length FORD S-MAX 2006 Service Repair Manual

\f\fDescrip\fion
Me\bsure\fthe\fcurrent\fusing\f\b\fdigit\bl\fmultimeter\f
Me\bsure\fthe\fvolt\bge\fusing\f\b\fdigit\bl\fmultimeter\f
Me\bsure\fthe\fresist\bnce\fusing\f\b\fdigit\bl\fmultimeter\f
Me\bsure\fthe\flength/dist\bnce\f
Check\fth\bt\fthe\fspecified\fpressure\fis\f\bv\bil\bble\fusing\f\b\fsuit\bble\fpressure\f
g\buge\f
Me\bsure\fthe\fpressure\f\bt\fthe\fspecified\fport\fusing\f\b\fsuit\bble\fpressure\f
g\buge\f
Me\bsure\fthe\ftime\fusing\f\b\fsuit\bble\fstopw\btch\f
W\bit\ffor\fthe\fspecified\fperiod\fof\ftime\f
The\fspecified\ft\bsk\frequires\fthe\fspecified\fminimum\ftemper\bture\f
The\fspecified\ft\bsk\frequires\fthe\fspecified\fm\bximum\ftemper\bture\fnot\fto\f
\b\fem
1
2
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4
5
6
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\f
Par\f Number -
-
-
-
-
-
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-
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Front Dr\bve H\flfsh\ffts - Front Dr\bve
H\flfsh\fftsS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Descr\bpt\bon \fnd Oper\ft\bon

The\fh\blfsh\bfts\fh\bve\fconst\bnt\fvelocity\f(CV)\fjoints\f\bt\fboth\fends\fto\fprovide\fsmooth\fdrive\fto\f
th

e\fro\bd\fwheels.\f\f

The\finner\fCV\fjoints\f\bre\fsliding\fjoints.\f\f

The\fouter\fCV\fjoints\f\bre\ffixed\fb\bll\fjoints.\f\f

The\fleft-h\bnd\fh\blfsh\bft\fCV\fjoint\fis\fsecured\fin\fthe\fdifferenti\bl\fwith\f\b\fsn\bp\fring.\f\f

The\fintermedi\bte\fsh\bft\f(right-h\bnd\fside)\fis\fsecured\fin\fthe\fdifferenti\bl\fby\fthe\fintermedi\bte\f
sh

\bft\fcenter\fbe\bring\f\bssembly.\f\f

The\fouter\fCV\fjoints\f\bre\f\btt\bched\fto\fthe\fwheel\fhubs.\f
\f\f
Descr\bpt\bon
H\blfsh\bft\fLH\f
Intermedi\bte\fsh\bft\fcenter\fbe\bring\f\bssembly\f
H\blfsh\bft\fRH\f
Authoring\fTempl\bte\f
Wo

rk\bng pr\bnc\bple of the h\flfsh\ffts

The\fh\blfsh\bfts\ftr\bnsmit\ftorque\ffrom\fthe\fengine\fto\fthe\fwheels.\f\f

In\forder\fto\f\bllow\fvertic\bl\fmovement\fof\fthe\fwheels\f\bnd\fengine,\fthe\fh\blfsh\bfts\foper\bte\f\bt\f
v\br

ying\flengths\f\bnd\f\bngles.\f\f

The\ftripode\fjoints\f\bllow\ffor\fch\bnges\fin\fh\blfsh\bft\flength\fduring\f\bxi\bl\fmovements.\f
H\fndl\bng h\flfsh\ffts
CA
UTION:\fThe\finner\fconst\bnt\fvelocity\f(CV)\fjoint\fmust\f n
ot\fbe\fbent\f\bt\fmore\fth\bn\f18\f
degrees,\fthe\fouter\fCV\fjoint\fmust\fnot\fbe\fbent\f\bt\fmore\fth\bn\f45\fdegrees.\f
NOTE:\fDo\fnot\fpl\bce\fthe\ftripode\fjoint\funder\ftension.\f
If\fremoving/inst\blling\f\bnd\fdis\bssembling/\bssembling\ft h
e\fh\blfsh\bfts,\fthe\ffollowing\fpoints\f
should\fbe\fobserved:\f Item
1
2
3
\f
P\frt Number -
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Steering\bCol\fmn\b-\bSteering\bCol\fmnS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal\band\bInstallation\b
Removal\b
WAR

NINGS:\f
T\bk
e\fextr\b\fc\bre\fwhen\fh\bndling\fsupplement\bl\frestr\bint\fsystem\f(SRS)\fcomponents.\f
The\fsupplement\bl\frestr\bint\fsystem\f(SRS)\fis\f\bctive\ffor\f\b\fcert\bin\flength\fof\ftime\f\bfter\f
the\fpower\fsupply\fh\bs\fbeen\fdisconnected.\fW\bit\ffor\f\b\fminimum\fof\f3\fminutes\fbefore\f
disconnecting\for\fremoving\f\bny\fSRS\fcomponents.\f
M\bke\fsure\fth\bt\fthe\fvehicle\felectric\bl\fsystem\fis\ffully\fdepowered\f\bnd\fno\fother\fpower\f
source\fis\fconnected.\f
Do\fnot\fprobe\fsupplement\bl\frestr\bint\fsystem\f(SRS)\felectric\bl\fconnectors.\f
NOTE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst\bll\btion\fdet\bils.\f
1. Refer\fto:\f B\bttery\fDisconnect\f\bnd\fConnect\f(414-
01\f
B\bttery,\fMounting\f\bnd\fC\bbles,\fGener\bl\f
Procedures).\f
2. NOTE:\fThis\fstep\fis\fonly\fnecess\bry\fwhen\f
in

st\blling\f\b\fnew\fcomponent.\f
Refer\fto:\f Cl
ockspring\f(501-20B\fSupplement\bl\f
Res
tr\bint\fSystem,\fRemov\bl\f\bnd\fInst\bll\btion).\f
3. NOTE:\fThis\fstep\fis\fnot\fnecess\bry\fwhen\f
in

st\blling\f\b\fnew\fcomponent.\f
4. NOTE:\fThis\fstep\fis\fnot\fnecess\bry\fwhen\f
i
n

st\blling\f\b\fnew\fcomponent.\f
5. NOTE:\fThis\fstep\fis\fnot\fnecess\bry\fwhen\f
in

st\blling\f\b\fnew\fcomponent.\f
NOTE:\fM\bke\fsure\fth\bt\fthe\fro\bd\fwheels\f\bre\fin\f
the\fstr\bight\f\bhe\bd\fposition.\f
6. CAUTIONS:\f
\f\f
\f\f
\f\f
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Valve Seats
Cylinder Head
Camshafts
Crankshaft
Crankshaft Main Bearing Selection
Descrip\biondegree
Int\bke\fv\blve\fse\bt\f\bngle45.33\f-\f45.67
Exh\bust\fv\blve\fse\bt\f\bngle45.33\f-\f45.67
Descrip\bionmm
Cylinder\fhe\bd\fheight149.25\f-\f149.55
M\bximum\fm\bting\ff\bce\fdistortion\f(lengthwise)0.05
M\bximum\fm\bting\ff\bce\fdistortion\f(crosswise)0.02
M\bximum\ff\bce\fmilling0.30
Descrip\bionmm
Int\bke\fc\bmsh\bft\flobe\flift8.68
Exh\bust\fc\bmsh\bft\flobe\flift9.05
Descrip\bionmm
Cr\bnksh\bft\f\bxi\bl\fcle\br\bnce0.08\f-\f0.19
Code - C\flinder block
ABC
Cr\bnksh\bft\f
m\bin\fbe\bring\f
for:Cylinder\fblockCr\bnksh\bft\f
m\bin\fbe\bring\f
c\brrierCylinder\fblockCr\bnksh\bft\f
m\bin\fbe\bring\f
c\brrierCylinder\fblockCr\bnksh\bft\f
m\bin\fbe\bring\f
c\brrier
Code -
Crankshaft
Ayellow\f
mediumyellow\fmediumyellow\f
mediumblue\fthickblue\fthickblue\fthick
Bred\fthinyellow\fmediumyellow\f
mediumyellow\fmediumyellow\f
mediumblue\fthick
Cred\fthinred\fthinred\fthinyellow\fmediumyellow\f
mediumyellow\fmedium
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Installation 44. \f
4
5

.NOTE:\fNote\fthe\fdifferent\flengths\fof\fthe\fbolts.\f
46. S\fecial Tool(s): 3
03-122\f
1.
Cle\bn\fthe\fm\bting\ff\bces\fof\fthe\fcylinder\fhe\bd\f\bnd\fcylinder\f
block\fwith\fcle\bner.\f
Material: Spoiler\fAdhesive\fKit\f2\fComponent\f(WSK-
M5 B

401-A1\f/\f2U7J-M2G376-AA) \f
\f\f
\f\f
\f\f
\f
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Piston Pin
Camshaft
Valves
Cylinder Head
Oil Pressure Specifications
Descrip\bion
Big end b\bre dia\feter
S\fall end b\bre dia\feter
C\bnnecting r\bd bearing clearance
Descrip\bion
Pist\bn pin length
Pist\bn pin dia\feter
Descrip\bion
Ca\fshaft end fl\bat
Ca\fshaft bearing j\burnal dia\feter
Descrip\bion
Valve ste\f dia\feter
Valve guide
Valve ste\f t\b valve guide clearance — intake valve
Valve ste\f t\b valve guide clearance — exhaust valve
Descrip\bion
Thickness \bf cylinder head gasket with pist\bn pr\btrusi\bn \bf 0.55 - 0.60
Thickness \bf cylinder head gasket with pist\bn pr\btrusi\bn \bf 0.61 - 0.65
Thickness \bf cylinder head gasket with pist\bn pr\btrusi\bn \bf 0.66 - 0.70
Thickness \bf cylinder head gasket with pist\bn pr\btrusi\bn \bf 0.71 - 0.75
Maxi\fu\f dist\brti\bn — \feasured l\bngitudinally and diag\bnally
Oil pressure at 2000 rp\f
Oil pressure at 4000 rp\f
Cylinder Bl\bck blanking plug
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Piston Pin
Camshaft
Valves
Cylinder Head
Oil Pressure Specifications
Descrip\bion
Big end b\bre dia\feter
S\fall end b\bre dia\feter
C\bnnecting r\bd bearing clearance
Descrip\bion
Pist\bn pin length
Pist\bn pin dia\feter
Descrip\bion
Ca\fshaft end fl\bat
Ca\fshaft bearing j\burnal dia\feter
Descrip\bion
Valve ste\f dia\feter
Valve guide
Valve ste\f t\b valve guide clearance — intake valve
Valve ste\f t\b valve guide clearance — exhaust valve
Descrip\bion
Thickness \bf cylinder head gasket with pist\bn pr\btrusi\bn \bf 0.55 - 0.60
Thickness \bf cylinder head gasket with pist\bn pr\btrusi\bn \bf 0.61 - 0.65
Thickness \bf cylinder head gasket with pist\bn pr\btrusi\bn \bf 0.66 - 0.70
Thickness \bf cylinder head gasket with pist\bn pr\btrusi\bn \bf 0.71 - 0.75
Maxi\fu\f dist\brti\bn — \feasured l\bngitudinally and diag\bnally
Oil pressure at 2000 rp\f
Oil pressure at 4000 rp\f
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Check\fthe\fturboch\brger\foil\freturn\ftube\ffor\fblock\bge\f
or\fsigns\fof\fd\bm\bge.\f
3
Is\fthe\fturboch\brger\foil\freturn\ftube\ffree\ffrom\fforeign\f
m\bteri\bl\f\bnd\fsigns\fof\fd\bm\bge?\f
Yes GO\fto\fEngine\ffor\ffurther\fdi\bgnostics.\f
REFER\fto:\f Engine\f(303-01D\fEngine\f-\f2.5L\fDur\btec\f
(16

2kW/220PS)\f-\fVI5,\fDi\bgnosis\f\bnd\fTesting).\f
No INSTALL\f\b\fnew\fturboch\brger\foil\freturn\fpipe,\fg\bsket\f
\bnd\fO-ring\fse\bl.\fTEST\fthe\fsystem\ffor\fnorm\bl\f
oper\btion.\f
PINPOINT TEST C : POOR ENGINE PERFORMANCE
TEST CON\fITIONS\fETAILS/RESULTS/ACTIONS
C1: CHECK THE BOOST PRESSURE
NOTE:\fThe\fboost\fpressure\fis\ff\bctory\fset\f\bnd\fmust\fnot\fbe\f\bdjusted.\f
This\ftest\fmust\fbe\fc\brried\fout\fon\f\b\flength\fof\fro\bd\fwith\f\b\fminimum\fspeed\flimit\fof\f100kmh\f
(60mph).\f
Disconnect\fthe\fw\bsteg\bte\fcontrol\fv\blve\f\bctu\btor\f
control\fpipe\ffrom\fthe\fw\bsteg\bte\fcontrol\fv\blve\f
\bctu\btor.\f1
Connect\f\b\fsuit\bble\flength\fof\fpipe\fto\fthe\fw\bsteg\bte\f
control\fv\blve\f\bctu\btor.\f2
Using\fthe\fboost\fpressure\fg\buge\f\bnd\fT\fconnector,\f
connect\fthe\fg\buge\fto\fthe\flength\fof\fpipe.\f3
Connect\fthe\fw\bsteg\bte\fcontrol\fv\blve\f\bctu\btor\f
control\fpipe\fto\fthe\fT\fconnector.\f4
\f\f
\f\f
\f\f
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Accessory\fDrive\fBelt\f(303-05D\fAccessory\fDrive\f-\f1.8L\fDur\btorq-TDCi\f(74kW/1 00PS)\f
-\fLynx/1.8L\fDur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05F\fAccessory\fDrive\f-\f2.2L\fDur\btorq-TDCi\f
(12

9kW/175PS)\f-\fDW,\fRemov\bl\f\bnd\fInst\bll\btion).\f
Chunking\f
C h

unking\fdescribes\fthe\fcondition\fwhere\flong\flengths\fof\frubber\fbecome\fdet\bched\ffrom\fthe\f
ribs\fof\fthe\f\bccessory\fdrive\fbelt.\fThis\fis\fconsidered\fto\fbe\f\b\ff\bilure\fof\fthe\f\bccessory\fdrive\fbelt.
\f
2. 2.\b
Check\fthe\f\bccessory\fdrive\fbelt\ffor\fd\bm\bge.\fIf\f\bny\fchunks\f\bre\ffound\fto\fbe\fmissing,\f
i nst\bll\f\b\fnew\f\bccessory\fdrive\fbelt.\fREFER\fto:\f\f
Accessory\fDrive\fBelt \f(
303-05A\fAccessory\fDrive\f-\f2.0L\fDur\btec-HE\f(107kW/145 PS)\f-\f
MI4/2.0L\fDur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05A\fAccessory\fDrive\f-\f2.0L\fDur\btec-HE\f(107kW/14 5
PS)\f-\f
MI4/2.0L\fDur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05C\fAccessory\fDrive\f-\f2.5L\fDur\btec\f(162kW/220PS)
\f-\f
VI5,\fRemov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05D\fAccessory\fDrive\f-\f1.8L\fDur\btorq-TDCi\f(74kW/1
00PS)\f
-\fLynx/1.8L\fDur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05F\fAccessory\fDrive\f-\f2.2L\fDur\btorq-TDCi\f
(12

9kW/175PS)\f-\fDW,\fRemov\bl\f\bnd\fInst\bll\btion).\f
Pilling\f
Pil
ling\fis\fdust\fth\bt\fforms\fin\fbetween\fthe\fribs\fof\fthe\f\bccessory\fdrive\fbelt\ffrom\frubber\fth\bt\fis\f
worn\foff\fthe\f\bccessory\fdrive\fbelt\fwhen\fit\fis\fnew.\fThere\fm\by\f\blso\fbe\floose\fp\brticles\fleft\fon\f
the\f\bccessory\fdrive\fbelt\fduring\fthe\fm\bnuf\bcturing\fprocess.\fThese\f\bre\fworn\foff\f\bnd\fform\f
into\fsm\bll\fb\blls\fof\frubber\fth\bt\fthen\fget\ftr\bpped\fin\fthe\fgrooves\fof\fthe\f\bccessory\fdrive\fbelt.\f
This\fcondition\fwill\fusu\blly\fcle\br\fitself\fwithin\f4800\fkm\f-\f8000\fkm\f(3000\fmiles\f-\f5000\fmiles)\f
of\fnorm\bl\fdriving.\f \f\f
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(129kW/175PS)\f-\fDW,\fRemov\bl\f\bnd\fInst\bll\btion).\f
Chunking\f
Ch
unking\fdescribes\fthe\fcondition\fwhere\flong\flengths\fof\frubber\fbecome\fdet\bched\ffrom\fthe\f
ribs\fof\fthe\f\bccessory\fdrive\fbelt.\fThis\fis\fconsidered\fto\fbe\f\b\ff\bilure\fof\fthe\f\bccessory\fdrive\fbelt.
\f
2. 2.\b
Check\fthe\f\bccessory\fdrive\fbelt\ffor\fd\bm\bge.\fIf\f\bny\fchunks\f\bre\ffound\fto\fbe\fmissing,\f
i nst\bll\f\b\fnew\f\bccessory\fdrive\fbelt.\fREFER\fto:\f\f
Accessory\fDrive\fBelt \f(
303-05A\fAccessory\fDrive\f-\f2.0L\fDur\btec-HE\f(107kW/145 PS)\f-\f
MI4/2.0L\fDur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05A\fAccessory\fDrive\f-\f2.0L\fDur\btec-HE\f(107kW/145
PS)\f-\f
MI4/2.0L\fDur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05C\fAccessory\fDrive\f-\f2.5L\fDur\btec\f(162kW/220PS )
\f-\f
VI5,\fRemov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05D\fAccessory\fDrive\f-\f1.8L\fDur\btorq-TDCi\f(74kW/1
00PS)\f
-\fLynx/1.8L\fDur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05F\fAccessory\fDrive\f-\f2.2L\fDur\btorq-TDCi\f
(12

9kW/175PS)\f-\fDW,\fRemov\bl\f\bnd\fInst\bll\btion).\f
Pilling\f
Pil
ling\fis\fdust\fth\bt\fforms\fin\fbetween\fthe\fribs\fof\fthe\f\bccessory\fdrive\fbelt\ffrom\frubber\fth\bt\fis\f
worn\foff\fthe\f\bccessory\fdrive\fbelt\fwhen\fit\fis\fnew.\fThere\fm\by\f\blso\fbe\floose\fp\brticles\fleft\fon\f
the\f\bccessory\fdrive\fbelt\fduring\fthe\fm\bnuf\bcturing\fprocess.\fThese\f\bre\fworn\foff\f\bnd\fform\f
into\fsm\bll\fb\blls\fof\frubber\fth\bt\fthen\fget\ftr\bpped\fin\fthe\fgrooves\fof\fthe\f\bccessory\fdrive\fbelt.\f
This\fcondition\fwill\fusu\blly\fcle\br\fitself\fwithin\f4800\fkm\f-\f8000\fkm\f(3000\fmiles\f-\f5000\fmiles)\f
of\fnorm\bl\fdriving.\f \f\f
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