clip FORD S-MAX 2006 Service Owner's Guide

Pi\fpoi\ft Tests
w\blls.\fTurboch\brger\fbe\brings\f
\bnd\foil\fse\bl(s).\f Turboch\brger\foil\f
supply\ftube\fblocked\for\f
d\bm\bged.\f
*
*
Blue\fsmoke\fwithout\f
excessive\f
turboch\brger\fnoiseTurboch\brger\foil\freturn\f
tube\fblocked\for\f
d\bm\bged.\f
*
GO\fto\fPinpoint\fTest\f
B.\f\f
*
Poor\fengine\f
perform\bnce\fCh\brge\f\bir\fcooler\f
system.\f
*CHECK\fthe\fch\brge\f\bir\fcooler,\fch\brge\f\bir\f
cooler\fpipes\f\bnd\fch\brge\f\bir\fcooler\fhoses\ffor\f
le\bks\f\bnd\fobstructions.\fREPAIR\f\bs\f
necess\bry.\f
*
Air\fcle\bner\fint\bke\fpipe.\f*CHECK\fthe\f\bir\fcle\bner\fint\bke\fpipe\ffor\f
obstruction.\fREPAIR\fthe\fnecess\bry.\f
*
Turboch\brger\f
electronic\f\bctu\btor.\f
*REFER\fto\fWDS.\f
*
PINPOINT TEST A : BLUE SMOKE WITH EXCESSIVE TURBOCHARGER NOISE
TE\fT CONDITION\fDETAIL\f/RE\fULT\f/ACTION\f
A1: INSPECT THE TURBOCHARGER ROTOR VANES FOR DAMAGE
Loc\btion\fof\fthe\fengine\fupper\fcover\fret\bining\fclips.\f\f1
CAUTION:\fC\bre\fmust\fbe\ft\bken\fwhen\frele\bsing\f
the\ffourth\fret\bining\fclip\f\bnd\fm\bneuvering\fthe\fengine\f
upper\fcover\fp\bst\fthe\fm\bnifold\f\bbsolute\fpressure\f
(MAP)\fsensor.\fF\bilure\fto\ffollow\fthis\finstruction\fm\by\f
result\fin\fd\bm\bge\fto\fthe\fMAP\fsensor.\f
NOTE:\fOnly\fremove\f\bnd\finst\bll\fthe\fengine\fupper\f
cover\fin\fthe\fsequence\fshown.\f Remove\fthe\fengine\fupper\fcover.\f
2
Det\bch\fthe\fturboch\brger\fint\bke\fpipe\f\bnd\fposition\fit\f
to\fone\fside.\f3
Inspect\fthe\fturboch\brger\frotor\fv\bnes\ffor\fd\bm\bge.\f4
\f\f
\f\f
\f\f
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Remove\fthe\fengine\fupper\fcover.\f1
Disconnect\fthe\fpositive\fcr\bnkc\bse\fventil\btion\f(PCV)\f
bre\bther\fhose\ffrom\fthe\fint\bke\fm\bnifold\fPCV\fv\blve.\f

Press\fin\fthe\frele\bse\fclip.\f
2
Remove\fthe\fturboch\brger\fint\bke\fpipe\fsupport\f
br\bcket\fret\bining\fbolt.\f3
R\bise\f\bnd\fsupport\fthe\fvehicle.\fFor\f\bddition\bl\f
inform\btion,\f\f
REFER\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des

cription\f\bnd\fOper\btion).\f
4
Remove\fthe\fengine\fundershield.\f

Rot\bte\fthe\flocking\ft\bngs\fcounterclockwise.\f5
Det\bch\fthe\fturboch\brger\fint\bke\fpipe.\f6
Inspect\fthe\fturboch\brger\frotor\fv\bnes\ffor\fd\bm\bge.\f7
\f\f
\f\f
\f\f
\f\f
\f\f
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Disconnect\fthe\fpositive\fcr\bnkc\bse\fventil\btion\f(PCV)\f
bre\bther\fhose\ffrom\fthe\fint\bke\fm\bnifold\fPCV\fv\blve.\f

Press\fin\fthe\frele\bse\fclip.\f
2
Remove\fthe\fturboch\brger\fint\bke\fpipe\fsupport\f
br\bcket\fret\bining\fbolt.\f3
R\bise\f\bnd\fsupport\fthe\fvehicle.\fFor\f\bddition\bl\f
inform\btion,\f\f
REFER\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des

cription\f\bnd\fOper\btion).\f
4
Remove\fthe\fengine\fundershield.\f

Rot\bte\fthe\flocking\ft\bngs\fcounterclockwise.\f5
Det\bch\fthe\fturboch\brger\fint\bke\fpipe.\f6
Inspect\fthe\fturboch\brger\frotor\fv\bnes\ffor\fd\bm\bge.\f7
\f\f
\f\f
\f\f
\f\f
\f\f
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I\fst\bll\btio\f Refer\fto:\f
Ex
h\bust\fM\bnifold \f(303-01G\fEngine\f-\f
2.2
L\fDur\btorq-TDCi\f(129kW/175PS)\f-\fDW,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
11. \f
1. NOTE:\fUse\f\b\fnew\fse\bl.\f
N
O

TE:\fOnly\ftighten\fthe\fbolts\ffinger\ftight\f\bt\f
this\fst\bge.\f
2. Torque:\b 1
0\fNm\f
3. CAUTION:\fM\bke\fsure\fth\bt\fthe\f
co

mponent\fis\fnot\fbent.\f
Do\fnot\fremove\fthe\fclip\f\bt\fthis\fst\bge.\f
4. Torque:\b 26\fNm\f
\f
\f
\f\f
\f\f
\f\f
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5.CAUTION:\fM\bke\fsure\fth\bt\fthe\f
co
mponent\fis\fnot\fbent.\f
Remove\fthe\fclip.\f
6. NOTE:\fM\bke\fsure\fth\bt\f\b\fnew\fcomponent\fis\f
in
st\blled.\f
7. Cle\bn\fthe\ffilter.\f Mat

er\fal:\bBr\bke\fCle\bner\f(3U7J-2C410-AA) \f
8. CAUTION:\fM\bke\fsure\fth\bt\fthe\f
co

mponent\fis\fnot\fbent.\f
NOTE:\fM\bke\fsure\fth\bt\f\b\fnew\fcomponent\fis\f
inst\blled.\f
NOTE:\fUse\fnew\fse\bls.\f
NOTE:\fOnly\ftighten\fthe\fbolt\ffinger\ftight\f\bt\f
this\fst\bge.\f
\f
\f\f
\f
\f\f
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Engine Emi\b\bion Cont\fol - 1.8L Du\fato\fq-
TDCi (74kW/100PS) - Lynx/1.8L Du\fato\fq-
TDCi (92kW/125PS) - Lynx - Exhau\bt Ga\b
Reci\fculation (EGR) Coole\f
S-MAX/G\bl\bxy\f2006.5\f(02/2006
\fPrint
Removal and In\btallation
Gene\fal Equipment
Removal
NO
TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
Hose\fcl\bmp\fremover/inst\bller
1. \f
2. \f\f1.
Torque:\b
22\fNm
3.Det\bch\f
the\fA
pill\br\f
exterior\f
trim\f
p\bnel\f
lower\f
clips.
3. \f\f2.
Torque:\b
10\fNm
4. \f
\f\f
\f
\f
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Engine Emi\b\bion Cont\fol - 2.0L Du\fato\fq-
TDCi (85kW/115PS) - DW/2.0L Du\fato\fq-
TDCi (100kW/136PS) - DW/2.0L Du\fato\fq-
TDCi (103kW/140PS) - DW, Emi\b\bion
Requi\fement\b: Stage IV - Exhau\bt Ga\b
Reci\fculation (EGR) Coole\f
S-MAX/G\bl\bxy\f2006.5\f(02/2006
\fPrint
Removal and In\btallation
Gene\fal Equipment
Removal
NO
TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\fins t
\bll\btion\fdet\bils.\f
Hose\fcl\bmp\fremover/inst\bller
1. Dr\bin\fthe\fcooling\fsystem.\fRefer\fto:\f
Cooling\fSystem\fDr\bining,\fFilling\f\bnd\fBleeding
(303-03E\fEngine\fCooling\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,\fGener\bl\fProcedures).\f 2. \f\f1.
Torque:\b
22\fNm
3.Det\bch\f
the\fA
pill\br\f
exterior\f
trim\f
p\bnel\f
lower\f
clips.
3. \f\f2.
Torque:\b
10\fNm
4.Genera\f\bEquipment:\b Hose\fcl\bmp\fremover/inst\bller \f
Tor
que:\b 10\fNm
\f
\f
\f
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Engine Emi\b\bion Cont\fol - 2.0L Du\fato\fq-
TDCi (85kW/115PS) - DW/2.0L Du\fato\fq-
TDCi (100kW/136PS) - DW/2.0L Du\fato\fq-
TDCi (103kW/140PS) - DW, Emi\b\bion
Requi\fement\b: Stage IV - Exhau\bt Manifold
to Exhau\bt Ga\b Reci\fculation (EGR) Valve
Tube
S-MAX/G\bl\bxy\f2006.5\f(02/2006
\fPrint
Removal and In\btallation
Removal
NO
TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
1. \f
2.

\f\f1.
Torque:\b
22\fNm
3.Det\bch\f
the\fA
pill\br\f
exterior\f
trim\f
p\bnel\f
lower\f
clips.
3. \f\f 2.
Torque:\b
10\fNm
4.NOTE:\fNote\fthe\forient\btion\fof\fthe\fcl\bmp\fto\f\bid\f
in
st\bll\btion.\f
NOTE:\fThe\fg\bskets\f\bre\fto\fbe\freused\funless\f
d\bm\bged.\f 1. Torque:\b 5
\fNm\f
2. Torque:\b 10\fNm
\f
3. Disc\brd\fthe\fcl\bmp.\f
\f\f
\f
\f
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Electro\bic E\bgi\be \fo\btrols - 2.0L Duratorq-
TD\fi (85kW/115PS) - DW/2.0L Duratorq-
TD\fi (100kW/136PS) - DW/2.0L Duratorq-
TD\fi (103kW/140PS) - DW - \famshaft
Positio\b (\fMP) Se\bsor
S-MAX/G\bl\bxy\f2006.5\f(02/2006
\fPrint
Removal a\bd I\bstallatio\b
Removal CA
UTION:\fM\bke\fsure\fth\bt\fthe\fignition\fkey\fis\fremoved.\f
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst\bll\btion\fdet\bils.\f
1. \f
2. \f\f1.
Torque:\b
22\fNm
3.Det\bch\f
the\fA
pill\br\f
exterior\f
trim\f
p\bnel\f
lower\f
clips.
3. \f\f2.
Torque:\b
10\fNm
4. \f
\f\f
\f
\f
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I\bstallatio\b 5. \f\f
1.

Det\bch\fthe\fclips.\f
2. Torque:\b 7\fNm
\f
4. Torque:\b 2\fNm
\f
1. CAUTION:\fOnly\frot\bte\fthe\fcr\bnksh\bft\f
c l

ockwise.\f
NOTE:\fM\bke\fsure\fth\bt\fthe\fsensor\fhousing\fis\fcle\bn\f
\bnd\ffree\fof\fforeign\fm\bteri\bl.\f
NOTE:\fM\bke\fsure\fth\bt\f\b\fnew\fcomponent\fis\f
inst\blled.\f 1.
Rot\bte\fthe\fengine\funtil\fthe\fb\bck\fof\fone\fof\fthe\f
three\fwebs\fof\fthe\fc\bmsh\bft\fpulley\fis\fin\fline\fwith\f
the\fCMP\fsensor\fhole\fin\fthe\ftiming\fbelt\fcover\fb\bck\f
pl\bte.\f
2.
Inst\bll\fthe\fCMP\fsensor\funtil\fthe\ftip\fof\fthe\fsensor\f
touches\fthe\fb\bck\fof\fthe\fc\bmsh\bft\fpulley.\f
\f
\f
\f\f
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