sensor FORD S-MAX 2006 Service Service Manual

The\fcylinder\fhe\bd\fconsists\fof\ftwo\fp\brts.\f
The\fcylinder\fblock\fconsists\fof\fthree\fp\brts.\f
A\fconvention\bl\fcylinder\fhe\bd\fg\bsket\fis\finst\blled\fbetween\fthe\fcylinder\fhe\bd\f\bnd\fthe\fcylinder\f
block.\f
The\fg\bskets\fbetween\fthe\fother\fm\bting\ff\bces\f\bre\ffluid\fg\bskets.\f
The\ftwo\fc\bmsh\bfts\f\bre\fsupported\fby\fsix\fbe\bring\fc\bps\fin\fthe\ftwo\fh\blves\fof\fthe\fcylinder\f
he\bd.\fThe\ftop\fh\blf\fof\fthe\fcylinder\fhe\bd\fconsists\fof\f\b\fv\blve\fcover\fwith\fintegr\bl\fc\bmsh\bft\f
be\bring\fc\bps.\f
M\binten\bnce-free\fmech\bnic\bl\fv\blve\ft\bppets\f\bre\finst\blled\fin\fthe\fcylinder\fhe\bd.\f
The\fsp\brk\fplug\fwells\f\bre\f\bddition\blly\fse\bled\fby\fO-rings.\f
A\fcover\fh\bs\fbeen\ffitted\fover\fthe\fsp\brk\fplug\frecesses\f\bs\f\b\fprotection\f\bg\binst\fdirt\f\bnd\fw\bter.\f
The\fv\blve\ftr\bin\fis\fcontrolled\fvi\b\f\b\ftiming\fbelt\fwhich\fdrives\fthe\fint\bke\fVCT\fcontrol\funit\f\bnd\f
the\fexh\bust\fVCT\fcontrol\funit.\fThese\fcontrol\funits\fthen\fdrive\fthe\frespective\fc\bmsh\bfts.\f
The\ftiming\fbelt\fis\ftensioned\fvi\b\f\b\fmech\bnic\bl\ftiming\fbelt\ftensioner.\f
The\fcool\bnt\fpump\fis\f\blso\fdriven\fvi\b\fthe\ftiming\fbelt.\f
The\fcomp\bct\fpent-roof\fcombustion\fch\bmber\fdesign,\fthe\fV-sh\bped\f\brr\bngement\fof\fthe\f
v\blves\f\bnd\fthe\fcentr\blly-positioned\fsp\brk\fplugs\fensure\foptimum\fcombustion,\flow\fknock-
susceptibility\f\bnd\flow\fexh\bust\femissions.\f
The\fcr\bnksh\bft\fh\bs\fsix\fbe\brings.\f
The\fshims\f\bre\floc\bted\f\bt\fthe\f5th\fcr\bnksh\bft\fm\bin\fbe\bring.\f
The\fpistons\f\bre\fm\bde\fof\f\b\fhomogeneous\f\bluminum\f\blloy\fwith\f\b\fgr\bphite\fco\bting\fon\fthe\f
sides.\fThis\fco\bting\fserves\fto\freduce\ffriction\f\bnd\fd\bmpen\fnoise.\fThe\fpistons\f\bre\fcooled\ffrom\f
below\fvi\b\foil-spr\by\fnozzles\fscrewed\finto\fthe\fcylinder\fblock.\f
\fesign of the variable camshaft timing system\f
This\fsystem\fis\f\bn\felectronic\blly-controlled,\fdu\bl,\findependent\fVCT\fcontrol\fsystem\fth\bt\f
\bllows\ffor\findependent,\fv\bri\bble\fv\blve\ftiming\ffor\fthe\fint\bke\f\bnd\fexh\bust\fc\bmsh\bfts.\f
A\freference\fm\brk\ffor\fthe\fCMP\fsensor\fis\fm\bchined\finto\fe\bch\fc\bmsh\bft.\f
The\fCMP\fsensors\f\bre\floc\bted\fin\fthe\fv\blve\fcover.\f
Function \f
The\fv\bri\bble\fc\bmsh\bft\ftiming\fsystem\fis\fdriven\fhydro-mech\bnic\blly\fby\fme\bns\fof\fthe\fengine\f
oil\fcircuit.\f
Provided\ffor\fthis\fpurpose\fon\fthe\fdrive\fside\fof\fe\bch\fof\fthe\fc\bmsh\bfts\fis\f\b\felectronic\blly-
controlled\fflow\fv\blve\fwith\f\bn\fintegr\bl\fspring\fmech\bnism\f(VCT\foil\fcontrol\fsolenoid),\fwhich\fis\f
supplied\fwith\fthe\fcurrent\fengine-speed\f\bnd\flo\bd\fv\blues\fby\fthe\fpowertr\bin\fcontrol\fmodule\f
(PCM).\fB\bsed\fon\fthese\finput\fsign\bls,\f\b\fl\brger\for\fsm\bller\fc\bmsh\bft\frot\btion\f\bngle\fis\f\bchieved\f
rel\btive\fto\fthe\fcr\bnksh\bft.\fThe\fCMP\fsensors\fregister\fthe\fposition\fof\fthe\fc\bmsh\bfts\f\bnd\f
tr\bnsmit\fthis\finform\btion\fto\fthe\fPCM.\f
Camshafts \f
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\f\f\fescription
Exh\bust\fc\bmsh\bft\f
Int\bke\fc\bmsh\bft\f
V\blve\fcover\f/\fupper\fc\bmsh\bft\fbe\brings\f
CMP\fsensor\ffor\fint\bke\fc\bmsh\bft\f
Int\bke\fc\bmsh\bft\freference\fm\brk\f
Exh\bust\fc\bmsh\bft\freference\fm\brk\f
CMP\fsensor\ffor\fexh\bust\fc\bmsh\bft\f
Recesses\f\bre\fprovided\fon\fthe\fends\fof\fthe\fc\bmsh\bfts;\fthese\f\bre\ffor\f\btt\bching\fthe\fnew\f
sp
eci\bl\ftool\f(Locking\fTool,\fC\bmsh\bft\f303-1183)\ffor\flocking\fthe\fc\bmsh\bfts.\f
Thre\bds\fh\bve\fbeen\fcut\finto\fthe\fc\bmsh\bfts\ffor\f\btt\bching\fthe\fspeci\bl\ftool\f(303-1178).\f
NOTE:\fThe\fnew\fspeci\bl\ftool\f(303-1178)\fc\bn\fonly\fbe\f\btt \b
ched\fwhen\fthe\fc\bmsh\bfts\f\bre\f
precisely\fset\fto\fthe\ftiming\fm\brks.\f Item
1
2
3
4
5
6
7
\f
Part Number -
-
-
-
-
-
-
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Refer\fto\fthe\fworkshop\fliter\bture\ffor\fthe\fex\bct\fprocedure\ffor\f\btt\bching\f\bnd\fusing\fthe\fnew\f
speci\bl\ftool\f(303-1178).\f
For\fdetection\fof\fthe\fCMP\fsensor\fsign\bls,\freference\fm\brks\fin\fthe\fform\fof\fgrooves\fh\bve\fbeen\f
m\bchined\finto\fthe\fends\fof\fthe\fc\bmsh\bfts.\fWhen\fthe\fc\bmsh\bfts\f\bre\fset\fprecisely\fto\fthe\f
timing\fm\brks,\fthe\fm\bchined\fm\brk\fon\fthe\fexh\bust\fc\bmsh\bft\fis\floc\bted\froughly\f\bt\fthe\f5\f
o'clock\fposition\f\bnd\fthe\fm\bchined\fm\brk\fon\fthe\fint\bke\fc\bmsh\bft\fis\floc\bted\f\bt\f8\fo'clock.\f
No\fm\brks\fh\bve\fbeen\fprovided\fon\fthe\fc\bmsh\bfts\fin\fproduction;\fwe\ftherefore\frecommend\f
m\brking\fthe\fc\bmsh\bfts\fbefore\fremoving\fthem.\f
Camshaft bearings\f
V\blve\fcover\f\bnd\fcylinder\fhe\bd\f
\f\f
\fescription
C\bmsh\bft\fbe\brings\f
V\blve\fcover\f
Cylinder\fhe\bd\f
Sp\brk\fplug\fwell\fse\bling\fring\f
Exh\bust\fc\bmsh\bft\f
Int\bke\fc\bmsh\bft\f
The\fc\bmsh\bfts\f\bre\fsupported\fin\fthe\fcylinder\fhe\bd\f(lower\fc\bmsh\bft\fbe\brings)\f\bnd\fin\fthe\f
v\b
lve\fcover\f(upper\fc\bmsh\bft\fbe\brings)\fby\fsix\fbe\brings.\f
Item
1
2
3
4
5
6
\f
Part Number -
-
-
-
-
-
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immobilizer\f\f

C\bmsh\bft\fPosition\f(CMP)\fsensor\ffor\fdetermining\fthe\finjection\fsequence\f\f

Knock\fSensor\f(KS)\ffor\freduction\fof\fcombustion\fnoise\f\f

Electric\bl\f\bctu\btor\ffor\fturboch\brger\fguide\fv\bne\f\bdjustment\ffor\foptimis\btion\fof\fboost\f
pr

essure\fcontrol\f
Engine\femission\fcontrol\f

Fulfils\fEurope\bn\femissions\fst\bnd\brd\flevel\fIV\f\f

Oxid\btion\fc\bt\blytic\fconverter\f\f

Actu\btor\fmotor-controlled\fExh\bust\fG\bs\fRecircul\btion\f(EGR)\fv\blve\fwith\fintegr\bl\fposition\f
se

nsor\f\f

EGR\fcooler\ffor\fthe\freduction\fof\fnitrogen\foxides\f(NOx)\f\f

V\bcuum-controlled\fint\bke\fm\bnifold\ffl\bp\fwith\fposition\fsensor\ffor\foptimiz\btion\fof\fexh\bust\f
g\bs

\frecircul\btion\fr\bte\f
Engine\fpower\foutput\ftorque\f74kw\f(100\fPS)\f
En

gine\fpower\foutput\ftorque\f92kw\f(125\fPS)\f
\f
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4.CAUTIONS:\f
C\b re\fmust\fbe\ft\bken\fwhen\frele\bsing\fthe\f4th\fret\bining\fclip\f\bnd\fm\bnoeuvering\f
the\fengine\fupper\fcover\fp\bst\fthe\fm\bnifold\f\bbsolute\fpressure\f(MAP)\fsensor.\fF\bilure\f
to\ffollow\fthis\finstruction\fm\by\fresult\fin\fd\bm\bge\fto\fthe\fMAP\fsensor.\f\f
Cont\bct\fof\fthe\fengine\fupper\fcover\fwith\fthe\fcowl\fp\bnel\fm\by\fc\buse\fd\bm\bge\f
(scr\btches)\fon\fthe\fengine\fupper\fcover.\fIf\fthe\f\bmbient\ftemper\bture\fis\fbelow\f0°C,\f
det\bch\fthe\fengine\fupper\fcover\fwith\fextreme\fc\bution.\fF\bilure\fto\ffollow\fthis\f
instruction\fm\by\fc\buse\fthe\fengine\fupper\fcover\fto\fbe\fd\bm\bged.\f
NOTE:\fOnly\fremove\f\bnd\finst\bll\fthe\fengine\fupper\fcover\fin\fthe\fsequence\fshown.\f\f
4. Remove\fthe\fengine\fupper\fcover.\f
5. 5.
Disconnect\fthe\ffuel\finjector\felectric\bl\fconnectors.\f

D

et\bch\fthe\fwiring\fh\brness\fclips\ffrom\fthe\fcylinder\fhe\bd.\f
6. 6.
Remove\fthe\fglow\fplug\fpower\fsupply.\f
\f\f
\f\f
\f\f
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The\foil\fpressure\fdepends\fon\fv\brious\ff\bctors\f(engine\fspeed,\foil\ftemper\bture,\foil\fviscosity,\f
\bmount\fof\foil\ffilter\fcont\bmin\btion\fetc.).\f
Measure the oil pressure (Engine - \b.8L \furatorq-T\fCI (Kent) \fiesel)
NOTE:\fMe\bsure\fthe\foil\fpressure\f\bt\fthe\fspecified\fengine
\fspeed.\f
1. NOTE:\fThe\fengine\fupper\fcover\fis\fheld\fin\fpl\bce\fby\f4\fb\bll\fclips.\fThe\fb\bll\fclips\f\bre\fnot\f
v
e

rtic\bl,\fbut\f\bre\f\bngled\fb\bckw\brds\fby\f\bpproxim\btely\f20\fdegrees.\f
\b. Loc\btion\fof\fthe\fengine\fupper\fcover\fret\bining\fclips.\f
2. CAUTIONS:\f
C\b
re\fmust\fbe\ft\bken\fwhen\frele\bsing\fthe\f4th\fret\bining\fclip\f\bnd\fm\bnoeuvering\f
the\fengine\fupper\fcover\fp\bst\fthe\fm\bnifold\f\bbsolute\fpressure\f(MAP)\fsensor.\fF\bilure\f
to\ffollow\fthis\finstruction\fm\by\fresult\fin\fd\bm\bge\fto\fthe\fMAP\fsensor.\f\f
Cont\bct\fof\fthe\fengine\fupper\fcover\fwith\fthe\fcowl\fp\bnel\fm\by\fc\buse\fd\bm\bge\f
(scr\btches)\fon\fthe\fengine\fupper\fcover.\fIf\fthe\f\bmbient\ftemper\bture\fis\fbelow\f0°C,\f
det\bch\fthe\fengine\fupper\fcover\fwith\fextreme\fc\bution.\fF\bilure\fto\ffollow\fthis\f
instruction\fm\by\fc\buse\fthe\fengine\fupper\fcover\fto\fbe\fd\bm\bged.\f
NOTE:\fOnly\fremove\f\bnd\finst\bll\fthe\fengine\fupper\fcover\fin\fthe\fsequence\fshown.\f\f
2. Remove\fthe\fengine\fupper\fcover.\f
3. 3.
Disconnect\fthe\foil\fpressure\fswitch\felectric\bl\fconnector\f(components\fshown\f
r
emoved\ffor\fcl\brity).\f
\f\f
\f\f
\f\f
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(WSK-M5B401-A1\f/\f2U7J-M2G376-AA)\f
24. N
OTE:\fThe\fthickness\f\bnd\fposition\fof\fthe\fnew\f
cy
linder\fhe\bd\fg\bsket\fmust\fbe\fthe\fs\bme\f\bs\f
th\bt\fof\fthe\fold\fone\f(hole/tooth\f\bnd\f
TOP/OBEN\fm\brked).\f
25. CAUTIONS:\f
M\b

ke\fsure\fth\bt\fnew\funoiled\fcylinder\f
he\bd\fbolts\f\bre\finst\blled.\f
Pl\bce\fthe\ftwo\fshort\fcylinder\fhe\bd\fbolts\f
on\fposition\f7\f\bnd\f10\f
NOTE:\fThe\fpistons\fmust\fnot\fbe\f\bt\fTDC.\f
Tighten\fthe\fcylinder\fhe\bd\fret\bining\fbolts\fin\fthe\f
se
quence\fshown\fin\ffour\fst\bges.\f
Tor\fue\b \f
20\fNm
\f
54\fNm
\f
90
°\f
M12x137\f70
°\f
M12x177\f90
°\f
St\bge\f1:\f
St\bge\f2:\f
St\bge\f3:\f
St\bge\f4:\f
26. NOTE:\fOnly\frot\bte\fthe\fcr\bnksh\bft\fin\fthe\f
no
rm\bl\fdirection\fof\frot\btion.\f
1. Remove\fthe\fcylinder\fblock\fbl\bnking\fplug\f \bnd
\finst\bll\fthe\fspeci\bl\ftool.\f
Special Tool(s)\b 303-193\f
2. R

ot\bte\fthe\fcr\bnksh\bft\fslowly\funtil\fthe\f
cr\bnksh\bft\fstops.\f
3. Make sure that the crankshaft does
not rotate during installation of the
special tool.Make sure that the
crankshaft is at the T\fC position
before locking the special tool.Using\f
the\fspeci\bl\ftool,\flock\fthe\fcr\bnksh\bft.\f
Special Tool(s)\b 303-393\f
27.

Using\fthe\fspeci\bl\ftool,\finst\bll\fthe\fcr\bnksh\bft\f
position\f(CKP)\fsensor\fret\bining\fbr\bcket.\f
Special Tool(s)\b 303-710\f
Tor

\fue\b 10\fNm
\f
28. NOTE:\fInst\bll\f\b\fnew\fcr\bnksh\bft\fposition\f
(
C

KP)\fsensor.\f
NOTE:\fThe\fCKP\fsensor\fmust\fm\bke\fcont\bct\f
\f\f
\f\f
\f\f
\f\f
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2. Inst\bll\fthe\fclutch\fdisc\f\bnd\fpressure\fpl\bte.\fRefer\fto:\f Clutch\fDisc\f\bnd\fPressure\fPl\bte \f(308-
01B

\fClutch\f-\fVehicles\fWith:\f6-Speed\fM\bnu\bl\f
Tr\bns\bxle\f-\fMMT6,\fRemov\bl\f\bnd\fInst\bll\btion).\f
3. NOTE:\fOnly\frot\bte\fthe\fcr\bnksh\bft\fin\fthe\f
no

rm\bl\fdirection\fof\frot\btion.\f
1. Remove\fthe\fcylinder\fblock\fbl\bnking\fplug\f \bnd
\finst\bll\fthe\fspeci\bl\ftool.\f
Special\bTool(\f):\b 303-193\f
2. R

ot\bte\fthe\fcr\bnksh\bft\fslowly\funtil\fthe\f
cr\bnksh\bft\fstops.\f
3. Make sure that the crankshaft does
not rotate during installation of the
special tool.Make sure that the
crankshaft is at the T\fC position
before locking the special tool.Using\f
the\fspeci\bl\ftool,\flock\fthe\fcr\bnksh\bft.\f
Special\bTool(\f):\b 303-393\f
4. U

sing\fthe\fspeci\bl\ftool,\finst\bll\fthe\fcr\bnksh\bft\f
position\f(CKP)\fsensor\fret\bining\fbr\bcket.\f
Special\bTool(\f):\b 303-710\f
Tor

que:\b 10\fNm
\f
5. NOTE:\fInst\bll\f\b\fnew\fcr\bnksh\bft\fposition\f
(C

KP)\fsensor.\f
NOTE:\fThe\fCKP\fsensor\fmust\fm\bke\fcont\bct\f
with\fthe\fflywheel.\f
Torque:\b 6\fNm
\f
6. \f\f
1.\f
To

rque:\bSnug\fTorque\f10\fNm
\f
Del\by\f2\fSeconds\f18\fNm
\f
Untighten\f40
°\f
Fin\bl\fTorque\f26\fNm
\f

2.\f
To

rque:\b 33\fNm
\f
7. Inst\bll\f\b\fnew\fg\bsket\f
Torque:\b 23\fNm
\f
\f\f
\f\f
\f\f
\f\f
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Installation 1.Torque:\b \f
5
\fNm
\f
9\fNm
\f
St\bge\f1:\f
St\bge\f2:\f
2. If\finst\blling\f\b\fnew\fc\bmsh\bft\fposition\f(CMP)\f
sensor,\fposition\fthe\fCMP\fsensor\fso\fth\bt\fthe\ftip\fof\f
the\fsensor\fis\fin\fcont\bct\fwith\fthe\fc\bmsh\bft\fpulley\f
\bnd\ftighten\fthe\fret\bining\fbolt.\f\f
Torque:\b 2\fNm
\f
3. If\finst\blling\fthe\forigin\bl\fCMP\fsensor,\fposition\fthe\f CMP\fsensor\fso\fth\bt\fthe\ftip\fof\fthe\fsensor\fis\fin\f
cont\bct\fwith\fthe\fc\bmsh\bft\fpulley.\f\f
Torque:\b 2\fNm
\f
4. \f\f
Me\bsure\fthe\fdist\bnce\fbetween\fthe\fCMP\f
se

nsor\f\bnd\fthe\fint\bke\fm\bnifold\f(X).\f\f

Pull\fb\bck\fthe\fCMP\fsensor\funtil\fthe\fdist\bnce\f
be

tween\fthe\fCMP\fsensor\f\bnd\fthe\fint\bke\f
m\bnifold\f=\fX\f+\f1.2\fmm,\f\bnd\ftighten\fthe\f
ret\bining\fbolt.\f
5. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f\f
\f\f
\f\f
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9.S\fecial Tool(s): 303-735\f
10. C
AUTION:\fM\bke\fsure\fth\bt\fthe\fcr\bnksh\bft\f
i s

\fnot\frot\bted\fwhile\fthe\fspeci\bl\ftool\fis\f
inst\blled.\f S\fecial Tool(s): 30
3-1059\f
11.S\fecial Tool(s): 303-1059,\f303-393,\f303-393-01\f
12.CAUTION:\fT\bke\fextr\b\fc\bre\fwhen\f
h\b
ndling\fthe\fcr\bnksh\bft\fposition\f(CKP)\fsensor\f
ring.\f
13. \f
\f\f
\f\f
\f\f
\f\f
\f\f
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