compressor FORD S-MAX 2006 Service Owner's Manual

20.CAUTION: Tw\fs\b\fng \bhe exhaus\b flex\fble p\fpe more \bhan 2 degrees may cause damage resul\b\fng \fn fa\flure.
21. Remove \bhe accessory dr\fve bel\b. Refer \bo: Accessory Dr\fve Bel\b (303-
05D Accessory Dr\fve
TDC\f (92kW/125PS) - Lynx, Removal and Ins\balla\b\fon).
22. Secure \bhe Power S\beer\fng Pump \bo one s\fde.
General \bqui\fment: Cable \b\fes
23.

Secure \bhe A/C compressor \bo one s\fde.
General \bqui\fment: Cable \b\fes
24.

D\fsconnec\b \bhe PCM elec\br\fcal connec\bors.
Refer \bo: Power\bra\fn Con\brol Module (PCM) (303-
14E Elec\bron\fc Eng\fne Con\brols
Lynx/1.8L Dura\borq-TDC\f (92kW/125PS) - Lynx, Removal and Ins\balla\b\fon).
25.D\fsconnec\b \bhe fuel supply l\fne and fuel re\burn l\fne qu\fck release coupl\fngs.
Refer \bo: Fuel F\fl\ber (310-01B Fuel Tank and L\fnes - 1.8L Dura\borq
(92kW/125PS) - Lynx, Removal and Ins\balla\b\fon).
26.
WARNING: Make sure \bha\b \bhe eng\fne and \bransm\fss\fon assembly \fs on wooden blocks and secured w\f\bh
su\f\bable re\ba\fn\fng s\braps.
Us\fng a su\f\bable workshop \bable.
Gen
eral \bqui\fment: Veh\fcle/axle s\bands
Ge n

eral \bqui\fment: Cable \b\fes




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19. Remove \bhe lef\b-hand halfshaf\b. Refer \bo: Fron\b Halfshaf\b LH (205-
04 Fron\b Dr\fve Halfshaf\bs, Removal and Ins\balla\b\fon).
20. Remove \bhe fron\b subframe.
Refer \bo: Fron\b Subframe (502-00 Un\f-
Body, Subframe and Moun\b\fng Sys\bem, Removal and Ins\balla\b\fon).
21.CAUTION: Tw\fs\b\fng \bhe exhaus\b flex\fble p\fpe more \bhan 2 degrees may cause damage resul\b\fng \fn fa\flure.
22. Remove \bhe accessory dr\fve bel\b.
Refer \bo: Accessory Dr\fve Bel\b (303-
05D Accessory Dr\fve
TDC\f (92kW/125PS) - Lynx, Removal and Ins\balla\b\fon).
23. Secure \bhe Power S\beer\fng Pump \bo one s\fde.
General \bqui\fment: Cable \b\fes
24.

Secure \bhe A/C compressor \bo one s\fde.
General \bqui\fment: Cable \b\fes
25 .

D\fsconnec\b \bhe PCM elec\br\fcal connec\bors.
Refer \bo: Power\bra\fn Con\brol Module (PCM) (303-
14E Elec\bron\fc Eng\fne Con\brols
Lynx/1.8L Dura\borq-TDC\f (92kW/125PS) - Lynx, Removal and Ins\balla\b\fon).
26.D\fsconnec\b \bhe fuel supply l\fne and fuel re\burn l\fne qu\fck release coupl\fngs.
Refer \bo: Fuel F\fl\ber (310-01B Fuel Tank and L\fnes - 1.8L Dura\borq
(92kW/125PS) - Lynx, Removal and Ins\balla\b\fon).




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Material\b Engine\fOil\f-\f5W-30\f(WSS-M2C912-A1) \f
2. CAUTION:\fM\bke\fsure\fth\bt\fnew\fbe\bring\f
c\b

p\fret\bining\fbolts\f\bre\finst\blled.\f
Tighten\fthe\fcr\bnksh\bft\fm\bin\fbe\bring\fc\bp\f
re
t\bining\fbolts\fin\fthe\fsequence\fshown.\f\f
Tor\fue\b \f
45\fNm
\f
70\fNm
\f
60
°\f
St\bge\f1:\f
St\bge\f2:\f
St\bge\f3:\f
3. \f\f
Co\bt\fthe\fcylinder\fbores\fwith\fcle\bn\fengine\f
oi

l.\f

The\fpiston\fring\fg\bps\f\bnd\foil\fsupply\fring\f
el

ements\fmust\fbe\fdistributed\fevenly\f
\bround\fthe\fcircumference\fof\fthe\fpiston.\f

Inst\bll\fthe\fpistons\fwith\fthe\f\brrows\fpointing\f
to

w\brds\fthe\ffront\fof\fthe\fengine.\f

Using\f\b\fsuit\bble\fpiston\fring\fcompressor,\f
in

st\bll\fthe\fpistons.\f\f
4. \f\f
Lubric\bte\fthe\fconnecting\frod\fjourn\bls\fwith\f
cl

e\bn\fengine\foil.\f

The\fconnecting\frod\fidentific\btion\fm\brks\f
mu

st\fpoint\ftow\brds\fthe\ffront\fof\fthe\fengine.
\f

CAUTION:\fM\bke\fsure\fth\bt\fnew\f
co
nnecting\frod\fbe\bring\fc\bps\fret\bining\f
bolts\f\bre\finst\blled.\f St\brt\ftighten\fthe\fconnecting\frod\fbe\bring\f
c\bp
s\fret\bining\fbolts\ffinger\ftight.\f\f
Tor\fue\b \f
27\fNm
\f
60
°\f
20
°\f
St\bge\f1:\f
St\bge\f2:\f
St\bge\f3:\f
5. The chain housing bottom sealing flange
surfaces must be within +/- 0,26mm of the
cylinder block bottom sealing flange
surfaces. \f
Tor\fue\b 23\fNm
\f
6. \f
\f\f
\f\f
\f\f
\f\f
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Engine - \b.0L \furatorq-T\fCi
(85kW/115PS) - \fW/\b.0L \furatorq-T\fCi
(100kW/136PS) - \fW/\b.0L \furatorq-
T\fCi (103kW/140PS) - \fW, Emission
Requirements: Stage IV - Valve Stem
Seals
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Installation
Special Tool(s)
Removal
303-037\f
Inst\bller,\fV\blve\fStem\fSe\bl
\f
303-060\f
Compressor,\fV\blve\fSpring
\f
303-060-07\f
Ad\bpter\ffor\f303-060\f
303-060-09A\f
Ad\bpter\ffor\f303-060\f
303-390\f
Pliers,\fV\blve\fStem\fSe\bl\f
1. Remove\fthe\fc\bmsh\bfts.\f\fRefer\fto:\f C\bmsh\bfts \f(303-01F\fEngine\f-\f2.0L\f
Du r

\btorq-TDCi\f(85kW/115PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(103kW/140PS)\f-\fDW,\fEmission\f
Requirements:\fSt\bge\fIV,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
2.
Position\fthe\f\bppropri\bte\fpiston\f\bt\ftop\fde\bd\fcenter\f
(TDC).\f
3. Special\bTool(\f):\b 303-060,\f303-060-07,\f 303-060-
09A \f
4

. \f
\f
\f
\f
\f
\f
\f\f
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Requirements:\fSt\bge\fIV,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
2. Front\fDrive\fH\blfsh\bfts\f
Refer\fto:\f Front\fH\blfsh\bft\fLH \f(205-04\fFront\f
Dri

ve\fH\blfsh\bfts,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
Refer\fto:\f Front\fH\blfsh\bft\fRH \f(205-04\fFront\f
Dri

ve\fH\blfsh\bfts,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
3. Front\fSubfr\bme.\f
Refer\fto:\f Front\fSubfr\bme \f(502-00\fUni-
Bod

y,\fSubfr\bme\f\bnd\fMounting\fSystem,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
18.
Det\bch\fthe\f\bir\fconditioning\f(A/C)\fcompressor\f\bnd\f
secure\fto\fone\fside.\f
19. Refer\fto:\f Quick\fRele\bse\fCoupling \f(310-00\fFuel\f
Sys

tem\f-\fGener\bl\fInform\btion,\fGener\bl\f
Procedures).\f
20. General \bqui\fment: Mounting\ft\bble\fset\f
21 .

\f
22. \f
\f\f
\f\f
\f\f
\f\f
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Engine - \b.0L \furatorq-T\fCi
(85kW/115PS) - \fW/\b.0L \furatorq-T\fCi
(100kW/136PS) - \fW/\b.0L \furatorq-
T\fCi (103kW/140PS) - \fW, Emission
Requirements: Stage IV - Cylinder Head
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
\fisassembly and Assembly of Subassemblies
Special Tool(s)
\fisassembly
205-047\f
Slide\fH\bmmer\f
303-037\f
Inst\bller,\fV\blve\fStem\fSe\bl\f
303-060\f
Compressor,\fV\blve\fSpring\f
303-060-07\f
Ad\bpter\ffor\f303-060\f
303-060-09A\f
Ad\bpter\ffor\f303-060\f
303-292\f
Remover,\fV\blve\fStem\fSe\bl
\f
1.Special\bTool(\f):\b 303-060,\f303-060-07,\f 303-060-
09A \f
2
. \f
3

. Special\bTool(\f):\b 205-047,\f303-292\f
\f
\f
\f
\f
\f
\f
\f\f
\f\f
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Engine - \b.0L \furatorq-T\fCi (85kW/115PS)
- \fW/\b.0L \furatorq-T\fCi (100kW/136PS) -
\fW/\b.0L \furatorq-T\fCi (103kW/140PS) -
\fW, Emission Requirements: Stage IV -
Engine
S-MAX/G\bl\bxy\f2006.5\f(02/2006
\fPrint
Assembly
Special Tool(s)
Ma
terials
General Equipment
NOTE: Make sure that these components are installed to the noted removal position.

205-307\f
Inst\bller,\fWheel\fSpeed\fSensor\fRing
\f
303-1057\f
Inst\bller,\fM\bin\fBe\bring\fCup\f
303-255\f
Inst\bller,\fTiming\fCover\fSe\bl\f
303-395\f
Inst\bller,\fCr\bnksh\bft\fSe\bl\f
303-684\f
Inst\bller,\fCr\bnksh\bft\fFront\fSe\bl\f
NameSpec\bf\bcat\bo\f
Engine\fOil\f-\f5W-30WSS-M2C913-B
Silicone\fSe\bl\bnt\fLBWSE-M4G323-A4\f/\f2U7J-M4G323-AA
\b mm punch
Piston ring compressor 1.Material\b En
gine\fOil\f-\f5W-30\f(WSS-M2C913-B) \f
2. \f
\f
\f
\f
\f
\f
\f\f
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3.Material\b Engine\fOil\f-\f5W-30\f(WSS-M2C913-B) \f
4. NOTE:\fOnly\ftighten\fthe\fbolts\ffinger\ftight\f\bt\fthis\f
st

\bge.\f
In\ftall the Special Tool(\f)\b 30
3-1057\f
5. Re
move the Special Tool(\f)\b 303-1057\f
6. To

rque\b \f
30\fNm
\f
63
°\f
St\bge\f1:\f
St\bge\f2:\f
7. General Equipment\b Piston\fring\fcompressor \f
Mate
rial\b Engine\fOil\f-\f5W-30\f(WSS-M2C913-B) \f
8. Mat

erial\b Engine\fOil\f-\f5W-30\f(WSS-M2C913-B) \f
\f
\f\f
\f\f
\f\f
\f\f
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Engine - \b.\bL D\fratorq-TDCi
(1\b9kW/175PS) - DW - Valve Stem SealsS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Installation
Special Tool(s)
Removal
303-037\f
Inst\bller,\fV\blve\fStem\fSe\bl
\f
303-060\f
Compressor,\fV\blve\fSpring
\f
303-060-07\f
Ad\bpter\ffor\f303-060\f
303-060-09A\f
Ad\bpter\ffor\f303-060\f
303-390\f
Pliers,\fV\blve\fStem\fSe\bl\f
1. Refer\fto:\fC\bmsh\bfts\f(303-01G\fEngine\f-\f2.2L\f
Dur

\btorq-TDCi\f(129kW/175PS)\f-\fDW,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
2. \f
3.
Position\fthe\f\bppropri\bte\fpiston\f\bt\ftop\fde\bd\fcenter\f
(TDC).\f
4. Special\bTool(\f):\b 303-060,\f303-060-07,\f 303-060-
09A \f
\f
\f
\f
\f
\f
\f\f
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Engine - \b.\bL D\fratorq-TDCi
(1\b9kW/175PS) - DW - Oil CoolerS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Installation
Removal
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
1. Refer\fto:\f Fu
el\fFilter\f(310-01D\fFuel\fT\bnk\f\bnd\f
Lin
es\f-\f2.2L\fDur\btorq-TDCi\f(129kW/175PS)\f-\f
DW,\fRemov\bl\f\bnd\fInst\bll\btion).\f
Refer\fto:\f Throttle\fBody \f(303-04F\fFuel\fCh\brging\f
\bnd

\fControls\f-\f2.2L\fDur\btorq-TDCi\f
(129kW/175PS)\f-\fDW,\fRemov\bl\f\bnd\fInst\bll\btion).
\f
Refer\fto:\f Accessory\fDrive\fBelt \f(303-05F\f
Acc
essory\fDrive\f-\f2.2L\fDur\btorq-TDCi\f
(129kW/175PS)\f-\fDW,\fRemov\bl\f\bnd\fInst\bll\btion).
\f
2. Remove\fthe\f\bir\fconditioning\fcompressor\f\bnd\f position\fto\fone\fside.\f
3. \f
4. NOTE:\fM\bke\fsure\fth\bt\f\b\fnew\fcl\bmp\fis\f
in

st\blled.\f\f
5. NOTE:\fM\bke\fsure\fth\bt\f\b\fnew\fcomponent\fis\f
i
n

st\blled.\f\f
Torque:\b 9\fNm
\f
6. NOTE:\fM\bke\fsure\fth\bt\fthe\fcomponent\fis\f
cl

e\bn\f\bnd\ffree\fof\fforeign\fm\bteri\bl.\f\f
NOTE:\fM\bke\fsure\fth\bt\f\b\fnew\fcomponent\fis\f
inst\blled.\f\f
Torque:\b \f
10

\fNm
\f
20\fNm
\f
St\bge\f1:\f
St\bge\f2:\f
\f\f
\f\f
\f\f
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