2000 FORD S-MAX 2006 Service Repair Manual

\bnd\fgoggles.\f
Individu\bls\fwith\fchronic\frespir\btory\fdise\bses,\f\bsthm\b,\fbronchi\bl\fmedic\bl\fproblems,\for\f
histories\fof\f\bllergic\fdise\bses\fshould\fnot\fwork\fin\for\fne\br\funcured\fm\bteri\bls.\f
The\fcomponents,\fv\bpors\for\fspr\by\fmists\fc\bn\fc\buse\fdirect\firrit\btion,\fsensitivity\fre\bctions\f\bnd\f
m\by\fbe\ftoxic\for\fh\brmful.\f
V\bpors\f\bnd\fspr\by\fmists\fmust\fnot\fbe\finh\bled.\fThese\fm\bteri\bls\fmust\fbe\f\bpplied\fwith\f
\bdequ\bte\fventil\btion\f\bnd\frespir\btory\fprotection.\fDo\fnot\fremove\fthe\frespir\btor\fimmedi\btely\f
\bfter\fspr\bying;\fw\bit\funtil\fthe\fv\bpors/mists\fh\bve\fcle\bred.\f
Burning\fof\fthe\funcured\fcomponents\f\bnd\fthe\fcured\ffo\bms\fc\bn\fgener\bte\ftoxic\f\bnd\fh\brmful\f
fumes.\fSmoking,\fn\bked\ffl\bmes\for\fthe\fuse\fof\felectric\bl\fequipment\fduring\ffo\bming\foper\btions\f
\bnd\funtil\fv\bpors/mists\fh\bve\fcle\bred\fshould\fnot\fbe\f\bllowed.\fAny\fhe\bt\fcutting\fof\fcured\ffo\bms\f
or\fp\brti\blly\fcured\ffo\bms\fshould\fbe\fconducted\fwith\fextr\bction\fventil\btion.\fSee\f\blso\fthe\f
vehicle\fBody\fRep\bir\fM\bnu\bl.\f
Freon
See\fAir\fConditioning\fRefriger\bnt.\f
Fuels
See\f\blso,\fFire,\fLeg\bl\fAspects,\fChemic\bls\f\bnd\fSolvents.\f
Avoid\fskin\fcont\bct\fwith\ffuel\fwhere\fpossible.\fShould\fcont\bct\foccur,\fw\bsh\fthe\f\bffected\fskin\f
with\fso\bp\f\bnd\fw\bter.\f
Gasoline (Pe\frol)
Highly\ffl\bmm\bble\f-\fobserve\fNo\fSmoking\fpolicy.\f\f
Fo
r\f\bddition\bl\finform\btion,\frefer\fto:\f Petrol\f\bnd\fPetrol-Eth\bnol\fFuel\fSystems\fHe\blth\f\bnd\f
S\bf

ety\fPrec\butions \f(100-00\fGener\bl\fInform\btion,\fDescription\f\bnd\fOper\btio
n).\f
Gas-oil (Diesel Fuel)
For\f\bddition\bl\finform\btion,\frefer\fto:\f Di
esel\fFuel\fSystem\fHe\blth\f\bnd\fS\bfety\fPrec\butions \f(100-
00\f
Gener\bl\fInform\btion,\fDescription\f\bnd\fOper\btion).\f
Kerosene (Paraffin)
Used\f\blso\f\bs\fhe\bting\ffuel,\fsolvent\f\bnd\fcle\bning\f\bgent.\f
F l

\bmm\bble\f-\fobserve\fNo\fSmoking\fpolicy.\f
Irrit\btion\fof\fthe\fmouth\f\bnd\fthro\bt\fm\by\fresult\ffrom\fsw\bllowing.\fThe\fm\bin\fh\bz\brd\ffrom\f
sw\bllowing\f\brises\fif\fliquid\f\bspir\btion\finto\fthe\flungs\foccurs.\f
Liquid\fcont\bct\fdries\fthe\fskin\f\bnd\fc\bn\fc\buse\firrit\btion\for\fderm\btitis.\fSpl\bshes\fin\fthe\feye\fm\by\f
be\fslightly\firrit\bting.\f
In\fnorm\bl\fcircumst\bnces\fthe\flow\fvol\btility\fdoes\fnot\fgive\frise\fto\fh\brmful\fv\bpors.\fExposure\fto\f
mists\f\bnd\fv\bpors\ffrom\fkerosene\f\bt\felev\bted\ftemper\bture\fshould\fbe\f\bvoided\f(mists\fm\by\f
\brise\fin\fdew\bxing).\fAvoid\fskin\f\bnd\feye\fcont\bct\f\bnd\fm\bke\fsure\fthere\fis\f\bdequ\bte\fventil\btion.
\f
Gas Cylinders
See\f\blso\fFire.\f
G\bses\fsuch\f\bs\foxygen,\f\bcetylene,\f\brgon\f\bnd\fprop\bne\f\bre\fnorm\blly\fstored\fin\fcylinders\f\bt\f
pressures\fof\fup\fto\f138\fb\br\f(2000\fpsi)\f\bnd\fgre\bt\fc\bre\fshould\fbe\ft\bken\fin\fh\bndling\fthese\f
cylinders\fto\f\bvoid\fmech\bnic\bl\fd\bm\bge\fto\fthem\for\fto\fthe\fv\blve\fge\br\f\btt\bched.\fThe\fcontents\f
of\fe\bch\fcylinder\fshould\fbe\fcle\brly\fidentified\fby\f\bppropri\bte\fm\brkings.\f
Cylinders\fshould\fbe\fstored\fin\fwell-ventil\bted\fenclosures,\f\bnd\fprotected\ffrom\fice\f\bnd\fsnow,\f
or\fdirect\fsunlight.\fFuel\fg\bses,\ffor\fex\bmple\f\bcetylene\f\bnd\fprop\bne,\fshould\fnot\fbe\fstored\fin\f
close\fproximity\fto\foxygen\fcylinders.\f
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For\fvehicles\fbuilt\fin\fcontinent\bl\fpl\bnts,\fthe\fsecond\fdigit\fof\fthe\fp\bint\fcode,\fon\fthe\fVIN\fl\bbel,\f
denotes\fthe\forigin\bl\fmodel\fye\br\fof\fthe\fcolor’s\fintroduction,\f(‘0’=color\fintroduction\fin\f2000\f
model\fye\br).\f\f
Item 13: Interior Trim \fodes
It

em 14: Transaxle Final Drive Ratio \fodes
\b)\fThe\f6-speed\fm\bnu\bl\ftr\bns\bxle\f(MMT6)\fh\bs\ftwo\foutput\fsh\bfts.\fFirst,\fsecond,\fthird\f\bnd\f
f o

urth\fge\brs\fh\bve\fthe\fhigher\ffin\bl\fdrove\fr\btio.\fFifth,\fsixth\f\bnd\freverse\fge\brs\fh\bve\fthe\flower\f
fin\bl\fdrive\fr\btio.\f\f
Item 15: Transaxle \fodes
It

em 16: Engine \fodes
FFrozen\fWhite
GP\bnther\fBl\bck
VDeep\fN\bvy
WKelp\f(Green)
XSe\b\fGrey
YWhite\fGr\bpe\f(Yellow)
ZT\bngo\f(Or\bnge)
4Blue\fAmbition
6St\brdust\fSilver
7M\bchine\fSilver
8Tonic\f(Blue)
CodeInterior\bTrim
APInterg\bte\f-\fGeneric\fOr\bnge
BRAr\bsi\b\f-\fInfinity\fBlue
BSN\bpoli\fPerfer\bted\f-\fInfinity\fBlue
BTAv\bnette\f-\fInfinity\fBlue
BVAlc\bnt\br\b\f-\fInfinity\fBlue
CZAv\bnette\f-\fLight\fDenim\fBlue
DSN\bpoli\fPerfer\bted\f-\fCh\brco\bl
EQBurlington\f-\fEbony
ERAr\bsi\b\f-\fEbony
EVAlc\bnt\br\b\f-\fEbony
FSN\bpoli\fPerfer\bted\f-\fAlp\bc\b\fBeige
CodeTransaxle\bFinal\bDrive\bRatio
A54.067
EV3.75
H64.0
153.56
253.56
273.81/2.77\f(\b)
3V3.604
473.81/2.77\f(\b)
CodeTransaxle
55-Speed\fM\bnu\bl\fTr\bns\bxle\f(MTX-75)
66-Speed\fM\bnu\bl\fTr\bns\bxle\f(M66)
76-Speed\fM\bnu\bl\fTr\bns\bxle\f(MMT6)
V6-Speed\fAutom\btic\fTr\bns\bxle\f(AWF21)
CodeEngine
A2.0L\fDur\btec-HE\f(MI4)\f(145\fPS)
E2.3L\fDur\btec-HE\f(MI4)\f(160\fPS)
H2.5L\fDur\btec-ST\f(VI5)\f(220\fPS)
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Piston ring gap position: The piston ring gaps must be distributed evenly around the circumference of the piston. This also applies to the oil control ring elements. Align the piston ring gaps at \b20 degrees to each other.
Crankshaft \fimensions
Connecting Rod \fimensions
Piston Pin \fimensions
Camshaft \fimensions
Cylinder Head \fimensions
Oil Pressure Specifications
Pi\bton diameter - Cla\b\b 1
Pi\bton diameter - Cla\b\b 2
Pi\bton ring end gap\b
- upper compre\b\bion ring
- lower compre\b\bion ring
- oil control ring
Descrip\bion
Crank\bhaft end play
Main bearing journal diameter
Connecting rod bearing journal diameter
Descrip\bion
Big end bore diameter
Small end bore diameter
Connecting rod bearing radial clearance
Descrip\bion
Pi\bton pin diameter
Descrip\bion
Cam\bhaft end float
Cam\bhaft bearing journal diameter
Descrip\bion
Val\fe guide inner diameter
Intake \fal\fe clearance
Exhau\bt \fal\fe clearance
Cam\bhaft bearing parent bore diameter
Maximum di\btortion - mea\bured longitudinally and diagonally
Thickne\b\b of cylinder head ga\bket with pi\bton protru\bion of 0.550 mm - 0.600 mm
Thickne\b\b of cylinder head ga\bket with pi\bton protru\bion of 0.601 mm - 0.650 mm
Thickne\b\b of cylinder head ga\bket with pi\bton protru\bion of 0.651 mm - 0.700 mm
Thickne\b\b of cylinder head ga\bket with pi\bton protru\bion of 0.701 mm - 0.750 mm
Thickne\b\b of cylinder head ga\bket with pi\bton protru\bion of 0.751 mm - 0.800 mm
Thickne\b\b of cylinder head ga\bket with pi\bton protru\bion of 0.801 mm - 0.850 mm
Minimum oil pre\b\bure at idle \bpeed
Minimum oil pre\b\bure at 2000 rpm
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4.4.
Remove\fthe\foil\fpressure\fswitch\f(components\fshown\fremoved\ffor\fcl\brity).\f
5
. NOTE:\fMe\bsure\fthe\foil\fpressure\f\bt\fthe\fspecified\fengine\fspeed.\fMe\bsure\fthe\foil\f
pr

essure\f\bt\f\bn\foil\ftemper\bture\fof\f80°\fC.\f
NOTE:\fMe\bsure\fthe\foil\fpressure\f\bt\fidle\fspeed\f\bnd\f\bt\f2000\frpm.\f
NOTE:\fOil\fpressure\f\bt\fidle\fspeed:\f0.75\fb\br.\f
NOTE:\fOil\fpressure\f\bt\f2000\frpm:\f1.5\fb\br.\f
5. Att\bch\fthe\foil\fpressure\fg\buge\fwith\fthe\foil\fpressure\fg\buge\fconnector.\f
6. 6.
Check\fthe\foil\fpressure.\f
7

. 7.
Det\bch\fthe\foil\fpressure\fg\buge\f\bnd\fthe\foil\fpressure\fg\buge\fconnector.\f
8

. 8.
Co\bt\fthe\foil\fpressure\fswitch\fwith\f \b
dhesive.\f
9. 9.
Inst\bll\fthe\foil\fpressure\fswitch.\f
1

0. \b0.
Connect\fthe\foil\fpressure\fswitch\felectric\bl\fconnector.\f
1

1. \b\b.
Apply\fso\bp\fsolution\fto\fthe\fb\bll\fclip\fmountings\fin\fthe\fengine\fupper\fcover.\f\f

S

o\bp\fsolution\f(m\bximum\fconcentr\btion\fof\fso\bp\fin\fw\bter\f1:200).\f\f \f
\f
\f\f
\f\f
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Piston Pin
Camshaft
Valves
Cylinder Head
Oil Pressure Specifications
Descrip\bion
Big end b\bre dia\feter
S\fall end b\bre dia\feter
C\bnnecting r\bd bearing clearance
Descrip\bion
Pist\bn pin length
Pist\bn pin dia\feter
Descrip\bion
Ca\fshaft end fl\bat
Ca\fshaft bearing j\burnal dia\feter
Descrip\bion
Valve ste\f dia\feter
Valve guide
Valve ste\f t\b valve guide clearance — intake valve
Valve ste\f t\b valve guide clearance — exhaust valve
Descrip\bion
Thickness \bf cylinder head gasket with pist\bn pr\btrusi\bn \bf 0.55 - 0.60
Thickness \bf cylinder head gasket with pist\bn pr\btrusi\bn \bf 0.61 - 0.65
Thickness \bf cylinder head gasket with pist\bn pr\btrusi\bn \bf 0.66 - 0.70
Thickness \bf cylinder head gasket with pist\bn pr\btrusi\bn \bf 0.71 - 0.75
Maxi\fu\f dist\brti\bn — \feasured l\bngitudinally and diag\bnally
Oil pressure at 2000 rp\f
Oil pressure at 4000 rp\f
Cylinder Bl\bck blanking plug
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Piston Pin
Camshaft
Valves
Cylinder Head
Oil Pressure Specifications
Descrip\bion
Big end b\bre dia\feter
S\fall end b\bre dia\feter
C\bnnecting r\bd bearing clearance
Descrip\bion
Pist\bn pin length
Pist\bn pin dia\feter
Descrip\bion
Ca\fshaft end fl\bat
Ca\fshaft bearing j\burnal dia\feter
Descrip\bion
Valve ste\f dia\feter
Valve guide
Valve ste\f t\b valve guide clearance — intake valve
Valve ste\f t\b valve guide clearance — exhaust valve
Descrip\bion
Thickness \bf cylinder head gasket with pist\bn pr\btrusi\bn \bf 0.55 - 0.60
Thickness \bf cylinder head gasket with pist\bn pr\btrusi\bn \bf 0.61 - 0.65
Thickness \bf cylinder head gasket with pist\bn pr\btrusi\bn \bf 0.66 - 0.70
Thickness \bf cylinder head gasket with pist\bn pr\btrusi\bn \bf 0.71 - 0.75
Maxi\fu\f dist\brti\bn — \feasured l\bngitudinally and diag\bnally
Oil pressure at 2000 rp\f
Oil pressure at 4000 rp\f
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4.4.
Remove\fthe\foil\fpressure\fswitch.\f
5
. 5.
Att\bch\fthe\foil\fpressure\fg\buge\fwith\fthe\foil\fpressure\fg\buge\fconnector.\f
6

. NOTE:\fMe\bsure\fthe\foil\fpressure\f\bt\fthe\fspecified\fengine\fspeed.\fMe\bsure\fthe\foil\f
pr

essure\f\bt\f\bn\foil\ftemper\bture\fof\f80°\fC.\f
NOTE:\fMe\bsure\fthe\foil\fpressure\f\bt\f2000\frpm\f\bnd\f\bt\f4000\frpm.\f
NOTE:\fOil\fpressure\f\bt\f2000\frpm:\f2.0\fb\br.\f
NOTE:\fOil\fpressure\f\bt\f4000\frpm:\f4.0\fb\br.\f
6. Check\fthe\foil\fpressure.\f
7. 7.
Det\bch\fthe\foil\fpressure\fg\buge\f\bnd\fthe\foil\fpressure\fg\buge\fconnector.\f
8

. 8.
Co\bt\fthe\foil\fpressure\fswitch\fwith\f \b
dhesive.\f
\f\f
\f\f
\f\f
\f\f
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Engine - \b.\bL D\fratorq-TDCi
(1\b9kW/175PS) - DW - SpecificationsS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Engine Data
L\fbricants, Fl\fids, Sealers and Adhesives
Engine Oil Capacity
Cylinder Head
Oil Press\fre Specifications
Balance Shaft Meas\frement Shims
Balance Shaft Shims
Descrip\bion
Engine\fcodeQ4BA
Firing\forder1-3-4-2
Emission\flevelSt\bge\fIV
Bore85.0\fmm
Stroke96.0\fmm
Cubic\fc\bp\bcity2179\fcm³
Compression\fr\btio16.6:1
Power\foutput\f\bt\f3500\frpm129\fkW\f(170\fPS)
Torque\f\bt\f1750\frpm400\fNm
Idle\fspeed800\frpm
Oil\fconsumption0.1L\f/\f1000\fKm
I\be\fSpecifica\bion
Engine\foilWSS-M2C913-B
Cool\bntWSS-M97B44-D
Se\bl\bntWSE-M4G323-A4
Descrip\bionLi\bers
Initi\bl\ffill\fincluding\foil\ffilter6.5
Service\ffill\fwith\foil\ffilter5.9
Service\ffill\fwithout\foil\ffilter5.3
Descrip\bion\f\f
Thickness\fof\fcylinder\fhe\bd\fg\bsket\fwith\fpiston\fprotrusion\fof\f0.55\fto\f0.60\f
mm1.25\f±\f0.04\f(1\fhole)
Thickness\fof\fcylinder\fhe\bd\fg\bsket\fwith\fpiston\fprotrusion\fof\f0.61\fto\f0.65\f
mm1.30\f±\f0.04\f(2\f
holes)
Thickness\fof\fcylinder\fhe\bd\fg\bsket\fwith\fpiston\fprotrusion\fof\f0.66\fto\f0.70\f
mm1.35\f±\f0.04\f(3\fholes)
Thickness\fof\fcylinder\fhe\bd\fg\bsket\fwith\fpiston\fprotrusion\fof\f0.71\fto\f0.75\f
mm1.40\f±\f0.04\f(4\fholes)
M\bximum\fdistortion\f—\fme\bsured\flongitudin\blly\f\bnd\fdi\bgon\blly0.03
Descrip\bionbar
Oil\fpressure\f\bt\f2000\frpm2.0
Oil\fpressure\f\bt\f4000\frpm4.0
Shi\f \bhickness \f\fShi\f \farking
1.5757
Mini\fu\f clearance \f\fShi\f \bhickness \f\fShi\f \farking
0.01\f-\f0.051.5757
0.051.5151
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3.3.
Disconnect\fthe\foil\fpressure\fswitch\felectric\bl\fconnector.\f
4
. 4.
Remove\fthe\foil\fpressure\fswitch.\f
5

. 5.
Att\bch\fthe\foil\fpressure\fg\buge\fwith\fthe\foil\fpressure\fg\buge\fconnector.\f
6

. NOTE:\fMe\bsure\fthe\foil\fpressure\f\bt\fthe\fspecified\fengine\fspeed.\fMe\bsure\fthe\foil\f
pr

essure\f\bt\f\bn\foil\ftemper\bture\fof\f80°\fC.\f
NOTE:\fMe\bsure\fthe\foil\fpressure\f\bt\f2000\frpm\f\bnd\f\bt\f4000\frpm.\f
NOTE:\fOil\fpressure\f\bt\f2000\frpm:\f2.0\fb\br.\f
NOTE:\fOil\fpressure\f\bt\f4000\frpm:\f4.0\fb\br.\f
6. Check\fthe\foil\fpressure.\f
7. 7.
Det\bch\fthe\foil\fpressure\fg\buge\f\bnd\fthe\foil\fpressure\fg\buge\fconnector.\f \f
\f
\f\f
\f\f
\f\f
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with\f\b\fhydrometer.\fThe\f\bccept\bble\fr\bnge\fof\fspecific\fgr\bvity\f(sg)\fmust\fbe\fm\bint\bined.\f\f
The\fcool\bnt\fused\fis\f\bn\for\bnge\fcolored\fMotorcr\bft\fSuper\fPlus\f2000\fengine\fcool\bnt.\fThis\fis\f\b\f
non\fsilic\bted\forg\bnic\f\bcid\ftechnology\f(OAT)\fcool\bnt\fth\bt\fmust\fnot\fbe\fmixed\fwith\fother\f
cool\bnt\ftypes.\fFor\fcooling\fsystem\ftop\fup,\fonly\fuse\fcool\bnt\fwhich\fmeets\fthe\fcorrect\f
specific\btion.\f
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