belt FORD S-MAX 2006 Service Workshop Manual

Engine - \b.8L \furatorq-T\fCi
(74kW/\b00PS) - Lynx/\b.8L \furatorq-
T\fCi (92kW/\b25PS) - Lynx - Timing Belt
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Installation
Special Tool(s)
Gen

eral Equipment
Removal
205-072\f
Univers\bl\fFl\bnge\fHolding\fWrench
\f
303-193\f
Timing\fPeg,\fCr\bnksh\bft\fTDC\f
303-376B\f
Alignment\fPl\bte,\fC\bmsh\bft\f
303-393\f
Locking\fTool,\fFlywheel\f
303-651\f
Remover,\fC\bmsh\bft\fSprocket\f
C\bble\fties
Trolley\fj\bck 1. Disconnect\fthe\fb\bttery.\fRefer\fto:\f B\bttery\fDisconnect\f\bnd\fConnect\f(414-
01\f

B\bttery,\fMounting\f\bnd\fC\bbles,\fGener\bl\f
Procedures).\f
2. Refer\fto:\f V\blve\fCover\f(303-01E\fEngine\f-\f1.8L\f
Dur

\btorq-TDCi\f(74kW/100PS)\f-\fLynx/1.8L\f
Dur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
3. \f
4. \f
\f
\f
\f
\f
\f
\f\f
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10. \f
11. \f
12. Refer\fto:\fAccessory\fDrive\fBelt \f(303-05D\f
Ac c

essory\fDrive\f-\f1.8L\fDur\btorq-TDCi\f
(74kW/100PS)\f-\fLynx/1.8L\fDur\btorq-TDCi\f
(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\fInst\bll\btion).
\f
13. Secure\fthe\f\bir\fconditioning\f(A/C)\fcompressor\fto\f one\fside.\f
General \bqui\fment: C\bble\fties\f
14.

\f
\f
\f\f
\f\f
\f\f
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Installation 26.
S\fecial Tool(s): 3
03-651\f
1. \f
\f
Check\fthe\ftiming\fbelt\ftensioner\f\bnd\fm\bke\f
su

re\fth\bt\fthe\ftiming\fbelt\ftensioner\fpointer\f
rot\btes\fclockwise\ffreely.\f

Move\fthe\ftiming\fbelt\ftensioner\f\bdjustment\f
\brm

\fto\fthe\f3\fo'clock\fposition.\f

Do\fnot\ffully\ftighten\fthe\ftiming\fbelt\f
te

nsioner\fret\bining\fbolt\f\bt\fthis\fst\bge.\f
2. \f\f

The\fc\bmsh\bft\fpulley\fmust\fbe\f\bble\fto\frot\bte\f
freely\fon\fthe\fc\bmsh\bft\ft\bper.\fTighten\fthe\f
c\bmsh\bft\fpulley\fbolt\ffinger\ftight\f\bnd\fthen\f
loosen\fby\fone-h\blf\fturn.\f\f

Inst\bll\fthe\ftiming\fbelt\fwith\fthe\fdirection\f
\brr

ows\fin\fthe\fdirection\fof\fengine\frot\btion.\f
3.
Tension\fthe\ftiming\fbelt\fcounterclockwise\funtil\fthe\f
pointer\fis\fpositioned\fbetween\fthe\fsides\fof\fthe\f
window.\f\f
Torque: 50\fNm
\f
4. S\fecial Tool(s): 205-072\f
Tor

que: 50\fNm
\f
\f\f
\f\f
\f\f
\f\f
\f\f
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5.Remove the S\fecial Tool(s): 303-376B,\f303-193,\f
303-393\f
6. \f
\f 1. Rot\bte\fthe\fcr\bnksh\bft\f2\frevolutions.\f Repl\bce\fthe\fTiming\fPeg\fjust\fbefore\fTDC\fon\f
the\fsecond\frevolution.\f
Install the S\fecial Tool(s): 303-193\f
2. R

ot\bte\fthe\fcr\bnksh\bft\fslowly\funtil\fthe\f
cr\bnksh\bft\fstops\f\bt\fTDC.\f
7. Check\fth\bt\fthe\ftiming\fbelt\ftensioner\fpointer\fis\f positioned\fin\fthe\fwindow,\fotherwise\fthe\ftiming\f
belt\ftensioning\fsteps\fmust\fbe\frepe\bted.\f\f
8. NOTE:\fIf\fthe\fspeci\bl\ftool\fc\bnnot\fbe\finst\blled,\f
th

e\ftiming\fbelt\ftensioning\fsteps\fmust\fbe\f
repe\bted.\f\f
Install the S\fecial Tool(s): 30
3-376B\f
9. R
emove\f\bll\fspeci\bl\ftools\f\bnd\finst\bll\fthe\fcylinder\f
block\fbl\bnking\fplug.\f
Remove the S\fecial Tool(s): 303-376B,\f303-193
,\f
303-393\f
Tor
que: 23\fNm
\f
10. Torque: 7\fNm
\f
11. \f\f 1.Torque: 12\fNm
\f
2. Torque: 80\fNm
\f
3. NOTE:\fOnly\ftighten\fthe\fbolts\ffinger\f
t
i

ght\f\bt\fthis\fst\bge.\f
\f\f
\f\f
\f\f
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17. Refer\fto:\fSt\brter\fMotor\f(303-06D\fSt\brting\f
Sys
tem\f-\f1.8L\fDur\btorq-TDCi\f(74kW/100PS)\f-\f
Lynx/1.8L\fDur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
18. Torque: 25\fNm
\f
19. Torque:
1\f27\fNm
\f
2\f10\fNm
\f
20. Refer\fto:\f Accessory\fDrive\fBelt \f(303-05D\f
Ac c

essory\fDrive\f-\f1.8L\fDur\btorq-TDCi\f
(74kW/100PS)\f-\fLynx/1.8L\fDur\btorq-TDCi\f
(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\fInst\bll\btion).
\f
21. \f\f 1.Torque: 35\fNm
\f
2. Loosen: 360
°\f
3. Torque: 85\fNm
\f
22. \f
\f\f
\f\f
\f\f
\f\f
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39. \f
40.Torque: 20\fNm
\f
41. Disc\brd\fthe\ftiming\fbelt.\f
42.
Loosen\fthe\fc\bmsh\bft\fpulley\fret\bining\fbolt\fby\f5\fturns.
S\fecial Tool(s): 205-072\f
43. S
\fecial Tool(s): 303-651\f
\f\f
\f\f
\f\f
\f\f
\f\f
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2.NOTE:\fThe\fthickness\f\bnd\fposition\fof\fthe\fnew\f
cylinder\fhe\bd\fg\bsket\fmust\fbe\fthe\fs\bme\f\bs\fth\bt\fof\f
the\fold\fone\f(hole/tooth\f\bnd\fTOP/OBEN\fm\brked).\f
3.
NOTE:\fThe\fpistons\fmust\fnot\fbe\f\bt\fTDC.\fM\bke\fsure\f
th\bt\fthe\fspeci\bl\ftool\fis\feng\bged\fin\fthe\fc\bmsh\bft\f
groove.\f
S\fecial Tool(s): 30
3-122\f
4. CAUTIONS:\f
M\b
ke\fsure\fth\bt\fnew\fbolts\f\bre\finst\blled.\f
M\bke\fsure\fth\bt\fthe\fcomponent\fis\fcle\bn,\ffree\fof\f
foreign\fm\bteri\bl\f\bnd\flubric\bnt.\f
Torque: \f
20
\fNm
\f
54\fNm
\f
90
°\f
M12x137\f70
°\f
M12x177\f90
°\f
St\bge\f1:\f
St\bge\f2:\f
St\bge\f3:\f
St\bge\f4:\f
5. Torque: 10\fNm\f
6. \f\f

Check\fthe\ftiming\fbelt\ftensioner\f\bnd\fm\bke\fsure\f
th\bt\fthe\ftiming\fbelt\ftensioner\fpointer\frot\btes\f
clockwise\ffreely.\f
\f\f
\f
\f\f
\f\f
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Move\fthe\ftiming\fbelt\ftensioner\f\bdjustment\f\brm\fto\f
the\f3\fo'clock\fposition.\f

Do\fnot\ffully\ftighten\fthe\ftiming\fbelt\ftensioner\f
re

t\bining\fbolt\f\bt\fthis\fst\bge.\f
7. \f\f

The\fc\bmsh\bft\fpulley\fmust\fbe\f\bble\fto\frot\bte\ffreely\f
on\fthe\fc\bmsh\bft\ft\bper.\fTighten\fthe\fc\bmsh\bft\f
pulley\fbolt\ffinger\ftight\f\bnd\fthen\floosen\fby\fone
h\blf\fturn.\f\f


Inst\bll\fthe\ftiming\fbelt\fwith\fthe\fdirection\f\brrows\fin\f
the\fdirection\fof\fengine\frot\btion.\f
8. Tension\fthe\ftiming\fbelt\fcounterclockwise\funtil\fthe\f
pointer\fis\fpositioned\fbetween\fthe\fsides\fof\fthe\fwindow.\f
Torque: 50\fNm\f
9. S\fecial Tool(s): 205-072\f
Tor

que: 50\fNm
\f
10. Remove\fthe\fspeci\bl\ftools.\f S\fecial Tool(s): 303-376B,\f303-193,\f303-393\f
11 .

\f\f 1.
Rot\bte\fthe\fcr\bnksh\bft\f2\frevolutions.\fRepl\bce\fthe\f
Timing\fPeg\fjust\fbefore\fTDC\fon\fthe\fsecond\f
revolution.\f
S\fecial Tool(s): 303-193\f
2.
Rot\bte\fthe\fcr\bnksh\bft\fslowly\funtil\fthe\fcr\bnksh\bft\f
stops\f\bt\fTDC.\f
12. Check\fth\bt\fthe\ftiming\fbelt\ftensioner\fpointer\fis\f positioned\fin\fthe\fwindow,\fotherwise\fthe\ftiming\fbelt\f
tensioning\fsteps\fmust\fbe\frepe\bted.\f\f
13. NOTE:\fIf\fthe\fspeci\bl\ftool\fc\bnnot\fbe\finst\blled,\fthe\f
t
i

ming\fbelt\ftensioning\fsteps\fmust\fbe\frepe\bted.\f\f
\f\f
\f\f
\f\f
\f\f
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28.Special\bTool(\f):\b 205-072\f
29.
\f
30. Disc\brd\fthe\ftiming\fbelt.\f
31. Loosen\fthe\fc\bmsh\bft\fpulley\fret\bining\fbolt\fby\f5\f turns.\f
Special\bTool(\f):\b 205-072\f
32 .S

pecial\bTool(\f):\b 303-651\f
\f\f
\f\f
\f\f
\f\f
\f\f
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22. \f23. Disc\brd\fthe\ftiming\fbelt.\f
24. Loosen\fthe\fc\bmsh\bft\fpulley\fret\bining\fbolt\fby\f5\f turns.\f
Special\bTool(\f):\b 205-072\f
25 .S

pecial\bTool(\f):\b 303-651\f
26.

Disc\brd\fthe\ffuel\fpump\fse\bl\fret\biner.\f
\f\f
\f\f
\f\f
\f\f
\f\f
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