drive FORD S-MAX 2006 Service Manual PDF

Engine - \b.0L \furatec-HE (107kW/145PS)
- MI4/\b.0L \furatec-HE Flex Fuel
(107kW/145PS) - MI4 - Engine
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal
Special 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
Center punch
Hose clamp remover/installer
Hydraulic jib crane
Mounting table set
Retaining Strap
Schlitzschraubendreher 1.General \bqui\fment: Sc
hlitzschr\bubendreher\f
2. R
efer\fto:\f Cooling\fSystem\fDr\bining,\fFilling\f\bnd\f
Bl e

eding \f(303-03A\fEngine\fCooling\f-\f2.0L\fDur\btec-
HE\f

(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\f
Fuel\f(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fGener\bl\fProcedures).\f
3. Remove\fthe\ffollowing\fitems:\f 1. Refer\fto:\f Accessory\fDrive\fBelt \f(303-05A\f
Acc

essory\fDrive\f-\f2.0L\fDur\btec-HE\f
(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\f
Fuel\f(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-
HE\f
(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
2. Remove\fthe\fright-h\bnd\fhe\bdl\bmp.\f
Refer\fto:\f He\bdl\bmp\fAssembly \f(417-01\f
Ext

erior\fLighting,\fRemov\bl\f\bnd\fInst\bll\btion).
\f
3. Refer\fto:\f B\bttery\f(414-01\fB\bttery,\fMounting\f
\bnd\fC\bbles,\fRemov\bl\f\bnd\fInst\bll\btion).\f
4. \f
\f
\f
\f\f
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40.Torque:\b 12\fNm\f
41. Torque:\b 12\fNm
\f
42. Refer\fto:\f Ge\brshift\fC\bble\fAdjustment\f-\fVehicles\f
Wit

h:\f5-Speed\fM\bnu\bl\fTr\bns\bxle\f(MTX-75) \f(308-
00\f

M\bnu\bl\fTr\bnsmission/Tr\bns\bxle\f\bnd\fClutch\f-\f
Gener\bl\fInform\btion,\fGener\bl\fProcedures).\f
43. Inst\bll\fthe\ffollowing\fitems:\f 1. Refer\fto:\f Accessory\fDrive\fBelt \f(303-05A\f
Ac c

essory\fDrive\f-\f2.0L\fDur\btec-HE\f
(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\f
Flex\fFuel\f(107kW/145PS)\f-\fMI4/2.3L\f
Dur\btec-HE\f(118kW/160PS)\f-\fMI4,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
2. Right-h\bnd\fhe\bdl\bmp\f
Refer\fto:\f He\bdl\bmp\fAssembly \f(417-01\f
Ext

erior\fLighting,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
3. Refer\fto:\f B\bttery\f(414-01\fB\bttery,\f
Mou

nting\f\bnd\fC\bbles,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
44. \f
\f\f
\f\f
\f\f
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Engine - \b.0L E\foBoost SCTi
(149kW/\b03PS) - MI4 - Spe\fifi\fationsS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Engine Data
Engine Oil
Engine Oil Capa\fity
Lubri\fants, Fluids, Sealers and Adhesives
Oil Pressure
Valve Clearan\fe
Cylinder Head
Descrip\bion
Engine\fcodeTNBA
Firing\forder1-4-3-2
Emission\flevelSt\bge\fV
Bore\f87.5\fmm
Stroke83.1\fmm
Cubic\fc\bp\bcity1999\fcm³
Compression\fr\btio10\f:\f1
Power\foutput\f\bt\f6000\frpm149\fkW\f(203\fPS)
M\bximum\ftorque\f\bt\f1750\f-\f4000\frpm300\fNm
M\bximum\fengine\fspeed\f(intermittent)6800
M\bximum\fengine\fspeed\f(continous)6500
Idle\fspeed760
Number\fof\fm\bin\fbe\brings5
C\bmsh\bft\fdriveCh\bin
Oil\fconsumption0.5\fl/1000\fKm
Viscosi\b\f / ambien\b \bempera\bureT\fpeSpecifica\bion
Re\fommended engine oil
SAE\f5W-30\f/\fbelow\f-20°C\fto\fover+40°CFord\fFormul\b\fEWSS-M2C913-C
Alternative engine oils (for topping up only)
SAE\f10W-40\f/\fbelow\f-20°C\fto\fover\f+40°CFord\fFormul\b\fXR+ACEA\fA3/B3
SAE\f5W-40\f/\fbelow\f-20°C\fto\fover\f+40°CFord\fFormul\b\fS/SDACEA\fA3/B3
Descrip\bionLi\bers
Service\ffill\fincluding\ffilter5.4
Service\ffill\fincluding\ffilter5.1
Spezifika\bionen
Se\bl\bnt,\foil\fp\bn\fcont\bct\fsurf\bce\fto\fcr\bnksh\bft\fre\br\fse\bl\fret\biner,\foil\fp\bn\fto\f
cylinder\fblock,\foil\fp\bn\fto\ffront\fcover,\fengine\ffront\fcover\fto\fcylinder\fblock/\foil\f p\bnWSE-M4G323-A4
Oil\fpressure\fswitch\f\bnd\fengine\ffront\fcover\fbl\bnking\fplug\fse\bl\bntWSK-M2G349- A7
Descrip\bionBar
Minimum\foil\fpressure\f\bt\f800\f-\f850\frpm\f(norm\bl\foper\bting\ftemper\bture)1.0
Minimum\foil\fpressure\f\bt\f4000\frpm\f(norm\bl\foper\bting\ftemper\bture)3.2\f-\f4.5
Descrip\bionmm
V\blve\fcle\br\bnce\f(engine\fcold),\fint\bke0.19\f-\f0.31
V\blve\fcle\br\bnce\f(engine\fcold),\fexh\bust0.29\f-\f0.41
Descrip\bionmm
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Engine - \b.0L E\foBoost SCTi (149kW/\b03PS)
- MI4 - Crankshaft PulleyS-MAX/G\bl\bxy\f2006.5\f(02/2006
\fPrint
Removal and Installation
Spe\fial Tool(s)
Removal
303-1504\f
Alignment\fTool,\fC\bmsh\bft\f
303-1521\f
Alignment\fTool,\fCr\bnksh\bft\fPosition\fSensor
\f
303-499\f
Socket,\fSp\brk\fPlug\f
303-748\f
Locking\fTool,\fCr\bnksh\bft\f
310-137\f
Disconnect\fTool,\fFuel\fLine\f1. Refer\fto:\f Fuel\fPump\fDrive\fAssembly \f(303-04B\fFuel\f
Ch\br

ging\f\bnd\fControls\f-\f2.0L\fEcoBoost\fSCTi\f
(149kW/203PS)\f-\fMI4,\fRemov\bl\f\bnd\fInst\bll\btion).\f
2.
WARNING:\fT\bke\fextr\b\fc\bre\fwhen\fh\bndling\fthe\f
compressed\fspring.\f
\f
\f
\f
\f
\f
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23. Refer\fto:\fFuel\fPump\fDrive\fAssembly \f(303-04B\fFuel\f
Ch\br
ging\f\bnd\fControls\f-\f2.0L\fEcoBoost\fSCTi\f
(149kW/203PS)\f-\fMI4,\fRemov\bl\f\bnd\fInst\bll\btion).\f
\f
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41.CAUTION:\fM\bke\fsure\fth\bt\fthe\fexh\bust\fflexible\f
pipe\fis\fnot\fforcibly\fbent\for\ftwisted.\f
42. Inst\bll\fthe\ffollowing\fitems:\f1. Refer\fto:\f Front\fH\blfsh\bft\fLH \f(205-
04\fFront\fDrive\f
H\blfsh\bfts,\fRemov\bl\f\bnd\fInst\bll\btion).\f
2. Refer\fto:\f Front\fH\blfsh\bft\fRH \f(205-
04\fFront\fDrive\f
H\blfsh\bfts,\fRemov\bl\f\bnd\fInst\bll\btion).\f
43.
WARNING:\fBe\fprep\bred\fto\fcollect\fesc\bping\ffluids.
44.WARNING:\fBe\fprep\bred\fto\fcollect\fesc\bping\ffluids.
45. Torque: 24\fNm\f
46.
WARNING:\fT\bke\fextr\b\fc\bre\fwhen\fh\bndling\fthe\f
compressed\fspring.\f
\f\f
\f\f
\f\f
\f\f
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Engine - \b.3L \furatec-HE (118kW/160PS)
- MI4 - SpecificationsS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Engine data
Engine oil
Capacities
Lubricants, Fluids, Sealants and Adhesives
Valve clearances
Cylinder head
CAUTION: The cylinder head sealing surfaces must not be re-worked.
Specifica\bion
CodeSEWA
Firing\forder1-3-4-2
Emission\flevelSt\bge\fIV
Bore87.5\fmm
Stroke94\fmm
Engine\fC\bp\bcity2,261\fcm³
Compression\fr\btio10.6\f:\f1
Power\foutput\f\bt\f6500\frpm118\fkW\f(161\fPS)
Torque\f\bt\f1500\frpm182\fNm
M\bximum\ftorque\f\bt\f4000\frpm208\fNm
M\bximum\fengine\fspeed\f(for\f\b\fshort\fperiod)6675\frev/min
M\bximum\fengine\fspeed\f(continuous)6450\frev/min
Engine\fidle\fspeed700\f±\f50\frpm
Number\fof\fcr\bnksh\bft\fm\bin\fbe\brings5
C\bmsh\bft\fdriveTiming\fch\bin
M\bximum\foil\fconsumption0.5\fL/1000\fKm
Vi\fco\fi\by/ambien\b \bempera\bureType\fpecifica\bion
Recommended engine oil
SAE\f5W-30\f/\fbelow\f-20°C\fto\fover\f+40°CFord\fFormul\b\fEWSS-M2C913-C
Alternative engine oils (for topping up only)
SAE\f10W-40\f/\f-20°C\fbelow\f-20°C\fto\fover\f+40°CFord\fFormul\b\fXR+ACEA\fA3,\fB3
SAE\f5W-40\f/\fbelow\f-20°C\fto\fover\f+40°CFord\fFormul\b\fS/SDACEA\fA3,\fB3
Li\ber\f
Initi\bl\ffill\fincluding\foil\ffilter4.6
Service\ffill\fincluding\foil\ffilter4.3
Service\ffill\fwithout\foil\ffilter3.9
Specifica\bion
Se\bl\bnt,\foil\fp\bn\fcont\bct\fsurf\bce\fto\fcr\bnksh\bft\fre\br\fse\bl\fret\biner,\foil\fp\bn\fto\f
cylinder\fblock,\foil\fp\bn\fto\ffront\fcover,\fengine\ffront\fcover\fto\fcylinder\fblock/\foil\f p\bnWSE-M4G323-
A4
Oil\fpressure\fswitch\f\bnd\fengine\ffront\fcover\fbl\bnking\fplug\fse\bl\bntWSK-M2G349- A7
Specifica\bion
V\blve\fcle\br\bnce\f(engine\fcold)\f-\fint\bke\fv\blves0,22\f-\f0,28
V\blve\fcle\br\bnce\f(engine\fcold)\f-\fexh\bust\fv\blves0,27\f-\f0,33
Specifica\bionmm
M\bximum\fdistortion,\fm\bting\ff\bce0,1
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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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\f\f\fescription
Bolts\f-\fB\bl\bncer\fsh\bfts\f
B\bl\bncer\fsh\bft\funit\f
The\f2.3L\fDur\btec-HE\fh\bs\f\b\fmodul\br\fb\bl\bncer\fsh\bft\funit\fwith\ftwo\fb\bl\bncer\fsh\bfts.\fThe\f
b\b
l\bncer\fsh\bft\funit\fis\fincorpor\bted\fin\fthe\foil\fp\bn\f\bnd\fmounted\fbene\bth\fthe\fcylinder\fblock.\f
The\fb\bl\bncer\fsh\bfts\f\bre\fdriven\fby\fthe\fcr\bnksh\bft\fvi\b\fsprockets\f\bnd\frot\bte\f\bt\ftwice\fthe\f
cr\bnksh\bft\fspeed.\f
The\fb\bl\bncer\fsh\bft\funit\fmust\fnot\fbe\fremoved\f\bnd\fstripped\fdown\fin\fService.\f
Adv\bnt\bges\fof\fthe\fb\bl\bncer\fsh\bft\funit:\f

Reduces\fthe\f2nd\forder\fforces\fof\finerti\b\f\f

The\fmodul\br\fdesign\fminimises\fimp\bct\fon\fengine\fconstruction\f
It

em
1
2
\f
Part Number -
-
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Oil Leaks - Engine
NOTE:\fBefore\frenewing\fg\bskets\for\foil\fse\bls,\fm\bke\fsure\f
th\bt\fthe\fc\buse\fof\fthe\ff\bult\fis\f
cle\brly\fest\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\fUV\ftest:\f
Ultraviolet (UV) Testing
1. 1.
Cle\bn\fthe\fengine\f\bnd\ftr\bnsmission\fwith\f\b\fsuit\bble\fcle\bning\ffluid.\f
2

. \b.
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
observe\fthis\finstruction\fc\bn\fle\bd\fto\finjuries.\f
3. 3.
St\brt\fthe\fengine\f\bnd\flet\fit\frun\ffor\f\bbout\ffive\fminutes.\f
4

. 4.
Stop\fthe\fengine.\f
N

OTE:\fIf\fno\fle\bk\fis\ffound,\fperform\f\b\fro\bd\ftest.\fDrive\f
the\fvehicle\funder\fdifferent\flo\bds\f\bnd\f
then\fre-check\fthe\fengine\ffor\fle\bks.\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
M

easure the compression pressure
Ventilspiel\feinstellen\f(Gener\bl\f
Procedures),\f
Steuerkette\f(Remov\bl\f\bnd\f
Inst\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
*ADJUST\fv\blve\fcle\br\bnce.\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\fd\bm\bged.\f
*INSTALL\f\b\fnew\ftiming\fch\bin.\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
*
Timing\fch\bin\fincorrectly\f
tensioned\f
*CHECK\fthe\ftiming\fch\bin\ftension.\fINSTALL\f
\b\fnew\ftiming\fch\bin\fif\frequired.\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
*
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\f
within\fspecific\btion.\fINSTALL\f\b\fnew\f
cylinder\fblock\fif\fnecess\bry.\f\f
REFER\fto:\fSpezifik\btionen\f(303-01\fMotor\f
-\f2.3L\fDur\btec-HE\f(MI4),\fSpecific\btions).
\f
*
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