torque FORD S-MAX 2006 Service Repair Manual

injector\f\bnd\fthe\fblue\fidentific\btion\fcoll\br\f\bdj\bcent\f
to\fthe\ffuel\fr\bil.\f
NOTE:\fThe\ffuel\fsupply\fline\fmust\fbe\finst\blled\fwith\f
the\fyellow\fidentific\btion\fcoll\br\f\bdj\bcent\fto\fthe\ffuel\f
pump\f\bnd\fthe\fblue\fidentific\btion\fcoll\br\f\bdj\bcent\fto\f
the\ffuel\fr\bil.\f
NOTE:\fThe\fhigh-
pressure\ffuel\fsupply\flines\fmust\fbe\f
connected\fimmedi\btely\f\bfter\fremoving\fthe\fbl\bnking\f
plugs.\f
NOTE:\fDo\fnot\f\bllow\fthe\funions\fto\fhit\fthe\fends\fof\f
the\fhigh-pressure\ffuel\fsupply\fline.\fTo\f\bid\f
inst\bll\btion\fof\fthe\fnew\fhigh-pressure\ffuel\fsupply\f
lines,\fthe\funions\f\bt\fthe\ffuel\fr\bil\fend\f\bre\fcolored\f
gold.\f
Tighten\fthe\ffuel\finjector\fhigh-
pressure\ffuel\fsupply\flines\f
in\fthe\fsequence\fshown.\f
Torque: 1-5\f25\fNm
\f
6-10\f38\fNm
\f
thermost\bt\fhousing\f23\fNm
\f
v\bcuum\fpipe\f18\fNm
\f
35. Torque:
1\f7\fNm
\f
2\f23\fNm
\f
3\f23\fNm
\f
36. Inst\bll\fthe\fFuel\fFilter.\f Refer\fto:\f Fuel\fFilter \f(310-01B\fFuel\fT\bnk\f\bnd\fLines\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\f
Inst\bll\btion).\f
37. Torque: 23\fNm
\f
38. \f\f 1.Torque: 3\fNm
\f
2. Torque: 5\fNm
\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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Installation 1.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
2. 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
ed
ge\fof\fthe\fOil\fP\bn.\f
Material:\b Silicone\fSe\bl\bnt\fLB\f(WSE-M4G323-A4\f/\f
2U 7

J-M4G323-AA) \f
3. Tighten\fthe\fOil\fP\bn\fret\bining\fnuts\f\bnd\fbolts\fin\f
the\fsequence\fshown.\f\f
Torque:\b 1-18\f\f 6.5\fNm
\f
14\fNm
\f
19\f36\fNm
\f
St\bge\f1:\f
St\bge\f2:\f
4. \f
5. Fill\fthe\fengine\fwith\fengine\foil.\f
\f
\f\f
\f\f
\f\f
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Engine - \b.8L \furatorq-T\fCi
(74kW/\b00PS) - Lynx/\b.8L \furatorq-
T\fCi (92kW/\b25PS) - Lynx - Crankshaft
Rear Seal
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Installation
Special Tool(s)
Removal
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
Installation
303-393\f
Locking\fTool,\fFlywheel
\f
1. Remove\fthe\fclutch\fdisc\f\bnd\fpressure\fpl\bte.\f Refer\fto:\f Clutch\fDisc\f\bnd\fPressure\fPl\bte \f(308-
01A

\fClutch\f-\fVehicles\fWith:\f5-Speed\fM\bnu\bl\f
Tr\bns\bxle\f-\fMTX75,\fRemov\bl\f\bnd\fInst\bll\btion).\f
2. Disc\brd\fthe\fflywheel\fret\bining\fbolts.\f
Special\bTool(\f):\b 303-393\f
Tor

que:\b \f
35\fNm
\f
45
°\f
St\bge\f1:\f
St\bge\f2:\f
3. Disc\brd\fthe\fcr\bnksh\bft\fre\br\fse\bl\fc\brrier.\f
1. NOTE:\fNew\fcr\bnksh\bft\fre\br\fse\bl\fc\brriers\f\bre\f
s
u

pplied\fwith\f\bn\f\blignment\fsleeve\fwhich\f
must\fbe\fremoved\f\bfter\finst\bll\btion.\f
Torque:\b 20\fNm
\f
2. Inspect\fthe\fflywheel.\f Refer\fto:\f M\bnu\bl\fTr\bns\bxle\f\bnd\fClutch \f(308-00\f
M\bn u

\bl\fTr\bnsmission/Tr\bns\bxle\f\bnd\fClutch\f-\f
\f
\f\f
\f\f
\f\f
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4. \f
5. \f
6.Torque:\b 20\fNm
\f
7. \f
\f
\f\f
\f\f
\f\f
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Vehicles built up to \b0/2007
Vehicles built \b0/2007 onwards
14. Inst\bll\f\b\fnew\fg\bsket\f
To

r\fue\b 23\fNm
\f
15. \f
16. Tor\fue\b
Snug\fTorque\f10\fNm
\f
Del\by\f2\fSeconds\f18\fNm
\f
Untighten\f40
°\f
Fin\bl\fTorque\f26\fNm
\f
17. \f
18. \f\f 1.Tor\fue\b 26\fNm
\f
2. Tor\fue\b 50\fNm
\f
\f\f
\f\f
\f\f
\f\f
\f\f
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Engine - \b.8L \furatorq-T\fCi (74kW/\b00PS) - Lynx/\b.8L \furatorq-T\fCi
(92kW/\b25PS) - Lynx - Engine—Vehicles With: 5-
Speed Manual Transaxle
(MTX-75)
Installation
General Equipment
WARNING: This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions.
Cable ties
Vehicle/axle stands
1. Refer \bo: D\fesel Fuel Sys\bem Heal\bh and Safe\by Precau\b\fons
2. Ins\ball \bhe \bransaxle \bo \bhe eng\fne.
3.Torque:\b 48 Nm

4. Torque:\b 48 Nm

5. Torque:\b 48 Nm

6. Torque:\b 48 Nm

7. Torque:\b 48 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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14. 1.Torque:\b 12 Nm

2. Torque:\b 80 Nm

3.
NOTE: Only \b\fgh\ben \bhe bol\bs f\fnger \b\fgh\b a\b \bh\fs s\bage.
15.Ra\fse \bhe veh\fcle and remove \bhe Veh\fcle/axle s\bands.
Genera\f\bEquipment:\b Veh\fcle/axle s\bands
16. T
orque:\b 80 Nm

17. Torque:\b 90 Nm

18.
Connec\b \bhe fuel supply l\fne and fuel re\burn l\fne qu\fck release coupl\fngs.
Refer \bo: Fuel F\fl\ber (310-01B Fuel Tank and L\fnes - 1.8L Dura\borq
(92kW/125PS) - Lynx, Removal and Ins\balla\b\fon).
19. Connec\b \bhe PCM elec\br\fcal connec\bors. Refer \bo: Power\bra\fn Con\brol Module (PCM) (303-
14E Elec\bron\fc Eng\fne Con\brols





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Lynx/1.8L Dura\borq-TDC\f (92kW/125PS) - Lynx, Removal and Ins\balla\b\fon).
20.Torque:\b 25 Nm
21. Torque:\b 23 Nm

22.
23.
CAUTION: Tw\fs\b\fng \bhe exhaus\b flex\fble p\fpe more \bhan 2 degrees may cause damage resul\b\fng \fn fa\flure.
Tighten all retaining nuts in the sequence shown.
Torque:\b 1-5: 25 Nm

6: 51 Nm

24. Remove \bhe fron\b subframe.
Refer \bo: Fron\b Subframe (502-00 Un\f-
Body, Subframe and Moun\b\fng Sys\bem, Removal and Ins\balla\b\fon).
25. Ins\ball \bhe lef\b-hand halfshaf\b.
Refer \bo: Fron\b Halfshaf\b LH (205-
04 Fron\b Dr\fve Halfshaf\bs, Removal and Ins\balla\b\fon).
26. Ins\ball \bhe r\fgh\b-hand halfshaf\b.
Refer \bo: Fron\b Halfshaf\b RH (205-
04 Fron\b Dr\fve Halfshaf\bs, Removal and Ins\balla\b\fon).
27. Ins\ball bo\bh fron\b wheels.
Refer \bo: Wheel and T\fre (204-
04 Wheels and T\fres, Removal and Ins\balla\b\fon).




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