2006 FORD S-MAX Service Repair Manual

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Page 1585 of 4402

$FORD S-MAX 2006 Service Repair Manual Is\fthere\fvisible\fd\bm\bge\fto\fthe\frotor\fv\bnes?\f Yes GO\fto\fA2.\f\f No GO \fto\fA3.\f\f A2: CHECK FOR FOREIGN MATERIAL IN THE INTAKE AIR SYSTEM COMPONENTS Check\fthe\fint\bke\f\bir\fsystem\f$

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\fof\f
foreign\fm\bteri\bl.\f1
Are\fthere\f\bny\fsigns\fof\fforeign\fm\bteri\bl?\f
Yes CLEAN\fthe\fint\bke\f\bir\fsystem\fcomponents.\fINSTALL\f\b\f
new\fturboch\brger.\f\f
REFER\fto:\f Turboch\brger \f(303-04I\fFuel\fCh\brging\f\bnd\f
Con

trols\f-\fTurboch\brger\f-\f1.8L\fDur\btorq-TDCi\f
(74kW/100PS)\f-\fLynx/1.8L\fDur\btorq-TDCi\f
(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\fInst\bll\btion).\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
No
GO\fto\fA4.\f\f
A3: CHECK THE TURBOCHARGER BEARINGS FOR EXCESSIVE MOVEMENT
NOTE:\fA\fsm\bll\f\bmount\fof\fmovement\fin\fthe\fbe\brings\fis\fnorm\bl.\f
M\bke\fsure\fthe\fturboch\brger\frotor\fspins\ffreely\fwithin\f
the\fhousing.\f
1.\fWith\fthe\fturboch\brger\fst\btion\bry,\fgently\flift\fthe\f
sh

\bft\f(the\fsh\bft\fwill\fn\btur\blly\fl\by\fin\fthe\fbottom\fof\f
the\fbe\brings).\f
2.\fM\bke\fsure\fthe\frotor\fspins\ffreely\fwithin\fthe\f
ho

using.\f
1
Does\fthe\frotor\fspin\ffreely\fwithin\fthe\fhousing\fwith\fno\f
excessive\fmovement?\f
Yes GO\fto\fA4.\f\f
No I

NSTALL\f\b\fnew\fturboch\brger.\f\f
REFER\fto:\f Turboch\brger \f(303-04I\fFuel\fCh\brging\f\bnd\f
Con

trols\f-\fTurboch\brger\f-\f1.8L\fDur\btorq-TDCi\f
(74kW/100PS)\f-\fLynx/1.8L\fDur\btorq-TDCi\f
(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\fInst\bll\btion).\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
A4: CHECK THE TURBOCHARGER OIL SUPPLY TUBE FOR BLOCKAGE
Remove\fthe\fturboch\brger.\f\f
REFER\fto:\f Turboch\brger \f(303-04I\fFuel\fCh\brging\f\bnd\f
Con

trols\f-\fTurboch\brger\f-\f1.8L\fDur\btorq-TDCi\f
(74kW/100PS)\f-\fLynx/1.8L\fDur\btorq-TDCi\f
(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\fInst\bll\btion).\f
1
Using\fworkshop\fcompressed\f\bir\f\bnd\f\b\fcompressed\f2
\f\f
\f\f
Стр. 3 из 5
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Page 1586 of 4402

$FORD S-MAX 2006 Service Repair Manual \bir\fnozzle,\fcheck\fthe\foil\fsupply\ftube\ffor\fblock\bge.\f Is\fthe\foil\fsupply\ftube\ffree\ffrom\fblock\bge?\f Yes GO\fto\fA5.\f\f No I NSTALL\f\b\fnew\fturboch\brger\f\bnd\fturboch\brger\foil$

Page 1587 of 4402

$FORD S-MAX 2006 Service Repair Manual Check\fthe\fturboch\brger\foil\freturn\fpipe\ffor\fblock\bge\f or\fsigns\fof\fd\bm\bge.\f 4 Is\fthe\fturboch\brger\foil\freturn\fpipe\ffree\ffrom\fblock\bge\f \bnd\fsigns\fof\fd\bm\bge?\f Yes GO\fto\$

Page 1588 of 4402

$FORD S-MAX 2006 Service Repair Manual Fuel Ch\brgi\fg \b\fd Co\ftrols - Turboch\brger - 1.8L Dur\btorq-TDCi (74kW/100PS) - Ly\fx/1.8L Dur\btorq-TDCi (92kW/125PS) - Ly\fx - Turboch\brger S-MAX/G\bl\bxy\f2006.5\f(02/2006 Remov\bl \b\fd I$

Page 1589 of 4402

$FORD S-MAX 2006 Service Repair Manual 2.NOTE:\fOnly\ftighten\fthe\fnuts\f\bnd\fbolts\ffinger\ftight\f\bt\f this\fst\bge.\f3.NOTE:\f M\bke\fsure\f th\bt\f\b\fnew\f component\f is\finst\blled. NOTE:\f M\bke\fsure\f th\bt\fthe\f cl\bmp\fis\f$

Page 1590 of 4402

$FORD S-MAX 2006 Service Repair Manual 5.CAUTION:\fM\bke\fsure\fth\bt\fthe\finside\fof\fthe\fpipe\f ends\f\bre\fcle\bn\f\bnd\ffree\fof\foil\fresidue.\f 6. Inst\bll\fthe\ffollowing\fitems:\fRefer\fto:\f C\bt \blytic\fConverter \f(309-00D\$

Page 1591 of 4402

$FORD S-MAX 2006 Service Repair Manual Fuel Ch\brgi\fg \b\fd Co\ftrols - Turboch\brger - 2.0L Dur\btorq-TDCi (85kW/115PS) - DW/2.0L Dur\btorq-TDCi (100kW/136PS) - DW/2.0L Dur\btorq- TDCi (103kW/140PS) - DW, Emissio\f Requireme\fts: St\$

Page 1592 of 4402

Fuel Ch\brgi\fg \b\fd Co\ftrols -
Turboch\brger - 2.0L Dur\btorq-TDCi
(85kW/115PS) - DW/2.0L Dur\btorq-TDCi
(100kW/136PS) - DW/2.0L Dur\btorq-
TDCi (103kW/140PS) - DW, Emissio\f
Requireme\fts: St\bge IV - 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
I\fspectio\f \b\fd Verific\btio\f
N O

TE:\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\foil\fsep\br\btor.\fSome\fengine\foil,\fin\fthe\fform\fof\f\b\f
v\bpor\fis\fc\brried\finto\fthe\f\bir\fint\bke\fsystem\fwith\fthe\fblow-by\fg\bses\f(this\fengine\foil\f\blso\f
contributes\fto\fv\blve\fse\bt\fdur\bbility).\fThis\fme\bns\fth\bt\foil\fwill\fcollect\finside\fthe\f\bir\fint\bke\f
components\f\bnd\fthe\fturboch\brger.\fThis\fis\fnot\f\bn\findic\btion\fth\bt\fthe\fturboch\brger\foil\fse\bl\f
h\bs\ff\biled.\fThe\fturboch\brger\foil\fse\bl\fwill\fnot\ff\bil\funless\fthe\fbe\brings\ff\bil\ffirst,\fwhich\fwill\f
c\buse\fthe\fturboch\brger\fto\fbecome\fnoisy\for\fseize.\fDo\fnot\finst\bll\f\b\fnew\fturboch\brger\fdue\f
to\foil\finside\fthe\fturboch\brger\for\fthe\f\bir\fint\bke\fcomponents.\fIf\f\b\fle\bk\fis\fdetected\fin\fthe\foil\f
supply\for\freturn\ftubes\for\fconnections,\floc\bte\f\bnd\frectify\fthe\fsource.\fDo\fnot\finst\bll\f\b\fnew\f
turboch\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
3. 3.
If\f\bn\fobvious\fc\buse\ffor\f\bn\fobserved\for\freported\fconcern\fis\ffound,\fcorrect\fthe\fc\buse\f
H\bnd\fV\bcuum/Pressure\fPump\f
416\f-\fD001\f(23\f-\f036A)\f
Fuel\fPressure\fG\buge\f
310-053\f(23-046)\f
Worldwide\fDi\bgnostic\fSystem\f(WDS)\f(418-
F224)
Mechanica\bE\bectrica\b

Oil\fle\bk(s)\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\foil\fsupply\for\foil\freturn\ftube\f\f
Turboch\brger\fint\bke\fpipe\f\f
Turboch\brger\fv\bcuum\fdi\bphr\bgm\funit\f\f
Turboch\brger\fhousing\f\f
Ch\brge\f\bir\fcooler\f\f
Ch\brge\f\bir\fcooler\fint\bke\fpipe\f\bnd\fhose(s)\f\f
Ch\brge\f\bir\fcooler\foutlet\fpipe\f\bnd\fhose(s)\fWiring\fh\brness\f\f
V\bne\f\bdjustment\fsolenoid\fv\blve\f\f
PCM\f
\f
\f\f
Стр. 1 из 11
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