engine FORD S-MAX 2006 Service Repair Manual

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 -
Radiat\br
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Rem\bval and Installati\bn
General Equipment
Rem\bval
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\fins t
\bll\btion\fdet\bils.\f
C\bble\fties
1. Dr\bin\fthe\fcooling\fsystem.\fRefer\fto:\f Cooling\fSystem\fDr\bining,\fFilling\f\bnd\f
Bl e

eding \f(303-03A\fEngine\fCooling\f-\f2.0L\f
Dur

\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,\fGener\bl\fProcedures).\f
2. Remove\fthe\fcooling\ff\bn\fmotor\f\bnd\fshroud.\f
Refer\fto:\f Cooling\fF\bn\fMotor\f\bnd\fShroud \f(303-
03A

\fEngine\fCooling\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. Remove\fthe\fch\brge\f\bir\fcooler\f(if\fequipped).\f
Refer\fto:\f Ch\brge\fAir\fCooler \f(303-12E\fInt\bke\fAir\f
Dis

tribution\f\bnd\fFiltering\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/2.0L\fDur\btorq-TDCi\f
(118kW/160PS)\f-\fDW,\fEmission\fRequirements:\f
St\bge\fIV/St\bge\fV,\fRemov\bl\f\bnd\fInst\bll\btion).\f
Refer\fto:\f Ch\brge\fAir\fCooler \f(303-12E\fInt\bke\fAir\f
Di s

tribution\f\bnd\fFiltering\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/2.0L\fDur\btorq-TDCi\f
(118kW/160PS)\f-\fDW,\fEmission\fRequirements:\f
St\bge\fIV/St\bge\fV,\fRemov\bl\f\bnd\fInst\bll\btion).\f
4. Secure\fthe\f\bir\fconditioning\f(A/C)\fcondenser\fto\f the\ffront\fp\bnel.\f
General \bqui\fment: C\bble\fties\f
5. \f
\f

\f
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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 - Bl\bck
Heater
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Rem\bval and Installati\bn
Materials
Rem\bval
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
NameSpec\bf\bcat\bo\f
Thre\bd\fLocking\fMSWSK-M2G349-A7\f/\f2U7J-M2G349-AA
1. \f
2. \f
3. \f\f1.Torque:\b 48\fNm
\f
2. Torque:\b 10\fNm
\f
4. Refer\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des

cription\f\bnd\fOper\btion).\f
5. \f
6. Refer\fto:\f Cooling\fSystem\fDr\bining,\fFilling\f\bnd\f
\f\f
\f\f
\f\f
\f\f
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Bleeding\f(303-03A\fEngine\fCooling\f-\f2.0L\f
Dur
\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,\fGener\bl\fProcedures).\f
7. \f
8. Torque:\b 20\fNm
\f
9. \f
10. Torque:\b 60\fNm
\f
11. Torque:\b 24\fNm
\f
\f
\f\f
\f\f
\f\f
\f\f
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Engine C\b\bling - 2\f0L Ec\bB\b\bst SCTi
(149kW/203PS) - MI4 - Specificati\bnsS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Lubricants, Fluids, Sealers and Adhesives
Antifreeze
C\b\bling System Refill Capacity
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\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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Engine C\b\bling - 2\f0L Ec\bB\b\bst SCTi
(149kW/203PS) - MI4 - Engine C\b\bling -
C\bmp\bnent L\bcati\bn
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Descripti\bn and Operati\bn
\f\f
Descripti\bn
R\bdi\btor\f
R\bdi\btor\ff\bn\fmotor\fwith\fbr\bcket\f
Cool\bnt\fexp\bnsion\ft\bnk\f
W\bte\fpump\f
Thermost\bt\fhousing\f
Cool\bnt\fconnection,\fturboch\brger\f
ECT\f(engine\fcool\bnt\ftemper\bture) \fsensor\f
Cool\bnt\fdistribution\fconnection\f
Oil\fcooler\f
Item
1
2
3
4
5
6
7
8
9
\f
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Engine C\b\bling - 2\f0L Ec\bB\b\bst SCTi
(149kW/203PS) - MI4 - C\b\bling System
Draining, Filling and Bleeding
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
General Pr\bcedures
General Equipment
Draining
WARNING:\fWhen\frele\bsing\fthe\fcooling\fsystem\fpressure,\fcover\fthe\fcool\bnt\fexp\bnsion\f
t\b

nk\fc\bp\fwith\f\b\fthick\fcloth.\f
Fluid\fcont\biner
1. Refer\fto:\f Engine\fCooling\fSystem\fHe\blth\f\bnd\f
S\bfe
ty\fPrec\butions\f(100-00\fGener\bl\fInform\btion,\f
Des

cription\f\bnd\fOper\btion).\f
2. Rele\bse\fthe\fcooling\fsystem\fpressure\fby\fslowly\f turning\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fc\bp\fbetween\f
2\f\bnd\f3\fturns.\f
3. \f
4. Refer\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des

cription\f\bnd\fOper\btion).\f
5. \f
6. \f
7. \f\f WARNING:\fBe\fprep\bred\fto\fcollect\f
e s

c\bping\ffluid.\f
\f\f
\f\f
\f\f
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Filling
CAUTION:\fThe\ffluid\flevel\fmust\frem\bin\fbetween\fthe\fMAX\f\bnd\fMIN\fm\brks.\f
Bleeding
Use\f\b\fsuit\bble\fcool\bnt\fhose\fto\fdr\bin\fthe\fcool\bnt.\f
Ge
n

eral \bqui\fment: Fluid\fcont\biner\f
Loo

sen: 3\fturn(s)
\f
8. \f
9. Lower\fthe\fvehicle.\f
1. Switch\fthe\finterior\fhe\bter\fblower\foff.\f
2. Fill\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fcool\bnt\flevel\fto\f the\fneck\fof\fthe\fcool\bnt\fexp\bnsion\ft\bnk.\f
1. St\brt\fthe\fengine.\f
2. R\bise\fthe\fengine\fspeed\fto\f2500\fRPM\f\bnd\f m\bint\bin\fit\ffor\f1\fminute.\f
3. Check\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fcool\bnt\flevel.\f
4. If\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fcool\bnt\flevel\fh\bs\f f\bllen\fbelow\fthe\fMIN\fm\brk,\fstop\fthe\fengine\f\bnd\f
refill\fthe\fcool\bnt\fexp\bnsion\ft\bnk\flevel\fto\fthe\fneck\f
of\fthe\fcool\bnt\fexp\bnsion\ft\bnk.\f
5. Inst\bll\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fc\bp.\f
6. St\brt\fthe\fengine\fif\fstopped.\f
7. R\bise\fthe\fengine\fspeed\fto\f2500\fRPM\f\bnd\f m\bint\bin\fit\ffor\f\bpproxim\btely\f11\fminutes\fwhile\f
observing\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fcool\bnt\f
level.\f
8. M\bint\bin\fthe\fengine\fspeed\f\bt\f2500\fRPM\ffor\f\b\f further\f3\fminutes.\f
9. Incre\bse\fthe\fengine\fspeed\fto\f4000\fRPM\f\bnd\f m\bint\bin\fit\ffor\f5\fseconds.\f
10. Decre\bse\fthe\fengine\fspeed\fto\f2500\fRPM\f\bnd\f m\bint\bin\fit\ffor\f3\fminutes.\f
11. Switch\fthe\fengine\foff.\f
12. Check\fthe\fcooling\fsystem\ffor\fle\bks.\f
\f\f
\f\f
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13. Check\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fcool\bnt\flevel.\f
14. Refer\fto:\fLifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des

cription\f\bnd\fOper\btion).\f
15. Torque: 8\fNm
\f
16. \f
17. Lower\fthe\fvehicle.\f
18. Allow\fthe\fengine\fto\fcool.\f
19. Fill\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fcool\bnt\flevel\fto\f the\fMAX\fm\brk.\f
\f\f
\f\f
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Engine C\b\bling - 2\f0L Ec\bB\b\bst SCTi
(149kW/203PS) - MI4 - C\b\bling System
Draining and Vacuum Filling
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
General Pr\bcedures
General Equipment
Draining
WARNING:\fWhen\frele\bsing\fthe\fcooling\fsystem\fpressure,\fcover\fthe\fcool\bnt\fexp\bnsion\f
t \b

nk\fc\bp\fwith\f\b\fthick\fcloth.\f
NOTE:\fAlw\bys\ffollow\fthe\fm\bnuf\bcturer's\finstructions\fwhen\fh\bndling\fthe\fequipment.\f
Cooling\fsystem\fv\bcuum\ftester\f\bnd\frefiller
Fluid\fcont\biner
1. Refer\fto:\f Engine\fCooling\fSystem\fHe\blth\f\bnd\f
S\bfe
ty\fPrec\butions\f(100-00\fGener\bl\fInform\btion,\f
Des

cription\f\bnd\fOper\btion).\f
2. \f\f Rele\bse\fthe\fcooling\fsystem\fpressure\fby\fslowly\f
turning\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fc\bp\fbetween\f
2\f\bnd\f3\fturns.\f
3. Refer\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des
cription\f\bnd\fOper\btion).\f
4. \f
5. \f
6. \f\f WARNING:\fBe\fprep\bred\fto\fcollect\f
e s

c\bping\ffluid.\f
Use\f\b\fsuit\bble\fcool\bnt\fhose\fto\fdr\bin\fthe\fcool\bnt.\f
\f\f
\f\f
\f\f
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Engine C\b\bling - 2\f0L Ec\bB\b\bst SCTi
(149kW/203PS) - MI4 - Therm\bstat
H\busing
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Rem\bval and Installati\bn
General Equipment
Rem\bval
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
Installati\bn
Hose\fcl\bmp\fremover/inst\bller 1. Refer\fto:\fCooling\fSystem\fDr\bining\f\bnd\fV\bcuum\f
Fil

ling \f(303-03B\fEngine\fCooling\f-\f2.0L\fEcoBoost\f
SC T

i\f(149kW/203PS)\f-\fMI4,\fGener\bl\fProcedures).
\f
2. \f
3. CAUTION:\fUse\fsuit\bble\fp\bper\fto\f\bbsorb\f
\bn

y\fesc\bping\ffluid.\f
General \bqui\fment: Ho
se\fcl\bmp\f
rem
over/inst\bller \f
4.CAUTION:\fUse\fsuit\bble\fp\bper\fto\f\bbsorb\f
\bn
y\fesc\bping\ffluid.\f
Torque: 10\fNm
\f
5. \f
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f\f
\f\f
\f\f
\f\f
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