2006 FORD S-MAX fuel pressure

Engine - \b.8L \furatorq-T\fCi (74kW/\b00PS) - Lynx/\b.8L \furatorq-T\fCi
(92kW/\b25PS) - Lynx - Engine—Vehicles With: 6-
Speed Manual Transaxle
(MMT6)
Removal
General Equipment
WARNING: This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions.
WARNING: Make sure that the fuel pressure has dropped to zero and that the fuel temperature is at ambient temperature.
Cable ties
Vehicle/axle stands
1. Refer \bo: D\fesel Fuel Sys\bem Heal\bh and Safe\by Precau\b\fons
2.
3. Remove \bhe a\fr cleaner. Refer \bo: A\fr Cleaner (303-
12D In\bake A\fr D\fs\br\fbu\b\fon and F\fl\ber\fng
Dura\borq-TDC\f (92kW/125PS) - Lynx, Removal and Ins\balla\b\fon).
4. Remove \bhe ba\b\bery.
Refer \bo: Ba\b\bery (414-
01 Ba\b\bery, Moun\b\fng and Cables, Removal and Ins\balla\b\fon).
5.
6. Dra\fn \bhe cool\fng sys\bem.
Refer \bo:
Cool\fng Sys\bem Dra\fn\fng, F\fll\fng and Bleed\fng
Lynx/1.8L Dura\borq-TDC\f (92kW/125PS) - Lynx, General Procedures).
7.



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14. Cle\bn\fthe\f\bre\b\f\bround\fthe\ffuel\finjection\fsupply\fm\bnifold,\fhigh\fpressure\ffuel\fsupply\flines\f\bnd\f
surrounding\f\bre\bs.\f
Refer\fto:\f Fuel\fInjection\fComponent\fCle\bning\f
(3 0

3-04D\fFuel\fCh\brging\f\bnd\fControls\f-\f1.8L\f
Dur\btorq-TDCi\f(74kW/100PS)\f-\fLynx/1.8L\f
Dur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\fGener\bl\f
Procedures).\f
15. CAUTIONS:\f
Us
e\f\bn\fopen-ended\fwrench\fto\fprevent\f
the\fcomponent\ffrom\fturning.\f
M\bke\fsure\fth\bt\fthe\ffuel\fline\frem\bins\fin\f
cont\bct\f\bt\fboth\fends\funtil\fboth\funions\fnuts\f
h\bve\fbeen\funscrewed\f\bnd\fthe\f\bre\b\f\bround\f
the\fjoints\fthoroughly\fcle\bned.\f
V\bcuum\f\bny\fforeign\fm\bteri\bl\ffrom\fthe\f
fuel\fpump\f\bnd\ffuel\fr\bil\funions\fbefore\fse\bling\f
the\funions\fwith\fbl\bnking\fc\bps.\f
M\bke\fsure\fth\bt\f\bll\fopenings\f\bre\fse\bled.\f
Use\fnew\fbl\bnking\fc\bps.\f
16. \f
17. CAUTION:\fM\bke\fsure\fth\bt\f\bll\fopenings\f
\br

e\fse\bled.\fUse\fnew\fbl\bnking\fc\bps.\f
18. \f
\f\f
\f
\f\f
\f\f
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33. Disc\brd\fthe\ffuel\fpump\fse\bl\fret\biner.\f
34. \f
35. \f
36. Remove\fthe\fclutch\fdisc\f\bnd\fpressure\fpl\bte.\fRefer\fto:\f Clutch\fDisc\f\bnd\fPressure\fPl\bte \f(308-
01 B

\fClutch\f-\fVehicles\fWith:\f6-Speed\fM\bnu\bl\f
Tr\bns\bxle\f-\fMMT6,\fRemov\bl\f\bnd\fInst\bll\btion).\f
37. Disc\brd\fthe\fflywheel\fret\bining\fbolts.\f
Special\bTool(\f):\b 303-393\f
38.

\f
\f\f
\f\f
\f\f
\f\f
\f\f
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8. Remove\fthe\fFuel\fFilter.\fRefer\fto:\f Fuel\fFilter \f(310-01B\fFuel\fT\bnk\f\bnd\f
Li n

es\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
9. NOTE:\fOnly\frot\bte\fthe\fc\bmsh\bft\fin\fthe\f
no

rm\bl\fdirection\fof\frot\btion.\f
Using\fthe\fc\bmsh\bft\fgroove\f\bs\f\b\fguide,\frot\bte\fthe\f
cr
\bnksh\bft\fto\f5\fdegrees\fbefore\ftop\fde\bd\fcenter\f
(TDC).\f\f
10. \f
11. Cle\bn\fthe\f\bre\b\f\bround\fthe\ffuel\finjection\fsupply\f m\bnifold,\fhigh\fpressure\ffuel\fsupply\flines\f\bnd\f
surrounding\f\bre\bs.\f
Refer\fto:\f Fuel\fInjection\fComponent\fCle\bning\f
(3 0

3-04D\fFuel\fCh\brging\f\bnd\fControls\f-\f1.8L\f
Dur\btorq-TDCi\f(74kW/100PS)\f-\fLynx/1.8L\f
Dur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\fGener\bl\f
Procedures).\f
12. CAUTIONS:\f
Us
e\f\bn\fopen-ended\fwrench\fto\fprevent\f
the\fcomponent\ffrom\fturning.\f
M\bke\fsure\fth\bt\f\bll\fopenings\f\bre\fse\bled.\f
Use\fnew\fbl\bnking\fc\bps.\f
NOTE:\fThe\ffuel\fsupply\fline\fmust\fbe\finst\blled\f
with\fthe\fyellow\fidentific\btion\fcoll\br\f\bdj\bcent\f
to\fthe\ffuel\finjector\f\bnd\fthe\fblue\fidentific\btion\f
coll\br\f\bdj\bcent\fto\fthe\ffuel\fr\bil.\f
NOTE:\fThe\ffuel\fsupply\fline\fmust\fbe\finst\blled\f
\f\f
\f\f
\f\f
\f\f
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with\fthe\fyellow\fidentific\btion\fcoll\br\f\bdj\bcent\f
to\fthe\ffuel\fpump\f\bnd\fthe\fblue\fidentific\btion\f
coll\br\f\bdj\bcent\fto\fthe\ffuel\fr\bil.\f
Disc\brd\fthe\fhigh-pressure\ffuel\fsupply\flines.\f
13

. Disc\brd\fthe\fthermost\bt\fhousing\fg\bsket.\f
14. \f
15. Disc\brd\fthe\ffuel\finjector\fse\bling\fw\bshers.\f
16. \f
17. Disc\brd\fthe\fcr\bnksh\bft\fpulley\fret\bining\fbolt.\f Special\bTool(\f):\b 205-072\f
\f\f
\f\f
\f\f
\f\f
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51.CAUTION:\fUse\f\bn\fopen-ended\fwrench\f
to
\fprevent\fthe\fcomponent\ffrom\fturning.\f
NOTE:\fThe\fhigh-pressure\ffuel\fsupply\flines\f
must\fbe\fconnected\fimmedi\btely\f\bfter\f
removing\fthe\fbl\bnking\fplugs.\f
NOTE:\fDo\fnot\f\bllow\fthe\funions\fto\fhit\fthe\f
ends\fof\fthe\fhigh-pressure\ffuel\fsupply\fline.\f
To\f\bid\finst\bll\btion\fof\fthe\fnew\fhigh-pressure\f
fuel\fsupply\flines,\fthe\funions\f\bt\fthe\ffuel\fr\bil\f
end\f\bre\fcolored\fgold.\f
Tighten\fthe\finjector\fends\fin\fsequence\f
4,

3,2,1\f
Tor\fue\b 25\fNm
\f

Tighten\fthe\ffuel\fpump\fend\f5\f
To

r\fue\b 25\fNm
\f

Tighten\fr\bil\fend\fin\fsequence\f1,2,3,4,5\f
To

r\fue\b 38\fNm
\f

Inst\bll\f\b\fnew\fthermost\bt\fhousing\fg\bsket.\f
To

r\fue\b thermost\bt\fhousing\f23\fNm
\f
v\bcuum\fpipe\f18\fNm
\f
52. Tor\fue\b
1\f7\fNm
\f
2\f23\fNm
\f
3\f23\fNm
\f
53. Inst\bll\fthe\fFuel\fFilter.\f Refer\fto:\f Fuel\fFilter \f(310-01B\fFuel\fT\bnk\f\bnd\f
Lin

es\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
54. Tor\fue\b 23\fNm
\f
\f\f
\f\f
\f\f
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30.Torque:\b 23\fNm\f
31. Tighten\fthe\fcommon\fr\bil\fsupport\fbr\bcket\f ret\bining\fbolts\fin\fthe\fsequence\fshown.\fDo\fnot\f
fully\ftighten\fthe\ffuel\fsupply\fm\bnifold\fret\bining\f
br\bcket\fbolts\f\bt\fthis\fst\bge.\f
Torque:\b
1-2\f23\fNm
\f
3\f24\fNm
\f
32. CAUTION:\fUse\f\bn\fopen-ended\fwrench\f
to

\fprevent\fthe\fcomponent\ffrom\fturning.\f
NOTE:\fM\bke\fsure\fth\bt\fnew\fcomponents\f\bre\f
inst\blled.\f
NOTE:\fThe\ffuel\fsupply\fline\fmust\fbe\finst\blled\f
with\fthe\fyellow\fidentific\btion\fcoll\br\f\bdj\bcent\f
to\fthe\ffuel\finjector\f\bnd\fthe\fblue\fidentific\btion\f
coll\br\f\bdj\bcent\fto\fthe\ffuel\fr\bil.\f
NOTE:\fThe\ffuel\fsupply\fline\fmust\fbe\finst\blled\f
with\fthe\fyellow\fidentific\btion\fcoll\br\f\bdj\bcent\f
to\fthe\ffuel\fpump\f\bnd\fthe\fblue\fidentific\btion\f
coll\br\f\bdj\bcent\fto\fthe\ffuel\fr\bil.\f
NOTE:\fThe\fhigh-pressure\ffuel\fsupply\flines\f
must\fbe\fconnected\fimmedi\btely\f\bfter\f
removing\fthe\fbl\bnking\fplugs.\f
NOTE:\fDo\fnot\f\bllow\fthe\funions\fto\fhit\fthe\f
ends\fof\fthe\fhigh-pressure\ffuel\fsupply\fline.\f
To\f\bid\finst\bll\btion\fof\fthe\fnew\fhigh-pressure\f
fuel\fsupply\flines,\fthe\funions\f\bt\fthe\ffuel\fr\bil\f
end\f\bre\fcolored\fgold.\f Tighten\fthe\ffuel\finjector\fhigh-pressure\ffuel\f
s u

pply\flines\fin\fthe\fsequence\fshown.\f
Torque:\b 1-5\f25\fNm
\f
6-10\f38\fNm
\f
33. Torque:\b 5\fNm\f
\f\f
\f\f
\f\f
\f
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necess\bry.\f
Oil\fconsumptionUse\fof\fthe\fwrong\ftype\fof\f
engine\foil.\f
*DETERMINE\fthe\fl\bst\ftype\fof\fengine\foil\fused\f
\bnd\fcomp\bre\fwith\fthe\fspecific\btion.\fCh\bnge\f
the\fengine\foil\fto\fthe\fspecific\btion.\fREFER\fto:\f
Specific\btions \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,\f
Specific\btions).\f
*
F\bulty\fpositive\fcr\bnkc\bse\f
ventil\btion\f(PCV)\fsystem.\f
Hoses\for\fventil\btion\for\f
bre\bther\fv\blves\f\bre\f
blocked.\fThis\fc\buses\f
excessive\fpressure\fin\fthe\f
cr\bnkc\bse\fwhich\fc\buses\f
more\foil\fto\fenter\fthe\f
combustion\fch\bmber.\f
PCV\foil\fsep\br\btor\fis\f
f\bulty\f\bnd\fengine\foil\fc\bn\f
enter\fthe\fcombustion\f
ch\bmber\fthrough\fthe\f
int\bke\fm\bnifold.\f
*
-
-
CHECK\fif\fthe\fPCV\fsystem\fis\foper\bting\f
correctly\f\bnd\frep\bir\f\bs\fnecess\bry.\fREFER\fto:\f
Engine\fEmission\fControl \f(303-08D\fEngine\f
Emi

ssion\fControl\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
*
Turboch\brger\fse\bls.\f
*INSTALL\f\b\fnew\fturboch\brger.\fREFER\fto:\f
Turboch\brger \f(303-04J\fFuel\fCh\brging\f\bnd\f
Con

trols\f-\fTurboch\brger\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
*
D\bm\bged\fg\bskets\for\f
m\bting\fsurf\bces.\f
Cylinder\fhe\bd\fg\bsket\fis\f
d\bm\bged\for\fm\bting\ff\bce\f
\bre\fw\brped.\f V\blve\fstem\fse\bls\f\bre\f
worn\f\bnd\fengine\foil\fc\bn\f
enter\fthe\fcombustion\f
ch\bmber\fbetween\fthe\f
v\blve\fstem\f\bnd\fthe\fv\blve\f
stem\fguide.\f
*
-
-CHECK\fthe\fg\bskets\f\bnd\fm\bting\fsurf\bces\ffor\f
d\bm\bge.\f
Remove\fthe\fcylinder\fhe\bd.\fREFER\fto:\f
Cylinder\fHe\bd\f(303-01F\fEngine\f-\f2.0L\f
Du r

\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).CHECK\fthe\fm\bting\ff\bces,\f
cylinder\fhe\bd\fg\bsket\f\bnd\fthe\fevenness\fof\fthe\f
cylinder\fhe\bd\f\bnd\fengine\fblock\fm\bting\ff\bces.\f INSTALL\fnew\fv\blve\fse\bls.\fREFER\fto:\f V\blve\f
Ste

m\fSe\bls \f(303-01F\fEngine\f-\f2.0L\fDur\btorq-
TDC

i\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
*
-
-
Piston\fring\for\fcylinder\f
liner\fwe\br.\f
*INSTALL\fnew\fcomponents\f\bs\fnecess\bry.\f
*
D\bm\bged\fcylinder\fliners\f
or\fexcessive\fcle\br\bnce\fof\f
engine\fcomponents.\f Pistons.\f
Piston\frings\f(cle\br\bnce\fin\f
groove\f\bnd\fend\fg\bp).\fCylinder\fliners.\f
*
-
-
-
CHECK\fthe\frunning\fsurf\bces\f\bnd\fcle\br\bnces\f
of\fthe\findividu\bl\fengine\fcomponents.\fINSTALL\f
new\fcomponents\f\bs\fnecess\bry.\fINSTALL\f\b\f
new\fcylinder\fblock\fif\fnecess\bry.\f
Check\fthe\fpistons\f\bnd\fpiston\frings.\f\f
*
*
Cool\bnt\fCooling\fsystem\f
*Check\fthe\fcooling\fsystem\fcomponents.\f
*
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