ECU FORD S-MAX 2006 Service Service Manual

\f\f\fescription
B\bnjo\fbolts\f
Oil\fspr\by\ftubes\f
The\fpiston\fskirts\f\bre\fcooled\ffrom\fbelow\fusing\foil\ffrom\fthe\foil\fspr\by\ftubes.\fThe\foil\fspr\by\f
tu
bes\f\bre\fsecured\fin\fthe\fcylinder\fblock\fwith\fb\bnjo\fbolts.\f
The\fb\bnjo\fbolts\f\bre\fconnected\fto\fthe\fengine\foil\fcircuit.\f
V\blves\f\bre\fbuilt\finto\fthe\fb\bnjo\fbolts,\f\bnd\ffrom\f\b\fminimum\foil\fpressure\fof\f\bbout\f0.5\fb\br\fthey\f
supply\fthe\foil\fspr\by\ftubes.\f Item
1
2
\f
Part Number -
-
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Requirements:\fSt\bge\fIV,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
2. Front\fDrive\fH\blfsh\bfts\f
Refer\fto:\f Front\fH\blfsh\bft\fLH \f(205-04\fFront\f
Dri

ve\fH\blfsh\bfts,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
Refer\fto:\f Front\fH\blfsh\bft\fRH \f(205-04\fFront\f
Dri

ve\fH\blfsh\bfts,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
3. Front\fSubfr\bme.\f
Refer\fto:\f Front\fSubfr\bme \f(502-00\fUni-
Bod

y,\fSubfr\bme\f\bnd\fMounting\fSystem,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
18.
Det\bch\fthe\f\bir\fconditioning\f(A/C)\fcompressor\f\bnd\f
secure\fto\fone\fside.\f
19. Refer\fto:\f Quick\fRele\bse\fCoupling \f(310-00\fFuel\f
Sys

tem\f-\fGener\bl\fInform\btion,\fGener\bl\f
Procedures).\f
20. General \bqui\fment: Mounting\ft\bble\fset\f
21 .

\f
22. \f
\f\f
\f\f
\f\f
\f\f
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Description
Rear timing c\bver
Upper timing c\bver
L\bwer timing c\bver
M\bunting b\blt
T\fe plastic timing c\bvers are secured t\b t\fe engine using a t\btal \bf nine b\blts.
T\fere is a \f\ble (arr\bw) in t\fe upper timing c\bver. T\fis \f\ble permits t\fe inserti\bn \bf t\fe special t\b\bl f\br securing t\fe ex\faust
cams\faft pulley. T\fis all\bws fast c\fecking \bf t\fe valve timing.
Camshaft Drive

Description
Cams\faft pulley
Ex\faust cams\faft
intake cams\faft
Timing c\fain
T\fe ex\faust cams\faft is driven by t\fe cranks\faft via a timing belt. Item
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2
3
4
I t

em
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3
4


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NOTE: Cylinder 1 is l\bcated \bn t\fe transaxle side \bf t\fe engine.
T\fe cylinder bl\bck is made fr\bm grey cast ir\bn and is
d\buble-walled. T\fis \felps t\b ac\fieve \fig\f strengt\f. It als\b f\brms a
blanket \bf air t\fat results in c\bnsiderable s\bund insulati\bn.
T\fe serial number \bf t\fe engine and t\fe engine c\bde are l\bcated \bn t\fe intake side \bf t\fe cylinder bl\bck (in line wit\f t\fe
sec\bnd cylinder).
T\fe running surfaces \bf t\fe cylinders are w\brked directly int\b t\fe cylinder bl\bck.
T\fere are tw\b \f\bles \bn t\fe cylinder bl\bck f\br t\fe guide bus\fings f\br securing t\fe cylinder \fead gasket and t\fe cylinder \fead.
Oil Spray Jets

Description
Oil spray n\bzzle retaining b\blt
Oil spray jet (4 \bff)
T\fe efficient c\bmbusti\bn pr\bvided by t\fe direct-
injecti\bn turb\bc\farged diesel engine means t\fat \fig\f temperatures are
transmitted t\b t\fe pist\bns.
T\fere is an \bil spray n\bzzle installed at t\fe l\bwer end \bf eac\f cylinder liner f\br c\b\bling t\fe pist\bns. T\fe \bil spray n\bzzles spray
engine \bil in a targeted manner under t\fe pist\bn cr\bwns.
T\fere are \bil passages integrated in t\fe pist\bn cr\bwns. T\fe sprayed engine \bil enters t\fese \bil passages and t\fus ensures t\fe
necessary pist\bn c\b\bling. Pist\bn c\b\bling is n\bt essential w\fen t\fe engine is c\bld. Lubricati\bn \bf t\fe crank gear and cams\faft
\fas a \fig\fer pri\brity \fere. F\br t\fis reas\bn, t\fe \bil spray n\bzzles \bnly \bpen if an \bil pressure \bf m\bre t\fan 0.5 bar is present at
t\fem.
Cylinder block extension Item
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Description
Cylinder bl\bck
Oil Pump Assembly
Retaining b\blt (4 pieces)
Pressure relief valve \f\busing
Oil pick up and strainer
M\bunting b\blt (1 \bff)
Oil pump \butlet p\brt
Oil pump supply t\b cylinder bl\bck
T\fe \bil pump is designed as a r\bt\br pump and is b\blted t\b t\fe balance s\faft unit using f\bur retaining b\blts. A furt\fer b\blt at
t\fe \bil strainer secures t\fe \bil pump wit\f t\fe \bil dipstick tube.
T\fe drive is pr\bvided by t\fe cranks\faft via a Simplex c\fain.
T\fe \bil pump generates a maximum permissible \bil pressure \bf appr\bx. 6.5 bar and a maximum delivery rate \bf 50 l/min.
A pressure relief valve wit\fin t\fe \bil pump \butlet pr\btects t\fe \bil pump and lubricati\bn system c\bmp\bnents fr\bm system \bver
pressure.
T\fe pressure relief valve \bpens at appr\bx. 8 bar. T\fe excess \bil runs directly back int\b t\fe \bil pan.
Oil filter/oil cooler \fnit Item
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5
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16. \f
17.General \bqui\fment: Hose\fcl\bmp\f
rem

over/inst\bller \f
18.

Refer\fto:\f Quick\fRele\bse\fCoupling \f(310-00\fFuel\f
Sy s

tem\f-\fGener\bl\fInform\btion,\fGener\bl\f
Procedures).\f
19. Secure\fthe\fpower\fsteering\fpump\fto\fone\fside.\f
\f
\f
\f\f
\f\f
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25. \f
26. Remove\fthe\ffollowing\fitems:\f1. Refer\fto:\f C\bt\blytic\fConverter \f(309-00F\f
Ex h

\bust\fSystem\f-\f2.2L\fDur\btorq-TDCi\f
(129kW/175PS)\f-\fDW,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
2. Refer\fto:\f Front\fDrive\fH\blfsh\bfts \f(205-04\f
Fro

nt\fDrive\fH\blfsh\bfts,\fDescription\f\bnd\f
Oper\btion).\f
3. Refer\fto:\f Front\fSubfr\bme \f(502-00\fUni-
Bod

y,\fSubfr\bme\f\bnd\fMounting\fSystem,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
27. Secure\fthe\f(A/C)\fcompressor\fto\fone\fside.\f
28. WARNING:\fM\bke\fsure\fth\bt\fthe\fengine\f
\b n

d\ftr\bnsmission\f\bssembly\fis\fon\fwooden\f
blocks\f\bnd\fsecured\fwith\fsuit\bble\fret\bining\f
str\bps.\f General \bqui\fment: Mo
unting\ft\bble\fset\f
\f\f
\f\f
\f\f
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5.Torque:\b 48\fNm\f
6. Refer\fto:\f St\brter\fMotor \f(303-06F\fSt\brting\f
Sy s

tem\f-\f2.2L\fDur\btorq-TDCi\f(129kW/175PS)\f-\f
DW,\fRemov\bl\f\bnd\fInst\bll\btion).\f
Refer\fto:\f Gener\btor\f-\f2.2L\fDur\btorq-TDCi\f
(12

9kW/175PS)\f-\fDW \f(414-02\fGener\btor\f\bnd\f
Reg

ul\btor,\fRemov\bl\f\bnd\fInst\bll\btion).\f
7. WARNING:\fM\bke\fsure\fth\bt\fthe\fengine\f
\bn

d\ftr\bnsmission\f\bssembly\fis\fon\fwooden\f
blocks\f\bnd\fsecured\fwith\fsuit\bble\fret\bining\f
str\bps.\f General\bEquipment:\b Mo
unting\ft\bble\fset\f
8. Lower\fthe\fvehicle.\f
9. Loo\fen:\b 2\fturn(s)
\f
\f\f
\f\f
\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 - Radiat\br L\bwer
M\bunting Repair
S-MAX/G\bl\bxy\f2006.5\f(02/2006
General Pr\bcedures
General Equipment
5\fmm\fdrill\fbit
C\bble\fties
Fl\bt\ffile1. On\fboth\fsides.\f
2.
Secure\fthe\fr\bdi\btor\f\bnd\fcondenser\f\bssembly\fto\fthe\ffront\f
p\bnel\f(on\fboth\fsides).\f
General \bqui\fment: C\bble\fties\f
3. R

\bise\f\bnd\fsupport\fthe\fvehicle.\f
Refer\fto:\f Lifting\f(100-
02\fJ\bcking\f\bnd\fLifting,\fDescription\f
\bnd\fOper\btion).\f
4. \f
5. \f
6. \f\f
\f\f
\f\f
\f\f
\f\f
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10. Lower\fthe\fvehicle.\f
11.
Remove\fthe\fc\bble\fties\fsecuring\fthe\fr\bdi\btor\f\bnd\fcondenser\f
\bssembly.\f
12. On\fboth\fsides.\f
\f\f
\f\f
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