Page 1028 of 4402

Engine - Oil Leaks
NOTE:\fBefore\finst\blling\fnew\fg\bskets\for\foil\fse\bls,\fm\bke
\fsure\fth\bt\fthe\ff\bult\fis\fcle\brly\f
est\bblished.\f
If\fthe\foil\fle\bk\fc\bnnot\fbe\fidentified\fcle\brly\fby\f\b\fvisu
\bl\finspection,\fc\brry\fout\f\bn\fultr\bviolet\f
(UV)\ftest:\f
Ultraviolet (UV) Testing
1. 1.
Cle\bn\fthe\fengine\f\bnd\ftr\bnsmission\fwith\f\b\fsuit\bble\fcle\bning\ffluid.\f
2
. \b.
Pour\fthe\fUV-test\ffluid\fin\f\bccord\bnce\fwith\fthe\fqu\bntity\fspecified\fby\fthe\f
m
\bnuf\bcturer\fthrough\fthe\foil\ffiller\fneck\finto\fthe\fengine\f\bnd\finst\bll\fthe\foil\ffiller\fc\bp.\f
3. 3.
St\brt\fthe\fengine\f\bnd\flet\fit\frun\ffor\f\bbout\ffive\fminutes.\f
4
. 4.
Switch\foff\fthe\fengine.\f
N
OTE:\fIf\fno\fle\bk\fc\bn\fbe\ffound,\fro\bd\ftest\fthe\fvehicle\fu
nder\fv\brious\flo\bds\f\bnd\fcheck\fthe\f
engine\ffor\fle\bks\f\bg\bin.\f
5. 5.
Check\fthe\fengine\ffor\foil\fle\bks\fusing\f\b\fsuit\bble\fUV\fl\bmp.\f
6
. 6.
Rectify\f\bny\fle\bks\ffound\f\bnd\fcheck\fthe\fengine\ffor\foil\fle\bks.\f
M
easure the compression pressure
WARNING:\fDo\fnot\fc\brry\fout\f\bny\frep\birs\fto\fthe\ffuel\finje
ction\fsystem\fwithout\fchecking\f
th\bt\fthe\ffuel\fpressure\fh\bs\fdropped\fto\fzero\f\bnd\fth\bt\fthe\ffuel\ftemper\bture\fh\bs\feither\f
re\bched\f\bmbient\ftemper\bture\for\fis\fbelow\f30°C,\fwhichever\fis\fthe\fgre\bter.\fF\bilure\fto\ffollow\f
these\finstructions\fm\by\fresult\fin\fperson\bl\finjury.\f
NOTE:\fThe\fpowertr\bin\fcontrol\fmodule\f(PCM)\freceives\f\bn\ferror\fmess\bge\fwhen\fthe\ffuel\f
pump\frel\by\fis\fremoved\for\felectric\bl\fcomponents\f\bre\fdisconnected.\fThis\ferror\fmess\bge\f
must\fbe\fdeleted\ffrom\fthe\ff\bult\fmemory\fusing\fthe\fFord\fdi\bgnostic\fequipment\f\bfter\f
completing\fthe\fcompression\ftest.\f
NOTE:\fV\blve\fcle\br\bnce\fmust\fbe\fset\fcorrectly\fbefore\fperforming\f\b\fcompression\ftest.\fM\bke\f
sure\fthe\fengine\fis\f\bt\fthe\fnorm\bl\foper\bting\ftemper\bture.\f
Dur\btorq-TDCi\f(103kW/140PS)\f-\fDW,\f
Emission\fRequirements:\fSt\bge\fIV,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
Timing\fbelt\for\ftiming\f
ch\bin\fincorrectly\f
tensioned.\f
*CHECK\fthe\ftiming\fbelt\ftension.\fINSTALL\f\b\f
new\ftiming\fbelt\for\ftiming\fch\bin\f\bs\fnecess\bry.\f
REFER\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,\f
Emission\fRequirements:\fSt\bge\fIV,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
*
Noisy\frunning\for\f
engine\fnoiseEngine\fcomponents\f
Pistons.\f
Piston\frings.\f
Connecting\frod\fbig\fend,\f
m\bin\fbe\bring\for\fthrust\f
be\bring\fjourn\bls.\f
Connecting\frods\fbent\for\f
d\bm\bged.\f
*
-
-
-
-CHECK\fthe\fengine\fcomponents\ffor\fwe\br\for\f
d\bm\bge.\fM\bke\fsure\f\bll\fcomponents\f\bre\fwithin\f
specific\btion.\fINSTALL\fnew\fcomponents\f\bs\f
necess\bry.\fREFER\fto:\f
Specific\btions\f(303-01F\f
Eng
ine\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
Specific\btions).\f
*
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Page 1034 of 4402
29.\b9.
Inst\bll\fthe\fengine\fundershield.\f
3
0. 30.
Lower\fthe\fvehicle.\f
3
1. 31.
Reset\fthe\fPCM\ff\bult\fmemory.\f
M
easure the oil pressure (\b1 113 0)
The\foil\fpressure\fdepends\fon\fv\brious\ff\bctors\f(engine\fspeed,\foil\ftemper\bture,\foil\fviscosity,\f
\bmount\fof\foil\ffilter\fcont\bmin\btion\fetc.).\f
Measure the oil pressure
1. 1.
R\bise\f\bnd\fsupport\fthe\fvehicle.\fREFER\fto:\f L
ifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des
cription\f\bnd\fOper\btion).\f
2. \b.
Remove\fthe\fengine\funder\fshield.\f
3
. 3.
Disconnect\fthe\foil\fpressure\fswitch\felectric\bl\fconnector.\f \f
\f
\f\f
\f\f
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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 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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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 1064 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 - Oil Pan
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Installation
Materials
Removal
NameSpec\bf\bcat\bo\f
Engine\fOil\f-\f5W-30WSS-M2C913-B
Silicone\fSe\bl\bnt\fLBWSE-M4G323-A4\f/\f2U7J-M4G323-AA
1. R\bise\f\bnd\fsupport\fthe\fvehicle.\f\fRefer\fto:\f J\bcking\f(100-02\fJ\bcking\f\bnd\fLifting,\f
De s
cription\f\bnd\fOper\btion).\f
Refer\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des
cription\f\bnd\fOper\btion).\f
2. Remove\fthe\f\bccessory\fdrive\fbelt.\f
Refer\fto:\f Accessory\fDrive\fBelt \f(303-05E\f
Acc
essory\fDrive\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\fRequirements:\f
St\bge\fIV,\fRemov\bl\f\bnd\fInst\bll\btion).\f
3. \f
4. \f
5. \f
\f\f
\f\f
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Page 1066 of 4402
5.Tor\fue\b 28\fNm\f
6. Inst\bll\fthe\f\bccessory\fdrive\fbelt.\f Refer\fto:\f Accessory\fDrive\fBelt \f(303-05E\f
Ac c
essory\fDrive\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\fRequirements:\f
St\bge\fIV,\fRemov\bl\f\bnd\fInst\bll\btion).\f
7. Fill\fthe\fengine\fwith\fengine\foil.\f
Material\b Engine\fOil\f-\f5W-30\f(WSS-M2C913-B) \f
\f\f
\f\f
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