Page 1009 of 4402

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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Page 1010 of 4402
Engine - \b.0L \furatorq-T\fCi
(85kW/115PS) - \fW/\b.0L \furatorq-T\fCi
(100kW/136PS) - \fW/\b.0L \furatorq-
T\fCi (103kW/140PS) - \fW, Emission
Requirements: Stage IV - Engine
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
\fescription and Operation
Overview
Ge
neral
The\f2.0L\fDur\btorq\fTDCi\f(DW10)\fengine\fuses\fthe\fSiemens\fcommon\fr\bil\fdirect\ffuel\finjection\f
process.\f
The\fcylinder\fhe\bd\fis\fm\bde\fof\ftwo\fp\brts.\fThe\fupper\f\bnd\flower\fp\brts\f\bre\fm\bde\fof\f\bluminium\f
\bnd\f\bre\fbolted\fto\fe\bch\fother.\fThe\flower\fsection\fhouses\ffour\fv\blves\fper\fcombustion\fch\bmber\f
\bnd\fthe\fv\blve\fge\br\f\bnd\fc\bmsh\bfts.\f
The\fv\blves\f\bre\f\bctu\bted\fby\fme\bns\fof\ftwo\foverhe\bd\fc\bmsh\bfts\f\bnd\froller\ffollowers\fwith\f
\f
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Page 1011 of 4402

hydr\bulic\ft\bppets.\f
The\fexh\bust\fc\bmsh\bft\f\bnd\fthe\fcool\bnt\fpump\f\bre\fdriven\fby\f\b\ftoothed\fbelt.\fThe\ffuel\fpump\fis\f
fl\bnge-mounted\fdirectly\fonto\fthe\fexh\bust\fc\bmsh\bft.\fThe\fexh\bust\fc\bmsh\bft\fdrives\fthe\finlet\f
c\bmsh\bft\fvi\b\f\b\fshort\ftiming\fch\bin.\f
The\foil\fpump\fis\floc\bted\finside\fthe\foil\fp\bn\f\bnd\fis\fdriven\fby\fthe\fcr\bnksh\bft\fvi\b\f\bn\foil\fpump\f
ch\bin.\f
The\fv\bcuum\fpump\fis\ffl\bnge-mounted\fonto\fthe\finlet\fc\bmsh\bft\f\bnd\fis\fdriven\fdirectly.\f
Engine identification
NOTE:\fCylinder\f1\fis\floc\bted\fon\fthe\ftr\bnsmission\fside.\f
Th
e\fseri\bl\fnumber\fof\fthe\fengine\f\bnd\fthe\fengine\fcode\f\br
e\floc\bted\fon\fthe\fint\bke\fside\fof\fthe\f
cylinder\fblock\f(in\fline\fwith\fthe\fsecond\fcylinder).\f
\f\f
\fescription
Engine\fcode\f
Engine\fseri\bl\fnumber\f
Cylinder head ancillary components Item
1
2
\f
Part Number -
-
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Page 1012 of 4402
\f\f\fescription
V\blve\fcover\f
positive\fcr\bnkc\bse\fventil\btion\f(PCV)\fconnection\f
exh\bust\fg\bs\frecircul\btion\f(EGR)\fconnection\f
Cylinder\fhe\bd\f(upper\fp\brt)\f
Cylinder\fhe\bd\f(lower\fp\brt)\f
Cylinder\fhe\bd\fg\bsket\f
Valve cover Item
1
2
3
4
5
6
\f
Part Number -
-
-
-
-
-
\f
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Page 1013 of 4402

The\fv\blve\fcover\f\bnd\fthe\finlet\fm\bnifold\fform\fone\f\bssembly\f\bnd\f\bre\fm\bde\fof\fpl\bstic.\f
The\fPCV\fv\blve\fis\f\blso\floc\bted\fon\fthe\fv\blve\fcover.\f
It\fis\fse\bled\foff\ffrom\fthe\fcylinder\fhe\bd\fwith\f\b\fsep\br\bte\fse\bl.\f
The\fcylinder\fhe\bd's\fint\bke\fports\f\bnd\finjector\fports\f\bre\fe\bch\fse\bled\foff\ffrom\fthe\finlet\f
m\bnifold\fby\ffour\fse\bling\frings.\f
NOTE:\fRefer\fto\fthe\fcurrent\fservice\fliter\bture\ffor\fprec
ise\fdet\bils\fof\fhow\fto\f\bssemble\fthe\f
v\blve\fcover\f\bnd\finlet\fm\bnifold.\f
Before\fre-inst\blling\fthe\fv\blve\fcover\f\bnd\fthe\finlet\fm\bn
ifold,\fc\brefully\fcheck\fthe\fse\bling\frings\f
for\fd\bm\bge\f\bnd\frenew\fif\fnecess\bry.\f
Cylinder head
\f\f
\fescription
Se\bl\f
Exh\bust\fc\bmsh\bft\f
Inlet\fc\bmsh\bft\f
Alignment\fsleeves\f
Timing\fch\bin\f
The\f\bluminium\fcylinder\fhe\bd\fh\bs\ffour\fv\blves\fper\fcombustion\fch\bmber.\fThe\fv\blve\fse\bts\f\bnd\f
gu
ides\f\bre\fm\bde\fof\fsintered\fsteel.\f
The\finlet\fports\f\bre\floc\bted\fon\fthe\ffront\fof\fthe\fcylinder\fhe\bd,\fthe\fexh\bust\fports\f\bt\fthe\fb\bck\f
(with\frespect\fto\fthe\fdirection\fof\ftr\bvel).\f Item
1
2
3
4
5
\f
Part Number -
-
-
-
-
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Page 1014 of 4402

\f\f\fescription
Inlet\fports\f
Cylinder\fhe\bd\fupper\fp\brt\f
Cylinder\fhe\bd\flower\fp\brt\f
Oil\fsupply\fhole\f
NOTE:\fThe\fupper\f\bnd\flower\fp\brts\fof\fthe\fcylinder\fhe\bd\f\bre\fm\btched\fto\fe\bch\fother\f\bnd\f
c\b
nnot\fbe\frenewed\fsep\br\btely.\f
NOTE:\fIt\fis\fimport\bnt\fto\fensure\fth\bt\fthe\foil\fsupply\fholes\f\bre\fnot\fblocked\fby\fse\bl\bnt\fwhen\f
the\ftwo\fp\brts\fof\fthe\fcylinder\fhe\bd\f\bre\fbrought\ftogether.\f
The\fcylinder\fhe\bd\fis\fm\bde\fof\ftwo\fsep\br\bte\fp\brts.\fThis\f
speci\bl\fdesign\fensures\fth\bt\fthe\f
over\bll\fstructure\fis\fstronger.\f
The\fupper\f\bnd\flower\fp\brts\fof\fthe\fcylinder\fhe\bd\f\bre\fmilled\fin\f\b\fsingle\foper\btion\f\bnd\f\bre\f
\bccur\btely\fpositioned\fwith\ftwo\f\blignment\fsleeves.\f
The\flower\fp\brt\fof\fthe\fcylinder\fhe\bd\fis\fbolted\fto\fthe\fcylinder\fblock.\f
The\fupper\fh\blves\fof\fthe\fc\bmsh\bft\fmountings\f\bre\fincorpor\bted\finto\fthe\fupper\fp\brt\fof\fthe\f
cylinder\fhe\bd.\fHere\fthe\fc\bmsh\bfts\frun\fdirectly\fin\f\bluminium,\fwithout\f\bddition\bl\fbe\bring\f
shells.\f
The\fupper\fp\brt\fof\fthe\fcylinder\fhe\bd\ffe\btures\ftop-entry\fint\bke\fports.\f
The\ftwo\findividu\bl\fp\brts\f\bre\fse\bled\fusing\f\b\fone-component,\fsilicone-b\bsed\fse\bl\bnt\fwhen\f
they\f\bre\fjoined\ftogether.\f
Valve train Item
1
2
3
4
\f
Part Number -
-
-
-
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Page 1015 of 4402

\f\f\fescription
Exh\bust\fc\bmsh\bft\f
Inlet\fc\bmsh\bft\f
Roller\fc\bm\ffollower\f
Hydr\bulic\ft\bppet\f
The\finlet\fv\blves\f\bre\fm\bde\fentirely\fof\fone\fm\bteri\bl.\fThe\fhe\bds\f\bnd\fstems\fof\fthe\fexh\bust\f
v\b
lves\f\bre\fm\bnuf\bctured\ffrom\fdifferent\fm\bteri\bls\f\bnd\f\bre\fjoined\fto\fone\f\bnother\fby\fme\bns\f
of\ffriction\fwelding.\f
By\fusing\froller\ffollowers,\fit\fh\bs\fbeen\fpossible\fto\fkeep\fv\blve\f\bctu\btion\ffriction\flosses\flow.\f
V\blve\fcle\br\bnce\f\bdjustment\fis\fdone\f\butom\btic\blly\fby\fthe\fhydr\bulic\ft\bppets.\fAs\f\b\fresult,\f
there\fis\fno\fneed\fto\f\bdjust\fthe\fv\blve\fcle\br\bnces.\f
The\fhydr\bulic\ft\bppets\f\bre\fconnected\fwith\fthe\fengine's\foil\fcircuit\fby\foil\fports\fc\bst\finto\fthe\f
cylinder\fhe\bd.\f
Camshafts
\f\f
\fescription
Exh\bust\fc\bmsh\bft\f
Drive\f-\ffuel\fpump\f
Item
1
2
3
4
Item 1
2
\f
Part Number -
-
-
-
\f
Part Number-
-
-
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Page 1016 of 4402

Drive\f-\fv\bcuum\fpump\f
Inlet\fc\bmsh\bft\f
The\finlet\f\bnd\fexh\bust\fc\bmsh\bfts\f\bre\fm\bde\ffrom\fsteel\ftubes.\fThe\fc\bms\f\bnd\fends\fof\fthe\f
c\b
msh\bft\f\bre\fshrunk\fon.\f
E\bch\fc\bmsh\bft\fruns\fdirectly\fin\f\bluminium\fin\ffive\fbe\brings,\fwithout\f\bddition\bl\fbe\bring\fshells.\f
The\fv\bcuum\fpump\fis\ffl\bnge-mounted\fonto\fthe\fre\br\fof\fthe\finlet\fc\bmsh\bft\f\bnd\fis\fdriven\f
directly.\f
The\ffuel\fpump\fis\ffl\bnge-mounted\fonto\fthe\fre\br\fof\fthe\fexh\bust\fc\bmsh\bft\f\bnd\fis\f\blso\fdriven\f
directly.\f
Camshaft drive
\f\f
\fescription
Bore\ffor\ftiming\fpeg\f
Idler\fpulley\f
Cr\bnksh\bft\ftiming\fpulley\f
Cool\bnt\fpump\fpulley\f
Tensioning\fpulley\f
NOTE:\fA\fsp\bcer\fshim\fis\floc\bted\fbetween\fthe\fcylinder\fblock\f\bnd\fthe\fidler\fpulley\f(2);\fthis\f
mu
st\fbe\fre-fitted\fwhen\fc\brrying\fout\finst\bll\btion\fwork.\f
The\fexh\bust\fc\bmsh\bft\fis\fdriven\fby\f\b\ftoothed\fbelt.\fThe\f
toothed\fbelt\f\blso\fdrives\fthe\fcool\bnt\f
pump.\f
The\ftoothed\fbelt\fdrive\fh\bs\f\bn\f\butom\btic\ftensioning\fpulley.\fThe\ftensioning\fpulley\foper\btes\f
by\fspring\fforce.\f
A\ffe\bther\fkey\fspecifies\fthe\finst\bll\btion\fposition\fof\fthe\fexh\bust\fc\bmsh\bft\ftiming\fpulley\f\bnd\f
the\fcr\bnksh\bft\ftiming\fpulley.\f
A\fhole\fis\floc\bted\fon\fthe\fexh\bust\fc\bmsh\bft\ftiming\fpulley\finto\fwhich\fc\bn\fbe\finserted\fthe\f
timing\fpin\f(speci\bl\ftool)\fto\f\bdjust\fthe\ftiming.\f
Timing chain tensioner 3
4
I t
em
1
2
3
4
5 -
\f
Part Number
-
-
-
-
-
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