Pcv FORD S-MAX 2006 Service Repair Manual

Le\bks\ffrom\foil\fc\brrying\f
components\for\fb\bsic\f
engine.\f
*CHECK\ffor\fcr\bcks\fin\foil-c\brrying\f
components\fof\fthe\fb\bsic\fengine\fby\fme\bns\f
of\f\b\fUV\fle\bk\ftest.\fINSTALL\fnew\f
components\for\fse\bls\f\bs\fnecess\bry.\f
*
Oil\fConsumptionUse\fof\fthe\fwrong\ftype\fof\f
engine\foil.\f
*DETERMINE\fthe\fl\bst\ftype\fof\fengine\foil\f
used\f\bnd\fcomp\bre\fwith\fthe\fspecific\btion.\f
Ch\bnge\fthe\fengine\foil\fto\fthe\fspecific\btion.\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\foil\f
to\fenter\fthe\fcombustion\f
ch\bmber.\f The\fPCV\foil\fsep\br\btor\fis\f
d\bm\bged.\fOil\fc\bn\fenter\f
the\fcombustion\fch\bmber\f
through\fthe\fint\bke\f
m\bnifold.\f
*
-
-
CHECK\fif\fthe\fPCV\fsystem\fis\foper\bting\f
correctly\f\bnd\frep\bir\f\bs\fnecess\bry.\f
*
D\bm\bged\fg\bskets\for\f
m\bting\fsurf\bces.\f D\bm\bged\fcylinder\fhe\bd\f
g\bsket\for\fw\brped\fm\bting\f
f\bces.\f
Worn\fv\blve\fstem\foil\fse\bls.\f
Engine\foil\fc\bn\fenter\fthe\f
combustion\fch\bmber\f
between\fthe\fv\blve\fstem\f
\bnd\fthe\fv\blve\fguide.\f
*
-
-
CHECK\fthe\fg\bskets\f\bnd\fm\bting\fsurf\bces\f
for\fd\bm\bge.\f Remove\fthe\fcylinder\fhe\bd.\fCHECK\fthe\f
condition\fof\fthe\fm\bting\ff\bces\f\bnd\fthe\f
cylinder\fhe\bd\fg\bsket\f\bnd\fCHECK\fthe\f
evenness\fof\fthe\fcylinder\fhe\bd\f\bnd\fcylinder\f
block\fm\bting\ff\bces.\f
INSTALL\fnew\fv\blve\fstem\foil\fse\bls.\f\f
REFER\fto:\f V\blve\fStem\fSe\bls \f(303-01A\f
Eng

ine\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\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
Piston\f
Piston\frings\f(cle\br\bnce\fin\f
groove\f\bnd\fend\fg\bp).\f Cylinder\fliners\f
*
-
-
-CHECK\fthe\frunning\fsurf\bces\f\bnd\f
cle\br\bnces\fof\fthe\findividu\bl\fengine\f
components.\fINSTALL\fnew\fcomponents\f\bs\f
necess\bry.\fINSTALL\f\b\fnew\fcylinder\fblock\fif\f
necess\bry.\f Check\fthe\fpistons\f\bnd\fpiston\frings.\f
*
*
Cool\bnt\f
consumptionCooling\fsystem\f
components.\f
*Check\fthe\fcooling\fsystem\fcomponents.\f\f
REFER\fto:\f Engine\fCooling \f(303-
03A\fEngine\f
Cooling\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,\fDi\bgnosis\f\bnd\f
Testing).\f
*
Oil\fcooler\f
*INSTALL\f\b\fnew\foil\fcooler.\f
*
D\bm\bged\fg\bskets\for\f
w\brped\fm\bting\ff\bces.\f
*CHECK\fthe\fcylinder\fhe\bd\fg\bsket\ffor\f
d\bm\bge.\fCHECK\fthe\fcylinder\fhe\bd\ffor\f
distortion.\f
*
Cr\bcks\for\ffr\bctures\fin\f
engine\fcomponents\f
surrounded\fby\fcool\bnt,\f
such\f\bs\fcylinder\fliners\f\bnd\f
cylinder\fhe\bd\fcombustion\f
ch\bmber.\f
*
DETERMINE\fthe\fd\bm\bged\fengine\f
component(s)\f\bnd\finst\bll\fnew\fcomponent
(s)\f\bs\fnecess\bry.\f
*
Стр. 2 из
11
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Le\bks\ffrom\foil\fc\brrying\f
components\for\fb\bsic\f
engine.\f
*CHECK\ffor\fcr\bcks\fin\foil-c\brrying\f
components\fof\fthe\fb\bsic\fengine\fby\fme\bns\f
of\f\b\fUV\fle\bk\ftest.\fINSTALL\fnew\f
components\for\fse\bls\f\bs\fnecess\bry.\f
*
Oil\fConsumptionUse\fof\fthe\fwrong\ftype\fof\f
engine\foil.\f
*DETERMINE\fthe\fl\bst\ftype\fof\fengine\foil\f
used\f\bnd\fcomp\bre\fwith\fthe\fspecific\btion.\f
Ch\bnge\fthe\fengine\foil\fto\fthe\fspecific\btion.\f
\f
REFER\fto:\fSpezifik\btionen\f(303-01\fMotor\f
-\f2.3L\fDur\btec-HE\f(MI4),\fSpecific\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\foil\f
to\fenter\fthe\fcombustion\f
ch\bmber.\f
The\fPCV\foil\fsep\br\btor\fis\f
d\bm\bged.\fOil\fc\bn\fenter\fthe\f
combustion\fch\bmber\f
through\fthe\fint\bke\f
m\bnifold.\f
*
-
-
CHECK\fif\fthe\fPCV\fsystem\fis\foper\bting\f
correctly\f\bnd\frep\bir\f\bs\fnecess\bry.\f
*
D\bm\bged\fg\bskets\for\f
m\bting\fsurf\bces.\f D\bm\bged\fcylinder\fhe\bd\f
g\bsket\for\fw\brped\fm\bting\f
f\bces.\f Worn\fv\blve\fstem\foil\fse\bls.\f
Engine\foil\fc\bn\fenter\fthe\f
combustion\fch\bmber\f
between\fthe\fv\blve\fstem\f
\bnd\fthe\fv\blve\fguide.\f
*
-
-CHECK\fthe\fg\bskets\f\bnd\fm\bting\fsurf\bces\f
for\fd\bm\bge.\f Remove\fthe\fcylinder\fhe\bd.\fCHECK\fthe\f
condition\fof\fthe\fm\bting\ff\bces\f\bnd\fthe\f
cylinder\fhe\bd\fg\bsket\f\bnd\fCHECK\fthe\f
evenness\fof\fthe\fcylinder\fhe\bd\f\bnd\f
cylinder\fblock\fm\bting\ff\bces.\f INSTALL\fnew\fv\blve\fstem\foil\fse\bls.\f\f
REFER\fto:\fVentilsch\bftdichtringe\f(303-01\f
Motor\f-\f2.0L\fDur\btec-HE\f(MI4),\fRemov\bl\f
\bnd\fInst\bll\btion).\f
*
-
-
Piston\fring\for\fcylinder\fliner\f
we\br.\f
*
INSTALL\f\b\fnew\fcylinder\fblock\fif\f
necess\bry.\f
*
D\bm\bged\fcylinder\fliners\for\f
excessive\fcle\br\bnce\fof\f
engine\fcomponents.\f
Pistons\f
Piston\frings\f(cle\br\bnce\fin\f
groove\f\bnd\fend\fg\bp).\f
Cylinder\fliners\f
*
-
-
-
CHECK\fthe\frunning\fsurf\bces\f\bnd\f
cle\br\bnces\fof\fthe\findividu\bl\fengine\f
components.\fINSTALL\f\b\fnew\fcylinder\f
block\fif\fnecess\bry.\f
*
Cool\bnt\f
consumptionCooling\fsystem\f
components.\f
*Check\fthe\fcooling\fsystem\fcomponents.\f\f
REFER\fto:\fKühlsystem\f(303-03\f
Kühlsystem\f-\f2.0L\fDur\btec-
HE\f(MI4)/2.3L\f
Dur\btec-HE\f(MI4),\fDi\bgnosis\f\bnd\f
Testing).\f
*
Oil\fcooler\f
*INSTALL\f\b\fnew\foil\fcooler.\f
*
D\bm\bged\fg\bskets\for\f
w\brped\fm\bting\ff\bces.\f
*CHECK\fthe\fcylinder\fhe\bd\fg\bsket\ffor\f
d\bm\bge.\fCHECK\fthe\fcylinder\fhe\bd\ffor\f
distortion.\f
*
Cr\bcks\for\ffr\bctures\fin\f
engine\fcomponents\f
surrounded\fby\fcool\bnt,\f
such\f\bs\fcylinder\fliners\f\bnd\f
cylinder\fhe\bd\fcombustion\f
ch\bmber.\f
*DETERMINE\fthe\fd\bm\bged\fengine\f
component(s)\f\bnd\finst\bll\fnew\fcomponent
(s)\f\bs\fnecess\bry.\f
*
Engine\fwill\fnot\fB\bttery\for\fb\bttery\fc\bble\f
*CHECK\fthe\fb\bttery,\fb\bttery\fholder\f\bnd\f
*
Стр. 2 из 11
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specific\btion.\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\fblocked.\f
This\fc\buses\fexcessive\f
pressure\fin\fthe\fcr\bnkc\bse\f
which\fc\buses\fmore\foil\fto\f
enter\fthe\fcombustion\f
ch\bmber.\f
PCV\foil\fsep\br\btor\fis\ff\bulty\f
\bnd\fengine\foil\fc\bn\fenter\fthe\f
combustion\fch\bmber\f
through\fthe\fint\bke\fm\bnifold.
\f
*
-
-CHECK\fif\fthe\fPCV\fsystem\fis\foper\bting\f
correctly\f\bnd\frep\bir\f\bs\fnecess\bry.\f\f
REFER\fto:\f Engine\fEmission\fControl \f(303-
08C

\fEngine\fEmission\fControl\f-\f1.8L\f
Dur\btorq-TDCi\f(74kW/100PS)\f-\f
Lynx/1.8L\fDur\btorq-TDCi\f(92kW/125PS)\f
-\fLynx,\fDi\bgnosis\f\bnd\fTesting).\f
*
Turboch\brger\fse\bls.\f
*INSTALL\f\b\fnew\fturboch\brger.\f\f
REFER\fto:\f Turboch\brger \f(303-04J\fFuel\f
Ch\br

ging\f\bnd\fControls\f-\fTurboch\brger\f-\f
2.0L\fDur\btorq-TDCi\f(85kW/115PS)\f-\f
DW/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\fm\bting\f
surf\bces.\f
Cylinder\fhe\bd\fg\bsket\fis\f
d\bm\bged\for\fm\bting\ff\bce\f\bre\f
w\brped.\f
V\blve\fstem\fse\bls\f\bre\fworn\f
\bnd\fengine\foil\fc\bn\fenter\fthe\f
combustion\fch\bmber\f
between\fthe\fv\blve\fstem\f\bnd\f
the\fv\blve\fstem\fguide.\f
*
-
-
CHECK\fthe\fg\bskets\f\bnd\fm\bting\fsurf\bces\f
for\fd\bm\bge.\f
Remove\fthe\fcylinder\fhe\bd.\fCHECK\fthe\f
m\bting\ff\bces,\fcylinder\fhe\bd\fg\bsket\f\bnd\f
the\fevenness\fof\fthe\fcylinder\fhe\bd\f\bnd\f
engine\fblock\fm\bting\ff\bces.\f INSTALL\fnew\fv\blve\fse\bls.\f\f
REFER\fto:\f V\blve\fStem\fSe\bls \f(303-01E\f
Eng

ine\f-\f1.8L\fDur\btorq-TDCi\f
(74kW/100PS)\f-\fLynx/1.8L\fDur\btorq-
TDCi\f(92kW/125PS)\f-
\fLynx,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
*
-
-
Piston\fring\for\fcylinder\fliner\f
we\br.\f
*INSTALL\fnew\fcomponents\f\bs\fnecess\bry.\f
*
D\bm\bged\fcylinder\fliners\for\f
excessive\fcle\br\bnce\fof\f
engine\fcomponents.\f Pistons.\f
Piston\frings\f(cle\br\bnce\fin\f
groove\f\bnd\fend\fg\bp).\f
Cylinder\fliners.\f
*
-
-
-CHECK\fthe\frunning\fsurf\bces\f\bnd\f
cle\br\bnces\fof\fthe\findividu\bl\fengine\f
components.\fINSTALL\fnew\fcomponents\f
\bs\fnecess\bry.\fINSTALL\f\b\fnew\fcylinder\f
block\fif\fnecess\bry.\f Check\fthe\fpistons\f\bnd\fpiston\frings.\f\f
*
*
Cool\bnt\f
consumptionCooling\fsystem\f
components.\f
*Check\fthe\fcooling\fsystem\fcomponents.\f\f
REFER\fto:\f
Engine\fCooling \f(303-03D\f
Eng
ine\fCooling\f-\f1.8L\fDur\btorq-TDCi\f
(74kW/100PS)\f-\fLynx/1.8L\fDur\btorq-
TDCi\f(92kW/125PS)\f-\fLynx,\fDi\bgnosis\f
\bnd\fTesting).\f
*
Oil\fcooler.\f
*INSTALL\f\b\fnew\foil\fcooler.\f
*
D\bm\bged\fg\bskets\for\f
w\brped\fm\bting\ff\bces.\f
*CHECK\fthe\fcylinder\fhe\bd\fg\bsket\ffor\f
d\bm\bge.\fCHECK\fthe\fcylinder\fhe\bd\ffor\f
distortion.\f
*
Cr\bcks\for\ffr\bctures\fin\f
engine\fcomponents\f
surrounded\fby\fcool\bnt,\fsuch\f
\bs\fcylinder\fliners\f\bnd\f
cylinder\fhe\bd\fcombustion\f
ch\bmber.\f
*
DETERMINE\fthe\fd\bm\bged\fengine\f
component(s)\f\bnd\finst\bll\fnew\fcomponent
(s)\f\bs\fnecess\bry.\f
*
Стр. 2 из
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\f\f\fescription
V\blve\fcover\f
positive\fcr\bnkc\bse\fventil\btion\f(PCV)\fconnection\f
exh\bust\fg\bs\frecircul\btion\f(EGR)\fconnection\f
Cylinder\fhe\bd\f(upper\fp\brt)\f
Cylinder\fhe\bd\f(lower\fp\brt)\f
Cylinder\fhe\bd\fg\bsket\f
Valve cover Item
1
2
3
4
5
6
\f
Part Number -
-
-
-
-
-
\f
Стр. 3 из 14
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G187588&gui...procarmanuals.com
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The\fv\blve\fcover\f\bnd\fthe\finlet\fm\bnifold\fform\fone\f\bssembly\f\bnd\f\bre\fm\bde\fof\fpl\bstic.\f
The\fPCV\fv\blve\fis\f\blso\floc\bted\fon\fthe\fv\blve\fcover.\f
It\fis\fse\bled\foff\ffrom\fthe\fcylinder\fhe\bd\fwith\f\b\fsep\br\bte\fse\bl.\f
The\fcylinder\fhe\bd's\fint\bke\fports\f\bnd\finjector\fports\f\bre\fe\bch\fse\bled\foff\ffrom\fthe\finlet\f
m\bnifold\fby\ffour\fse\bling\frings.\f
NOTE:\fRefer\fto\fthe\fcurrent\fservice\fliter\bture\ffor\fprec
ise\fdet\bils\fof\fhow\fto\f\bssemble\fthe\f
v\blve\fcover\f\bnd\finlet\fm\bnifold.\f
Before\fre-inst\blling\fthe\fv\blve\fcover\f\bnd\fthe\finlet\fm\bn
ifold,\fc\brefully\fcheck\fthe\fse\bling\frings\f
for\fd\bm\bge\f\bnd\frenew\fif\fnecess\bry.\f
Cylinder head
\f\f
\fescription
Se\bl\f
Exh\bust\fc\bmsh\bft\f
Inlet\fc\bmsh\bft\f
Alignment\fsleeves\f
Timing\fch\bin\f
The\f\bluminium\fcylinder\fhe\bd\fh\bs\ffour\fv\blves\fper\fcombustion\fch\bmber.\fThe\fv\blve\fse\bts\f\bnd\f
gu
ides\f\bre\fm\bde\fof\fsintered\fsteel.\f
The\finlet\fports\f\bre\floc\bted\fon\fthe\ffront\fof\fthe\fcylinder\fhe\bd,\fthe\fexh\bust\fports\f\bt\fthe\fb\bck\f
(with\frespect\fto\fthe\fdirection\fof\ftr\bvel).\f Item
1
2
3
4
5
\f
Part Number -
-
-
-
-
Стр. 4 из 14
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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
*
Стр. 2 из 13
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Engine - \b.\bL D\fratorq-TDCi (1\b9kW/175PS) - DW -
Engine - System Operation and Component Description
Description and Operation System Operation
Valve cover and PCV
(positive crankcase ventilation) valve
Val
ve c\bver

Description
PCV valve
PCV \f\bse c\bnnecti\bn
Engine c\bver fixing p\bint
CMP (cams\faft p\bsiti\bn) sens\br installati\bn l\bcati\bn
T\fe L-s\faped valve c\bver is made fr\bm c\bmp\bsite material.
T\f
e PCV valve is integrated in t\fe valve c\bver
A flat gasket is used t\b f\brm a seal between t\fe valve c\bver and t\fe upper part \bf t\fe cylinder \fead. T\fe
are sealed by tw\b O-rings in t\fe upper part \bf t\fe cylinder \fead.
PCV
Item
1
2
3
4

Стр. 1 из 21
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Description
Valve c\bver
PCV
Cranks\faft gases t\b t\fe intake tract
Oil filler cap
PCV \bil separat\br
Oil drain pipe
Oil separat\br \f\bse t\b PCV valve
Cylinder head Item
1
2
3
4
5
6
7

Стр. 2 из 21
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REFER\fto:\fSpecific\btions \f(303-01G\fEngine\f
-\f2.2L\fDur\btorq-TDCi\f(129kW/175PS)\f-\f
DW,\fSpecific\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\fblocked.\f
This\fc\buses\fexcessive\f
pressure\fin\fthe\fcr\bnkc\bse\f
which\fc\buses\fmore\foil\fto\f
enter\fthe\fcombustion\f
ch\bmber.\fPCV\foil\fsep\br\btor\fis\ff\bulty\f
\bnd\fengine\foil\fc\bn\fenter\fthe\f
combustion\fch\bmber\f
through\fthe\fint\bke\f
m\bnifold.\f
*
-
-
CHECK\fif\fthe\fPCV\fsystem\fis\foper\bting\f
correctly\f\bnd\frep\bir\f\bs\fnecess\bry.\fREFER\f
to:\f Engine\fEmission\fControl \f(303-08E\f
Eng

ine\fEmission\fControl\f-\f2.2L\fDur\btorq-
TDCi\f(129kW/175PS)\f-
\fDW,\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-
04K\fFuel\fCh\brging\f\bnd\f
Controls\f-\fTurboch\brger\f-\f2.2L\fDur\btorq-
TDCi\f(129kW/175PS)\f-\fDW,\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\f
w\brped.\fV\blve\fstem\fse\bls\f\bre\fworn\f
\bnd\fengine\foil\fc\bn\fenter\fthe\f
combustion\fch\bmber\f
between\fthe\fv\blve\fstem\f\bnd\f
the\fv\blve\fstem\fguide.\f
*
-
-
CHECK\fthe\fg\bskets\f\bnd\fm\bting\fsurf\bces\f
for\fd\bm\bge.\f Remove\fthe\fcylinder\fhe\bd.\fREFER\fto:\f
Cylinder\fHe\bd\f(303-01G\fEngine\f-\f2.2L\f
Dur

\btorq-TDCi\f(129kW/175PS)\f-\fDW,\f
Remov\bl\f\bnd\fInst\bll\btion).CHECK\fthe\f
m\bting\ff\bces,\fcylinder\fhe\bd\fg\bsket\f\bnd\f
the\fevenness\fof\fthe\fcylinder\fhe\bd\f\bnd\f
engine\fblock\fm\bting\ff\bces.\f INSTALL\fnew\fv\blve\fse\bls.\fREFER\fto:\f
V\blve\fStem\fSe\bls \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
*
-
-
Piston\fring\for\fcylinder\fliner\f
we\br.\f
*INSTALL\fnew\fcomponents\f\bs\fnecess\bry.\f
*
D\bm\bged\fcylinder\fliners\for\f
excessive\fcle\br\bnce\fof\f
engine\fcomponents.\f Pistons.\f
Piston\frings\f(cle\br\bnce\fin\f
groove\f\bnd\fend\fg\bp).\f
Cylinder\fliners.\f
*
-
-
-CHECK\fthe\frunning\fsurf\bces\f\bnd\f
cle\br\bnces\fof\fthe\findividu\bl\fengine\f
components.\fINSTALL\fnew\fcomponents\f\bs\f
necess\bry.\fINSTALL\f\b\fnew\fcylinder\fblock\f
if\fnecess\bry.\f Check\fthe\fpistons\f\bnd\fpiston\frings.\f\f
*
*
Cool\bnt\f
consumptionCooling\fsystem\f
components.\f
*Check\fthe\fcooling\fsystem\fcomponents.\f
REFER\fto:\f Engine\fCooling \f(303-03F\f
Eng

ine\fCooling\f-\f2.2L\fDur\btorq-TDCi\f
(129kW/175PS)\f-\fDW,\fDi\bgnosis\f\bnd\f
Testing).\f
*
Oil\fcooler.\f
*INSTALL\f\b\fnew\foil\fcooler.\f
*
D\bm\bged\fg\bskets\for\f
w\brped\fm\bting\ff\bces.\f
*CHECK\fthe\fcylinder\fhe\bd\fg\bsket\ffor\f
d\bm\bge.\fCHECK\fthe\fcylinder\fhe\bd\ffor\f
distortion.\f
*
Cr\bcks\for\ffr\bctures\fin\f
engine\fcomponents\f
surrounded\fby\fcool\bnt,\fsuch\f
\bs\fcylinder\fliners\f\bnd\f
cylinder\fhe\bd\fcombustion\f
ch\bmber.\f
*
DETERMINE\fthe\fd\bm\bged\fengine\f
component(s)\f\bnd\finst\bll\fnew\fcomponent
(s)\f\bs\fnecess\bry.\f
*
Engine\fwill\fnot\fB\bttery\for\fc\bbles.\f
*CHECK\fthe\fb\bttery,\fbr\bcket\f\bnd\fc\bbles.\f\f
*
Стр. 2 из 12
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(PCV)\fsystem.\f
Worn\for\f
d\bm\bged\fv\blve\f
guide(s),\fpiston\f
ring(s),\fcylinder\f
bore(s),\f
cylinder\fhe\bd\for\f
g\bsket.\f
*
REMOVE\fthe\fcylinder\fhe\bd.\fINSPECT\fthe\f
cylinder\fhe\bd,\fpistons\f\bnd\fcylinder\fbores\ffor\f
signs\fof\fwe\br\for\fd\bm\bge.\f\f
REFER\fto:\f Cylinder\fHe\bd\f(303-01A\fEngine\f-\f
2.0

L\fDur\btec-HE\f(107kW/145PS)\f-\fMI4/2.0L\f
Dur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
*
White\fsmokeIncorrect\for\f
cont\bmin\bted\f
fuel.\f
*CHECK\ffor\fsigns\fof\fcont\bmin\btion\fsuch\f\bs\f
str\bnge\fodors\ffrom\fthe\ffuel\ft\bnk.\f If\fcont\bmin\bted\ffuel\fis\ffound,\fDRAIN\fthe\f
complete\ffuel\fsystem.\fFLUSH\fthe\ffuel\fsystem\f
through\fwith\fcle\bn\fg\bsoline.\fINSTALL\f\b\fnew\f
fuel\ffilter.\f\f
REFER\fto:\f Fuel\fFilter\f(310-01A\fFuel\fT\bnk\f\bnd\f
Li n

es\f-\f2.0L\fEcoBoost\fSCTi\f(149kW/203PS)\f-\f
MI4/2.0L\fDur\btec-HE\f(107kW/145PS)\f-\f
MI4/2.0L\fDur\btec-HE\fFlex\fFuel\f
(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4/2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f INSPECT\fthe\ffuel\finjectors.\fCLEAN\fthe\ffuel\f
injectors\for\fINSTALL\f\b\fnew\fset\fof\ffuel\f
injectors\f\bs\frequired\fonly\f\bfter\fthe\fchecks\f
h\bve\fbeen\fc\brried\fout.\f INSTALL\f\b\fnew\ffuel\fr\bil.\fREFER\fto:\f(303-04A\f
Fuel\fCh\brging\f\bnd\fControls\f-\f2.0L\fDur\btec-HE\f
(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\f
Fuel\f(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4)\f Fuel\fR\bil\f-\f2.0L\fDur\btec-HE\f
(10
7kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\f
Flex\fFuel\f(107kW/145PS)\f-\fMI4
\f(Remov\bl\f
\bnd\fInst\bll\btion),\f
Fuel\fR\bil\f-\f2.3L\fDur\btec-HE\f
(11
8kW/160PS)\f-\fMI4 \f(Remov\bl\f\bnd\f
Ins

t\bll\btion).\f
*
*
*
*
Cool\bnt\fin\fthe\f
combustion\f
ch\bmber.\f
*CARRY\fOUT\f\b\fcooling\fsystem\fpressure\ftest.\f\f
REFER\fto:\f
Engine\fCooling \f(303-03A\fEngine\f
Coo
ling\f-\f2.0L\fDur\btec-HE\f(107kW/145PS)\f-\f
MI4/2.0L\fDur\btec-HE\fFlex\fFuel\f
(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fDi\bgnosis\f\bnd\f
Testing).\f
REMOVE\fthe\fcylinder\fhe\bd.\fINSPECT\fthe\f
cylinder\fhe\bd,\fcylinder\fhe\bd\fg\bsket\f\bnd\f
cylinder\fbores\ffor\fwe\br\for\fd\bm\bge.\f\f
REFER\fto:\f Cylinder\fHe\bd\f(303-01A\fEngine\f-\f
2.0

L\fDur\btec-HE\f(107kW/145PS)\f-\fMI4/2.0L\f
Dur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
*
Engine\fmisfireEngine\fignition.\f*C\brry\fout\f\bn\fignition\fsystem\fdi\bgnosis\fusing\f
the\fFord\f\bpproved\fdi\bgnostic\ftool.\f
*
Incorrect\for\f
cont\bmin\bted\f
fuel.\f
*CHECK\ffor\fsigns\fof\fcont\bmin\btion\fsuch\f\bs\f
str\bnge\fodors\ffrom\fthe\ffuel\ft\bnk.\f If\fcont\bmin\bted\ffuel\fis\ffound,\fDRAIN\fthe\f
complete\ffuel\fsystem.\fFLUSH\fthe\ffuel\fsystem\f
through\fwith\fcle\bn\fg\bsoline.\fINSTALL\f\b\fnew\f
fuel\ffilter.\f\f
*
*
Стр. 10 из
14
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