2006 FORD S-MAX Service Repair Manual

battery climate settings tire pressure auxiliary battery fuel reserve spare tire location

Page 1689 of 4402

$FORD S-MAX 2006 Service Repair Manual Starting\bSyste\f\b-\b2.0L\bEcoBoost\bSCTi\b (149kW/203PS)\b-\bMI4\b-\bStarter\bMotorS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f Re\foval\band\bInstallation\b Re\foval\b NO TE:\fRemov\bl\fsteps\fin\$

Page 1690 of 4402

$FORD S-MAX 2006 Service Repair Manual Installation\b7. Torque:\b 1 \f48\fNm \f 2\f12\fNm \f 3\f10\fNm \f 8. NOTE:\fM\bke\fsure\fth\bt\f\b\fnew\fcomponent\fis\f in st\blled.\f 1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f \f \f$

Page 1691 of 4402

$FORD S-MAX 2006 Service Repair Manual Starting\bSyste\f\b-\b2.0L\bEcoBoost\bSCTi\b (149kW/203PS)\b-\bMI4\b-\bStart\bInhibit\b Switch S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f Re\foval\band\bInstallation\b Re\foval\b CA UTION:\fM\bke\f$

Page 1692 of 4402

$FORD S-MAX 2006 Service Repair Manual Starting\bSyste\f\b-\b2.5L\bDuratec\b (162kW/220PS)\b-\bVI5\b-\bStarting\bSyste\fS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f Diagnosis\band\bTesting\b General\bEquip\fent\b Principles\bof\bOperation\$

Starting\bSyste\f\b-\b2.5L\bDuratec\b
(162kW/220PS)\b-\bVI5\b-\bStarting\bSyste\fS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Diagnosis\band\bTesting\b
General\bEquip\fent\b
Principles\bof\bOperation\b
Th

e\fst\brter\fmotor\ffunction\fis\fcontrolled\fby\f\b\fst\brter\frel\by.\fThe\fst\brter\frel\by\fis\foper\bted\fby\f
the\fignition\fswitch.\f\f
B\bttery\fvolt\bge\fis\fsupplied\fto\fthe\fignition\fswitch\ffrom\fb\bttery\fjunction\fbox\f(BJB)\ffuse\fF17.\f
When\fthe\fignition\fswitch\fis\fturned\fto\fposition\fIII,\fb\bttery\fvolt\bge\fis\fsupplied\fto\fthe\fst\brter\f
rel\by\fcoil.\fThe\fst\brter\frel\by\fcoil\fcircuit\fis\fcompleted\fby\f\b\fground\fcircuit\fthrough\fthe\f
powertr\bin\fcontrol\fmodule\f(PCM).\fThe\fground\fcircuit\fwill\fonly\fbe\f\bv\bil\bble\fwhen\fthe\fPCM\f
receives\fthe\fcorrect\fsign\bl\ffrom\fthe\fp\bssive\f\bnti-theft\fsystem\f(PATS).\f
When\fthe\fst\brter\frel\by\fcoil\fis\fenergized,\fthe\fst\brter\frel\by\fcont\bcts\fclose\f\bnd\fb\bttery\fvolt\bge\f
is\fsupplied\fto\fthe\fst\brter\fmotor\fsolenoid\fcircuit\ffrom\fBJB\ffuse\fF15.\fThe\fst\brter\fmotor\f
solenoid\fcircuit\fis\fcompleted\fby\f\b\fground\fcircuit\fthrough\fthe\fst\brter\fmotor\fc\bsing.\f
The\fst\brter\fmotor\fsolenoid\fh\bs\ftwo\ffunctions.\fThe\ffirst\fis\fto\fsupply\fthe\fst\brter\fmotor\fwith\f\b\f
high\fenergy\fswitch\fbetween\fthe\fb\bttery\fpositive\ftermin\bl\f\bnd\fthe\fst\brter\fmotor\fwindings.\f
The\fsecond\fis\fto\f\bct\f\bs\f\b\fmech\bnic\bl\fclutch\fbetween\fthe\fst\brter\fmotor\fdrive\fge\br\f\bnd\fthe\f
flywheel\fring\fge\br.\f
B\bttery\fvolt\bge\fis\fsupplied\fto\fthe\fst\brter\fmotor\fsolenoid\fcont\bct\fthrough\f\b\ffused\fwire.\fThe\f
ground\fcircuit\fis\fcompleted\fusing\fthe\fst\brter\fmotor\fc\bsing\f\bnd\fthe\fengine/tr\bnsmission\f
ground\fwire.\f
Inspection\band\bVerification\b
1. 1.\b
Verify\fthe\fcustomer\fconcern.\f
2

. 2.\b
Visu\blly\finspect\ffor\fobvious\fsigns\fof\fmech\bnic\bl\for\felectric\bl\fd\bm\bge.\f
3

. 3.\b
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.\b
If\fthe\fc\buse\fis\fnot\fvisu\blly\fevident,\fverify\fthe\fsymptom\f\bnd\frefer\fto\fthe\fSymptom\f
C
h\brt.\f
Visual\bInspection\bChart\b
Sy\fpto\f\bChart\b
Worldwide\fDi\bgnostic\fSystem\f(WDS)
Mechanica\bE\bectrica\b
St\brter\fmotor\fFuse(s)\f\f
Wiring\fh\brness(es)\f\f
Electric\bl\fconnector(s)\f\f
Rel\by(s)\f\f
Switch(es)\f\f
B\bttery\f
\fymptomPossib\be
\fourcesAction
The\fengine\fdoes\f
not\fcr\bnk\f\bnd\fthe\f
rel\by\fdoes\fnot\fclickB\bttery\f\f
*REFER\fto:\fCh\brging\fSystem\f(414-00,\fDi\bgnosis\f\bnd\f
Testing).\f
*
Circuit(s)\f
*GO\fto\fPinpoint\fTest\f A.\f\f
*
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Page 1693 of 4402

$FORD S-MAX 2006 Service Repair Manual St\brter\f rel\by\f Ignition\f switch\f PCM\f BJB\f * * * * PATS\f*REFER\fto:\fAnti-Theft\f-\fP\bssive\f(419-01B,\fDi\bgnosis\f\bnd\f Testing).\f * The\fengine\fdoes\f not\fcr\bnk\fbut\fthe\f rel\by\f$

St\brter\f
rel\by\f Ignition\f
switch\f
PCM\f
BJB\f
*
*
*
*
PATS\f*REFER\fto:\fAnti-Theft\f-\fP\bssive\f(419-01B,\fDi\bgnosis\f\bnd\f
Testing).\f
*
The\fengine\fdoes\f
not\fcr\bnk\fbut\fthe\f
rel\by\fclicksB\bttery\f
*REFER\fto:\fCh\brging\fSystem\f(414-00,\fDi\bgnosis\f\bnd\f
Testing).\f
*
Circuit(s)\f
St\brter\f
rel\by\f
St\brter\f
motor\f
*
*
*GO\fto\fPinpoint\fTest\f
B.\f\f
*
The\fengine\fcr\bnks\f
slowlyB\bttery\f
*REFER\fto:\fCh\brging\fSystem\f(414-00,\fDi\bgnosis\f\bnd\f
Testing).\f
*
B\bttery\f
c\bble\f St\brter\f
motor\f
*
*GO\fto\fPinpoint\fTest\f
C.\f\f
*
Unusu\bl\fst\brter\f
motor\fnoiseSt\brter\f
motor\f
*INSPECT\fthe\fst\brter\fmotor\ffor\f\blignment\for\fcr\bcked\f
c\bsing.\fM\bke\fsure\fthe\fmounting\fbolts\f\bre\ftightened.\fIf\f
necess\bry,\fINSTALL\f\b\fnew\fst\brter\fmotor.\f\f
REFER\fto:\f St\brter\fMotor \f(303-06A\fSt\brting\fSystem\f-\f2.0L\f
Dur

\btec-HE\f(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\f
Fuel\f(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\fInst\bll\btion)\f/\f\f
St\brter\fMotor\f(303-06B\fSt\brting\fSystem\f-\f2.5L\fDur\btec-
ST\f
(VI5),\fRemov\bl\f\bnd\fInst\bll\btion)\f/\f\f
St\brter\fMotor\f(303-06C\fSt\brting\fSystem\f-\f1.8L\fDur\btorq-
TDCi\f(Kent)\fDiesel,\fRemov\bl\f\bnd\fInst\bll\btion)\f/\f\f
St\brter\fMotor\f(303-06D\fSt\brting\fSystem\f-\f2.0L\fDur\btorq-
TDCi\f(DW)\fDiesel,\fRemov\bl\f\bnd\fInst\bll\btion).\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
*
Flywheel\f
ring\fge\br\f
*CHECK\fthe\fflywheel\fring\fge\br.\fINSTALL\f\b\fnew\fflywheel\f
ring\fge\br\f\bs\fnecess\bry.\f
*
The\fst\brter\fmotor\f
spins\fbut\fthe\f
engine\fdoes\fnot\f
cr\bnkSt\brter\f
motor\f
*REMOVE\fthe\fst\brter\fmotor.\fINSPECT\fthe\fst\brter\fmotor\f
ge\br\ffor\fd\bm\bge.\fINSTALL\f\b\fnew\fst\brter\fmotor\f\bs\f
necess\bry.\f\f
REFER\fto:\f St\brter\fMotor \f(303-06A\fSt\brting\fSystem\f-\f2.0L\f
Dur

\btec-HE\f(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\f
Fuel\f(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\fInst\bll\btion)\f/\f\f
St\brter\fMotor\f(303-06B\fSt\brting\fSystem\f-\f2.5L\fDur\btec-
ST\f
(VI5),\fRemov\bl\f\bnd\fInst\bll\btion)\f/\f\f
St\brter\fMotor\f(303-06C\fSt\brting\fSystem\f-\f1.8L\fDur\btorq-
TDCi\f(Kent)\fDiesel,\fRemov\bl\f\bnd\fInst\bll\btion)\f/\f\f
St\brter\fMotor\f(303-06D\fSt\brting\fSystem\f-\f2.0L\fDur\btorq-
TDCi\f(DW)\fDiesel,\fRemov\bl\f\bnd\fInst\bll\btion).\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
*
Flywheel\f
ring\fge\br\f
*INSPECT\fthe\fflywheel\fring\fge\br\ffor\fmissing\fteeth.\fCHECK\f
the\fst\brter\fmotor\ffor\fcorrect\fmounting.\fIf\fthe\fconcern\f
persists,\fINSTALL\f\b\fnew\fst\brter\fmotor.\f\f
REFER\fto:\f St\brter\fMotor \f(303-06A\fSt\brting\fSystem\f-\f2.0L\f
Du r

\btec-HE\f(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\f
Fuel\f(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\fInst\bll\btion)\f/\f\f
St\brter\fMotor\f(303-06B\fSt\brting\fSystem\f-\f2.5L\fDur\btec-
ST\f
*
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Page 1694 of 4402

$FORD S-MAX 2006 Service Repair Manual Pinpoint\bTests\b NOTE:\fUse\f\b\fdigit\bl\fmultimeter\ffor\f\bll\felectric\bl\fme\bs urements.\f (VI5),\fRemov\bl\f\bnd\fInst\bll\btion)\f/\f\f St\brter\fMotor\f(303-06C\fSt\brting\fSystem\f-\f1.8L\f$

Page 1695 of 4402

$FORD S-MAX 2006 Service Repair Manual Is\fthe\fresist\bnce\fless\fth\bn\f1\fohm?\f Yes\bINSTALL\f\b\fnew\fst\brter\frel\by.\fTEST\fthe\fsystem\ffor\f norm\bl\foper\btion.\f No\b For\fvehicles\fwith\f1.8L\fDur\btorq\fTDCi\f(Kent)\fDiesel\f$

Page 1696 of 4402

$FORD S-MAX 2006 Service Repair Manual \bll\fDTCs.\fTEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\fIf\f the\fconcern\fpersists,\fINSTALL\f\b\fnew\fPCM.\fTEST\fthe\f system\ffor\fnorm\bl\foper\btion.\f No\b REPAIR\fthe\fcircuit.\fTEST\fthe\f$

\bll\fDTCs.\fTEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\fIf\f
the\fconcern\fpersists,\fINSTALL\f\b\fnew\fPCM.\fTEST\fthe\f
system\ffor\fnorm\bl\foper\btion.\f
No\b
REPAIR\fthe\fcircuit.\fTEST\fthe\fsystem\ffor\fnorm\bl\f
oper\btion.\fIf\fthe\fconcern\fpersists,\fINSTALL\f\b\fnew\f
BJB.\fTEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
A6:\bCHECK\bCIRCUIT\bCDC35G\b(BU/WH)\bFOR\bCONTINUITY
Ignition\fswitch\fin\fposition\f0.\f1\b
Disconnect\fPCM\fC1E108-B.\f2\b
Me\bsure\fthe\fresist\bnce\fbetween\fthe\fBJB\fst\brter\frel\by\f
R1\fconnector\fpin\f1,\fcircuit\fCDC35G\f(BU/WH),\f
h\brness\fside\f\bnd\fthe\fPCM\fC1E108-B\fpin\f17,\fcircuit\f
CDC35G\f(BU/WH),\fh\brness\fside.\f
3\b
Is\fthe\fresist\bnce\fless\fth\bn\f1\fohm?\f
Yes\b GO\fto\fA7.\f\f
No\b
R

EPAIR\fcircuit\fCDC35G\f(BU/WH).\fTEST\fthe\fsystem\f
for\fnorm\bl\foper\btion.\fIf\fthe\fconcern\fpersists,\f
INSTALL\f\b\fnew\fBJB.\fTEST\fthe\fsystem\ffor\fnorm\bl\f
oper\btion.\f
A7:\bCHECK\bCIRCUIT\bCDC12A\b(YE)\bFOR\bCONTINUITY
Disconnect\fBJB\fC1E108-B.\f1\b
Me\bsure\fthe\fresist\bnce\fbetween\fthe\fBJB\fst\brter\frel\by\f
R1\fconnector\fpin\f2,\fcircuit\fCDC12A\f(YE),\fh\brness\f
side\f\bnd\fthe\fPCM\fC1E108-B\fpin\f9,\fcircuit\fCDC12A\f
(YE),\fh\brness\fside.\f
2\b
Is\fthe\fresist\bnce\fless\fth\bn\f1\fohm?\f
Yes\b Using\fthe\fWDS,\fCHECK\ffor\fcurrent\fDTC's.\fCORRECT\f
\bll\fDTC's.\fTEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\fIf\f
the\fconcern\fpersists,\fINSTALL\f\b\fnew\fPCM.\fTEST\fthe\f
system\ffor\fnorm\bl\foper\btion.\f
No\b
REPAIR\fcircuit\fCDC12A\f(YE).\fTEST\fthe\fsystem\ffor\f
norm\bl\foper\btion.\fIf\fthe\fconcern\fpersists,\fINSTALL\f\b\f
new\fBJB.\fTEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
PINPOINT\bTEST\bB\b:\bTHE\bENGINE\bDOES\bNOT\bCRANK\bBUT\bTHE\bRELAY\bCLICKS\b
TE\fT CONDITION\fDETAIL\f/RE\fULT\f/ACTION\f
B1:\bCHECK\bCIRCUIT\bCDC35B\b(GN/RD)\bFOR\bVOLTAGE
Ignition\fswitch\fin\fposition\fIII.\f1\b
Me\bsure\fthe\fvolt\bge\fbetween\fthe\fst\brter\fmotor\f
solenoid\fC1DC35-B-1\fcircuit\fCDC35B\f(GN/RD),\f
component\fside\f\bnd\fground.\f2\b
\f\f
\f\f
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