fuel FORD S-MAX 2006 Service Workshop Manual

Engine - \b.0L E\foBoost SCTi
(149kW/\b03PS) - MI4 - Exhaust ManifoldS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Installation
Removal and Installation
1. Refer\fto:\fTu
rboch\brger\f(303-04G\fFuel\fCh\brging\f
\bnd
\fControls\f-\fTurboch\brger\f-\f2.0L\fEcoBoost\f
SCTi\f(149kW/203PS)\f-\fMI4,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
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5. Remove\fthe\ffollowing\fitems:\f1. Refer\fto:\f C\bmsh\bfts\f(303-01B\fEngine\f-\f2.0L\f
Eco

Boost\fSCTi\f(149kW/203PS)\f-
\fMI4,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
2. Refer\fto:\f Int\bke\fM\bnifold\f(303-01B\fEngine\f-
\f2.0L\f
EcoBoost\fSCTi\f(149kW/203PS)\f-\fMI4,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
3. Refer\fto:\f Turboch\brger \f(303-
04G\fFuel\fCh\brging\f
\bnd\fControls\f-\fTurboch\brger\f-\f2.0L\fEcoBoost\f
SCTi\f(149kW/203PS)\f-\fMI4,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
6. Torque:\b 24\fNm
\f
7. \f\f 1.Torque:\b 24\fNm
\f
2. Torque:\b 10\fNm
\f
\f
\f
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Engine - \b.0L E\foBoost SCTi
(149kW/\b03PS) - MI4 - EngineS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal
Spe\fial Tool(s)
Ge

neral Equipment
303-122\f
Lifting\fBr\bcket,\fEngine\f
310-137\f
Disconnect\fTool,\fFuel\fLine
\f
3.5 mm drill bit
Cable ties
Center pun\fh
Hose \flamp remover/installer
Hydrauli\f jib \frane
Mounting table set
Retaining Strap
Transmission ja\fk 1. \f
2. R
efer\fto:\f Cooling\fSystem\fDr\bining\f\bnd\fV\bcuum\f
Fi l

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

i\f(149kW/203PS)\f-\fMI4,\fGener\bl\fProcedures).\f
3. Remove\fthe\ffollowing\fitems:\f 1. Refer\fto:\f B\bttery\f(414-
01\fB\bttery,\fMounting\f
\bnd\fC\bbles,\fRemov\bl\f\bnd\fInst\bll\btion).\f
2. Refer\fto:\f Air\fCle\bner\f(303-12B\fInt\bke\fAir\f
Dis

tribution\f\bnd\fFiltering\f-\f2.0L\fEcoBoost\f
SCTi\f(149kW/203PS)\f-\fMI4,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
4. \f
\f
\f
\f\f
\f\f
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\f\f\fescription
Control\funit\f-\fv\bri\bble\fc\bmsh\bft\ftiming\f
C\bmsh\bft\fbe\bring\fc\bp\f
VCT\foil\fcontrol\fsolenoid\f
V\blve\fcover\f
C\bmsh\bft\fPosition\fSensor\f
C\bmsh\bft\fsensor\fring\f
This\fsystem\fis\f\bn\felectronic\blly\fcontrolled\fc\bmsh\bft\f\bdjuster\fth\bt\f\bllows\fv\bri\bble\ftiming\ffor\f
th
e\finlet\fc\bmsh\bft.\f
The\fv\blves\f\bre\fdriven\fby\f\b\ftiming\fch\bin\fwhich\fdrives\fthe\finlet\fc\bmsh\bft\ftiming\fcontrol\funit.\f
This\funit\fdrives\fthe\f\bssoci\bted\fc\bmsh\bfts.\fThe\ftiming\fch\bin\fis\ftensioned\fusing\f\b\f
convention\bl\ftiming\fch\bin\ftensioner.\f
The\finlet\fc\bmsh\bft\fis\ffitted\fwith\f\b\fsensor\fring\ffor\fthe\f\bctive\fc\bmsh\bft\fposition\f(CMP)\fsensor.
\f
This\fCMP\fsensor\fis\fmounted\finside\fthe\fv\blve\fcover.\f
Timing\fch\bin\frepl\bcement\fdoes\fnot\frequire\fthe\fv\bri\bble\fc\bmsh\bft\ftiming\fcontrol\funit\fto\fbe\f
disconnected.\f
To\fensure\ftrouble-free\foper\btion\fof\fthe\fv\bri\bble\fc\bmsh\bft\ftiming\fsystem\f\bnd\foptimum\f
engine\fperform\bnce,\fit\fis\fessenti\bl\fto\f\bdhere\fprecisely\fto\fthe\fv\blve\ftiming\f\bdjustment\f
procedure.\f
A\fspeci\bl\ftool\fis\fneeded\fto\ffix\fthe\fc\bmsh\bfts\fin\fthe\f\bdjustment\fposition.\f
Remember\fth\bt\fthis\fspeci\bl\ftool\fmust\fnot\fbe\fused\fto\fkeep\fthe\fc\bmsh\bft\ffrom\frot\bting\fwhen\f
mounting\fthe\fc\bmsh\bft\fsprocket.\fThey\fm\by\fonly\fbe\fkept\ffrom\frot\bting\fby\fusing\fthe\f
hex\bgon,\fwhich\fh\bs\fbeen\fspeci\blly\fprovided\ffor\fthis\fpurpose.\f
Adv\bnt\bges\fof\fv\bri\bble\fc\bmsh\bft\ftiming\f(VCT)\f

Lower\ffuel\fconsumption\fdue\fto\fimproved\fvolumetric\fefficiency\f\f

Enh\bnced\fengine\fpower\f\bnd\ftorque\f\f

Improved\fidling\fch\br\bcteristics\f
I
t

em
1
2
3
4
5
6
\f
Part Number -
-
-
-
-
-
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Engine - \b.3L \furatec-HE (118kW/160PS)
- MI4 - EngineS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
\fiagnosis and Testing
Special Tool(s)
Gen

eral Equipment
Materials
Specification
WSK-M2G349-A7\f\f
1. 1.
Verify\fthe\fcustomer\fconcern.\f
2

. \b.
Visu\blly\finspect\ffor\fobvious\fsigns\fof\fmech\bnic\bl\for\felectric\bl\fd\bm\bge.\f
3

. 3.
Resolve\f\bny\fobvious\fc\buses\ffor\f\b\fconcern\ffound\fduring\fthe\fvisu\bl\finspection\fbefore\f
c
\brrying\fout\f\bny\ffurther\ftests.\f
4. 4.
If\fthe\fconcern\fpersists,\fcheck\fthe\fsymptoms\f\bnd\fcontinue\fwith\fthe\fSymptom\f
C
h\brt.\f
Visual Inspection Chart
Symptom Chart
Symptom chart
Socket,\fSp\brk\fPlug\f
303-499\f
Use\f\b\fcompression\ftester
Name
Adhesive\f-\fLoctite\f243
Mechanica\bE\bectrica\b

Cool\bnt\fle\bks\f\f

Le\bking\foil.\f\f

Fuel\fle\bks\f\f

Visibly\fd\bm\bged\for\fworn\fp\brts\f\f

Loose\for\fmissing\fnuts\for\fbolts\f
Fuse(s)\f\f

Loose\for\fcorroded\fconnector(s)\f\f

Control\funit\f\f

D\bm\bged\for\fworn\fswitch(es)\f
\fymptomPossib\be \fourcesAction
Loss\fof\foilOil\fle\bks\fon\fcomponents\f
th\bt\f\bre\feither\fco\bted\fin\foil\f
themselves\for\fon\f
components\floc\bl\fto\fthem.\f
*CHECK\ffor\fevidence\fof\foil\fle\bks\fon\f
components.\fUse\f\bn\fultr\bviolet\f(UV)\fle\bk\f
tester\fif\f\bn\foil\fle\bk\fis\fnot\fevident.\f
INSTALL\fnew\fg\bskets\for\fcomponents\f\bs\f
required.\f
*
Intern\bl\for\fextern\bl\fle\bk\f\bt\f
the\foil\fcooler.\f
*
CHECK\fwhether\fthere\fis\f\bn\foil\ffilm\fon\fthe\f
cool\bnt\fin\fthe\fcool\bnt\fexp\bnsion\ft\bnk.\f
INSTALL\f\b\fnew\foil\fcooler\for\foil\fcooler\f
se\bl.\f
*
Le\bk\fon\fthe\fcr\bnksh\bft\foil\f
se\bl\f
*INSTALL\f\b\fnew\fcr\bnksh\bft\foil\fse\bl.\fREFER\f
to:\f
Kurbelwellendichtring\fvorn\f(303-01\f
Motor\f-\f2.0L\fDur\btec-HE\f(MI4),\f
Remov\bl\f\bnd\fInst\bll\btion),\f
Kurbelwellendichtring\fhinten\f(303-
01\f
Motor\f-\f2.3L\fDur\btec-HE\f(MI4),\f
Remov\bl\f\bnd\fInst\bll\btion).\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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1.1.
Remove\fthe\fcentr\bl\fjunction\fbox\fcover.\f
2
. \b.
Det\bch\fthe\fcentr\bl\fjunction\fbox\f(CJB).\f
3

. 3.
Open\fthe\fCJB\f\bnd\fremove\ffuse\f23\f-\ffuel\fpump\frel\by.\f
N

OTE:\fThe\fengine\fwill\fst\brt,\frun\ffor\f\b\ffew\fseconds\f\bnd
\fthen\fstop.\f
4. 4.
St\brt\fthe\fengine.\f
5

. 5.
Det\bch\fthe\fengine\fcover.\f \f
\f
\f\f
\f\f
\f\f
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14.14.
Inst\bll\ffuse\f23\f(fuel\fpump\frel\by)\f\bnd\fclose\fthe\fcentr\bl\fjunction\fbox\f(CJB).\f
1
5. 15.
Att\bch\fthe\fCJB.\f
1

6. 16.
Inst\bll\fthe\fcentr\bl\fjunction\fbox\fcover.\f
1

7. 17.
Reset\fthe\fPCM\ff\bult\fmemory.\f
M

easuring the oil pressure
1. 1.
R\bise\fvehicle.\fREFER\fto:\f(100-02\fJ\bcking\f\bnd\fLifting)\f\f
J
\bcking \f(Description\f\bnd\fOper\btion),\f
L
ifting \f(Description\f\bnd\fOper\btion).\f \f\f
\f\f
\f\f
\f\f
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Engine - \b.3L \furatec-HE (118kW/160PS)
- MI4 - Intake ManifoldS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Installation
General Equipment
Removal
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
Schlitzschr\bubendreher
Trolley\fj\bck
1.General \bqui\fment: Schlitzschr\bubendreher \f
2. \f
3

. Refer\fto:\f Air\fCle\bner\f(303-12A\fInt\bke\fAir\f
Di s

tribution\f\bnd\fFiltering\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
4. Refer\fto:\f B\bttery\fDisconnect\f\bnd\fConnect\f(414-
01 \f

B\bttery,\fMounting\f\bnd\fC\bbles,\fGener\bl\f
Procedures).\f
5. Refer\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des

cription\f\bnd\fOper\btion).\f
6. \f
7. \f\f 1.Torque: 48\fNm
\f
2. Torque: 80\fNm
\f
\f\f
\f\f
\f\f
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Engine - \b.3L \furatec-HE (118kW/160PS)
- MI4 - Engine Front CoverS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Installation
Materials
Gen

eral Equipment
Removal
NO
TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\fins t
\bll\btion\fdet\bils.\f
NameSpec\bf\bcat\bo\f
Silicone\fSe\bl\bnt\fLBWSE-M4G323-A4\f/\f2U7J-M4G323-AA
Trolley\fj\bck
1. Refer\fto:\fHe\bdl\bmp\fAssembly \f(417-01\fExterior\f
Li g

hting,\fRemov\bl\f\bnd\fInst\bll\btion).\f
2. Refer\fto:\f Cr\bnksh\bft\fPulley \f(303-01A\fEngine\f-\f
2.0

L\fDur\btec-HE\f(107kW/145PS)\f-\fMI4/2.0L\f
Dur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
3. \f
4. \f
5. General \bqui\fment: Trolley\fj\bck\f
6. \f
\f

\f
\f\f
\f\f
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