2006 FORD S-MAX Service Repair Manual

wheelbase spark plugs high beam lock engine oil capacity fuse box diagram

Page 1641 of 4402

$FORD S-MAX 2006 Service Repair Manual TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f Accessory\fdrive\f belt\fincorrectly\f inst\blled.\f *CHECK\fthe\f\bccessory\fdrive\fbelt\fis\fcorrectly\f inst\blled\fin\fthe\fpulley\fgrooves.\fINSTALL$

TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
Accessory\fdrive\f
belt\fincorrectly\f
inst\blled.\f
*CHECK\fthe\f\bccessory\fdrive\fbelt\fis\fcorrectly\f
inst\blled\fin\fthe\fpulley\fgrooves.\fINSTALL\f\b\fnew\f
\bccessory\fdrive\fbelt\f\bs\fnecess\bry.\fREFER\fto:\f Accessory\fDrive\fBelt \f(303-05A\fAccessory\f
Dri

ve\f-\f2.0L\fDur\btec-HE\f(107kW/145PS)\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\f
Inst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05A\fAccessory\f
Dri

ve\f-\f2.0L\fDur\btec-HE\f(107kW/145PS)\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\f
Inst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05C\fAccessory\f
Dr i

ve\f-\f2.5L\fDur\btec\f(162kW/220PS)\f-\fVI5,\f
Remov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05D\fAccessory\f
Dri

ve\f-\f1.8L\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
Accessory\fDrive\fBelt \f(303-05F\fAccessory\f
Dri

ve\f-\f2.2L\fDur\btorq-TDCi\f(129kW/175PS)\f-
\f
DW,\fRemov\bl\f\bnd\fInst\bll\btion).\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
*
Pulley(s).\f
*CHECK\fthe\fpulley(s)\ffor\fd\bm\bge,\ffreedom\fof\f
rot\btion,\fstone\fentr\bpment\f\bnd\f\blignment.\f
INSTALL\fnew\fcomponents\f\bs\fnecess\bry.\fTEST\fthe\f
system\ffor\fnorm\bl\foper\btion.\f
*
Lubric\bnt\for\f
other\f
cont\bmin\btion.\f
*CHECK\fthe\f\bccessory\fdrive\fbelt\ffor\fcont\bmin\btion\f
or\fd\bm\bge.\fRECTIFY\fthe\fsource\fof\fthe\fle\bk\f\bnd\f
INSTALL\f\b\fnew\f\bccessory\fdrive\fbelt.\fREFER\fto:\f
Accessory\fDrive\fBelt \f(303-05A\fAccessory\f
Dr i

ve\f-\f2.0L\fDur\btec-HE\f(107kW/145PS)\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\f
Inst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05A\fAccessory\f
Dri

ve\f-\f2.0L\fDur\btec-HE\f(107kW/145PS)\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\f
Inst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05C\fAccessory\f
Dri

ve\f-\f2.5L\fDur\btec\f(162kW/220PS)\f-\fVI5,\f
Remov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05D\fAccessory\f
Dri

ve\f-\f1.8L\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
Accessory\fDrive\fBelt \f(303-05F\fAccessory\f
Dri

ve\f-\f2.2L\fDur\btorq-TDCi\f(129kW/175PS)\f-
\f
DW,\fRemov\bl\f\bnd\fInst\bll\btion).\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
*
NOTE:\fSque\bl\fis\f
defined\f\bs\f\b\f
continuous\fshriek,\fAccessory\fdrive\f
belt\ftensioner\f
worn,\fd\bm\bged\f
*CHECK\fthe\f\bccessory\fdrive\fbelt\ftensioner\ffor\f
correct\foper\btion,\fd\bm\bge\for\fcont\bmin\btion.\f
REFER\fto\fthe\fAccessory\fDrive\fBelt\fTensioner\f
*
Стр. 5 из
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Page 1642 of 4402

$FORD S-MAX 2006 Service Repair Manual most\fnotice\bble\f when\fthe\fengine\fis\f being\f\bcceler\bted\f or\fwith\felectric\bl\f lo\bd.\f Accessory\fdrive\fbelt\f sq ue\bl or\fcont\bmin\bted\f with\foil.\fComponent\fTest\fin\fthis\fproced$

most\fnotice\bble\f
when\fthe\fengine\fis\f
being\f\bcceler\bted\f
or\fwith\felectric\bl\f
lo\bd.\f
Accessory\fdrive\fbelt\f
sq
ue\bl
or\fcont\bmin\bted\f
with\foil.\fComponent\fTest\fin\fthis\fprocedure.\fINSTALL\f\b\f
new\f\bccessory\fdrive\fbelt\ftensioner\f\bs\fnecess\bry.\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
NOTE:\fWhine\fis\f
defined\f\bs\f\b\f
continuous\fnoise\f\bt\f
the\fs\bme\f
frequency,\f
gener\blly\f
\bssoci\bted\fwith\f
pl\bstic\fpulleys.\f
Accessory\fdrive\fbelt\f
wh

ine
Poor\fsurf\bce\f
finish\fon\f
\bccessory\fdrive\f
belt\fidler\fpulley\f
fl\bt\fsurf\bce(s).\f
*REMOVE\fthe\f\bccessory\fdrive\fbelt.\fREFER\fto:\f
Accessory\fDrive\fBelt \f(303-05A\fAccessory\f
Dri

ve\f-\f2.0L\fDur\btec-HE\f(107kW/145PS)\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\f
Inst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05A\fAccessory\f
Dr i

ve\f-\f2.0L\fDur\btec-HE\f(107kW/145PS)\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\f
Inst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05C\fAccessory\f
Dri

ve\f-\f2.5L\fDur\btec\f(162kW/220PS)\f-\fVI5,\f
Remov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05D\fAccessory\f
Dri

ve\f-\f1.8L\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
Accessory\fDrive\fBelt \f(303-05F\fAccessory\f
Dri

ve\f-\f2.2L\fDur\btorq-TDCi\f(129kW/175PS)\f-
\f
DW,\fRemov\bl\f\bnd\fInst\bll\btion).\f
INSPECT\fthe\fidler\fpulley(s)\ffor\fsurf\bce\ffinish.\f
INSTALL\f\b\fnew\fidler\fpulley(s)\f\bs\fnecess\bry.\fTEST\f
the\fsystem\ffor\fnorm\bl\foper\btion.\f
*
Accessory\fdrive\f
belt\fidler\fpulley\f
be\bring\ff\bilure.\f
*REMOVE\fthe\f\bccessory\fdrive\fbelt.\fREFER\fto:\f
Accessory\fDrive\fBelt \f(303-05A\fAccessory\f
Dr i

ve\f-\f2.0L\fDur\btec-HE\f(107kW/145PS)\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\f
Inst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05A\fAccessory\f
Dri

ve\f-\f2.0L\fDur\btec-HE\f(107kW/145PS)\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\f
Inst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05C\fAccessory\f
Dri

ve\f-\f2.5L\fDur\btec\f(162kW/220PS)\f-\fVI5,\f
Remov\bl\f\bnd\fInst\bll\btion),\f
Accessory\fDrive\fBelt \f(303-05D\fAccessory\f
Dri

ve\f-\f1.8L\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
Accessory\fDrive\fBelt \f(303-05F\fAccessory\f
Dri

ve\f-\f2.2L\fDur\btorq-TDCi\f(129kW/175PS)\f-
\f
DW,\fRemov\bl\f\bnd\fInst\bll\btion).\f
INSPECT\fthe\fidler\fpulley(s)\ffor\fsmooth\frot\btion.\f
INSTALL\f\b\fnew\fidler\fpulley(s)\f\bs\fnecess\bry.\fTEST\f
the\fsystem\ffor\fnorm\bl\foper\btion.\f
*
NOTE:\fChirp\fis\fPulley\f*CHECK\fth\bt\fthe\f\bccessory\fdrive\fbelt\fis\frunning\f
*
Стр. 6 из 8
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Page 1643 of 4402

$FORD S-MAX 2006 Service Repair Manual Component\bTests\b Accessory\bDrive\bBelt\bTensioner\b\f\bStatic\bCheck\b The\f\bccessory\fdrive\fbelt\ftensioner\fm\by\fbe\fchecked\fst\btic\blly\f\bs\ffollows:\f1. 1.\b Inspect\fthe\f\bre\b\fsurroun$

Component\bTests\b
Accessory\bDrive\bBelt\bTensioner\b\f\bStatic\bCheck\b
The\f\bccessory\fdrive\fbelt\ftensioner\fm\by\fbe\fchecked\fst\btic\blly\f\bs\ffollows:\f1. 1.\b
Inspect\fthe\f\bre\b\fsurrounding\fthe\f\bccessory\fdrive\fbelt\ftensioner\ffor\flubric\bnt\for\f
o
ther\fcont\bmin\btion.\fRectify\f\bny\fle\bks\fbefore\finst\blling\f\b\fnew\f\bccessory\fdrive\fbelt\f
tensioner.\fIf\fthe\f\bccessory\fdrive\fbelt\ftensioner\fis\fcont\bmin\bted,\fdo\fnot\f\bttempt\fto\f
cle\bn\fit\f\bs\fthe\fd\bmping\fmech\bnism\finside\fm\by\fbe\fd\bm\bged.\fINSTALL\f\b\fnew\f
\bccessory\fdrive\fbelt\ftensioner\f\bs\fnecess\bry.\fTEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
2. 2.\b
Det\bch\fthe\f\bccessory\fdrive\fbelt\fin\fthe\f\bre\b\fof\fthe\f\bccessory\fdrive\fbelt\ftensioner.\f
3

. NOTE:\fThe\f\bccessory\fdrive\fbelt\ftensioner\fh\bs\f\b\fd\bmping\ffe\bture,\fwhich\fis\fusu\blly\f\b\f
fr

iction\fdevice,\ftherefore\fsome\ffriction\fwithin\fthe\fsystem\fis\fnorm\bl.\f
3.\b Using\fthe\fcorrect\ftool,\fmove\fthe\f\bccessory\fdrive\fbelt\ftensioner\ffrom\fits\frel\bxed\f
po
sition\fthrough\fits\ffull\fstroke\f\bnd\fb\bck\fto\fthe\frel\bxed\fposition\fto\fm\bke\fsure\fthere\f
is\fno\fexcessive\fstick,\fgr\bb\for\fbind,\f\bnd\fto\fm\bke\fsure\fthere\fis\ftension\fon\fthe\f
\bccessory\fdrive\fbelt\ftensioner\fspring.\f
4. 4.\b
Rot\bte\fthe\f\bccessory\fdrive\fbelt\ftensioner\fpulley\f\bnd\fcheck\ffor\fd\bm\bge,\ffreedom\fof\f
r
ot\btion\f\bnd\f\blignment.\fINSTALL\f\b\fnew\f\bccessory\fdrive\fbelt\ftensioner\f\bs\fnecess\bry.\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
5. 5.\b
If\fthe\f\bccessory\fdrive\fbelt\ftensioner\fmeets\fthe\f\bbove\fcriteri\b,\fproceed\fto\ftest\fthe\f
\b
ccessory\fdrive\fbelt\ftensioner\fdyn\bmic\blly.\fIf\fthe\f\bccessory\fdrive\fbelt\ftensioner\f
does\fnot\fmeet\fthe\f\bbove\fcriteri\b,\fINSTALL\f\b\fnew\f\bccessory\fdrive\fbelt\ftensioner.\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
Accessory\bDrive\bBelt\bTensioner\b\f\bDynamic\bCheck\b
defined\f\bs\f\b\f
twittering\fnoise,\f
often\fintermittent\f
Accessory\fdrive\fbelt\f
ch
irp
mis\blignment\f
(usu\blly\fevident\f
\bt\fidle).\fcentr\blly\fon\fthe\ffl\bt\fpulleys.\fTEST\fthe\fsystem\ffor\f
norm\bl\foper\btion.\fCHECK\fthe\fpulleys\ffor\fexcessive\fend\fflo\bt\f\bnd\f
bent\ffl\bnges.\f
With\fthe\fengine\frunning\f\bt\fidle,\fuse\f\b\f
stethoscope\fto\fidentify\fthe\fsource\fof\fthe\fnoise.\f
INSTALL\fnew\fcomponents\f\bs\fnecess\bry.\fTEST\fthe\f
system\ffor\fnorm\bl\foper\btion.\f
*
*
NOTE:\fR\bttle\fis\f
defined\f\bs\f\b\f
met\bllic\fknocking\f
noise\f
Accessory\fdrive\fbelt\f
r
\bt

tle
Accessory\fdrive\f
belt\ftensioner\f
hitting\fthe\fend\f
stops.\f
*CHECK\fthe\f\bccessory\fdrive\fbelt\ftensioner\ffor\f
correct\foper\btion\for\fd\bm\bge.\fREFER\fto\fthe\f
Accessory\fDrive\fBelt\fTensioner\fComponent\fTest\f
in\fthis\fprocedure.\fINSTALL\f\b\fnew\f\bccessory\fdrive\f
belt\ftensioner\f\bs\fnecess\bry.\fTEST\fthe\fsystem\ffor\f
norm\bl\foper\btion.\f
*
Loose\f
components\for\f
h\brdw\bre.\f
*CHECK\fthe\fcomponents\for\fh\brdw\bre\ffor\fcorrect\f
inst\bll\btion\f\bnd\ftighten\f\bs\fnecess\bry.\fTEST\fthe\f
system\ffor\fnorm\bl\foper\btion.\f
*
Accessory\fdrive\fbelt\f
fr\byingAccessory\fdrive\f
belt.\f Pulley(s).\f
*
*CHECK\fthe\fextent\fof\fthe\ffr\bying\fby\freferring\fto\f
the\fillustr\btions\fshown\fin\fthe\fVisu\bl\fInspection\f
section.\fOnly\fINSTALL\f\b\fnew\f\bccessory\fdrive\fbelt\f
if\fthe\ffr\bying\fis\fwithin\fthe\fcriteri\b\fquoted\fin\fthe\f
Visu\bl\fInspection\fsection.\fTEST\fthe\fsystem\ffor\f
norm\bl\foper\btion.\f CHECK\fthe\fpulley(s)\ffor\fd\bm\bge,\ffreedom\fof\f
rot\btion\f\bnd\f\blignment.\fINSTALL\fnew\fcomponents\f
\bs\fnecess\bry.\fTEST\fthe\fsystem\ffor\fnorm\bl\f
oper\btion.\f
*
*
Стр. 7 из
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Page 1644 of 4402

$FORD S-MAX 2006 Service Repair Manual The\f\bccessory\fdrive\fbelt\ftensioner\fm\by\fbe\fchecked\fdyn\bmic\blly\f\bs\ffollows:\f1. 1.\b With\fthe\fengine\frunning,\fobserve\fthe\f\bccessory\fdrive\fbelt\ftensioner\fmovement.\f T he\f\bcc$

The\f\bccessory\fdrive\fbelt\ftensioner\fm\by\fbe\fchecked\fdyn\bmic\blly\f\bs\ffollows:\f1. 1.\b
With\fthe\fengine\frunning,\fobserve\fthe\f\bccessory\fdrive\fbelt\ftensioner\fmovement.\f
T
he\f\bccessory\fdrive\fbelt\ftensioner\fshould\fmove\f(respond)\fwhen\fthe\fengine\fis\f
\bcceler\bted\fr\bpidly\for\fwhen\fthe\fA/C\fclutch\fcycles\fON\f\bnd\fOFF\f(the\fdegree\fof\f
movement\fc\bn\fbe\fup\fto\f4\fmm).\fIf\fthe\f\bccessory\fdrive\fbelt\ftensioner\fmovement\fis\f
not\fconst\bnt\fwithout\fengine\f\bcceler\btion\for\fA/C\fclutch\fcycling,\f\b\fpulley\for\fsh\bft\fis\f
possibly\fbent,\fout\fof\fround,\for\fthe\fd\bmping\fmech\bnism\finside\fthe\f\bccessory\fdrive\f
belt\ftensioner\fm\by\fbe\fd\bm\bged.\fINSTALL\f\b\fnew\f\bccessory\fdrive\fbelt\ftensioner\f\bs\f
necess\bry.\fTEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
2. 2.\b
Excessive\f\bccessory\fdrive\fbelt\frideout\f(uneven\fdepth\fof\fgrooves\fin\fthe\f\bccessory\f
d
rive\fbelt)\fm\by\fc\buse\fexcessive\f\bccessory\fdrive\fbelt\ftensioner\fmovement.\fCheck\f
the\fcondition\fby\finst\blling\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
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
Стр. 8 из 8
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Page 1645 of 4402

$FORD S-MAX 2006 Service Repair Manual Accessory\bDrive\b\f\b2.5L\bDuratec\b (162kW/220PS)\b\f\bVI5\b\f\bAccessory\bDrive\b Belt S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f Removal\band\bInstallation\b Removal\b In stallation\b 1. Remove$

Page 1646 of 4402

$FORD S-MAX 2006 Service Repair Manual Accessory\bDrive\b\f\b2.5L\bDuratec\b (162kW/220PS)\b\f\bVI5\b\f\bAir\bConditioning\b (A/C)\bCompressor\bBelt S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f Removal\band\bInstallation\b Special\bTool(s)$

Page 1647 of 4402

$FORD S-MAX 2006 Service Repair Manual 3. \f 4.Torque: 25\fNm \f 5. Refer\fto:\f Accessory\fDrive\fBelt \f(303-05C\f Acc essory\fDrive\f-\f2.5L\fDur\btec\f(162kW/220PS)\f- \f VI5,\fRemov\bl\f\bnd\fInst\bll\btion).\f \f \f \f\f Стр. 2$

Page 1648 of 4402

$FORD S-MAX 2006 Service Repair Manual Accessory\bDrive\b\f\b1.8L\bDuratorq\fTDCi\b (74kW/100PS)\b\f\bLynx/1.8L\bDuratorq\f TDCi\b(92kW/125PS)\b\f\bLynx\b\f\bAccessory\b Drive S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f Description\band\b$

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four wheel drive MPG hood open oil capacity water pump drain bolt