FORD S-MAX 2006 Service Repair Manual
Manufacturer: FORD, Model Year: 2006, Model line: S-MAX, Model: FORD S-MAX 2006Pages: 4402, PDF Size: 93.08 MB
Page 1651 of 4402
3.3.\b
Check\fthe\f\bccessory\fdrive\fbelt\ffor\fpilling.\fThe\fcondition\fof\fthe\f\bccessory\fdrive\fbelt\f
s hould\fbe\fcomp\bred\f\bg\binst\fthe\fillustr\btion.\f
1. Sm\bll\fsc\bttered\fpills.\fNot\fconsidered\f\b\fconcern.\fNo\f\bction\frequired.\f
2.
Sm\bll\fsc\bttered\fpills.\fNot\fconsidered\f\b\fconcern.\fNo\f\bction\frequired.\f
3. Longer\fpills\fup\fto\f50%\fof\fthe\frib\fheight.\fPossible\fnoise\fconcern.\fINSTALL\f\b\fnew\f \bccessory\fdrive\fbelt\fif\fnoise\fis\f\bpp\brent.\fREFER\fto:\f Accessory\fDrive\fBelt \f(303-05A\fAccessory\fDrive\f-\f2.0L\fDur\btec-HE\f
(10
7kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4/2.3L\f
Dur\btec-HE\f(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05A\fAccessory\fDrive\f-\f2.0L\fDur\btec-HE\f
(10
7kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4/2.3L\f
Dur\btec-HE\f(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05C\fAccessory\fDrive\f-
\f2.5L\fDur\btec\f(162kW/220PS)\f
-\fVI5,\fRemov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt\f(303-05D\fAccessory\fDrive\f-\f1.8L\fDur\btorq-TDCi\f
(74
kW/100PS)\f-\fLynx/1.8L\fDur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\f
Inst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05F\fAccessory\fDrive\f-\f2.2L\fDur\btorq-TDCi\f
(12
9kW/175PS)\f-\fDW,\fRemov\bl\f\bnd\fInst\bll\btion).\f
4. Longer\fpills\fup\fto\f50%\fof\fthe\frib\fheight.\fPossible\fnoise\fconcern.\fINSTALL\f\b\fnew\f \bccessory\fdrive\fbelt\fif\fnoise\fis\f\bpp\brent.\fREFER\fto:\f Accessory\fDrive\fBelt \f(303-05A\fAccessory\fDrive\f-\f2.0L\fDur\btec-HE\f
(10
7kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4/2.3L\f
Dur\btec-HE\f(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05A\fAccessory\fDrive\f-\f2.0L\fDur\btec-HE\f
(10
7kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4/2.3L\f
Dur\btec-HE\f(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05C\fAccessory\fDrive\f-
\f2.5L\fDur\btec\f(162kW/220PS)\f
-\fVI5,\fRemov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt\f(303-05D\fAccessory\fDrive\f-\f1.8L\fDur\btorq-TDCi\f
(74
kW/100PS)\f-\fLynx/1.8L\fDur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\f
Inst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05F\fAccessory\fDrive\f-\f2.2L\fDur\btorq-TDCi\f
(1 2
9kW/175PS)\f-\fDW,\fRemov\bl\f\bnd\fInst\bll\btion).\f
5. He\bvy\fdeposits\fin\fthe\fgrooves.\fPossible\fnoise\f\bnd\fst\bbility\fconcern.\fINSTALL\f\b\fnew\f \bccessory\fdrive\fbelt.\fREFER\fto:\f Accessory\fDrive\fBelt \f(303-05A\fAccessory\fDrive\f-\f2.0L\fDur\btec-HE\f
\f
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Page 1652 of 4402
(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4/2.3L\f
Dur\btec-HE\f(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt\f(303-05A\fAccessory\fDrive\f-\f2.0L\fDur\btec-HE\f
(10
7kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4/2.3L\f
Dur\btec-HE\f(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05C\fAccessory\fDrive\f-
\f2.5L\fDur\btec\f(162kW/220PS)\f
-\fVI5,\fRemov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt\f(303-05D\fAccessory\fDrive\f-\f1.8L\fDur\btorq-TDCi\f
(74
kW/100PS)\f-\fLynx/1.8L\fDur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\f
Inst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05F\fAccessory\fDrive\f-\f2.2L\fDur\btorq-TDCi\f
(12
9kW/175PS)\f-\fDW,\fRemov\bl\f\bnd\fInst\bll\btion).\f
6. He\bvy\fdeposits\fin\fthe\fgrooves.\fPossible\fnoise\f\bnd\fst\bbility\fconcern.\fINSTALL\f\b\fnew\f \bccessory\fdrive\fbelt.\fREFER\fto:\f
Accessory\fDrive\fBelt \f(303-05A\fAccessory\fDrive\f-\f2.0L\fDur\btec-HE\f
(1 0
7kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4/2.3L\f
Dur\btec-HE\f(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05A\fAccessory\fDrive\f-\f2.0L\fDur\btec-HE\f
(10
7kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4/2.3L\f
Dur\btec-HE\f(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05C\fAccessory\fDrive\f-
\f2.5L\fDur\btec\f(162kW/220PS)\f
-\fVI5,\fRemov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt\f(303-05D\fAccessory\fDrive\f-\f1.8L\fDur\btorq-TDCi\f
(74
kW/100PS)\f-\fLynx/1.8L\fDur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\f
Inst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05F\fAccessory\fDrive\f-\f2.2L\fDur\btorq-TDCi\f
(12
9kW/175PS)\f-\fDW,\fRemov\bl\f\bnd\fInst\bll\btion).\f
Incorrect\ffitment\f
Ac
cessory\fdrive\fbelt\fnoise\fc\bn\fbe\fgener\bted\fby\fthe\f\bccessory\fdrive\fbelt\fbeing\fincorrectly\f
fitted\fon\fthe\fpulley\f\bs\fshown\fin\fthe\ffollowing\fillustr\btion.\fM\bke\fsure\fth\bt\f\bll\fthe\fV\fgrooves\f
on\fthe\f\bccessory\fdrive\fbelt\fcont\bct\fcorrectly\fwith\fthe\fpulley.\f
4. 4.\b
If\fthe\fc\buse\fis\fnot\fvisu\blly\fevident,\fverify\fthe\fsymptom\f\bnd\frefer\fto\fthe\fSymptom\f
C
h\brt.\f
Symptom\bChart\b
Sym\ftomPossib\be SourcesAction
Accessory\fdrive\fbelt\f
noiseAccessory\fdrive\f
system\f
*CHECK\fthe\fsystem\fwith\fthe\fengine\frunning\f\bnd\f
the\f\bccessory\fdrive\fbelt\fremoved\f(only\frun\fthe\f
engine\ffor\f\b\fvery\fshort\fperiod).\fIf\f\b\fnoise\fis\f
\bpp\brent,\fthe\fc\buse\fis\fnot\fthe\f\bccessory\fdrive\f
system.\fIf\f\b\fnoise\fis\fnot\f\bpp\brent,\fthe\fc\buse\fis\f
the\f\bccessory\fdrive\fsystem.\fCHECK\fwhere\fthe\f
noise\fis\fcoming\ffrom.\fUse\f\b\fstethoscope\for\fother\f
listening\fdevice\fto\fdetermine\fthe\fsource\fof\fthe\f
noise.\fINSTALL\fnew\fcomponents\f\bs\fnecess\bry.\f
*
\f\f
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Page 1653 of 4402
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
Accessory\fdrive\f
belt\fincorrectly\f
inst\blled.\f
*CHECK\fthe\f\bccessory\fdrive\fbelt\fis\fcorrectly\f
inst\blled\fin\fthe\fpulley\fgrooves.\fINSTALL\f\b\fnew\f
\bccessory\fdrive\fbelt\f\bs\fnecess\bry.\fREFER\fto:\f Accessory\fDrive\fBelt \f(303-05A\fAccessory\f
Dri
ve\f-\f2.0L\fDur\btec-HE\f(107kW/145PS)\f-\f
MI4/2.0L\fDur\btec-HE\fFlex\fFuel\f
(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\f
Inst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05A\fAccessory\f
Dri
ve\f-\f2.0L\fDur\btec-HE\f(107kW/145PS)\f-\f
MI4/2.0L\fDur\btec-HE\fFlex\fFuel\f
(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\f
Inst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05C\fAccessory\f
Dr i
ve\f-\f2.5L\fDur\btec\f(162kW/220PS)\f-\fVI5,\f
Remov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05D\fAccessory\f
Dri
ve\f-\f1.8L\fDur\btorq-TDCi\f(74kW/100PS)\f-\f
Lynx/1.8L\fDur\btorq-TDCi\f(92kW/125PS)\f-\f
Lynx,\fRemov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05F\fAccessory\f
Dri
ve\f-\f2.2L\fDur\btorq-TDCi\f(129kW/175PS)\f-
\f
DW,\fRemov\bl\f\bnd\fInst\bll\btion).\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
*
Pulley(s).\f
*CHECK\fthe\fpulley(s)\ffor\fd\bm\bge,\ffreedom\fof\f
rot\btion,\fstone\fentr\bpment\f\bnd\f\blignment.\f
INSTALL\fnew\fcomponents\f\bs\fnecess\bry.\fTEST\fthe\f
system\ffor\fnorm\bl\foper\btion.\f
*
Lubric\bnt\for\f
other\f
cont\bmin\btion.\f
*CHECK\fthe\f\bccessory\fdrive\fbelt\ffor\fcont\bmin\btion\f
or\fd\bm\bge.\fRECTIFY\fthe\fsource\fof\fthe\fle\bk\f\bnd\f
INSTALL\f\b\fnew\f\bccessory\fdrive\fbelt.\fREFER\fto:\f
Accessory\fDrive\fBelt \f(303-05A\fAccessory\f
Dr i
ve\f-\f2.0L\fDur\btec-HE\f(107kW/145PS)\f-\f
MI4/2.0L\fDur\btec-HE\fFlex\fFuel\f
(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\f
Inst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05A\fAccessory\f
Dri
ve\f-\f2.0L\fDur\btec-HE\f(107kW/145PS)\f-\f
MI4/2.0L\fDur\btec-HE\fFlex\fFuel\f
(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\f
Inst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05C\fAccessory\f
Dri
ve\f-\f2.5L\fDur\btec\f(162kW/220PS)\f-\fVI5,\f
Remov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05D\fAccessory\f
Dri
ve\f-\f1.8L\fDur\btorq-TDCi\f(74kW/100PS)\f-\f
Lynx/1.8L\fDur\btorq-TDCi\f(92kW/125PS)\f-\f
Lynx,\fRemov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05F\fAccessory\f
Dri
ve\f-\f2.2L\fDur\btorq-TDCi\f(129kW/175PS)\f-
\f
DW,\fRemov\bl\f\bnd\fInst\bll\btion).\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
*
NOTE:\fSque\bl\fis\f
defined\f\bs\f\b\f
continuous\fshriek,\fAccessory\fdrive\f
belt\ftensioner\f
worn,\fd\bm\bged\f
*CHECK\fthe\f\bccessory\fdrive\fbelt\ftensioner\ffor\f
correct\foper\btion,\fd\bm\bge\for\fcont\bmin\btion.\f
REFER\fto\fthe\fAccessory\fDrive\fBelt\fTensioner\f
*
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Page 1654 of 4402
most\fnotice\bble\f
when\fthe\fengine\fis\f
being\f\bcceler\bted\f
or\fwith\felectric\bl\f
lo\bd.\f
Accessory\fdrive\fbelt\f
sq
ue\bl
or\fcont\bmin\bted\f
with\foil.\fComponent\fTest\fin\fthis\fprocedure.\fINSTALL\f\b\f
new\f\bccessory\fdrive\fbelt\ftensioner\f\bs\fnecess\bry.\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
NOTE:\fWhine\fis\f
defined\f\bs\f\b\f
continuous\fnoise\f\bt\f
the\fs\bme\f
frequency,\f
gener\blly\f
\bssoci\bted\fwith\f
pl\bstic\fpulleys.\f
Accessory\fdrive\fbelt\f
wh
ine
Poor\fsurf\bce\f
finish\fon\f
\bccessory\fdrive\f
belt\fidler\fpulley\f
fl\bt\fsurf\bce(s).\f
*REMOVE\fthe\f\bccessory\fdrive\fbelt.\fREFER\fto:\f
Accessory\fDrive\fBelt \f(303-05A\fAccessory\f
Dri
ve\f-\f2.0L\fDur\btec-HE\f(107kW/145PS)\f-\f
MI4/2.0L\fDur\btec-HE\fFlex\fFuel\f
(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\f
Inst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05A\fAccessory\f
Dr i
ve\f-\f2.0L\fDur\btec-HE\f(107kW/145PS)\f-\f
MI4/2.0L\fDur\btec-HE\fFlex\fFuel\f
(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\f
Inst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05C\fAccessory\f
Dri
ve\f-\f2.5L\fDur\btec\f(162kW/220PS)\f-\fVI5,\f
Remov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05D\fAccessory\f
Dri
ve\f-\f1.8L\fDur\btorq-TDCi\f(74kW/100PS)\f-\f
Lynx/1.8L\fDur\btorq-TDCi\f(92kW/125PS)\f-\f
Lynx,\fRemov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05F\fAccessory\f
Dri
ve\f-\f2.2L\fDur\btorq-TDCi\f(129kW/175PS)\f-
\f
DW,\fRemov\bl\f\bnd\fInst\bll\btion).\f
INSPECT\fthe\fidler\fpulley(s)\ffor\fsurf\bce\ffinish.\f
INSTALL\f\b\fnew\fidler\fpulley(s)\f\bs\fnecess\bry.\fTEST\f
the\fsystem\ffor\fnorm\bl\foper\btion.\f
*
Accessory\fdrive\f
belt\fidler\fpulley\f
be\bring\ff\bilure.\f
*REMOVE\fthe\f\bccessory\fdrive\fbelt.\fREFER\fto:\f
Accessory\fDrive\fBelt \f(303-05A\fAccessory\f
Dr i
ve\f-\f2.0L\fDur\btec-HE\f(107kW/145PS)\f-\f
MI4/2.0L\fDur\btec-HE\fFlex\fFuel\f
(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\f
Inst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05A\fAccessory\f
Dri
ve\f-\f2.0L\fDur\btec-HE\f(107kW/145PS)\f-\f
MI4/2.0L\fDur\btec-HE\fFlex\fFuel\f
(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\f
Inst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05C\fAccessory\f
Dri
ve\f-\f2.5L\fDur\btec\f(162kW/220PS)\f-\fVI5,\f
Remov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05D\fAccessory\f
Dri
ve\f-\f1.8L\fDur\btorq-TDCi\f(74kW/100PS)\f-\f
Lynx/1.8L\fDur\btorq-TDCi\f(92kW/125PS)\f-\f
Lynx,\fRemov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05F\fAccessory\f
Dri
ve\f-\f2.2L\fDur\btorq-TDCi\f(129kW/175PS)\f-
\f
DW,\fRemov\bl\f\bnd\fInst\bll\btion).\f
INSPECT\fthe\fidler\fpulley(s)\ffor\fsmooth\frot\btion.\f
INSTALL\f\b\fnew\fidler\fpulley(s)\f\bs\fnecess\bry.\fTEST\f
the\fsystem\ffor\fnorm\bl\foper\btion.\f
*
NOTE:\fChirp\fis\fPulley\f*CHECK\fth\bt\fthe\f\bccessory\fdrive\fbelt\fis\frunning\f
*
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Page 1655 of 4402
Component\bTests\b
Accessory\bDrive\bBelt\bTensioner\b\f\bStatic\bCheck\b
The\f\bccessory\fdrive\fbelt\ftensioner\fm\by\fbe\fchecked\fst\btic\blly\f\bs\ffollows:\f1. 1.\b
Inspect\fthe\f\bre\b\fsurrounding\fthe\f\bccessory\fdrive\fbelt\ftensioner\ffor\flubric\bnt\for\f
o
ther\fcont\bmin\btion.\fRectify\f\bny\fle\bks\fbefore\finst\blling\f\b\fnew\f\bccessory\fdrive\fbelt\f
tensioner.\fIf\fthe\f\bccessory\fdrive\fbelt\ftensioner\fis\fcont\bmin\bted,\fdo\fnot\f\bttempt\fto\f
cle\bn\fit\f\bs\fthe\fd\bmping\fmech\bnism\finside\fm\by\fbe\fd\bm\bged.\fINSTALL\f\b\fnew\f
\bccessory\fdrive\fbelt\ftensioner\f\bs\fnecess\bry.\fTEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
2. 2.\b
Det\bch\fthe\f\bccessory\fdrive\fbelt\fin\fthe\f\bre\b\fof\fthe\f\bccessory\fdrive\fbelt\ftensioner.\f
3
. NOTE:\fThe\f\bccessory\fdrive\fbelt\ftensioner\fh\bs\f\b\fd\bmping\ffe\bture,\fwhich\fis\fusu\blly\f\b\f
fr
iction\fdevice,\ftherefore\fsome\ffriction\fwithin\fthe\fsystem\fis\fnorm\bl.\f
3.\b Using\fthe\fcorrect\ftool,\fmove\fthe\f\bccessory\fdrive\fbelt\ftensioner\ffrom\fits\frel\bxed\f
po
sition\fthrough\fits\ffull\fstroke\f\bnd\fb\bck\fto\fthe\frel\bxed\fposition\fto\fm\bke\fsure\fthere\f
is\fno\fexcessive\fstick,\fgr\bb\for\fbind,\f\bnd\fto\fm\bke\fsure\fthere\fis\ftension\fon\fthe\f
\bccessory\fdrive\fbelt\ftensioner\fspring.\f
4. 4.\b
Rot\bte\fthe\f\bccessory\fdrive\fbelt\ftensioner\fpulley\f\bnd\fcheck\ffor\fd\bm\bge,\ffreedom\fof\f
r
ot\btion\f\bnd\f\blignment.\fINSTALL\f\b\fnew\f\bccessory\fdrive\fbelt\ftensioner\f\bs\fnecess\bry.\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
5. 5.\b
If\fthe\f\bccessory\fdrive\fbelt\ftensioner\fmeets\fthe\f\bbove\fcriteri\b,\fproceed\fto\ftest\fthe\f
\b
ccessory\fdrive\fbelt\ftensioner\fdyn\bmic\blly.\fIf\fthe\f\bccessory\fdrive\fbelt\ftensioner\f
does\fnot\fmeet\fthe\f\bbove\fcriteri\b,\fINSTALL\f\b\fnew\f\bccessory\fdrive\fbelt\ftensioner.\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
Accessory\bDrive\bBelt\bTensioner\b\f\bDynamic\bCheck\b
defined\f\bs\f\b\f
twittering\fnoise,\f
often\fintermittent\f
Accessory\fdrive\fbelt\f
ch
irp
mis\blignment\f
(usu\blly\fevident\f
\bt\fidle).\fcentr\blly\fon\fthe\ffl\bt\fpulleys.\fTEST\fthe\fsystem\ffor\f
norm\bl\foper\btion.\fCHECK\fthe\fpulleys\ffor\fexcessive\fend\fflo\bt\f\bnd\f
bent\ffl\bnges.\f
With\fthe\fengine\frunning\f\bt\fidle,\fuse\f\b\f
stethoscope\fto\fidentify\fthe\fsource\fof\fthe\fnoise.\f
INSTALL\fnew\fcomponents\f\bs\fnecess\bry.\fTEST\fthe\f
system\ffor\fnorm\bl\foper\btion.\f
*
*
NOTE:\fR\bttle\fis\f
defined\f\bs\f\b\f
met\bllic\fknocking\f
noise\f
Accessory\fdrive\fbelt\f
r
\bt
tle
Accessory\fdrive\f
belt\ftensioner\f
hitting\fthe\fend\f
stops.\f
*CHECK\fthe\f\bccessory\fdrive\fbelt\ftensioner\ffor\f
correct\foper\btion\for\fd\bm\bge.\fREFER\fto\fthe\f
Accessory\fDrive\fBelt\fTensioner\fComponent\fTest\f
in\fthis\fprocedure.\fINSTALL\f\b\fnew\f\bccessory\fdrive\f
belt\ftensioner\f\bs\fnecess\bry.\fTEST\fthe\fsystem\ffor\f
norm\bl\foper\btion.\f
*
Loose\f
components\for\f
h\brdw\bre.\f
*CHECK\fthe\fcomponents\for\fh\brdw\bre\ffor\fcorrect\f
inst\bll\btion\f\bnd\ftighten\f\bs\fnecess\bry.\fTEST\fthe\f
system\ffor\fnorm\bl\foper\btion.\f
*
Accessory\fdrive\fbelt\f
fr\byingAccessory\fdrive\f
belt.\f Pulley(s).\f
*
*CHECK\fthe\fextent\fof\fthe\ffr\bying\fby\freferring\fto\f
the\fillustr\btions\fshown\fin\fthe\fVisu\bl\fInspection\f
section.\fOnly\fINSTALL\f\b\fnew\f\bccessory\fdrive\fbelt\f
if\fthe\ffr\bying\fis\fwithin\fthe\fcriteri\b\fquoted\fin\fthe\f
Visu\bl\fInspection\fsection.\fTEST\fthe\fsystem\ffor\f
norm\bl\foper\btion.\f CHECK\fthe\fpulley(s)\ffor\fd\bm\bge,\ffreedom\fof\f
rot\btion\f\bnd\f\blignment.\fINSTALL\fnew\fcomponents\f
\bs\fnecess\bry.\fTEST\fthe\fsystem\ffor\fnorm\bl\f
oper\btion.\f
*
*
Стр. 7 из
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Page 1656 of 4402
The\f\bccessory\fdrive\fbelt\ftensioner\fm\by\fbe\fchecked\fdyn\bmic\blly\f\bs\ffollows:\f1. 1.\b
With\fthe\fengine\frunning,\fobserve\fthe\f\bccessory\fdrive\fbelt\ftensioner\fmovement.\f
T
he\f\bccessory\fdrive\fbelt\ftensioner\fshould\fmove\f(respond)\fwhen\fthe\fengine\fis\f
\bcceler\bted\fr\bpidly\for\fwhen\fthe\fA/C\fclutch\fcycles\fON\f\bnd\fOFF\f(the\fdegree\fof\f
movement\fc\bn\fbe\fup\fto\f4\fmm).\fIf\fthe\f\bccessory\fdrive\fbelt\ftensioner\fmovement\fis\f
not\fconst\bnt\fwithout\fengine\f\bcceler\btion\for\fA/C\fclutch\fcycling,\f\b\fpulley\for\fsh\bft\fis\f
possibly\fbent,\fout\fof\fround,\for\fthe\fd\bmping\fmech\bnism\finside\fthe\f\bccessory\fdrive\f
belt\ftensioner\fm\by\fbe\fd\bm\bged.\fINSTALL\f\b\fnew\f\bccessory\fdrive\fbelt\ftensioner\f\bs\f
necess\bry.\fTEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
2. 2.\b
Excessive\f\bccessory\fdrive\fbelt\frideout\f(uneven\fdepth\fof\fgrooves\fin\fthe\f\bccessory\f
d
rive\fbelt)\fm\by\fc\buse\fexcessive\f\bccessory\fdrive\fbelt\ftensioner\fmovement.\fCheck\f
the\fcondition\fby\finst\blling\f\b\fnew\f\bccessory\fdrive\fbelt.\fREFER\fto:\f\f
Accessory\fDrive\fBelt \f(
303-05A\fAccessory\fDrive\f-\f2.0L\fDur\btec-HE\f(107kW/145 PS)\f-\f
MI4/2.0L\fDur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05A\fAccessory\fDrive\f-\f2.0L\fDur\btec-HE\f(107kW/145
PS)\f-\f
MI4/2.0L\fDur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05C\fAccessory\fDrive\f-\f2.5L\fDur\btec\f(162kW/220PS)
\f-\f
VI5,\fRemov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05D\fAccessory\fDrive\f-\f1.8L\fDur\btorq-TDCi\f(74kW/1
00PS)\f
-\fLynx/1.8L\fDur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05F\fAccessory\fDrive\f-\f2.2L\fDur\btorq-TDCi\f
(12
9kW/175PS)\f-\fDW,\fRemov\bl\f\bnd\fInst\bll\btion).\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
Стр. 8 из 8
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Page 1657 of 4402
Accessory\bDrive\b\f\b1.8L\bDuratorq\fTDCi\b
(74kW/100PS)\b\f\bLynx/1.8L\bDuratorq\f
TDCi\b(92kW/125PS)\b\f\bLynx\b\f\bAccessory\b
Drive\bBelt
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal\band\bInstallation\b
General\bEquipment\b
Removal\b
WAR
NING:\fM\bke\fsure\fth\bt\fthe\fignition\fkey\fis\fremoved.\f
N O
TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst\bll\btion\fdet\bils.\f
Dowel\fwith\f\b\fdi\bmeter\fof\f4\fmm
1. \f
2. \f
3. CAUTION:\fM\bke\fsure\fth\bt\fthe\finside\fof\f
t h
e\fpipe\fends\f\bre\fcle\bn\f\bnd\ffree\fof\foil\f
residue.\f
NOTE:\fNote\fthe\forient\btion\fof\fthe\fcl\bmp\fto\f
\bid\finst\bll\btion.\f
4. Remove\fthe\ffront\fright\fwheel.\f
Refer\fto:\f Wheel\f\bnd\fTire\f(204-04\fWheels\f\bnd\f
Tir
es,\fRemov\bl\f\bnd\fInst\bll\btion).\f
5. \f
\f\f
\f\f
\f\f
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Page 1658 of 4402
Installation\b6. \f\f
2.Ge
neral \bqui\fment:
Dowel\fwith\f\b\fdi\bmeter\f
of\f4\fmm\f
1. NOTE:\fM\bke\fsure\fth\bt\fthe\fcl\bmp\fis\finst\blled\f
t
o
\fthe\fs\bme\forient\btion\f\bs\fwhen\fremoved.\f
To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
2.
For\f\bccessory\fdrive\fbelt\frouting.\f
Refer\fto:\f Accessory\fDrive \f(303-05D\fAccessory\f
Dri
ve\f-\f1.8L\fDur\btorq-TDCi\f(74kW/100PS)\f-\f
Lynx/1.8L\fDur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\f
Description\f\bnd\fOper\btion).\f
\f
\f\f
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Page 1659 of 4402
Accessory\bDrive\b\f\b2.0L\bDuratorq\fTDCi\b
(85kW/115PS)\b\f\bDW/2.0L\bDuratorq\fTDCi\b
(100kW/136PS)\b\f\bDW/2.0L\bDuratorq\f
TDCi\b(103kW/140PS)\b\f\bDW,\bEmission\b
Requirements:\bStage\bIV\b\f\bAccessory\bDrive
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Description\band\bOperation\b
\f\f
Description\b
Accessory\fdrive\fbelt\ftensioner\fpulley\f
Gener\btor\f
Accessory\fdrive\fbelt\f
Air\fconditioning\f(A/C)\fcompressor\f
Cr\bnksh\bft\fpulley\f
Item
1
2
3
4
5
\f
Part\bNumber -
-
-
-
-
Стр. 1 из 1
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Page 1660 of 4402
Accessory\bDrive\b\f\b2.0L\bDuratorq\fTDCi\b
(85kW/115PS)\b\f\bDW/2.0L\bDuratorq\fTDCi\b
(100kW/136PS)\b\f\bDW/2.0L\bDuratorq\f
TDCi\b(103kW/140PS)\b\f\bDW,\bEmission\b
Requirements:\bStage\bIV\b\f\bAccessory\bDrive
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Diagnosis\band\bTesting\b
Inspection\band\bVerification\b
1. 1.\b
Verify\fthe\fcustomer\fconcern.\f
2
. 2.\b
Visu\blly\finspect\ffor\fobvious\fsigns\fof\fmech\bnic\bl\fd\bm\bge.\f
V
isual\bInspection\bChart\b
3. 3.\b
If\f\bn\fobvious\fc\buse\ffor\f\bn\fobserved\for\freported\fconcern\fis\ffound,\fcorrect\fthe\fc\buse\f
(if\fpossible)\fbefore\fproceeding\fto\fthe\fnext\fstep.\f
Accessory\bDrive\bBelt\bConcerns\b
CAUTION:\fDo\fnot\flubric\bte\fthe\f\bccessory\fdrive\fbelt,\f\b c
cessory\fdrive\fbelt\ftensioner\for\f
idler\fpulley(s)\f\bs\fpotenti\bl\fd\bm\bge\fto\fthe\f\bccessory\fdrive\fbelt\fm\bteri\bl\fconstruction,\f
\bccessory\fdrive\fbelt\ftensioner\fd\bmping\fmech\bnism,\f\bccessory\fdrive\fbelt\ftensioner\fpulley\f
be\bring\f\bnd\fidler\fpulley(s)\fbe\bring\fm\by\foccur.\f
Cr\bcking\f
Acc
essory\fdrive\fbelts\f\bre\fm\bde\ffrom\frubber\fwhich\fh\brdens\fwith\ftime\f\bnd\fc\bn\fdevelop\f
cr\bcks.\fAs\fthe\f\bccessory\fdrive\fbelt\fruns\fon\fthe\fb\bck\fof\fsome\fof\fthe\fpulleys,\fthe\fcr\bcks\f\bre\f
opened\fup.\fSm\bll\fcr\bcks\f\bre\fnot\fconsidered\fto\fbe\f\b\ff\bilure\fof\fthe\f\bccessory\fdrive\fbelt.\fOnly\f
if\fthe\fcr\bck\fis\fdeep\fenough\fto\fre\bch\fthe\fbottom\fof\fthe\fgroove\fto\fexpose\fthe\fcord\for\f\bny\f
chunks\f\bre\ffound\fto\fbe\fmissing\ffrom\fthe\f\bccessory\fdrive\fbelt,\fis\fthe\f\bccessory\fdrive\fbelt\f
condition\fconsidered\fto\fbe\fun\bccept\bble.\f
1. 1.\b
Check\fthe\f\bccessory\fdrive\fbelt\ffor\fcr\bcks.\fIf\fthe\fd\bm\bge\fexceeds\fthe\f\bccept\bble\f
l
imit,\finst\bll\f\b\fnew\f\bccessory\fdrive\fbelt.\fREFER\fto:\f\f
Accessory\fDrive\fBelt \f(
303-05A\fAccessory\fDrive\f-\f2.0L\fDur\btec-HE\f(107kW/145 PS)\f-\f
MI4/2.0L\fDur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05A\fAccessory\fDrive\f-\f2.0L\fDur\btec-HE\f(107kW/14 5
PS)\f-\f
MI4/2.0L\fDur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05C\fAccessory\fDrive\f-\f2.5L\fDur\btec\f(162kW/220PS )
\f-\f
VI5,\fRemov\bl\f\bnd\fInst\bll\btion),\f
Mechanica\b
D\bm\bged\for\fcont\bmin\bted\f\bccessory\fdrive\fbelt\f\f
D\bm\bged\for\fcont\bmin\bted\fpulley(s)\f\f
Incorrect\f\bccessory\fdrive\fbelt\f\f
Incorrect\ffitment\fof\fthe\f\bccessory\fdrive\fbelt\f\f
Accessory\fdrive\fbelt\ftensioner\f\f
Accessory\fdrive\fbelt\fidler\fpulley\f\f
Gener\btor\f\f
Power\fsteering\fpump\f\f
Power\fsteering\fpump\fle\bk\bge\f\f
Air\fconditioning\f(A/C)\fcompressor\f\f
Pulley(s)\f\f
Loose\fh\brdw\bre\f
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