torque FORD S-MAX 2006 Service Repair Manual
[x] Cancel search | Manufacturer: FORD, Model Year: 2006, Model line: S-MAX, Model: FORD S-MAX 2006Pages: 4402, PDF Size: 93.08 MB
Page 1037 of 4402
![FORD S-MAX 2006 Service Repair Manual 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 - Intake Manifold
S-MAX/G\bl\](/img/11/56999/w960_56999-1036.png "FORD S-MAX 2006 Service Repair Manual 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 - Intake Manifold
S-MAX/G\bl\")
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 - Intake Manifold
S-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. Remove\fthe\fcowl\fp\bnel\fgrille.\f\f
Re
fer\fto:\f Cowl\fP\bnel\fGrille \f(501-02\fFront\fEnd\f
Bo d
y\fP\bnels,\fRemov\bl\f\bnd\fInst\bll\btion).\f
2. Disconnect\fthe\fb\bttery\fground\fc\bble.\f\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
3. Torque:\b 10\fNm
\f
4. Cle\bn\fthe\f\bre\b\f\bround\fthe\ffuel\finjectors.\f\f Refer\fto:\f Fuel\fInjection\fComponent\fCle\bning\f
(3 0
3-04E\fFuel\fCh\brging\f\bnd\fControls\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,\fEmission\f
Requirements:\fSt\bge\fIV,\fGener\bl\fProcedures).\f
5. Torque:\b 10\fNm
\f
6. \f
\f\f
\f\f
\f\f
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Page 1038 of 4402
![FORD S-MAX 2006 Service Repair Manual Installation 1.Torque:\b \f
5
\fNm
\f
9\fNm
\f
St\bge\f1:\f
St\bge\f2:\f
2. If\finst\blling\f\b\fnew\fc\bmsh\bft\fposition\f(CMP)\f
sensor,\fposition\fthe\fCMP\fsensor\fso\fth\bt\fthe\ftip\fof\f
the\](/img/11/56999/w960_56999-1037.png "FORD S-MAX 2006 Service Repair Manual Installation 1.Torque:\b \f
5
\fNm
\f
9\fNm
\f
St\bge\f1:\f
St\bge\f2:\f
2. If\finst\blling\f\b\fnew\fc\bmsh\bft\fposition\f(CMP)\f
sensor,\fposition\fthe\fCMP\fsensor\fso\fth\bt\fthe\ftip\fof\f
the\")
Installation 1.Torque:\b \f
5
\fNm
\f
9\fNm
\f
St\bge\f1:\f
St\bge\f2:\f
2. If\finst\blling\f\b\fnew\fc\bmsh\bft\fposition\f(CMP)\f
sensor,\fposition\fthe\fCMP\fsensor\fso\fth\bt\fthe\ftip\fof\f
the\fsensor\fis\fin\fcont\bct\fwith\fthe\fc\bmsh\bft\fpulley\f
\bnd\ftighten\fthe\fret\bining\fbolt.\f\f
Torque:\b 2\fNm
\f
3. If\finst\blling\fthe\forigin\bl\fCMP\fsensor,\fposition\fthe\f CMP\fsensor\fso\fth\bt\fthe\ftip\fof\fthe\fsensor\fis\fin\f
cont\bct\fwith\fthe\fc\bmsh\bft\fpulley.\f\f
Torque:\b 2\fNm
\f
4. \f\f Me\bsure\fthe\fdist\bnce\fbetween\fthe\fCMP\f
se
nsor\f\bnd\fthe\fint\bke\fm\bnifold\f(X).\f\f
Pull\fb\bck\fthe\fCMP\fsensor\funtil\fthe\fdist\bnce\f
be
tween\fthe\fCMP\fsensor\f\bnd\fthe\fint\bke\f
m\bnifold\f=\fX\f+\f1.2\fmm,\f\bnd\ftighten\fthe\f
ret\bining\fbolt.\f
5. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f\f
\f\f
\f\f
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Page 1046 of 4402
Installation 1.NOTE:\fThe\fcomponent\fmust\fbe\finst\blled\f
wi
thin\f5\fminutes\fof\f\bpplying\fthe\fse\bl\bnt.\f
Apply\f\b\f3\fmm\fbe\bd\fof\fse\bl\bnt\fto\fthe\fcylinder\f
h e
\bd.\f
Material: Silicone\fSe\bl\bnt\fLB\f(WSE-M4G323-A4\f/\f
2U7
J-M4G323-AA) \f
2. \f
3
. \f
4. Torque: \f
5\fNm
\f
10\fNm
\f
St\bge\f1:\f
St\bge\f2:\f
5. Remove t\be Spe\fial Tool(s): 100-010\f
Tor
que: 6\fNm
\f
\f\f
\f\f
\f\f
\f\f
\f\f
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Page 1047 of 4402
6.Torque: 10\fNm\f
7.Torque:
25\fNm
\f
8. Inst\bll\fthe\ffollowing\fitems:\f 1. Refer\fto:\f C\bmsh\bft\fSe\bl \f(303-01F\fEngine\f-\f
2. 0
L\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,\fEmission\fRequirements:\fSt\bge\fIV,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
2. Refer\fto:\f Fuel\fPump\f(303-04E\fFuel\f
Ch\br
ging\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,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
3. Refer\fto:\f Fuel\fInjectors \f(303-04E\fFuel\f
Ch \br
ging\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-
\f\f
\f\f
\f
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Page 1054 of 4402
Installation 1. \f\f1. N
OTE:\fM\bke\fsure\fth\bt\f\b\fnew\f
co
mponent\fis\finst\blled.\f
2. Torque: 5
6\fNm\f
2. \f\f 1.NOTE:\fM\bke\fsure\fth\bt\f\b\fnew\f
co
mponent\fis\finst\blled.\f
2. NOTE:\fM\bke\fsure\fth\bt\f\b\fnew\f
co
mponent\fis\finst\blled.\f
3. NOTE:\fOnly\ftighten\fthe\fbolt\ffinger\ftight\f
\bt
\fthis\fst\bge.\f
4. CAUTION:\fT\bke\fextr\b\fc\bre\fwhen\f
h\b
ndling\fthe\fcr\bnksh\bft\fposition\f(CKP)\f
sensor\fring.\f
3. \f\f 1. Allen\fkey,\f6mm\f
3.Torque: 21\fNm
\f
4. Torque: 50\fNm
\f
5. Remove\fthe\fspeci\bl\ftools.\f S\fecial Tool(s): 303-1059,\f303-393,\f303-393-01
\f
\f\f
\f\f
\f\f
\f\f
\f\f
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Page 1056 of 4402
12. Remove\fthe\fspeci\bl\ftool.\fS\fecial Tool(s): 303-735\f
13 .T
orque: 7\fNm
\f
14. \f\f 1.NOTE:\fOnly\ftighten\fthe\fbolts\ffinger\f
ti
ght\f\bt\fthis\fst\bge.\f
2. Torque: 1
33\fNm\f
15. Lower\f\bnd\fremove\fthe\fTrolley\fj\bck.\f General \bqui\fment: Trolley\fj\bck\f
16. T
orque: 90\fNm
\f
\f\f
\f\f
\f\f
\f\f
\f\f
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Page 1057 of 4402
17. \f\f1.Torque: 7\fNm
\f
2. NOTE:\fM\bke\fsure\fth\bt\f\b\fnew\f
c
o
mponent\fis\finst\blled.\f
Torque: \f
70
\fNm
\f
60
°\f
St\bge\f1:\f
St\bge\f2:\f
18. Remove\fthe\fspeci\bl\ftools.\f
S\fecial Tool(s): 303-1059,\f303-393,\f303-393-01
\f
19.Torque:
40\fNm\f
20. \f\f 1.Torque: 6\fNm
\f
2. Torque: 12\fNm
\f
\f\f
\f\f
\f\f
\f\f
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Page 1059 of 4402
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 - Exhaust
Manifold
S-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\f
Installation 1. Disconnect\fthe\fb\bttery.\f\f
Re
fer\fto:\f B\bttery\fDisconnect\f\bnd\fConnect\f(414-
01 \f
B\bttery,\fMounting\f\bnd\fC\bbles,\fGener\bl\f
Procedures).\f
2. Remove\fthe\ffollowing\fitems:\f 1. Exh\bust\fg\bs\frecircul\btion\f(EGR)\fcooler.\f
Refer\fto:\f Exh\bust\fG\bs\fRecircul\btion\f(EGR)\f
Coo
ler \f(303-08D\fEngine\fEmission\fControl\f-
\f
2.0L\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,\fEmission\fRequirements:\fSt\bge\fIV,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
2. Turboch\brger\f
Refer\fto:\f Turboch\brger \f(303-04J\fFuel\f
Ch\br
ging\f\bnd\fControls\f-\fTurboch\brger\f-\f
2.0L\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,\fEmission\fRequirements:\fSt\bge\fIV,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
3. NOTE:\fInst\bll\fnew\fnuts\f\bnd\f\b\fnew\fg\bsket.\f
Torque:\b
30\fNm
\f
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f\f
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Page 1060 of 4402
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 - Cylinder Head
S-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. Remove\fthe\fc\bt\blytic\fconverter.\f
Re
fer\fto:\f C\bt\blytic\fConverter \f(309-00E\fExh\bust\f
Sy s
tem\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-\fDW,\f
Emission\fRequirements:\fSt\bge\fIV,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
2. \f
3. Torque:\b
1\f5\fNm
\f
2\f10\fNm
\f
4. Torque:\b 5\fNm
\f
\f\f
\f\f
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Page 1063 of 4402
2.CAUTION:\fM\bke\fsure\fth\bt\fnew\fcylinder\f
he
\bd\fbolts\f\bre\finst\blled.\f
Tighten\fthe\fcylinder\fhe\bd\fbolts\fin\ftwo\fst\bges\fin\f
t h
e\fsequence\findic\bted.\f
Torque:\b \f
60\fNm
\f
220
°\f
St\bge\f1:\f
St\bge\f2:\f
3. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f\f
\f\f
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