rear FORD S-MAX 2006 Service Owner's Guide

renewed as individual parts.
NOTE: T\fe parts \bf t\fe cylinder \fead must n\bt be rew\brked.
B\bt\f cylinder \fead parts \fave been matc\fed t\b eac\f \bt\fer during pr\bducti\bn. Tw\b guide sleeves p\bsiti\bn t\fe cylinder \fead
parts exactly.
T\fe upper part \bf t\fe cylinder \fead is b\blted t\b t\fe l\bwer part \bf t\fe cylinder \fead and sealed as f\bll\bws:

using silic\bn sealer (seals t\fe \buter area),

using a ready-made gasket (seals t\fe swirl ducts and t\fe guides f\br t\fe fuel inject\brs).
T\fe upper \falves \bf t\fe cams\faft m\buntings are inc\brp\brated int\b t\fe upper part \bf t\fe cylinder \fead. T\fe cams\fafts run
directly in t\fe aluminium.
T\fe cams\fafts are made fr\bm cast ir\bn. T\fe intake cams\faft drives t\fe vacuum pump at t\fe rearward end. T\fe ex\faust
cams\faft drives t\fe fuel pump at t\fe rearward end. An O-ring pr\bvides t\fe seal in eac\f case.
T\fe l\bwer part \bf t\fe cylinder \fead is b\blted t\b t\fe cylinder bl\bck wit\f a t\btal \bf 10 b\blts. T\fe \bld cylinder \fead b\blts may n\bt
be reused during servicing.
Cylinder head gasket

Description
Cylinder \fead gasket t\fickness
Cylinder \fead gasket t\fickness
T\fe multi-
layer steel cylinder \fead gasket is available in f\bur t\ficknesses depending \bn t\fe pist\bn pr\btrusi\bn.
Camshaft and camshaft drive
Overview \bf t\fe c\bmp\bnents Item
C\bnnecting
r\bd
retaining
b\blts b
Number \bf cut\f\butsPist\bn pr\btrusi\bnCylinder head gasket thickness
10.55 - 0.60 mm1.25 +/
20.61 - 0.65 mm1.30 +/
30.66 - 0.70 mm1.35 +/
40.71 - 0.75 mm1.40 +/

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Description
Rear timing c\bver
Upper timing c\bver
L\bwer timing c\bver
M\bunting b\blt
T\fe plastic timing c\bvers are secured t\b t\fe engine using a t\btal \bf nine b\blts.
T\fere is a \f\ble (arr\bw) in t\fe upper timing c\bver. T\fis \f\ble permits t\fe inserti\bn \bf t\fe special t\b\bl f\br securing t\fe ex\faust
cams\faft pulley. T\fis all\bws fast c\fecking \bf t\fe valve timing.
Camshaft Drive

Description
Cams\faft pulley
Ex\faust cams\faft
intake cams\faft
Timing c\fain
T\fe ex\faust cams\faft is driven by t\fe cranks\faft via a timing belt. Item
1
2
3
4
I t

em
1
2
3
4


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Engine - \b.\bL D\fratorq-TDCi
(1\b9kW/175PS) - DW - Crankshaft Rear
Seal
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Installation
Special Tool(s)
Removal
205-044\f
Holding\fFixture,\fDi\bl\fIndic\btor\fG\buge
\f
205-044-01\f
Ad\bpter\ffor\f205-044\f
205-307\f
Inst\bller,\fWheel\fSpeed\fSensor\fRing\f
303-254\f
Locking\fTool,\fFlywheel\f
303-336\f
Remover,\fCr\bnksh\bft\fRe\br\fSe\bl\f
1. Refer\fto:\fClutch\fDisc\f\bnd\fPressure\fPl\bte \f(308-
01C

\fClutch\f-\fVehicles\fWith:\f6-Speed\fM\bnu\bl\f
Tr\bns\bxle\f-\fM66,\fRemov\bl\f\bnd\fInst\bll\btion).\f
2. Special\bTool(\f):\b 205-044,\f205-044-01,\f 303-254\f
3. \f
4

. \f
\f
\f
\f
\f
\f
\f\f
\f\f
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Exhaust\bSyste\f\b-\b2.0L\bDuratec-HE\b
(107kW/145PS)\b-\bMI4/2.3L\bDuratec-HE\b
(118kW/160PS)\b-\bMI4\b-\bRear\bMuffler—
2.0L\bDuratec-HE\b(107kW/145PS)\b-\b
MI4/2.0L\bDuratec-HE\bFlex\bFuel\b
(107kW/145PS)\b-\bMI4
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Re\foval\band\bInstallation\b
Re\foval\b
In

stallation\b 1. R\bise\f\bnd\fsupport\fthe\fvehicle.\f
Re
fer\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
De s

cription\f\bnd\fOper\btion).\f
2. \f
1. Torque:\b 45\fNm
\f
\f\f
\f\f
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Exhaust\bSyste\f\b-\b2.0L\bDuratec-HE\b
(107kW/145PS)\b-\bMI4/2.3L\bDuratec-HE\b
(118kW/160PS)\b-\bMI4\b-\bRear\bMuffler—2.3L\b
Duratec-HE\b(118kW/160PS)\b-\bMI4
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Re\foval\band\bInstallation\b
Re\foval\b
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
Installation\b 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. Step\frequired\f
when\f
repl\bcing\f
both\fre\br\f
mufflers.\f
3. Step\frequired\fwhen\frepl\bcing\f\b\fsingle\fre\br\fmuffler.\f
\f
\f
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Exhaust\bSyste\f\b-\b2.5L\bDuratec\b
(162kW/220PS)\b-\bVI5\b-\bRear\bMufflerS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Re\foval\band\bInstallation\b
Re\foval\b
In

stallation\b 1. R\bise\f\bnd\fsupport\fthe\fvehicle.\f
Re
fer\fto:\fLifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Description\f\bnd\fOper\btion).\f
2. \f
3. \f
1. \f\f 4.Torque:\b 54\fNm
\f
5. Torque:\b 45\fNm
\f
2. \f\f 3.Torque:\b 54\fNm
\f
\f\f
\f\f
\f\f
\f\f
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Exhaust\bSyste\f\b-\b1.8L\bDuratorq-TDCi\b
(74kW/100PS)\b-\bLynx/1.8L\bDuratorq-
TDCi\b(92kW/125PS)\b-\bLynx\b-\bRear\bMuffler
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Re\foval\band\bInstallation\b
Re\foval\b
In

stallation\b 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
1. Torque:\b 45\fNm
\f
\f\f
\f\f
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Exhaust\bSyste\f\b-\b2.0L\bDuratorq-TDCi\b
(85kW/115PS)\b-\bDW/2.0L\bDuratorq-TDCi\b
(100kW/136PS)\b-\bDW/2.0L\bDuratorq-
TDCi\b(103kW/140PS)\b-\bDW,\bE\fission\b
Require\fents:\bStage\bIV\b-\bRear\bMuffler
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Re\foval\band\bInstallation\b
Re\foval\b
All\fvehicles\f
Ve

hicles\fwithout\fdiesel\fp\brticul\bte\ffilter\f
Vehicles\fwith\fdiesel\fp\brticul\bte\ffilter\f
Installation\b 1. R\bise\f\bnd\fsupport\fthe\fvehicle.\f
Re
fer\fto:\fLifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Description\f\bnd\fOper\btion).\f
2. \f
3. \f
1. \f\f 3.Torque:\b 45\fNm
\f
\f\f
\f\f
\f\f
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Exhaust\bSyste\f\b-\b2.2L\bDuratorq-TDCi\b
(129kW/175PS)\b-\bDW\b-\bRear\bMufflerS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Re\foval\band\bInstallation\b
General\bEquip\fent\b
Re\foval\b
In

stallation\b
Air\fBody\fS\bw 1. Refer\fto:\fLifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des

cription\f\bnd\fOper\btion).\f
2. \f\f 1.General \bqui\fment: Air\fBody\fS\bw\f
3. \f
1

. Torque:
4:\f54\fNm
\f
5:\f45\fNm
\f
2. \f\f 3.Torque: 54\fNm
\f
\f\f
\f\f
\f\f
\f\f
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Auxiliar\b Clima\fe Con\frol - Auxiliar\b
Evapora\for Rear Ou\fle\f and Inle\f LineS-MAX/G\bl\bxy\f2006.5\f(02/2006
Removal and Ins\falla\fion
Ma\ferials
Removal
NO
TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
All\fexcept\fvehicles\fwith\fdiesel\fengine\f
A l

l\fvehicles\f
NameSpec\bf\bcat\bo\f
Compressor\fOil\f-\fAir\fConditioningWSH-M1C231-B\f/\f6U7J-M1C231-AA 1.
C\brry\fout\fthe\f\bir\fconditioning\f(A/C)\fsystem\frecovery\f
procedure.\f
Refer\fto:\f Air\fConditioning\f(A/C)\fSystem\fRecovery,\f
Ev\b

cu\btion\f\bnd\fCh\brging\f(412-
00\fClim\bte\fControl\fSystem\f
-\fGener\bl\fInform\btion,\fGener\bl\fProcedures).\f
2. R\bise\fthe\fvehicle.\f
Refer\fto:\f Lifting\f(100-
02\fJ\bcking\f\bnd\fLifting,\fDescription\f
\bnd\fOper\btion).\f
3. Refer\fto:\f Petrol\f\bnd\fPetrol-
Eth\bnol\fFuel\fSystems\fHe\blth\f
\bnd\fS\bfety\fPrec\butions\f(100-00\fGener\bl\fInform\btion,\f
Description\f\bnd\fOper\btion).\f
4.
CAUTION:\f
M\bke\fsure\f
th\bt\f\bll\f
openings\f\bre\f
se\bled.\fUse\f
new\fbl\bnking\f
c\bps.\f1.
Torque:\b
Nm\f
2.
Torque:\b
Nm\f
5.CAUTION:\f
M\bke\fsure\f
th\bt\f\bll\f
openings\f\bre\f
se\bled.\f
1.
Torque:\b
\f
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