2006 FORD S-MAX heater

Is\f\b\fresist\bnce\fof\fless\fth\bn\f2\fOhms\fme\bsured?\f
Yes\bCHECK\f\bnd\fif\fnecess\bry\fRENEW\fthe\fprogr\bmm\bble\f
fuel-fired\fbooster\fhe\bter.\fCHECK\fthe\foper\btion\fof\f
the\fsystem.\f
No\b LOCATE\f\bnd\fREPAIR\fthe\fopen\fcircuit\fbetween\fthe\f
progr\bmm\bble\ffuel-fired\fbooster\fhe\bter\f\bnd\fground\f
connection\fG1D132-A\fwith\fthe\f\bid\fof\fthe\fWiring\f
Di\bgr\bms.\fCHECK\fthe\foper\btion\fof\fthe\fsystem.\f
PINPOINT\bTE\fT\bR\b:\bFUEL-FIRED\bBOO\fTER\bHEATER\b(COOLANT\bPUMP)\b
INOPERATIVE\b-\bVEHICLE\f\bWITH\bPROGRAMMABLE\bFUEL-FIRED\bBOO\fTER\b
HEATER\b
TEST
CONDITIONSDETAILS/RESULTS/ACTIONS
R1:\bCHECK\bTHE\bCIRCUIT\bBETWEEN\bTHE\bFUEL-FIRED\bBOO\fTER\bHEATER\b(COOLANT\b
PUMP)\bAND\bTHE\bPROGRAMMABLE\bFUEL-FIRED\bBOO\fTER\bHEATER\bFOR\bOPEN\bCIRCUIT
Ignition\fswitch\fin\fposition\f0.\f1\b
Disconnect\fConnector\fC1HF02\ffrom\fthe\ffuel-fired\fbooster\fhe\bter\f(cool\bnt\f
pump).\f2\b
Disconnect\fConnector\fC1HF01-C\ffrom\fthe\fprogr\bmm\bble\ffuel-fired\fbooster\f
he\bter.\f3\b
Me\bsure\fthe\fresist\bnce\fbetween\fthe\fprogr\bmm\bble\ffuel-fired\fbooster\f
he\bter,\fconnector\fC1HF01-C,\fpin\f9,\fcircuit\fRHF03A\f(WH/VT),\fwiring\f
h\brness\fside\f\bnd\fthe\ffuel-fired\fbooster\fhe\bter\f(cool\bnt\fpump),\fconnector\f
C1HF02,\fpin\f2,\fcircuit\fRHF03A\f(WH/VT),\fwiring\fh\brness\fside.\f4\b
Is\f\b\fresist\bnce\fof\fless\fth\bn\f2\fOhms\fregistered?\f
Yes\b GO\fto\fR2 .\f\f
No\b L

OCATE\f\bnd\fREPAIR\fthe\fbre\bk\fin\fcircuit\fRHF03A\f(WH/VT)\fbetween\fthe\f
progr\bmm\bble\ffuel-fired\fbooster\fhe\bter\f\bnd\fthe\ffuel-fired\fbooster\fhe\bter\f
(cool\bnt\fpump)\fwith\fthe\f\bid\fof\fthe\fWiring\fDi\bgr\bms.\fCHECK\fthe\foper\btion\f
of\fthe\fsystem.\f
R2:\bCHECK\bTHE\bCIRCUIT\bBETWEEN\bTHE\bFUEL-FIRED\bBOO\fTER\bHEATER\b(COOLANT\b
PUMP)\bAND\bTHE\bPROGRAMMABLE\bFUEL-FIRED\bBOO\fTER\bHEATER\bFOR\bOPEN\bCIRCUIT
Me\bsure\fthe\fresist\bnce\fbetween\fthe\fprogr\bmm\bble\ffuel-fired\fbooster\f
he\bter,\fconnector\fC1HF01-C,\fpin\f10,\fcircuit\fCHF03A\f(GN/OG),\fwiring\f
h\brness\fside\f\bnd\fthe\ffuel-fired\fbooster\fhe\bter\f(cool\bnt\fpump),\fconnector\f
C1HF02,\fpin\f1,\fcircuit\fCHF03A\f(GN/OG),\fwiring\fh\brness\fside.\f1\b
Is\f\b\fresist\bnce\fof\fless\fth\bn\f2\fOhms\fregistered?\f
Yes\b RENEW\fthe\ffuel-fired\fbooster\fhe\bter\f(cool\bnt\fpump).\fCHECK\fthe\foper\btion\f
of\fthe\fsystem.\f
No\b
LOCATE\f\bnd\fREPAIR\fthe\fbre\bk\fin\fcircuit\fCHF03A\f(GN/OG)\fbetween\fthe\f
progr\bmm\bble\ffuel-fired\fbooster\fhe\bter\f\bnd\fthe\ffuel-fired\fbooster\fhe\bter\f
(cool\bnt\fpump)\fwith\fthe\f\bid\fof\fthe\fWiring\fDi\bgr\bms.\fCHECK\fthe\foper\btion\f \f\f
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Component\bTests\b
Blower\brelay\bH402\b
of\fthe\fsystem.\f
PINPOINT\bTE\fT\b\f\b:\bBOO\fTER\bHEATER\bFUEL\bPUMP\bINOPERATIVE\b
TEST CONDITIONSDETAILS/RESULTS/ACTIONS
\f1:\bCHECK\bFOR\bOPEN\bCIRCUIT\bBETWEEN\bTHE\bBOO\fTER\bHEATER\bFUEL\bPUMP\bAND\bTHE\b
FUEL-FIRED\bBOO\fTER\bHEATER\b
Ignition\fswitch\fin\fposition\f0.\f1\b
Disconnect\fConnector\fC3HF02\ffrom\fthe\fbooster\f
he\bter\ffuel\fpump.\f2\b
Disconnect\fConnector\fC1HF01-C\ffrom\fthe\ffuel-fired\f
booster\fhe\bter.\f3\b
Me\bsure\fthe\fresist\bnce\fbetween\fthe\fprogr\bmm\bble\f
fuel-fired\fbooster\fhe\bter,\fconnector\fC1HF01-C,\fpin\f
7,\fcircuit\fCHF01A\f(BN/BU),\fwiring\fh\brness\fside\f\bnd\f
the\fbooster\fhe\bter\ffuel\fpump,\fconnector\fC3HF02,\fpin\f
1,\fcircuit\fCHF01C\f(BN/BU),\fwiring\fh\brness\fside.\f
4\b
Is\f\b\fresist\bnce\fof\fless\fth\bn\f2\fOhms\fregistered?\f
Yes\b GO\fto\fS2.\f\f
No\b L

OCATE\f\bnd\fREPAIR\fthe\fopen\fcircuit\fbetween\fthe\f
progr\bmm\bble\ffuel-fired\fbooster\fhe\bter\f\bnd\fthe\f
booster\fhe\bter\ffuel\fpump\fwith\fthe\f\bid\fof\fthe\fWiring\f
Di\bgr\bms.\fCHECK\fthe\foper\btion\fof\fthe\fsystem.\f
\f2:\bCHECK\bTHE\bGROUND\bCONNECTION\bOF\bTHE\bBOO\fTER\bHEATER\bFUEL\bPUMP
Me\bsure\fthe\fresist\bnce\fbetween\fthe\fbooster\fhe\bter\f
fuel\fpump,\fconnector\fC3HF02,\fpin\f2,\fcircuit\fGD152F\f
(BK/BU),\fwiring\fh\brness\fside.\f1\b
Is\f\b\fresist\bnce\fof\fless\fth\bn\f2\fOhms\fregistered?\f
Yes\b RENEW\fthe\fbooster\fhe\bter\ffuel\fpump.\fCHECK\fthe\f
oper\btion\fof\fthe\fsystem.\f
No\b
LOCATE\f\bnd\fRECTIFY\fthe\fbre\bk\fin\fthe\fcircuit\f
between\fground\fconnection\fG4D151\f\bnd\fthe\fbooster\f
he\bter\ffuel\fpump\fwith\fthe\f\bid\fof\fthe\fWiring\f
Di\bgr\bms.\fCHECK\fthe\foper\btion\fof\fthe\fsystem.\f
\f\f
\f\f
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Climate\bControl\b\f\bHeater\bCoreS-MAX/G\bl\bxy\f2006.5\f(02/2006
\f
Removal\band\bInstallation\b
General\bEquipment\b
Removal\b
NO
TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f\f
Vehicles\fwith\f1.8L\fdiesel\fengine\f
V e

hicles\fwith\f2.5L\fengine\f
Vehicles\fwith\f2.0L\fengine\f
Vehicles\fwith\f2.0L\fdiesel\fengine\f
Hose\fcl\bmp\fremover/inst\bller 1. Refer\fto:\fEngine\fCooling\fSystem\fHe\blth\f\bnd\fS\bfety\f
Pre

c\butions \f(100-
00\fGener\bl\fInform\btion,\fDescription\f
\bnd\fOper\btion).\f
2. R\bise\f\bnd\fsupport\fthe\fvehicle.\f Refer\fto:\f Lifting\f(100-
02\fJ\bcking\f\bnd\fLifting,\fDescription\f
\bnd\fOper\btion).\f
3. \f
4. CAUTION:\fThe\finside\fsurf\bces\fof\fthe\fends\fof\f
th

e\fpipe\fmust\fbe\fcle\bn\f\bnd\ffree\ffrom\foil\fresidues.
\f
Torque:\b 10\fNm\f
5. \f
6. \f
\f\f
\f\f
\f\f
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Climate\bControl\b\f\bHeater\bCore—Vehicles\bBuilt\b
From:\b05/2007S-MAX/G\bl\bxy\f2006.5\f(02/2006
\f
Removal\band\bInstallation\b
General\bEquipment\b
Removal\b
NO
TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
Vehicles\fwith\f1.8L\fdiesel\fengine\f
V e

hicles\fwith\f2.5L\fengine\f
Vehicles\fwith\f2.0L\fengine\f
Vehicles\fwith\f2.0L\fdiesel\fengine\f
Hose\fcl\bmp\fremover/inst\bller 1. Refer\fto:\fEngine\fCooling\fSystem\fHe\blth\f\bnd\fS\bfety\f
Pre

c\butions \f(100-
00\fGener\bl\fInform\btion,\fDescription\f
\bnd\fOper\btion).\f
2. Refer\fto:\f Lifting\f(100-
02\fJ\bcking\f\bnd\fLifting,\fDescription\f
\bnd\fOper\btion).\f
3. \f
4.
CAUTION:\fM\bke\fsure\fth\bt\fthe\finside\fof\fthe\fpipe\f
ends\f\bre\fcle\bn\f\bnd\ffree\fof\foil\fresidue.\f
Torque:\b 10\fNm
\f
5. \f
6. \f
\f\f
\f\f
\f\f
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Is\fthe\fresist\bnce\fless\fth\bn\f5\fohms?\f
Y\bs INSTALL\f\b\fnew\fh\bz\brd\fswitch.\fTEST\fthe\fsystem\ffor\f
norm\bl\foper\btion.\f
No
REPAIR\fthe\fcircuit\fGD133CF\f(BK)\for\fcircuit\fGD133AW\f
(BK)\f\bs\fnecess\bry.\fTEST\fthe\fsystem\ffor\fnorm\bl\f
oper\btion.\f
PINPOINT TEST C : THE FRONT SEAT HEATER SWITCH ILLUMINATION IS
INOPERATIVE
TE\fT CONDITION\fDETAIL\f/RE\fULT\f/ACTION\f
C1: CHECK INOPERATIVE FRONT SEAT HEATER SWITCH FOR VOLTAGE
Disconnect\fFront\fSe\bt\fHe\bter\fSwitch\f-\fC3HS29.\f1
Ignition\fswitch\fin\fposition\fII.\f2
M\bke\fsure\fth\bt\fthe\fillumin\btion\fdimmer\fswitch\fis\fin\f
the\ffull\fillumin\btion\fposition.\f3
Pl\bce\fthe\fhe\bdl\bmp\fswitch\fin\fthe\fON\fposition.\f4
Me\bsure\fthe\fvolt\bge\fbetween\fthe\ffront\fse\bt\fhe\bter\f
switch\fC3HS29\fpin\f3,\fcircuit\fCLN17H\f(BN),\fh\brness\f
side\f\bnd\fground.\f5
Is\fthe\fvolt\bge\fgre\bter\fth\bn\f10\fvolts?\f
Y\bs
GO\fto\fC2 .\f\f
No R

EPAIR\fcircuit\fCLN17H\f(BN),\fcircuit\fCLN17J\f(BN)\for\f
circuit\fCLN17G\f(BN)\f\bs\fnecess\bry.\fTEST\fthe\fsystem\f
for\fnorm\bl\foper\btion.\f
C2: CHECK THE FRONT SEAT HEATER SWITCH FOR OPEN
Me\bsure\fthe\fresist\bnce\fbetween\fthe\ffront\fse\bt\f
he\bter\fswitch\fC3HS29\fpin\f1,\fcircuit\fGD138AP\f(BK),\f
h\brness\fside\f\bnd\fground.\f1
Is\fthe\fresist\bnce\fless\fth\bn\f5\fohms?\f
Y\bs
\f\f
\f\f
\f\f
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LOCATE\f\bnd\fRECTIFY\fthe\fbre\bk\fin\fthe\fcircuit\f
between\fthe\fDVD\fdrive\f\bnd\fsoldered\fconnection\f
SP354\fwith\fthe\f\bid\fof\fthe\fWiring\fDi\bgr\bms.\fCHECK\f
the\foper\btion\fof\fthe\fsystem.\f
H8: \bHE\bK FOR OPEN \bIR\bUIT BETWEEN THE DVD DRIVE AND THE DL\b
CAUTION:\fThe\ffollowing\fme\bsurement\fmust\fonly\fbe\fperformed\fusing\fthe\fFord\f
\bpproved\fdi\bgnostic\ftool\fdigit\bl\fmultimeter.\fF\bilure\fto\fobserve\fthis\finstruction\fc\bn\fle\bd\fto\f
d\bm\bge.\f
Me\bsure\fthe\fresist\bnce\fbetween\fthe\fDVD\fdrive,\f
connector\fC2ME04,\fpin\f5,\fcircuit\fVDB13E\f(BU/GY),\f
wiring\fh\brness\fside\f\bnd\fthe\fDLC,\fconnector\f
C3DB04,\fpin\f1,\fcircuit\fVDB13F\f(BU/GY),\fwiring\f
h\brness\fside.\f1
Is\f\b\fresist\bnce\fof\fless\fth\bn\f2\fOhms\fregistered?\f
Yes CHECK\fthe\fDVD\fdrive\f\bnd\fRENEW\fit\fif\fnecess\bry.\f
CHECK\fthe\foper\btion\fof\fthe\fsystem.\f
No LOCATE\f\bnd\fRECTIFY\fthe\fbre\bk\fin\fthe\fcircuit\f
between\fthe\fDVD\fdrive\f\bnd\fsoldered\fconnection\f
SP344\fwith\fthe\f\bid\fof\fthe\fWiring\fDi\bgr\bms.\fCHECK\f
the\foper\btion\fof\fthe\fsystem.\f
PINPOINT TEST I : FUEL-FIRED BOOSTER HEATER/PROGRAMMABLE FUEL-
FIRED BOOSTER HEATER NOT \bOMMUNI\bATING WITH THE FORD
APPROVED DIAGNOSTI\b TOOL
TEST CONDITIONSDETAILS/RESULTS/ACTIONS
I1: \bHE\bK \bOMMUNI\bATION WITH THE GENERI\b ELE\bTRONI\b MODULE (GEM)
Ignition\fswitch\fin\fposition\f0.\f1
Connect\fthe\fdi\bgnostic\ftool.\f2
Select\fthe\fgeneric\felectronic\fmodule\f(GEM)\fwith\fthe\f
Ford\f\bpproved\fdi\bgnostic\ftool.\f3
Is\fit\fpossible\fto\fest\bblish\fcommunic\btions\fwith\fthe\fGEM?\f
Yes GO\fto\fI2.\f\f
No GO

\fto\fPinpoint\fTest\f AF.\f\f
I2: \bHE\bK FUSE F27
Ignition\fswitch\fin\fposition\f0.\f1
CHECK\fFuse\fF27\f(EJB).\f2
Is\fthe\ffuse\fOK?\f
Yes
GO\fto\fI3.\f\f
No
R

ENEW\ffuse\fF27\f(30\fA).\fCHECK\fthe\foper\btion\fof\fthe\f
system.\fIf\fthe\ffuse\fblows\f\bg\bin,\fLOCATE\f\bnd\fREPAIR\f
the\fshort\fusing\fthe\fWiring\fDi\bgr\bms.\f
I3: \bHE\bK THE VOLTAGE AT FUSE F27
Connect\fFuse\fF27\f(EJB).\f1
Me\bsure\fthe\fvolt\bge\fbetween\ffuse\fF27\f(30\fA)\f\bnd\f
ground.\f2
\f\f
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Does\fthe\fmeter\fdispl\by\fb\bttery\fvolt\bge?\f
Yes GO\fto\fI4.\f\f
No
REPAIR\fthe\fvolt\bge\fsupply\fto\ffuse\fF27\fwith\fthe\f\bid\fof\f
the\fWiring\fDi\bgr\bms.\fCHECK\fthe\foper\btion\fof\fthe\f
system.\f
I4: \bHE\bK THE VOLTAGE AT THE FUEL-FIRED BOOSTER HEATER / PROGRAMMABLE
FUEL-FIRED BOOSTER HEATER
Disconnect\fConnector\fC1HF01-C\ffrom\fthe\ffuel-fired\f
booster\fhe\bter\f/\fprogr\bmm\bble\ffuel-fired\fbooster\f
he\bter.\f1
Me\bsure\fthe\fvolt\bge\fbetween\fthe\ffuel-fired\fbooster\f
he\bter\f/\fprogr\bmm\bble\ffuel-fired\fbooster\fhe\bter,\f
connector\fC1HF01-C,\fpin\f3,\fcircuit\fSBB27A\f(BU/RD),\f
wiring\fh\brness\fside\f\bnd\fground.\f2
Does\fthe\fmeter\fdispl\by\fb\bttery\fvolt\bge?\f
Yes GO\fto\fI5.\f\f
No L

OCATE\f\bnd\fRECTIFY\fthe\fbre\bk\fin\fcircuit\fSBB27A\f
(BU/RD)\fbetween\fthe\ffuel-fired\fbooster\fhe\bter\f/\f
progr\bmm\bble\ffuel-fired\fbooster\fhe\bter\f\bnd\fthe\fEJB\f
with\fthe\f\bid\fof\fthe\fWiring\fDi\bgr\bms.\fCHECK\fthe\f
oper\btion\fof\fthe\fsystem.\f
I5: \bHE\bK THE GROUND \bONNE\bTION OF THE FUEL-FIRED BOOSTER HEATER /
PROGRAMMABLE FUEL-FIRED BOOSTER HEATER
Me\bsure\fthe\fresist\bnce\fbetween\fthe\ffuel-fired\f
booster\fhe\bter\f/\fprogr\bmm\bble\ffuel-fired\fbooster\f
he\bter,\fconnector\fC1HF01-C,\fpin\f4,\fcircuit\fGD132L\f
(BK/VT),\fwiring\fh\brness\fside\f\bnd\fground.\f1
Is\f\b\fresist\bnce\fof\fless\fth\bn\f2\fOhms\fregistered?\f
Yes GO\fto\fI6.\f\f
No L

OCATE\f\bnd\fRECTIFY\fthe\fopen\fcircuit\fbetween\fthe\f
fuel-fired\fbooster\fhe\bter\f/\fprogr\bmm\bble\ffuel-fired\f
booster\fhe\bter\f\bnd\fsoldered\fconnection\fSP380\fwith\f
the\f\bid\fof\fthe\fWiring\fDi\bgr\bms.\fCHECK\fthe\foper\btion\f
of\fthe\fsystem.\f
I6: \bHE\bK FOR OPEN \bIR\bUIT BETWEEN THE FUEL-FIRED BOOSTER HEATER /
PROGRAMMABLE FUEL-FIRED BOOSTER HEATER AND THE DATA LINK \bONNE\bTOR
(DL\b)
CAUTION:\fThe\ffollowing\fme\bsurement\fmust\fonly\fbe\fperformed\fusing\fthe\fFord\f
\bpproved\fdi\bgnostic\ftool\fdigit\bl\fmultimeter.\fF\bilure\fto\fobserve\fthis\finstruction\fc\bn\fle\bd\fto\f
d\bm\bge.\f
\f\f
\f\f
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Me\bsure\fthe\fresist\bnce\fbetween\fthe\ffuel-fired\f
booster\fhe\bter\f/\fprogr\bmm\bble\ffuel-fired\fbooster\f
he\bter,\fconnector\fC1HF01-C,\fpin\f6,\fcircuit\fVDB07F\f
(VT/OG),\fwiring\fh\brness\fside\f\bnd\fthe\fDLC,\fconnector\f
C3DB04,\fpin\f11,\fcircuit\fVDB07D\f(VT/OG),\fwiring\f
h\brness\fside.\f
1
Is\f\b\fresist\bnce\fof\fless\fth\bn\f2\fOhms\fregistered?\f
Yes GO\fto\fI7.\f\f
No
L

OCATE\f\bnd\fRECTIFY\fthe\fopen\fcircuit\fbetween\fthe\f
fuel-fired\fbooster\fhe\bter\f/\fprogr\bmm\bble\ffuel-fired\f
booster\fhe\bter\f\bnd\fsoldered\fconnection\fSP282\fwith\f
the\f\bid\fof\fthe\fWiring\fDi\bgr\bms.\fCHECK\fthe\foper\btion\f
of\fthe\fsystem.\f
I7: \bHE\bK FOR OPEN \bIR\bUIT BETWEEN THE FUEL-FIRED BOOSTER HEATER /
PROGRAMMABLE FUEL-FIRED BOOSTER HEATER AND THE DL\b
CAUTION:\fThe\ffollowing\fme\bsurement\fmust\fonly\fbe\fperformed\fusing\fthe\fFord\f
\bpproved\fdi\bgnostic\ftool\fdigit\bl\fmultimeter.\fF\bilure\fto\fobserve\fthis\finstruction\fc\bn\fle\bd\fto\f
d\bm\bge.\f
Me\bsure\fthe\fresist\bnce\fbetween\fthe\ffuel-fired\f
booster\fhe\bter\f/\fprogr\bmm\bble\ffuel-fired\fbooster\f
he\bter,\fconnector\fC1HF01-C,\fpin\f11,\fcircuit\fVDB06Z\f
(GY/OG),\fwiring\fh\brness\fside\f\bnd\fthe\fDLC,\fconnector\f
C3DB04,\fpin\f3,\fcircuit\fVDB06X\f(GY/OG),\fwiring\f
h\brness\fside.\f
1
Is\f\b\fresist\bnce\fof\fless\fth\bn\f2\fOhms\fregistered?\f
Yes CHECK\f\bnd\fif\fnecess\bry\fRENEW\fthe\ffuel-
fired\fbooster\f
he\bter\f/\fprogr\bmm\bble\ffuel-fired\fbooster\fhe\bter.\f
CHECK\fthe\foper\btion\fof\fthe\fsystem.\f
No LOCATE\f\bnd\fRECTIFY\fthe\fopen\fcircuit\fbetween\fthe\f
fuel-fired\fbooster\fhe\bter\f/\fprogr\bmm\bble\ffuel-fired\f
booster\fhe\bter\f\bnd\fsoldered\fconnection\fSP290\fwith\f
the\f\bid\fof\fthe\fWiring\fDi\bgr\bms.\fCHECK\fthe\foper\btion\f
of\fthe\fsystem.\f
PINPOINT TEST J : KEYLESS VEHI\bLE MODULE NOT \bOMMUNI\bATING
WITH THE FORD APPROVED DIAGNOSTI\b TOOL
TEST
CONDITIONSDETAILS/RESULTS/ACTIONS
J1: \bHE\bK \bOMMUNI\bATIONS WITH THE GENERI\b ELE\bTRONI\b MODULE (GEM)
Ignition\fswitch\fin\fposition\f0.\f1
Connect\fthe\fdi\bgnostic\ftool.\f2
Select\fthe\fgeneric\felectronic\fmodule\f(GEM)\fwith\fthe\fFord\f\bpproved\f
di\bgnostic\ftool.\f3
Is\fit\fpossible\fto\fest\bblish\fcommunic\btions\fwith\fthe\fGEM?\f
Yes GO\fto\fJ2.\f\f \f\f
\f\f
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