Page 905 of 4402

Installation 26.
S\fecial Tool(s): 3
03-651\f
1. \f
\f Check\fthe\ftiming\fbelt\ftensioner\f\bnd\fm\bke\f
su
re\fth\bt\fthe\ftiming\fbelt\ftensioner\fpointer\f
rot\btes\fclockwise\ffreely.\f
Move\fthe\ftiming\fbelt\ftensioner\f\bdjustment\f
\brm
\fto\fthe\f3\fo'clock\fposition.\f
Do\fnot\ffully\ftighten\fthe\ftiming\fbelt\f
te
nsioner\fret\bining\fbolt\f\bt\fthis\fst\bge.\f
2. \f\f
The\fc\bmsh\bft\fpulley\fmust\fbe\f\bble\fto\frot\bte\f
freely\fon\fthe\fc\bmsh\bft\ft\bper.\fTighten\fthe\f
c\bmsh\bft\fpulley\fbolt\ffinger\ftight\f\bnd\fthen\f
loosen\fby\fone-h\blf\fturn.\f\f
Inst\bll\fthe\ftiming\fbelt\fwith\fthe\fdirection\f
\brr
ows\fin\fthe\fdirection\fof\fengine\frot\btion.\f
3.
Tension\fthe\ftiming\fbelt\fcounterclockwise\funtil\fthe\f
pointer\fis\fpositioned\fbetween\fthe\fsides\fof\fthe\f
window.\f\f
Torque: 50\fNm
\f
4. S\fecial Tool(s): 205-072\f
Tor
que: 50\fNm
\f
\f\f
\f\f
\f\f
\f\f
\f\f
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Page 906 of 4402

5.Remove the S\fecial Tool(s): 303-376B,\f303-193,\f
303-393\f
6. \f
\f 1. Rot\bte\fthe\fcr\bnksh\bft\f2\frevolutions.\f Repl\bce\fthe\fTiming\fPeg\fjust\fbefore\fTDC\fon\f
the\fsecond\frevolution.\f
Install the S\fecial Tool(s): 303-193\f
2. R
ot\bte\fthe\fcr\bnksh\bft\fslowly\funtil\fthe\f
cr\bnksh\bft\fstops\f\bt\fTDC.\f
7. Check\fth\bt\fthe\ftiming\fbelt\ftensioner\fpointer\fis\f positioned\fin\fthe\fwindow,\fotherwise\fthe\ftiming\f
belt\ftensioning\fsteps\fmust\fbe\frepe\bted.\f\f
8. NOTE:\fIf\fthe\fspeci\bl\ftool\fc\bnnot\fbe\finst\blled,\f
th
e\ftiming\fbelt\ftensioning\fsteps\fmust\fbe\f
repe\bted.\f\f
Install the S\fecial Tool(s): 30
3-376B\f
9. R
emove\f\bll\fspeci\bl\ftools\f\bnd\finst\bll\fthe\fcylinder\f
block\fbl\bnking\fplug.\f
Remove the S\fecial Tool(s): 303-376B,\f303-193
,\f
303-393\f
Tor
que: 23\fNm
\f
10. Torque: 7\fNm
\f
11. \f\f 1.Torque: 12\fNm
\f
2. Torque: 80\fNm
\f
3. NOTE:\fOnly\ftighten\fthe\fbolts\ffinger\f
t
i
ght\f\bt\fthis\fst\bge.\f
\f\f
\f\f
\f\f
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Page 907 of 4402
12. Lower\f\bnd\fremove\fthe\fTrolley\fj\bck.\fGeneral \bqui\fment: Trolley\fj\bck\f
13 .T
orque: 90\fNm
\f
14. \f
15. Torque: 24\fNm
\f
16. Torque: 24\fNm
\f
\f\f
\f\f
\f\f
\f\f
\f\f
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Page 908 of 4402
17. Refer\fto:\fSt\brter\fMotor\f(303-06D\fSt\brting\f
Sys
tem\f-\f1.8L\fDur\btorq-TDCi\f(74kW/100PS)\f-\f
Lynx/1.8L\fDur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
18. Torque: 25\fNm
\f
19. Torque:
1\f27\fNm
\f
2\f10\fNm
\f
20. Refer\fto:\f Accessory\fDrive\fBelt \f(303-05D\f
Ac c
essory\fDrive\f-\f1.8L\fDur\btorq-TDCi\f
(74kW/100PS)\f-\fLynx/1.8L\fDur\btorq-TDCi\f
(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\fInst\bll\btion).
\f
21. \f\f 1.Torque: 35\fNm
\f
2. Loosen: 360
°\f
3. Torque: 85\fNm
\f
22. \f
\f\f
\f\f
\f\f
\f\f
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Page 909 of 4402
23. \f
24. Inst\bll\fthe\ffront\fright\fwheel.\fRefer\fto:\f Wheel\f\bnd\fTire\f(204-04\fWheels\f\bnd\f
Ti r
es,\fRemov\bl\f\bnd\fInst\bll\btion).\f
25. Torque: 23\fNm
\f
26. Torque:
1\f23\fNm
\f
1\f10\fNm
\f
\f
\f\f
\f
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Page 910 of 4402
27.Torque: 10\fNm\f
28. Torque: 23\fNm
\f
29. Inst\bll\fthe\ffollowing\fitems:\f 1. Refer\fto:\f V\blve\fCover\f(303-01E\fEngine\f-\f
1. 8
L\fDur\btorq-TDCi\f(74kW/100PS)\f-\f
Lynx/1.8L\fDur\btorq-TDCi\f(92kW/125PS)\f-\f
Lynx,\fRemov\bl\f\bnd\fInst\bll\btion).\f
2. Refer\fto:\f Air\fCle\bner\f(303-12D\fInt\bke\fAir\f
Dis
tribution\f\bnd\fFiltering\f-\f1.8L\fDur\btorq-
TDCi\f(74kW/100PS)\f-\fLynx/1.8L\fDur\btorq-
TDCi\f(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
30. Connect\fthe\fb\bttery.\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
\f
\f\f
\f\f
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Page 911 of 4402

Engine - \b.8L \furatorq-T\fCi
(74kW/\b00PS) - Lynx/\b.8L \furatorq-
T\fCi (92kW/\b25PS) - Lynx - 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
Installation 1. Remove\fthe\fturboch\brger.\f\f
Re
fer\fto:\f Turboch\brger \f(303-04I\fFuel\fCh\brging\f
\bnd
\fControls\f-\fTurboch\brger\f-\f1.8L\fDur\btorq-
TDCi\f(74kW/100PS)\f-\fLynx/1.8L\fDur\btorq-TDCi\f
(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\fInst\bll\btion).
\f
Refer\fto:\f Exh\bust\fG\bs\fRecircul\btion\f(EGR)\fCooler \f
(30
3-08C\fEngine\fEmission\fControl\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. Torque:\b 20\fNm
\f
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f\f
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Page 912 of 4402

Engine - \b.8L \furatorq-T\fCi (74kW/\b00PS) -
Lynx/\b.8L \furatorq-T\fCi (92kW/\b25PS) -
Lynx - Cylinder Head
S-MAX/G\bl\bxy\f2006.5\f(02/2006
\f
Removal and Installation
Special Tool(s)
Mat
erials
General Equipment
Removal
WA R
NINGS:\f
This\fprocedure\finvolves\ffuel\fh\bndling.\fBe\fprep\bred\ffor\ffuel\fspill\bge\f\bt\f\bll\ftimes\f\bnd\f\blw\bys\f
observe\ffuel\fh\bndling\fprec\butions.\f\f
M\bke\fsure\fth\bt\fthe\ffuel\fpressure\fh\bs\fdropped\fto\fzero\f\bnd\fth\bt\fthe\ffuel\ftemper\bture\fis\f\bt\f
\bmbient\ftemper\bture.\f
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
303-651\f
Remover,\fC\bmsh\bft\fSprocket\f
NameSpec\bf\bcat\bo\f
Engine\fOil\f-\f5W-30WSS-M2C912-A1
Spoiler\fAdhesive\fKit\f2\fComponentWSK-M5B401-A1\f/\f2U7J-M2G376-AA
C\bble\fties
Dowel\fwith\f\b\fdi\bmeter\fof\f4\fmm
Trolley\fj\bck
1. Refer\fto:\f Fuel\fInjection\fComponent\fCle\bning\f(303-04D\f
Fuel\fCh\brging\f\bnd\fControls\f-\f1.8L\fDur\btorq-TDCi\f
(74kW/100PS)\f-\fLynx/1.8L\fDur\btorq-TDCi\f
(92kW/125PS)\f-\fLynx,\fGener\bl\fProcedures).\f
\f
\f
\f
\f
\f
\f
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