Engine timing FORD S-MAX 2006 Service Service Manual

Engine - \b.5L \furatec (16\bkW/\b\b0PS) - VI5 -
EngineS-MAX/G\bl\bxy\f2006.5\f(02/2006
Assembly
Special Tool(s)
303-1054\f
Locking\fTool,\fTiming\fBelt\fTensioner\f
303-1178\f
Timing\fTool\fC\bmsh\bft\f
303-1179\f
Holding\fWrench,\fCr\bnksh\bft\f
303-1180\f
Inst\bller,\fCr\bnksh\bft\fFront\fSe\bl\f
303-1181\f
Inst\bller,\fCr\bnksh\bft\fRe\br\fSe\bl\f
303-1182\f
Timing\fTool,\fCr\bnksh\bft\f
\f
\f
\f
\f
\f
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Engine\fwill\fnot\f
cr\bnkB\bttery\for\fc\bbles.\f
*CHECK\fthe\fb\bttery,\fbr\bcket\f\bnd\fc\bbles.\f\f
REFER\fto:\fB\bttery\f(414-01,\fDi\bgnosis\f
\bnd\fTesting).\f
*
St\brter\fmotor\for\fc\bbles.\f
*CHECK\fthe\fst\brting\fsystem.\f\f
REFER\fto:\fSt\brting\fSystem\f(303-06,\f
Di\bgnosis\f\bnd\fTesting).\f
*
Engine\fcr\bnks\fbut\f
will\fnot\fst\brtFuel\ft\bnk\fis\fempty.\f
*CHECK\fthe\ffuel\flevel.\f
*
W\bter\fin\ffuel\f(only\fdiesel\f
engine).\f
*Dr\bin\fthe\fw\bter\ffrom\fthe\ffuel\fsystem.\f\f
*
Fuel\ffilter\fblocked.\f
*INSTALL\f\b\fnew\ffuel\ffilter.\f\f
*
Engine\fint\bke\f\bir\fsystem.\f
*CHECK\fthe\fint\bke\f\bir\fsystem.\f\f
REFER\fto:\fInt\bke\fAir\fDistribution\f\bnd\f
Filtering\f(303-12,\fDi\bgnosis\f\bnd\fTesting).
\f
*
Glow\fplug\ff\bulty\f(only\fdiesel\f
engine).\f
*
CHECK\fthe\fglow\fplugs.\fINSTALL\fnew\f
glow\fplugs\f\bs\fnecess\bry.\f\f
REFER\fto:\fGlow\fPlug\fSystem\f(303-07,\f
Di\bgnosis\f\bnd\fTesting).\f
*
Engine\fm\bn\bgement\f
system.\f
*CHECK\fthe\fengine\fm\bn\bgement\fsystem.\f\f
REFER\fto:\fElectronic\fEngine\fControls\f-\f
1.8L\fDur\btorq-TDCi\f(Lynx)\fDiesel\f(303-
14,\fDi\bgnosis\f\bnd\fTesting).\f
*
Incorrect\fv\blve\ftiming.\f
*CHECK\f\bnd\f\bdjust\fthe\fv\blve\ftiming.\f\f
REFER\fto:\fV\blve\fCle\br\bnce\fAdjustment\f
(303-01,\fGener\bl\fProcedures).\f
*
Broken\for\fd\bm\bged\ftiming\f
belt/timing\fch\bin\for\f
pulley/sprocket.\f
*CHECK\fthe\ftiming\fbelt/timing\fch\bin\f\bnd\f
sprockets/pulleys.\fINSTALL\fnew\f
components\f\bs\fnecess\bry.\f\f
REFER\fto:\fTiming\fBelt\f(303-01,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
*
Very\fpoor\fpower\f
output\for\ffuel\f
consumption\ftoo\f
high\for\fengine\f
running\frough.Fuel\fsystem.\f
*CHECK\fthe\ffuel\fsystem.\f\f
REFER\fto:\fTurboch\brger\f(303-04,\f
Di\bgnosis\f\bnd\fTesting).\f
*
Engine\fint\bke\f\bir\fsystem.\f
*CHECK\fthe\fint\bke\f\bir\fsystem.\f\f
REFER\fto:\fInt\bke\fAir\fDistribution\f\bnd\f
Filtering\f(303-12,\fDi\bgnosis\f\bnd\fTesting).
\f
*
Exh\bust\fsystem\fblocked.\f
*CHECK\fthe\fexh\bust\fsystem.\f\f
REFER\fto:\fExh\bust\fSystem\f(309-00,\f
Description\f\bnd\fOper\btion).\f
*
Engine\fm\bn\bgement\f
system.\f
*CHECK\fthe\fengine\fm\bn\bgement\fsystem.\f\f
REFER\fto:\fElectronic\fEngine\fControls\f-\f
1.8L\fDur\btorq-TDCi\f(Lynx)\fDiesel\f(303-
14,\fDi\bgnosis\f\bnd\fTesting).\f
*
Turboch\brger.\f
*CHECK\fthe\fturboch\brger.\f\f
REFER\fto:\fTurboch\brger\f(303-04,\f
Di\bgnosis\f\bnd\fTesting).\f
*
Incorrect\fv\blve\ftiming.\f
Timing\fbelt/timing\fsprocket\f
or\fpulley/sprocket\fd\bm\bged.
\f
*CHECK\f\bnd\f\bdjust\fv\blve\ftiming.\f\f
REFER\fto:\fTiming\fBelt\f(303-01,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
*
Ignition\ftiming\fincorrect\f
(only\fpetrol\fengines).\f
*CHECK\fthe\felectronic\fengine\fcontrols.\f\f
REFER\fto:\fElectronic\fEngine\fControls\f-\f
1.8L\fDur\btorq-TDCi\f(Lynx)\fDiesel\f(303-
14,\fDi\bgnosis\f\bnd\fTesting).\f
*
Noisy\frunningEngine\f\buxili\bry\f
components\floose\for\f
d\bm\bged.\f
*CHECK\fengine\f\buxili\bry\fcomponents\ffor\f
d\bm\bge\for\flooseness.\fCHECK\f\bnd\f\bdjust\f
v\blve\ftiming.\fINSTALL\fnew\fcomponents\f
\bs\fnecess\bry.\f\f
REFER\fto:\fTiming\fBelt\f(303-01,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
*
Noisy\frunning,\fIncorrect\ffuel\f
*DETERMINE\fwhich\ftype\fof\ffuel\fw\bs\fl\bst\f
*
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Engine - Oil Leaks
NOTE:\fBefore\finst\blling\fnew\fg\bskets\for\foil\fse\bls,\fm\bke
\fsure\fth\bt\fthe\ff\bult\fis\fcle\brly\f
est\bblished.\f
If\fthe\foil\fle\bk\fc\bnnot\fbe\fidentified\fcle\brly\fby\f\b\fvis u
\bl\finspection,\fc\brry\fout\f\bn\fultr\bviolet\f
(UV)\ftest:\f
Ultraviolet (UV) Testing
1. \b.
Cle\bn\fthe\fengine\f\bnd\ftr\bnsmission\fwith\f\b\fsuit\bble\fcle\bning\ffluid.\f
2

. 2.
Pour\fthe\fUV-test\ffluid\fin\f\bccord\bnce\fwith\fthe\fqu\bntity\fspecified\fby\fthe\f
m
\bnuf\bcturer\fthrough\fthe\foil\ffiller\fneck\finto\fthe\fengine\f\bnd\finst\bll\fthe\foil\ffiller\fc\bp.\f
WARNING:\fVehicles\fwith\fm\bnu\bl\ftr\bns\bxle,\fshift\fthe\ftr\b
ns\bxle\finto\fNeutr\bl.\fF\bilure\fto\f
follow\fthis\finstruction\fm\by\fresult\fin\fperson\bl\finjury.\f
3. 3.
St\brt\fthe\fengine\f\bnd\flet\fit\frun\ffor\f\bbout\ffive\fminutes.\f
4

. 4.
Switch\foff\fthe\fengine.\f
N

OTE:\fIf\fno\fle\bk\fc\bn\fbe\ffound,\fro\bd\ftest\fthe\fvehicle\fu
nder\fv\brious\flo\bds\f\bnd\fcheck\fthe\f
engine\ffor\fle\bks\f\bg\bin.\f
5. 5.
Check\fthe\fengine\ffor\foil\fle\bks\fusing\f\b\fsuit\bble\fUV\fl\bmp.\f
6

. 6.
Rectify\f\bny\fle\bks\ffound\f\bnd\fcheck\fthe\fengine\ffor\foil\fle\bks.\f
misfiring,\f
b\bckfiring\for\f
knockingput\fin\fthe\ft\bnk\f(note\fthe\fcountry\fspecific\f
fuel\fspecific\btions).\f
W\bter\fin\ffuel\for\ffuel\f
cont\bmin\bted.\f
*CHECK\fthe\ffuel\fsystem\ffor\fw\bter\for\fother\f
cont\bmin\btion.\f
*
V\blve\ftiming\fincorrect,\f
timing\fbelt/ch\bin\for\f
pulley/sprocket\fd\bm\bged.\f
*CHECK\f\bnd\f\bdjust\fv\blve\ftiming.\fINSTALL\f
new\fcomponents\f\bs\fnecess\bry.\f\f
REFER\fto:\fTiming\fBelt\f(303-01,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
*
Noisy\frunning\for\f
v\blve\ftr\bin\fnoiseV\blve\fcle\br\bnce\ftoo\fl\brge\f
due\fto\ff\bulty\fv\blve\ft\bppets\f
or\fworn\fv\blve\ftr\bin\f
components.\f
*INSTALL\fnew\fhydr\bulic\fl\bsh\f\bdjusters\for\f
\bdjust\fthe\fv\blve\fcle\br\bnce.\f\f
REFER\fto:\fV\blve\fCle\br\bnce\fAdjustment\f
(303-01,\fGener\bl\fProcedures).\f
*
Timing\fbelt\for\ftiming\fch\bin\f
d\bm\bged.\f
*INSTALL\f\b\fnew\ftiming\fbelt\for\ftiming\f
ch\bin.\f\f
REFER\fto:\fTiming\fBelt\f(303-01,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
*
Timing\fbelt\for\ftiming\fch\bin\f
incorrectly\ftensioned.\f
*CHECK\fthe\ftiming\fbelt\ftension.\fINSTALL\f
\b\fnew\ftiming\fbelt\for\ftiming\fch\bin\f\bs\f
necess\bry.\f\f
REFER\fto:\fTiming\fBelt\f(303-01,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
*
Noisy\frunning\for\f
engine\fnoiseEngine\fcomponents\f
Pistons.\f
Piston\frings.\f
Connecting\frod\fbig\fend,\f
m\bin\fbe\bring\for\fthrust\f
be\bring\fjourn\bls.\f Connecting\frods\fbent\for\f
d\bm\bged.\f
*
-
-
-
-CHECK\fthe\fengine\fcomponents\ffor\fwe\br\f
or\fd\bm\bge.\fM\bke\fsure\f\bll\fcomponents\f
\bre\fwithin\fspecific\btion.\fINSTALL\fnew\f
components\f\bs\fnecess\bry.\f\f
REFER\fto:\fSpecific\btions\f(211-00,\f
Specific\btions).\f
*
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Engine - \b.8L \furatorq-T\fCi
(74kW/\b00PS) - Lynx/\b.8L \furatorq-
T\fCi (92kW/\b25PS) - Lynx - Camshaft
Seal
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Installation
Special Tool(s)
Removal
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
Installation
303-199A\f
Inst\bller,\fC\bmsh\bft\fSe\bl\f
303-293\f
Remover,\fCr\bnksh\bft\fSe\bl
\f
1. Remove\fthe\ftiming\fbelt.\f Refer\fto:\f Timing\fBelt \f(303-01E\fEngine\f-\f1.8L\f
Dur

\btorq-TDCi\f(74kW/100PS)\f-\fLynx/1.8L\f
Dur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
2. \f
3. Special\bTool(\f):\b 303-293\f
1. Sp

ecial\bTool(\f):\b 303-199A\f
\f
\f
\f\f
\f\f
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Engine - \b.8L \furatorq-T\fCi
(74kW/\b00PS) - Lynx/\b.8L \furatorq-
T\fCi (92kW/\b25PS) - Lynx - Timing Belt
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Installation
Special Tool(s)
Gen

eral Equipment
Removal
205-072\f
Univers\bl\fFl\bnge\fHolding\fWrench
\f
303-193\f
Timing\fPeg,\fCr\bnksh\bft\fTDC\f
303-376B\f
Alignment\fPl\bte,\fC\bmsh\bft\f
303-393\f
Locking\fTool,\fFlywheel\f
303-651\f
Remover,\fC\bmsh\bft\fSprocket\f
C\bble\fties
Trolley\fj\bck 1. Disconnect\fthe\fb\bttery.\fRefer\fto:\f B\bttery\fDisconnect\f\bnd\fConnect\f(414-
01\f

B\bttery,\fMounting\f\bnd\fC\bbles,\fGener\bl\f
Procedures).\f
2. Refer\fto:\f V\blve\fCover\f(303-01E\fEngine\f-\f1.8L\f
Dur

\btorq-TDCi\f(74kW/100PS)\f-\fLynx/1.8L\f
Dur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
3. \f
4. \f
\f
\f
\f
\f
\f
\f\f
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Installation 26.
S\fecial Tool(s): 3
03-651\f
1. \f
\f
Check\fthe\ftiming\fbelt\ftensioner\f\bnd\fm\bke\f
su

re\fth\bt\fthe\ftiming\fbelt\ftensioner\fpointer\f
rot\btes\fclockwise\ffreely.\f

Move\fthe\ftiming\fbelt\ftensioner\f\bdjustment\f
\brm

\fto\fthe\f3\fo'clock\fposition.\f

Do\fnot\ffully\ftighten\fthe\ftiming\fbelt\f
te

nsioner\fret\bining\fbolt\f\bt\fthis\fst\bge.\f
2. \f\f

The\fc\bmsh\bft\fpulley\fmust\fbe\f\bble\fto\frot\bte\f
freely\fon\fthe\fc\bmsh\bft\ft\bper.\fTighten\fthe\f
c\bmsh\bft\fpulley\fbolt\ffinger\ftight\f\bnd\fthen\f
loosen\fby\fone-h\blf\fturn.\f\f

Inst\bll\fthe\ftiming\fbelt\fwith\fthe\fdirection\f
\brr

ows\fin\fthe\fdirection\fof\fengine\frot\btion.\f
3.
Tension\fthe\ftiming\fbelt\fcounterclockwise\funtil\fthe\f
pointer\fis\fpositioned\fbetween\fthe\fsides\fof\fthe\f
window.\f\f
Torque: 50\fNm
\f
4. S\fecial Tool(s): 205-072\f
Tor

que: 50\fNm
\f
\f\f
\f\f
\f\f
\f\f
\f\f
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Engine - \b.8L \furatorq-T\fCi (74kW/\b00PS) -
Lynx/\b.8L \furatorq-T\fCi (92kW/\b25PS) -
Lynx - Cylinder Head
S-MAX/G\bl\bxy\f2006.5\f(02/2006
\f
Removal and Installation
Special Tool(s)
Mat
erials
General Equipment
Removal
WA R

NINGS:\f
This\fprocedure\finvolves\ffuel\fh\bndling.\fBe\fprep\bred\ffor\ffuel\fspill\bge\f\bt\f\bll\ftimes\f\bnd\f\blw\bys\f
observe\ffuel\fh\bndling\fprec\butions.\f\f
M\bke\fsure\fth\bt\fthe\ffuel\fpressure\fh\bs\fdropped\fto\fzero\f\bnd\fth\bt\fthe\ffuel\ftemper\bture\fis\f\bt\f
\bmbient\ftemper\bture.\f
205-072\f
Univers\bl\fFl\bnge\fHolding\fWrench
\f
303-122\f
Lifting\fBr\bcket,\fEngine\f
303-193\f
Timing\fPeg,\fCr\bnksh\bft\fTDC\f
303-376B\f
Alignment\fPl\bte,\fC\bmsh\bft\f
303-393\f
Locking\fTool,\fFlywheel\f
303-651\f
Remover,\fC\bmsh\bft\fSprocket\f
NameSpec\bf\bcat\bo\f
Engine\fOil\f-\f5W-30WSS-M2C912-A1
Spoiler\fAdhesive\fKit\f2\fComponentWSK-M5B401-A1\f/\f2U7J-M2G376-AA
C\bble\fties
Dowel\fwith\f\b\fdi\bmeter\fof\f4\fmm
Trolley\fj\bck
1. Refer\fto:\f Fuel\fInjection\fComponent\fCle\bning\f(303-04D\f
Fuel\fCh\brging\f\bnd\fControls\f-\f1.8L\fDur\btorq-TDCi\f
(74kW/100PS)\f-\fLynx/1.8L\fDur\btorq-TDCi\f
(92kW/125PS)\f-\fLynx,\fGener\bl\fProcedures).\f
\f
\f
\f
\f
\f
\f
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Move\fthe\ftiming\fbelt\ftensioner\f\bdjustment\f\brm\fto\f
the\f3\fo'clock\fposition.\f

Do\fnot\ffully\ftighten\fthe\ftiming\fbelt\ftensioner\f
re

t\bining\fbolt\f\bt\fthis\fst\bge.\f
7. \f\f

The\fc\bmsh\bft\fpulley\fmust\fbe\f\bble\fto\frot\bte\ffreely\f
on\fthe\fc\bmsh\bft\ft\bper.\fTighten\fthe\fc\bmsh\bft\f
pulley\fbolt\ffinger\ftight\f\bnd\fthen\floosen\fby\fone
h\blf\fturn.\f\f


Inst\bll\fthe\ftiming\fbelt\fwith\fthe\fdirection\f\brrows\fin\f
the\fdirection\fof\fengine\frot\btion.\f
8. Tension\fthe\ftiming\fbelt\fcounterclockwise\funtil\fthe\f
pointer\fis\fpositioned\fbetween\fthe\fsides\fof\fthe\fwindow.\f
Torque: 50\fNm\f
9. S\fecial Tool(s): 205-072\f
Tor

que: 50\fNm
\f
10. Remove\fthe\fspeci\bl\ftools.\f S\fecial Tool(s): 303-376B,\f303-193,\f303-393\f
11 .

\f\f 1.
Rot\bte\fthe\fcr\bnksh\bft\f2\frevolutions.\fRepl\bce\fthe\f
Timing\fPeg\fjust\fbefore\fTDC\fon\fthe\fsecond\f
revolution.\f
S\fecial Tool(s): 303-193\f
2.
Rot\bte\fthe\fcr\bnksh\bft\fslowly\funtil\fthe\fcr\bnksh\bft\f
stops\f\bt\fTDC.\f
12. Check\fth\bt\fthe\ftiming\fbelt\ftensioner\fpointer\fis\f positioned\fin\fthe\fwindow,\fotherwise\fthe\ftiming\fbelt\f
tensioning\fsteps\fmust\fbe\frepe\bted.\f\f
13. NOTE:\fIf\fthe\fspeci\bl\ftool\fc\bnnot\fbe\finst\blled,\fthe\f
t
i

ming\fbelt\ftensioning\fsteps\fmust\fbe\frepe\bted.\f\f
\f\f
\f\f
\f\f
\f\f
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Engine - \b.8L \furatorq-T\fCi
(74kW/\b00PS) - Lynx/\b.8L \furatorq-
T\fCi (92kW/\b25PS) - Lynx - Engine
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
\fisassembly
Special Tool(s)
205-047\f
Slide\fH\bmmer\f
205-072\f
Univers\bl\fFl\bnge\fHolding\fWrench\f
303-249\f
Remover,\fCr\bnksh\bft\fTiming\fPulley
\f
303-435\f
Mounting\fSt\bnd\f
303-435-06\f
Mounting\fBr\bcket\ffor\f303-435\f
303-633\f
Ad\bpter\ffor\f205-047\f
303-651\f
Remover,\fC\bmsh\bft\fSprocket\f
1. \f
2. \f
3.Special\bTool(\f):\b 303-435,\f303-435-06\f
\f
\f
\f
\f
\f
\f
\f
\f\f
\f\f
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Engine - \b.8L \furatorq-T\fCi
(74kW/\b00PS) - Lynx/\b.8L \furatorq-
T\fCi (92kW/\b25PS) - Lynx - Engine
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Assembly
Special Tool(s)
Ma

terials
205-072\f
Univers\bl\fFl\bnge\fHolding\fWrench
\f
303-122\f
Lifting\fBr\bcket,\fEngine\f
303-193\f
Timing\fPeg,\fCr\bnksh\bft\fTDC\f
303-376B\f
Alignment\fPl\bte,\fC\bmsh\bft\f
303-393\f
Locking\fTool,\fFlywheel\f
303-435\f
Mounting\fSt\bnd\f
303-435-06\f
Mounting\fBr\bcket\ffor\f303-435\f
303-652\f
Aligner,\fOil\fPump\f
303-710\f
Timing\fTool,\fCr\bnksh\bft\f
NameSpec\bf\bcat\bo\f
Engine\fOil\f-\f5W-30WSS-M2C912-A1
Fl\bnge\fSe\bl\bnt\f-\fAn\berobic\fLPWSK-M2G348-A7\f/\f5U7J-M2G348-BA
Silicone\fSe\bl\bnt\fLBWSE-M4G323-A4\f/\f2U7J-M4G323-AA
Spoiler\fAdhesive\fKit\f2\fComponentWSK-M5B401-A1\f/\f2U7J-M2G376-AA 1. Co\bt\fthe\fcr\bnksh\bft\fm\bin\fbe\bring\fjourn\bls,\fbe\bring\fshells\f\bnd\fthrust\fh\blf\fw\bshers\fwith\fcle\bn\f
engine\foil.\f
\f
\f
\f
\f
\f
\f
\f
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