ESP FORD S-MAX 2006 Service Manual PDF
[x] Cancel search | Manufacturer: FORD, Model Year: 2006, Model line: S-MAX, Model: FORD S-MAX 2006Pages: 4402, PDF Size: 93.08 MB
Page 931 of 4402
Engine - \b.8L \furatorq-T\fCi
(74kW/\b00PS) - Lynx/\b.8L \furatorq-
T\fCi (92kW/\b25PS) - Lynx - Oil Pan
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Installation
Special Tool(s)
Mat
erials
Removal
205-047\f
Slide\fH\bmmer\f
303-633\f
Ad\bpter\ffor\f205-047
\f
NameSpec\bf\bcat\bo\f
Engine\fOil\f-\f5W-30WSS-M2C912-A1
Silicone\fSe\bl\bnt\fLBWSE-M4G323-A4\f/\f2U7J-M4G323-AA 1. Refer\fto:\fLifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des
cription\f\bnd\fOper\btion).\f
2. \f
3. NOTE:\fThe\fse\bl\fis\fto\fbe\freused\funless\f
d
\b
m\bged.\f
Dr\bin\fthe\fengine\foil\finto\f\b\fsuit\bble\fcont\biner.\f
4. C
AUTION:\fT\bke\fextr\b\fc\bre\fnot\fto\f
d\b
m\bge\fthe\fm\bting\ff\bces.\f
Special\bTool(\f):\b 30
3-633,\f205-047\f
\f
\f
\f\f
\f\f
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Page 967 of 4402
Engine - \b.8L \furatorq-T\fCi
(74kW/\b00PS) - Lynx/\b.8L \furatorq-
T\fCi (92kW/\b25PS) - Lynx - 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
303-122\f
Lifting\fBr\bcket,\fEngine\f
303-193\f
Timing\fPeg,\fCr\bnksh\bft\fTDC\f
303-376B\f
Alignment\fPl\bte,\fC\bmsh\bft\f
303-393\f
Locking\fTool,\fFlywheel\f
303-435\f
Mounting\fSt\bnd\f
303-435-06\f
Mounting\fBr\bcket\ffor\f303-435\f
303-652\f
Aligner,\fOil\fPump\f
303-710\f
Timing\fTool,\fCr\bnksh\bft\f
NameSpec\bf\bcat\bo\f
Engine\fOil\f-\f5W-30WSS-M2C912-A1
Fl\bnge\fSe\bl\bnt\f-\fAn\berobic\fLPWSK-M2G348-A7\f/\f5U7J-M2G348-BA
Silicone\fSe\bl\bnt\fLBWSE-M4G323-A4\f/\f2U7J-M4G323-AA
Spoiler\fAdhesive\fKit\f2\fComponentWSK-M5B401-A1\f/\f2U7J-M2G376-AA 1. Co\bt\fthe\fcr\bnksh\bft\fm\bin\fbe\bring\fjourn\bls,\fbe\bring\fshells\f\bnd\fthrust\fh\blf\fw\bshers\fwith\fcle\bn\f
engine\foil.\f
\f
\f
\f
\f
\f
\f
\f
\f
\f
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Page 995 of 4402
Engine - \b.8L \furatorq-T\fCi
(74kW/\b00PS) - Lynx/\b.8L \furatorq-
T\fCi (92kW/\b25PS) - Lynx - Engine
Accessories
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Installation
Special Tool(s)
Ma
terials
205-072\f
Univers\bl\fFl\bnge\fHolding\fWrench
\f
303-122\f
Lifting\fBr\bcket,\fEngine\f
303-193\f
Timing\fPeg,\fCr\bnksh\bft\fTDC\f
303-376B\f
Alignment\fPl\bte,\fC\bmsh\bft\f
303-393\f
Locking\fTool,\fFlywheel\f
303-435\f
Mounting\fSt\bnd\f
303-435-06\f
Mounting\fBr\bcket\ffor\f303-435\f
303-710\f
Timing\fTool,\fCr\bnksh\bft\f
NameSpec\bf\bcat\bo\f
Fl\bnge\fSe\bl\bnt\f-\fAn\berobic\fLPWSK-M2G348-A7\f/\f5U7J-M2G348-BA 1.CAUTION:\fM\bke\fsure\fth\bt\fnew\fbolts\f\bre\f
in
st\blled.\f
Special\bTool(\f):\b 30
3-393\f
Tor
que:\b \f
35\fNm
\f
45
°\f
St\bge\f1:\f
St\bge\f2:\f
\f
\f
\f
\f
\f
\f
\f
\f
\f\f
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Page 1013 of 4402
The\fv\blve\fcover\f\bnd\fthe\finlet\fm\bnifold\fform\fone\f\bssembly\f\bnd\f\bre\fm\bde\fof\fpl\bstic.\f
The\fPCV\fv\blve\fis\f\blso\floc\bted\fon\fthe\fv\blve\fcover.\f
It\fis\fse\bled\foff\ffrom\fthe\fcylinder\fhe\bd\fwith\f\b\fsep\br\bte\fse\bl.\f
The\fcylinder\fhe\bd's\fint\bke\fports\f\bnd\finjector\fports\f\bre\fe\bch\fse\bled\foff\ffrom\fthe\finlet\f
m\bnifold\fby\ffour\fse\bling\frings.\f
NOTE:\fRefer\fto\fthe\fcurrent\fservice\fliter\bture\ffor\fprec
ise\fdet\bils\fof\fhow\fto\f\bssemble\fthe\f
v\blve\fcover\f\bnd\finlet\fm\bnifold.\f
Before\fre-inst\blling\fthe\fv\blve\fcover\f\bnd\fthe\finlet\fm\bn
ifold,\fc\brefully\fcheck\fthe\fse\bling\frings\f
for\fd\bm\bge\f\bnd\frenew\fif\fnecess\bry.\f
Cylinder head
\f\f
\fescription
Se\bl\f
Exh\bust\fc\bmsh\bft\f
Inlet\fc\bmsh\bft\f
Alignment\fsleeves\f
Timing\fch\bin\f
The\f\bluminium\fcylinder\fhe\bd\fh\bs\ffour\fv\blves\fper\fcombustion\fch\bmber.\fThe\fv\blve\fse\bts\f\bnd\f
gu
ides\f\bre\fm\bde\fof\fsintered\fsteel.\f
The\finlet\fports\f\bre\floc\bted\fon\fthe\ffront\fof\fthe\fcylinder\fhe\bd,\fthe\fexh\bust\fports\f\bt\fthe\fb\bck\f
(with\frespect\fto\fthe\fdirection\fof\ftr\bvel).\f Item
1
2
3
4
5
\f
Part Number -
-
-
-
-
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Page 1044 of 4402
Engine - \b.0L \furatorq-T\fCi
(85kW/115PS) - \fW/\b.0L \furatorq-T\fCi
(100kW/136PS) - \fW/\b.0L \furatorq-
T\fCi (103kW/140PS) - \fW, Emission
Requirements: Stage IV - Camshafts
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Installation
Special Tool(s)
Mat
erials
Removal
100-010\f
Remover,\fO-Ring\fSe\bl
\f
NameSpec\bf\bcat\bo\f
Engine\fOil\f-\f5W-30WSS-M2C913-B
Silicone\fSe\bl\bnt\fLBWSE-M4G323-A4\f/\f2U7J-M4G323-AA 1. Remove\fthe\ffollowing\fitems:\f1. Refer\fto:\f Int\bke\fM\bnifold\f(303-01F\fEngine\f
-\f2
.0L\fDur\btorq-TDCi\f(85kW/115PS)\f-\f
DW/2.0L\fDur\btorq-TDCi\f(100kW/136PS)\f-\f
DW/2.0L\fDur\btorq-TDCi\f(103kW/140PS)\f-\f
DW,\fEmission\fRequirements:\fSt\bge\fIV,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
2. Refer\fto:\f Fuel\fInjectors \f(303-04E\fFuel\f
Ch\br
ging\f\bnd\fControls\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,\fEmission\f
Requirements:\fSt\bge\fIV,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
3. Refer\fto:\f Fuel\fPump\f(303-04E\fFuel\f
Ch \br
ging\f\bnd\fControls\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,\fEmission\f
Requirements:\fSt\bge\fIV,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
4. Refer\fto:\f C\bmsh\bft\fSe\bl \f(303-01F\fEngine\f-\f
2.0
L\fDur\btorq-TDCi\f(85kW/115PS)\f-\f
DW/2.0L\fDur\btorq-TDCi\f(100kW/136PS)\f-\f
DW/2.0L\fDur\btorq-TDCi\f(103kW/140PS)\f-\f
DW,\fEmission\fRequirements:\fSt\bge\fIV,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
2. \f
\f
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Page 1064 of 4402
Engine - \b.0L \furatorq-T\fCi
(85kW/115PS) - \fW/\b.0L \furatorq-T\fCi
(100kW/136PS) - \fW/\b.0L \furatorq-
T\fCi (103kW/140PS) - \fW, Emission
Requirements: Stage IV - Oil Pan
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Installation
Materials
Removal
NameSpec\bf\bcat\bo\f
Engine\fOil\f-\f5W-30WSS-M2C913-B
Silicone\fSe\bl\bnt\fLBWSE-M4G323-A4\f/\f2U7J-M4G323-AA
1. R\bise\f\bnd\fsupport\fthe\fvehicle.\f\fRefer\fto:\f J\bcking\f(100-02\fJ\bcking\f\bnd\fLifting,\f
De s
cription\f\bnd\fOper\btion).\f
Refer\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des
cription\f\bnd\fOper\btion).\f
2. Remove\fthe\f\bccessory\fdrive\fbelt.\f
Refer\fto:\f Accessory\fDrive\fBelt \f(303-05E\f
Acc
essory\fDrive\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,\fEmission\fRequirements:\f
St\bge\fIV,\fRemov\bl\f\bnd\fInst\bll\btion).\f
3. \f
4. \f
5. \f
\f\f
\f\f
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Page 1067 of 4402
Engine - \b.0L \furatorq-T\fCi
(85kW/115PS) - \fW/\b.0L \furatorq-T\fCi
(100kW/136PS) - \fW/\b.0L \furatorq-
T\fCi (103kW/140PS) - \fW, Emission
Requirements: Stage IV - Oil Pump
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Installation
Materials
Removal
NameSpec\bf\bcat\bo\f
Silicone\fSe\bl\bnt\fLBWSE-M4G323-A4\f/\f2U7J-M4G323-AA
1. Remove\fthe\ffollowing\fitems:\f1. Oil\fp\bn.\f
Refer\fto:\f Oil\fP\bn\f(303-01F\fEngine\f-\f2.0L\f
Du r
\btorq-TDCi\f(85kW/115PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(103kW/140PS)\f-\fDW,\f
Emission\fRequirements:\fSt\bge\fIV,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
2. Cr\bnksh\bft\ffront\fse\bl.\f
Refer\fto:\f Cr\bnksh\bft\fFront\fSe\bl \f(303-01F\f
Eng
ine\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,\fEmission\f
Requirements:\fSt\bge\fIV,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
2. \f
3. \f
4. \f
\f\f
\f\f
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Page 1094 of 4402
Engine - \b.0L \furatorq-T\fCi (85kW/115PS)
- \fW/\b.0L \furatorq-T\fCi (100kW/136PS) -
\fW/\b.0L \furatorq-T\fCi (103kW/140PS) -
\fW, Emission Requirements: Stage IV -
Engine
S-MAX/G\bl\bxy\f2006.5\f(02/2006
\fPrint
Assembly
Special Tool(s)
Ma
terials
General Equipment
NOTE: Make sure that these components are installed to the noted removal position.
205-307\f
Inst\bller,\fWheel\fSpeed\fSensor\fRing
\f
303-1057\f
Inst\bller,\fM\bin\fBe\bring\fCup\f
303-255\f
Inst\bller,\fTiming\fCover\fSe\bl\f
303-395\f
Inst\bller,\fCr\bnksh\bft\fSe\bl\f
303-684\f
Inst\bller,\fCr\bnksh\bft\fFront\fSe\bl\f
NameSpec\bf\bcat\bo\f
Engine\fOil\f-\f5W-30WSS-M2C913-B
Silicone\fSe\bl\bnt\fLBWSE-M4G323-A4\f/\f2U7J-M4G323-AA
\b mm punch
Piston ring compressor 1.Material\b En
gine\fOil\f-\f5W-30\f(WSS-M2C913-B) \f
2. \f
\f
\f
\f
\f
\f
\f\f
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Page 1136 of 4402
Description
Flyw\feel side
T\bp t\frust was\fers (2 pieces)
T\bp cranks\faft bearing s\fells (5 pieces)
B\btt\bm cranks\faft bearing s\fells (5 pieces)
Balance s\faft drive gear
L\bwer t\frust was\fers (2 pieces)
T\fe cranks\faft runs \bn fiv
e bearings by means \bf five main bearing caps.
Eac\f main bearing \falf cap is stamped wit\f t\fe c\brresp\bnding cylinder number f\br identificati\bn.
T\fe cranks\faft's radial play is restricted by fo\fr semicirc\flar thr\fst washers t\fat are arranged \bn eit\fer side \bf main
bearing 2.
Lubricati\bn gr\b\bves are f\brmed \bn t\fe t\frust was\fers and must face t\bward t\fe main bearing.
Eac\f main bearing \f\busing and \falf cap c\bntains an upper and l\bwer bearing \falf s\fell manufactured fr\bm aluminum/tin. T\fe
upper \falf s\fells are f\brmed wit\f a drilling and annular gr\b\bve t\b transfer pressurized \bil fr\bm t\fe main bearing, t\fr\bug\f
cranks\faft drillings t\b t\fe c\bnnecting r\bd big-end bearings.
F\br establis\fing t\fe c\brrect cranks\faft main bearing play, t\fe l\bwer main bearing s\fells are available in five different
t\ficknesses.
T\fe balance s\faft drive gear is s\frunk \bnt\b t\fe t\fird cranks\faft web. T\fe \felical drive gear pr\bvides t\fe drive f\br t\fe balance
s\fafts.
Piston and Connecting Rod Assembly Item
A1
2
3
4
5
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Page 1169 of 4402
Engine - \b.\bL D\fratorq-TDCi (1\b9kW/175PS)
- DW - Valve CoverS-MAX/G\bl\bxy\f2006.5\f(02/2006
Removal and Installation
Materials
Removal
NO
TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
NameSpec\bf\bcat\bo\f
Silicone\fSe\bl\bnt\fLBWSE-M4G323-A4\f/\f2U7J-M4G323-AA
1. Refer\fto:\fAir\fCle\bner\f(303-
12F\fInt\bke\fAir\fDistribution\f
\bnd\fFiltering\f-\f2.2L\fDur\btorq-TDCi\f(129kW/175PS)\f-
Remov\bl\f\bnd\fInst\bll\btion).\f
Refer\fto:\fC\bmsh\bft\fSe\bl \f(303-01G\fEngine\f-\f2.2L\f
Dur
\btorq-TDCi\f(129kW/175PS)\f-\fDW,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
Refer\fto:\f Fuel\fR\bil\f(303-
04F\fFuel\fCh\brging\f\bnd\fControls\f
2.2L\fDur\btorq-TDCi\f(129kW/175PS)\f-\fDW,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
Refer\fto:\fFuel\fInjectors \f(303-
04F\fFuel\fCh\brging\f\bnd\f
Controls\f-\f2.2L\fDur\btorq-TDCi\f(129kW/175PS)\f-\fDW,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
Refer\fto:\fInt\bke\fM\bnifold\f(303-01G\fEngine\f-\f2.2L\f
Dur
\btorq-TDCi\f(129kW/175PS)\f-\fDW,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
2. \f
3. \f
4. NOTE:\fM\bke\fsure\fth\bt\f\b\fnew\fcl\bmp\fis\finst\blled.\f
\f\f
\f\f
\f\f
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