fuel FORD S-MAX 2006 Service Service Manual

Engine - \b.0L \furatec-HE (107kW/145PS)
- MI4/\b.0L \furatec-HE Flex Fuel
(107kW/145PS) - MI4 - Engine
Accessories
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal
Special Tool(s)
Ge

neral Equipment
303-122\f
Lifting\fBr\bcket,\fEngine\f
303-254\f
Locking\fTool,\fFlywheel\f
303-397\f
Remover/Inst\bller,\fHose\fCl\bmp
\f
303-435\f
Mounting\fSt\bnd\f
303-435-06\f
Mounting\fBr\bcket\ffor\f303-435\f
303-435-11A\f
Mounting\fPl\bte\ffor\f303-435-06\f
Hose clamp remover/installer
Hydraulic jib crane 1. Inst\bll\fthe\fspeci\bl\ftools.\f
Spe
cial\bTool(\f):\b 303-435,\f303-435-06,\f 303-435-
11A \f
2

. R

emove\fthe\fspeci\bl\ftool.\f
Special\bTool(\f):\b 303-122\f
Ge n

eral\bEquipment:\b Hydr\bulic\fjib\fcr\bne \f
\f
\f
\f
\f
\f
\f
\f\f
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Engine - \b.0L \furatec-HE (107kW/145PS)
- MI4/\b.0L \furatec-HE Flex Fuel
(107kW/145PS) - MI4 - Engine
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
\fisassembly
Special Tool(s)
100-010\f
Remover,\fO-Ring\fSe\bl\f
205-072\f
Univers\bl\fFl\bnge\fHolding\fWrench
\f
205-072-01\f
Ad\bpter\ffor\f205-072\f
205-072-02\f
Ad\bpter\ffor\f205-072\f
303-293\f
Remover,\fCr\bnksh\bft\fSe\bl\f
303-699\f
Wrench,\fOil\fFilter\f
1. \f
2.CAUTION:\fOnly\frot\bte\fthe\fcr\bnksh\bft\f
c l

ockwise.\f
Rot\bte\fthe\fcr\bnksh\bft\funtil\fpiston\fNo.\f1\fis\f
\bpproxim\btely\f45\fdegrees\fbefore\ftop\fde\bd\fcenter\f
(TDC).\f
3. Special\bTool(\f):\b 205-072,\f205-072-02\f
\f
\f
\f
\f
\f
\f
\f\f
\f\f
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Engine - \b.0L \furatec-HE (107kW/145PS)
- MI4/\b.0L \furatec-HE Flex Fuel
(107kW/145PS) - MI4 - Engine
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Assembly
Special Tool(s)
Ma

terials
205-072\f
Univers\bl\fFl\bnge\fHolding\fWrench
\f
205-072-01\f
Ad\bpter\ffor\f205-072\f
205-072-02\f
Ad\bpter\ffor\f205-072\f
303-376B\f
Alignment\fPl\bte,\fC\bmsh\bft\f
303-509\f
Remover,\fVibr\btion\fD\bmper\fHub
\f
303-699\f
Wrench,\fOil\fFilter\f
303-748\f
Locking\fTool,\fCr\bnksh\bft\f
NameSpec\bf\bcat\bo\f
Hypoid\fOil\f85W-90SQ-M2C9002-AA\f/\fA72SX-19K261-CA
Silicone\fSe\bl\bnt\fLBWSE-M4G323-A4\f/\f2U7J-M4G323-AA 1.NOTE:\fNew\fcr\bnksh\bft\fre\br\fse\bl\fc\brriers\f\bre\f
su

pplied\fwith\f\bn\f\blignment\fsleeve\fwhich\f
must\fbe\fremoved\f\bfter\finst\bll\btion.\f
Torque:\b 10\fNm
\f
2. Torque:\b \f
10\fNm
\f
23\fNm
\f
St\bge\f1:\f
St\bge\f2:\f
\f
\f
\f
\f
\f
\f
\f
\f\f
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Engine - \b.0L \furatec-HE (107kW/145PS)
- MI4/\b.0L \furatec-HE Flex Fuel
(107kW/145PS) - MI4 - Engine
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Installation
Special Tool(s)
Ma

terials
General Equipment
303-122\f
Lifting\fBr\bcket,\fEngine
\f
NameSpec\bf\bcat\bo\f
Gre\bse\fKS-PSSA-M1C9107-A\f/\fYS5J-M1C9107-AA
Hose clamp remover/installer
Hydraulic jib crane
Mounting table set
Retaining Strap 1.Torque:\b 48
\fNm\f
2. Torque:\b 48\fNm
\f
3. WARNING:\fSupport\fthe\f
e n

gine/tr\bnsmission\fon\fwood\fblocks\f\bnd\f
secure\fwith\fsuit\bble\fstr\bps.\f Genera\f\bEquipment:\b Mo
unting\ft\bble\fset\f
Gen
era\f\bEquipment:\b Ret\bining\fStr\bp\f
\f
\f\f
\f\f
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40.Torque:\b 12\fNm\f
41. Torque:\b 12\fNm
\f
42. Refer\fto:\f Ge\brshift\fC\bble\fAdjustment\f-\fVehicles\f
Wit

h:\f5-Speed\fM\bnu\bl\fTr\bns\bxle\f(MTX-75) \f(308-
00\f

M\bnu\bl\fTr\bnsmission/Tr\bns\bxle\f\bnd\fClutch\f-\f
Gener\bl\fInform\btion,\fGener\bl\fProcedures).\f
43. Inst\bll\fthe\ffollowing\fitems:\f 1. Refer\fto:\f Accessory\fDrive\fBelt \f(303-05A\f
Ac c

essory\fDrive\f-\f2.0L\fDur\btec-HE\f
(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\f
Flex\fFuel\f(107kW/145PS)\f-\fMI4/2.3L\f
Dur\btec-HE\f(118kW/160PS)\f-\fMI4,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
2. Right-h\bnd\fhe\bdl\bmp\f
Refer\fto:\f He\bdl\bmp\fAssembly \f(417-01\f
Ext

erior\fLighting,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
3. Refer\fto:\f B\bttery\f(414-01\fB\bttery,\f
Mou

nting\f\bnd\fC\bbles,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
44. \f
\f\f
\f\f
\f\f
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45. Refer\fto:\fPower\fSteering\fSystem\fFilling \f(211-00\f
Ste
ering\fSystem\f-\fGener\bl\fInform\btion,\fGener\bl\f
Procedures).\f
46. Refer\fto:\f Power\fSteering\fSystem\fBleeding \f(211-
00 \f

Steering\fSystem\f-\fGener\bl\fInform\btion,\f
Gener\bl\fProcedures).\f
47. Refer\fto:\f Cooling\fSystem\fDr\bining,\fFilling\f\bnd\f
Ble

eding \f(303-03A\fEngine\fCooling\f-\f2.0L\f
Dur

\btec-HE\f(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-
HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-
HE\f(118kW/160PS)\f-\fMI4,\fGener\bl\fProcedures).\f
48. \f
49.
Check\fthe\ftoe\fsetting\f\bnd\f\bdjust\f\bs\fnecess\bry\fon\f
both\fsides.\f
Refer\fto:\f Front\fToe\fAdjustment \f(204-00\f
Sus

pension\fSystem\f-\fGener\bl\fInform\btion,\f
Gener\bl\fProcedures).\f
\f\f
\f\f
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Engine - \b.0L \furatec-HE (107kW/145PS)
- MI4/\b.0L \furatec-HE Flex Fuel
(107kW/145PS) - MI4 - Engine
Accessories
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Installation
Special Tool(s)
Ge

neral Equipment
303-122\f
Lifting\fBr\bcket,\fEngine\f
303-254\f
Locking\fTool,\fFlywheel\f
303-397\f
Remover/Inst\bller,\fHose\fCl\bmp
\f
303-435\f
Mounting\fSt\bnd\f
303-435-06\f
Mounting\fBr\bcket\ffor\f303-435\f
303-435-11A\f
Mounting\fPl\bte\ffor\f303-435-06\f
308-204\f
Aligner,\fClutch\fDisc\f
Hose clamp remover/installer
Hydraulic jib crane 1.CAUTION:\fM\bke\fsure\fth\bt\fnew\fbolts\f\bre\f
in

st\blled.\f
Special\bTool(\f):\b 30
3-254\f
Tor
que:\b \f
50\fNm
\f
80\fNm
\f
112\fNm
\f
St\bge\f1:\f
St\bge\f2:\f
St\bge\f3:\f
2. Special\bTool(\f):\b 308-204\f
Tor
que:\b 29\fNm
\f
\f
\f
\f
\f
\f
\f
\f
\f\f
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Engine - \b.0L E\foBoost SCTi
(149kW/\b03PS) - MI4 - Valve Clearan\fe
Adjustment
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
General Pro\fedures
Spe\fial Tool(s)
Adjustment
303-499\f
Socket,\fSp\brk\fPlug\f
310-137\f
Disconnect\fTool,\fFuel\fLine
\f
1. \f
2. Torque:\b 10\fNm
\f
3. \f 4. \f
\f
\f
\f\f
\f\f
\f\f
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Engine - \b.0L E\foBoost SCTi (149kW/\b03PS)
- MI4 - Crankshaft PulleyS-MAX/G\bl\bxy\f2006.5\f(02/2006
\fPrint
Removal and Installation
Spe\fial Tool(s)
Removal
303-1504\f
Alignment\fTool,\fC\bmsh\bft\f
303-1521\f
Alignment\fTool,\fCr\bnksh\bft\fPosition\fSensor
\f
303-499\f
Socket,\fSp\brk\fPlug\f
303-748\f
Locking\fTool,\fCr\bnksh\bft\f
310-137\f
Disconnect\fTool,\fFuel\fLine\f1. Refer\fto:\f Fuel\fPump\fDrive\fAssembly \f(303-04B\fFuel\f
Ch\br

ging\f\bnd\fControls\f-\f2.0L\fEcoBoost\fSCTi\f
(149kW/203PS)\f-\fMI4,\fRemov\bl\f\bnd\fInst\bll\btion).\f
2.
WARNING:\fT\bke\fextr\b\fc\bre\fwhen\fh\bndling\fthe\f
compressed\fspring.\f
\f
\f
\f
\f
\f
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23. Refer\fto:\fFuel\fPump\fDrive\fAssembly \f(303-04B\fFuel\f
Ch\br
ging\f\bnd\fControls\f-\f2.0L\fEcoBoost\fSCTi\f
(149kW/203PS)\f-\fMI4,\fRemov\bl\f\bnd\fInst\bll\btion).\f
\f
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