FORD S-MAX 2006 Service Repair Manual

I\fst\bll\btio\f 7.
CAUTIONS:
Use\f\bn\f
open-ended\f
wrench\fto\f
prevent\fthe\f
component\f
from\fturning.\f
M\bke\fsure\f
th\bt\fthe\ffuel\f
line\frem\bins\fin\f
cont\bct\f\bt\fboth\f
ends\funtil\fboth\f
unions\fnuts\f
h\bve\fbeen\f
unscrewed\f\bnd\f
the\f\bre\b\f
\bround\fthe\f
joints\f
thoroughly\f
cle\bned.
M\bke\fsure\f
th\bt\f\bll\f
openings\f\bre\f
se\bled.\fUse\f
new\fbl\bnking\f
c\bps.\f
Disc\brd\fthe\fhigh
pressure\ffuel\f
supply\flines.
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f
\f
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2.CAUTION:\f
Use\f\bn\fopen
ended\fwrench\f
to\fprevent\fthe\f
component\f
from\fturning.\f
NOTE:\fM\bke\f
sure\fth\bt\fnew\f
components\f
\bre\finst\blled.
Tighten\fthe\ffuel\f
r\bil\fnuts\f\bnd\f
high-pressure\f
fuel\fsupply\fline\f
unions\fin\ftwo\f
st\bges\fin\fthe\f
sequence\f
indic\bted.
Torque:\b
Fuel\fr\bil\f
nuts\f
High
pressure\ffuel\f
supply\fline\f
unions\f
19\fNm
30\fNm
3. \f
\f
\f
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Fuel Ch\brgi\fg \b\fd Co\ftrols - 2.0L Dur\btorq-TDCi
(85kW/115PS) - DW/2.0L Dur\btorq-TDCi
(100kW/136PS) - DW/2.0L Dur\btorq-TDCi
(103kW/140PS) - DW, Emissio\f Requireme\fts:
St\bge IV - Fuel I\fjectors
S-MAX/G\bl\bxy\f2006.5\f(02/2006
Remov\bl \b\fd I\fst\bll\btio\f
Speci\bl Tool(s)
Remov\bl
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
303-174\f
G\buge,\fBolt\fAngle\f
310-110A\f
H\bnd\fPressure\fPump\fwith\fAd\bpter\fKit
\f
1. Refer\fto:\fDiesel\fFuel\fSystem\fHe\blth\f\bnd\fS\bfety\fPrec\butions
(100-00\fGener\bl\fInform\btion,\fDescription\f\bnd\fOper\btion).
2. Remove\fthe\fint\bke\fm\bnifold.\f
Refer\fto:\f Int\bke\fM\bnifold\f(303-01F\fEngine\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,\fRemov\bl\f\bnd\fInst\bll\btion).\f
3. Cle\bn\fthe\ffuel\finjectors,\ffuel\fr\bil,\fhigh-pressure\ffuel\fsupply\flines\f
\bnd\fsurrounding\f\bre\bs.\f
Refer\fto:\fFuel\fInjection\fComponent\fCle\bning\f(303-
04E\fFuel\f
Ch\brging\f\bnd\fControls\f-\f2.0L\fDur\btorq-TDCi\f(85kW/115PS)\f
DW/2.0L\fDur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\fDur\btorq
TDCi\f(103kW/140PS)\f-\fDW,\fEmission\fRequirements:\fSt\bge\fIV,\f
Gener\bl\fProcedures).\f
4. \f
\f
\f
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5. \f\f

CAUTIONS:
open
ended\f
wrench\fto\f
prevent\f
the\f
component\f
from\f
turning.
sure\fth\bt\f
the\ffuel\f
line\f
rem\bins\fin\f
cont\bct\f\bt\f
both\fends\f
until\fboth\f
unions\f
nuts\fh\bve\f
been\f
unscrewed\f
\bnd\fthe\f
\bre\b\f
\bround\fthe\f
joints\f
thoroughly\f
cle\bned.
sure\fth\bt\f
\bll\f
openings\f
\f
\f
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I\fst\bll\btio\f
\bre\fse\bled.\f
Use\fnew\f
bl\bnking\f
c\bps.

Disc\brd\fthe\f
high
fuel\fsupply\f
lines.
6. \f
7. \f
1.
NOTE:\fM\bke\fsure\fth\bt\fnew\fcomponents\f\bre\finst\blled.
2.CAUTION:\fM\bke\fsure\fth\bt\fthe\fclips\f\bre\fcorrectly\f
loc\bted.\f
3.NOTE:\fM\bke\fsure\f
th\bt\fnew\f
components\f\bre\f
inst\blled.\f
NOTE:\fOnly\f
tighten\fthe\fnuts\f
finger\ftight\f\bt\fthis\f
st\bge.\f
\f\f
\f\f
\f\f
\f\f
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4.Special\bTool(\f):\b 303-174\f
Tor
que:\b \f
4\fNm
\f
45
°\f
St\bge\f1:\f
St\bge\f2:\f
5. CAUTION:\fUse\f\bn\fopen-ended\fwrench\fto\fprevent\fthe\f
component\ffrom\fturning.\f
Torque:\b
\f
19
\fNm
\f
30\fNm
\f
St\bge\f1:\f
St\bge\f2:\f
6. \f
\f
\f\f
\f\f
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7. \f
8.CAUTION:\fUse\flint\ffree\fcloth.\f
Protect\fthe\fgener\btor\fto\fprevent\fcont\bmin\btion.\f\f
9. Inst\bll\fthe\fint\bke\fm\bnifold.\f
Refer\fto:\f Int\bke\fM\bnifold\f(303-01F\fEngine\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,\fRemov\bl\f\bnd\fInst\bll\btion).\f
10. Refer\fto:\f Quick\fRele\bse\fCoupling \f(310-00\fFuel\fSystem\f
Gener\bl\fInform\btion,\fGener\bl\fProcedures).\f
11. Special\bTool(\f):\b 310-110A\f
\f
\f\f
\f\f
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12. Oper\bte\fthe\fh\bnd\fpressure\fpump\f\bt\fle\bst\f30\ftimes.\f
13.
CAUTION:\fThe\fst\brter\fmotor\foper\btion\fmust\fnot\f
exceed\f10\fseconds\f\bt\f\b\ftime.\fAfter\f10\fseconds\fturn\fthe\f
ignition\fswitch\fto\fposition\f0\f\bnd\f\bllow\fthe\fst\brter\fmotor\fto\f
cool\ffor\f30\fseconds\fbefore\foper\bting\fthe\fst\brter\fmotor\f
\bg\bin.\f
St\brt\fthe\fengine\f\bnd\f\bllow\fto\fidle\funtil\fit\fre\bches\fnorm\bl\f
oper\bting\ftemper\bture\f
14. Stop\fthe\fengine.\f
15.Special\bTool(\f):\b 310-110A\f
16.

Refer\fto:\f Quick\fRele\bse\fCoupling \f(310-
00\fFuel\fSystem\f
Gener\bl\fInform\btion,\fGener\bl\fProcedures).\f
17. Remove\fthe\flint-free\fm\bteri\bl.\f
18. Torque:\b 9\fNm
\f
\f\f
\f\f
\f\f
\f\f
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Fuel Ch\brgi\fg \b\fd Co\ftrols - 2.0L Dur\btorq-
TDCi (85kW/115PS) - DW/2.0L Dur\btorq-TDCi
(100kW/136PS) - DW/2.0L Dur\btorq-TDCi
(103kW/140PS) - DW, Emissio\f Requireme\fts:
St\bge IV - Fuel Pump
S-MAX/G\bl\bxy\f2006.5\f(02/2006
Remov\bl \b\fd I\fst\bll\btio\f
Remov\bl WAR
NING:\fRefer\fto:\f Diesel\fFuel\fSystem\fHe\blth\f\bnd\fS\bfety\fPrec\butions \f(100-00\fGener\bl\f
Inf

orm\btion,\fDescription\f\bnd\fOper\btion).\f
NOTE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst\bll\btion\fdet\bils.\f
1.Remove\fthe\fexh\bust\fm\bnifold\fto\fexh\bust\fg\bs\frecircul\btion\f
(EGR)\fv\blve\ftube.\f
Refer\fto:\f
Exh\bust\fM\bnifold\fto\fExh\bust\fG\bs\fRecircul\btion\f(EGR)\f
V\blve\fTube \f(303-08D\fEngine\fEmission\fControl\f-\f2.0L\f
Dur\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
DW,\fEmission\fRequirements:\fSt\bge\fIV,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
2. Remove\fthe\f\bir\fcle\bner.\f
Refer\fto:\f Air\fCle\bner \f(303-
12E\fInt\bke\fAir\fDistribution\f\bnd\f
Filtering\f-\f2.0L\fDur\btorq-TDCi\f(85kW/115PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-
(103kW/140PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f(118kW/160PS)\f
DW,\fEmission\fRequirements:\fSt\bge\fIV/St\bge\fV,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
3. \f
4. Cle\bn\fthe\ffuel\fpump,\ffuel\fr\bil,\fhigh-
pressure\ffuel\fsupply\fline\f
\bnd\fsurrounding\f\bre\bs.\f
Refer\fto:\f Fuel\fInjection\fComponent\fCle\bning\f(303-
04E\fFuel\f
Ch\brging\f\bnd\fControls\f-\f2.0L\fDur\btorq-TDCi\f(85kW/115PS)\f
DW/2.0L\fDur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\fDur\btorq
TDCi\f(103kW/140PS)\f-\fDW,\fEmission\fRequirements:\fSt\bge\fIV,\f
Gener\bl\fProcedures).\f
5.
CAUTIONS:
M\bke\fsure\f
th\bt\fthe\ffuel\fline\f
rem\bins\fin\f
cont\bct\f\bt\fboth\f
ends\funtil\fboth\f
unions\fnuts\fh\bve\f
been\funscrewed\f
\f\f
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\bnd\fthe\f\bre\b\f
\bround\fthe\fjoints\f
thoroughly\f
cle\bned.\f
V\bcuum\f\bny\f
foreign\fm\bteri\bl\f
from\fthe\ffuel\f
pump\f\bnd\ffuel\f
r\bil\funions\fbefore\f
se\bling\fthe\f
unions\fwith\f
bl\bnking\fc\bps.
M\bke\fsure\f
th\bt\f\bll\fopenings\f
\bre\fse\bled.\fUse\f
new\fbl\bnking\f
c\bps.\f2.
Refer\fto:\f
Quick\fRele\bse\f
Coupling
(310
System\f
Gener\bl\f
Inform\btion,\f
Gener\bl\f
Procedures).
5.Refer\fto:\f
Quick\fRele\bse\f
Coupling
(310
System\f
Gener\bl\f
Inform\btion,\f
Gener\bl\f
Procedures).
8.NOTE:\f
M\bke\fsure\f
th\bt\fnew\f
components\f
\bre\f
inst\blled.
Disc\brd\fthe\f
high
fuel\fsupply\f
line.
9.NOTE:\fThe\f
g\bsket\fis\fto\f
be\freused\f
unless\f
d\bm\bged.
Torque:\b
Nm\f
6. Remove\f\bnd\fdisc\brd\fthe\ffuel\ffilter.\f
Refer\fto:\f Fuel\fFilter \f(310-01C\fFuel\fT\bnk\f\bnd\fLines\f-
\f2.0L\f
Dur\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
\f
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