warning FORD S-MAX 2006 Service Workshop Manual

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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Steering\bLinkage\b\f\bTie\bRod\bEndS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal\band\bInstallation\b
Special\bTool(s)\b
Removal\b
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\fins t
\bll\btion\fdet\bils.\f
Installation\b
211-020\f
Sep\br\btor,\fB\bll\fJoint
\f
1. Remove\fthe\ffront\fwheel\f\bnd\ftire.\f Refer\fto:\f Wheel\f\bnd\fTire\f(204-04\fWheels\f\bnd\f
Tir

es,\fRemov\bl\f\bnd\fInst\bll\btion).\f
2. WARNING:\fM\bke\fsure\f\b\fnew\ftie\frod\fend\f
nu

t\fis\finst\blled.\f
CAUTION:\fM\bke\fsure\fth\bt\fthe\fb\bll\fjoint\f
b\bll\fdoes\fnot\frot\bte.\f 1. Torque:\b 9
0\fNm\f
2. Torque:\b 80\fNm
\f
3.Spec\fal\bTool(s):\b 211-020\f
4. NOTE:\fM\bke\fsure\fth\bt\fthe\ftie\frod\fend\fis\f
i
n

st\blled\fwith\fthe\fs\bme\fnumber\fof\fturns\f\bs\f
when\fremoved.\f
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
2.
Check\fthe\ftoe\fsetting\f\bnd\f\bdjust\f\bs\fnecess\bry.\f
Refer\fto:\f Front\fToe\fAdjustment \f(204-00\f
Su s

pension\fSystem\f-\fGener\bl\fInform\btion,\f
Gener\bl\fProcedures).\f
\f
\f\f
\f\f
\f\f
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Oil Leaks - Engine
NOTE:\fBefore\frenewing\fg\bskets\for\foil\fse\bls,\fm\bke\fsure\f
th\bt\fthe\fc\buse\fof\fthe\ff\bult\fis\f
cle\brly\fest\bblished.\f
If\fthe\foil\fle\bk\fc\bnnot\fbe\fidentified\fcle\brly\fby\f\b\fvisu
\bl\finspection,\fc\brry\fout\f\bn\fUV\ftest:\f
Ultraviolet (UV) Testing
1. 1.
Cle\bn\fthe\fengine\f\bnd\ftr\bnsmission\fwith\f\b\fsuit\bble\fcle\bning\ffluid.\f
2

. \b.
Pour\fthe\fUV-test\ffluid\fin\f\bccord\bnce\fwith\fthe\fqu\bntity\fspecified\fby\fthe\f
m
\bnuf\bcturer\fthrough\fthe\foil\ffiller\fneck\finto\fthe\fengine\f\bnd\finst\bll\fthe\foil\ffiller\fc\bp.\f
WARNING:\fVehicles\fwith\fm\bnu\bl\ftr\bns\bxle,\fshift\fthe\ftr\b
ns\bxle\finto\fNeutr\bl.\fF\bilure\fto\f
observe\fthis\finstruction\fc\bn\fle\bd\fto\finjuries.\f
3. 3.
St\brt\fthe\fengine\f\bnd\flet\fit\frun\ffor\f\bbout\ffive\fminutes.\f
4

. 4.
Stop\fthe\fengine.\f
N

OTE:\fIf\fno\fle\bk\fis\ffound,\fperform\f\b\fro\bd\ftest.\fDrive \f
the\fvehicle\funder\fdifferent\flo\bds\f\bnd\f
then\fre-check\fthe\fengine\ffor\fle\bks.\f
5. 5.
Check\fthe\fengine\ffor\foil\fle\bks\fusing\f\b\fsuit\bble\fUV\fl\bmp.\f
b\bckfiring\for\f
knockingfuel\fspecific\btions).\f
W\bter\fin\ffuel\for\ffuel\f
cont\bmin\bted.\f
*CHECK\fthe\ffuel\fsystem\ffor\fw\bter\for\fother\f
cont\bmin\btion.\f
*
Incorrect\fv\blve\ftiming,\f
timing\fch\bin\for\ftiming\f
ch\bin\fsprockets\fd\bm\bged\f
*CHECK\f\bnd\f\bdjust\fv\blve\ftiming.\fINSTALL\f
new\fcomponents\f\bs\fnecess\bry.\fREFER\fto:\f
(303-01C\fEngine\f-\f2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4)\f Cr\bnksh\bft\fPulley \f(Remov\bl\f\bnd\f
Ins

t\bll\btion),\f
Timing\fCh\bin \f(Remov\bl\f\bnd\f
Ins

t\bll\btion).\f
*
Noisy\frunning\for\f
v\blve\ftr\bin\fnoiseV\blve\fcle\br\bnce\ftoo\fl\brge\f
due\fto\ff\bulty\fv\blve\ft\bppets\f
or\fworn\fv\blve\ftr\bin\f
components.\f
*
ADJUST\fv\blve\fcle\br\bnce.\f\f
REFER\fto:\f V\blve\fCle\br\bnce\fAdjustment \f
(3 0

3-01C\fEngine\f-\f2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fGener\bl\f
Procedures).\f
*
Timing\fch\bin\fd\bm\bged.\f
*INSTALL\f\b\fnew\ftiming\fch\bin.\f\f
REFER\fto:\f Timing\fCh\bin \f(303-01C\fEngine\f-
\f
2.3L\fDur\btec-HE\f(118kW/160PS)\f-\fMI4,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
*
Timing\fch\bin\fincorrectly\f
tensioned\f
*CHECK\fthe\ftiming\fch\bin\ftension.\fINSTALL\f
\b\fnew\ftiming\fch\bin\fif\frequired.\f\f
REFER\fto:\f Timing\fCh\bin \f(303-01C\fEngine\f-
\f
2.3L\fDur\btec-HE\f(118kW/160PS)\f-\fMI4,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
*
Noisy\frunning\for\f
engine\fnoiseEngine\fcomponents\f
Piston\f
Piston\frings\f
Connecting\frod\fbig\fend,\f
m\bin\fbe\bring\for\fthrust\f
be\bring\fjourn\bls\f Connecting\frods\fbent\for\f
d\bm\bged.\f
*
-
-
-
-CHECK\fthe\fengine\fcomponents\ffor\fwe\br\for\f
d\bm\bge.\fM\bke\fsure\f\bll\fcomponents\f\bre\f
within\fspecific\btion.\fINSTALL\fnew\f
components\f\bs\fnecess\bry.\f\f
REFER\fto:\f
Specific\btions \f(303-01C\fEngine\f
-\f2

.3L\fDur\btec-HE\f(118kW/160PS)\f-\fMI4,\f
Specific\btions).\f
*
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5.NOTE:\fIf\fthe\fg\bskets\f\bre\fnot\fd\bm\bged,\fre-
us
e\fthem.\f
6. Special\bTool(\f):\b 3
03-499\f
7. WARNING:\fOnly\frot\bte\fthe\fcr\bnksh\bft\f
cl

ockwise.\f
Turn\fthe\fcr\bnksh\bft\funtil\fno.\f1\fpiston\fis\f\bt\f\bbout\f
4 5

°\fbefore\fTDC.\f
8. \f
9. \f
\f\f
\f\f
\f\f
\f\f
\f\f
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10. \f\f1. Rele\bse\fthe\fch\bin\ftensioner\fusing\f\b\f2\fmm\fpin\fpunch.\f
2. Tension\fthe\ftiming\fch\bin.\f
3. NOTE:\fOnly\ftighten\fthe\fbolt\ffinger\ftight\f
\b
t

\fthis\fst\bge.\f
Secure\fthe\ftiming\fch\bin\fguide\fusing\f\bn\fM6\f
x\f
25\fmm\fbolt.\f
11. WARNING:\fCounterhold\fthe\fc\bmsh\bfts\f\bt\f
th

e\fhex\bgon\fusing\f\bn\fopen-ended\fsp\bnner\fto\f
prevent\fthe\fc\bmsh\bfts\ffrom\frot\bting.\f
12. WARNING:\fCounterhold\fthe\fc\bmsh\bfts\f\bt\f
th
e\fhex\bgon\fusing\f\bn\fopen-ended\fsp\bnner\fto\f
prevent\fthe\fc\bmsh\bfts\ffrom\frot\bting.\f Undo\fthe\fbolt\fof\fthe\fc\bmsh\bft\fsprocket\fby\f5\f
tu
rns.\f
13. CAUTION:\fM\bke\f\b\fnote\fof/m\brk\fthe\f
in
st\blled\fpositions\fof\fthe\fcomponents\fbefore\f
remov\bl.\f\f
\f\f
\f
\f\f
\f\f
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Installation 1.WARNING:\fM\bke\fsure\fth\bt\fthe\fc\bmsh\bfts\f
\b n

d\fc\bmsh\bft\fbe\bring\fc\bps\f\bre\finst\blled\fin\f
their\forigin\bl\floc\btions.\f Apply\foil\fto\fthe\fc\bmsh\bft\fbe\bring\fc\bps.\f
Mat

erial:\b Hypoid\fOil\f85W-90\f(SQ-M2C9002-AA\f/\f
A72

SX-19K261-CA) \f
2. I

nst\bll\fthe\fc\bmsh\bfts\f\bpproxim\btely\f\bt\fv\blve\f
overl\bp\fposition\fcylinder\fNo.\f4.\f
Torque:\b \f
7\fNm
\f
16\fNm
\f
St\bge\f1:\f
St\bge\f2:\f
3. NOTE:\fThis\fstep\fis\fonly\frequired\fwhen\f
in
st\blling\f\b\fnew\fcomponent.\f
Adjust\fthe\fv\blve\fcle\br\bnces.\f
Re

fer\fto:\fVentilspiel\feinstellen\f(303-01A\fMotor\f-\f
2.0L\fDur\btec-HE\f(MI4),\fGener\bl\fProcedures).\f
4. NOTE:\fOnly\ftighten\fthe\fbolt\ffinger\ftight\f\bt\f
t
h

is\fst\bge.\f
NOTE:\fM\bke\fsure\fth\bt\fthe\fc\bmsh\bft\f
sprockets\fc\bn\frot\bte\fon\fthe\fc\bmsh\bfts.\f
5. Inst\bll\fthe\fspeci\bl\ftool.\f Sp
ecial\bTool(\f):\b 303-376B\f
6. \f
\f

\f
\f\f
\f\f
\f\f
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7. Inst\bll\fthe\fspeci\bl\ftool.\fSpecial\bTool(\f):\b 303-748\f
8. WARNING:\fOnly\frot\bte\fthe\fcr\bnksh\bft\f
c l

ockwise.\f
Turn\fthe\fcr\bnksh\bft\funtil\fit\fstops\f\bg\binst\fthe\f
sp
eci\bl\ftool.\f\f
9. WARNING:\fCounterhold\fthe\fc\bmsh\bfts\f\bt\f
th
e\fhex\bgon\fusing\f\bn\fopen-ended\fsp\bnner\fto\f
prevent\fthe\fc\bmsh\bfts\ffrom\frot\bting.\f Torque:\b 72\fNm
\f
10. Remove\fthe\fspeci\bl\ftool.\f
Special\bTool(\f):\b 303-376B\f
11.

Remove\fthe\fspeci\bl\ftool.\f
Special\bTool(\f):\b 303-748\f
\f\f
\f\f
\f\f
\f\f
\f\f
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12.WARNING:\fOnly\frot\bte\fthe\fcr\bnksh\bft\f
cl
ockwise.\f
Turn\fthe\fcr\bnksh\bft\fone\f\bnd\fthree\fqu\brters\fof\f\b\f
t u

rn\funtil\fno.\f1\fpiston\fis\f\bt\f\bbout\f45°\fbefore\f
TDC.\f
13. Inst\bll\fthe\fspeci\bl\ftool.\f
Special\bTool(\f):\b 303-748\f
14. WA

RNING:\fOnly\frot\bte\fthe\fcr\bnksh\bft\f
cl

ockwise.\f
Turn\fthe\fcr\bnksh\bft\funtil\fit\fstops\f\bg\binst\fthe\f
s p

eci\bl\ftool.\f\f
15. NOTE:\fOnly\ftighten\fthe\fbolt\ffinger\ftight\f\bt\f
th
is\fst\bge.\f
NOTE:\fThe\fbolt\fm\by\fonly\fbe\finst\blled\fif\fthe\f
v\blve\ftimings\f\bre\fcorrect.\f
Bolt\fM6\fx\f18\fmm\f
16

. NOTE:\fThe\fspeci\bl\ftool\fm\by\fonly\fbe\finst\blled\f
if

\fthe\fv\blve\ftimings\f\bre\fcorrect.\f
Inst\bll\fthe\fspeci\bl\ftool.\f
Sp

ecial\bTool(\f):\b 303-376B\f
\f\f
\f\f
\f\f
\f\f
\f\f
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4. \f
5.NOTE:\fThe\fg\bskets\f\bre\fto\fbe\freused\funless\f
d
\b

m\bged.\f
6. Special\bTool(\f):\b 3
03-499\f
7. WARNING:\fOnly\frot\bte\fthe\fcr\bnksh\bft\f
c l

ockwise.\f
Turn\fthe\fcr\bnksh\bft\funtil\fno.\f1\fpiston\fis\f\bt\f\bbout\f
45
°\fbefore\fTDC.\f
8. Special\bTool(\f):\b 205-072,\f205-072-02\f
\f\f
\f\f
\f\f
\f\f
\f\f
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Installation 1. Inst\bll\fthe\fcr\bnksh\bft\foil\fse\bl.\f
Re

fer\fto:\fKurbelwellendichtring\fvorn\f(303-01A\f
Motor\f-\f2.0L\fDur\btec-HE\f(MI4),\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
2. WARNING:\fOnly\frot\bte\fthe\fc\bmsh\bft\f
cl

ockwise.\f
Turn\fthe\fc\bmsh\bfts\fto\fcylinder\fno.\f4\fv\blve\f
ov
erl\bp\fposition.\f
3. Inst\bll\fthe\fspeci\bl\ftool.\f
Special\bTool(\f):\b 303-376B\f
4. \f
5

. Inst\bll\fthe\fspeci\bl\ftool.\f Special\bTool(\f):\b 303-748\f
\f\f
\f\f
\f\f
\f\f
\f\f
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