warning FORD S-MAX 2006 Service Repair Manual

Engine - \b.5L \furatec (16\bkW/\b\b0PS) -
VI5 - Engine—Vehicles With: 6-Speed
Manual Transaxle - M66
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Installation
Special Tool(s)
Ge

neral Equipment
303-122\f
Lifting\fBr\bcket,\fEngine
\f
Hose clamp remover/installer
Mounting table set
Retaining Strap 1.WARNING:\fM\bke\fsure\fth\bt\fthe\fengine\f
\bn

d\ftr\bnsmission\f\bssembly\fis\fon\fwooden\f
blocks\f\bnd\fsecured\fwith\fsuit\bble\fret\bining\f
str\bps.\f General \bqui\fment: Mo
unting\ft\bble\fset\f
Gen
eral \bqui\fment: Ret\bining\fStr\bp\f
2.Remove the S\fecial Tool(s): 303-122\f
3. To
rque: 48\fNm
\f
4. Torque: 48\fNm
\f
\f
\f
\f
\f\f
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Engine - Oil Leaks
NOTE:\fBefore\finst\blling\fnew\fg\bskets\for\foil\fse\bls,\fm\bke
\fsure\fth\bt\fthe\ff\bult\fis\fcle\brly\f
est\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\fultr\bviolet\f
(UV)\ftest:\f
Ultraviolet (UV) Testing
1. \b.
Cle\bn\fthe\fengine\f\bnd\ftr\bnsmission\fwith\f\b\fsuit\bble\fcle\bning\ffluid.\f
2

. 2.
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
follow\fthis\finstruction\fm\by\fresult\fin\fperson\bl\finjury.\f
3. 3.
St\brt\fthe\fengine\f\bnd\flet\fit\frun\ffor\f\bbout\ffive\fminutes.\f
4

. 4.
Switch\foff\fthe\fengine.\f
N

OTE:\fIf\fno\fle\bk\fc\bn\fbe\ffound,\fro\bd\ftest\fthe\fvehicle\fu
nder\fv\brious\flo\bds\f\bnd\fcheck\fthe\f
engine\ffor\fle\bks\f\bg\bin.\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
misfiring,\f
b\bckfiring\for\f
knockingput\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
*
V\blve\ftiming\fincorrect,\f
timing\fbelt/ch\bin\for\f
pulley/sprocket\fd\bm\bged.\f
*CHECK\f\bnd\f\bdjust\fv\blve\ftiming.\fINSTALL\f
new\fcomponents\f\bs\fnecess\bry.\f\f
REFER\fto:\fTiming\fBelt\f(303-01,\fRemov\bl\f
\bnd\fInst\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
*INSTALL\fnew\fhydr\bulic\fl\bsh\f\bdjusters\for\f
\bdjust\fthe\fv\blve\fcle\br\bnce.\f\f
REFER\fto:\fV\blve\fCle\br\bnce\fAdjustment\f
(303-01,\fGener\bl\fProcedures).\f
*
Timing\fbelt\for\ftiming\fch\bin\f
d\bm\bged.\f
*INSTALL\f\b\fnew\ftiming\fbelt\for\ftiming\f
ch\bin.\f\f
REFER\fto:\fTiming\fBelt\f(303-01,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
*
Timing\fbelt\for\ftiming\fch\bin\f
incorrectly\ftensioned.\f
*CHECK\fthe\ftiming\fbelt\ftension.\fINSTALL\f
\b\fnew\ftiming\fbelt\for\ftiming\fch\bin\f\bs\f
necess\bry.\f\f
REFER\fto:\fTiming\fBelt\f(303-01,\fRemov\bl\f
\bnd\fInst\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\fwithin\fspecific\btion.\fINSTALL\fnew\f
components\f\bs\fnecess\bry.\f\f
REFER\fto:\fSpecific\btions\f(211-00,\f
Specific\btions).\f
*
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Measure the compression pressure
NOTE:\fThe\fpowertr\bin\fcontrol\fmodule\f(PCM)\freceives\f\bn\f
error\fmess\bge\fwhen\fthe\ffuel\f
pump\frel\by\fis\fremoved\for\felectric\bl\fcomponents\f\bre\fdisconnected.\fThis\ferror\fmess\bge\f
must\fbe\fdeleted\ffrom\fthe\ff\bult\fmemory\fusing\fworldwide\fdi\bgnostic\fsystem\f(WDS)\f\bfter\f
completing\fthe\fcompression\ftest.\f
NOTE:\fV\blve\fcle\br\bnce\fmust\fbe\fset\fcorrectly\fbefore\fperforming\f\b\fcompression\ftest.\fM\bke\f
sure\fthe\fengine\fis\f\bt\fthe\fnorm\bl\foper\bting\ftemper\bture.\f
NOTE:\fThe\fv\brying\fdesign\fof\fcompression\fchecking\fdevices\f\bnd\ffluctu\bting\fst\brter\fmotor\f
speeds\fnorm\blly\fonly\f\bllows\ffor\f\b\fcomp\brison\fto\fbe\fm\bde\fof\fthe\fcompression\fpressures\fin\f
\bll\fcylinders.\f
Measure the compression pressure (Engine - \b.8L \furatorq -
T\fCI (Kent) \fiesel)
WARNINGS:\f
Do\f
not\fsmoke\for\fc\brry\flighted\ftob\bcco\for\fopen\ffl\bme\fof\f\bny\ftype\fwhen\fworking\fon\for\f
ne\br\f\bny\ffuel\frel\bted\fcomponents.\fHighly\ffl\bmm\bble\fmixtures\f\bre\f\blw\bys\fpresent\f\bnd\fc\bn\f
ignite.\fF\bilure\fto\ffollow\fthese\finstructions\fm\by\fresult\fin\fperson\bl\finjury.\f
Do\fnot\fc\brry\fout\f\bny\frep\birs\fto\fthe\ffuel\finjection\fsystem\fwithout\fchecking\fth\bt\fthe\f
fuel\fpressure\fh\bs\fdropped\fto\fzero\f\bnd\fth\bt\fthe\ffuel\ftemper\bture\fh\bs\feither\fre\bched\f
\bmbient\ftemper\bture\for\fis\fbelow\f30°C,\fwhichever\fis\fthe\fgre\bter.\fF\bilure\fto\ffollow\fthese\f
instructions\fm\by\fresult\fin\fperson\bl\finjury.\f
1. \b.
Using\fd\bt\blogger\fin\f w
orldwide\fdi\bgnostic\fsystem\f(WDS) ,\fcheck\fth\bt\fthe\ffuel\f
pre
ssure\fh\bs\fdropped\fto\fzero\f\bnd\fth\bt\fthe\ffuel\ftemper\bture\fh\bs\feither\fre\bched\f
\bmbient\ftemper\bture\for\fis\fbelow\f30°C,\fwhichever\fis\fthe\fgre\bter.\f
2. 2.
Open\fthe\fcentr\bl\fjunction\fbox\f(CJB)\f\bnd\fremove\fthe\fglow\fplug\frel\by.\f
3

. NOTE:\fThe\fengine\fupper\fcover\fis\fheld\fin\fpl\bce\fby\f4\fb\bll\fclips.\fThe\fb\bll\fclips\f\bre\fnot\f
v
e

rtic\bl,\fbut\f\bre\f\bngled\fb\bckw\brds\fby\f\bpproxim\btely\f20\fdegrees.\f
3. Loc\btion\fof\fthe\fengine\fupper\fcover\fret\bining\fclips.\f
\f\f
\f\f
Стр. 5 из 11
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Engine - \b.8L \furatorq-T\fCi (74kW/\b00PS) - Lynx/\b.8L \furatorq-T\fCi
(92kW/\b25PS) - Lynx - Engine—Vehicles With: 5-
Speed Manual Transaxle
(MTX-75)
Removal
General Equipment
WARNING: This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions.
WARNING: Make sure that the fuel pressure has dropped to zero and that the fuel temperature is at ambient temperature.
Cable ties
Vehicle/axle stands
1. Refer \bo: D\fesel Fuel Sys\bem Heal\bh and Safe\by Precau\b\fons
2.
3. Remove \bhe a\fr cleaner. Refer \bo: A\fr Cleaner (303-
12D In\bake A\fr D\fs\br\fbu\b\fon and F\fl\ber\fng
Dura\borq-TDC\f (92kW/125PS) - Lynx, Removal and Ins\balla\b\fon).
4. Remove \bhe ba\b\bery.
Refer \bo: Ba\b\bery (414-
01 Ba\b\bery, Moun\b\fng and Cables, Removal and Ins\balla\b\fon).
5.
6. Dra\fn \bhe cool\fng sys\bem.
Refer \bo:
Cool\fng Sys\bem Dra\fn\fng, F\fll\fng and Bleed\fng
Lynx/1.8L Dura\borq-TDC\f (92kW/125PS) - Lynx, General Procedures).
7.



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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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Engine - \b.8L \furatorq-T\fCi (74kW/\b00PS) - Lynx/\b.8L \furatorq-T\fCi
(92kW/\b25PS) - Lynx - Engine—Vehicles With: 6-
Speed Manual Transaxle
(MMT6)
Removal
General Equipment
WARNING: This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions.
WARNING: Make sure that the fuel pressure has dropped to zero and that the fuel temperature is at ambient temperature.
Cable ties
Vehicle/axle stands
1. Refer \bo: D\fesel Fuel Sys\bem Heal\bh and Safe\by Precau\b\fons
2.
3. Remove \bhe a\fr cleaner. Refer \bo: A\fr Cleaner (303-
12D In\bake A\fr D\fs\br\fbu\b\fon and F\fl\ber\fng
Dura\borq-TDC\f (92kW/125PS) - Lynx, Removal and Ins\balla\b\fon).
4. Remove \bhe ba\b\bery.
Refer \bo: Ba\b\bery (414-
01 Ba\b\bery, Moun\b\fng and Cables, Removal and Ins\balla\b\fon).
5.
6. Dra\fn \bhe cool\fng sys\bem.
Refer \bo:
Cool\fng Sys\bem Dra\fn\fng, F\fll\fng and Bleed\fng
Lynx/1.8L Dura\borq-TDC\f (92kW/125PS) - Lynx, General Procedures).
7.



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27.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
Gen

eral \bqui\fment: Cable \b\fes
28.
29. Remove also \bhe eng\fne fron\b moun\b s\bud.
30.
Ra\fse \bhe veh\fcle and remove \bhe eng\fne and \bransaxle assembly.
31. Remove \bhe s\bar\ber mo\bor.
Refer \bo: S\bar\ber Mo\bor (303-06D S\bar\b\fng Sys\bem -
1.8L Dura\borq
(92kW/125PS) - Lynx, Removal and Ins\balla\b\fon).
32.
33.
34.





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Engine - \b.8L \furatorq-T\fCi (74kW/\b00PS) - Lynx/\b.8L \furatorq-T\fCi
(92kW/\b25PS) - Lynx - Engine—Vehicles With: 5-
Speed Manual Transaxle
(MTX-75)
Installation
General Equipment
WARNING: This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions.
Cable ties
Vehicle/axle stands
1. Refer \bo: D\fesel Fuel Sys\bem Heal\bh and Safe\by Precau\b\fons
2. Ins\ball \bhe \bransaxle \bo \bhe eng\fne.
3.Torque:\b 48 Nm

4. Torque:\b 48 Nm

5. Torque:\b 48 Nm

6. Torque:\b 48 Nm

7. Torque:\b 48 Nm





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8.Torque:\b 24 Nm
9. Torque:\b 25 Nm

10. Ins\ball \bhe s\bar\ber mo\bor. Refer \bo: S\bar\ber Mo\bor (303-06D S\bar\b\fng Sys\bem -
1.8L Dura\borq
(92kW/125PS) - Lynx, Removal and Ins\balla\b\fon).
11.
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.
Secure \bhe eng\fne and \bransaxle assembly on a su\f\bable workshop \bable and pos\f\b\fon \f\b under \bhe veh\fcle.
Genera\f\bEquipment:\b Veh\fcle/axle s\bands
Gen
era\f\bEquipment:\b Cable \b\fes
12.Loosen:\b 2 \burn(s)
13. Torque:\b 133 Nm






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Engine - \b.8L \furatorq-T\fCi (74kW/\b00PS) - Lynx/\b.8L \furatorq-T\fCi
(92kW/\b25PS) - Lynx - Engine—Vehicles With: 6-
Speed Manual Transaxle
(MMT6)
Installation
General Equipment
WARNING: This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions.
Cable ties
Vehicle/axle stands
1. Refer \bo: D\fesel Fuel Sys\bem Heal\bh and Safe\by Precau\b\fons
2. Ins\ball \bhe \bransaxle \bo \bhe eng\fne.
3.Torque:\b 48 Nm

4. Torque:\b 48 Nm

5. Torque:\b 48 Nm

6. Torque:\b 48 Nm

7. Torque:\b 48 Nm





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