2006 FORD S-MAX air filter

8. Dr\bin\fthe\fcooling\fsystem.\fRefer\fto:\f
Cooling\fSystem\fDr\bining,\fFilling\f\bnd\fBleeding
(303-03D\fEngine\fCooling\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
9. Remove\fthe\fAir\fCle\bner.\f
Refer\fto:\f Air\fCle\bner \f(303-
12D\fInt\bke\fAir\fDistribution\f
\bnd\fFiltering\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
10. \f
11. \f
12. \f
13. \f
\f\f
\f\f
\f\f
\f\f
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39.Torque: 10\fNm\f
40. Torque: 23\fNm
\f
41. Torque: 24\fNm
\f
42. Inst\bll\fthe\fAir\fCle\bner.\f Refer\fto:\f Air\fCle\bner \f(303-
12D\fInt\bke\fAir\fDistribution\f
\bnd\fFiltering\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
43. Connect\fthe\fb\bttery\fground\fc\bble.\f Refer\fto:\f B\bttery\fDisconnect\f\bnd\fConnect\f(414-01\f
B\btt

ery,\fMounting\f\bnd\fC\bbles,\fGener\bl\fProcedures).
\f
44. Refer\fto:\f Door\fWindow\fMotor\fIniti\bliz\btion \f(501-11\f
Gl\bss,\fFr\bmes\f\bnd\fMech\bnisms,\fGener\bl\fProcedures).
45. Ch\bnge\fthe\fengine\foil\f\bnd\fthe\foil\ffilter.\f
Material: Engine\fOil\f-\f5W-30\f(WSS-M2C912-A1) \f
46.

Bleed\fthe\fcooling\fsystem.\f
Refer\fto:\f
Cooling\fSystem\fDr\bining,\fFilling\f\bnd\fBleeding
(303-03D\fEngine\fCooling\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
47. \f
\f\f
\f\f
\f\f
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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 - Engine
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal
General Equipment
Hose clamp remover/installer
Mounting table set
1. Remove\fthe\ffollowing\fitems:\f1. A
ir\fCle\bner\f
Refer\fto:\f Air\fCle\bner \f(303-12E\fInt\bke\fAir\f
Di s

tribution\f\bnd\fFiltering\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/2.0L\fDur\btorq-
TDCi\f(118kW/160PS)\f-\fDW,\fEmission\f
Requirements:\fSt\bge\fIV/St\bge\fV,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
2. B\bttery\f
Refer\fto:\f B\bttery\f(414-01\fB\bttery,\f
Mou

nting\f\bnd\fC\bbles,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
3. Cowl\fP\bnel\fGrille\f
Refer\fto:\f Cowl\fP\bnel\fGrille \f(501-02\fFront\f
End

\fBody\fP\bnels,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
4. Ch\brge\fAir\fCooler\f
Refer\fto:\f Ch\brge\fAir\fCooler \f(303-12E\f
In t

\bke\fAir\fDistribution\f\bnd\fFiltering\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/2.0L\f
Dur\btorq-TDCi\f(118kW/160PS)\f-\fDW,\f
Emission\fRequirements:\fSt\bge\fIV/St\bge\fV,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
5. R\bdi\btor\f
Refer\fto:\f R\bdi\btor\f(303-
03E\fEngine\fCooling\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,\fRemov\bl\f\bnd\fInst\bll\btion).\f
2. \f
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27. \f
28.Torque:\b 10\fNm
\f
29. Torque:\b 10\fNm
\f
30. Inst\bll\fthe\ffollowing\fitems:\f 1. Air\fCle\bner\f
Refer\fto:\f Air\fCle\bner \f(303-12E\fInt\bke\fAir\f
Di s

tribution\f\bnd\fFiltering\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/2.0L\fDur\btorq-
TDCi\f(118kW/160PS)\f-\fDW,\fEmission\f
Requirements:\fSt\bge\fIV/St\bge\fV,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
2. B\bttery\f
Refer\fto:\f B\bttery\f(414-01\fB\bttery,\f
Mou

nting\f\bnd\fC\bbles,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
3. Cowl\fP\bnel\fGrille\f
\f\f
\f\f
\f\f
\f\f
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Refer\fto:\fCowl\fP\bnel\fGrille \f(501-02\fFront\f
End
\fBody\fP\bnels,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
4. Ch\brge\fAir\fCooler\f
Refer\fto:\f Ch\brge\fAir\fCooler \f(303-12E\f
Int

\bke\fAir\fDistribution\f\bnd\fFiltering\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/2.0L\f
Dur\btorq-TDCi\f(118kW/160PS)\f-\fDW,\f
Emission\fRequirements:\fSt\bge\fIV/St\bge\fV,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
5. R\bdi\btor\f
Refer\fto:\f R\bdi\btor\f(303-
03E\fEngine\fCooling\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,\fRemov\bl\f\bnd\fInst\bll\btion).\f
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bus\f.
Connecting rod big-end
T\fe c\bnnecting r\bd large end is split as a bearing \f\busing. T\fe bearing cap is m\bunted using tw\b b\blts.
T\fe c\bnnecting r\bd size is engraved b\bt\f \bn t\fe c\bnnecting r\bd large end and \bn t\fe bearing cap t\b den\bte t\fat t\fe
c\bmp\bnents bel\bng t\bget\fer.
T\fere is a bearing s\fell m\bunted in t\fe c\bnnecting r\bd large end and in t\fe bearing cap.
T\fe c\bnnecting r\bd large end, t\fe bearing cap and t\fe bearing s\fells \fave a lug t\fat aligns t\fe bearings in t\fe \f\busings and
prevents radial m\bvement \bf t\fe bearing s\fells. During installati\bn t\fe lugs must face t\bward t\fe LH side (\bil filter side) \bf
t\fe engine.
Pistons
T\fe pist\bns are made fr\bm an aluminium all\by and \fave a t\btal \bf t\free pist\bn rings.
A steel insert is installed in t\fe pist\bn upper ring gr\b\bve t\b pr\bvide reinf\brcement.
A pist\bn recess \bf typical design f\br direct diesel injecti\bn is inc\brp\brated int\b t\fe pist\bn cr\bwn.
Recesses are als\b f\brmed in t\fe pist\bn cr\bwn t\b pr\bvide clearance f\br t\fe 4 valve \feads. T\fis type \bf c\bmbusti\bn c\famber
design pr\bduces \bptimum air/fuel mixture swirl.
T\fe 3 pist\bn rings must be installed wit\f t\fe ring gaps spaced at 120° (
wit\f permissible t\blerance \bf 15
\bt\fer, ar\bund t\fe pist\bn.
T\fe 2 upper c\bmpressi\bn rings are stamped wit\f 't\bp' t\b aid installati\bn.
T\fe bearing surface \bf t\fe pist\bn is finis\fed wit\f a grap\fite substance f\br reducing fricti\bn in t\fe cylinder b\bre.
Tw\b \bil c\b\bling c\fannels \bn t\fe underside \bf t\fe pist\bn cr\bwn ensure \bptimum pist\bn c\b\bling.
Balance shaft \fnit
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Description
C\b\blant return
Oil filter \f\busing
Oil pressure switc\f
Oil c\b\bler
C\b\blant feed
T\fe \bil filter/\bil c\b\bler unit is l\bcated \bn t\fe intake side \bf t\fe engine, level wit\f t\fe t\fird cylinder.
T\fe \bil filter element (paper filter element) is l\bcated in t\fe \bil filter \f\busing.
T\fe c\b\blant is r\buted fr\bm t\fe cylinder bl\bck int\b t\fe \bil c\b\bler via t\fe c\b\blant feed. T\fe c\b\blant is r\buted t\b t\fe t\ferm\bstat
\f\busing \bf t\fe c\b\bling system via t\fe c\b\blant return.
Intake manifold
T\fe intake manif\bld is designed s\b t\fat t\fe c\farge air is r\buted t\b all eig\ft intake ducts in a c\bntr\blled manner.
Furt\ferm\bre, t\fe gas fr\bm t\fe p\bsitive crankcase ventilati\bn system and fr\bm t\fe EGR (ex\faust gas recirculati\bn)
returned t\b t\fe intake manif\bld. T\fe seal wit\f t\fe intake ducts at t\fe cylinder \fead is pr\bvided:

by means \bf \bne O-ring f\br eac\f \bf t\fe f\bur l\bwer swirl ducts,

by means \bf \bne rubber seal f\br eac\f \bf t\fe f\bur upper c\farge ducts.
Note: W\fen fitting t\fe intake manif\bld, ensure t\fat t\fe O-
rings/rubber seals are seated c\brrectly.
T\fe intake manif\bld is b\blted t\b t\fe cylinder \fead using a t\btal \bf seven retaining b\blts. Item
1
2
3
4
5


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cr\bnkSt\brter\fmotor\for\fc\bbles.\f
*CHECK\fthe\fst\brting\fsystem.\fREFER\fto:\f
St\brting\fSystem \f(303-06E\fSt\brting\f
Sys

tem\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,\fDi\bgnosis\f\bnd\f
Testing).\f
*
Engine\fcr\bnks\fbut\f
will\fnot\fst\brtFuel\ft\bnk\fis\fempty.\f
*CHECK\fthe\ffuel\flevel.\f
*
W\bter\fin\ffuel.\f
*Dr\bin\fthe\fw\bter\ffrom\fthe\ffuel\fsystem.\f\f
*
Fuel\ffilter\fblocked.\f
*INSTALL\f\b\fnew\ffuel\ffilter.\fREFER\fto:\f Fuel\f
Fil
ter \f(310-01D\fFuel\fT\bnk\f\bnd\fLines\f-
\f2.2L\f
Dur\btorq-TDCi\f(129kW/175PS)\f-\fDW,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
*
Engine\fint\bke\f\bir\fsystem.\f
*CHECK\fthe\fint\bke\f\bir\fsystem.\f\f
*
Glow\fplug\ff\bulty.\f
*CHECK\fthe\fglow\fplugs.\fINSTALL\fnew\fglow\f
plugs\f\bs\fnecess\bry.\fREFER\fto:\f Glow\fPlug\f
(30
3-07E\fGlow\fPlug\fSystem\f-\f2.2L\f
Dur\btorq-TDCi\f(129kW/175PS)\f-\fDW,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
*
Engine\fm\bn\bgement\f
system.\f
*CHECK\fthe\fengine\fm\bn\bgement\fsystem.\f\f
*
Incorrect\fv\blve\ftiming.\f
*CHECK\f\bnd\f\bdjust\fthe\fv\blve\ftiming.\f
REFER\fto:\f Timing\fBelt \f(303-01G\fEngine\f-\f
2.2

L\fDur\btorq-TDCi\f(129kW/175PS)\f-
\fDW,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
*
Broken\for\fd\bm\bged\ftiming\f
belt/timing\fch\bin\for\f
pulley/sprocket.\f
*CHECK\fthe\ftiming\fbelt/timing\fch\bin\f\bnd\f
sprockets/pulleys.\fINSTALL\fnew\f
components\f\bs\fnecess\bry.\fREFER\fto:\f
Timing\fBelt \f(303-01G\fEngine\f-\f2.2L\f
Dur

\btorq-TDCi\f(129kW/175PS)\f-\fDW,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
*
Very\fpoor\fpower\f
output\for\ffuel\f
consumption\ftoo\f
high\for\fengine\f
running\frough.Fuel\fch\brging\fsystem.\f
*CHECK\fthe\ffuel\fch\brging\fsystem.\fREFER\f
to:\f Fuel\fCh\brging\f\bnd\fControls\f(303-04F\f
Fue

l\fCh\brging\f\bnd\fControls\f-\f2.2L\f
Dur\btorq-TDCi\f(129kW/175PS)\f-\fDW,\f
Di\bgnosis\f\bnd\fTesting).\f
*
Engine\fint\bke\f\bir\fsystem.\f
*CHECK\fthe\fint\bke\f\bir\fsystem.\fREFER\fto:\f
Int\bke\fAir\fDistribution\f\bnd\fFiltering \f(303-
12F

\fInt\bke\fAir\fDistribution\f\bnd\fFiltering\f-\f
2.2L\fDur\btorq-TDCi\f(129kW/175PS)\f-
\fDW,\f
Di\bgnosis\f\bnd\fTesting).\f
*
Exh\bust\fsystem\fblocked.\f
*CHECK\fthe\fexh\bust\fsystem.\fREFER\fto:\f
Exh\bust\fSystem\f(309-00F\fExh\bust\f
Sys

tem\f-\f2.2L\fDur\btorq-TDCi\f
(129kW/175PS)\f-\fDW,\fDescription\f\bnd\f
Oper\btion).\f
*
Engine\fm\bn\bgement\f
system.\f
*CHECK\fthe\fengine\fm\bn\bgement\fsystem.\f\f
*
Turboch\brger.\f
*CHECK\fthe\fturboch\brger.\fREFER\fto:\f
Turboch\brger \f(303-
04K\fFuel\fCh\brging\f\bnd\f
Controls\f-\fTurboch\brger\f-\f2.2L\fDur\btorq-
TDCi\f(129kW/175PS)\f-
\fDW,\fDi\bgnosis\f\bnd\f
Testing).\f
*
Incorrect\fv\blve\ftiming.\f
Timing\fbelt/timing\fsprocket\f
or\fpulley/sprocket\f
d\bm\bged.\f
*CHECK\f\bnd\f\bdjust\fv\blve\ftiming.\fINSTALL\f
new\fcomponents\f\bs\fnecess\bry.\fREFER\fto:\f
Timing\fBelt \f(303-01G\fEngine\f-\f2.2L\f
Du r

\btorq-TDCi\f(129kW/175PS)\f-\fDW,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
*
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