fto\fv\blve\fse\bt\fdur\bbility).\fThis\fme\bns\fth\bt\foil\fwill\fcollect\finside\fthe\f\bir\f
int\bke\fcomponents\f\bnd\fthe\fturboch\brger.\fThis\fis\fnot\f\bn\findic\btion\fth\bt\fthe\fturboch\brger\f
oil\fse\bl\fh\bs\ff\biled.\fThe\fturboch\brger\foil\fse\bl\fwill\fnot\ff\bil\funless\fthe\fbe\brings\ff\bil\ffirst,\f
which\fwill\fc\buse\fthe\fturboch\brger\fto\fbecome\fnoisy\for\fseize.\fDo\fnot\finst\bll\f\b\fnew\f
turboch\brger\fdue\fto\foil\finside\fthe\fturboch\brger\for\fthe\f\bir\fint\bke\fcomponents.\fIf\f\b\fle\bk\fis\f
detected\fin\fthe\foil\fsupply\for\freturn\ftubes\for\fconnections,\floc\bte\f\bnd\frectify\fthe\fsource.\fDo\f
not\finst\bll\f\b\fnew\fturboch\brger\fdue\fto\f\bn\foil\fle\bk.\f
1. 1.
Verify\fthe\fcustomer\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
Boost\fPressure\fG\buge\f
310-020\f(23-021)\f
H\bnd\fV\bcuum/Pressure\fPump\f
416-D001\f(23-036A)\f
Ford\fdi\bgnostic\fequipment
Mechanica\bE\bectrica\b
Oil\fle\bk(s)\f\f
Cool\bnt\fle\bk(s)\f\fWiring\fh\brness(es)\f\f
Electric\bl\fconnector(s)\f\f
\f
\f
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Page 1570 of 4402

$FORD S-MAX 2006 Service Repair Manual 3.3. If\f\bn\fobvious\fc\buse\ffor\f\bn\fobserved\for\freported\fconcern\fis\ffound,\fcorrect\fthe\fc\buse\f (if\fpossible)\fbefore\fproceeding\fto\fthe\fnext\fstep.\f 4. 4. If\fthe\fconcern\fis\fnot$

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\fconcern\fis\fnot\fvisu\blly\fevident,\fverify\fthe\fsymptom\f\bnd\frefer\fto\fthe\f
D
i\bgnostic\fTrouble\fCode\f(DTC)\fIndex.\f
Di\bg\fostic Trouble Code (DTC) I\fdex
Symptom Ch\brt
W\bsteg\bte\fcontrol\fv\blve\f\f
W\bsteg\bte\fcontrol\fv\blve\fv\bcuum\fhose(s)\f\f
Turboch\brger\fhousing\f\f
Air\fcle\bner\felement\f\f
Air\fcle\bner\foutlet\fpipe\f\f
Air\fcle\bner\fint\bke\fpipe\f\f
Turboch\brger\fint\bke\ftube\f\f
Ch\brge\f\bir\fcooler\f\f
Ch\brge\f\bir\fcooler\fint\bke\fpipe\f\bnd\fhoses\f\f
Ch\brge\f\bir\fcooler\foutlet\fpipe\f\bnd\fhoses\f\f
Ch\brge\f\bir\fcooler\fr\bdi\btor\f\f
V\blve\fcover\foil\fsep\br\btor\f\f
Turboch\brger\foil\fsupply\ftube\f\f
Turboch\brger\foil\freturn\ftube\fCh\brge\f\bir\fcooler\fcooling\ff\bn\f\f
Ch\brge\f\bir\fcooler\fcooling\ff\bn\fswitch\f\f
Ch\brge\f\bir\fcooler\fw\bter\fpump\f\f
Boost\fcontrol\fsolenoid\fv\blve\f\f
Powertr\bin\fcontrol\fmodule\f(PCM)\f
\fTC\fescriptionPossib\be SourceAction
P0236Turboch\brger\fboost\fpressure\f
sensor\fcircuit\fr\bnge/perform\bnce\f
concern
Turboch\brger\fboost\f
pressure\fsensorREFER\fto\fengine\fm\bn\bgement\fguided\fdi\bgnostics\fwithin\fthe\f Ford\fdi\bgnostic\fequipment.
P0237Turboch\brger\fboost\fpressure\f sensor\fcircuit\flow\finputTurboch\brger\fboost\fpressure\fsensor\f
circuitREFER\fto\fengine\fm\bn\bgement\fguided\fdi\bgnostics\fwithin\fthe\f
Ford\fdi\bgnostic\fequipment.
P0238Turboch\brger\fboost\fpressure\f sensor\fcircuit\fhigh\finputTurboch\brger\fboost\fpressure\fsensor\f circuitREFER\fto\fengine\fm\bn\bgement\f
guided\fdi\bgnostics\fwithin\fthe\f Ford\fdi\bgnostic\fequipment.
P0243Turboch\brger\fboost\fcontrol\f solenoid\fconcernTurboch\brger\fboost\fcontrol\fsolenoidREFER\fto\fengine\fm\bn\bgement\fdi\bgnostics\fwithin\fthe\fFord\f di\bgnostic\fequipment.
NOTE: The w\bsteg\bte co\ftrol v\blve u\fit is \b fixed p\brt of the turboch\brger \b\fd
c\b
\f\fot be \bdjusted or re\fewed.
SymptomPossib\be SourcesAction
Blue\fsmoke\fwith\f
excessive\f
turboch\brger\f
noiseTurboch\brger\f
compressor\frubbing\f
on\fhousing\fw\blls.\f Turboch\brger\fturbine\f
rubbing\fon\fhousing\f
w\blls.\f
Turboch\brger\f
be\brings\f\bnd\foil\fse\bl
(s).\f Turboch\brger\foil\f
supply\ftube\fblocked\f
or\fd\bm\bged.\f
*
*
*
*GO\fto\fPinpoint\fTest\f
A.\f\f
*
Blue\fsmoke\f
without\fexcessive\f
turboch\brger\f
noiseBlocked\for\fd\bm\bged\f
v\blve\fcover\foil\f
sep\br\btor.\f
*REFER\fto:\f
Engine\fEmission\fControl \f(303-08B\f
Eng
ine\fEmission\fControl\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fDi\bgnosis\f\bnd\fTesting).\f
*
Turboch\brger\foil\f
return\ftube\fblocked\for\f
d\bm\bged.\f
*
GO\fto\fPinpoint\fTest\f
B.\f\f
*
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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
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Page 1572 of 4402

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

Page 1573 of 4402

$FORD S-MAX 2006 Service Repair Manual GO\fto\fA5.\f\f No I NSTALL\f\b\fnew\foil\fsupply\ftube.\fINSTALL\f\b\fnew\f turboch\brger.\f\f REFER\fto:\f Turboch\brger \f(303-04H\fFuel\fCh\brging\f \bnd \fControls\f-\fTurboch\brger\f-\f2.5L\fD$

Page 1574 of 4402

$FORD S-MAX 2006 Service Repair Manual Check\fthe\fturboch\brger\foil\freturn\ftube\ffor\fblock\bge\f or\fsigns\fof\fd\bm\bge.\f 3 Is\fthe\fturboch\brger\foil\freturn\ftube\ffree\ffrom\fforeign\f m\bteri\bl\f\bnd\fsigns\fof\fd\bm\bge?\f Y$

Page 1575 of 4402

$FORD S-MAX 2006 Service Repair Manual NOTE:\fM\bke\fsure\fthe\fboost\fpressure\fg\buge\fpipe\f does\fnot\fbecome\fkinked\for\ftr\bpped.\fRoute\fthe\fboost\fpressure\fg\buge\f\bnd\fpipe\finto\fthe\f ve hicle\fthrough\fthe\fp\bssenger\fwin$

Page 1576 of 4402

$FORD S-MAX 2006 Service Repair Manual No INSTALL\f\b\fnew\fturboch\brger.\f\f REFER\fto:\f Turboch\brger \f(303-04H\fFuel\fCh\brging\f \bnd \fControls\f-\fTurboch\brger\f-\f2.5L\fDur\btec\f (162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\fInst\bl$

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