2006 FORD S-MAX 107kW
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51. \f
52. \f\f3. Disc\brd\fthe\fbolt.\f
53. CAUTION:\fM\bke\fsure\fth\bt\fno\f
c o
mponents\fc\btch.\f
Refer\fto:\f Li
fting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des
cription\f\bnd\fOper\btion).\f
54. Att\bch\fthe\fspeci\bl\ftool.\f
S\fecial Tool(s): 303-122\f
Gen
eral \bqui\fment: Hydr\bulic\fjib\fcr\bne \f
55.
Refer\fto:\f St\brter\fMotor \f(303-06A\fSt\brting\f
Sys
tem\f-\f2.0L\fDur\btec-HE\f(107kW/145PS)\f-\f
MI4/2.0L\fDur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\f
MI4/2.3L\fDur\btec-HE\f(118kW/160PS)\f-\fMI4,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
56. \f
\f\f
\f\f
\f\f
\f\f
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Page 740 of 4402
4. Secure\fthe\fengine\fto\fthe\f\bssembly\ft\bble\fwith\fret\bining\fstr\bps.\f
Genera\f\bEquipment:\b Mounting\ft\bble\fset\f
5. R
emove\fthe\fspeci\bl\ftool.\f
Specia\f\bToo\f(s):\b 303-122\f
Ge n
era\f\bEquipment:\b Hydr\bulic\fjib\fcr\bne \f
6. To
rque:\b 36\fNm
\f
7. Refer\fto:\f St\brter\fMotor \f(303-06A\fSt\brting\f
Sys
tem\f-\f2.0L\fDur\btec-HE\f(107kW/145PS)\f-\f
MI4/2.0L\fDur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\f
MI4/2.3L\fDur\btec-HE\f(118kW/160PS)\f-\fMI4,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
8. CAUTION:\fM\bke\fsure\fth\bt\fno\f
\f\f
\f
\f\f
\f\f
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Page 1051 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 - Timing Belt
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Installation
Special Tool(s)
Gen
eral Equipment
Removal
303-1059\f
Alignment\fPeg,\fCr\bnksh\bft
\f
303-393\f
Locking\fTool,\fFlywheel\f
303-393-01\f
Ad\bpter\ffor\f303-393\f
303-735\f
Alignment\fPeg,\fC\bmsh\bft\f
Trolley\fj\bck
1. Disconnect\fthe\fb\bttery.\fRefer\fto:\f B\bttery\fDisconnect\f\bnd\fConnect\f(414-
01 \f
B\bttery,\fMounting\f\bnd\fC\bbles,\fGener\bl\f
Procedures).\f
2. Remove\fthe\f\bccessory\fdrive\fbelt.\f
Refer\fto:\f Accessory\fDrive\fBelt \f(303-05A\f
Acc
essory\fDrive\f-\f2.0L\fDur\btec-HE\f
(107kW/145PS)\f-\fMI4/2.0L\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
3. \f
\f
\f
\f
\f
\f\f
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Page 1058 of 4402
21. Inst\bll\fthe\f\bccessory\fdrive\fbelt.\fRefer\fto:\f Accessory\fDrive\fBelt \f(303-05A\f
Ac c
essory\fDrive\f-\f2.0L\fDur\btec-HE\f
(107kW/145PS)\f-\fMI4/2.0L\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
22. 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
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Page 1280 of 4402
Engine C\b\bling - 2\f0L Duratec-HE
(107kW/145PS) - MI4/2\f0L Duratec-HE
Flex Fuel (107kW/145PS) - MI4/2\f3L
Duratec-HE (118kW/160PS) - MI4 -
Specificati\bns
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Lubricants, Fluids, Sealers and Adhesives
Antifreeze
C\b\bling System Refill Capacity - Vehicles with 2\f0L Duratec-HE (MI4) engine
C\b\bling System Refill Capacity - Vehicles with 2\f3L Duratec-HE (MI4) engine
C\b\bling System Pressure Specificati\bn
ItemSpec\bf\bcat\bo\f
Motorcr\bft\fSuper\fPlus\fAntifreezeWSS-M97B44–D
Spec\bf\bc Grav\bty (prov\bd\b\fg \fo
other add\bt\bve \bs \b\f coola\ft)Approx\bmate perce\ftage of A\ft\b-Freeze (by volume)Rema\b\fs Flu\bd toSol\bd\bf\bes at
1.061\f\bt\f+15°C50%–25°C\f(–13° F)–37°C\f(–35°F)
Descr\bpt\bo\fL\bters
Cooling\fsystem\f\bnd\fhe\bter6.2
Descr\bpt\bo\fL\bters
Cooling\fsystem\f\bnd\fhe\bter6.9
Descr\bpt\bo\fPressure kpa (ps\b)
R\bdi\btor\fpressure\ftest138\f(20)
Cool\bnt\fexp\bnsion\ft\bnk\fc\bp\frele\bse\fpressure135\fto\f155\f(19.6\fto\f22.5)
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Page 1281 of 4402
Engine C\b\bling - 2\f0L Duratec-HE
(107kW/145PS) - MI4/2\f0L Duratec-HE
Flex Fuel (107kW/145PS) - MI4/2\f3L
Duratec-HE (118kW/160PS) - MI4 -
Engine C\b\bling
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Descripti\bn and Operati\bn
\f\f
Descripti\bn
Cool\bnt\fexp\bnsion\ft\bnk\f
Cool\bnt\foutlet\fconnector\f
Cooling\ff\bn\fmotor\f\bnd\fshroud\f
R\bdi\btor\f
Thermost\bt\fhousing\f
Cool\bnt\fpump\f
CAUTION:\fIf\fthe\fcool\bnt\fconcentr\btion\fis\finsufficient,\flow\ftemper\bture\fprotection\f\bnd\f
co
rrosion\fresist\bnce\fwill\fbe\fimp\bired.\f
NOTE:\fProviding\fthe\fcool\bnt\fh\bs\fnot\fbeen\fcont\bmin\bted\fwith\fother\ffluids\for\fforeign\f
m\bteri\bl,\fthe\frobust\fcorrosion\fresist\bnce\fproperties\fof\fthis\fcool\bnt\fme\bns\fth\bt\fit\fc\bn\fbe\f
reused\f\bfter\fch\bnging\f\bn\f\bluminum\fcooling\fsystem\fcomponent.\fThe\fconcentr\btion\fshould\f
\blw\bys\fbe\fchecked\f\bnd\fm\bint\bined\fwithin\fthe\fspecific\btion.\f\f
Cool\bnt\fconcentr\btion\fshould\fbe\fchecked\fthrough\fthe\fn e
ck\fof\fthe\fcool\bnt\fexp\bnsion\ft\bnk\f
Item
1
2
3
4
5
6
\f
Part Number -
-
-
-
-
-
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Page 1283 of 4402
Engine C\b\bling - 2\f0L Duratec-HE
(107kW/145PS) - MI4/2\f0L Duratec-HE
Flex Fuel (107kW/145PS) - MI4/2\f3L
Duratec-HE (118kW/160PS) - MI4 -
Engine C\b\bling
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Diagn\bsis and Testing
Special T\b\bl(s)
Gen
eral Equipment
Inspecti\bn and Verificati\bn 1. 1\f
Verify\fthe\fcustomer\fconcern.\f
2
. 2\f
Visu\blly\finspect\ffor\fobvious\fsigns\fof\fmech\bnic\bl\for\felectric\bl\fd\bm\bge.\f
V
isual Inspecti\bn Chart
3. 3\f
If\f\bn\fobvious\fc\buse\ffor\f\bn\fobserved\for\freported\fconcern\fis\ffound,\fcorrect\fthe\fc\buse\f
(if\fpossible)\fbefore\fproceeding\fto\fthe\fnext\fstep\f
4. 4\f
If\fthe\fc\buse\fis\fnot\fvisu\blly\fevident,\fverify\fthe\fsymptom\f\bnd\frefer\fto\fthe\fSymptom\f
C
h\brt.\f
Sympt\bm Chart
Pressure\fTester,\fCooling\fSystem\f
303-396\f(24-001\fA)\f
Ad\bptor\ffor\f303-396\f
303-396-09\f
Ford\f\bpproved\fdi\bgnostic\ftool
Mechanica\bE\bectrica\b
Cool\bnt\fle\bk(s)\f\f
G\bsket(s)\for\fse\bl(s)\f\f
Hose(s)\for\fhose\fjoints\f\f
Cool\bnt\fexp\bnsion\ft\bnk\fc\bp\f\bnd\fse\bl\f
\f
Cool\bnt\fexp\bnsion\ft\bnk\f\f
R\bdi\btor\f\f
Cool\bnt\fpump\f\f
Thermost\bt\fhousing\f\f
He\bter\fcore\f\f
Accessory\fdrive\fbelt\f\f
Cool\bnt\foutlet\fconnector\f
Fuse(s)\f\f
Wiring\fh\brness\f\f
Electric\bl\fconnector(s)\f\f
Engine\fcool\bnt\ftemper\bture\f(ECT)\fsensor\f
\f
Cooling\ff\bn\f\f
Powertr\bin\fcontrol\fmodule\f(PCM)\f
\fymptomPossib\be \fourcesAction
Loss\fof\fcool\bntHose(s)\for\f
hose\fjoint(s).\f
*INSPECT\fthe\fhoses\f\bnd\fhose\fjoints.\fINSTALL\f\b\fnew\f
hose(s)\f\bs\fnecess\bry.\f
*
R\bdi\btor.\f
*INSPECT\fthe\fr\bdi\btor\ffor\fle\bks.\fCARRY\fOUT\fthe\f
Pressure\fTest\fComponent\fTest\fin\fthis\fsection.\fINSTALL\f
\b\fnew\fr\bdi\btor\f\bs\fnecess\bry.\f\f
*
\f
\f
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Page 1284 of 4402
REFER\fto:\fR\bdi\btor\f(303-03A\fEngine\fCooling\f-\f2.0L\f
Dur
\btec-HE\f(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\f
Flex\fFuel\f(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\fInst\bll\btion).\f
Cool\bnt\fpump.\f
*INSPECT\fthe\fcool\bnt\fpump\ffor\fle\bks.\fCARRY\fOUT\fthe\f
Pressure\fTest\fComponent\fTest\fin\fthis\fsection.\fINSTALL\f
\b\fnew\fcool\bnt\fpump\for\fcool\bnt\fpump\fg\bsket\f\bs\f
necess\bry.\f\f
REFER\fto:\f Cool\bnt\fPump \f(303-03A\fEngine\fCooling\f-\f
2.0
L\fDur\btec-HE\f(107kW/145PS)\f-\fMI4/2.0L\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
*
Thermost\bt\f
housing.\f
*INSPECT\fthe\fthermost\bt\fhousing\ffor\fle\bks.\fCARRY\f
OUT\fthe\fPressure\fTest\fComponent\fTest\fin\fthis\fsection.\f
INSTALL\f\b\fnew\fthermost\bt\fhousing\f\bnd\fthermost\bt\f
housing\fg\bsket\f\bs\fnecess\bry.\f\f
REFER\fto:\f
Thermost\bt\f-\f2.0L\fDur\btec-HE\f
(10
7kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\fFuel\f
(107kW/145PS)\f-\fMI4\f(303-03A\fEngine\fCooling\f-\f2.0L\f
Dur
\btec-HE\f(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\f
Flex\fFuel\f(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\fInst\bll\btion).\f
*
Cool\bnt\f
exp\bnsion\ft\bnk\f
c\bp\for\fse\bl(s).\f
*CHECK\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fc\bp\ffor\ftightness\f
\bnd\fd\bm\bge.\fINSTALL\f\b\fnew\fcool\bnt\fexp\bnsion\fc\bp\f\bs\f
necess\bry.\f
*
Cool\bnt\f
exp\bnsion\ft\bnk.
\f
*INSPECT\fthe\fcool\bnt\fexp\bnsion\ft\bnk\ffor\fd\bm\bge.\f
INSTALL\f\b\fnew\fcool\bnt\fexp\bnsion\ft\bnk\f\bs\fnecess\bry.\f
*
He\bter\fcore.\f
*CHECK\fthe\fhe\bter\fcore\ffor\fle\bks.\f
*
Engine.\f
*INSPECT\fthe\fengine,\fcylinder\fhe\bd,\fcylinder\fblock\f\bnd\f
cylinder\fhe\bd\fg\bsket.\fREFER\fto:\f
Cylinder\fHe\bd\f(303-01A\fEngine\f-\f2.0L\fDur\btec-
HE\f
(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\fFuel\f
(107kW/145PS)\f-\fMI4,\fRemov\bl\f\bnd\fInst\bll\btion),
\f
Cylinder\fHe\bd\f(303-01C\fEngine\f-\f2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\fInst\bll\btion).\f
*
The\fengine\f
overhe\bts\f(signs\f
of\fcool\bnt\fboiling)Cooling\fsystem\f
does\fnot\fhold\f
pressure.\f
*
INSPECT\fthe\fcool\bnt\fexp\bnsion\ft\bnk\ffor\fd\bm\bge.\f
INSTALL\f\b\fnew\fcool\bnt\fexp\bnsion\ft\bnk\f\bs\fnecess\bry.\f
INSPECT\fthe\fcool\bnt\fpump\for\fcool\bnt\fpump\fg\bsket\ffor\f
d\bm\bge.\fINSTALL\f\b\fnew\fcool\bnt\fpump\for\fcool\bnt\f
pump\fg\bsket\f\bs\fnecess\bry.\f\f
REFER\fto:\f Cool\bnt\fPump \f(303-03A\fEngine\fCooling\f-\f
2.0
L\fDur\btec-HE\f(107kW/145PS)\f-\fMI4/2.0L\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
INSPECT\fthe\fengine,\fcylinder\fhe\bd,\fcylinder\fblock\f\bnd\f
cylinder\fhe\bd\fg\bsket.\fREFER\fto:\f Cylinder\fHe\bd\f(303-01A\fEngine\f-\f2.0L\fDur\btec-
HE\f
(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\fFuel\f
(107kW/145PS)\f-\fMI4,\fRemov\bl\f\bnd\fInst\bll\btion),
\f
Cylinder\fHe\bd\f(303-01C\fEngine\f-\f2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\fInst\bll\btion).\f
*
*
*
Air\fin\fcooling\f
system.\f
*BLEED\fthe\fcooling\fsystem.\f\f
REFER\fto:\f Cooling\fSystem\fDr\bining,\fFilling\f\bnd\f
Ble
eding \f(303-03A\fEngine\fCooling\f-\f2.0L\fDur\btec-HE\f
(10
7kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\fFuel\f
(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fGener\bl\fProcedures).\f
*
Cool\bnt\f
exp\bnsion\ft\bnk\f
*CHECK\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fc\bp\ffor\ftightness\f
\bnd\fd\bm\bge.\fINSTALL\f\b\fnew\fcool\bnt\fexp\bnsion\fc\bp\f\bs\f
*
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