Ford Galaxy / Ford S-MAX. Manual — part 242

2.0L Duratorq-TDCi (85kW/115PS) - DW/2.0L
Duratorq-TDCi (100kW/136PS) - DW/2.0L
Duratorq-TDCi (103kW/140PS) - DW, Emission
Requirements: Stage IV, Removal and
Installation).

37.

38.

NOTE: The seal is to be reused unless
damaged.

Drain the engine oil into a suitable container.

39. Remove the oil pan retaining nuts and bolts.

40.

CAUTION: Take extra care not to

damage the mating faces.

Special Tool(s):

303-633

,

205-047

41.

42.

43.

44.

NOTE: Note the position of each component
before removal.

Discard the connecting rod bearing cap retaining
bolts.

45.

NOTE: Note the position of the bearing caps
in relation to the rotation of the crankshaft.
The bearing caps are not interchangeable.

Discard the crankshaft main bearing cap
retaining bolts.

Engine - 1.8L Duratorq-TDCi
(74kW/100PS) - Lynx/1.8L Duratorq-
TDCi (92kW/125PS) - Lynx - Engine

S-MAX/Galaxy 2006.5 (02/2006-)

Print

Assembly

Special Tool(s)

Materials

205-072
Universal Flange Holding Wrench

303-122
Lifting Bracket, Engine

303-193
Timing Peg, Crankshaft TDC

303-376B
Alignment Plate, Camshaft

303-393
Locking Tool, Flywheel

303-435
Mounting Stand

303-435-06
Mounting Bracket for 303-435

303-652
Aligner, Oil Pump

303-710
Timing Tool, Crankshaft

Name

Specification

Engine Oil - 5W-30

WSS-M2C912-A1

Flange Sealant - Anaerobic LP

WSK-M2G348-A7 / 5U7J-M2G348-BA

Silicone Sealant LB

WSE-M4G323-A4 / 2U7J-M4G323-AA

Spoiler Adhesive Kit 2 Component WSK-M5B401-A1 / 2U7J-M2G376-AA

1. Coat the crankshaft main bearing journals,

bearing shells and thrust half washers with clean
engine oil.

Material:

Engine Oil - 5W-30 (WSS-M2C912-A1)

2.

CAUTION: Make sure that new bearing

cap retaining bolts are installed.

Tighten the crankshaft main bearing cap
retaining bolts in the sequence shown.

Torque:

45 Nm
70 Nm
60°

Stage 1:
Stage 2:
Stage 3:

3.

Coat the cylinder bores with clean engine
oil.
The piston ring gaps and oil supply ring
elements must be distributed evenly
around the circumference of the piston.
Install the pistons with the arrows pointing
towards the front of the engine.
Using a suitable piston ring compressor,
install the pistons.

4.

Lubricate the connecting rod journals with
clean engine oil.
The connecting rod identification marks
must point towards the front of the engine.

CAUTION: Make sure that new

connecting rod bearing caps retaining
bolts are installed.

Start tighten the connecting rod bearing
caps retaining bolts finger tight.

Torque:

27 Nm
60°
20°

Stage 1:
Stage 2:
Stage 3:

5. The chain housing bottom sealing flange

surfaces must be within +/- 0,26mm of the
cylinder block bottom sealing flange
surfaces.

Torque:

23 Nm

6.