lock FORD S-MAX 2006 Service Repair Manual

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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7. \f\f
Align\fthe\fl\bdder\ffr\bme\fflush\fwith\fthe\f
cy

linder\fblock.\f

Tighten\fthe\fl\bdder\ffr\bme\fret\bining\fbolts\fin\f
th

e\fsequence\fshown.\f
Tor\fue\b 11\fNm
\f
8. Tor\fue\b 10\fNm
\f
9. Inst\bll\fthe\fCr\bnksh\bft\fRe\br\fSe\bl.\f Refer\fto:\f Cr\bnksh\bft\fRe\br\fSe\bl \f(303-01E\fEngine\f-
\f
1.8L\fDur\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
10. NOTE:\fM\bke\fsure\fth\bt\fthe\fm\bting\ff\bces\f\bre\f
cl

e\bn\f\bnd\ffree\fof\fforeign\fm\bteri\bl.\f
11. CAUTION:\fM\bke\fsure\fth\bt\fno\fexcess\f
se

\bl\bnt\fresidue\fis\fevident.\f
NOTE:\fThe\fcomponent\fmust\fbe\finst\blled\f
within\f5\fminutes\fof\f\bpplying\fthe\fse\bl\bnt.\f Apply\f\b\f2.5\fmm\fdi\bmeter\fbe\bd\fof\fse\bl\bnt\fto\fthe\f
e d

ge\fof\fthe\fOil\fP\bn.\f
Material\b Silicone\fSe\bl\bnt\fLB\f(WSE-M4G323-A4\f/\f
2U7

J-M4G323-AA) \f
12. Tighten\fthe\fOil\fP\bn\fret\bining\fnuts\f\bnd\fbolts\fin\f
the\fsequence\fshown.\f\f
Tor\fue\b 1-18\f\f 6.5\fNm
\f
14\fNm
\f
19\f36\fNm
\f
St\bge\f1:\f
St\bge\f2:\f
13. Tor\fue\b
1\f23\fNm
\f
2\f48\fNm
\f
\f\f
\f\f
\f\f
\f\f
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All vehicles
19. Tor\fue\b
1
\f23\fNm
\f
2\f24\fNm
\f
3\f65\fNm
\f
20. \f
21. Loc\bte\fAlignment\fTool\finto\fOil\fPump\f\bnd\fSe\bl\f Pocket\f\bnd\f\blign\fwith\fCr\bnk\fSprocket.\fSt\brt\f
tighten\fthe\ftiming\fch\bin\fhousing\fcover\fret\bining\f
bolts\fby\fh\bnd,\fin\fthe\fsequence\fshown.\f
Special Tool(s)\b 303-652\f
To r

\fue\b Alignment\fTool\f10\fNm
\f
1-5\f10\fNm
\f
6\f23\fNm
\f
7-19\f10\fNm
\f
22. Tor\fue\b
1\f10\fNm
\f
2\f23\fNm
\f
23. Cle\bn\fthe\fm\bting\ff\bces\fof\fthe\fcylinder\fhe\bd\f\bnd\f cylinder\fblock\fwith\fcle\bner.\f
Material\b Spoiler\fAdhesive\fKit\f2\fComponent\f
\f\f
\f\f
\f\f
\f\f
\f\f
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(WSK-M5B401-A1\f/\f2U7J-M2G376-AA)\f
24. N
OTE:\fThe\fthickness\f\bnd\fposition\fof\fthe\fnew\f
cy
linder\fhe\bd\fg\bsket\fmust\fbe\fthe\fs\bme\f\bs\f
th\bt\fof\fthe\fold\fone\f(hole/tooth\f\bnd\f
TOP/OBEN\fm\brked).\f
25. CAUTIONS:\f
M\b

ke\fsure\fth\bt\fnew\funoiled\fcylinder\f
he\bd\fbolts\f\bre\finst\blled.\f
Pl\bce\fthe\ftwo\fshort\fcylinder\fhe\bd\fbolts\f
on\fposition\f7\f\bnd\f10\f
NOTE:\fThe\fpistons\fmust\fnot\fbe\f\bt\fTDC.\f
Tighten\fthe\fcylinder\fhe\bd\fret\bining\fbolts\fin\fthe\f
se
quence\fshown\fin\ffour\fst\bges.\f
Tor\fue\b \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
26. NOTE:\fOnly\frot\bte\fthe\fcr\bnksh\bft\fin\fthe\f
no
rm\bl\fdirection\fof\frot\btion.\f
1. Remove\fthe\fcylinder\fblock\fbl\bnking\fplug\f \bnd
\finst\bll\fthe\fspeci\bl\ftool.\f
Special Tool(s)\b 303-193\f
2. R

ot\bte\fthe\fcr\bnksh\bft\fslowly\funtil\fthe\f
cr\bnksh\bft\fstops.\f
3. Make sure that the crankshaft does
not rotate during installation of the
special tool.Make sure that the
crankshaft is at the T\fC position
before locking the special tool.Using\f
the\fspeci\bl\ftool,\flock\fthe\fcr\bnksh\bft.\f
Special Tool(s)\b 303-393\f
27.

Using\fthe\fspeci\bl\ftool,\finst\bll\fthe\fcr\bnksh\bft\f
position\f(CKP)\fsensor\fret\bining\fbr\bcket.\f
Special Tool(s)\b 303-710\f
Tor

\fue\b 10\fNm
\f
28. NOTE:\fInst\bll\f\b\fnew\fcr\bnksh\bft\fposition\f
(
C

KP)\fsensor.\f
NOTE:\fThe\fCKP\fsensor\fmust\fm\bke\fcont\bct\f
\f\f
\f\f
\f\f
\f\f
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with\fthe\fflywheel.\f
Tor\fue\b 6\fNm
\f
29. Att\bch\fthe\ffuel\fpump\fpulley\fto\fthe\ffuel\fpump\f sprocket.\fApply\fse\bl\bnt\fto\fthe\ffuel\fpump\fpulley\f
\bnd\fto\fthe\fouter\fedge\fof\fthe\ffuel\fpump\fpulley\f
ret\bining\fbolt\fholes.\f\f
Material\b Fl\bnge\fSe\bl\bnt\f-\fAn\berobic\fLP\f(WSK-
M2 G3

48-A7\f/\f5U7J-M2G348-BA) \f
30.

Tighten\fthe\ffuel\fpump\fse\bl\fret\biner\fret\bining\f
bolts\fin\fthe\fsequence\fshown.\f
Tor\fue\b
1-7\f\bnd\ftiming\fbelt\fre\br\fcover\f10\fNm
\f
Engine\ffront\fmount\fbr\bcket\f28\fNm
\f
31. Tighten\fthe\fc\bmsh\bft\fpulley\fbolt\ffinger\ftight\f\bnd\f then\floosen\fby\fone-h\blf\fturn.\f\f
32. \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
33. \f\f

The\fc\bmsh\bft\fpulley\fmust\fbe\f\bble\fto\frot\bte\f
freely\fon\fthe\fc\bmsh\bft\ft\bper.\f

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

ows\fin\fthe\fdirection\fof\fengine\frot\btion.\f
\f\f
\f\f
\f\f
\f\f
\f\f
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34.Tension\fthe\ftiming\fbelt\fcounterclockwise\funtil\fthe\f
pointer\fis\fpositioned\fbetween\fthe\fsides\fof\fthe\f
window.\f\f
Tor\fue\b 50\fNm
\f
35. Special Tool(s)\b 205-072\f
Tor

\fue\b 50\fNm
\f
36. Remove\fthe\fspeci\bl\ftools.\f Special Tool(s)\b 303-376B,\f303-193,\f303-393\f
37 .

\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
Special Tool(s)\b 303-193\f
2. R

ot\bte\fthe\fcr\bnksh\bft\fslowly\funtil\fthe\f
cr\bnksh\bft\fstops\f\bt\fTDC.\f
38. 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
39. 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
Inst\bll\fthe\fspeci\bl\ftool.\f
Sp

ecial Tool(s)\b 303-376B\f
40.

Remove\fthe\fspeci\bl\ftools\f\bnd\finst\bll\fthe\fcylinder\f
block\fbl\bnking\fplug.\f
\f\f
\f\f
\f\f
\f\f
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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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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
Accessories
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Installation
Special Tool(s)
Ma

terials
205-072\f
Univers\bl\fFl\bnge\fHolding\fWrench
\f
303-122\f
Lifting\fBr\bcket,\fEngine\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
303-435\f
Mounting\fSt\bnd\f
303-435-06\f
Mounting\fBr\bcket\ffor\f303-435\f
303-710\f
Timing\fTool,\fCr\bnksh\bft\f
NameSpec\bf\bcat\bo\f
Fl\bnge\fSe\bl\bnt\f-\fAn\berobic\fLPWSK-M2G348-A7\f/\f5U7J-M2G348-BA 1.CAUTION:\fM\bke\fsure\fth\bt\fnew\fbolts\f\bre\f
in

st\blled.\f
Special\bTool(\f):\b 30
3-393\f
Tor
que:\b \f
35\fNm
\f
45
°\f
St\bge\f1:\f
St\bge\f2:\f
\f
\f
\f
\f
\f
\f
\f
\f
\f\f
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2. Inst\bll\fthe\fclutch\fdisc\f\bnd\fpressure\fpl\bte.\fRefer\fto:\f Clutch\fDisc\f\bnd\fPressure\fPl\bte \f(308-
01B

\fClutch\f-\fVehicles\fWith:\f6-Speed\fM\bnu\bl\f
Tr\bns\bxle\f-\fMMT6,\fRemov\bl\f\bnd\fInst\bll\btion).\f
3. NOTE:\fOnly\frot\bte\fthe\fcr\bnksh\bft\fin\fthe\f
no

rm\bl\fdirection\fof\frot\btion.\f
1. Remove\fthe\fcylinder\fblock\fbl\bnking\fplug\f \bnd
\finst\bll\fthe\fspeci\bl\ftool.\f
Special\bTool(\f):\b 303-193\f
2. R

ot\bte\fthe\fcr\bnksh\bft\fslowly\funtil\fthe\f
cr\bnksh\bft\fstops.\f
3. Make sure that the crankshaft does
not rotate during installation of the
special tool.Make sure that the
crankshaft is at the T\fC position
before locking the special tool.Using\f
the\fspeci\bl\ftool,\flock\fthe\fcr\bnksh\bft.\f
Special\bTool(\f):\b 303-393\f
4. U

sing\fthe\fspeci\bl\ftool,\finst\bll\fthe\fcr\bnksh\bft\f
position\f(CKP)\fsensor\fret\bining\fbr\bcket.\f
Special\bTool(\f):\b 303-710\f
Tor

que:\b 10\fNm
\f
5. NOTE:\fInst\bll\f\b\fnew\fcr\bnksh\bft\fposition\f
(C

KP)\fsensor.\f
NOTE:\fThe\fCKP\fsensor\fmust\fm\bke\fcont\bct\f
with\fthe\fflywheel.\f
Torque:\b 6\fNm
\f
6. \f\f
1.\f
To

rque:\bSnug\fTorque\f10\fNm
\f
Del\by\f2\fSeconds\f18\fNm
\f
Untighten\f40
°\f
Fin\bl\fTorque\f26\fNm
\f

2.\f
To

rque:\b 33\fNm
\f
7. Inst\bll\f\b\fnew\fg\bsket\f
Torque:\b 23\fNm
\f
\f\f
\f\f
\f\f
\f\f
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