2006 FORD S-MAX Ignition

Turn\fthe\fignition\fkey\fto\fposition\fII\f\bnd\fw\bit\ffor\f
one\fminute\fto\finiti\blize\fthe\fthrottle\fbody.\f\f
3. Turn\fthe\fignition\fkey\fto\fthe\fOFF\fposition.\f
Стр. 2 из 2
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G896037&gui...procarmanuals.com
http://vnx.su

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\f
Wiring\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
*
Стр. 1 из 13
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G842047&gui...procarmanuals.com
http://vnx.su

the\ffuel\finjectors\for\fINSTALL\f\b\fnew\f
set\fof\ffuel\finjectors\f\bs\frequired\fonly\f
\bfter\fthe\fchecks\fh\bve\fbeen\fc\brried\f
out.\f
CKP\fsensor.\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
*
Knock\fsensor\f
(KS).\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
*
FRP\fsensor.\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\fstumblingEngine\fignition.\f
*C\brry\fout\f\bn\fignition\fsystem\f
di\bgnosis\fusing\fthe\fFord\f\bpproved\f
di\bgnostic\ftool.\f
*
Fuel\finjectors.\f
*INSPECT\fthe\ffuel\finjectors.\fCLEAN\f
the\ffuel\finjectors\for\fINSTALL\f\b\fnew\f
set\fof\ffuel\finjectors\f\bs\frequired\fonly\f
\bfter\fthe\fchecks\fh\bve\fbeen\fc\brried\f
out.\f
*
Low\ffuel\fsystem\f
pressure.\f
*Check\fthe\ffuel\fsystem\fpressure.\f\f
REFER\fto:\f Fuel\fSystem\fPressure\f
Che

ck\f-
\f2.5L\fDur\btec\f(162kW/220PS)\f
-\fVI5 \f(310-00\fFuel\fSystem\f-\fGener\bl\f
Inf
orm\btion,\fGener\bl\fProcedures).\f
*
FRP\fsensor.\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\fl\bcks\fpowerEngine\fignition.\f
*C\brry\fout\f\bn\fignition\fsystem\f
di\bgnosis\fusing\fthe\fFord\f\bpproved\f
di\bgnostic\ftool.\f
*
Br\bkes\fbinding.\f
*CHECK\fthe\fbr\bking\fsystem.\f\f
REFER\fto:\f Anti-Lock\fControl\f(206-
09 A

\fAnti-Lock\fControl,\fDi\bgnosis\f\bnd\f
Testing).\f
*
Vehicle\f
overlo\bded,\for\f
excessive\fwind\f
resist\bnce\f(roof\f
r\bcks,\ftowing\f
etc).\f
*ADVISE\fthe\fcustomer\f\bbout\fthe\f
effects\fof\foverlo\bding\fthe\fvehicle\f\bnd\f
wind\fresist\bnce\fon\fthe\ffuel\f
consumption.\f
*
Air\fcle\bner\f
element\fblocked.\f
*INSTALL\f\b\fnew\f\bir\fcle\bner\felement\f
\bs\fnecess\bry.\f
*
Low\ffuel\fsystem\f
pressure.\f
*Check\fthe\ffuel\fsystem\fpressure.\f\f
REFER\fto:\f Fuel\fSystem\fPressure\f
Che

ck\f-
\f2.5L\fDur\btec\f(162kW/220PS)\f
-\fVI5 \f(310-00\fFuel\fSystem\f-\fGener\bl\f
Inf
orm\btion,\fGener\bl\fProcedures).\f
*
Kinked\for\f
restricted\ffuel\f
lines.\f
*INSPECT\fthe\ffuel\flines.\fINSTALL\fnew\f
components\f\bs\fnecess\bry.\fTEST\fthe\f
system\ffor\fnorm\bl\foper\btion.\f\f
*
Incorrect\for\f
cont\bmin\bted\f
fuel.\f
*CHECK\ffor\fsigns\fof\fcont\bmin\btion\f
such\f\bs\fstr\bnge\fodors\ffrom\fthe\ffuel\f
t\bnk.\f If\fcont\bmin\bted\ffuel\fis\ffound,\fDRAIN\f
the\fcomplete\ffuel\fsystem.\fFLUSH\fthe\f
fuel\fsystem\fthrough\fwith\fcle\bn\f
g\bsoline.\fINSTALL\f\b\fnew\ffuel\ffilter.\f\f
*
*
Стр. 5 из
13
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G842047&gui...procarmanuals.com
http://vnx.su

(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
Positive\f
cr\bnkc\bse\f
ventil\btion\f(PCV)\f
system.\f
*INSPECT\ffor\fvisible\fsigns\fof\fd\bm\bge\f
or\fblock\bge.\fCLEAN,\fREPAIR\for\f
INSTALL\fnew\fp\brts\f\bs\fnecess\bry.\f
*
Worn\for\fd\bm\bged\f
v\blve\fguide(s),\f
piston\fring(s),\f
cylinder\fbore(s),\f
cylinder\fhe\bd\for\f
g\bsket.\f
*
REMOVE\fthe\fcylinder\fhe\bd.\fINSPECT\f
the\fcylinder\fhe\bd,\fpistons\f\bnd\f
cylinder\fbores\ffor\fsigns\fof\fwe\br\for\f
d\bm\bge.\f\f
REFER\fto:\fCylinder\fHe\bd\f(303-01\f
Engine\f-
\f2.5L\fDur\btec\f(VI5),\fRemov\bl\f
\bnd\fInst\bll\btion).\f
*
White\fsmokeIncorrect\for\f
cont\bmin\bted\f
fuel.\f
*CHECK\ffor\fsigns\fof\fcont\bmin\btion\f
such\f\bs\fstr\bnge\fodors\ffrom\fthe\ffuel\f
t\bnk.\f If\fcont\bmin\bted\ffuel\fis\ffound,\fDRAIN\f
the\fcomplete\ffuel\fsystem.\fFLUSH\fthe\f
fuel\fsystem\fthrough\fwith\fcle\bn\f
g\bsoline.\fINSTALL\f\b\fnew\ffuel\ffilter.\f\f
REFER\fto:\f Fuel\fFilter\f(310-01A\fFuel\f
T\bnk

\f\bnd\fLines\f-\f2.0L\fEcoBoost\fSCTi\f
(149kW/203PS)\f-\fMI4/2.0L\fDur\btec-
HE\f(107kW/145PS)\f-\fMI4/2.0L\f
Dur\btec-
HE\fFlex\fFuel\f(107kW/145PS)\f
-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4/2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f INSPECT\fthe\ffuel\finjectors.\fCLEAN\f
the\ffuel\finjectors\for\fINSTALL\f\b\fnew\f
set\fof\ffuel\finjectors\f\bs\frequired\fonly\f
\bfter\fthe\fchecks\fh\bve\fbeen\fc\brried\f
out.\f INSTALL\f\b\fnew\ffuel\fr\bil.\f\f
REFER\fto:\f Fuel\fR\bil\f(303-04C\fFuel\f
Ch \br

ging\f\bnd\fControls\f-
\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
*
*
*
*
Cool\bnt\fin\fthe\f
combustion\f
ch\bmber.\f
*CARRY\fOUT\f\b\fcooling\fsystem\f
pressure\ftest.\f\f
REFER\fto:\fEngine\fCooling\f(303-03\f
Engine\fCooling\f-\f2.5L\fDur\btec\f(VI5),\f
Di\bgnosis\f\bnd\fTesting).\f
REMOVE\fthe\fcylinder\fhe\bd.\fINSPECT\f
the\fcylinder\fhe\bd,\fcylinder\fhe\bd\f
g\bsket\f\bnd\fcylinder\fbores\ffor\fwe\br\for\f
d\bm\bge.\f\f
REFER\fto:\fCylinder\fHe\bd\f(303-01\f
Engine\f-
\f2.5L\fDur\btec\f(VI5),\fRemov\bl\f
\bnd\fInst\bll\btion).\f
*
Engine\fmisfireEngine\fignition.\f
*C\brry\fout\f\bn\fignition\fsystem\f
di\bgnosis\fusing\fthe\fFord\f\bpproved\f
di\bgnostic\ftool.\f
*
Incorrect\for\f
cont\bmin\bted\f
fuel.\f
*CHECK\ffor\fsigns\fof\fcont\bmin\btion\f
such\f\bs\fstr\bnge\fodors\ffrom\fthe\ffuel\f
t\bnk.\f If\fcont\bmin\bted\ffuel\fis\ffound,\fDRAIN\f
the\fcomplete\ffuel\fsystem.\fFLUSH\fthe\f
fuel\fsystem\fthrough\fwith\fcle\bn\f
*
*
Стр. 9 из
13
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G842047&gui...procarmanuals.com
http://vnx.su

Fuel Ch\brgi\fg \b\fd Co\ftrols - 2.5L Dur\btec
(162kW/220PS) - VI5 - Throttle BodyS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Remov\bl \b\fd I\fst\bll\btio\f
Remov\bl
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
I\fst\bll\btio\f 1. Remove\fthe\fright-h\bnd\fside\fhe\bdl\bmp\f\bssembly.\f
Re
fer\fto:\f He\bdl\bmp\fAssembly \f(417-01\fExterior\f
Lig

hting,\fRemov\bl\f\bnd\fInst\bll\btion).\f
2. \f
3. NOTE:\fThe\fg\bsket\fis\fto\fbe\freused\funless\f
d
\b

m\bged.\f
Torque:\b 10\fNm
\f
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
2. NOTE:\fM\bke\fsure\fth\bt\fthe\fped\bls\frem\bin\fin\f
t
h

e\frest\fposition.\f
Turn\fthe\fignition\fkey\fto\fposition\fII\f\bnd\fw\bit\ffor\f
on
e\fminute\fto\finiti\blize\fthe\fthrottle\fbody.\f\f
3. Turn\fthe\fignition\fkey\fto\fthe\fOFF\fposition.\f
\f\f
\f\f
Стр. 1 из
1
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G837191&gui...procarmanuals.com
http://vnx.su

\f\fDescriptio\f
M\bnifold\f\bbsolute\fpressure\f(MAP)\fsensor\f
Int\bke\f\bir\ftemper\bture\f(IAT)\fsensor\f
Int\bke\f\bir\fshutoff\fthrottle\f
The\fint\bke\f\bir\fshutoff\fthrottle\fis\floc\bted\fon\fthe\fint\bke\f\bir\fside\fof\fthe\fint\bke\fm\bnifold.\f
Th

e\fint\bke\f\bir\fshutoff\fthrottle\fis\felectronic\blly\fcontrolled\fby\fthe\fPCM\f\bnd\fis\fused\fto\fcontrol\f
vehicle\fch\br\bcteristics\fwhile\fthe\fengine\fis\fswitched\foff.\fThis\fwill\f\blso\fprevent\fthe\fengine\f
being\fcontinuously\ffuelled\fby\fthe\fengine\foil\f\bfter\fthe\fignition\fkey\fh\bs\fbeen\fturned\fto\f
position\f0.\fThis\fis\f\bchieved\fby\freducing\fthe\fint\bke\f\bir\fthrough\fthe\fint\bke\fm\bnifold.\f Item
1
2
3 P\brt Number
-
-
-
Стр. 5 из 5
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G546693&gui...procarmanuals.com
http://vnx.su

12. Oper\bte\fthe\fh\bnd\fpressure\fpump\f\bt\fle\bst\f30\ftimes.\f
13.
CAUTION:\fThe\fst\brter\fmotor\foper\btion\fmust\fnot\f
exceed\f10\fseconds\f\bt\f\b\ftime.\fAfter\f10\fseconds\fturn\fthe\f
ignition\fswitch\fto\fposition\f0\f\bnd\f\bllow\fthe\fst\brter\fmotor\fto\f
cool\ffor\f30\fseconds\fbefore\foper\bting\fthe\fst\brter\fmotor\f
\bg\bin.\f
St\brt\fthe\fengine\f\bnd\f\bllow\fto\fidle\funtil\fit\fre\bches\fnorm\bl\f
oper\bting\ftemper\bture\f
14. Stop\fthe\fengine.\f
15.Special\bTool(\f):\b 310-110A\f
16.

Refer\fto:\f Quick\fRele\bse\fCoupling \f(310-
00\fFuel\fSystem\f
Gener\bl\fInform\btion,\fGener\bl\fProcedures).\f
17. Remove\fthe\flint-free\fm\bteri\bl.\f
18. Torque:\b 9\fNm
\f
\f\f
\f\f
\f\f
\f\f
Стр. 6 из
6
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G543704&gui...procarmanuals.com
http://vnx.su

Pi\fpoi\ft Tests
Poor\fengine\f
perform\bnce\fW\bsteg\bte\fcontrol\f
v\blve\f\bctu\btor\frod.\f V\bcuum\fline(s).\f
*
*GO\fto\fPinpoint\fTest\f
C.\f\f
*
Ch\brge\f\bir\fcooler\f
pipes\f Ch\brge\f\bir\fcooler\f
r\bdi\btor\f Ch\brge\f\bir\fcooler\f
w\bter\fpump\f Ch\brge\f\bir\fcooler\f
*
*
*
*REFER\fto\f
in\fthis\fsection. \f
*
Air\fcle\bner\fint\bke\f
pipe\f
*CHECK\fthe\f\bir\fcle\bner\fint\bke\fpipe\ffor\f
obstruction.\fREPAIR\f\bs\fnecess\bry.\f
*
Turboch\brger\fboost\f
pressure\f
*GO\fto\fPinpoint\fTest\f
C.\f\f
*
Un\buthorized\f
\bdjustment\fof\fthe\f
w\bsteg\bte\fcontrol\f
v\blve\f\bctu\btor\frod.\f
*The\fturboch\brger\fboost\fpressure\fis\ff\bctory\fset\f
\bnd\fmust\fnot\fbe\f\bdjusted.\fCHECK\fthe\fp\bint\fse\bl\f
on\fthe\fw\bsteg\bte\fcontrol\fv\blve\funit\f\bctu\btor\frod\f
h\bs\fnot\fbeen\fbroken.\fIf\fthe\fp\bint\fse\bl\fh\bs\fbeen\f
broken,\fINSTALL\f\b\fnew\fturboch\brger.\f\f
REFER\fto:\f Turboch\brger \f(303-
04H\fFuel\fCh\brging\f
\bnd\fControls\f-\fTurboch\brger\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
*
Ignition\fsystem.\f
*CHECK\fthe\fignition\fsystem.\f\f
REFER\fto:\f Fuel\fCh\brging\f\bnd\fControls \f(303-04C\f
Fue

l\fCh\brging\f\bnd\fControls\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fDi\bgnosis\f\bnd\fTesting).\f
*
Fuel\fch\brging\fsystem.\f*CHECK\fthe\ffuel\fch\brging\fsystem.\f\f
REFER\fto:\f Fuel\fCh\brging\f\bnd\fControls \f(303-04C\f
Fue

l\fCh\brging\f\bnd\fControls\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fDi\bgnosis\f\bnd\fTesting).\f
*
PINPOINT TEST A : BLUE SMOKE WITH EXCESSIVE TURBOCHARGER NOISE
TEST CON\fITIONS\fETAILS/RESULTS/ACTIONS
A1: INSPECT THE TURBOCHARGER ROTOR VANES FOR DAMAGE
Remove\fthe\f\bir\fcle\bner.\f\f
REFER\fto:\f
Air\fCle\bner \f(303-12C\fInt\bke\fAir\f
Dis

tribution\f\bnd\fFiltering\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\fInst\bll\btion).\f
1
Inspect\fthe\fturboch\brger\frotor\fv\bnes\ffor\fd\bm\bge.\f2
Is\fthere\fvisible\fd\bm\bge\fto\fthe\frotor\fv\bnes?\f
Yes GO\fto\fA2.\f\f
No
GO

\fto\fA3.\f\f
A2: CHECK FOR FOREIGN MATERIAL IN THE INTAKE AIR SYSTEM COMPONENTS
Check\fthe\fint\bke\f\bir\fsystem\fcomponents\ffor\fsigns\f1
\f\f
Стр. 3 из 8
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G510108&gui...procarmanuals.com
http://vnx.su