service FORD S-MAX 2006 Service Owner's Manual

Engine - \b.0L \furatorq-T\fCi (85kW/115PS) - \fW/\b.0L \furatorq-T\fCi (100kW/136PS) -
(103kW/140PS) - \fW, Emission Requirements: Stage IV - Specifications
Engine \fata
Lu
bricants, Fluids, Sealers and Adhesives
Engine Oil Capacity
Cylinder Block
Pistons
Piston ring gap position: The piston ring gaps must be distributed evenly around the circumference of the piston. This also applies to the oil control ring elements. Align the piston ring gaps at 1\b0 degrees to each other.
Crankshaft
Connecting Rod
Descrip\bion
Engine c\bde
Firing \brder
E\fissi\bn level
B\bre
Str\bke
Cubic capacity
C\b\fpressi\bn rati\b
P\bwer \butput at 4000 rp\f
T\brque at 1750 rp\f
Maxi\fu\f engine speed (inter\fittent)
Maxi\fu\f engine speed (c\bntin\bus)
Idle speed
Oil c\bnsu\fpti\bn
I\be\f
Engine \bil
C\b\blant
Sealant
Initial fill including \bil filter
Service fill including \bil filter
Service fill with\but \bil filter
Descrip\bion
Cylinder b\bre dia\feter
Main bearing parent b\bre dia\feter
Main bearing clearance - radial
Descrip\bion
Pist\bn dia\feter
Pist\bn clearance in cylinder
Pist\bn ring end gaps
— upper c\b\fpressi\bn ring
— l\bwer c\b\fpressi\bn ring
— \bil c\bntr\bl ring
Descrip\bion
Main bearing j\burnal dia\feter
C\bnnecting r\bd bearing j\burnal dia\feter
Crankshaft end play
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Engine - \b.0L \furatorq-T\fCi (85kW/115PS) - \fW/\b.0L \furatorq-T\fCi (100kW/136PS) -
(103kW/140PS) - \fW, Emission Requirements: Stage IV - Specifications
Engine \fata
Lu
bricants, Fluids, Sealers and Adhesives
Engine Oil Capacity
Cylinder Block
Pistons
Piston ring gap position: The piston ring gaps must be distributed evenly around the circumference of the piston. This also applies to the oil control ring elements. Align the piston ring gaps at 1\b0 degrees to each other.
Crankshaft
Connecting Rod
Descrip\bion
Engine c\bde
Firing \brder
E\fissi\bn level
B\bre
Str\bke
Cubic capacity
C\b\fpressi\bn rati\b
P\bwer \butput at 4000 rp\f
T\brque at 1750 rp\f
Maxi\fu\f engine speed (inter\fittent)
Maxi\fu\f engine speed (c\bntin\bus)
Idle speed
Oil c\bnsu\fpti\bn
I\be\f
F\brd F\br\fula E SAE 10W-30 M\bt\bröl
C\b\blant
Sealant
Initial fill including \bil filter
Service fill including \bil filter
Service fill with\but \bil filter
Descrip\bion
Cylinder b\bre dia\feter
Main bearing parent b\bre dia\feter
Main bearing clearance - radial
Descrip\bion
Pist\bn dia\feter
Pist\bn clearance in cylinder
Pist\bn ring end gaps
— upper c\b\fpressi\bn ring
— l\bwer c\b\fpressi\bn ring
— \bil c\bntr\bl ring
Descrip\bion
Main bearing j\burnal dia\feter
C\bnnecting r\bd bearing j\burnal dia\feter
Crankshaft end play
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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 -
-
-
-
-
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NOTE:\fRefer\fto\fthe\fcurrent\fservice\fliter\bture\ffor\fthe\fex\bct\fprocedure\f\bnd\fthe\fcorrect\f
me\bsurements\ffor\fm\bchining.\f
The\fcylinder\fblock\fis\fm\bde\fof\fc\bst\firon\f\bnd\fh\bs\fno\fcyl
inder\fliners.\f
The\frunning\fsurf\bces\fof\fthe\fcylinders\f\bre\fworked\fdirectly\finto\fthe\fcylinder\fblock.\f
The\fm\bting\ff\bce\fof\fthe\fcylinder\fblock\fwith\fthe\fcylinder\fhe\bd\fc\bn\fbe\fre-worked.\f
Two\fholes\f\bre\fprovided\fin\fthe\fcylinder\fblock,\ffor\fthe\fguide\fsleeves\fused\fto\fsecure\fthe\f
cylinder\fhe\bd\fg\bsket.\f
Connecting rods
\f\f
\fescription
Big-end\fbe\bring\fshells\f
NOTE:\fRefer\fto\fthe\fcurrent\fservice\fliter\bture\ffor\fthe\fex\bct\fprocedure\f\bnd\fthe\fcorrect\f
ti
ghtening\ftorques\ffor\finst\blling\fthe\fbig\fend\fbe\brings.\f
The\fconnecting\frods\f\bre\fm\bde\fof\fforged\fsteel.\f
The

\fbig-end\fbe\bring\fc\bps\f\bre\fcut\f\bnd\fm\bchined\f\bt\fthe\fjoins\fto\fthe\fconnecting\frod.\f
The\fbig\fend\fbe\bring\fshells\fh\bve\fret\bining\flugs\fto\fprevent\fr\bdi\bl\fmovement.\f
The\fret\bining\fnuts\f\bre\ftightened\fin\fthree\fst\bges.\fIn\fthe\fthird\fst\bge\fthe\fnuts\f\bre\ftightened\f
to\f\b\fspecified\f\bngle.\f
The\fconnecting\frods\f\bnd\fbig-end\fbe\bring\fc\bps\f\bre\fp\bired\f\bnd\fmust\fnot\fbe\fmixed\fup.\f
Crankshaft main bearings Item
1
\f
\f\f
Part Number -
Стр. 10 из 14
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\f\f\fescription
Colour\fm\brking\f
M\brking\f
B\brcode\f
Alph\bnumeric\bl\fcode\f
Thrust\fw\bshers\f
M\brking\f
For\f\bccur\bte\f\bdjustment\fof\fthe\fcr\bnksh\bft\fbe\bring\fcle\br\bnce,\fthe\fcr\bnksh\bft\fbe\bring\fshells\f
in
\fthe\fcr\bnksh\bft\fm\bin\fbe\bring\fc\bps\f\bre\f\bv\bil\bble\fin\ffive\fdifferent\fthicknesses.\f
The\fupper\fcr\bnksh\bft\fm\bin\fbe\brings\f(cylinder\fblock\fside)\f\bre\fonly\f\bv\bil\bble\fin\fone\f
thickness.\f
M\brks\fon\fthe\fcylinder\fblock\f(1)\f\bnd\fon\fthe\fcr\bnksh\bft\f(timing\fside)\f(4)\findic\bte\fthe\f
thicknesses\fof\fthe\fcr\bnksh\bft\fbe\bring\fshells\finst\blled.\f
The\fb\brcode\f(2)\fis\ffor\fproduction\f\bnd\fthe\f\blph\bnumeric\fcode\f(3)\ffor\fservice\foper\btions.\f
Ret\bining\flugs\fon\fthe\fcr\bnksh\bft\fbe\bring\fshells\fprevent\fr\bdi\bl\fmovement.\f
NOTE:\fThe\fcr\bnksh\bft\fm\bin\fbe\bring\fc\bps\fmust\fbe\finst\bl l
ed\fin\fthe\fcorrect\fposition.\f
NOTE:\fCylinder\f1\fis\floc\bted\fon\fthe\ftr\bnsmission\fside.\f Item
A1
2
3
4
5
\f
Part Number -
-
-
-
-
-
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Engine - \b.\bL D\fratorq-TDCi
(1\b9kW/175PS) - DW - SpecificationsS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Engine Data
L\fbricants, Fl\fids, Sealers and Adhesives
Engine Oil Capacity
Cylinder Head
Oil Press\fre Specifications
Balance Shaft Meas\frement Shims
Balance Shaft Shims
Descrip\bion
Engine\fcodeQ4BA
Firing\forder1-3-4-2
Emission\flevelSt\bge\fIV
Bore85.0\fmm
Stroke96.0\fmm
Cubic\fc\bp\bcity2179\fcm³
Compression\fr\btio16.6:1
Power\foutput\f\bt\f3500\frpm129\fkW\f(170\fPS)
Torque\f\bt\f1750\frpm400\fNm
Idle\fspeed800\frpm
Oil\fconsumption0.1L\f/\f1000\fKm
I\be\fSpecifica\bion
Engine\foilWSS-M2C913-B
Cool\bntWSS-M97B44-D
Se\bl\bntWSE-M4G323-A4
Descrip\bionLi\bers
Initi\bl\ffill\fincluding\foil\ffilter6.5
Service\ffill\fwith\foil\ffilter5.9
Service\ffill\fwithout\foil\ffilter5.3
Descrip\bion\f\f
Thickness\fof\fcylinder\fhe\bd\fg\bsket\fwith\fpiston\fprotrusion\fof\f0.55\fto\f0.60\f
mm1.25\f±\f0.04\f(1\fhole)
Thickness\fof\fcylinder\fhe\bd\fg\bsket\fwith\fpiston\fprotrusion\fof\f0.61\fto\f0.65\f
mm1.30\f±\f0.04\f(2\f
holes)
Thickness\fof\fcylinder\fhe\bd\fg\bsket\fwith\fpiston\fprotrusion\fof\f0.66\fto\f0.70\f
mm1.35\f±\f0.04\f(3\fholes)
Thickness\fof\fcylinder\fhe\bd\fg\bsket\fwith\fpiston\fprotrusion\fof\f0.71\fto\f0.75\f
mm1.40\f±\f0.04\f(4\fholes)
M\bximum\fdistortion\f—\fme\bsured\flongitudin\blly\f\bnd\fdi\bgon\blly0.03
Descrip\bionbar
Oil\fpressure\f\bt\f2000\frpm2.0
Oil\fpressure\f\bt\f4000\frpm4.0
Shi\f \bhickness \f\fShi\f \farking
1.5757
Mini\fu\f clearance \f\fShi\f \bhickness \f\fShi\f \farking
0.01\f-\f0.051.5757
0.051.5151
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T\fe intake cams\faft is driven by t\fe ex\faust cams\faft via a timing c\fain.
Pretensi\bning \bf t\fe timing c\fain is perf\brmed by a \fydraulic timing c\fain tensi\bner.
Hydra\flic timing chain tensioner
T\fe \fydraulic timing c\fain tensi\bner is m\bunted between t\fe cams\faft spr\bckets \bn t\fe upper part \bf t\fe cylinder \fead.
T\fe \fydraulic c\fain tensi\bner is supplied wit\f t\fe appr\bpriate \bil pressure via an \bil b\bre. Als\b integrated in t\fe \fydraulic
timing c\fain tensi\bner is a c\bmpressi\bn spring. T\fis ensures t\fe necessary pretensi\bning \bf t\fe drive c\fain.
T\fere is a service pin at t\fe c\fain tensi\bner f\br releasing t\fe pretensi\bn during servicing.
Locking and disengaging the hydra\flic timing chain tensioner

Description
C\fain tensi\bner l\bcked
C\fain tensi\bner disengaged
Service pin
Upper c\fain guide
L\bwer c\fain guide
NOTE: After installing t\fe upper part \bf t\fe cylinder \fead, make sure t\fat t\fe \fydraulic c\fain tensi\bner is in t\fe
disengaged p\bsiti\bn.
T\fe c\fain tensi\bner can be l\bcked and disengaged again
f\br servicing using t\fe service pin.
T\b l\bck t\fe c\fain tensi\bner, lift t\fe service pin and t\fen turn it 90 degrees.
T\b pretensi\bn t\fe c\fain tensi\bner, turn t\fe service pin \bnce m\bre by 90 degrees. T\fe unl\bcking can be clearly felt.
Cylinder block Item
A
B1
2
3


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EGR\fcooler\f
Therm\bstat h\busing
\f\f
Descripti\bn
Byp\bss\fsolenoid\fv\blve\f
Connection\fto\fcool\bnt\freservoir\f
Connection\fto\fr\bdi\btor\finlet\f
Connection\fto\fthe\foil/cool\bnt\fhe\bt\fexch\bnger\f
Connection\fto\fr\bdi\btor\foutlet\f
Connection\fto\fcool\bnt\fpump\f
Connection\fto\fhe\bt\fexch\bnger\f
engine\fcool\bnt\ftemper\bture\f(ECT)\fsensor\f
WARNING:\fThe\fECT\fsensor\fmust\fnot\fbe\fremoved\fwhile\fthe\fcooling\fsystem\fis\f
pr

essurised.\f
The\fthermost\bt\fhousing\fis\f\btt\bched\fto\fthe\fcylinder\fhe\b
d\fon\fthe\ftr\bnsmission\fside\fof\fthe\f
engine.\f
The\fECT\fsensor\fis\floc\bted\fon\fthe\fthermost\bt\fhousing\f\bnd\fis\f\btt\bched\fby\fme\bns\fof\f\b\fclip.\f
The\fthermost\bt\fhousing\fcont\bins\fthe\fthermost\bt\f\bnd\fthe\fbyp\bss\fsolenoid\fv\blve.\fThe\f
thermost\bt\fis\f\b\fconvention\bl\fdesign.\f
The\fthermost\bt\fhousing\fis\fm\bde\fof\fpl\bstic\f\bnd\fc\bnnot\fbe\fdis\bssembled\fwhen\fthe\fvehicle\fis\f
serviced.\fThe\fECT\fsensor\fc\bn\fbe\frepl\bced\fsep\br\btely.\f
Operating principle
The\fshut-
off\fsolenoid\fv\blve\fis\floc\bted\fin\fthe\ffeed\ffrom\fthe\fthermost\bt\fhousing\fto\fthe\fcool\bnt\f
reservoir.\fIt\flimits\fcool\bnt\fflow\fto\fthe\fcool\bnt\freservoir\fduring\fthe\fengine\fw\brm\fup\fph\bse.\f
The\fbyp\bss\fsolenoid\fv\blve\fis\floc\bted\fbetween\fthe\fcool\bnt\foutlet\fon\fthe\fcylinder\fhe\bd\f\bnd\f
the\fsupply\fto\fthe\fcool\bnt\fpump.\fIt\flimits\fthe\fcool\bnt\fflow\fto\fthe\fcool\bnt\fpump\fduring\fthe\f 11
I t

em
1
2
3
4
5
6
7
8
-
\f
Part Number -
-
-
-
-
-
-
-
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Installat\fon\bTorque:\b
24 Nm

1. To \fnstall, reverse the removal procedure.
2. Us\fng the d\fagnost\fc tool, select\b TOOLBOX/POWERTRAIN/SERVICE
FUNCTIONS/RESET KAM, to reset the EGR valve.
Genera\f\bEquipment:\b Ford approved d\fagnost\fc tool

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the\fPCV\fv\blve\fis\fpushed\fopen\f\bssisted\fby\fthe\fPCV\fv\blve\fspring.\fThis\f\bllows\fthe\fpositive\f
cr\bnkc\bse\fg\bsses\fto\fbe\fsc\bvenged\fby\fthe\f\bir\fint\bke\fsystem.\f
In\bpection and Ve\fification 1. 1.
Verify\fthe\fcustomer\fconcern.\f
2

. 2.
Visu\blly\finspect\ffor\fobvious\fsigns\fof\fmech\bnic\bl\for\felectric\bl\fd\bm\bge.\f
V

i\bual In\bpection Cha\ft
3. 3.
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.
If\fthe\fc\buse\fis\fnot\fvisu\blly\fevident,\fverify\fthe\fsymptom\f\bnd\frefer\fto\fthe\fDTC\fIndex\f
C
h\brt.\f
5. 5.
If\fno\fDTCs\frel\bted\fto\fthe\fconcern\f\bre\fretrieved,\fproceed\fto\fthe\fSymptom\fCh\brt\fto\f
c
ontinue\fdi\bgnosis.\f
Diagno\btic T\fouble Code (DTC) Index Cha\ft
Symptom Cha\ft
Pinpoint Te\bt\b
Mechanica\bE\bectrica\b

Exh\bust\fg\bs\frecircul\btion\f(EGR)\fv\blve\f\f

EGR\ftube\f\f

EGR\fcooler\f\f

EGR\ftube\fcl\bmp\f\f

G\bsket\f\f

PCV\fhose\f\f

PCV\foil\fsep\br\btor\f
Electric\bl\fconnector\f\f

Wiring\fh\brness\f
\fTC\fescription
Possib\be
Source
Action
P1412MIL\fillumin\btedEGR\fv\blveREFER\fto\fExcessive\fexh\bust\fbl\bck\fsmoke\fin\f
the\fSymptom\fCh\brt
P0404MIL\fillumin\btedEGR\fv\blveREFER\fto\fExcessive\fexh\bust\fbl\bck\fsmoke\fin\f
the\fSymptom\fCh\brt
P1335Powertr\bin\fw\brning\findic\btor\f illumin\btedEGR\fv\blveREFER\fto\fExcessive\fexh\bust\fbl\bck\fsmoke\fin\f
the\fSymptom\fCh\brt
SymptomPossib\be
SourcesAction
Excessive\f
exh\bust\f
bl\bck\fsmokeEGR\fv\blve.\f
*Using\fthe\fWDS,\fCHECK\fthe\fPCM\fc\blibr\btion.\fIf\fnecess\bry\f
UPDATE\fthe\fPCM\fc\blibr\btion\fto\fthe\fl\btest\flevel.\fUsing\fthe\f
WDS,\fTOOLBOX/POWERTRAIN/SERVICE\fFUNCTIONS/RESET\f
KAM,\fRESET\fthe\fEGR\fv\blve.\fC\brry\fout\f\b\fro\bd\ftest,\fif\fthe\f
concern\fpersists\fGO\fto\fPinpoint\fTest\f A.\f\f
*
Excessive\f
cr\bnkc\bse\f
pressureBlocked\for\f
d\bm\bged\fPCV\f
hose(s).\f Blocked\fPCV\f
oil\fsep\br\btor.\f
*
*GO\fto\fPinpoint\fTest\f
B.\f\f
*
Worn\for\f
d\bm\bged\f
engine\f
components.\f
*REFER\fto:\f
Engine\f(303-01F\fEngine\f-\f2.0L\fDur\btorq-TDCi\f
(85
kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f(100kW/136PS)\f-\f
DW/2.0L\fDur\btorq-TDCi\f(103kW/140PS)\f-\fDW,\fEmission\f
Requirements:\fSt\bge\fIV,\fDi\bgnosis\f\bnd\fTesting).\f
*
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