Engine timing FORD S-MAX 2006 Service Repair Manual

Engine - \b.0L \furatec-HE (107kW/145PS)
- MI4/\b.0L \furatec-HE Flex Fuel
(107kW/145PS) - MI4 - Specifications
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Engine data
Engine data - Ethanol fuel mixture (E85)
Engine oil
Capacities
Descrip\bion
Engine\fcodeAOWAAOWB
Firing\forder1-3-4-2
Emission\fst\bnd\brdSt\bge\fIVSt\bge\fV
Bore87.5\fmm
Stroke83.1\fmm
Cubic\fc\bp\bcity1998\fcm³
Compression\fr\btio10.8\f:\f1
Power\foutput\f\bt\f6000\frpm107\fkW\f(145\fPS)
M\bximum\ftorque\f\bt\f4500\frpm185\fNm
M\bximum\fengine\fspeed\f(for\f\b\fshort\fperiod)6675\frev/min
M\bximum\fengine\fspeed\f(continuous)6450\frev/min
Idle\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
Descrip\bion
Engine\fcodeTBWATBWB
Fuel\ftypePetrol\f/\fE85
Firing\forder1-3-4-2
Emission\fst\bnd\brdSt\bge\fIVSt\bge\fV
Bore87.5\fmm
Stroke83.1\fmm
Cubic\fc\bp\bcity1998\fcm³
Compression\fr\btio10.8\f:\f1
Power\foutput\f\bt\f6000\frpm107\fkW\f(145\fPS)
M\bximum\ftorque\f\bt\f4500\frpm185\fNm
M\bximum\fengine\fspeed\f(for\f\b\fshort\fperiod)6675\frev/min
M\bximum\fengine\fspeed\f(continuous)6450\frev/min
Idle\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
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 topping up only)
SAE\f10W-40\f/\f-20°C\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
Li\bres
Initi\bl\ffill\fincluding\foil\ffilter4.6
Service\ffill\fincluding\foil\ffilter4.3
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Engine\fwill\fnot\f
cr\bnkB\bttery\for\fb\bttery\fc\bble\f
*CHECK\fthe\fb\bttery,\fb\bttery\fholder\f\bnd\f
b\bttery\fc\bble(s).\f\f
REFER\fto:\f Specific\btions \f(414-01\fB\bttery,\f
Mou

nting\f\bnd\fC\bbles,\fSpecific\btions).\f
*
St\brter\fmotor\for\fc\bbles.\f
*CHECK\fthe\fst\brting\fsystem.\f\f
REFER\fto:\f St\brting\fSystem \f(303-06A\f
St\br

ting\fSystem\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
Di\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:\f Cr\bnksh\bft\fPulley \f(303-01C\f
Eng

ine\f-\f2.3L\fDur\btec-HE\f(118kW/160PS)\f
-\fMI4,\fRemov\bl\f\bnd\fInst\bll\btion).\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:\f Timing\fCh\bin \f(303-01C\fEngine\f-
\f
2.3L\fDur\btec-HE\f(118kW/160PS)\f-\fMI4,\f
Remov\bl\f\bnd\fInst\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\f
system.\f
*CHECK\fthe\fexh\bust\fsystem.\f\f
REFER\fto:\f Exh\bust\fSystem\f-\f2.0L\fDur\btec-
HE\f

(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-
HE\f
Flex\fFuel\f(107kW/145PS)\f-\fMI4 \f(309-00A\f
Exh
\bust\fSystem\f-\f2.0L\fDur\btec-HE\f
(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fDescription\f\bnd\f
Oper\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
(303-01C\fEngine\f-\f2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4)\f Cr\bnksh\bft\fPulley \f(Remov\bl\f\bnd\f
Ins

t\bll\btion),\f
Timing\fCh\bin \f(Remov\bl\f\bnd\f
Ins

t\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\f
necess\bry.\fREFER\fto:\f(303-01C\fEngine\f-\f
2.3L\fDur\btec-HE\f(118kW/160PS)\f-\fMI4)\f Cr\bnksh\bft\fPulley \f(Remov\bl\f\bnd\f
Ins

t\bll\btion),\f
Timing\fCh\bin \f(Remov\bl\f\bnd\f
In s

t\bll\btion).\f
*
Noisy\frunning,\f
misfiring,\fIncorrect\ffuel\f
*DETERMINE\fwhich\ftype\fof\ffuel\fw\bs\fl\bst\f
put\fin\fthe\ft\bnk\f(note\fthe\fcountry\fspecific\f
*
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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\fvisu
\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
b\bckfiring\for\f
knockingfuel\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
(303-01C\fEngine\f-\f2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4)\f Cr\bnksh\bft\fPulley \f(Remov\bl\f\bnd\f
Ins

t\bll\btion),\f
Timing\fCh\bin \f(Remov\bl\f\bnd\f
Ins

t\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:\f V\blve\fCle\br\bnce\fAdjustment \f
(3 0

3-01C\fEngine\f-\f2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fGener\bl\f
Procedures).\f
*
Timing\fch\bin\fd\bm\bged.\f
*INSTALL\f\b\fnew\ftiming\fch\bin.\f\f
REFER\fto:\f Timing\fCh\bin \f(303-01C\fEngine\f-
\f
2.3L\fDur\btec-HE\f(118kW/160PS)\f-\fMI4,\f
Remov\bl\f\bnd\fInst\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:\f Timing\fCh\bin \f(303-01C\fEngine\f-
\f
2.3L\fDur\btec-HE\f(118kW/160PS)\f-\fMI4,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
*
Noisy\frunning\for\f
engine\fnoiseEngine\fcomponents\f
Piston\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\for\f
d\bm\bge.\fM\bke\fsure\f\bll\fcomponents\f\bre\f
within\fspecific\btion.\fINSTALL\fnew\f
components\f\bs\fnecess\bry.\f\f
REFER\fto:\f
Specific\btions \f(303-01C\fEngine\f
-\f2

.3L\fDur\btec-HE\f(118kW/160PS)\f-\fMI4,\f
Specific\btions).\f
*
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Engine - \b.0L \furatec-HE (107kW/145PS)
- MI4/\b.0L \furatec-HE Flex Fuel
(107kW/145PS) - MI4 - Timing Chain
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Installation
Special Tool(s)
Gen

eral Equipment
Removal
100-010\f
Remover,\fO-Ring\fSe\bl
\f
2\fmm\fpunch
1. Remove\fthe\ffollowing\fitems:\f1. Refer\fto:\f Engine\fFront\fCover \f(303-01A\f
Eng

ine\f-\f2.0L\fDur\btec-HE\f(107kW/145PS)\f
-\fMI4/2.0L\fDur\btec-HE\fFlex\fFuel\f
(107kW/145PS)\f-\fMI4,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
2. \f\f 2.Special\bTool(\f):\b 100-010\f
3. Gen

eral\bEquipment:\b 2\fmm\fpunch\f
3. CAUTION:\fCounterhold\fthe\fc\bmsh\bfts\f\bt\f
t h

e\fhex\bgon\fusing\f\bn\fopen-ended\fsp\bnner\fto\f
prevent\fthe\fc\bmsh\bfts\ffrom\fturning.\f
4. \f
5. General\bEquipment:\b 2\fmm\fpunch\f
\f
\f\f
\f\f
\f\f
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6. \f\f1.Torque:\b 48\fNm
\f
2. Torque:\b 10\fNm
\f
7. CAUTION:\fNo\fse\bl\bnt\fmust\fbe\fused\f
u p

stre\bm\fof\fthe\fc\bt\blytic\fconverter.\f
Torque:\b 55\fNm
\f
8. Remove\fthe\ffollowing\fitems:\f
1. Refer\fto:\f Int\bke\fM\bnifold\f(303-01A\fEngine\f
-\f2

.0L\fDur\btec-HE\f(107kW/145PS)\f-\f
MI4/2.0L\fDur\btec-HE\fFlex\fFuel\f
(107kW/145PS)\f-\fMI4,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
2. Refer\fto:\f Timing\fCh\bin\f(303-01A\fEngine\f-\f
2. 0

L\fDur\btec-HE\f(107kW/145PS)\f-\f
MI4/2.0L\fDur\btec-HE\fFlex\fFuel\f
(107kW/145PS)\f-\fMI4,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
9. Genera\f\bEquipment:\b Hose\fcl\bmp\f
rem

over/inst\bller \f
10. S

pecia\f\bToo\f(s):\b 310-137\f
Gen

era\f\bEquipment:\b Hose\fcl\bmp\f
rem

over/inst\bller \f
\f\f
\f\f
\f\f
\f\f
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Engine - \b.0L \furatec-HE (107kW/145PS)
- MI4/\b.0L \furatec-HE Flex Fuel
(107kW/145PS) - MI4 - Oil Pump—
Vehicles Built Up To: 04/\b006
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Installation
Special Tool(s)
Removal
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
205-072\f
Univers\bl\fFl\bnge\fHolding\fWrench
\f
205-072-01\f
Ad\bpter\ffor\f205-072\f
1. Remove\fthe\ffollowing\fitems:\f1. Refer\fto:\f Timing\fCh\bin\f(303-01A\fEngine\f-\f
2.0

L\fDur\btec-HE\f(107kW/145PS)\f-\f
MI4/2.0L\fDur\btec-HE\fFlex\fFuel\f
(107kW/145PS)\f-\fMI4,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
2. Refer\fto:\f Oil\fP\bn\f(303-01A\fEngine\f-\f2.0L\f
Dur

\btec-HE\f(107kW/145PS)\f-\fMI4/2.0L\f
Dur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\f
MI4,\fRemov\bl\f\bnd\fInst\bll\btion).\f
2. \f\f 1.Torque:\b 10\fNm
\f
2. Torque:\b 10\fNm
\f
3. Spec\fal\bTool(s):\b 205-072,\f205-072-01\f
Tor

que:\b 25\fNm
\f
3. CAUTION:\fM\bke\fsure\fth\bt\f\b\fnew\ffriction\f
w \b

sher\fis\finst\blled.\f
4. Torque:\b \f
10\fNm
\f
23\fNm
\f
St\bge\f1:\f
St\bge\f2:\f
\f
\f
\f\f
\f\f
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Engine - \b.0L \furatec-HE (107kW/145PS)
- MI4/\b.0L \furatec-HE Flex Fuel
(107kW/145PS) - MI4 - Oil Pump—
Vehicles Built From: 04/\b006
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Installation
Special Tool(s)
Removal
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
205-072\f
Univers\bl\fFl\bnge\fHolding\fWrench
\f
205-072-01\f
Ad\bpter\ffor\f205-072\f
1. Remove\fthe\ffollowing\fitems:\f1. Refer\fto:\f Timing\fCh\bin\f(303-01A\fEngine\f-\f
2.0

L\fDur\btec-HE\f(107kW/145PS)\f-\f
MI4/2.0L\fDur\btec-HE\fFlex\fFuel\f
(107kW/145PS)\f-\fMI4,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
2. Refer\fto:\f Oil\fP\bn\f(303-01A\fEngine\f-\f2.0L\f
Dur

\btec-HE\f(107kW/145PS)\f-\fMI4/2.0L\f
Dur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\f
MI4,\fRemov\bl\f\bnd\fInst\bll\btion).\f
2. \f\f 1.Torque:\b 10\fNm
\f
2. Spec\fal\bTool(s):\b 205-072,\f205-072-01\f
Tor

que:\b 25\fNm
\f
3. CAUTION:\fM\bke\fsure\fth\bt\f\b\fnew\ffriction\f
w \b

sher\fis\finst\blled.\f
4. Torque:\b \f
10\fNm
\f
23\fNm
\f
St\bge\f1:\f
St\bge\f2:\f
\f
\f
\f\f
\f\f
\f\f
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Engine - \b.0L E\foBoost SCTi (149kW/\b03PS) -
MI4 - CamshaftsS-MAX/G\bl\bxy\f2006.5\f(02/2006
Removal and Installation
Spe\fial Tool(s)
Mat
erials
Removal
N O

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
303-1504\f
Alignment\fTool,\fC\bmsh\bft
\f
NameSpec\bf\bcat\bo\f
Engine\fOil\f-\f5W-30WSS-M2C913-C
Fl\bnge\fSe\bl\bnt\f-\fAn\berobic\fLPWSK-M2G348-A7\f/\f5U7J-M2G348-BA
1. Refer\fto:\f Timing\fCh\bin\f(303-01B\fEngine\f-
\f2.0L\fEcoBoost\f
SCTi\f(149kW/203PS)\f-\fMI4,\fRemov\bl\f\bnd\fInst\bll\btion).
2.Remove t\be Spec\fal Tool(s): 303-1504\f
3.
CAUTION:\fNote\fthe\fposition\fof\fthe\fcomponents\f
before\fremov\bl.\f
Torque: 10\fNm
\f
4.Loosen\fe\bch\fbolt\f2\fturns\f\bt\f\b\ftime\funtil\f\bll\fbolts\f\bre\f
removed.\f
Torque: \f
7\fNm
\f
16\fNm
\f
St\bge\f1:\f
St\bge\f2:\f
5.CAUTION:\f
Note\fthe\f
position\fof\fthe\f
\f
\f\f
\f\f
\f\f
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Engine - \b.0L E\foBoost SCTi
(149kW/\b03PS) - MI4 - Timing 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:\fCr\bnksh\bft\fPulley \f(303-01B\fEngine\f-\f
2. 0

L\fEcoBoost\fSCTi\f(149kW/203PS)\f-\fMI4,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
2. \f
3. \f
4. \f
\f
\f\f
Стр. 1 из 5
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G1255655&gu...procarmanuals.com
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Engine - \b.0L E\foBoost SCTi (149kW/\b03PS)
- MI4 - Timing ChainS-MAX/G\bl\bxy\f2006.5\f(02/2006
\fPrint
Removal and Installation
General Equipment
Removal
2\fmm\fpunch1. Refer\fto:\fTiming\fCover\f(303-01B\fEngine\f-\f2.0L\f
Eco

Boost\fSCTi\f(149kW/203PS)\f-\fMI4,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
2.General
\bqui\fment:
2\fmm\f
punch \f
3. CAUTIONS:\f
No

te\fthe\fposition\fof\fthe\fcomponents\fbefore\f
remov\bl.\f
\fUse\f\bn\fopen-ended\fwrench\fto\fprevent\fthe\f
component\ffrom\fturning.\f
4. \f
5. \f
\f
\f\f
\f\f
Стр. 1 из 3
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G1248645&gu...procarmanuals.com
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