Page 1035 of 4402
4.4.
Remove\fthe\foil\fpressure\fswitch.\f
5
. 5.
Att\bch\fthe\foil\fpressure\fg\buge\fwith\fthe\foil\fpressure\fg\buge\fconnector.\f
6
. NOTE:\fMe\bsure\fthe\foil\fpressure\f\bt\fthe\fspecified\fengine\fspeed.\fMe\bsure\fthe\foil\f
pr
essure\f\bt\f\bn\foil\ftemper\bture\fof\f80°\fC.\f
NOTE:\fMe\bsure\fthe\foil\fpressure\f\bt\f2000\frpm\f\bnd\f\bt\f4000\frpm.\f
NOTE:\fOil\fpressure\f\bt\f2000\frpm:\f2.0\fb\br.\f
NOTE:\fOil\fpressure\f\bt\f4000\frpm:\f4.0\fb\br.\f
6. Check\fthe\foil\fpressure.\f
7. 7.
Det\bch\fthe\foil\fpressure\fg\buge\f\bnd\fthe\foil\fpressure\fg\buge\fconnector.\f
8
. 8.
Co\bt\fthe\foil\fpressure\fswitch\fwith\f \b
dhesive.\f
\f\f
\f\f
\f\f
\f\f
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Page 1036 of 4402
9.9.
Inst\bll\fthe\foil\fpressure\fswitch.\f
1
0. 10.
Connect\fthe\foil\fpressure\fswitch\felectric\bl\fconnector.\f
1
1. 11.
Inst\bll\fthe\fengine\funder\fshield.\f
1
2. 1\b.
Lower\fthe\fvehicle.\f
V
alve train analysis - static (engine off)
Remove\fthe\fv\blve\fcover.\f\f
Check\f\bll\fv\blve\ftr\bin\fcomponents\ffor\fd\bm\bge\f\bnd\fwe\br.\fEnsure\fth\bt\fonly\forigin\bl\f
components\f\bre\finst\blled\f\bnd\fth\bt\f\bll\fbolts\f\bnd\fnuts\fh\bve\fbeen\ftightened\fto\fthe\fcorrect\f
tightening\ftorque.\fREFER\fto:\f Specific\btions\f(303-01F\fEngine\f-\f2.0L\fDur\btorq-TDCi\f
(8 5
kW/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:\fSt\bge\fIV,\fSpecific\btions).\f \f\f
\f\f
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Page 1037 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 - Intake Manifold
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Installation
Removal
NO
TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
1. Remove\fthe\fcowl\fp\bnel\fgrille.\f\f
Re
fer\fto:\f Cowl\fP\bnel\fGrille \f(501-02\fFront\fEnd\f
Bo d
y\fP\bnels,\fRemov\bl\f\bnd\fInst\bll\btion).\f
2. Disconnect\fthe\fb\bttery\fground\fc\bble.\f\f
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
3. Torque:\b 10\fNm
\f
4. Cle\bn\fthe\f\bre\b\f\bround\fthe\ffuel\finjectors.\f\f Refer\fto:\f Fuel\fInjection\fComponent\fCle\bning\f
(3 0
3-04E\fFuel\fCh\brging\f\bnd\fControls\f-\f2.0L\f
Dur\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,\fEmission\f
Requirements:\fSt\bge\fIV,\fGener\bl\fProcedures).\f
5. Torque:\b 10\fNm
\f
6. \f
\f\f
\f\f
\f\f
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Page 1039 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 - Crankshaft
Front Seal
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Installation
Special Tool(s)
Removal
In
stallation
303-255\f
Inst\bller,\fTiming\fCover\fSe\bl
\f
303-293\f
Remover,\fCr\bnksh\bft\fSe\bl\f
303-395\f
Inst\bller,\fCr\bnksh\bft\fSe\bl\f 1. Remove\fthe\ftiming\fbelt.\fRefer\fto:\f Timing\fBelt \f(303-01F\fEngine\f-\f2.0L\f
Dur
\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,\fEmission\f
Requirements:\fSt\bge\fIV,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
2. \f
3. Special\bTool(\f):\b 303-293\f
1. Sp
ecial\bTool(\f):\b 303-255,\f303-395\f
\f
\f
\f
\f\f
\f\f
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Page 1040 of 4402
2. \f
3. Inst\bll\fthe\ftiming\fbelt.\fRefer\fto:\f Timing\fBelt \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,\fEmission\f
Requirements:\fSt\bge\fIV,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
\f\f
\f\f
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Page 1041 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 - Valve Stem
Seals
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Installation
Special Tool(s)
Removal
303-037\f
Inst\bller,\fV\blve\fStem\fSe\bl
\f
303-060\f
Compressor,\fV\blve\fSpring
\f
303-060-07\f
Ad\bpter\ffor\f303-060\f
303-060-09A\f
Ad\bpter\ffor\f303-060\f
303-390\f
Pliers,\fV\blve\fStem\fSe\bl\f
1. Remove\fthe\fc\bmsh\bfts.\f\fRefer\fto:\f C\bmsh\bfts \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,\fEmission\f
Requirements:\fSt\bge\fIV,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
2.
Position\fthe\f\bppropri\bte\fpiston\f\bt\ftop\fde\bd\fcenter\f
(TDC).\f
3. Special\bTool(\f):\b 303-060,\f303-060-07,\f 303-060-
09A \f
4
. \f
\f
\f
\f
\f
\f
\f\f
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Page 1042 of 4402
Installation 5.
Special\bTool(\f):\b 3
03-390\f
1. Sp
ecial\bTool(\f):\b 303-037\f
2. \f
3
. Special\bTool(\f):\b 303-060,\f303-060-07,\f 303-060-
09 A\f
4
. I
nst\bll\fthe\fc\bmsh\bfts.\f\f
Refer\fto:\f C\bmsh\bfts \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,\fEmission\f
\f\f
\f\f
\f\f
\f\f
\f\f
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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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