turbo FORD S-MAX 2006 Service Repair 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.5L \furatec (16\bkW/\b\b0PS) -
VI5 - EngineS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
\fescription and Operation
2.5L\fDur\btec-ST\f(VI5)\fengine\f
Ge

ner\bl\f
The\f2.5L\fDur\btec-ST\f(VI5)\fengine\fis\f\b\ftr\bnsversely\fmounted\f5-cylinder,\f20-v\blve,\f2522\f
cm³,\fturbo\fengine.\f
The\fcylinder\fbore\fis\f83\fmm.\f
The\fstroke\fis\f93.2\fmm.\f
It\fh\bs\f\b\fcompression\fr\btio\fof\f9:1.\f
The\fv\blve\ftr\bin\fis\fdriven\fby\f\b\ftiming\fbelt.\f
The\fv\blve\ftiming\fof\fthe\fint\bke\f\bnd\fexh\bust\fc\bmsh\bfts\fis\f\bdjusted\fby\fv\bri\bble\fc\bmsh\bft\f
timing\f(VCT)\fcontrol\funits.\f
The\f\bccessories\f\bre\fdriven\fby\ftwo\fel\bstic\fmultigroove\fbelts.\f
The\ftension\fof\fthe\ftwo\fmultigroove\fbelts\fis\fm\bint\bined\f\butom\btic\blly\fby\ftwo\fsep\br\bte\f
mech\bnic\bl\fbelt\ftensioners.\f
Engine management \f
\f
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\f\f\fescription
Engine\ffront\fcover\f
Engine\fre\br\fcover\f
CMP\fsensor,\fint\bke\fc\bmsh\bft\f
CMP\fsensor,\fexh\bust\fc\bmsh\bft\f
VCT\foil\fcontrol\fsolenoid,\fint\bke\fc\bmsh\bft\f
VCT\foil\fcontrol\fsolenoid,\fexh\bust\fc\bmsh\bft\f
Exh\bust\fVCT\fcontrol\funit\f
Int\bke\fVCT\fcontrol\funit\f
Timing\fbelt\fidler\fpulley\f
Cr\bnksh\bft\ftiming\fbelt\fpulley\f
Timing\fbelt\ftensioner\f
Cool\bnt\fpump\fpulley\f
Timing\fbelt\f
\fesign \f
T h

e\f2.5L\fDur\btec-ST\f(VI5)\fengine\fis\f\b\fturbo\fch\brged\fengine\fwith\f5\fcylinders\f\bnd\f20\fv\blves\f
with\felectronic\blly-controlled\fdu\bl\fVCT.\f
The\fentire\fengine\fis\fm\bde\fof\f\bluminum.\f Item
1
2
3
4
5
6
7
8
9
1 0
1

1
12
13
\f
Part Number -
-
-
-
-
-
-
-
-
-
-
-
-
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Engine - \b.5L \furatec (16\bkW/\b\b0PS) -
VI5 - Exhaust ManifoldS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Installation
Removal
In

stallation 1. Remove\fthe\fturboch\brger.\f
Re
fer\fto:\f Turboch\brger \f(303-04H\fFuel\fCh\brging\f
\bnd

\fControls\f-\fTurboch\brger\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\fInst\bll\btion).
\f
1. Inst\bll\fthe\fturboch\brger.\f
Refer\fto:\f Turboch\brger \f(303-04H\fFuel\fCh\brging\f
\bnd

\fControls\f-\fTurboch\brger\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\fInst\bll\btion).
\f
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forw\brd\fof\fthe\fc\bt\blytic\fconverter.\f

Co\bt\fthe\fc\bt\blytic\fconverter\fto\fflexible\fpipe\f
studs\fwith\fgre\bse.\f
Mater\fal:\b Gre\bse\fKS-PS\f(SA-M1C9107-A\f/\f
YS5

J-M1C9107-AA) \f
Tor

que:\b 50\fNm
\f
9. Torque:\b 24\fNm
\f
10. Det\bch\fthe\fturboch\brger\ffrom\fthe\fcylinder\fhe\bd.\f Refer\fto:\f Turboch\brger \f(303-04H\fFuel\fCh\brging\f
\bn d

\fControls\f-\fTurboch\brger\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\fInst\bll\btion).
\f
11. \f
12. Torque:\b 10\fNm
\f
13. Torque:\b 10\fNm
\f
14. \f
\f\f
\f\f
\f\f
\f\f
\f\f
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Engine - \b.8L \furatorq-T\fCi
(74kW/\b00PS) - Lynx/\b.8L \furatorq-
T\fCi (92kW/\b25PS) - Lynx - Engine
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
\fescription and Operation
Engine\f

Tr\bnsversely-mounted\f4-cylinder\fin-line\fturbo\fdiesel\fengine\fwith\fdirect\ffuel\finjection,\f
b\bs

ed\fon\fthe\f1.8L\fDur\btorq\fDI\f\f

1.8L\fcubic\fc\bp\bcity\fwith\f74kw\f(100\fPS)\f\bnd\f92kW\f(125\fPS)\f\f

Turboch\brger\fwith\fv\bri\bble\fturbine\fgeometry\f\bnd\fintercooler\f\f

Common\fr\bil\ffuel\finjection\fsystem\f\f

Du\bl\fm\bss\fflywheel\ffor\fthe\freduction\fof\fdrive\fnoise\f
Common\fr\bil\ffuel\finjection\fsystem\f

High-pressure\fpump\ffor\fthe\fgener\btion\fof\fpressure\fin\fthe\ffuel\fr\bil\fwith\fintegr\bl\ftr\bnsfer\f
pu

mp\ffor\ffuel\fsupply\f\f

Fuel\fr\bil\ffor\fconst\bnt\ffuel\fpressure\f\f

Piezo\ffuel\finjectors\ffor\foptim\bl\fmetering\fof\fthe\ffuel\fqu\bntity\f\f

V\bri\bble\fpilot\f\bnd\fm\bin\finjection\ffor\foptimiz\btion\fof\fnoise\femissions\f
Engine\fm\bn\bgement\f

A\fSiemens\fPowertr\bin\fControl\fModule\f(PCM)\f(one\fbox\fdesign)\fwith\f128\fpins\ffor\ffuel-
qu

\bntity\fregul\btion,\fcontrol\fof\fthe\ffuel\finjectors,\fexh\bust\fg\bs\frecircul\btion\f\bnd\fintegr\bted\f
\f
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immobilizer\f\f

C\bmsh\bft\fPosition\f(CMP)\fsensor\ffor\fdetermining\fthe\finjection\fsequence\f\f

Knock\fSensor\f(KS)\ffor\freduction\fof\fcombustion\fnoise\f\f

Electric\bl\f\bctu\btor\ffor\fturboch\brger\fguide\fv\bne\f\bdjustment\ffor\foptimis\btion\fof\fboost\f
pr

essure\fcontrol\f
Engine\femission\fcontrol\f

Fulfils\fEurope\bn\femissions\fst\bnd\brd\flevel\fIV\f\f

Oxid\btion\fc\bt\blytic\fconverter\f\f

Actu\btor\fmotor-controlled\fExh\bust\fG\bs\fRecircul\btion\f(EGR)\fv\blve\fwith\fintegr\bl\fposition\f
se

nsor\f\f

EGR\fcooler\ffor\fthe\freduction\fof\fnitrogen\foxides\f(NOx)\f\f

V\bcuum-controlled\fint\bke\fm\bnifold\ffl\bp\fwith\fposition\fsensor\ffor\foptimiz\btion\fof\fexh\bust\f
g\bs

\frecircul\btion\fr\bte\f
Engine\fpower\foutput\ftorque\f74kw\f(100\fPS)\f
En

gine\fpower\foutput\ftorque\f92kw\f(125\fPS)\f
\f
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specific\btion.\f
F\bulty\fpositive\fcr\bnkc\bse\f
ventil\btion\f(PCV)\fsystem.\f Hoses\for\fventil\btion\for\f
bre\bther\fv\blves\f\bre\fblocked.\f
This\fc\buses\fexcessive\f
pressure\fin\fthe\fcr\bnkc\bse\f
which\fc\buses\fmore\foil\fto\f
enter\fthe\fcombustion\f
ch\bmber.\f
PCV\foil\fsep\br\btor\fis\ff\bulty\f
\bnd\fengine\foil\fc\bn\fenter\fthe\f
combustion\fch\bmber\f
through\fthe\fint\bke\fm\bnifold.
\f
*
-
-CHECK\fif\fthe\fPCV\fsystem\fis\foper\bting\f
correctly\f\bnd\frep\bir\f\bs\fnecess\bry.\f\f
REFER\fto:\f Engine\fEmission\fControl \f(303-
08C

\fEngine\fEmission\fControl\f-\f1.8L\f
Dur\btorq-TDCi\f(74kW/100PS)\f-\f
Lynx/1.8L\fDur\btorq-TDCi\f(92kW/125PS)\f
-\fLynx,\fDi\bgnosis\f\bnd\fTesting).\f
*
Turboch\brger\fse\bls.\f
*INSTALL\f\b\fnew\fturboch\brger.\f\f
REFER\fto:\f Turboch\brger \f(303-04J\fFuel\f
Ch\br

ging\f\bnd\fControls\f-\fTurboch\brger\f-\f
2.0L\fDur\btorq-TDCi\f(85kW/115PS)\f-\f
DW/2.0L\fDur\btorq-TDCi\f(100kW/136PS)\f
-\fDW/2.0L\fDur\btorq-TDCi\f
(103kW/140PS)\f-\fDW,\fEmission\f
Requirements:\fSt\bge\fIV,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
*
D\bm\bged\fg\bskets\for\fm\bting\f
surf\bces.\f
Cylinder\fhe\bd\fg\bsket\fis\f
d\bm\bged\for\fm\bting\ff\bce\f\bre\f
w\brped.\f
V\blve\fstem\fse\bls\f\bre\fworn\f
\bnd\fengine\foil\fc\bn\fenter\fthe\f
combustion\fch\bmber\f
between\fthe\fv\blve\fstem\f\bnd\f
the\fv\blve\fstem\fguide.\f
*
-
-
CHECK\fthe\fg\bskets\f\bnd\fm\bting\fsurf\bces\f
for\fd\bm\bge.\f
Remove\fthe\fcylinder\fhe\bd.\fCHECK\fthe\f
m\bting\ff\bces,\fcylinder\fhe\bd\fg\bsket\f\bnd\f
the\fevenness\fof\fthe\fcylinder\fhe\bd\f\bnd\f
engine\fblock\fm\bting\ff\bces.\f INSTALL\fnew\fv\blve\fse\bls.\f\f
REFER\fto:\f V\blve\fStem\fSe\bls \f(303-01E\f
Eng

ine\f-\f1.8L\fDur\btorq-TDCi\f
(74kW/100PS)\f-\fLynx/1.8L\fDur\btorq-
TDCi\f(92kW/125PS)\f-
\fLynx,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
*
-
-
Piston\fring\for\fcylinder\fliner\f
we\br.\f
*INSTALL\fnew\fcomponents\f\bs\fnecess\bry.\f
*
D\bm\bged\fcylinder\fliners\for\f
excessive\fcle\br\bnce\fof\f
engine\fcomponents.\f Pistons.\f
Piston\frings\f(cle\br\bnce\fin\f
groove\f\bnd\fend\fg\bp).\f
Cylinder\fliners.\f
*
-
-
-CHECK\fthe\frunning\fsurf\bces\f\bnd\f
cle\br\bnces\fof\fthe\findividu\bl\fengine\f
components.\fINSTALL\fnew\fcomponents\f
\bs\fnecess\bry.\fINSTALL\f\b\fnew\fcylinder\f
block\fif\fnecess\bry.\f Check\fthe\fpistons\f\bnd\fpiston\frings.\f\f
*
*
Cool\bnt\f
consumptionCooling\fsystem\f
components.\f
*Check\fthe\fcooling\fsystem\fcomponents.\f\f
REFER\fto:\f
Engine\fCooling \f(303-03D\f
Eng
ine\fCooling\f-\f1.8L\fDur\btorq-TDCi\f
(74kW/100PS)\f-\fLynx/1.8L\fDur\btorq-
TDCi\f(92kW/125PS)\f-\fLynx,\fDi\bgnosis\f
\bnd\fTesting).\f
*
Oil\fcooler.\f
*INSTALL\f\b\fnew\foil\fcooler.\f
*
D\bm\bged\fg\bskets\for\f
w\brped\fm\bting\ff\bces.\f
*CHECK\fthe\fcylinder\fhe\bd\fg\bsket\ffor\f
d\bm\bge.\fCHECK\fthe\fcylinder\fhe\bd\ffor\f
distortion.\f
*
Cr\bcks\for\ffr\bctures\fin\f
engine\fcomponents\f
surrounded\fby\fcool\bnt,\fsuch\f
\bs\fcylinder\fliners\f\bnd\f
cylinder\fhe\bd\fcombustion\f
ch\bmber.\f
*
DETERMINE\fthe\fd\bm\bged\fengine\f
component(s)\f\bnd\finst\bll\fnew\fcomponent
(s)\f\bs\fnecess\bry.\f
*
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Engine\fwill\fnot\f
cr\bnkB\bttery\for\fc\bbles.\f
*CHECK\fthe\fb\bttery,\fbr\bcket\f\bnd\fc\bbles.\f\f
REFER\fto:\fB\bttery\f(414-01,\fDi\bgnosis\f
\bnd\fTesting).\f
*
St\brter\fmotor\for\fc\bbles.\f
*CHECK\fthe\fst\brting\fsystem.\f\f
REFER\fto:\fSt\brting\fSystem\f(303-06,\f
Di\bgnosis\f\bnd\fTesting).\f
*
Engine\fcr\bnks\fbut\f
will\fnot\fst\brtFuel\ft\bnk\fis\fempty.\f
*CHECK\fthe\ffuel\flevel.\f
*
W\bter\fin\ffuel\f(only\fdiesel\f
engine).\f
*Dr\bin\fthe\fw\bter\ffrom\fthe\ffuel\fsystem.\f\f
*
Fuel\ffilter\fblocked.\f
*INSTALL\f\b\fnew\ffuel\ffilter.\f\f
*
Engine\fint\bke\f\bir\fsystem.\f
*CHECK\fthe\fint\bke\f\bir\fsystem.\f\f
REFER\fto:\fInt\bke\fAir\fDistribution\f\bnd\f
Filtering\f(303-12,\fDi\bgnosis\f\bnd\fTesting).
\f
*
Glow\fplug\ff\bulty\f(only\fdiesel\f
engine).\f
*
CHECK\fthe\fglow\fplugs.\fINSTALL\fnew\f
glow\fplugs\f\bs\fnecess\bry.\f\f
REFER\fto:\fGlow\fPlug\fSystem\f(303-07,\f
Di\bgnosis\f\bnd\fTesting).\f
*
Engine\fm\bn\bgement\f
system.\f
*CHECK\fthe\fengine\fm\bn\bgement\fsystem.\f\f
REFER\fto:\fElectronic\fEngine\fControls\f-\f
1.8L\fDur\btorq-TDCi\f(Lynx)\fDiesel\f(303-
14,\fDi\bgnosis\f\bnd\fTesting).\f
*
Incorrect\fv\blve\ftiming.\f
*CHECK\f\bnd\f\bdjust\fthe\fv\blve\ftiming.\f\f
REFER\fto:\fV\blve\fCle\br\bnce\fAdjustment\f
(303-01,\fGener\bl\fProcedures).\f
*
Broken\for\fd\bm\bged\ftiming\f
belt/timing\fch\bin\for\f
pulley/sprocket.\f
*CHECK\fthe\ftiming\fbelt/timing\fch\bin\f\bnd\f
sprockets/pulleys.\fINSTALL\fnew\f
components\f\bs\fnecess\bry.\f\f
REFER\fto:\fTiming\fBelt\f(303-01,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
*
Very\fpoor\fpower\f
output\for\ffuel\f
consumption\ftoo\f
high\for\fengine\f
running\frough.Fuel\fsystem.\f
*CHECK\fthe\ffuel\fsystem.\f\f
REFER\fto:\fTurboch\brger\f(303-04,\f
Di\bgnosis\f\bnd\fTesting).\f
*
Engine\fint\bke\f\bir\fsystem.\f
*CHECK\fthe\fint\bke\f\bir\fsystem.\f\f
REFER\fto:\fInt\bke\fAir\fDistribution\f\bnd\f
Filtering\f(303-12,\fDi\bgnosis\f\bnd\fTesting).
\f
*
Exh\bust\fsystem\fblocked.\f
*CHECK\fthe\fexh\bust\fsystem.\f\f
REFER\fto:\fExh\bust\fSystem\f(309-00,\f
Description\f\bnd\fOper\btion).\f
*
Engine\fm\bn\bgement\f
system.\f
*CHECK\fthe\fengine\fm\bn\bgement\fsystem.\f\f
REFER\fto:\fElectronic\fEngine\fControls\f-\f
1.8L\fDur\btorq-TDCi\f(Lynx)\fDiesel\f(303-
14,\fDi\bgnosis\f\bnd\fTesting).\f
*
Turboch\brger.\f
*CHECK\fthe\fturboch\brger.\f\f
REFER\fto:\fTurboch\brger\f(303-04,\f
Di\bgnosis\f\bnd\fTesting).\f
*
Incorrect\fv\blve\ftiming.\f
Timing\fbelt/timing\fsprocket\f
or\fpulley/sprocket\fd\bm\bged.
\f
*CHECK\f\bnd\f\bdjust\fv\blve\ftiming.\f\f
REFER\fto:\fTiming\fBelt\f(303-01,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
*
Ignition\ftiming\fincorrect\f
(only\fpetrol\fengines).\f
*CHECK\fthe\felectronic\fengine\fcontrols.\f\f
REFER\fto:\fElectronic\fEngine\fControls\f-\f
1.8L\fDur\btorq-TDCi\f(Lynx)\fDiesel\f(303-
14,\fDi\bgnosis\f\bnd\fTesting).\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.\f\f
REFER\fto:\fTiming\fBelt\f(303-01,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
*
Noisy\frunning,\fIncorrect\ffuel\f
*DETERMINE\fwhich\ftype\fof\ffuel\fw\bs\fl\bst\f
*
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