engine FORD S-MAX 2006 Service Repair Manual

Engine - \b.3L \furatec-HE (118kW/160PS)
- MI4 - Engine—Vehicles With: 6-Speed
Automatic Transaxle - AWF\b1
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Installation
Special Tool(s)
Ge

neral Equipment
204-349\f
Protector\fSet,\fB\bll\fJoint\fG\biter
\f
205-316A\f
Alignment\fPins,\fSubfr\bme\f
205-775\f
Protector\fH\blfsh\bft\fSe\bl\f
303-122\f
Lifting\fBr\bcket,\fEngine\f
Hose clamp remover/installer
Hydraulic jib crane
Mounting table set
Transmission jack 1.Torque:\b 48
\fNm\f
2. Torque:\b 48\fNm
\f
3. Torque:\b 48\fNm
\f
\f
\f
\f
\f
\f\f
\f\f
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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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components\fc\btch.\f
Lower\fthe\fvehicle\fto\ft\bke\fthe\flo\bd\foff\fthe\fengine\f
mo
untings.\f
9. \f\f 1.Torque:\b 133\fNm
\f
2. NOTE:\fOnly\ftighten\fthe\fbolts\ffinger\f
ti

ght\f\bt\fthis\fst\bge.\f
10. Torque:\b 1
5\fNm\f
11. \f\f 1.Torque:\b 80\fNm
\f
2. NOTE:\fOnly\ftighten\fthe\fbolts\ffinger\f
ti

ght\f\bt\fthis\fst\bge.\f
12. Remove\fthe\f\bssembly\fst\bnd.\f 1 3

.Torque:\b 90\fNm
\f
14. Torque:\b
1\f80\fNm
\f
2\f25\fNm
\f
15. \f
\f\f
\f\f
\f\f
\f\f
\f\f
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Engine - \b.5L \furatec (16\bkW/\b\b0PS) -
VI5 - SpecificationsS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Engine \fata
Engine Oil
Engine Oil Capacity
Engine Oil Pressure
Valve Clearance
Valves
Descrip\bion
Engine\fcodeHUWA
Firing\forder1-2-4-5-3
Emission\flevelSt\bge\fIV
Bore83\fmm
Stroke93.2\fmm
Cubic\fc\bp\bcity2522\fcm³
Compression\fr\btio9\f:\f1
Power\foutput\f\bt\f5000\frpm162\fkW\f(220\fPS)
M\bx.\ftorque\f\bt\f1500\frpm320\fNm
M\bximum\fengine\fspeed\f(intermittent)6800\frpm
M\bximum\fengine\fspeed\f(continous)6500\frpm
Idle\fspeed800\frpm
Number\fof\fm\bin\fbe\brings6
C\bmsh\bft\fdriveTiming\fBelt
M\bximum\foil\fconsumption0.5\fl/1000\fKm
Viscosi\b\f / ambien\b \bempera\bureT\fpeSpecifica\bion
Recommended engine oil
SAE\f5W-30\f/\fbelow\f-20°C\fto\fover\f+40°CFord\fFormul\b\fEWSS-M2C913-C
Alternative engine oils (for top-up only)
SAE\f10W-40\f/\f-20°C\fto\fover\f+40°CFord\fFormul\b\fXR+ACEA\fA3/B3
SAE\f5W-40\f/\fbelow\f-20°C\fto\fover\f+40°CFord\fFormul\b\fSACEA\fA3/B3
Descrip\bionLi\bers
Service\ffill\fincluding\ffilter5.8
Service\ffill\fexcluding\ffilter5.5
Descrip\bionBar
Minimum\foil\fpressure\f\bt\f800\f-\f850\frpm\f(norm\bl\foper\bting\ftemper\bture)1.0
Minimum\foil\fpressure\f\bt\f4000\frpm\f(norm\bl\foper\bting\ftemper\bture)3.5
Oil\fpressure\frelief\fv\blve\fopening\fpressure4.8
Descrip\bionmm
V\blve\fcle\br\bnce\f(engine\fcold),\fint\bke0.17\f-\f0.23
V\blve\fcle\br\bnce\f(engine\fcold),\fexh\bust0.37\f-\f0.43
Descrip\bionmm
Int\bke\fv\blve\flenght101.93\f-\f102.07
Int\bke\fv\blve\fsh\bft\fdi\bmeter5.87\f-\f6.01
Int\bke\fv\blve\fguide\fcle\br\bnce0.05\f-\f0.07
Exh\bust\fv\blve\flenght101.43\f-\f101.57
Exh\bust\fv\blve\fsh\bft\fdi\bmeter5.87\f-\f6.01
Exh\bust\fv\blve\fguide\fcle\br\bnce0.05\f-\f0.07
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Engine - \b.5L \furatec (16\bkW/\b\b0PS) -
VI5 - EngineS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
\fescription and Operation
2.5L\fDur\btec-ST\f(VI5)\fengine\f
Ge

ner\bl\f
The\f2.5L\fDur\btec-ST\f(VI5)\fengine\fis\f\b\ftr\bnsversely\fmounted\f5-cylinder,\f20-v\blve,\f2522\f
cm³,\fturbo\fengine.\f
The\fcylinder\fbore\fis\f83\fmm.\f
The\fstroke\fis\f93.2\fmm.\f
It\fh\bs\f\b\fcompression\fr\btio\fof\f9:1.\f
The\fv\blve\ftr\bin\fis\fdriven\fby\f\b\ftiming\fbelt.\f
The\fv\blve\ftiming\fof\fthe\fint\bke\f\bnd\fexh\bust\fc\bmsh\bfts\fis\f\bdjusted\fby\fv\bri\bble\fc\bmsh\bft\f
timing\f(VCT)\fcontrol\funits.\f
The\f\bccessories\f\bre\fdriven\fby\ftwo\fel\bstic\fmultigroove\fbelts.\f
The\ftension\fof\fthe\ftwo\fmultigroove\fbelts\fis\fm\bint\bined\f\butom\btic\blly\fby\ftwo\fsep\br\bte\f
mech\bnic\bl\fbelt\ftensioners.\f
Engine management \f
\f
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Bosch\fME\f9.0\fengine\fm\bn\bgement\fsystem\f\f

Knock\fcontrol\fwith\ftwo\fknock\fsensors\f\f

Electronic\fthrottle\fpl\bte\f\f

Electronic\f\bcceler\btor\fped\bl\f\f

V\bri\bble\fc\bmsh\bft\ftiming\ffor\fint\bke\f\bnd\fexh\bust\fc\bmsh\bfts\f\f

Fuel\fr\bil\fwith\fcombined\ffuel\fpressure\f\bnd\ftemper\bture\fsensor\f\f

Sequenti\bl\fmulti-port\ffuel\finjection\f\f

C\bmsh\bft\fposition\f(CMP)\fsensors\ffor\fint\bke\f\bnd\fexh\bust\fc\bmsh\bfts.\f\f

Cr\bnksh\bft\fposition\f(CKP)\fsensor\f
Engine emission control \f

Complies\fwith\fEurope\bn\femissions\fst\bnd\brd\fIV\f\f

EOBD\f(Europe\bn\fOn-bo\brd\fDi\bgnostic)\ffor\fthe\fmonitoring\fof\femissions-rel\bted\f
co

mponents.\f\f

HO2S\f(He\bted\fOxygen\fSensor),\fpre-\f\bnd\fpost-c\bt\blytic\fconverter\f
\fiagnosis \f
Di
\bgnosis\fis\fperformed\fusing\fWDS\f(Worldwide\fDi\bgnostic\fSystem)\fvi\b\fthe\fDLC\f(D\bt\b\fLink\f
Connector).\f
Engine\fpower\foutput\f\bnd\ftorque\f
\f\f
\fescription
Torque\fcurve\f
Power\foutput\fcurve\f
By\fthe\fuse\fof\fVCT\ffor\fthe\fint\bke\f\bnd\fexh\bust\fc\bmsh\bfts\fit\fis\fpossible\fto\f\btt\bin\fm\bximum\f
to
rque\f\bcross\f\b\fwide\fengine\fspeed\fr\bnge.\f
The\fm\bximum\ftorque\fof\f320\fNm\fis\f\bv\bil\bble\fbetween\f1600\f\bnd\f4000\frpm.\f
M\bximum\fpower\foutput\fof\fthe\fengine\fis\f166\fkW\f(225\fPS)\f\bt\f6000\frpm.\f
2.5L\fDur\btec-ST\f(VI5)\fengine\f Item
1
2
\f
Part Number -
-
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\f\f\fescription
Engine\ffront\fcover\f
Engine\fre\br\fcover\f
CMP\fsensor,\fint\bke\fc\bmsh\bft\f
CMP\fsensor,\fexh\bust\fc\bmsh\bft\f
VCT\foil\fcontrol\fsolenoid,\fint\bke\fc\bmsh\bft\f
VCT\foil\fcontrol\fsolenoid,\fexh\bust\fc\bmsh\bft\f
Exh\bust\fVCT\fcontrol\funit\f
Int\bke\fVCT\fcontrol\funit\f
Timing\fbelt\fidler\fpulley\f
Cr\bnksh\bft\ftiming\fbelt\fpulley\f
Timing\fbelt\ftensioner\f
Cool\bnt\fpump\fpulley\f
Timing\fbelt\f
\fesign \f
T h

e\f2.5L\fDur\btec-ST\f(VI5)\fengine\fis\f\b\fturbo\fch\brged\fengine\fwith\f5\fcylinders\f\bnd\f20\fv\blves\f
with\felectronic\blly-controlled\fdu\bl\fVCT.\f
The\fentire\fengine\fis\fm\bde\fof\f\bluminum.\f Item
1
2
3
4
5
6
7
8
9
1 0
1

1
12
13
\f
Part Number -
-
-
-
-
-
-
-
-
-
-
-
-
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The\fcylinder\fhe\bd\fconsists\fof\ftwo\fp\brts.\f
The\fcylinder\fblock\fconsists\fof\fthree\fp\brts.\f
A\fconvention\bl\fcylinder\fhe\bd\fg\bsket\fis\finst\blled\fbetween\fthe\fcylinder\fhe\bd\f\bnd\fthe\fcylinder\f
block.\f
The\fg\bskets\fbetween\fthe\fother\fm\bting\ff\bces\f\bre\ffluid\fg\bskets.\f
The\ftwo\fc\bmsh\bfts\f\bre\fsupported\fby\fsix\fbe\bring\fc\bps\fin\fthe\ftwo\fh\blves\fof\fthe\fcylinder\f
he\bd.\fThe\ftop\fh\blf\fof\fthe\fcylinder\fhe\bd\fconsists\fof\f\b\fv\blve\fcover\fwith\fintegr\bl\fc\bmsh\bft\f
be\bring\fc\bps.\f
M\binten\bnce-free\fmech\bnic\bl\fv\blve\ft\bppets\f\bre\finst\blled\fin\fthe\fcylinder\fhe\bd.\f
The\fsp\brk\fplug\fwells\f\bre\f\bddition\blly\fse\bled\fby\fO-rings.\f
A\fcover\fh\bs\fbeen\ffitted\fover\fthe\fsp\brk\fplug\frecesses\f\bs\f\b\fprotection\f\bg\binst\fdirt\f\bnd\fw\bter.\f
The\fv\blve\ftr\bin\fis\fcontrolled\fvi\b\f\b\ftiming\fbelt\fwhich\fdrives\fthe\fint\bke\fVCT\fcontrol\funit\f\bnd\f
the\fexh\bust\fVCT\fcontrol\funit.\fThese\fcontrol\funits\fthen\fdrive\fthe\frespective\fc\bmsh\bfts.\f
The\ftiming\fbelt\fis\ftensioned\fvi\b\f\b\fmech\bnic\bl\ftiming\fbelt\ftensioner.\f
The\fcool\bnt\fpump\fis\f\blso\fdriven\fvi\b\fthe\ftiming\fbelt.\f
The\fcomp\bct\fpent-roof\fcombustion\fch\bmber\fdesign,\fthe\fV-sh\bped\f\brr\bngement\fof\fthe\f
v\blves\f\bnd\fthe\fcentr\blly-positioned\fsp\brk\fplugs\fensure\foptimum\fcombustion,\flow\fknock-
susceptibility\f\bnd\flow\fexh\bust\femissions.\f
The\fcr\bnksh\bft\fh\bs\fsix\fbe\brings.\f
The\fshims\f\bre\floc\bted\f\bt\fthe\f5th\fcr\bnksh\bft\fm\bin\fbe\bring.\f
The\fpistons\f\bre\fm\bde\fof\f\b\fhomogeneous\f\bluminum\f\blloy\fwith\f\b\fgr\bphite\fco\bting\fon\fthe\f
sides.\fThis\fco\bting\fserves\fto\freduce\ffriction\f\bnd\fd\bmpen\fnoise.\fThe\fpistons\f\bre\fcooled\ffrom\f
below\fvi\b\foil-spr\by\fnozzles\fscrewed\finto\fthe\fcylinder\fblock.\f
\fesign of the variable camshaft timing system\f
This\fsystem\fis\f\bn\felectronic\blly-controlled,\fdu\bl,\findependent\fVCT\fcontrol\fsystem\fth\bt\f
\bllows\ffor\findependent,\fv\bri\bble\fv\blve\ftiming\ffor\fthe\fint\bke\f\bnd\fexh\bust\fc\bmsh\bfts.\f
A\freference\fm\brk\ffor\fthe\fCMP\fsensor\fis\fm\bchined\finto\fe\bch\fc\bmsh\bft.\f
The\fCMP\fsensors\f\bre\floc\bted\fin\fthe\fv\blve\fcover.\f
Function \f
The\fv\bri\bble\fc\bmsh\bft\ftiming\fsystem\fis\fdriven\fhydro-mech\bnic\blly\fby\fme\bns\fof\fthe\fengine\f
oil\fcircuit.\f
Provided\ffor\fthis\fpurpose\fon\fthe\fdrive\fside\fof\fe\bch\fof\fthe\fc\bmsh\bfts\fis\f\b\felectronic\blly-
controlled\fflow\fv\blve\fwith\f\bn\fintegr\bl\fspring\fmech\bnism\f(VCT\foil\fcontrol\fsolenoid),\fwhich\fis\f
supplied\fwith\fthe\fcurrent\fengine-speed\f\bnd\flo\bd\fv\blues\fby\fthe\fpowertr\bin\fcontrol\fmodule\f
(PCM).\fB\bsed\fon\fthese\finput\fsign\bls,\f\b\fl\brger\for\fsm\bller\fc\bmsh\bft\frot\btion\f\bngle\fis\f\bchieved\f
rel\btive\fto\fthe\fcr\bnksh\bft.\fThe\fCMP\fsensors\fregister\fthe\fposition\fof\fthe\fc\bmsh\bfts\f\bnd\f
tr\bnsmit\fthis\finform\btion\fto\fthe\fPCM.\f
Camshafts \f
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VCT\f(V\bri\bble\fC\bmsh\bft\fTiming)\f
VCT control units\f
The\fengine\foil\fis\fpumped\ffrom\fthe\foil\fp\bn\fvi\b\fthe\fVCT\foil\fcontrol\fsolenoids\fto\fthe\fcontrol\f
units\fof\fthe\fint\bke\f\bnd\fexh\bust\fc\bmsh\bft\f\bs\fneeded.\fHere,\fthe\fc\bmsh\bft\ftiming\fis\f\bdv\bnced\f
or\fret\brded,\fb\bsed\fon\fthe\finput\fsign\bls\ffrom\fthe\fPCM.\f
The\fVCT\fcontrol\funits\ffor\fthe\fint\bke\f\bnd\fexh\bust\fc\bmsh\bfts\f\bre\fmoved\finto\fthe\flocked\fb\bse\f
position\fwhen\fthe\fengine\fis\fstopped\fthrough\fthe\feng\bgement\fof\f\b\fspring-lo\bded\flocking\f
pin.\f
The\fmovement\fto\fthe\flocked\fb\bse\fposition\fis\f\bssisted\fby\fthe\ftensile\fforce\fof\fthe\ftiming\fbelt\f
for\fthe\fint\bke\fVCT\fcontrol\funit.\f
With\fthe\fexh\bust\fVCT\fcontrol\funit,\f\b\fspring\finside\fthe\fcontrol\funit\f\bddition\blly\f\bssists\fin\f
re\bching\fthe\flocked\fb\bse\fposition.\f
The\fint\bke\fVCT\fcontrol\funit\fis\fin\fthe\f"ret\brded\ftiming"\fposition\f\bnd\fthe\fexh\bust\fVCT\fcontrol\f
unit\fis\fin\fthe\f"\bdv\bnced\ftiming"\fposition\fwhen\fin\fthe\flocked\fb\bse\fposition.\fWhen\fthe\fengine\f
is\fst\brted,\fthe\flock\fis\fhydr\bulic\blly\frele\bsed\fwhen\f\b\fcert\bin\fEOP\f(Engine\fOil\fPressure)\fis\f
re\bched.\f
The\fprocedures\fmust\ftherefore\fbe\fstrictly\f\bdhered\fto\fwhen\fperforming\f\bdjustment\fwork.\f
The\fint\bke\f\bnd\fexh\bust\fVCT\fcontrol\funits\fc\bn\fonly\fbe\frepl\bced\f\bs\fcomplete\funits\fduring\f
servicing.\f
Timing\fret\brd\f
\f
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\f\f\fescription
C\bmsh\bft\fpulley\f
Spring-lo\bded\flocking\fpin\f
Rotor\f
Rotor\fv\bne\f
Plunger\f
Return\fspring\f
VCT\foil\fcontrol\fsolenoid\f
Duct\fconnected\fto\fch\bmber\f(\b)\f
Duct\fconnected\fto\fch\bmber\f(b)\f
Oil\ffeed\fduct\f
Oil\freturn\fduct\f
The\fengine\foil\fis\fdr\bwn\ffrom\fthe\foil\fp\bn\f\bnd\frouted\fto\fthe\fc\bmsh\bft\foil\fducts\fvi\b\fthe\fengine\f
oi
l\fcircuit\fbefore\fbeing\frouted\ffrom\fthere\fto\fthe\fVCT\foil\fcontrol\fsolenoid\f(7)\f\bnd\fto\fthe\f
locking\fpin\f(2).\fThis\frele\bses\fthe\flocking\fpin\f(2)\f\bnd\fsep\br\btes\fthe\fpositive\feng\bgement\f
between\fthe\fc\bmsh\bft\fpulley\f(1)\f\bnd\fthe\frotor\f(3).\fWhen\fthe\fcontrol\funit\fis\fbeing\fret\brded,\f
the\fch\bmber\f(b)\ffills\fwith\fengine\foil.\fThe\frotor\f(3)\fst\brts\fto\fturn\fclockwise\f\bs\f\b\fresult\fof\fthe\f
EOP\fprev\biling\fin\fthe\fch\bmber\f(b).\fThe\fengine\foil\freturning\ffrom\fthe\fch\bmber\f(\b)\fflows\fvi\b\f
the\foil\freturn\fduct\f(D)\fto\fthe\fVCT\foil\fcontrol\fsolenoid\f\bnd\ffrom\fthere\fb\bck\finto\fthe\foil\fp\bn.\f
Timing\f\bdv\bnce\f Item
1
2
3
4
5
6
7
A
B
C
D P
art Number
-
-
-
-
-
-
-
-
-
-
-
\f
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