2006 FORD S-MAX Service Repair Manual

audio automatic transmission fluid cabin filter infotainment ESP inoperative lumbar support

Page 641 of 4402

$FORD S-MAX 2006 Service Repair Manual \f\f\fescription Bolts\f-\fB\bl\bncer\fsh\bfts\f B\bl\bncer\fsh\bft\funit\f The\f2.3L\fDur\btec-HE\fh\bs\f\b\fmodul\br\fb\bl\bncer\fsh\bft\funit\fwith\ftwo\fb\bl\bncer\fsh\bfts.\fThe\f b\b l\bncer\f$

Page 642 of 4402

$FORD S-MAX 2006 Service Repair Manual Engine - \b.3L \furatec-HE (118kW/160PS) - MI4 - EngineS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f \fiagnosis and Testing Special Tool(s) Gen eral Equipment Materials Specification WSK-M2G349-$

Engine - \b.3L \furatec-HE (118kW/160PS)
- MI4 - EngineS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
\fiagnosis and Testing
Special Tool(s)
Gen

eral Equipment
Materials
Specification
WSK-M2G349-A7\f\f
1. 1.
Verify\fthe\fcustomer\fconcern.\f
2

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

. 3.
Resolve\f\bny\fobvious\fc\buses\ffor\f\b\fconcern\ffound\fduring\fthe\fvisu\bl\finspection\fbefore\f
c
\brrying\fout\f\bny\ffurther\ftests.\f
4. 4.
If\fthe\fconcern\fpersists,\fcheck\fthe\fsymptoms\f\bnd\fcontinue\fwith\fthe\fSymptom\f
C
h\brt.\f
Visual Inspection Chart
Symptom Chart
Symptom chart
Socket,\fSp\brk\fPlug\f
303-499\f
Use\f\b\fcompression\ftester
Name
Adhesive\f-\fLoctite\f243
Mechanica\bE\bectrica\b
Cool\bnt\fle\bks\f\f
Le\bking\foil.\f\f
Fuel\fle\bks\f\f
Visibly\fd\bm\bged\for\fworn\fp\brts\f\f
Loose\for\fmissing\fnuts\for\fbolts\fFuse(s)\f\f
Loose\for\fcorroded\fconnector(s)\f\f
Control\funit\f\f
D\bm\bged\for\fworn\fswitch(es)\f
\fymptomPossib\be \fourcesAction
Loss\fof\foilOil\fle\bks\fon\fcomponents\f
th\bt\f\bre\feither\fco\bted\fin\foil\f
themselves\for\fon\f
components\floc\bl\fto\fthem.\f
*CHECK\ffor\fevidence\fof\foil\fle\bks\fon\f
components.\fUse\f\bn\fultr\bviolet\f(UV)\fle\bk\f
tester\fif\f\bn\foil\fle\bk\fis\fnot\fevident.\f
INSTALL\fnew\fg\bskets\for\fcomponents\f\bs\f
required.\f
*
Intern\bl\for\fextern\bl\fle\bk\f\bt\f
the\foil\fcooler.\f
*
CHECK\fwhether\fthere\fis\f\bn\foil\ffilm\fon\fthe\f
cool\bnt\fin\fthe\fcool\bnt\fexp\bnsion\ft\bnk.\f
INSTALL\f\b\fnew\foil\fcooler\for\foil\fcooler\f
se\bl.\f
*
Le\bk\fon\fthe\fcr\bnksh\bft\foil\f
se\bl\f
*INSTALL\f\b\fnew\fcr\bnksh\bft\foil\fse\bl.\fREFER\f
to:\f
Kurbelwellendichtring\fvorn\f(303-01\f
Motor\f-\f2.0L\fDur\btec-HE\f(MI4),\f
Remov\bl\f\bnd\fInst\bll\btion),\f
Kurbelwellendichtring\fhinten\f(303-
01\f
Motor\f-\f2.3L\fDur\btec-HE\f(MI4),\f
Remov\bl\f\bnd\fInst\bll\btion).\f
*
\f
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Page 643 of 4402

$FORD S-MAX 2006 Service Repair Manual Le\bks\ffrom\foil\fc\brrying\f components\for\fb\bsic\f engine.\f *CHECK\ffor\fcr\bcks\fin\foil-c\brrying\f components\fof\fthe\fb\bsic\fengine\fby\fme\bns\f of\f\b\fUV\fle\bk\ftest.\fINSTALL\fnew\f c$

Le\bks\ffrom\foil\fc\brrying\f
components\for\fb\bsic\f
engine.\f
*CHECK\ffor\fcr\bcks\fin\foil-c\brrying\f
components\fof\fthe\fb\bsic\fengine\fby\fme\bns\f
of\f\b\fUV\fle\bk\ftest.\fINSTALL\fnew\f
components\for\fse\bls\f\bs\fnecess\bry.\f
*
Oil\fConsumptionUse\fof\fthe\fwrong\ftype\fof\f
engine\foil.\f
*DETERMINE\fthe\fl\bst\ftype\fof\fengine\foil\f
used\f\bnd\fcomp\bre\fwith\fthe\fspecific\btion.\f
Ch\bnge\fthe\fengine\foil\fto\fthe\fspecific\btion.\f
\f
REFER\fto:\fSpezifik\btionen\f(303-01\fMotor\f
-\f2.3L\fDur\btec-HE\f(MI4),\fSpecific\btions).
\f
*
F\bulty\fpositive\fcr\bnkc\bse\f
ventil\btion\f(PCV)\fsystem.\f Hoses\for\fventil\btion\for\f
bre\bther\fv\blves\f\bre\f
blocked.\fThis\fc\buses\f
excessive\fpressure\fin\fthe\f
cr\bnkc\bse\fwhich\fc\buses\foil\f
to\fenter\fthe\fcombustion\f
ch\bmber.\f
The\fPCV\foil\fsep\br\btor\fis\f
d\bm\bged.\fOil\fc\bn\fenter\fthe\f
combustion\fch\bmber\f
through\fthe\fint\bke\f
m\bnifold.\f
*
-
-
CHECK\fif\fthe\fPCV\fsystem\fis\foper\bting\f
correctly\f\bnd\frep\bir\f\bs\fnecess\bry.\f
*
D\bm\bged\fg\bskets\for\f
m\bting\fsurf\bces.\f D\bm\bged\fcylinder\fhe\bd\f
g\bsket\for\fw\brped\fm\bting\f
f\bces.\f Worn\fv\blve\fstem\foil\fse\bls.\f
Engine\foil\fc\bn\fenter\fthe\f
combustion\fch\bmber\f
between\fthe\fv\blve\fstem\f
\bnd\fthe\fv\blve\fguide.\f
*
-
-CHECK\fthe\fg\bskets\f\bnd\fm\bting\fsurf\bces\f
for\fd\bm\bge.\f Remove\fthe\fcylinder\fhe\bd.\fCHECK\fthe\f
condition\fof\fthe\fm\bting\ff\bces\f\bnd\fthe\f
cylinder\fhe\bd\fg\bsket\f\bnd\fCHECK\fthe\f
evenness\fof\fthe\fcylinder\fhe\bd\f\bnd\f
cylinder\fblock\fm\bting\ff\bces.\f INSTALL\fnew\fv\blve\fstem\foil\fse\bls.\f\f
REFER\fto:\fVentilsch\bftdichtringe\f(303-01\f
Motor\f-\f2.0L\fDur\btec-HE\f(MI4),\fRemov\bl\f
\bnd\fInst\bll\btion).\f
*
-
-
Piston\fring\for\fcylinder\fliner\f
we\br.\f
*
INSTALL\f\b\fnew\fcylinder\fblock\fif\f
necess\bry.\f
*
D\bm\bged\fcylinder\fliners\for\f
excessive\fcle\br\bnce\fof\f
engine\fcomponents.\f
Pistons\f
Piston\frings\f(cle\br\bnce\fin\f
groove\f\bnd\fend\fg\bp).\f
Cylinder\fliners\f
*
-
-
-
CHECK\fthe\frunning\fsurf\bces\f\bnd\f
cle\br\bnces\fof\fthe\findividu\bl\fengine\f
components.\fINSTALL\f\b\fnew\fcylinder\f
block\fif\fnecess\bry.\f
*
Cool\bnt\f
consumptionCooling\fsystem\f
components.\f
*Check\fthe\fcooling\fsystem\fcomponents.\f\f
REFER\fto:\fKühlsystem\f(303-03\f
Kühlsystem\f-\f2.0L\fDur\btec-
HE\f(MI4)/2.3L\f
Dur\btec-HE\f(MI4),\fDi\bgnosis\f\bnd\f
Testing).\f
*
Oil\fcooler\f
*INSTALL\f\b\fnew\foil\fcooler.\f
*
D\bm\bged\fg\bskets\for\f
w\brped\fm\bting\ff\bces.\f
*CHECK\fthe\fcylinder\fhe\bd\fg\bsket\ffor\f
d\bm\bge.\fCHECK\fthe\fcylinder\fhe\bd\ffor\f
distortion.\f
*
Cr\bcks\for\ffr\bctures\fin\f
engine\fcomponents\f
surrounded\fby\fcool\bnt,\f
such\f\bs\fcylinder\fliners\f\bnd\f
cylinder\fhe\bd\fcombustion\f
ch\bmber.\f
*DETERMINE\fthe\fd\bm\bged\fengine\f
component(s)\f\bnd\finst\bll\fnew\fcomponent
(s)\f\bs\fnecess\bry.\f
*
Engine\fwill\fnot\fB\bttery\for\fb\bttery\fc\bble\f
*CHECK\fthe\fb\bttery,\fb\bttery\fholder\f\bnd\f
*
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Page 644 of 4402

$FORD S-MAX 2006 Service Repair Manual cr\bnkb\bttery\fc\bble(s).\f\f REFER\fto:\fB\btterie\f(414-01\fB\btterie,\f Befestigung\fund\fB\btteriek\bbel,\fRemov\bl\f \bnd\fInst\bll\btion).\f St\brter\fmotor\for\fc\bbles.\f *CHECK\fthe\fst\brti$

cr\bnkb\bttery\fc\bble(s).\f\f
REFER\fto:\fB\btterie\f(414-01\fB\btterie,\f
Befestigung\fund\fB\btteriek\bbel,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
St\brter\fmotor\for\fc\bbles.\f
*CHECK\fthe\fst\brting\fsystem.\f\f
REFER\fto:\fAnl\bsssystem\f(303-06\f
Anl\bsssystem\f-\f2.0L\fDur\btorq-TDCi\f(DW)\f
Diesel,\fDi\bgnosis\f\bnd\fTesting).\f
*
Engine\fcr\bnks\fbut\f
will\fnot\fst\brt.Fuel\ft\bnk\fis\fempty.\f
*CHECK\fthe\ffuel\flevel.\f
*
Int\bke\fAir\fDistribution\f\bnd\f
Filtering\f
*CHECK\fthe\fint\bke\f\bir\fsystem.\f
*
Engine\fm\bn\bgement\f
*CHECK\fthe\fengine\fm\bn\bgement\fsystem.\f
*
Ignition\fsystem\f
*CHECK\fthe\fignition\fsystem.\f
*
Incorrect\fv\blve\ftiming.\f
*CHECK\f\bnd\f\bdjust\fv\blve\ftiming.\f\f
REFER\fto:\fVentilspiel\feinstellen\f(303-01\f
Motor\f-\f2.3L\fDur\btec-HE\f(MI4),\fGener\bl\f
Procedures).\f
*
Timing\fch\bin\for\ftiming\f
ch\bin\fsprockets\fd\bm\bged\f
or\fbroken\f
*CHECK\fthe\ftiming\fch\bin\f\bnd\ftiming\fch\bin\f
sprockets.\fINSTALL\fnew\fcomponents\f\bs\f
necess\bry.\f\f
REFER\fto:\fSteuerkette\f(303-01\fMotor\f-\f
2.3L\fDur\btec-HE\f(MI4),\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
*
Very\fpoor\fpower\f
output\for\ffuel\f
consumption\ftoo\f
high\for\fengine\f
running\froughFuel\fsystem\f
*CHECK\fthe\ffuel\fsystem.\f
*
Int\bke\fAir\fDistribution\f\bnd\f
Filtering\f
*CHECK\fthe\fint\bke\f\bir\fsystem.\f
*
Restricted\fexh\bust\fsystem.\f*CHECK\fthe\fexh\bust\fsystem.\f\f
REFER\fto:\fAuspuffsystem\f-\f2.3L\fDur\btec-
HE\f(MI4)\f(309-00\fAuspuffsystem\f-\f
Allgemeine\fInform\btionen\f-\f2.0L\fDur\btec-
HE\f(MI4)/2.3L\fDur\btec-HE\f(MI4),\f
Description\f\bnd\fOper\btion).\f
*
Engine\fm\bn\bgement\f
*CHECK\fthe\fengine\fm\bn\bgement\fsystem.\f
*
Ignition\fsystem\fis\ff\bulty\f
*CHECK\fthe\fignition\fsystem.\f
*
Incorrect\fv\blve\ftiming,\f
timing\fch\bin\for\ftiming\f
ch\bin\fsprockets\fd\bm\bged\f
*CHECK\f\bnd\f\bdjust\fv\blve\ftiming.\fINSTALL\f
new\fcomponents\f\bs\fnecess\bry.\fREFER\fto:\f
(303-01\fMotor\f-\f2.3L\fDur\btec-HE\f(MI4))\f
Ventilspiel\feinstellen\f(Gener\bl\f
Procedures),\f
Steuerkette\f(Remov\bl\f\bnd\f
Inst\bll\btion).\f
*
Incorrect\fignition\ftiming\f
*CHECK\fthe\felectronic\fengine\fcontrols.\f
*
Noisy\frunningEngine\f\buxili\bry\f
components\floose\for\f
d\bm\bged.\f
*CHECK\fengine\f\buxili\bry\fcomponents\ffor\f
d\bm\bge\for\flooseness.\fCHECK\f\bnd\f\bdjust\f
v\blve\ftiming.\fINSTALL\fnew\fcomponents\f
\bs\fnecess\bry.\fREFER\fto:\f(303-01\fMotor\f-\f
2.3L\fDur\btec-HE\f(MI4))\f Ventilspiel\feinstellen\f(Gener\bl\f
Procedures),\f
Steuerkette\f(Remov\bl\f\bnd\f
Inst\bll\btion).\f
*
Noisy\frunning,\f
misfiring,\fb\bckfiring\f
or\fknocking
Incorrect\ffuel\f
*DETERMINE\fwhich\ftype\fof\ffuel\fw\bs\fl\bst\f
put\fin\fthe\ft\bnk\f(note\fthe\fcountry\fspecific\f
fuel\fspecific\btions).\f
*
W\bter\fin\ffuel\for\ffuel\f
cont\bmin\bted.\f
*CHECK\fthe\ffuel\fsystem\ffor\fw\bter\for\fother\f
cont\bmin\btion.\f
*
Incorrect\fv\blve\ftiming,\f
timing\fch\bin\for\ftiming\f
ch\bin\fsprockets\fd\bm\bged\f
*CHECK\f\bnd\f\bdjust\fv\blve\ftiming.\fINSTALL\f
new\fcomponents\f\bs\fnecess\bry.\fREFER\fto:\f
(303-01\fMotor\f-\f2.3L\fDur\btec-HE\f(MI4))\f
*
Стр. 3 из
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Page 645 of 4402

$FORD S-MAX 2006 Service Repair Manual Oil Leaks - Engine NOTE:\fBefore\frenewing\fg\bskets\for\foil\fse\bls,\fm\bke\fsure\f th\bt\fthe\fc\buse\fof\fthe\ff\bult\fis\f cle\brly\fest\bblished.\f If\fthe\foil\fle\bk\fc\bnnot\fbe\fidentified\$

Oil Leaks - Engine
NOTE:\fBefore\frenewing\fg\bskets\for\foil\fse\bls,\fm\bke\fsure\f
th\bt\fthe\fc\buse\fof\fthe\ff\bult\fis\f
cle\brly\fest\bblished.\f
If\fthe\foil\fle\bk\fc\bnnot\fbe\fidentified\fcle\brly\fby\f\b\fvis u
\bl\finspection,\fc\brry\fout\f\bn\fUV\ftest:\f
Ultraviolet (UV) Testing
1. 1.
Cle\bn\fthe\fengine\f\bnd\ftr\bnsmission\fwith\f\b\fsuit\bble\fcle\bning\ffluid.\f
2

. \b.
Pour\fthe\fUV-test\ffluid\fin\f\bccord\bnce\fwith\fthe\fqu\bntity\fspecified\fby\fthe\f
m
\bnuf\bcturer\fthrough\fthe\foil\ffiller\fneck\finto\fthe\fengine\f\bnd\finst\bll\fthe\foil\ffiller\fc\bp.\f
WARNING:\fVehicles\fwith\fm\bnu\bl\ftr\bns\bxle,\fshift\fthe\ftr\b
ns\bxle\finto\fNeutr\bl.\fF\bilure\fto\f
observe\fthis\finstruction\fc\bn\fle\bd\fto\finjuries.\f
3. 3.
St\brt\fthe\fengine\f\bnd\flet\fit\frun\ffor\f\bbout\ffive\fminutes.\f
4

. 4.
Stop\fthe\fengine.\f
N

OTE:\fIf\fno\fle\bk\fis\ffound,\fperform\f\b\fro\bd\ftest.\fDrive\f
the\fvehicle\funder\fdifferent\flo\bds\f\bnd\f
then\fre-check\fthe\fengine\ffor\fle\bks.\f
5. 5.
Check\fthe\fengine\ffor\foil\fle\bks\fusing\f\b\fsuit\bble\fUV\fl\bmp.\f
6

. 6.
Rectify\f\bny\fle\bks\ffound\f\bnd\fcheck\fthe\fengine\ffor\foil\fle\bks.\f
M

easure the compression pressure
Ventilspiel\feinstellen\f(Gener\bl\f
Procedures),\f
Steuerkette\f(Remov\bl\f\bnd\f
Inst\bll\btion).\f
Noisy\frunning\for\f
v\blve\ftr\bin\fnoiseV\blve\fcle\br\bnce\ftoo\fl\brge\f
due\fto\ff\bulty\fv\blve\ft\bppets\f
or\fworn\fv\blve\ftr\bin\f
components.\f
*ADJUST\fv\blve\fcle\br\bnce.\f\f
REFER\fto:\fVentilspiel\feinstellen\f(303-01\f
Motor\f-\f2.3L\fDur\btec-HE\f(MI4),\fGener\bl\f
Procedures).\f
*
Timing\fch\bin\fd\bm\bged.\f
*INSTALL\f\b\fnew\ftiming\fch\bin.\f\f
REFER\fto:\fSteuerkette\f(303-01\fMotor\f-\f
2.3L\fDur\btec-HE\f(MI4),\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
*
Timing\fch\bin\fincorrectly\f
tensioned\f
*CHECK\fthe\ftiming\fch\bin\ftension.\fINSTALL\f
\b\fnew\ftiming\fch\bin\fif\frequired.\f\f
REFER\fto:\fSteuerkette\f(303-01\fMotor\f-\f
2.3L\fDur\btec-HE\f(MI4),\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
*
Noisy\frunning\for\f
engine\fnoiseEngine\fcomponents\f
Pistons\f
Piston\frings\f
Connecting\frod\fbig\fend,\f
m\bin\fbe\bring\for\fthrust\f
be\bring\fjourn\bls\f Connecting\frods\fbent\for\f
d\bm\bged.\f
*
-
-
-
-CHECK\fthe\fengine\fcomponents\ffor\fwe\br\f
or\fd\bm\bge.\fM\bke\fsure\f\bll\fcomponents\f\bre\f
within\fspecific\btion.\fINSTALL\f\b\fnew\f
cylinder\fblock\fif\fnecess\bry.\f\f
REFER\fto:\fSpezifik\btionen\f(303-01\fMotor\f
-\f2.3L\fDur\btec-HE\f(MI4),\fSpecific\btions).
\f
*
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Page 646 of 4402

$FORD S-MAX 2006 Service Repair Manual 1.1. Remove\fthe\fcentr\bl\fjunction\fbox\fcover.\f 2 . \b. Det\bch\fthe\fcentr\bl\fjunction\fbox\f(CJB).\f 3 . 3. Open\fthe\fCJB\f\bnd\fremove\ffuse\f23\f-\ffuel\fpump\frel\by.\f N OTE:\fThe\fen$

Page 647 of 4402

$FORD S-MAX 2006 Service Repair Manual 6.6. Disconnect\fthe\fignition\fcoil-on-plug\felectric\bl\fconnectors.\f 7 . 7. Remove\fthe\fignition\fcoil-on-plug\f 8 . 8. Remove\fthe\fsp\brk\fplugs\fusing\fthe\fspeci\bl\ftool.\f N OTE:\fOper$

Page 648 of 4402

$FORD S-MAX 2006 Service Repair Manual 10.10. Inst\bll\fthe\fsp\brk\fplugs\fusing\fthe\fspeci\bl\ftool.\f 1 1. 11. Inst\bll\fthe\fignition\fcoil-on-plug.\f 1 2. 1\b. Connect\fthe\fignition\fcoil-on-plug\felectric\bl\fconnectors.\f 1 3$

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dashboard bolt pattern differential fuel consumption sport mode cabin filter