FORD S-MAX 2006 Service Repair Manual

Power S\beering \f Power S\beering Pump—
2.5L Dura\bec (162kW/220PS) \f VI5S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Ins\balla\bion
Removal
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
1. Remove\fthe\ffollowing\fitems:\f 1.
Remove\fthe\fright-h\bnd\fhe\bdl\bmp\f
\bssembly.\f
Refer\fto:\fHe\bdl\bmp\fAssembly\f(417-01\f
Exterior\fLighting,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
2. Remove\fthe\f\bccessory\fdrive\fbelt.\f
Refer\fto:\fAccessory\fDrive\fBelt\f(303-05B\f
Accessory\fDrive\f-\f2.5L\fDur\btec-ST\f(VI5),\f
Remov\bl\f\bnd\fInst\bll\btion).\f
2. Lower\fthe\fvehicle.\f
3. Position\fthe\fpower\fsteering\ffluid\freservoir\fto\fone\f side.\f
4. CAUTION:\fM\bke\fsure\fth\bt\f\bll\fopenings\f
\b r

e\fse\bled.\f
Torque:\b 23\fNm
\f
5. R\bise\f\bnd\fsupport\fthe\fvehicle.\f
Refer\fto:\fLifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Description\f\bnd\fOper\btion).\f
6. \f
7. Position\fthe\f\bir\fconditioning\f(A/C)\fcompressor\fto\f one\fside.\f
\f\f
\f\f
\f\f
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Ins\balla\bion Torque:\b
25\fNm
\f
8. \f\f 1.Torque:\b 25\fNm
\f
3. Torque:\b 25\fNm
\f
9. CAUTION:\fM\bke\fsure\fth\bt\f\bll\fopenings\f
\b r

e\fse\bled.\f 1. Torque:\b 2
5\fNm\f
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
2. Fill\fthe\fpower\fsteering\fsystem.\f
Refer\fto:\fPower\fSteering\fSystem\fFilling\f(211-00\f
Steering\fSystem\f-\fGener\bl\fInform\btion,\fGener\bl\f
Procedures).\f
3. Bleed\fthe\fpower\fsteering\fsystem.\f
Refer\fto:\fPower\fSteering\fSystem\fBleeding\f(211-
00\fSteering\fSystem\f-\fGener\bl\fInform\btion,\f
Gener\bl\fProcedures).\f
\f\f
\f\f
\f\f
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Power S\beering \f Power S\beering Pump—
1.8L Dura\borq\fTDCi (74kW/100PS) \f
Lynx/1.8L Dura\borq\fTDCi (92kW/125PS)
\f Lynx
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Ins\balla\bion
Removal
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
Ins\balla\bion 1. R\bise\f\bnd\fsupport\fthe\fvehicle.\f
Re
fer\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des

cription\f\bnd\fOper\btion).\f
2. \f
3. Remove\fthe\f\bccessory\fdrive\fbelt.\f
Refer\fto:\f Accessory\fDrive\fBelt \f(303-05D\f
Ac c

essory\fDrive\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\fInst\bll\btion).
\f
4. CAUTION:\fM\bke\fsure\fth\bt\f\bll\fopenings\f
\br
e\fse\bled.\f 2. Torque:\b 2
3\fNm\f
5.Torque:\b 25\fNm\f
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
2. Fill\fthe\fpower\fsteering\fsystem.\f Refer\fto:\f Power\fSteering\fSystem\fFilling \f(211-00\f
St e

ering\fSystem\f-\fGener\bl\fInform\btion,\fGener\bl\f
\f\f
\f\f
\f\f
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Procedures).\f
3. Bleed\fthe\fpower\fsteering\fsystem.\f
Refer\fto:\f Power\fSteering\fSystem\fBleeding \f(211-
00\f

Steering\fSystem\f-\fGener\bl\fInform\btion,\f
Gener\bl\fProcedures).\f
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Power S\beering \f Power S\beering Pump—
2.0L Dura\borq\fTDCi (103kW/140PS) \f
DW/2.0L Dura\borq\fTDCi (118kW/160PS)
\f DW, Vehicles Wi\bh: Elec\bro\fHydraulic
Power S\beering (EHPS)
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Ins\balla\bion
Removal
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
1. Remove\fthe\ffront\fright-h\bnd\fwheel\f\bnd\ftire.\f
Re
fer\fto:\f Wheel\f\bnd\fTire\f(204-04\fWheels\f\bnd\f
Ti r

es,\fRemov\bl\f\bnd\fInst\bll\btion).\f
2. \f
3. \f
4. WARNING:\fBe\fprep\bred\fto\fcollect\f
e s

c\bping\ffluids.\f
CAUTION:\fM\bke\fsure\fth\bt\f\bll\fopenings\f
\bre\fse\bled.\f
5. WARNING:\fBe\fprep\bred\fto\fcollect\f
es
c\bping\ffluids.\f
CAUTION:\fM\bke\fsure\fth\bt\f\bll\fopenings\f
\bre\fse\bled.\f Torque:\b 20\fNm
\f
6.Torque:\b 10\fNm\f
\f\f
\f\f
\f\f
\f\f
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Ins\balla\bion 7.
Torque:\b 1
0\fNm\f
8. \f
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
2. Refer\fto:\f Power\fSteering\fSystem\fFilling \f(211-00\f
St e

ering\fSystem\f-\fGener\bl\fInform\btion,\fGener\bl\f
Procedures).\f
3. Refer\fto:\f Power\fSteering\fSystem\fBleeding \f(211-
00\f

Steering\fSystem\f-\fGener\bl\fInform\btion,\f
Gener\bl\fProcedures).\f
\f\f
\f\f
\f\f
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Power S\beering \f Power S\beering Pump—
2.2L Dura\borq\fTDCi (129kW/175PS) \f DWS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Ins\balla\bion
Ma\berials
Removal
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
Ins\balla\bion
NameSpec\bf\bcat\bo\f
Hydr\bulic\fFluid\fDP-PSWSS-M2C204-A2\f/\f5U7J-M2C204-AA 1. Refer\fto:\fAccessory\fDrive\fBelt \f(303-05F\f
Acc

essory\fDrive\f-\f2.2L\fDur\btorq-TDCi\f
(129kW/175PS)\f-\fDW,\fRemov\bl\f\bnd\fInst\bll\btion).
\f
2. WARNING:\fBe\fprep\bred\fto\fcollect\f
es
c\bping\ffluids.\f
CAUTION:\fM\bke\fsure\fth\bt\f\bll\fopenings\f
\bre\fse\bled.\f Material\b Hy
dr\bulic\fFluid\fDP-PS\f(WSS-M2C204-
A2\f
/\f5U7J-M2C204-AA) \f
Tor

\fue\b 23\fNm
\f
3.Tor\fue\b 24\fNm\f
4. Tor\fue\b 24\fNm
\f
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
2. Refer\fto:\f Power\fSteering\fSystem\fFilling \f(211-00\f
Ste

ering\fSystem\f-\fGener\bl\fInform\btion,\fGener\bl\f
Procedures).\f
3. Refer\fto:\f Power\fSteering\fSystem\fBleeding \f(211-
00 \f

Steering\fSystem\f-\fGener\bl\fInform\btion,\f
Gener\bl\fProcedures).\f
\f\f
\f\f
\f\f
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Power S\beering \f Power S\beering Pump \bo Quick
Release Coupling Pressure Line—2.0L Dura\borq\f
TDCi (100kW/136PS) \f DW\fC/2.0L Dura\borq\f
TDCi (85kW/115PS) \f DW/2.0L Dura\borq\fTDCi
(103kW/140PS) \f DW
S-MAX/G\bl\bxy\f2006.5\f(02/2006
Removal and Ins\balla\bion
Special Tool(s)
Removal
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
308-440\f
Disconnect\fTool,\fHydr\bulic\fLine
\f
1. Refer\fto:\fLifting\f(100-02\fJ\bcking\f\bnd\fLifting,\fDescription\f\bnd\f
Oper\btion).\f
2. Refer\fto:\f Wheel\f\bnd\fTire\f(204-
04\fWheels\f\bnd\fTires,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
3. \f
4. \f
5. Torque:\b 10\fNm
\f
6.
WARNING:\f
Be\fprep\bred\fto\f
collect\f
esc\bping\ffluid.
\f
\f\f
\f\f
\f\f
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Ins\balla\bion
CAUTION:\f
M\bke\fsure\fth\bt\f
\bll\fopenings\f
\bre\fse\bled.
Spec\fal\bTool(s):\b
308-440\f
7.WARNING:\fBe\fprep\bred\fto\fcollect\fesc\bping\ffluid.
CAUTION:\fM\bke\fsure\fth\bt\f\bll\fopenings\f\bre\fse\bled.
Torque:\b20\fNm\f
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
2. Refer\fto:\f Power\fSteering\fSystem\fFilling \f(211-
00\fSteering\f
System\f-\fGener\bl\fInform\btion,\fGener\bl\fProcedures).
3. Refer\fto:\fPower\fSteering\fSystem\fBleeding \f(211-00\fSteering\f
System\f-\fGener\bl\fInform\btion,\fGener\bl\fProcedures).
\f
\f\f
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Power S\beering \f Power S\beering Pump \bo Quick
Release Coupling Pressure Line—2.2L Dura\borq\f
TDCi (129kW/175PS) \f DWS-MAX/G\bl\bxy\f2006.5\f(02/2006
Removal and Ins\balla\bion
Special Tool(s)
Removal
NO
TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\fins t
\bll\btion\fdet\bils.\f
308-440\f
Disconnect\fTool,\fHydr\bulic\fLine
\f
1. R\bise\f\bnd\fsupport\fthe\fvehicle.\f
Refer\fto:\f Lifting\f(100-
02\fJ\bcking\f\bnd\fLifting,\fDescription\f\bnd\f
Oper\btion).\f
2.
WARNING:\f
Be\fprep\bred\fto\f
collect\f
esc\bping\ffluid.
CAUTION:\f
M\bke\fsure\fth\bt\f
\bll\fopenings\f
\bre\fse\bled.
Special\bTool(\f):\b
308-440\f
3. Lower\fthe\fvehicle.\f
4. \f
5.
WARNING:\fBe\fprep\bred\fto\fcollect\fesc\bping\ffluids.
CAUTION:\fM\bke\fsure\fth\bt\f\bll\fopenings\f\bre\fse\bled.
1.Torque:\b 24\fNm\f
2. Torque:\b 10\fNm
\f
\f
\f\f
\f\f
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