FORD S-MAX 2006 Service Repair Manual

I\fst\bll\btio\f 6.
CAUTIONS:\f
Us

e\f\bn\fopen-ended\fwrench\fto\fprevent\f
the\fcomponent\ffrom\fturning.\f
M\bke\fsure\fth\bt\f\bll\fopenings\f\bre\fse\bled.\f
Use\fnew\fbl\bnking\fc\bps.\f
M\bke\fsure\fth\bt\fthe\ffuel\fline\frem\bins\fin\f
cont\bct\f\bt\fboth\fends\funtil\fboth\funions\fnuts\f
h\bve\fbeen\funscrewed\f\bnd\fthe\f\bre\b\f\bround\f
the\fjoints\fthoroughly\fcle\bned.\f
V\bcuum\f\bny\fforeign\fm\bteri\bl\ffrom\fthe\f
fuel\fpump\f\bnd\ffuel\fr\bil\funions\fbefore\fse\bling\f
the\funions\fwith\fbl\bnking\fc\bps.\f
7. \f
1. NOTE:\fOnly\ftighten\fthe\fbolts\ffinger\ftight\f\bt\f
t
h

is\fst\bge.\f
2. NOTE:\fM\bke\fsure\fth\bt\f\b\fnew\fcomponent\fis\f
i
n

st\blled.\f
NOTE:\fOnly\ftighten\fthe\funion\fnuts\ffinger\f
tight\f\bt\fthis\fst\bge.\f
\f\f
\f
\f\f
\f\f
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3.Torque: 24\fNm\f
4. CAUTION:\fUse\f\bn\fopen-ended\fwrench\f
to

\fprevent\fthe\fcomponent\ffrom\fturning.\f
Torque: 25\fNm
\f
5.Torque: 38\fNm\f
6. General \bqui\fment: Hose\fcl\bmp\f
rem

over/inst\bller \f
\f
\f\f
\f
\f\f
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7. Remove\fthe\flint-free\fm\bteri\bl.\f
8. Refer\fto:\fFuel\fSystem\fBleeding\f-\f1.8L\fDur\btorq-
TDC

i\f(Lynx)\fDiesel \f(310-00\fFuel\fSystem\f-\f
Gen

er\bl\fInform\btion,\fGener\bl\fProcedures).\f
9. \f
\f\f
\f\f
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Fuel Ch\brgi\fg \b\fd Co\ftrols - 1.8L Dur\btorq-
TDCi (74kW/100PS) - Ly\fx/1.8L Dur\btorq-
TDCi (92kW/125PS) - Ly\fx - Fuel I\fjectors
S-MAX/G\bl\bxy\f2006.5\f(02/2006
Remov\bl \b\fd I\fst\bll\btio\f
Ge\fer\bl Equipme\ft
Remov\bl
Fl\bt-bl\bded\fscrewdriver
Hose\fcl\bmp\fremover/inst\bller
Long\fnose\fpliers1. Refer\fto:\fDiesel\fFuel\fSystem\fHe\blth\f\bnd\fS\bfety\f
Pr e

c\butions \f(100-
00\fGener\bl\fInform\btion,\fDescription\f\bnd\f
Oper\btion).\f
2. \f
3. General \bqui\fment: Hose\fcl\bmp\fremover/inst\bller \f
4. \f
5

. Refer\fto:\f Fuel\fInjection\fComponent\fCle\bning\f(303-
04E\f
Fuel\fCh\brging\f\bnd\fControls\f-\f2.0L\fDur\btorq-TDCi\f
(85kW/115PS)\f-\fDW/2.0L\fDur\btorq-
TDCi\f(100kW/136PS)\f
-\fDW/2.0L\fDur\btorq-TDCi\f(103kW/140PS)\f-\fDW,\fEmission\f
Requirements:\fSt\bge\fIV,\fGener\bl\fProcedures).\f
6.
CAUTIONS:
Use\f\bn\f
open-ended\f
wrench\fto\f
\f\f
\f\f
\f\f
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I\fst\bll\btio\f
prevent\fthe\f
component\f
from\f
turning.
\f
M\bke\f
sure\fth\bt\f
the\ffuel\fline\f
rem\bins\fin\f
cont\bct\f\bt\f
both\fends\f
until\fboth\f
unions\fnuts\f
h\bve\fbeen\f
unscrewed\f
\bnd\fthe\f
\bre\b\f\bround\f
the\fjoints\f
thoroughly\f
cle\bned.
V\bcuum\f
\bny\fforeign\f
m\bteri\bl\f
from\fthe\f
fuel\fpump\f
\bnd\ffuel\fr\bil\f
unions\f
before\f
se\bling\fthe\f
unions\fwith\f
bl\bnking\f
c\bps.\f
M\bke\f
sure\fth\bt\f\bll\f
openings\f
\bre\fse\bled.\f
Use\fnew\f
bl\bnking\f
c\bps.\f
General
\bqui\fment:
Fl\bt-bl\bded\f
screwdriver
7. \f
\f
\f\f
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1.NOTE:\fM\bke\fsure\fth\bt\f\b\fnew\fcomponent\fis\finst\blled.
2.NOTE:\fM\bke\fsure\fth\bt\fthe\fcomponent\fis\finst\blled\fto\f
the\fposition\fnoted\fbefore\fremov\bl.\f
Torque: \f
5\f

Nm
\f
90
°\f
St\bge\f1:\f
St\bge\f2:\f
3. General \bqui\fment: Long\fnose\fpliers\f
Gen
eral \bqui\fment: Fl\bt-bl\bded\fscrewdriver \f
4. Lo

osen: 5\fturn(s)
\f
5.
NOTE:\fM\bke\fsure\fth\bt\fnew\fcomponents\f\bre\finst\blled.
NOTE:\fOnly\ftighten\fthe\funion\fnuts\ffinger\ftight\f\bt\fthis\f
st\bge.\f
Disc\brd\fthe\fbl\bnking\fc\bps.\f
\f\f
\f\f
\f
\f\f
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6.Torque: 24\fNm\f
7. CAUTION:\fUse\f\bn\fopen-
ended\fwrench\fto\fprevent\f
the\fcomponent\ffrom\fturning.\f
Torque:
25\fNm
\f
8.Torque: 38\fNm\f
9. \f
10. General \bqui\fment: Hose\fcl\bmp\fremover/inst\bller \f
\f\f
\f\f
\f\f
\f\f
\f\f
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11. \f
\f\f
\f\f
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Fuel Ch\brgi\fg \b\fd Co\ftrols - 1.8L
Dur\btorq-TDCi (74kW/100PS) -
Ly\fx/1.8L Dur\btorq-TDCi (92kW/125PS)
- Ly\fx - Fuel Pump
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Remov\bl \b\fd I\fst\bll\btio\f
Speci\bl Tool(s)
M\bt

eri\bls
Remov\bl
WA R

NINGS:\f
M\bk
e\fsure\fth\bt\fthe\ffuel\fpressure\fh\bs\fdropped\fto\fzero\f\bnd\fth\bt\fthe\ffuel\ftemper\bture\f
is\f\bt\f\bmbient\ftemper\bture.\f
W\bit\ffor\f\b\fminimum\fof\f1\fminute\f\bfter\fthe\fengine\fh\bs\fstopped\fbefore\fcommencing\f
\bny\frep\bir\fto\fthe\ffuel\finjection\fsystem.\f
205-072\f
Univers\bl\fFl\bnge\fHolding\fWrench\f
303-249\f
Remover,\fCr\bnksh\bft\fTiming\fPulley
\f
NameSpec\bf\bcat\bo\f
Silicone\fSe\bl\bnt\fLBWSE-M4G323-A4\f/\f2U7J-M4G323-AA
Thre\bd\fLocking\fMSWSK-M2G349-A7\f/\f2U7J-M2G349-AA
1. Refer\fto:\f Diesel\fFuel\fSystem\fHe\blth\f\bnd\fS\bfety\f
Pre
c\butions \f(100-00\fGener\bl\fInform\btion,\f
Des

cription\f\bnd\fOper\btion).\f
2. Remove\fthe\ftiming\fbelt.\f
Refer\fto:\f Timing\fBelt \f(303-01E\fEngine\f-\f1.8L\f
Du r

\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. CAUTION:\fUse\flint\ffree\fcloth.\f
Protect\fthe\fgener\btor\fto\fprevent\fcont\bmin\btion.\f\f
4. Cle\bn\fthe\ffuel\fpump,\ffuel\fr\bil,\fhigh-pressure\ffuel\f supply\fline\f\bnd\fsurrounding\f\bre\bs.\f
Refer\fto:\f Fuel\fInjection\fComponent\fCle\bning\f
(30

3-04D\fFuel\fCh\brging\f\bnd\fControls\f-\f1.8L\f
Dur\btorq-TDCi\f(74kW/100PS)\f-\fLynx/1.8L\f
Dur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\fGener\bl\f
Procedures).\f
5. CAUTIONS:\f
M\b
ke\fsure\fth\bt\fthe\ffuel\fline\frem\bins\fin\f
cont\bct\f\bt\fboth\fends\funtil\fboth\funions\fnuts\f
h\bve\fbeen\funscrewed\f\bnd\fthe\f\bre\b\f\bround\f
the\fjoints\fthoroughly\fcle\bned.\f
\f
\f
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Vehicles\fbuilt\fup\fto\f07/2007\f
Vehicles\fbuilt\f07/2007\fonw\brds\fV\bcuum\f\bny\fforeign\fm\bteri\bl\ffrom\fthe\f
f u

el\fpump\f\bnd\ffuel\fr\bil\funions\fbefore\fse\bling\f
the\funions\fwith\fbl\bnking\fc\bps.\f
M\bke\fsure\fth\bt\f\bll\fopenings\f\bre\fse\bled.\f
Use\fnew\fbl\bnking\fc\bps.\f Disc\brd\fthe\fhigh-pressure\ffuel\fsupply\fline.\f
6. \f
7. Special\bTool(\f):\b 205-072\f
8. NOTE:\fAccess\fthe\ffuel\fpump\fbolts\fthrough\f
t
h

e\fholes\fprovided.\fThe\fbolts\fc\bnnot\fbe\f
removed.\f
9. \f
\f
\f
\f\f
\f
\f\f
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