2006 FORD S-MAX Service Repair Manual

service interval dimensions fog light bulb headrest fuse box location dead battery open trunk

Page 2593 of 4402

$FORD S-MAX 2006 Service Repair Manual O4:\bCHECK\bTHE\bCIRCUIT\bBETWEEN\bTHE\bINTERIOR\bTEMPERATURE\b\fEN\fOR\bAND\bTHE\b ELECTRONIC\bAUTOMATIC\bTEMPERATURE\bCONTROL\b(EATC)\bMODULE\bFOR\bOPEN\b CIRCUIT Disconnect\fConnector\fC2H101-B\ffr$

O4:\bCHECK\bTHE\bCIRCUIT\bBETWEEN\bTHE\bINTERIOR\bTEMPERATURE\b\fEN\fOR\bAND\bTHE\b
ELECTRONIC\bAUTOMATIC\bTEMPERATURE\bCONTROL\b(EATC)\bMODULE\bFOR\bOPEN\b
CIRCUIT
Disconnect\fConnector\fC2H101-B\ffrom\fthe\fEATC\f
module.\f1\b
Me\bsure\fthe\fresist\bnce\fbetween\fthe\finterior\f
temper\bture\fsensor,\fconnector\fC2H415,\fpin\f3,\f
circuit\fRH104FA\f(BU/GN),\fwiring\fh\brness\fside\f\bnd\f
the\fEATC\fmodule,\fconnector\fC2H101-B,\fPin\f20,\f
circuit\fRH104FA\f(BU/GN),\fwiring\fh\brness\fside.\f2\b
Is\f\b\fresist\bnce\fof\fless\fth\bn\f2\fOhms\fregistered?\f
Yes\b
CHECK\fthe\fEATC\fmodule,\fif\fnecess\bry\fINSTALL\f\b\f
new\fone.\fCHECK\fthe\foper\btion\fof\fthe\fsystem.\f
No\b LOCATE\f\bnd\fREPAIR\fthe\fbre\bk\fin\fthe\fcircuit\fbetween\f
the\fp\bssenger\fcomp\brtment\ftemper\bture\fsensor\f\bnd\f
the\fEATC\fmodule\fusing\fthe\fWiring\fDi\bgr\bms.\fCHECK\f
the\foper\btion\fof\fthe\fsystem.\f
PINPOINT\bTE\fT\bP\b:\bELECTRIC\bBOO\fTER\bHEATER\bINOPERATIVE\b
TEST CONDITIONSDETAILS/RESULTS/ACTIONS
P1:\bCHECK\bFU\fE\bF16
Ignition\fswitch\fin\fposition\f0.\f1\b
CHECK\fF16\f(EJB).\f2\b
Is\fthe\ffuse\fOK?\f
Yes\bGO\fto\fP2 .\f\f
No\b R

ENEW\ffuse\fF16\f(80\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
P2:\bCHECK\bTHE\bVOLTAGE\bAT\bFU\fE\bF16
Connect\fF16\f(EJB).\f1\b
Me\bsure\fthe\fvolt\bge\fbetween\ffuse\fF16\f(80\fA)\f\bnd\f
ground.\f2\b
Does\fthe\fmeter\fdispl\by\fb\bttery\fvolt\bge?\f
Yes\b GO\fto\fP3 .\f\f
No\b R

EPAIR\fthe\fvolt\bge\fsupply\fto\ffuse\fF16.\fCHECK\fthe\f
oper\btion\fof\fthe\fsystem.\f
P3:\bCHECK\bFU\fE\bF4
CHECK\fF4\f(CJB).\f1\b
Is\fthe\ffuse\fOK?\f
Yes\b
GO\fto\fP4 .\f\f
No\b R

ENEW\ffuse\fF4\f(7.5\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
P4:\bCHECK\bTHE\bVOLTAGE\bAT\bFU\fE\bF4
Connect\fF4\f(CJB).\f1\b
\f\f
Стр. 83 из 92
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Page 2594 of 4402

$FORD S-MAX 2006 Service Repair Manual Ignition\fswitch\fin\fposition\fII.\f2\b Me\bsure\fthe\fvolt\bge\fbetween\ffuse\fF4\f(7.5\fA)\f\bnd\f ground.\f3\b Does\fthe\fmeter\fdispl\by\fb\bttery\fvolt\bge?\f Yes\bGO\fto\fP5 .\f\f No\b R EPAIR$

Ignition\fswitch\fin\fposition\fII.\f2\b
Me\bsure\fthe\fvolt\bge\fbetween\ffuse\fF4\f(7.5\fA)\f\bnd\f
ground.\f3\b
Does\fthe\fmeter\fdispl\by\fb\bttery\fvolt\bge?\f
Yes\bGO\fto\fP5 .\f\f
No\b R

EPAIR\fthe\fvolt\bge\fsupply\fto\ffuse\fF4.\fCHECK\fthe\f
oper\btion\fof\fthe\fsystem.\f
P5:\bCHECK\bTHE\bREQUE\fT\b\fIGNAL\b"ELECTRIC\bBOO\fTER\bHEATER\bON"\bWITH\bTHE\bFORD\b
APPROVED\bDIAGNO\fTIC\bTOOL
Ignition\fswitch\fin\fposition\f0.\f1\b
Connect\fthe\fdi\bgnostic\ftool.\f2\b
Select\fthe\fgeneric\felectronic\fmodule\f(GEM)\fwith\fthe\f
di\bgnostic\ftester.\f3\b
Set\fthe\finterior\ftemper\bture\fto\fHI\for\fthe\f
temper\bture\fcontrols\fto\ftheir\fhighest\fsetting.\f4\b
Check\fwhether\f\bn\f"electric\fbooster\fhe\bter\fON"\f
request\fsign\bl\fis\fdispl\byed\fin\fthe\fd\bt\b\flogger.\f5\b
Is\f\bn\f"electric\fbooster\fhe\bter\fON"\frequest\fsign\bl\f
displ\byed\fin\fthe\fd\bt\b\flogger\fof\fthe\fGEM?\f
Yes\b
GO\fto\fP7 .\f\f
No\b -

\fVehicles\fwith\felectronic\f\butom\btic\ftemper\bture\f
control:CHECK\fthe\fEATC\fmodule\fwith\fthe\fFord\f
\bpproved\fdi\bgnostic\ftool.\fRENEW\fthe\fEATC\fmodule\f
\bs\frequired.\fCHECK\fthe\foper\btion\fof\fthe\fsystem.\f
-\fVehicles\fwithout\felectronic\f\butom\btic\ftemper\bture\f
control: GO\fto\fP6 .\f\f
P6:\bTE\fT\bTHE\bCIRCUIT\bBETWEEN\bTHE\bA/C\bCONTROL\bA\f\fEMBLY\bAND\bTHE\bGEM\bFOR\b
OPEN\bCIRCUIT
Ignition\fswitch\fin\fposition\f0.\f1\b
Disconnect\fConnector\fC1BP02-C\ffrom\fthe\fGEM.\f2\b
Disconnect\fConnector\fC2H101-C\ffrom\fthe\f\bir\f
conditioning\fcontrol\f\bssembly.\f3\b
Me\bsure\fthe\fresist\bnce\fbetween\fthe\fGEM,\fconnector\f
C1BP02-C,\fpin\f16,\fcircuit\fCHP03A\f(GN/BN),\fwiring\f
h\brness\fside\f\bnd\fthe\fA/C\fcontrol\f\bssembly,\f
connector\fC2H101-
C,\fpin\f5,\fcircuit\fCHP03A\f(GN/BN),\f
wiring\fh\brness\fside.\f
4\b
Is\f\b\fresist\bnce\fof\fless\fth\bn\f2\fOhms\fregistered?\f
Yes\b RENEW\fthe\fA/C\fcontrol\f\bssembly.\fCHECK\fthe\f
oper\btion\fof\fthe\fsystem.\fIf\fthe\fsystem\fis\fstill\f
inoper\btive,\fCHECK\fthe\fGEM\f\bnd\fRENEW\fif\f
necess\bry.\fCHECK\fthe\foper\btion\fof\fthe\fsystem.\f
No\b LOCATE\f\bnd\fREPAIR\fthe\fbre\bk\fin\fcircuit\fCHP03A\f
(GN/BN)\fbetween\fthe\fGEM\f\bnd\fthe\fA/C\fcontrol\f
\bssembly\fusing\fthe\fWiring\fDi\bgr\bms.\fCHECK\fthe\f
oper\btion\fof\fthe\fsystem.\f
P7:\bCHECK\bTHE\bVOLTAGE\bAT\bTHE\bELECTRIC\bBOO\fTER\bHEATER
\f\f
Стр. 84 из 92
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Page 2595 of 4402

$FORD S-MAX 2006 Service Repair Manual Ignition\fswitch\fin\fposition\f0.\f1\b Disconnect\fConnector\fC2HP01-A\ffrom\fthe\felectric\f booster\fhe\bter.\f2\b Me\bsure\fthe\fvolt\bge\fbetween\fthe\felectric\fbooster\f he\bter,\fconnector\fC2$

Page 2596 of 4402

$FORD S-MAX 2006 Service Repair Manual GO\fto\fP11.\f\f No\b GO \fto\fP10 .\f\f P10:\bCHECK\bFOR\bOPEN\bCIRCUIT\bBETWEEN\bTHE\bELECTRIC\bBOO\fTER\bHEATER\bAND\bTHE\b GEM\b(TERMINAL\b15) Ignition\fswitch\fin\fposition\f0.\f1\b Disconnect\fC$

GO\fto\fP11.\f\f
No\b GO
\fto\fP10 .\f\f
P10:\bCHECK\bFOR\bOPEN\bCIRCUIT\bBETWEEN\bTHE\bELECTRIC\bBOO\fTER\bHEATER\bAND\bTHE\b
GEM\b(TERMINAL\b15)
Ignition\fswitch\fin\fposition\f0.\f1\b
Disconnect\fConnector\fC1BP02-C\ffrom\fthe\fGEM.\f2\b
Me\bsure\fthe\fresist\bnce\fbetween\fthe\felectric\fbooster\f
he\bter,\fconnector\fC2HP03,\fpin\f1,\fcircuit\fCBP04P\f
(VT),\fwiring\fh\brness\fside\f\bnd\fthe\fGEM,\fconnector\f
C1BP02-C,\fpin\f68,\fcircuit\fCBP04T\f(VT),\fwiring\f
h\brness\fside.\f3\b
Is\f\b\fresist\bnce\fof\fless\fth\bn\f2\fOhms\fregistered?\f
Yes\b TEST\fthe\fGEM\f\bnd\fRENEW\f\bs\fnecess\bry.\fCHECK\fthe\f
oper\btion\fof\fthe\fsystem.\f
No\b LOCATE\f\bnd\fRECTIFY\fthe\fbre\bk\fin\fthe\fcircuit\f
between\fthe\fGEM\f\bnd\fthe\felectric\fbooster\fhe\bter\f
using\fthe\fWiring\fDi\bgr\bms.\fCHECK\fthe\foper\btion\fof\f
the\fsystem.\f
P11:\bCHECK\bFOR\bOPEN\bCIRCUIT\bBETWEEN\bTHE\bELECTRIC\bBOO\fTER\bHEATER\bAND\bTHE\b
GEM\b(PWM)
Ignition\fswitch\fin\fposition\f0.\f1\b
Disconnect\fConnector\fC1BP02-C\ffrom\fthe\fGEM.\f2\b
Me\bsure\fthe\fresist\bnce\fbetween\fthe\felectric\fbooster\f
he\bter,\fconnector\fC2HP03,\fpin\f2,\fcircuit\fCBP01A\f
(BU/GN),\fwiring\fh\brness\fside\f\bnd\fthe\fGEM,\f
connector\fC1BP02-C,\fpin\f39,\fcircuit\fCBP01A\f
(BU/GN),\fwiring\fh\brness\fside.\f3\b
Is\f\b\fresist\bnce\fof\fless\fth\bn\f2\fOhms\fregistered?\f
Yes\b GO\fto\fP12 .\f\f
No\b L

OCATE\f\bnd\fRECTIFY\fthe\fbre\bk\fin\fcircuit\fCBP01A\f
(BU/GN)\fbetween\fthe\fGEM\f\bnd\fthe\felectric\fbooster\f
he\bter\fusing\fthe\fWiring\fDi\bgr\bms.\fCHECK\fthe\f
oper\btion\fof\fthe\fsystem.\f
P12:\bCHECK\bTHE\bCIRCUIT\bBETWEEN\bTHE\bELECTRIC\bBOO\fTER\bHEATER\bAND\bTHE\bGEM\b
FOR\bA\b\fHORT\bTO\bVOLTAGE
Ignition\fswitch\fin\fposition\fII.\f1\b
Me\bsure\fthe\fvolt\bge\fbetween\fthe\felectric\fbooster\f
he\bter,\fconnector\fC2HP03,\fpin\f2,\fcircuit\fCBP01A\f
(BU/GN),\fwiring\fh\brness\fside\f\bnd\fground.\f2\b
\f\f
\f\f
Стр. 86 из 92
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Page 2597 of 4402

$FORD S-MAX 2006 Service Repair Manual Is\f\b\fvolt\bge\fme\bsured?\f Yes\bLOCATE\f\bnd\fRECTIFY\fthe\fshort\fto\fvolt\bge\fin\fcircuit\f CBP01A\f(BU/GN)\fbetween\fthe\fGEM\f\bnd\fthe\felectric\f booster\fhe\bter\fusing\fthe\fWiring\fDi\bg$

Page 2598 of 4402

$FORD S-MAX 2006 Service Repair Manual system.\fIf\fthe\ffuse\fblows\f\bg\bin,\fLOCATE\f\bnd\f REPAIR\fthe\fshort\fusing\fthe\fWiring\fDi\bgr\bms.\f Q2:\bCHECK\bTHE\bVOLTAGE\bAT\bFU\fE\bF27 Connect\fFuse\fF27\f(EJB).\f1\b Me\bsure\fthe\fvo$

system.\fIf\fthe\ffuse\fblows\f\bg\bin,\fLOCATE\f\bnd\f
REPAIR\fthe\fshort\fusing\fthe\fWiring\fDi\bgr\bms.\f
Q2:\bCHECK\bTHE\bVOLTAGE\bAT\bFU\fE\bF27
Connect\fFuse\fF27\f(EJB).\f1\b
Me\bsure\fthe\fvolt\bge\fbetween\ffuse\fF27\f(30\fA)\f\bnd\f
ground.\f2\b
Does\fthe\fmeter\fdispl\by\fb\bttery\fvolt\bge?\f
Yes\bGO\fto\fQ3.\f\f
No\b R

EPAIR\fthe\fvolt\bge\fsupply\fto\ffuse\fF27.\fCHECK\fthe\f
oper\btion\fof\fthe\fsystem.\f
Q3:\bCHECK\bTHE\bVOLTAGE\bAT\bTHE\bPROGRAMMABLE\bFUEL-FIRED\bBOO\fTER\bHEATER
Disconnect\fConnector\fC1HF01-C\ffrom\fthe\f
progr\bmm\bble\ffuel-fired\fbooster\fhe\bter.\f1\b
Me\bsure\fthe\fvolt\bge\fbetween\fthe\fprogr\bmm\bble\f
fuel-fired\fbooster\fhe\bter,\fconnector\fC1HF01-C,\fpin\f
3,\fcircuit\fSBB27A\f(BU/RD),\fwiring\fh\brness\fside\f\bnd\f
ground.\f2\b
Does\fthe\fmeter\fdispl\by\fb\bttery\fvolt\bge?\f
Yes\b GO\fto\fQ5.\f\f
No\b GO

\fto\fQ4.\f\f
Q4:\bCHECK\bFOR\bOPEN\bCIRCUIT\bBETWEEN\bTHE\bPROGRAMMABLE\bFUEL-FIRED\b
BOO\fTER\bHEATER\bAND\bTHE\bEJB
Disconnect\fConnector\fC1BB01-A\ffrom\fthe\fEJB.\f1\b
Me\bsure\fthe\fresist\bnce\fbetween\fthe\fprogr\bmm\bble\f
fuel-fired\fbooster\fhe\bter,\fconnector\fC1HF01-C,\fpin\f
3,\fcircuit\fSBB27A\f(BU/RD),\fwiring\fh\brness\fside\f\bnd\f
the\fEJB,\fconnector\fC1BB01-A,\fcircuit\fSBB32A\f
(BU/RD),\fwiring\fh\brness\fside.\f2\b
Is\f\b\fresist\bnce\fof\fless\fth\bn\f2\fOhms\fme\bsured?\f
Yes\b CHECK\fthe\fEJB\f\bnd\fRENEW\fit\fif\fnecess\bry.\fCHECK\f
the\foper\btion\fof\fthe\fsystem.\f
No\b LOCATE\f\bnd\fREPAIR\fthe\fbre\bk\fin\fcircuit\fSBB27A\f
(VT/RD)\fbetween\fthe\fprogr\bmm\bble\ffuel-fired\f
booster\fhe\bter\f\bnd\fthe\fEJB\fwith\fthe\f\bid\fof\fthe\f
Wiring\fDi\bgr\bms.\fCHECK\fthe\foper\btion\fof\fthe\f
system.\f
Q5:\bCHECK\bTHE\bGROUND\bCONNECTION\bOF\bTHE\bPROGRAMMABLE\bFUEL-FIRED\b
BOO\fTER\bHEATER
Me\bsure\fthe\fresist\bnce\fbetween\fthe\fprogr\bmm\bble\f
fuel-fired\fbooster\fhe\bter,\fconnector\fC1HF01-C,\fpin\f
4,\fcircuit\fGD132L\f(BK/VT),\fwiring\fh\brness\fside\f\bnd\f
ground.\f1\b
\f\f
Стр. 88 из 92
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Page 2599 of 4402

$FORD S-MAX 2006 Service Repair Manual Is\f\b\fresist\bnce\fof\fless\fth\bn\f2\fOhms\fme\bsured?\f Yes\bCHECK\f\bnd\fif\fnecess\bry\fRENEW\fthe\fprogr\bmm\bble\f fuel-fired\fbooster\fhe\bter.\fCHECK\fthe\foper\btion\fof\f the\fsystem.\f No$

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
Стр. 89 из
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Page 2600 of 4402

$FORD S-MAX 2006 Service Repair Manual Component\bTests\b Blower\brelay\bH402\b of\fthe\fsystem.\f PINPOINT\bTE\fT\b\f\b:\bBOO\fTER\bHEATER\bFUEL\bPUMP\bINOPERATIVE\b TEST CONDITIONSDETAILS/RESULTS/ACTIONS \f1:\bCHECK\bFOR\bOPEN\bCIRCUIT\b$

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