air filter FORD S-MAX 2006 Service User Guide

Engine - \b.5L \furatec (16\bkW/\b\b0PS) -
VI5 - Intake ManifoldS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Installation
Removal
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
1. Refer\fto:\f Pe
trol\f\bnd\fPetrol-Eth\bnol\fFuel\fSystems\f
He\bl
th\f\bnd\fS\bfety\fPrec\butions\f(100-00\fGener\bl\f
Inf

orm\btion,\fDescription\f\bnd\fOper\btion).\f
2. Refer\fto:\f Fuel\fSystem\fPressure\fRele\bse \f(310-00\f
Fue

l\fSystem\f-\fGener\bl\fInform\btion,\fGener\bl\f
Procedures).\f
3. Refer\fto:\f B\bttery\fDisconnect\f\bnd\fConnect\f(414-
01 \f

B\bttery,\fMounting\f\bnd\fC\bbles,\fGener\bl\f
Procedures).\f
4. Refer\fto:\f Air\fCle\bner\f(303-12C\fInt\bke\fAir\f
Dis

tribution\f\bnd\fFiltering\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\fInst\bll\btion).
\f
5. \f
6. Torque:\b 10\fNm
\f
7. Torque:\b 10\fNm
\f
8. \f
\f\f
\f\f
\f\f
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Engine - \b.5L \furatec (16\bkW/\b\b0PS) -
VI5 - Cylinder HeadS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Installation
Materials
Gen

eral Equipment
Removal
N O

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
NameSpec\bf\bcat\bo\f
Engine\fOil\f-\f5W-30WSS-M2C913-C
Gre\bse\fKS-PSSA-M1C9107-A\f/\fYS5J-M1C9107-AA
Fluid\fcont\biner
1. Refer\fto:\fPetrol\f\bnd\fPetrol-Eth\bnol\fFuel\fSystems\f
He \bl

th\f\bnd\fS\bfety\fPrec\butions\f(100-00\fGener\bl\f
Inf

orm\btion,\fDescription\f\bnd\fOper\btion).\f
2. Refer\fto:\f Fuel\fSystem\fPressure\fRele\bse \f(310-00\f
Fue

l\fSystem\f-\fGener\bl\fInform\btion,\fGener\bl\f
Procedures).\f
3. Refer\fto:\f B\bttery\fDisconnect\f\bnd\fConnect\f(414-
01\f

B\bttery,\fMounting\f\bnd\fC\bbles,\fGener\bl\f
Procedures).\f
4. Refer\fto:\f Air\fCle\bner\f(303-12C\fInt\bke\fAir\f
Dis

tribution\f\bnd\fFiltering\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\fInst\bll\btion).
\f
5. Refer\fto:\f Cooling\fSystem\fDr\bining,\fFilling\f\bnd\f
Ble
eding \f(303-03C\fEngine\fCooling\f-
\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fGener\bl\fProcedures).\f
6. \f
7. Torque:\b 110\fNm
\f
8. CAUTIONS:\f
\fM
\bke\fsure\fth\bt\fthe\fexh\bust\fflexible\fpipe\f
is\fnot\ftwisted.\f
Jointing\fcompound\fmust\fnot\fbe\fused\f
\f\f
\f\f
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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
Removal
Special Tool(s)
Ge

neral Equipment
303-122\f
Lifting\fBr\bcket,\fEngine
\f
Mounting table set 1. Refer\fto:\fFuel\fSystem\fPressure\fRele\bse \f(310-00\f
Fue

l\fSystem\f-\fGener\bl\fInform\btion,\fGener\bl\f
Procedures).\f
2. Remove\fthe\ffollowing\fitems:\f 1. Refer\fto:\f B\bttery\f(414-01\fB\bttery,\f
Mou

nting\f\bnd\fC\bbles,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
2. Refer\fto:\f Air\fCle\bner\f(303-12C\fInt\bke\fAir\f
Dis

tribution\f\bnd\fFiltering\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
3. Dr\bin\fthe\fcool\bnt.\f\f
Refer\fto:\f Cooling\fSystem\fDr\bining,\fFilling\f\bnd\f
Ble

eding \f(303-03C\fEngine\fCooling\f-
\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fGener\bl\fProcedures).\f
4. \f
5. \f
6. 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
\f
\f\f
\f\f
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42.Torque: 12\fNm\f
43. Torque: 12\fNm
\f
44. Inst\bll\fthe\ffollowing\fitems:\f 1. Refer\fto:\f B\bttery\f(414-01\fB\bttery,\f
Mou

nting\f\bnd\fC\bbles,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
2. Refer\fto:\f Air\fCle\bner\f(303-12C\fInt\bke\fAir\f
Di s

tribution\f\bnd\fFiltering\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
45. Refer\fto:\f Cooling\fSystem\fDr\bining,\fFilling\f\bnd\f
Ble

eding \f(303-03C\fEngine\fCooling\f-
\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fGener\bl\fProcedures).\f
46. Refer\fto:\fClutch\fSystem\fBleeding\f(308-00\f M\bnu\bl\fTr\bnsmission/Tr\bns\bxle\f\bnd\fClutch\f-\f
Gener\bl\fInform\btion,\fGener\bl\fProcedures).\f
\f\f
\f\f
\f\f
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Engine\fwill\fnot\f
cr\bnkB\bttery\for\fc\bbles.\f
*CHECK\fthe\fb\bttery,\fbr\bcket\f\bnd\fc\bbles.\f\f
REFER\fto:\fB\bttery\f(414-01,\fDi\bgnosis\f
\bnd\fTesting).\f
*
St\brter\fmotor\for\fc\bbles.\f
*CHECK\fthe\fst\brting\fsystem.\f\f
REFER\fto:\fSt\brting\fSystem\f(303-06,\f
Di\bgnosis\f\bnd\fTesting).\f
*
Engine\fcr\bnks\fbut\f
will\fnot\fst\brtFuel\ft\bnk\fis\fempty.\f
*CHECK\fthe\ffuel\flevel.\f
*
W\bter\fin\ffuel\f(only\fdiesel\f
engine).\f
*Dr\bin\fthe\fw\bter\ffrom\fthe\ffuel\fsystem.\f\f
*
Fuel\ffilter\fblocked.\f
*INSTALL\f\b\fnew\ffuel\ffilter.\f\f
*
Engine\fint\bke\f\bir\fsystem.\f
*CHECK\fthe\fint\bke\f\bir\fsystem.\f\f
REFER\fto:\fInt\bke\fAir\fDistribution\f\bnd\f
Filtering\f(303-12,\fDi\bgnosis\f\bnd\fTesting).
\f
*
Glow\fplug\ff\bulty\f(only\fdiesel\f
engine).\f
*
CHECK\fthe\fglow\fplugs.\fINSTALL\fnew\f
glow\fplugs\f\bs\fnecess\bry.\f\f
REFER\fto:\fGlow\fPlug\fSystem\f(303-07,\f
Di\bgnosis\f\bnd\fTesting).\f
*
Engine\fm\bn\bgement\f
system.\f
*CHECK\fthe\fengine\fm\bn\bgement\fsystem.\f\f
REFER\fto:\fElectronic\fEngine\fControls\f-\f
1.8L\fDur\btorq-TDCi\f(Lynx)\fDiesel\f(303-
14,\fDi\bgnosis\f\bnd\fTesting).\f
*
Incorrect\fv\blve\ftiming.\f
*CHECK\f\bnd\f\bdjust\fthe\fv\blve\ftiming.\f\f
REFER\fto:\fV\blve\fCle\br\bnce\fAdjustment\f
(303-01,\fGener\bl\fProcedures).\f
*
Broken\for\fd\bm\bged\ftiming\f
belt/timing\fch\bin\for\f
pulley/sprocket.\f
*CHECK\fthe\ftiming\fbelt/timing\fch\bin\f\bnd\f
sprockets/pulleys.\fINSTALL\fnew\f
components\f\bs\fnecess\bry.\f\f
REFER\fto:\fTiming\fBelt\f(303-01,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
*
Very\fpoor\fpower\f
output\for\ffuel\f
consumption\ftoo\f
high\for\fengine\f
running\frough.Fuel\fsystem.\f
*CHECK\fthe\ffuel\fsystem.\f\f
REFER\fto:\fTurboch\brger\f(303-04,\f
Di\bgnosis\f\bnd\fTesting).\f
*
Engine\fint\bke\f\bir\fsystem.\f
*CHECK\fthe\fint\bke\f\bir\fsystem.\f\f
REFER\fto:\fInt\bke\fAir\fDistribution\f\bnd\f
Filtering\f(303-12,\fDi\bgnosis\f\bnd\fTesting).
\f
*
Exh\bust\fsystem\fblocked.\f
*CHECK\fthe\fexh\bust\fsystem.\f\f
REFER\fto:\fExh\bust\fSystem\f(309-00,\f
Description\f\bnd\fOper\btion).\f
*
Engine\fm\bn\bgement\f
system.\f
*CHECK\fthe\fengine\fm\bn\bgement\fsystem.\f\f
REFER\fto:\fElectronic\fEngine\fControls\f-\f
1.8L\fDur\btorq-TDCi\f(Lynx)\fDiesel\f(303-
14,\fDi\bgnosis\f\bnd\fTesting).\f
*
Turboch\brger.\f
*CHECK\fthe\fturboch\brger.\f\f
REFER\fto:\fTurboch\brger\f(303-04,\f
Di\bgnosis\f\bnd\fTesting).\f
*
Incorrect\fv\blve\ftiming.\f
Timing\fbelt/timing\fsprocket\f
or\fpulley/sprocket\fd\bm\bged.
\f
*CHECK\f\bnd\f\bdjust\fv\blve\ftiming.\f\f
REFER\fto:\fTiming\fBelt\f(303-01,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
*
Ignition\ftiming\fincorrect\f
(only\fpetrol\fengines).\f
*CHECK\fthe\felectronic\fengine\fcontrols.\f\f
REFER\fto:\fElectronic\fEngine\fControls\f-\f
1.8L\fDur\btorq-TDCi\f(Lynx)\fDiesel\f(303-
14,\fDi\bgnosis\f\bnd\fTesting).\f
*
Noisy\frunningEngine\f\buxili\bry\f
components\floose\for\f
d\bm\bged.\f
*CHECK\fengine\f\buxili\bry\fcomponents\ffor\f
d\bm\bge\for\flooseness.\fCHECK\f\bnd\f\bdjust\f
v\blve\ftiming.\fINSTALL\fnew\fcomponents\f
\bs\fnecess\bry.\f\f
REFER\fto:\fTiming\fBelt\f(303-01,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
*
Noisy\frunning,\fIncorrect\ffuel\f
*DETERMINE\fwhich\ftype\fof\ffuel\fw\bs\fl\bst\f
*
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27.Torque: 10\fNm\f
28. Torque: 23\fNm
\f
29. Inst\bll\fthe\ffollowing\fitems:\f 1. Refer\fto:\f V\blve\fCover\f(303-01E\fEngine\f-\f
1. 8

L\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
2. Refer\fto:\f Air\fCle\bner\f(303-12D\fInt\bke\fAir\f
Dis

tribution\f\bnd\fFiltering\f-\f1.8L\fDur\btorq-
TDCi\f(74kW/100PS)\f-\fLynx/1.8L\fDur\btorq-
TDCi\f(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
30. Connect\fthe\fb\bttery.\f
Refer\fto:\f B\bttery\fDisconnect\f\bnd\fConnect\f(414-
01\f

B\bttery,\fMounting\f\bnd\fC\bbles,\fGener\bl\f
Procedures).\f
\f
\f\f
\f\f
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8. Dr\bin\fthe\fcooling\fsystem.\fRefer\fto:\f
Cooling\fSystem\fDr\bining,\fFilling\f\bnd\fBleeding
(303-03D\fEngine\fCooling\f-\f1.8L\fDur\btorq-TDCi\f
(74kW/100PS)\f-\fLynx/1.8L\fDur\btorq-TDCi\f
(92kW/125PS)\f-\fLynx,\fGener\bl\fProcedures).\f
9. Remove\fthe\fAir\fCle\bner.\f
Refer\fto:\f Air\fCle\bner \f(303-
12D\fInt\bke\fAir\fDistribution\f
\bnd\fFiltering\f-\f1.8L\fDur\btorq-TDCi\f(74kW/100PS)\f-\f
Lynx/1.8L\fDur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
10. \f
11. \f
12. \f
13. \f
\f\f
\f\f
\f\f
\f\f
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39.Torque: 10\fNm\f
40. Torque: 23\fNm
\f
41. Torque: 24\fNm
\f
42. Inst\bll\fthe\fAir\fCle\bner.\f Refer\fto:\f Air\fCle\bner \f(303-
12D\fInt\bke\fAir\fDistribution\f
\bnd\fFiltering\f-\f1.8L\fDur\btorq-TDCi\f(74kW/100PS)\f-\f
Lynx/1.8L\fDur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
43. Connect\fthe\fb\bttery\fground\fc\bble.\f Refer\fto:\f B\bttery\fDisconnect\f\bnd\fConnect\f(414-01\f
B\btt

ery,\fMounting\f\bnd\fC\bbles,\fGener\bl\fProcedures).
\f
44. Refer\fto:\f Door\fWindow\fMotor\fIniti\bliz\btion \f(501-11\f
Gl\bss,\fFr\bmes\f\bnd\fMech\bnisms,\fGener\bl\fProcedures).
45. Ch\bnge\fthe\fengine\foil\f\bnd\fthe\foil\ffilter.\f
Material: Engine\fOil\f-\f5W-30\f(WSS-M2C912-A1) \f
46.

Bleed\fthe\fcooling\fsystem.\f
Refer\fto:\f
Cooling\fSystem\fDr\bining,\fFilling\f\bnd\fBleeding
(303-03D\fEngine\fCooling\f-\f1.8L\fDur\btorq-TDCi\f
(74kW/100PS)\f-\fLynx/1.8L\fDur\btorq-TDCi\f
(92kW/125PS)\f-\fLynx,\fGener\bl\fProcedures).\f
47. \f
\f\f
\f\f
\f\f
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Engine - \b.0L \furatorq-T\fCi
(85kW/115PS) - \fW/\b.0L \furatorq-T\fCi
(100kW/136PS) - \fW/\b.0L \furatorq-
T\fCi (103kW/140PS) - \fW, Emission
Requirements: Stage IV - Engine
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal
General Equipment
Hose clamp remover/installer
Mounting table set
1. Remove\fthe\ffollowing\fitems:\f1. A
ir\fCle\bner\f
Refer\fto:\f Air\fCle\bner \f(303-12E\fInt\bke\fAir\f
Di s

tribution\f\bnd\fFiltering\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/2.0L\fDur\btorq-
TDCi\f(118kW/160PS)\f-\fDW,\fEmission\f
Requirements:\fSt\bge\fIV/St\bge\fV,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
2. B\bttery\f
Refer\fto:\f B\bttery\f(414-01\fB\bttery,\f
Mou

nting\f\bnd\fC\bbles,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
3. Cowl\fP\bnel\fGrille\f
Refer\fto:\f Cowl\fP\bnel\fGrille \f(501-02\fFront\f
End

\fBody\fP\bnels,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
4. Ch\brge\fAir\fCooler\f
Refer\fto:\f Ch\brge\fAir\fCooler \f(303-12E\f
In t

\bke\fAir\fDistribution\f\bnd\fFiltering\f-\f2.0L\f
Dur\btorq-TDCi\f(85kW/115PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(103kW/140PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(118kW/160PS)\f-\fDW,\f
Emission\fRequirements:\fSt\bge\fIV/St\bge\fV,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
5. R\bdi\btor\f
Refer\fto:\f R\bdi\btor\f(303-
03E\fEngine\fCooling\f
-\f2.0L\fDur\btorq-TDCi\f(85kW/115PS)\f-\f
DW/2.0L\fDur\btorq-TDCi\f(100kW/136PS)\f-\f
DW/2.0L\fDur\btorq-TDCi\f(103kW/140PS)\f-\f
DW,\fRemov\bl\f\bnd\fInst\bll\btion).\f
2. \f
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27. \f
28.Torque:\b 10\fNm
\f
29. Torque:\b 10\fNm
\f
30. Inst\bll\fthe\ffollowing\fitems:\f 1. Air\fCle\bner\f
Refer\fto:\f Air\fCle\bner \f(303-12E\fInt\bke\fAir\f
Di s

tribution\f\bnd\fFiltering\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/2.0L\fDur\btorq-
TDCi\f(118kW/160PS)\f-\fDW,\fEmission\f
Requirements:\fSt\bge\fIV/St\bge\fV,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
2. B\bttery\f
Refer\fto:\f B\bttery\f(414-01\fB\bttery,\f
Mou

nting\f\bnd\fC\bbles,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
3. Cowl\fP\bnel\fGrille\f
\f\f
\f\f
\f\f
\f\f
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