Ford employee help required

[dfp454]

Anybody work in the service area

Need a copy of the TSB 44/2008

Friend of mine owns a Ford S-Max and he changed the intercooler hose with a new item which no-longer has the hole for the sensor.

Cat says against part number:1521483 refer to TSB 44/2008 Less IAT Hole; PCM Calibration Required, Please Refer To Ford IDS; S-Max/Galaxy 2006-

Car is running bad and dealers are doing nothing about getting his car re-calibrated.

Does anyone have any way I can get my mate to move forward with Ford

Many Thanks

[grcossie]

TECHNICAL SERVICE BULLETIN	No.44/2008 30 July 2008
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© 2008 Ford Motor Company All rights reserved. This bulletin represents technical service information only. Without exception all gratis repairs and replacements are subject to the individual warranty and policy procedures of the supervisory Ford Company. The illustrations, technical information, data and descriptive text in this issue, to the best of our knowledge, were correct at the time of publication. Loss of power and unusual engine noise Model: S-MAX/Galaxy 2006.5 (03/2006–12/2014) Build Date: Up to 09/2007 Build Code: Up to 7J Assembly Plant: Genk Engine: 1.8L Duratorq-TDCi (Lynx) Diesel Mondeo 2007.5 (02/2007–09/2014) Build Date: Up to 09/2007 Build Code: Up to 7J Assembly Plant: Genk Engine: 1.8L Duratorq-TDCi (Lynx) Diesel All 303-01D Summary Should a customer express concern that the vehicle has severe loss of power and unusual engine noise, one probable cause is a damaged charge air cooler outlet pipe. To rectify this concern, the damaged charge air cooler outlet pipe should be renewed. The production service part including the fixing for the intake air temperature (IAT) sensor is no longer available because the IAT sensor is not required any more. Furthermore the powertrain control module (PCM) should be re-programmed with the latest PCM calibration. NOTE: Use IDS B56 DVD or a later version. NOTE: Before commencing module configuration or programming, connect the vehicle battery to a suitable external power supply in order to maintain a constant battery voltage throughout the procedure. For detailed information refer to TSB 62/2007. Parts Finis Code Description Quantity 1 521 483 Charge air cooler outlet pipe 1 1 488 233 Blind cap 1 Locally procured Cable tie - Labor Times Description Operation No. Time Charge Air Cooler Outlet Pipe - Remove And Install 23 622 0 - Engine Undershield (If Equipped) - Remove And Install 21 130 4 - IDS - Vehicle Connection/Communication 29 099 1 - IDS - Powertrain Control Module (PCM) - Reprogramming - 29 120 5 Repair/Claim Coding Causal Part: Finis Code of the charge air cooler outlet pipe Condition Code: 01 Service Instruction Charge Air Cooler Outlet Pipe - Renew NOTE: The engine upper cover is held in place by four ball clips. The ball clips are not vertical, but are angled backwards by about 20 degrees. Location of the engine upper cover retaining clips. CAUTION: Only remove the engine upper cover in the sequence shown. If the ambient temperature is below 0° C, detach the engine upper cover with extreme caution. Failure to follow this instruction may cause the engine upper cover to be damaged! Remove the engine upper cover. NOTE: Note the orientation of the clamp to aid installation. Loosen the charge air cooler outlet pipe. Raise and support the vehicle. For additional information, refer to S-MAX/Galaxy 2006.5 Workshop Manual Section 100-02. Remove the engine undershield (if equipped). Partially loosen the radiator splash shield. Remove and discard the charge air cooler outlet pipe. The service part does NOT include the fixing for the IAT sensor: 1. IAT sensor installed to the production part 2. Charge air cooler outlet pipe 3. Install a blind cap (see Parts Required) to the IAT sensor electrical connector. Secure the IAT sensor electrical connector to the main wiring harness using cable ties (see Parts Required). CAUTION: Make sure that the inside of the pipe ends are clean and free of oil residue. NOTE: Make sure that the new charge air cooler outlet pipe is fully installed to the end stops and not misaligned. Tighten the clamps to 6 Nm. Install a new charge air cooler outlet pipe (see Parts Required) in reverse order. CAUTION: Contact of the engine upper cover with the cowl panel may cause damage (scratches) on the engine upper cover. Install the engine upper cover in the sequence shown. Apply soap solution (maximum concentration of soap in water 1:200) to the ball clip mountings in the engine upper cover. PCM - Re-program NOTE: Before commencing module configuration or programming, connect the vehicle battery to a suitable external power supply in order to maintain a constant battery voltage throughout the procedure. For detailed information refer to TSB 62/2007. Connect the IDS portable diagnostic unit to the vehicle and establish communication (VID the vehicle). Confirm the vehicle details are correct. CAUTION: The backup Central Car Configuration (CCC) gets erased during configuration. NOTE: Use IDS B56 DVD or a later version. Re-program the PCM with the latest calibration. Select the <Toolbox> tab at the top of the screen. Select <Module Programming> and then press the tick. Select <Module Reprogramming> and then press the tick. • Confirm the next screen. • Follow the further instructions from IDS to switch the ignition ON and OFF. Select <PCM> and then press the tick. Module Reprogramming starts. Follow the on screen instructions and confirm. Reload the backup vehicle configuration data stored on the Service Tool. For detailed information refer to TSB 57/2006. Clear any stored DTCs. Disconnect IDS from the vehicle.

[dfp454]