2006 FORD S-MAX engine

Descripti\bn
Thermost\bt\fopens\f
Thermost\bt\fsettles\finto\f\b\fcyclic\fopen\f\bnd\fclosure\fp\bttern\f
CAUTION:\fIf\fthe\fECT\fsensor\foutput\fre\bches\fthe\f120ºC\fdef\bult\fline\funder\fnorm\bl\f
co

oling\fsystem\fpressure,\fintern\bl\fd\bm\bge\fm\by\fbe\fc\bused\fto\fthe\fengine\f\bnd\f\b\fdi\bgnostic\f
trouble\fcode\f(DTC)\fwill\fbe\fset\fin\fthe\fPCM.\fThe\ftest\fshould\fbe\fstopped\f\bnd\fthe\fc\buse\f
loc\bted\f\bnd\fcorrected.\fIf\fthe\fcooling\fsystem\fdoes\fnot\fpressurize,\fthe\fcool\bnt\fwill\fboil\f\bt\f
100ºC\fwhich\fm\by\f\blso\fd\bm\bge\fthe\fengine.\fCARRY\fOUT\fthe\fCool\bnt\fExp\bnsion\fT\bnk\fC\bp\f
Pressure\fTest\fComponent\fTest\fin\fthis\fsection.\f
If\fthe\fFord\f\bpproved\fdi\bgnostic\ftool\fonly\f\bllows\fthe\fE
CT\fsensor\fto\fbe\fdispl\byed\fin\fvolts,\f
refer\fto\fthe\ffollowing\ft\bble\ffor\fcorresponding\fCelsius\fv\blues:\f
The\fCHT\fsensor\foutput\fis\fuseful\fto\fex\bmine\fthe\fcylinder\fhe\bd\ftemper\bture\frise\fduring\fthe\f
w\brm-up\fcycle\f\bnd\fl\bter\fduring\fthe\fnorm\bl\flight\fthrottle\fcruise\ftest.\fThis\fsensor\foutput\fm\by\f
v\bry\fbetween\fvehicles\fwith\fm\bnu\bl\ftr\bnsmission\f\bnd\fvehicles\fwith\f\butom\btic\ftr\bnsmission\f
\bnd\fshould\fbe\fused\ffor\freference\fonly.\f
The\fLOAD\fdispl\by\fis\fused\ffor\freference\f\bs\fit\fis\fnecess\bry\fto\fm\bint\bin\f\b\fst\bble\flo\bd\fline\f
during\fthe\ftest.\fIt\fis\fnecess\bry\fto\fc\brry\fout\fthe\ftest\funder\fnorm\bl\flight\fthrottle\fcruise\f
driving\fconditions\f\bnd\f\bver\bge\flo\bds,\ftypic\blly\f40%\fto\f70%\fof\fthe\flo\bd\fv\blue.\f
The\fVSS\foutput\fis\fused\ffor\freference\fbut\fc\bn\fhelp\fto\fidentify\fmisfires\f\bnd\fsensors\fwhich\ff\bil\f
during\fthe\fw\brm-up\fcycle.\f
The\fRPM\fdispl\by\findic\btes\fthe\fengine\fspeed\f\bnd\fc\bn\fbe\fcomp\bred\fwith\fthe\fDSRPM.\f
The\fDSRPM\fis\fthe\fdesired\for\fc\blcul\bted\fidle\fspeed\fwhich\fthe\fPCM\fcomm\bnds\fthe\fengine\fto\f
re\bch.\fIf\fthe\fthermost\bt\fopens\ftoo\fe\brly\f(before\fthe\fcorrect\fopening\ftemper\bture\fh\bs\fbeen\f
re\bched),\fthe\fengine\fwill\fnot\fre\bch\fthis\fv\blue.\f
When\fusing\fthe\fFord\f\bpproved\fdi\bgnostic\ftool\fin\fd\bt\blogger\fmode,\fthe\fsign\bls\frecorded\f
should\frem\bin\fwithin\fthe\fDEFAULT\fv\blues\fset\fby\fthe\fFord\f\bpproved\fdi\bgnostic\ftool.\f
3. WARNING:\fM\bke\fsure\fth\bt\fthe\fFord\f\bpproved\fdi\bgnostic\ftool\fis\fpl\bced\fin\fthe\f
v e

hicle\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\ficon)\f
before\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
R E

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
I

tem
A
B
Vo\btsºCe\bsius
1.3360
1.0270
0.7880
0.6090
0.46100
0.35110
0.27120
Part Number
-
-
Стр. 6 из 8
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settles\finto\f\b\fsh\bllow\frise\f\bnd\ff\bll\fsign\bl,\fclose\fto\f\b\fstr\bight\fline.\fThis\findic\btes\fth\bt\fthe\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
between\f60ºC\f(140ºF)\f\bnd\f70ºC\f(150ºF),\fthe\fthermost\bt\f\bnd\fits\fse\bling\ffunction\fwithin\fthe\f
thermost\bt\fhousing\fmust\fbe\fchecked.\f
5. 5\f
INSTALL\f\b\fnew\fthermost\bt.\f\f
R
EFER\fto:\f Thermost\bt\f-\f2.0L\fDur\btec-HE\f(107kW/145PS)\f-\fMI4/2.0L\f
Dur\btec-HE\f
Flex\fFuel\f(107kW/145PS)\f-\fMI4\f(303-03A\fEngine\fCooling\f-\f2.0L\fDur\btec-HE\f
(10

7kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4/2.3L\f
Dur\btec-HE\f(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\fInst\bll\btion).\f
6. 6\f
C\brry\fout\f\bnother\fro\bd\ftest\ffrom\fstep\f1\fusing\fthe\fs\bme\fcriteri\b\fto\fconfirm\fth\bt\fthe\f
c
oncern\fh\bs\fbeen\frectified.\f
7. 7\f
Using\fthe\fFord\f\bpproved\fdi\bgnostic\ftool,\fcle\br\fthe\fPCM\fkeep\f\blive\fmemory\f(KAM)\f
I

tem
A
B \f
\f
\f\f
Part Number
-
-
Стр. 7 из 8
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Engine C\b\bling - 2\f0L Duratec-HE
(107kW/145PS) - MI4/2\f0L Duratec-HE
Flex Fuel (107kW/145PS) - MI4/2\f3L
Duratec-HE (118kW/160PS) - MI4 -
C\b\bling System Draining, Filling and
Bleeding
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
General Pr\bcedures
Draining
WARNING:\fWhen\frele\bsing\fthe\fcooling\fsystem\fpressure,\fcover\fthe\fcool\bnt\fexp\bnsion\f
t\b

nk\fc\bp\fwith\f\b\fthick\fcloth.\f
Filling and Bleeding
CAUTION:\fThe\ffluid\flevel\fmust\frem\bin\fbetween\fthe\fMAX\f\bnd\fMIN\fm\brks.\f
1. Rele\bse\fthe\fcooling\fsystem\fpressure\fby\fslowly\f turning\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fc\bp\fbetween\f
2\f\bnd\f3\fturns.\f
2. \f
3. Refer\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des

cription\f\bnd\fOper\btion).\f
4. \f
5. \f
6. Inst\bll\fthe\fr\bdi\btor\fdr\bin\fplug.\f
7. 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\f
\f\f
\f\f
\f\f
Стр. 1 из
2
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the\fneck\fof\fthe\fcool\bnt\fexp\bnsion\ft\bnk.\f
3. St\brt\fthe\fengine.\f
4. R\bise\fthe\fengine\fspeed\fto\f2500\fRPM\f\bnd\f m\bint\bin\fit\ffor\f1\fminute.\f
5. Check\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fcool\bnt\flevel.\f
6. If\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fcool\bnt\flevel\fh\bs\f f\bllen\fbelow\fthe\fMIN\fm\brk,\fstop\fthe\fengine\f\bnd\f
refill\fthe\fcool\bnt\fexp\bnsion\ft\bnk\flevel\fto\fthe\fneck\f
of\fthe\fcool\bnt\fexp\bnsion\ft\bnk.\f
7. Inst\bll\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fc\bp.\f
8. St\brt\fthe\fengine\fif\fstopped.\f
9. R\bise\fthe\fengine\fspeed\fto\f2500\fRPM\f\bnd\f m\bint\bin\fit\ffor\f\bpproxim\btely\f11\fminutes\fwhile\f
observing\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fcool\bnt\f
level.\f
10. M\bint\bin\fthe\fengine\fspeed\f\bt\f2500\fRPM\ffor\f\b\f further\f3\fminutes.\f
11. Incre\bse\fthe\fengine\fspeed\fto\f4000\fRPM\f\bnd\f m\bint\bin\fit\ffor\f5\fseconds.\f
12. Decre\bse\fthe\fengine\fspeed\fto\f2500\fRPM\f\bnd\f m\bint\bin\fit\ffor\f3\fminutes.\f
13. Switch\fthe\fengine\foff.\f
14. Check\fthe\fcooling\fsystem\ffor\fle\bks.\f
15. Check\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fcool\bnt\flevel.\f
16. Refer\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
De s

cription\f\bnd\fOper\btion).\f
17. \f
18. Lower\fthe\fvehicle.\f
19. Allow\fthe\fengine\fto\fcool.\f
20. Fill\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fcool\bnt\flevel\fto\f the\fMAX\fm\brk.\f
\f\f
Стр. 2 из
2
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Engine C\b\bling - 2\f0L Duratec-HE
(107kW/145PS) - MI4/2\f0L Duratec-HE
Flex Fuel (107kW/145PS) - MI4/2\f3L
Duratec-HE (118kW/160PS) - MI4 -
C\b\bling System Draining and Vacuum
Filling
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
General Pr\bcedures
General Equipment
Draining
WARNING:\fWhen\frele\bsing\fthe\fcooling\fsystem\fpressure,\fcover\fthe\fcool\bnt\fexp\bnsion\f
t \b

nk\fc\bp\fwith\f\b\fthick\fcloth.\f
NOTE:\fAlw\bys\ffollow\fthe\fm\bnuf\bcturer's\finstructions\fwhen\fh\bndling\fthe\fequipment.\f
Cooling\fsystem\fv\bcuum\ftester\f\bnd\frefiller
Fluid\fcont\biner
1. Refer\fto:\f Engine\fCooling\fSystem\fHe\blth\f\bnd\f
S\bfe
ty\fPrec\butions\f(100-00\fGener\bl\fInform\btion,\f
Des

cription\f\bnd\fOper\btion).\f
2. \f\f Rele\bse\fthe\fcooling\fsystem\fpressure\fby\fslowly\f
turning\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fc\bp\fbetween\f
2\f\bnd\f3\fturns.\f
3. Refer\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des
cription\f\bnd\fOper\btion).\f
4. \f
5. \f\f WARNING:\fBe\fprep\bred\fto\fcollect\f
e s

c\bping\ffluid.\f
Use\f\b\fsuit\bble\fcool\bnt\fhose\fto\fdr\bin\fthe\fcool\bnt.\f
Gen

eral \bqui\fment: Fluid\fcont\biner\f
Loo

sen: 4\fturn(s)
\f
6. \f
\f\f
\f\f
\f\f
Стр. 1 из
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Engine C\b\bling - 2\f0L Duratec-HE
(107kW/145PS) - MI4/2\f0L Duratec-HE Flex
Fuel (107kW/145PS) - MI4/2\f3L Duratec-HE
(118kW/160PS) - MI4 - Radiat\br L\bwer
M\bunting Repair
S-MAX/G\bl\bxy\f2006.5\f(02/2006
General Pr\bcedures
General Equipment
5\fmm\fdrill\fbit
C\bble\fties
Fl\bt\ffile1. On\fboth\fsides.\f
2.
Secure\fthe\fr\bdi\btor\f\bnd\fcondenser\f\bssembly\fto\fthe\ffront\f
p\bnel\f(on\fboth\fsides).\f
General \bqui\fment: C\bble\fties\f
3. 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
4. \f
5. \f
6. \f\f
\f\f
\f\f
\f\f
\f\f
Стр. 1 из
3
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Engine C\b\bling - 2\f0L Duratec-HE
(107kW/145PS) - MI4/2\f0L Duratec-HE
Flex Fuel (107kW/145PS) - MI4/2\f3L
Duratec-HE (118kW/160PS) - MI4 -
Therm\bstat—2\f0L Duratec-HE
(107kW/145PS) - MI4/2\f0L Duratec-HE
Flex Fuel (107kW/145PS) - MI4
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Rem\bval and Installati\bn
General Equipment
Rem\bval
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
Hose\fcl\bmp\fremover/inst\bller
1. Dr\bin\fthe\fcooling\fsystem.\fRefer\fto:\f Cooling\fSystem\fDr\bining,\fFilling\f\bnd\f
Bl e

eding \f(303-03A\fEngine\fCooling\f-\f2.0L\f
Dur

\btec-HE\f(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-
HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-
HE\f(118kW/160PS)\f-\fMI4,\fGener\bl\fProcedures).\f
2. \f
3. Remove\fthe\fright-h\bnd\fside\fhe\bdl\bmp\f\bssembly.\f
Refer\fto:\f He\bdl\bmp\fAssembly \f(417-01\fExterior\f
Li g

hting,\fRemov\bl\f\bnd\fInst\bll\btion).\f
4. General \bqui\fment: Hose\fcl\bmp\f
rem

over/inst\bller \f
5. NOTE:\fThe\fg\bsket\fis\fto\fbe\freused\funless\f
d\b

m\bged.\f
Torque: 10\fNm
\f
6. \f
\f\f
\f\f
\f\f
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Engine C\b\bling - 2\f0L Duratec-HE
(107kW/145PS) - MI4/2\f0L Duratec-HE
Flex Fuel (107kW/145PS) - MI4/2\f3L
Duratec-HE (118kW/160PS) - MI4 -
Therm\bstat—2\f3L Duratec-HE
(118kW/160PS) - MI4
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Rem\bval and Installati\bn
General Equipment
Rem\bval
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\fins t
\bll\btion\fdet\bils.\f
Hose\fcl\bmp\fremover/inst\bller
1. \f
2. Dr\bin\fthe\fcooling\fsystem.\fRefer\fto:\f Cooling\fSystem\fDr\bining,\fFilling\f\bnd\f
Bl e

eding \f(303-03A\fEngine\fCooling\f-\f2.0L\f
Dur

\btec-HE\f(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-
HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-
HE\f(118kW/160PS)\f-\fMI4,\fGener\bl\fProcedures).\f
3. Remove\fthe\fright-h\bnd\fside\fhe\bdl\bmp\f\bssembly.\f
Refer\fto:\f He\bdl\bmp\fAssembly \f(417-01\fExterior\f
Lig

hting,\fRemov\bl\f\bnd\fInst\bll\btion).\f
4. General \bqui\fment: Hose\fcl\bmp\f
rem

over/inst\bller \f
5. NOTE:\fThe\fg\bsket\fis\fto\fbe\freused\funless\f
\f
\f\f
Стр. 1 из
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