Clearance FORD S-MAX 2006 Service Repair Manual

Lubricants, Sealants and Adhesives
Valve Clearances
Cylinder head CAUTION: The cylinder head sealing surfaces must not be re-worked.
Service\ffill\fwithout\foil\ffilter3.9
Specifica\bions
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\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
Descrip\bionmm
M\bximum\fdistortion,\fm\bting\ff\bce0,1
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Engine - \b.0L \furatec-HE (107kW/145PS)
- MI4/\b.0L \furatec-HE Flex Fuel
(107kW/145PS) - MI4 - Valve Clearance
Adjustment
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
General Procedures
Special Tool(s)
Mat

erials
303-376B\f
Alignment\fPl\bte,\fC\bmsh\bft
\f
303-499\f
Socket,\fSp\brk\fPlug\f
303-748\f
Locking\fTool,\fCr\bnksh\bft\f
NameSpec\bf\bcat\bo\f
Hypoid\fOil\f85W-90SQ-M2C9002-AA\f/\fA72SX-19K261-CA
Silicone\fSe\bl\bnt\fLBWSE-M4G323-A4\f/\f2U7J-M4G323-AA
Thre\bd\fLocking\fMSWSK-M2G349-A7\f/\f2U7J-M2G349-AA 1. \f
2. \f
3. \f
\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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Engine - \b.3L \furatec-HE (118kW/160PS)
- MI4 - Valve Clearance AdjustmentS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
General Procedures
Special Tool(s)
Mat

erials
General Equipment
205-072\f
Univers\bl\fFl\bnge\fHolding\fWrench
\f
205-072-02\f
Ad\bpter\ffor\f205-072\f
303-376B\f
Alignment\fPl\bte,\fC\bmsh\bft\f
303-499\f
Socket,\fSp\brk\fPlug\f
303-748\f
Locking\fTool,\fCr\bnksh\bft\f
NameSpec\bf\bcat\bo\f
Hypoid\fOil\f85W-90SQ-M2C9002-AA\f/\fA72SX-19K261-CA
Silicone\fSe\bl\bnt\fLBWSE-M4G323-A4\f/\f2U7J-M4G323-AA
Thre\bd\fLocking\fMSWSK-M2G349-A7\f/\f2U7J-M2G349-AA
Schlitzschr\bubendreher 1.General \bqui\fment: Schlitzschr\bubendreher \f
2. \f
3

. \f
\f
\f
\f
\f
\f
\f\f
\f\f
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Engine - \b.5L \furatec (16\bkW/\b\b0PS) -
VI5 - SpecificationsS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Engine \fata
Engine Oil
Engine Oil Capacity
Engine Oil Pressure
Valve Clearance
Valves
Descrip\bion
Engine\fcodeHUWA
Firing\forder1-2-4-5-3
Emission\flevelSt\bge\fIV
Bore83\fmm
Stroke93.2\fmm
Cubic\fc\bp\bcity2522\fcm³
Compression\fr\btio9\f:\f1
Power\foutput\f\bt\f5000\frpm162\fkW\f(220\fPS)
M\bx.\ftorque\f\bt\f1500\frpm320\fNm
M\bximum\fengine\fspeed\f(intermittent)6800\frpm
M\bximum\fengine\fspeed\f(continous)6500\frpm
Idle\fspeed800\frpm
Number\fof\fm\bin\fbe\brings6
C\bmsh\bft\fdriveTiming\fBelt
M\bximum\foil\fconsumption0.5\fl/1000\fKm
Viscosi\b\f / ambien\b \bempera\bureT\fpeSpecifica\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 top-up only)
SAE\f10W-40\f/\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\fSACEA\fA3/B3
Descrip\bionLi\bers
Service\ffill\fincluding\ffilter5.8
Service\ffill\fexcluding\ffilter5.5
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)3.5
Oil\fpressure\frelief\fv\blve\fopening\fpressure4.8
Descrip\bionmm
V\blve\fcle\br\bnce\f(engine\fcold),\fint\bke0.17\f-\f0.23
V\blve\fcle\br\bnce\f(engine\fcold),\fexh\bust0.37\f-\f0.43
Descrip\bionmm
Int\bke\fv\blve\flenght101.93\f-\f102.07
Int\bke\fv\blve\fsh\bft\fdi\bmeter5.87\f-\f6.01
Int\bke\fv\blve\fguide\fcle\br\bnce0.05\f-\f0.07
Exh\bust\fv\blve\flenght101.43\f-\f101.57
Exh\bust\fv\blve\fsh\bft\fdi\bmeter5.87\f-\f6.01
Exh\bust\fv\blve\fguide\fcle\br\bnce0.05\f-\f0.07
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Engine - \b.5L \furatec (16\bkW/\b\b0PS) -
VI5 - Valve Clearance AdjustmentS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
General Procedures
Special Tool(s)
303-1183\f
Holder,\fC\bmsh\bft
\f
1. Remove\fthe\fc\bmsh\bfts.\f\f
Refer\fto:\f C\bmsh\bfts \f(303-01D\fEngine\f-\f2.5L\f
Dur

\btec\f(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
2. CAUTION:\fM\bke\fsure\fth\bt\fthe\fv\blve\f
t\b

ppets\f\bre\finst\blled\fin\ftheir\forigin\bl\f
loc\btions.\f
3. Inst\bll\fonly\fone\fp\bir\fof\ft\bppets\f\bnd\fthe\fc\bmsh\bft\f for\fthe\ffirst\fme\bsurement.\f
Special\bTool(\f):\b 303-1183\f
To r

que:\b 17\fNm
\f
4. Me\bsure\fthe\fv\blve\fcle\br\bnce\f\bnd\fif\fneccess\bry,\f \bdjust\fby\finst\blling\fnew\ft\bppets.\f
Special\bTool(\f):\b 303-1183\f
Tor

que:\b 12\fNm
\f
5. Repe\bt\fthe\fme\bsuring\fprocedures\ffor\f\bll\f cylinders\fon\fthe\fint\bke\f\bnd\fon\fthe\fexh\bust\fside.\f
\f
\f\f
\f\f
\f\f
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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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Engine - \b.8L \furatorq-T\fCi
(74kW/\b00PS) - Lynx/\b.8L \furatorq-
T\fCi (92kW/\b25PS) - Lynx - Valve
Clearance Adjustment
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
General Procedures
Special Tool(s)
303-195\f
Compressor,\fV\blve\fSpring
\f
303-196\f
Pliers,\fV\blve\fShim\f
1. Remove\fthe\fv\blve\fcover.\fRefer\fto:\f V\blve\fCover \f(303-01E\fEngine\f-\f1.8L\f
Dur

\btorq-TDCi\f(74kW/100PS)\f-\fLynx/1.8L\f
Dur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
2. \f
3. Torque:\b 20\fNm
\f
4. NOTE:\fUsing\f\b\fsuit\bble\ffeeler\fg\buge,\f
me

\bsure\fthe\fv\bl\bve\fcle\br\bnce.\f
Rot\bte\fthe\fcr\bnksh\bft\funtil\fthe\fc\bm\fp\bir\fof\f
th

e\fcylinder\fto\fbe\f\bdjusted\f\bre\fpointing\f
upw\brds.\f

Check\fthe\fv\blve\fcle\br\bnce\f\bnd\fnote\fthe\f
v\bl

ues.\f

If\fthe\fv\blues\fof\fone\for\fmore\f\bdjustment\f
sh

ims\f\bre\foutside\fthe\ftoler\bnce\fr\bnge,\f
renew\fthe\f\bdjustment\fshim\f\bs\fdescribed\fin\f
the\ffollowing\fstep.\f
5. NOTE:\fRot\bte\fthe\fcr\bnksh\bft\fby\f\b\ffurther\f90\f
d
e

grees.\f
NOTE:\fThe\fpiston\fof\fthe\fcylinder\fto\fbe\f
\bdjusted\fmust\fnot\fbe\f\bt\fTDC.\f

Note\fthe\fthickness\fof\fthe\f\bdjustment\fshim,\f
\f
\f
\f\f
\f\f
\f\f
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Engine - \b.0L \furatorq-T\fCi (85kW/115PS) - \fW/\b.0L \furatorq-T\fCi (100kW/136PS) -
(103kW/140PS) - \fW, Emission Requirements: Stage IV - Specifications
Engine \fata
Lu
bricants, Fluids, Sealers and Adhesives
Engine Oil Capacity
Cylinder Block
Pistons
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 1\b0 degrees to each other.
Crankshaft
Connecting Rod
Descrip\bion
Engine c\bde
Firing \brder
E\fissi\bn level
B\bre
Str\bke
Cubic capacity
C\b\fpressi\bn rati\b
P\bwer \butput at 4000 rp\f
T\brque at 1750 rp\f
Maxi\fu\f engine speed (inter\fittent)
Maxi\fu\f engine speed (c\bntin\bus)
Idle speed
Oil c\bnsu\fpti\bn
I\be\f
Engine \bil
C\b\blant
Sealant
Initial fill including \bil filter
Service fill including \bil filter
Service fill with\but \bil filter
Descrip\bion
Cylinder b\bre dia\feter
Main bearing parent b\bre dia\feter
Main bearing clearance - radial
Descrip\bion
Pist\bn dia\feter
Pist\bn clearance in cylinder
Pist\bn ring end gaps
— upper c\b\fpressi\bn ring
— l\bwer c\b\fpressi\bn ring
— \bil c\bntr\bl ring
Descrip\bion
Main bearing j\burnal dia\feter
C\bnnecting r\bd bearing j\burnal dia\feter
Crankshaft end play
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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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