Ignition FORD S-MAX 2006 Service Service Manual

10.10.
Inst\bll\fthe\fsp\brk\fplugs\fusing\fthe\fspeci\bl\ftool.\f
1
1. 11.
Inst\bll\fthe\fignition\fcoil-on-plug.\f
1

2. 1\b.
Connect\fthe\fignition\fcoil-on-plug\felectric\bl\fconnectors.\f
1

3. 13.
Inst\bll\fthe\fengine\fcover.\f \f
\f
\f\f
\f\f
\f\f
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Installation 14.
Torque:\b
B
olts\f-\ffront\fengine\fmounting\f80\fNm
\f
Nuts\f-\ffront\fengine\fmounting\f90\fNm
\f
15. \f
16. Genera\f\bEquipment:\b Hose\fcl\bmp\f
re m

over/inst\bller \f
Tor

que:\b 18\fNm
\f
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
2. NOTE:\fDuring\finiti\blis\btion\fthe\fped\bls\fmust\f
b
e

\fin\fthe\frest\fposition.\f
Turn\fthe\fignition\fkey\fto\fposition\fII\f\bnd\fthen\fw\bit\f
on
e\fminute\fin\forder\fto\finiti\blise\fthe\fthrottle\f
v\blve.\f
3. Turn\fthe\fignition\fkey\fto\fthe\fOFF\fposition.\f
\f\f
\f\f
\f\f
\f\f
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Engine - \b.3L \furatec-HE (118kW/160PS)
- MI4 - EngineS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
\fescription and Operation
2.3L\fDur\btec-HE\f(MI4)\f
Ap

\brt\ffrom\f\b\ffew\fch\bnges,\fthe\f2.3L\fDur\btec-HE\f(MI4)\fengine\fis\fl\brgely\fb\bsed\fon\fthe\f2.0L\f
Dur\btec-HE\fengine\f\blre\bdy\fused\fin\fthe\fS-MAX/G\bl\bxy\f2006.5\f(03/2006-).\f
Key\ffe\btures\fof\fthe\fengine\finclude:\f

Direct\fignition\fcoils\f\f

Electronic\fthrottle\fv\blve\f\f

Mech\bnic\bl\fthermost\bt\f\f

v\bri\bble\fM\bnifold\fRunner\fControl\f\f

Du\bl-m\bss\fflywheel\f\f

High-perform\bnce\foil\fpump\f
Differences\ffrom\fthe\f2.0L\fDur\btec-HE\f(MI4)\fengine\fv\bri\bnt\ffitted\fto\fthe\fS-
MA

X/G\bl\bxy\f2006.5\f(03/2006-)\fMI4)\f\bre:\f

V\bri\bble\fc\bmsh\bft\ftiming\f(VCT)\f\f

Integr\bl\fdipstick\f\f

B\bl\bnce\fsh\bfts\f
V\bri\bble\fc\bmsh\bft\ftiming\f(VCT)\f
\f
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cr\bnkb\bttery\fc\bble(s).\f\f
REFER\fto:\fB\btterie\f(414-01\fB\btterie,\f
Befestigung\fund\fB\btteriek\bbel,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
St\brter\fmotor\for\fc\bbles.\f
*CHECK\fthe\fst\brting\fsystem.\f\f
REFER\fto:\fAnl\bsssystem\f(303-06\f
Anl\bsssystem\f-\f2.0L\fDur\btorq-TDCi\f(DW)\f
Diesel,\fDi\bgnosis\f\bnd\fTesting).\f
*
Engine\fcr\bnks\fbut\f
will\fnot\fst\brt.Fuel\ft\bnk\fis\fempty.\f
*CHECK\fthe\ffuel\flevel.\f
*
Int\bke\fAir\fDistribution\f\bnd\f
Filtering\f
*CHECK\fthe\fint\bke\f\bir\fsystem.\f
*
Engine\fm\bn\bgement\f
*CHECK\fthe\fengine\fm\bn\bgement\fsystem.\f
*
Ignition\fsystem\f
*CHECK\fthe\fignition\fsystem.\f
*
Incorrect\fv\blve\ftiming.\f
*CHECK\f\bnd\f\bdjust\fv\blve\ftiming.\f\f
REFER\fto:\fVentilspiel\feinstellen\f(303-01\f
Motor\f-\f2.3L\fDur\btec-HE\f(MI4),\fGener\bl\f
Procedures).\f
*
Timing\fch\bin\for\ftiming\f
ch\bin\fsprockets\fd\bm\bged\f
or\fbroken\f
*CHECK\fthe\ftiming\fch\bin\f\bnd\ftiming\fch\bin\f
sprockets.\fINSTALL\fnew\fcomponents\f\bs\f
necess\bry.\f\f
REFER\fto:\fSteuerkette\f(303-01\fMotor\f-\f
2.3L\fDur\btec-HE\f(MI4),\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
*
Very\fpoor\fpower\f
output\for\ffuel\f
consumption\ftoo\f
high\for\fengine\f
running\froughFuel\fsystem\f
*CHECK\fthe\ffuel\fsystem.\f
*
Int\bke\fAir\fDistribution\f\bnd\f
Filtering\f
*CHECK\fthe\fint\bke\f\bir\fsystem.\f
*
Restricted\fexh\bust\fsystem.\f*CHECK\fthe\fexh\bust\fsystem.\f\f
REFER\fto:\fAuspuffsystem\f-\f2.3L\fDur\btec-
HE\f(MI4)\f(309-00\fAuspuffsystem\f-\f
Allgemeine\fInform\btionen\f-\f2.0L\fDur\btec-
HE\f(MI4)/2.3L\fDur\btec-HE\f(MI4),\f
Description\f\bnd\fOper\btion).\f
*
Engine\fm\bn\bgement\f
*CHECK\fthe\fengine\fm\bn\bgement\fsystem.\f
*
Ignition\fsystem\fis\ff\bulty\f
*CHECK\fthe\fignition\fsystem.\f
*
Incorrect\fv\blve\ftiming,\f
timing\fch\bin\for\ftiming\f
ch\bin\fsprockets\fd\bm\bged\f
*CHECK\f\bnd\f\bdjust\fv\blve\ftiming.\fINSTALL\f
new\fcomponents\f\bs\fnecess\bry.\fREFER\fto:\f
(303-01\fMotor\f-\f2.3L\fDur\btec-HE\f(MI4))\f
Ventilspiel\feinstellen\f(Gener\bl\f
Procedures),\f
Steuerkette\f(Remov\bl\f\bnd\f
Inst\bll\btion).\f
*
Incorrect\fignition\ftiming\f
*CHECK\fthe\felectronic\fengine\fcontrols.\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.\fREFER\fto:\f(303-01\fMotor\f-\f
2.3L\fDur\btec-HE\f(MI4))\f Ventilspiel\feinstellen\f(Gener\bl\f
Procedures),\f
Steuerkette\f(Remov\bl\f\bnd\f
Inst\bll\btion).\f
*
Noisy\frunning,\f
misfiring,\fb\bckfiring\f
or\fknocking
Incorrect\ffuel\f
*DETERMINE\fwhich\ftype\fof\ffuel\fw\bs\fl\bst\f
put\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
*
Incorrect\fv\blve\ftiming,\f
timing\fch\bin\for\ftiming\f
ch\bin\fsprockets\fd\bm\bged\f
*CHECK\f\bnd\f\bdjust\fv\blve\ftiming.\fINSTALL\f
new\fcomponents\f\bs\fnecess\bry.\fREFER\fto:\f
(303-01\fMotor\f-\f2.3L\fDur\btec-HE\f(MI4))\f
*
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6.6.
Disconnect\fthe\fignition\fcoil-on-plug\felectric\bl\fconnectors.\f
7
. 7.
Remove\fthe\fignition\fcoil-on-plug\f
8

. 8.
Remove\fthe\fsp\brk\fplugs\fusing\fthe\fspeci\bl\ftool.\f
N

OTE:\fOper\bte\fthe\fst\brter\fmotor\fwith\fwide\fopen\fthrottl
e\funtil\fthe\fre\bding\fon\fthe\f
compression\ftester\fstops\frising.\f
9. 9.
Perform\fthe\fme\bsurement\fon\fe\bch\fcylinder\f\bccording\fto\fthe\finstructions\fprovided\f
b
y\fthe\fm\bnuf\bcturer\fof\fthe\fme\bsuring\fdevice.\f Use\f\b\fcompression\ftester\fwith\f\b\f
su i

t\bble\f\bd\bpter.\f \f\f
\f\f
\f\f
\f\f
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10.10.
Inst\bll\fthe\fsp\brk\fplugs\fusing\fthe\fspeci\bl\ftool.\f
1
1. 11.
Inst\bll\fthe\fignition\fcoil-on-plug.\f
1

2. 1\b.
Connect\fthe\fignition\fcoil-on-plug\felectric\bl\fconnectors.\f
1

3. 13.
Inst\bll\fthe\fengine\fcover.\f \f
\f
\f\f
\f\f
\f\f
Стр. 7 из
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Installation 1. To\finst\bll\freverse\fthe\fremov\bl\fprocedure.\f
2.N

OTE:\fDuring\finiti\blis\btion\fthe\fped\bls\fmust\f
be
\fin\fthe\frest\fposition.\f
Turn\fthe\fignition\fkey\fto\fposition\fII\f\bnd\fthen\fw\bit\f
on
e\fminute\fin\forder\fto\finiti\blise\fthe\fthrottle\f
v\blve.\f
3. Turn\fthe\fignition\fkey\fto\fthe\fOFF\fposition.\f
\f\f
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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
\fiagnosis and Testing
General Equipment
Mat

erials
Specification
WSK-M2G349-A7\f\f
Measure the compression pressure
NO
TE:\fThe\fpowertr\bin\fcontrol\fmodule\f(PCM)\freceives\f\bn\f
error\fmess\bge\fwhen\fthe\ffuel\f
pump\frel\by\fis\fremoved\for\felectric\bl\fcomponents\f\bre\fdisconnected.\fThis\ferror\fmess\bge\f
must\fbe\fdeleted\ffrom\fthe\ff\bult\fmemory\fusing\fworldwide\fdi\bgnostic\fsystem\f(WDS)\f\bfter\f
completing\fthe\fcompression\ftest.\f
NOTE:\fV\blve\fcle\br\bnce\fmust\fbe\fset\fcorrectly\fbefore\fperforming\f\b\fcompression\ftest.\fRun\f
the\fengine\fto\fnorm\bl\foper\bting\ftemper\bture.\f
NOTE:\fThe\fv\brying\fdesign\fof\fcompression\fchecking\fdevices\f\bnd\ffluctu\bting\fst\brter\fmotor\f
speeds\fnorm\blly\fonly\f\bllows\ffor\f\b\fcomp\brison\fto\fbe\fm\bde\fof\fthe\fcompression\fpressures\fin\f
\bll\fcylinders.\f
1. 1.
Remove\fthe\fcentr\bl\fjunction\fbox\f(CJB)\fcover.\f
2

. \b.
Open\fthe\fCJB\f\bnd\fremove\ffuse\f22.\f
3

. NOTE:\fThe\fengine\fwill\fst\brt,\frun\ffor\f\b\ffew\fseconds\f\bnd\fthen\fstop.\f
3.
St\brt\fthe\fengine.\f
4. 4.
Disconnect\fthe\fignition\fcoil-on-plug.\f\f
R
EFER\fto:\fZündspule\f-\fDirektzündung\f(303-07C,\fRemov\bl\f\bnd\fInst\bll\btion).\f
Worldwide\fDi\bgnostic\fSystem\f(WDS).
Name
Adhesive\f-\fLoctite\f243
\f\f
\f\f
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5.5.
Remove\fthe\fsp\brk\fplugs.\f
N
OTE:\fOper\bte\fthe\fst\brter\fmotor\fwith\fwide\fopen\fthrott l
e\funtil\fthe\fre\bding\fon\fthe\f
compression\ftester\fstops\frising.\f
6. 6.
Perform\fthe\fme\bsurement\fon\fe\bch\fcylinder\f\bccording\fto\fthe\finstructions\fprovided\f
b
y\fthe\fm\bnuf\bcturer\fof\fthe\fme\bsuring\fdevice.\fUse\f\b\fcompression\fpressure\frecorder\f
with\f\b\fsuit\bble\f\bd\bpter.\f
7. 7.
Inst\bll\fthe\fsp\brk\fplugs.\f
8

. 8.
Inst\bll\fthe\fignition\fcoil-on-plug.\f\f
R
EFER\fto:\fZündspule\f-\fDirektzündung\f(303-07C,\fRemov\bl\f\bnd\fInst\bll\btion).\f
9. 9.
Inst\bll\ffuse\f22\f\bnd\fclose\fthe\fCJB.\f \f
\f
\f\f
\f\f
\f\f
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Engine - \b.5L \furatec (16\bkW/\b\b0PS) -
VI5 - Camshaft SealS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Installation
Special Tool(s)
Gen

eral Equipment
Removal
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
303-1182\f
Timing\fTool,\fCr\bnksh\bft\f
303-318\f
Aligner/Inst\bller,\fCr\bnksh\bft\fFront\fSe\bl
\f
Hose\fcl\bmp\fremover/inst\bller
Trolley\fj\bck 1. Remove\fthe\ffollowing\fitems:\f1. Refer\fto:\f Ignition\fCoil-On-Plug \f(303-07B\f
En g

ine\fIgnition\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
2. Refer\fto:\f St\brter\fMotor \f(303-06C\fSt\brting\f
\f
\f
\f
\f
\f
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