2006 FORD S-MAX wiring

coolant level change language gas tank size fuel reserve change key battery warning lights

Page 1361 of 4402

$FORD S-MAX 2006 Service Repair Manual \f\fDescripti\bn Opening\ftemper\bture\f Fully\fopen\ftemper\bture\f NOTE:\fGener\blly,\fmost\fthermost\bts\fm\bint\bin\f\b\fcool\bnt\ftemper\bture\fbetween\f88ºC\f (1 90ºF)\f\bnd\f92ºC\f(198ºF)$

Page 1385 of 4402

$FORD S-MAX 2006 Service Repair Manual w\brm\fup\fph\bse.\f Most\fof\fthe\fcool\bnt\fis\fp\bssed\fto\fthe\fhe\bt\fexch\bnger\f\bnd\fflows\fb\bck\fto\fthe\fcool\bnt\fpump\fvi\b\f the\fexh\bust\fg\bs\frecircul\btion\f(EGR)\fcooler.\f At\f\b\$

Page 1387 of 4402

$FORD S-MAX 2006 Service Repair Manual Engine C\b\bling - 2\f0L Durat\brq-TDCi (85kW/115PS) - DW/2\f0L Durat\brq-TDCi (100kW/136PS) - DW/2\f0L Durat\brq- TDCi (103kW/140PS) - DW - Engine C\b\bling S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPri$

Page 1392 of 4402

$FORD S-MAX 2006 Service Repair Manual vehicle\fso\fth\bt\fit\fdoes\fnot\finterfere\fwith\fthe\fs\bfe\foper\btion\fof\fthe\fvehicle.\fDo\fnot\f pl\bce\fthe\fFord\f\bpproved\fdi\bgnostic\ftool\fin\fthe\fdeployment\fp\bth\fof\f\bny\f\bir\fb\$

vehicle\fso\fth\bt\fit\fdoes\fnot\finterfere\fwith\fthe\fs\bfe\foper\btion\fof\fthe\fvehicle.\fDo\fnot\f
pl\bce\fthe\fFord\f\bpproved\fdi\bgnostic\ftool\fin\fthe\fdeployment\fp\bth\fof\f\bny\f\bir\fb\bg.\f
F\bilure\fto\ffollow\fthese\finstructions\fm\by\fresult\fin\fperson\bl\finjury.\f
NOTE:\fThe\fro\bd\ftest\fis\fbest\fc\brried\fout\fwith\fthe\f\bid\fof\f\bnother\ftechnici\bn\fin\fthe\f
vehicle\fto\fen\bble\fthe\fvehicle\fto\fbe\fdriven\fs\bfely\fwhile\fthe\fsensor\foutputs\f\bre\f
monitored\fwithin\fd\bt\blogger.\fIf\fthere\fis\fonly\fone\ftechnici\bn\f\bv\bil\bble,\fthe\fFord\f
\bpproved\fdi\bgnostic\ftool\fc\bn\fbe\fset\fup\f(using\fthe\frecord/c\bpture\fmode\fc\bmer\b\f
icon)\fbefore\fle\bving\fthe\fworkshop\fto\frecord\f\b\f16\fkm\f(10\fmile)\ftest.\f
NOTE:\fThe\fresults\ffrom\fthe\ftest\f\bre\fmore\fconclusive\fif\fthe\fengine\fis\fcold\fwhen\fthe\f
test\fis\fst\brted.\f
3\f C\brry\fout\f\b\fro\bd\ftest.\f\f
RE
FER\fto:\f Ro\bd/Roller\fTesting \f(100-00\fGener\bl\fInform\btion,\fDescription\f\bnd\f
Ope

r\btion).\f
4. 4\f
Drive\fthe\fvehicle\f\bt\f\b\fconst\bnt\fthrottle\fopening\f\bnd\fset\fspeed\funtil\fthe\fECT\fv\blue\f
s
ettles\finto\f\b\fsh\bllow\frise\f\bnd\ff\bll\fsign\bl,\fclose\fto\f\b\fstr\bight\fline.\fThis\findic\btes\fth\bt\f
the\fthermost\bt\fis\ffunctioning\fcorrectly.\f
NOTE:\fSome\fthermost\bts\findic\bte\fthe\ftemper\bture(s)\fin\f
Celsius\f\bnd\fF\bhrenheit.\f
The\fgr\bphic\fbelow\fshows\fthe\floc\btion\f\bnd\f\bn\fex\bmple\fof
\fthe\fopening\ftemper\bture\f(88ºC)\f
\bnd\ffully\fopen\ftemper\bture\f(102ºC)\fof\f\b\fthermost\bt.\f
The\fgr\bphic\fbelow\fshows\f\bn\f\bltern\btive\fmethod\fused\fto\fshow\fthe\fopening\ftemper\bture\f
(88ºC)\f\bnd\ffully\fopen\ftemper\bture\f(112ºC)\fof\f\b\fthermost\bt.\f
\f\f
Descripti\bn
Opening\ftemper\bture\f
Fully\fopen\ftemper\bture\f
NOTE:\fGener\blly,\fmost\fthermost\bts\fm\bint\bin\f\b\fcool\bnt\ftemper\bture\fbetween\f88ºC\f
(1
90ºF)\f\bnd\f92ºC\f(198ºF)\f\blthough\fdu\bl\fst\bge\felectric\fthermost\bts\fm\by\fincre\bse\fthe\f
cool\bnt\ftemper\bture\fup\fto\f100ºC\f(212ºF)\funder\flight\fengine\flo\bd\fconditions.\f
The\fengine\fshould\fst\brt\fcle\bnly\f\bnd\fthe\fECT\fv\blue\fwill
\frise\fquite\fquickly\fwith\fsmooth\f
progression.\fIf\fthe\fECT\fsign\bl\f\bppe\brs\funst\bble\for\ferr\btic,\fthe\fECT\fsensor,\felectric\bl\f
connector\f\bnd\fwiring\fh\brness\fto\fthe\fPCM\fneed\fto\fbe\fvisu\blly\finspected\ffor\fd\bm\bge,\fch\bfing\f
or\fw\bter\fingress.\f
The\ftemper\bture\fshould\frise\fto\f\bpproxim\btely\f90ºC\ffor\f\b\fthermost\bt\fth\bt\fh\bs\f\bn\f88ºC\f
v\blue.\fThe\fsign\bl\fv\blue\fwill\fthen\ff\bll\f\bs\fcooler\fcool\bnt\fenters\fthe\fengine.\f Item
A
B \f\f
\f\f
Part Number
-
-
Стр. 6 из 7
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G510017&gui...procarmanuals.com
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Page 1407 of 4402

$FORD S-MAX 2006 Service Repair Manual Engine C\b\bling - 2\f2L Durat\brq-TDCi (129kW/175PS) - DW - Engine C\b\blingS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f Diagn\bsis and Testing Special T\b\bl(s) Gen eral Equipment Inspecti\bn a$

Engine C\b\bling - 2\f2L Durat\brq-TDCi
(129kW/175PS) - DW - Engine C\b\blingS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Diagn\bsis and Testing
Special T\b\bl(s)
Gen

eral Equipment
Inspecti\bn and Verificati\bn 1. 1\f
Verify\fthe\fcustomer\fconcern.\f
2

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

isual Inspecti\bn Chart
3. 3\f
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\f
If\fthe\fc\buse\fis\fnot\fvisu\blly\fevident,\fverify\fthe\fsymptom\f\bnd\frefer\fto\fthe\fSymptom\f
C
h\brt.\f
Sympt\bm Chart
Pressure\fTester,\fCooling\fSystem\f
303-396\f(24-001\fA)\f
Ad\bptor\ffor\f303-396\f
303-396-09\f
Ford\f\bpproved\fdi\bgnostic\ftool
Mechanica\bE\bectrica\b
Cool\bnt\fle\bks\f\f
G\bskets/se\bls\f\f
Core\fplug(s)\f\f
Hose(s)/hose\fjoints\f\f
Cool\bnt\fexp\bnsion\ft\bnk\fc\bp\f\bnd\fse\bl(s)\f
\f
Cool\bnt\fexp\bnsion\ft\bnk\f\f
R\bdi\btor\f\f
Cool\bnt\fpump\f\f
Thermost\bt\f\f
He\bter\fcore\f\f
Exh\bust\fg\bs\frecircul\btion\f(EGR)\fcooler\f
Fuse(s)\f\f
Wiring\fh\brness\f\f
Electric\bl\fconnector(s)\f\f
Engine\fcool\bnt\ftemper\bture\f(ECT)\fsensor\f
\f
Cooling\ff\bn\fmotor\f\f
Cooling\ff\bn\fmodule\f\f
Powertr\bin\fcontrol\fmodule\f(PCM)\f
\fymptomPossib\be \fourcesAction
Loss\fof\fcool\bntCool\bnt\f
exp\bnsion\ft\bnk\f
c\bp\for\fse\bl(s).\f
*CHECK\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fc\bp\ffor\ftightness\f
\bnd\fd\bm\bge.\fINSTALL\f\b\fnew\fcool\bnt\fexp\bnsion\fc\bp\f
\bs\fnecess\bry.\f
*
Cooling\fsystem.\f
*INSPECT\fthe\fcooling\fsystem\ffor\fle\bks.\fCARRY\fOUT\f
the\fPressure\fTest\fComponent\fTest\fin\fthis\fsection.\f
INSTALL\fnew\fcomponent(s)\f\bs\fnecess\bry.\f
*
Engine.\f
*INSPECT\fthe\fengine,\fcylinder\fhe\bd,\fcylinder\fblock\f
\bnd\fcylinder\fhe\bd\fg\bsket.\f\f
*
\f
\f
Стр. 1 из
7
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G510017&gui...procarmanuals.com
http://vnx.su

Page 1412 of 4402

$FORD S-MAX 2006 Service Repair Manual F\bilure\fto\ffollow\fthese\finstructions\fm\by\fresult\fin\fperson\bl\finjury.\f NOTE:\fThe\fro\bd\ftest\fis\fbest\fc\brried\fout\fwith\fthe\f\bid\fof\f\bnother\ftechnici\bn\fin\fthe\f vehicle\fto\fe$

F\bilure\fto\ffollow\fthese\finstructions\fm\by\fresult\fin\fperson\bl\finjury.\f
NOTE:\fThe\fro\bd\ftest\fis\fbest\fc\brried\fout\fwith\fthe\f\bid\fof\f\bnother\ftechnici\bn\fin\fthe\f
vehicle\fto\fen\bble\fthe\fvehicle\fto\fbe\fdriven\fs\bfely\fwhile\fthe\fsensor\foutputs\f\bre\f
monitored\fwithin\fd\bt\blogger.\fIf\fthere\fis\fonly\fone\ftechnici\bn\f\bv\bil\bble,\fthe\fFord\f
\bpproved\fdi\bgnostic\ftool\fc\bn\fbe\fset\fup\f(using\fthe\frecord/c\bpture\fmode\fc\bmer\b\f
icon)\fbefore\fle\bving\fthe\fworkshop\fto\frecord\f\b\f16\fkm\f(10\fmile)\ftest.\f
NOTE:\fThe\fresults\ffrom\fthe\ftest\f\bre\fmore\fconclusive\fif\fthe\fengine\fis\fcold\fwhen\fthe\f
test\fis\fst\brted.\f
3\f C\brry\fout\f\b\fro\bd\ftest.\f\f
RE
FER\fto:\f Ro\bd/Roller\fTesting \f(100-00\fGener\bl\fInform\btion,\fDescription\f\bnd\f
Ope

r\btion).\f
4. 4\f
Drive\fthe\fvehicle\f\bt\f\b\fconst\bnt\fthrottle\fopening\f\bnd\fset\fspeed\funtil\fthe\fECT\fv\blue\f
s
ettles\finto\f\b\fsh\bllow\frise\f\bnd\ff\bll\fsign\bl,\fclose\fto\f\b\fstr\bight\fline.\fThis\findic\btes\fth\bt\f
the\fthermost\bt\fis\ffunctioning\fcorrectly.\f
NOTE:\fSome\fthermost\bts\findic\bte\fthe\ftemper\bture(s)\fin\f
Celsius\f\bnd\fF\bhrenheit.\f
The\fgr\bphic\fbelow\fshows\fthe\floc\btion\f\bnd\f\bn\fex\bmple\fof
\fthe\fopening\ftemper\bture\f(88ºC)\f
\bnd\ffully\fopen\ftemper\bture\f(102ºC)\fof\f\b\fthermost\bt.\f
The\fgr\bphic\fbelow\fshows\f\bn\f\bltern\btive\fmethod\fused\fto\fshow\fthe\fopening\ftemper\bture\f
(88ºC)\f\bnd\ffully\fopen\ftemper\bture\f(112ºC)\fof\f\b\fthermost\bt.\f
\f\f
Descripti\bn
Opening\ftemper\bture\f
Fully\fopen\ftemper\bture\f
NOTE:\fGener\blly,\fmost\fthermost\bts\fm\bint\bin\f\b\fcool\bnt\ftemper\bture\fbetween\f88ºC\f
(1
90ºF)\f\bnd\f92ºC\f(198ºF)\f\blthough\fdu\bl\fst\bge\felectric\fthermost\bts\fm\by\fincre\bse\fthe\f
cool\bnt\ftemper\bture\fup\fto\f100ºC\f(212ºF)\funder\flight\fengine\flo\bd\fconditions.\f
The\fengine\fshould\fst\brt\fcle\bnly\f\bnd\fthe\fECT\fv\blue\fwill
\frise\fquite\fquickly\fwith\fsmooth\f
progression.\fIf\fthe\fECT\fsign\bl\f\bppe\brs\funst\bble\for\ferr\btic,\fthe\fECT\fsensor,\felectric\bl\f
connector\f\bnd\fwiring\fh\brness\fto\fthe\fPCM\fneed\fto\fbe\fvisu\blly\finspected\ffor\fd\bm\bge,\fch\bfing\f
or\fw\bter\fingress.\f
The\ftemper\bture\fshould\frise\fto\f\bpproxim\btely\f90ºC\ffor\f\b\fthermost\bt\fth\bt\fh\bs\f\bn\f88ºC\f
v\blue.\fThe\fsign\bl\fv\blue\fwill\fthen\ff\bll\f\bs\fcooler\fcool\bnt\fenters\fthe\fengine.\f
If\fthe\fECT\fv\blue\ff\bils\fto\fm\bint\bin\f\b\fconst\bnt\fv\blue\f\bnd\ff\blls\fb\bck\fto\flower\ffigures,\ftypic\blly\f Item
A
B \f\f
\f\f
Part Number
-
-
Стр. 6 из 7
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G510017&gui...procarmanuals.com
http://vnx.su

Page 1425 of 4402

$FORD S-MAX 2006 Service Repair Manual Fuel Ch\brgi\fg \b\fd Co\ftrols - 2.0L Dur\btec-HE (107kW/145PS) - MI4/2.0L Dur\btec-HE Flex Fuel (107kW/145PS) - MI4/2.3L Dur\btec-HE (118kW/160PS) - MI4 - Fuel Ch\brgi\fg \b\fd Co\ftrols S-MAX/G$

Fuel Ch\brgi\fg \b\fd Co\ftrols - 2.0L
Dur\btec-HE (107kW/145PS) - MI4/2.0L
Dur\btec-HE Flex Fuel (107kW/145PS) -
MI4/2.3L Dur\btec-HE (118kW/160PS) -
MI4 - Fuel Ch\brgi\fg \b\fd Co\ftrols
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Di\bg\fosis \b\fd Testi\fg
Ge\fer\bl Equipme\ft
I\fspectio\f \b\fd Verific\btio\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
(if\fpossible)\fbefore\fproceeding\fto\fthe\fnext\fstep.\f
4. 4.
If\fthe\fc\buse\fis\fnot\fvisu\blly\fevident,\fverify\fthe\fsymptom\f\bnd\frefer\fto\fthe\fSymptom\f
C
h\brt.\f
Symptom Ch\brt
Ford\f\bpproved\fdi\bgnostic\ftool
Mechanica\bE\bectrica\b
Fuel\fle\bk(s)\f\f
V\bcuum\fline(s)\f\f
G\bsket(s)\f\f
Se\bl(s)\f\f
Fuel\finjector(s)\f\f
Throttle\fbody\f\f
Fuel\fr\bil\f\f
Fuel\fsupply\fline\fWiring\fh\brness\f\f
Electric\bl\fconnector(s)\f\f
Throttle\fbody\f\f
Fuel\finjector(s)\f\f
Powertr\bin\fcontrol\fmodule\f(PCM)\f
\fymptomPossib\be \fourcesAction
Engine\fdoes\fnot\fcr\bnkP\bssive\f\bnti-
theft\fsystem\f
(PATS).\f
*CHECK\fthe\fPATS\fLED\fextinguishes\fwithin\f3\f
seconds\fwhen\fthe\fignition\fis\fturned\fon.\f\f
REFER\fto:\f Anti-Theft\f-\fP\bssive \f(419-01B\fAnti-
The

ft\f-\fP\bssive,\fDi\bgnosis\f\bnd\fTesting).\f
*
St\brting\f
system.\f
*REFER\fto:\f
St\brter\fMotor \f(303-06A\fSt\brting\f
Sys
tem\f-\f2.0L\fDur\btec-HE\f(107kW/145PS)\f-\f
MI4/2.0L\fDur\btec-HE\fFlex\fFuel\f
(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\f
Inst\bll\btion)\f/\f St\brting\fSystem \f(303-06C\f
St\br

ting\fSystem\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fDi\bgnosis\f\bnd\f
Testing)\f/\f St\brting\fSystem \f(303-06E\fSt\brting\f
Sys

tem\f-\f2.0L\fDur\btorq-TDCi\f(85kW/115PS)\f-
\f
DW/2.0L\fDur\btorq-TDCi\f(100kW/136PS)\f-\f
DW/2.0L\fDur\btorq-TDCi\f(103kW/140PS)\f-\f
DW,\fEmission\fRequirements:\fSt\bge\fIV,\f
Di\bgnosis\f\bnd\fTesting).\f
*
Ignition\fswitch.\f*REFER\fto\fthe\fWiring\fDi\bgr\bms.\f
*
Powertr\bin\f
control\fmodule\f
*C\brry\fout\f\b\ffull\fengine\fdi\bgnosis\fusing\fthe\f
guided\fdi\bgnostic\fmenu\fin\fthe\fFord\f\bpproved\f
*
Стр. 1 из
14
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G842046&gui...procarmanuals.com
http://vnx.su

Page 1457 of 4402

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

Fuel Ch\brgi\fg \b\fd Co\ftrols - 2.5L Dur\btec
(162kW/220PS) - VI5 - Fuel Ch\brgi\fg \b\fd
Co\ftrols
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Di\bg\fosis \b\fd Testi\fg
Ge\fer\bl Equipme\ft
I\fspectio\f \b\fd Verific\btio\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
(if\fpossible)\fbefore\fproceeding\fto\fthe\fnext\fstep.\f
4. 4.
If\fthe\fc\buse\fis\fnot\fvisu\blly\fevident,\fverify\fthe\fsymptom\f\bnd\frefer\fto\fthe\fSymptom\f
C
h\brt.\f
Symptom Ch\brt
Ford\f\bpproved\fdi\bgnostic\ftool
Mechanica\bE\bectrica\b
Fuel\fle\bk(s)\f\f
V\bcuum\fline(s)\f\f
G\bsket(s)\f\f
Se\bl(s)\f\f
Fuel\finjector(s)\f\f
Throttle\fbody\f\f
Fuel\fr\bil\f\f
Fuel\fsupply\fline\fWiring\fh\brness\f\f
Electric\bl\fconnector(s)\f\f
Throttle\fbody\f\f
Fuel\finjector(s)\f\f
Powertr\bin\fcontrol\fmodule\f(PCM)\f
\fymptomPossib\be \fourcesAction
Engine\fdoes\fnot\fcr\bnkP\bssive\f\bnti-theft\f
system\f(PATS).\f
*
CHECK\fthe\fPATS\fLED\fextinguishes\f
within\f3\fseconds\fwhen\fthe\fignition\fis\f
turned\fon.\f\f
REFER\fto:\f Anti-Theft\f-\fP\bssive \f(419-
01B

\fAnti-Theft\f-\fP\bssive,\fDi\bgnosis\f
\bnd\fTesting).\f
*
St\brting\fsystem.\f
*REFER\fto:\fSt\brting\fSystem\f(303-
06A,\fDi\bgnosis\f\bnd\fTesting)\f/\f
St\brting\fSystem\f(303-06B,\f
Description\f\bnd\fOper\btion)\f/\fSt\brting\f
System\f(303-06C,\fDi\bgnosis\f\bnd\f
Testing)\f/\fSt\brting\fSystem\f(303-
06D,\f
Di\bgnosis\f\bnd\fTesting)\f/\fSt\brting\f
System\f(303-06E,\fDi\bgnosis\f\bnd\f
Testing).\f
*
Ignition\fswitch.\f
*REFER\fto\fthe\fWiring\fDi\bgr\bms.\f
*
Powertr\bin\f
control\fmodule\f
(PCM).\f
*C\brry\fout\f\b\ffull\fengine\fdi\bgnosis\f
using\fthe\fguided\fdi\bgnostic\fmenu\fin\f
the\fFord\f\bpproved\fdi\bgnostic\ftool.\f
*
Engine\fcr\bnks\fbut\fdoes\fnot\fst\brtInerti\b\ffuel\f
shutoff\f(IFS)\f
switch.\f
*RESET\fthe\fIFS\fswitch.\f
*
Low\ffuel\fsystem\f
*Check\fthe\ffuel\fsystem\fpressure.\f\f
*
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05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G842047&gui...procarmanuals.com
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key battery adding oil open bonnet ad blue mirror controls cooling