Page 1045 of 4402
3. \f
4.Install t\be Spe\fial Tool(s): 100-010\f
5. \f 6
. Material: Engine\fOil\f-\f5W-30\f(WSS-M2C913-B) \f
\f
\f\f
\f\f
\f\f
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Page 1047 of 4402
6.Torque: 10\fNm\f
7.Torque:
25\fNm
\f
8. Inst\bll\fthe\ffollowing\fitems:\f 1. 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. 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
3. 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-
\f\f
\f\f
\f
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Page 1048 of 4402
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 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
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Page 1049 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 - Camshaft Seal
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Installation
Special Tool(s)
Removal
In
stallation
205-072\f
Univers\bl\fFl\bnge\fHolding\fWrench
\f
303-174\f
G\buge,\fBolt\fAngle\f
303-293\f
Remover,\fCr\bnksh\bft\fSe\bl\f
303-684\f
Inst\bller,\fCr\bnksh\bft\fFront\fSe\bl\f 1. Remove\fthe\ftiming\fbelt.\f\fRefer\fto:\f Timing\fBelt \f(303-01E\fEngine\f-\f1.8L\f
Dur
\btorq-TDCi\f(74kW/100PS)\f-\fLynx/1.8L\f
Dur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
2. Special\bTool(\f):\b 205-072\f
3. Sp
ecial\bTool(\f):\b 303-293\f
1. Sp
ecial\bTool(\f):\b 303-684\f
\f
\f
\f
\f
\f\f
\f\f
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Page 1050 of 4402
2.Special\bTool(\f):\b 303-174,\f205-072\f
Tor
que:\b \f
20\fNm
\f
60
°\f
St\bge\f1:\f
St\bge\f2:\f
3. Inst\bll\fthe\ftiming\fbelt.\f\f
Refer\fto:\f Timing\fBelt \f(303-01E\fEngine\f-\f1.8L\f
Dur
\btorq-TDCi\f(74kW/100PS)\f-\fLynx/1.8L\f
Dur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
\f\f
\f\f
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Page 1051 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 - Timing Belt
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Installation
Special Tool(s)
Gen
eral Equipment
Removal
303-1059\f
Alignment\fPeg,\fCr\bnksh\bft
\f
303-393\f
Locking\fTool,\fFlywheel\f
303-393-01\f
Ad\bpter\ffor\f303-393\f
303-735\f
Alignment\fPeg,\fC\bmsh\bft\f
Trolley\fj\bck
1. Disconnect\fthe\fb\bttery.\fRefer\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. Remove\fthe\f\bccessory\fdrive\fbelt.\f
Refer\fto:\f Accessory\fDrive\fBelt \f(303-05A\f
Acc
essory\fDrive\f-\f2.0L\fDur\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,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
3. \f
\f
\f
\f
\f
\f\f
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Page 1059 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 - Exhaust
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\f
Installation 1. Disconnect\fthe\fb\bttery.\f\f
Re
fer\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. Remove\fthe\ffollowing\fitems:\f 1. Exh\bust\fg\bs\frecircul\btion\f(EGR)\fcooler.\f
Refer\fto:\f Exh\bust\fG\bs\fRecircul\btion\f(EGR)\f
Coo
ler \f(303-08D\fEngine\fEmission\fControl\f-
\f
2.0L\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. Turboch\brger\f
Refer\fto:\f Turboch\brger \f(303-04J\fFuel\f
Ch\br
ging\f\bnd\fControls\f-\fTurboch\brger\f-\f
2.0L\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
3. NOTE:\fInst\bll\fnew\fnuts\f\bnd\f\b\fnew\fg\bsket.\f
Torque:\b
30\fNm
\f
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f\f
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Page 1060 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 - Cylinder Head
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\fc\bt\blytic\fconverter.\f
Re
fer\fto:\f C\bt\blytic\fConverter \f(309-00E\fExh\bust\f
Sy s
tem\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-\fDW,\f
Emission\fRequirements:\fSt\bge\fIV,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
2. \f
3. Torque:\b
1\f5\fNm
\f
2\f10\fNm
\f
4. Torque:\b 5\fNm
\f
\f\f
\f\f
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