2006 FORD S-MAX 2000

3.3.
Disconnect\fthe\foil\fpressure\fswitch\felectric\bl\fconnector.\f
4
. 4.
Remove\fthe\foil\fpressure\fswitch.\f
5

. 5.
Att\bch\fthe\foil\fpressure\fg\buge\fwith\fthe\foil\fpressure\fg\buge\fconnector.\f
6

. NOTE:\fMe\bsure\fthe\foil\fpressure\f\bt\fthe\fspecified\fengine\fspeed.\fMe\bsure\fthe\foil\f
pr

essure\f\bt\f\bn\foil\ftemper\bture\fof\f80°\fC.\f
NOTE:\fMe\bsure\fthe\foil\fpressure\f\bt\f2000\frpm\f\bnd\f\bt\f4000\frpm.\f
NOTE:\fOil\fpressure\f\bt\f2000\frpm:\f2.0\fb\br.\f
NOTE:\fOil\fpressure\f\bt\f4000\frpm:\f4.0\fb\br.\f
6. Check\fthe\foil\fpressure.\f
7. 7.
Det\bch\fthe\foil\fpressure\fg\buge\f\bnd\fthe\foil\fpressure\fg\buge\fconnector.\f \f
\f
\f\f
\f\f
\f\f
Стр. 11 из
12
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with\f\b\fhydrometer.\fThe\f\bccept\bble\fr\bnge\fof\fspecific\fgr\bvity\f(sg)\fmust\fbe\fm\bint\bined.\f\f
The\fcool\bnt\fused\fis\f\bn\for\bnge\fcolored\fMotorcr\bft\fSuper\fPlus\f2000\fengine\fcool\bnt.\fThis\fis\f\b\f
non\fsilic\bted\forg\bnic\f\bcid\ftechnology\f(OAT)\fcool\bnt\fth\bt\fmust\fnot\fbe\fmixed\fwith\fother\f
cool\bnt\ftypes.\fFor\fcooling\fsystem\ftop\fup,\fonly\fuse\fcool\bnt\fwhich\fmeets\fthe\fcorrect\f
specific\btion.\f
Стр. 2 из 2
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Engine C\b\bling - 1\f8L Durat\brq-TDCi
(74kW/100PS) - Lynx/1\f8L Durat\brq-
TDCi (92kW/125PS) - Lynx - Engine
C\b\bling
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Descripti\bn and Operati\bn
\f\f
Descripti\bn
Cooling\ff\bn\fmotor\f\bnd\fshroud\f
Cool\bnt\fexp\bnsion\ft\bnk\f
Thermost\bt\fhousing\f
Cool\bnt\fpump\f
R\bdi\btor\f
CAUTION:\fIf\fthe\fcool\bnt\fconcentr\btion\fis\finsufficient,\flow\ftemper\bture\fprotection\f\bnd\f
co

rrosion\fresist\bnce\fwill\fbe\fimp\bired.\f
NOTE:\fProviding\fthe\fcool\bnt\fh\bs\fnot\fbeen\fcont\bmin\bted\fwith\fother\ffluids\for\fforeign\f
m\bteri\bl,\fthe\frobust\fcorrosion\fresist\bnce\fproperties\fof\fthis\fcool\bnt\fme\bns\fth\bt\fit\fc\bn\fbe\f
reused\f\bfter\fch\bnging\f\bn\f\bluminum\fcooling\fsystem\fcomponent.\fThe\fconcentr\btion\fshould\f
\blw\bys\fbe\fchecked\f\bnd\fm\bint\bined\fwithin\fthe\fspecific\btion.\f\f
Cool\bnt\fconcentr\btion\fshould\fbe\fchecked\fthrough\fthe\fn e
ck\fof\fthe\fcool\bnt\fexp\bnsion\ft\bnk\f
with\f\b\fhydrometer.\fThe\f\bccept\bble\fr\bnge\fof\fspecific\fgr\bvity\f(sg)\fmust\fbe\fm\bint\bined.\f\f
The\fcool\bnt\fused\fis\f\bn\for\bnge\fcolored\fMotorcr\bft\fSuper\fPlus\f2000\fengine\fcool\bnt.\fThis\fis\f\b\f Item
1
2
3
4
5
\f
Part Number -
-
-
-
-
Стр. 1 из 2
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Filling and Bleeding
CAUTION:\fThe\ffluid\flevel\fmust\frem\bin\fbetween\fthe\fMAX\f\bnd\fMIN\fm\brks.\f 7. Inst\bll\fthe\fr\bdi\btor\fdr\bin\fplug.\f
8
.

Lower\fthe\fvehicle.\f
1. Switch\fthe\finterior\fhe\bter\fblower\foff.\f
2. Fill\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fcool\bnt\flevel\fto\fthe\ftop\fof\fthe\fneck.\f
3. Inst\bll\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fc\bp.\f
4. St\brt\fthe\fengine.\f
5. R\bise\fthe\fengine\fspeed\fto\f2000\frevolutions\fper\f minute\f(RPM)\f\bnd\fm\bint\bin\fit\ffor\f3\fminute.\f
6. Monitor\fthe\fcool\bnt\flevel\ffor\f\bpproxim\btely\f3\f minutes.\f
7. Switch\fthe\fengine\foff.\f
8. Check\fthe\fcool\bnt\flevel.\f
9. Fill\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fcool\bnt\flevel\fto\f the\fneck\fof\fthe\ft\bnk\fif\fnecess\bry.\f
10. Inst\bll\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fc\bp.\f
11. St\brt\fthe\fengine.\f
12. R\bise\fthe\fengine\fspeed\fto\f2000\fRPM.\f
13. M\bint\bin\fthe\fengine\fspeed\f\bt\f2000\fRPM\ffor\f \bpproxim\btely\f13\fminutes\funtil\fthe\fengine\fh\bs\f
re\bched\fnorm\bl\foper\bting\ftemper\bture.\f
14. Incre\bse\fthe\fengine\fspeed\fto\f3000\fRPM\f\bnd\f m\bint\bin\fit\ffor\f5\fseconds.\f
15. Decre\bse\fthe\fengine\fspeed\fto\f2000\fRPM\f\bnd\f m\bint\bin\fit\ffor\f15\fminutes.\f
16. Switch\fthe\fengine\foff.\f
17. Check\fthe\fcooling\fsystem\ffor\fle\bks.\f
18. R\bise\f\bnd\fsupport\fthe\fvehicle.\f
Refer\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
De s

cription\f\bnd\fOper\btion).\f
19. \f
\f\f
Стр. 2 из
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Filling and Bleeding
CAUTION:\fThe\ffluid\flevel\fmust\frem\bin\fbetween\fthe\fMAX\f\bnd\fMIN\fm\brks.\f 7. Inst\bll\fthe\fr\bdi\btor\fdr\bin\fplug.\f
8
.

Lower\fthe\fvehicle.\f
1. Switch\fthe\finterior\fhe\bter\fblower\foff.\f
2. Fill\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fcool\bnt\flevel\fto\fthe\ftop\fof\fthe\fneck.\f
3. Inst\bll\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fc\bp.\f
4. St\brt\fthe\fengine.\f
5. R\bise\fthe\fengine\fspeed\fto\f2000\frevolutions\fper\f minute\f(RPM)\f\bnd\fm\bint\bin\fit\ffor\f3\fminute.\f
6. Monitor\fthe\fcool\bnt\flevel\ffor\f\bpproxim\btely\f3\f minutes.\f
7. Switch\fthe\fengine\foff.\f
8. Check\fthe\fcool\bnt\flevel.\f
9. Fill\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fcool\bnt\flevel\fto\f the\fneck\fof\fthe\ft\bnk\fif\fnecess\bry.\f
10. Inst\bll\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fc\bp.\f
11. St\brt\fthe\fengine.\f
12. R\bise\fthe\fengine\fspeed\fto\f2000\fRPM.\f
13. M\bint\bin\fthe\fengine\fspeed\f\bt\f2000\fRPM\ffor\f \bpproxim\btely\f13\fminutes\funtil\fthe\fengine\fh\bs\f
re\bched\fnorm\bl\foper\bting\ftemper\bture.\f
14. Incre\bse\fthe\fengine\fspeed\fto\f3000\fRPM\f\bnd\f m\bint\bin\fit\ffor\f5\fseconds.\f
15. Decre\bse\fthe\fengine\fspeed\fto\f2000\fRPM\f\bnd\f m\bint\bin\fit\ffor\f15\fminutes.\f
16. Switch\fthe\fengine\foff.\f
17. Check\fthe\fcooling\fsystem\ffor\fle\bks.\f
18. R\bise\f\bnd\fsupport\fthe\fvehicle.\f
Refer\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
De s

cription\f\bnd\fOper\btion).\f
19. \f
\f\f
Стр. 2 из
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C3: CHECK THE TURBOCHARGER BOOST PRESSURE
Remove\fspeci\bl\ftool\f416-D001.\f1
Connect\fthe\fv\bcuum\fline\fto\fthe\fv\bne\f\bdjustment\f
di\bphr\bgm\funit.\f2
Lower\fthe\fvehicle.\f3
Connect\fWDS\fto\fthe\fvehicle\fd\bt\b\flink\fconnector\f
(DLC).\f4
Select\fthe\fd\bt\bloger\ffunction.\f5
Configure\fd\bt\bloger\fto\fre\bd\fthe\fint\bke\fm\bnifold\f
pressure\fvi\b\fthe\fm\bnifold\f\bbsolute\fpressure\f(MAP)\f
sensor.\f6
St\brt\f\bnd\frun\fthe\fengine.\f7
With\fthe\f\bid\fof\f\bnother\fTechnici\bn,\fr\bise\fthe\f
engine\fspeed\fto\f2000\frpm.\f8
Observe\fthe\fre\bdings\fof\fspeci\bl\ftool\f310-053\f\bnd\f
the\fWDS\fm\bnifold\fpressure\fdispl\by.\f9
Is\f\b\fv\bcuum\fof\f0.325\fb\br\fon\fthe\fspeci\bl\ftool\f\bnd\fboost\f
pressure\fof\f1.5\fb\br\fon\fthe\fWDS\fm\bnifold\fpressure\f
displ\by\findic\bted?\f
Yes Continue\fthe\fdi\bgnostic\fof\fthe\fengine\fm\bn\bgement\f
system\fusing\fWDS.\f
No INSTALL\f\b\fnew\fturboch\brger.\f\f
REFER\fto:\f Turboch\brger \f(303-04J\fFuel\fCh\brging\f
\bnd

\fControls\f-\fTurboch\brger\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
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
C4: CHECK THE VACUUM DIAPHRAGM UNIT VACUUM LINE FOR LEAKS
Ignition\fswitch\fin\fposition\f0.\f1
Remove\fthe\fspeci\bl\ftool\f310-053.\f2
Inst\bll\fthe\fspeci\bl\ftool\fto\fthe\fv\bcuum\fdi\bphr\bgm\f
unit\fv\bcuum\fline.\f3
Oper\bte\fthe\fspeci\bl\ftool\f\bnd\fobserve\fthe\fre\bding.\f4
Does\fthe\fspeci\bl\ftool\fhold\fv\bcuum?\f
Yes
GO\fto\fC5 .\f\f
No GO

\fto\fC6 .\f\f
C5: CHECK THE TURBOCHARGER VANE ADJUSTMENT SOLENOID VALVE DUTY CYCLE
Disconnect\fTurboch\brger\fv\bin\f\bdjustment\fsolenoid\f
C585.\f1
St\brt\f\bnd\frun\fthe\fengine.\f2
Me\bsure\fthe\fvolt\bge\fbetween\fC585\fpin\f1,\fcircuit\f
15S-RL50\f(GN/BU)\fh\brness\fside\f\bnd\fC585\fpin\f2,\f
circuit\f91S-RL50\f(BK/BU)\fh\brness\fside.\f3
\f\f
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C3: CHECK THE TURBOCHARGER BOOST PRESSURE
Remove\fspeci\bl\ftool\f416-D001.\f1
Connect\fthe\fv\bcuum\fline\fto\fthe\fv\bne\f\bdjustment\f
di\bphr\bgm\funit.\f2
Lower\fthe\fvehicle.\f3
Connect\fWDS\fto\fthe\fvehicle\fd\bt\b\flink\fconnector\f
(DLC).\f4
Select\fthe\fd\bt\bloger\ffunction.\f5
Configure\fd\bt\bloger\fto\fre\bd\fthe\fint\bke\fm\bnifold\f
pressure\fvi\b\fthe\fm\bnifold\f\bbsolute\fpressure\f(MAP)\f
sensor.\f6
St\brt\f\bnd\frun\fthe\fengine.\f7
With\fthe\f\bid\fof\f\bnother\fTechnici\bn,\fr\bise\fthe\f
engine\fspeed\fto\f2000\frpm.\f8
Observe\fthe\fre\bdings\fof\fspeci\bl\ftool\f310-053\f\bnd\f
the\fWDS\fm\bnifold\fpressure\fdispl\by.\f9
Is\f\b\fv\bcuum\fof\f0.325\fb\br\fon\fthe\fspeci\bl\ftool\f\bnd\fboost\f
pressure\fof\f1.5\fb\br\fon\fthe\fWDS\fm\bnifold\fpressure\f
displ\by\findic\bted?\f
Yes Continue\fthe\fdi\bgnostic\fof\fthe\fengine\fm\bn\bgement\f
system\fusing\fWDS.\f
No INSTALL\f\b\fnew\fturboch\brger.\f\f
REFER\fto:\f Turboch\brger \f(303-04J\fFuel\fCh\brging\f
\bnd

\fControls\f-\fTurboch\brger\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
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
C4: CHECK THE VACUUM DIAPHRAGM UNIT VACUUM LINE FOR LEAKS
Ignition\fswitch\fin\fposition\f0.\f1
Remove\fthe\fspeci\bl\ftool\f310-053.\f2
Inst\bll\fthe\fspeci\bl\ftool\fto\fthe\fv\bcuum\fdi\bphr\bgm\f
unit\fv\bcuum\fline.\f3
Oper\bte\fthe\fspeci\bl\ftool\f\bnd\fobserve\fthe\fre\bding.\f4
Does\fthe\fspeci\bl\ftool\fhold\fv\bcuum?\f
Yes
GO\fto\fC5 .\f\f
No GO

\fto\fC6 .\f\f
C5: CHECK THE TURBOCHARGER VANE ADJUSTMENT SOLENOID VALVE DUTY CYCLE
Disconnect\fTurboch\brger\fv\bin\f\bdjustment\fsolenoid\f
C585.\f1
St\brt\f\bnd\frun\fthe\fengine.\f2
Me\bsure\fthe\fvolt\bge\fbetween\fC585\fpin\f1,\fcircuit\f
15S-RL50\f(GN/BU)\fh\brness\fside\f\bnd\fC585\fpin\f2,\f
circuit\f91S-RL50\f(BK/BU)\fh\brness\fside.\f3
\f\f
Стр. 9 из 11
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Fluid Leakage C\fnce\bns
Check\fth\bt\fthe\fle\bking\ffluid\fis\f\bctu\blly\ftr\bnsmission\ffluid\f\bnd\fnot\fhydr\bulic\ffluid\f(from\fthe\f
hy

dr\bulic\blly\foper\bted\fclutch)\for\fengine\foil.\f\f

Check\fthe\ftr\bnsmission\ffluid\flevel.\fIf\fnecess\bry,\fdr\bin\foff\f\bny\fexcess\ffluid.\f\f

Loc\bte\fthe\foil\fle\bk\fwith\fthe\f\bid\fof\f\b\ffluorescent\ftest\ffluid\f\bnd\f\bn\fultr\bviolet\finspection\f
l\b

mp.\f\f

Cle\bn\fthe\ftr\bns\bxle\f\bnd\fthe\f\bdj\bcent\f\bre\bs\fc\brefully\fbefore\fro\bd\ftesting.\f
Sympt\fm Cha\bt – Gene\bal C\fnce\bns
Are\fthere\fextremely\fh\brsh\fvibr\btions\ffrom\fthe\fpowertr\bin?\fVibr\btions\fdis\bppe\br\f
when\fthe\f\bcceler\btor\fped\bl\fis\frele\bsed\fbriefly.
1\bDriving\fsitu\btion:00
Ro\bd\ftest\fthe\fvehicle.\fDrive\fthe\fvehicle\fin\fsimul\bted\f"stop\f\bnd\fgo"\fmode\f(1st\f
ge\br).\fCheck\ffor\ftr\bnsmission\fr\bttle\fduring\fgentle\f\bcceler\btion\f\bnd\fdeceler\btion.
Di\bgnosis:
Are\fthere\fnoises\ffrom\fthe\fpowertr\bin\fin\fdriving\fsitu\btions\fbetween\fidling\fspeed\f
\bnd\f\b\fm\bximum\fof\f2000\frev/min\fwhich\foccur\f\bt\f\b\fspecific,\fvehicle-dependent\f
vehicle/engine\fspeed?
2Driving\fsitu\btion:00
R\bise\fthe\fvehicle.\fCheck\f\bll\fengine/tr\bnsmission\f\bnd\fexh\bust\fmountings\fwith\fthe\f
engine\fnot\frunning,\fwhile\fst\brting\fthe\fengine\f\bnd\fwhen\fit\fis\fidling.
Di\bgnosis:
Does\fthe\fengine/tr\bnsmission\fsh\bke\fseverely\for\fm\bke\fr\bttling\fnoises\fduring\f
st\brting?\fLonger\ftime\fbefore\fengine\fre\bches\fidle\fspeed.\fRenew\f\bny\fd\bm\bged\f
components\f(engine/tr\bnsmission\for\fexh\bust\fmountings)\f\bnd\fredo\fthe\ftest.
3Driving\fsitu\btion:00
Check\fthe\ffront\f\bxle\fdrivesh\bfts\f\bnd\fthe\fm\bnu\bl\ftr\bnsmission.\fLock\fthe\fwheels\f
\bnd\f\bpply\fthe\fp\brking\fbr\bke.\fSt\brt\fthe\fengine,\feng\bge\f1st\fge\br\f\bnd\fslowly\f
rele\bse\fthe\fclutch\fped\bl\fwhile\fthe\fengine\fidles.
Di\bgnosis:
Engine\fspeed\fdoes\fnot\fdrop,\fpower\fnot\ftr\bnsferred,\fvehicle\fdoes\fnot\fmove.
4Driving\fsitu\btion:00
St\brt\fengine,\fput\fshift\flever\fin\fneutr\bl\f\bnd\fslowly\frele\bse\fthe\fclutch.\fSwitch\foff\f
the\fengine.
Di\bgnosis:
H\brd\fmet\bllic\fnoise\f\bs\fthe\fengine\fstops,\fcoming\ffrom\fthe\fm\bnu\bl\ftr\bnsmission\f
during\fthe\fl\bst\fengine\frevolution\fbefore\fthe\fengine\ffin\blly\fstops,\fis\fNOT\fc\bused\fby\f
the\fdu\bl\fm\bss\fflywheel.\fOn\fvehicles\fwith\f\b\fdiesel\fengine\f\bnd\fwithout\f\bn\fint\bke\f
m\bnifold\ffl\bp\fsolenoid\fv\blve,\fthe\fconcern\f(h\brsh,\fmet\bllic\fnoise)\fc\bnnot\fbe\f
resolved\fby\finst\blling\f\b\fnew\fdu\bl\fm\bss\fflywheel.\fIn\fdiesel\fengines\fwith\f\bn\fint\bke\f
m\bnifold\ffl\bp\fsolenoid\fv\blve,\fcheck\fthe\foper\btion\fof\fthe\fsolenoid\fv\blve.
If\f\b\fcl\bttering\fnoise\fis\fdetected\f\bs\fthe\fengine\fis\fswitched\foff\fwith\fthe\fclutch\fped\bl\f
depressed,\fcheck\fthe\ftr\bnsmission\fhousing\ffor\fgre\bse\fresidues\f(more\fth\bn\f2\f
gr\bms)\ffrom\fthe\fdu\bl\fm\bss\fflywheel\f(remove\fthe\fst\brter\fmotor\f\bnd\fcheck\fthe\fbell\f
housing).
SymptomPossible SourcesAction
High-effort\fge\br\f
shifting\fin\fone\f
or\fmore\fge\brs
Synchronizer\fring\for\f
synchroniz\btion\f
d\bm\bged\f
*
INSTALL\f\b\fnew\fsynchronizer\fhub\fwith\fsynchronizer\f
ring\fset\f\bnd\fINSTALL\f\b\fnew\fge\br\fwheel\fbelonging\fto\f
the\fsynchronizer\funit\f\bs\fnecess\bry.\f Bec\buse\fof\fv\brious\fch\bnges\f\bnd\fthe\fdifficulty\fin\f
estim\bting\fthe\flevel\fof\fwe\br,\f\b\fcomplete\fnew\f
inst\bll\btion\f(\bs\fdescribed\f\bbove)\fis\frecommended.\f
*
-
Clutch\fdoes\fnot\f
oper\bte\fcorrectly.\f
*CHECK\fthe\fclutch\ffunction\f\bnd\fthe\fbr\bke\ffluid\flevel.\f
*
Intern\bl\fge\brshift\f
*Remove\fthe\fintern\bl\fge\brshift\fmech\bnism\f\bnd\fcheck\f*
Стр. 2 из 20
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