2006 FORD S-MAX drive

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 - Timing Belt
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Installation
Special Tool(s)
Gen

eral Equipment
Removal
303-1059\f
Alignment\fPeg,\fCr\bnksh\bft
\f
303-393\f
Locking\fTool,\fFlywheel\f
303-393-01\f
Ad\bpter\ffor\f303-393\f
303-735\f
Alignment\fPeg,\fC\bmsh\bft\f
Trolley\fj\bck
1. Disconnect\fthe\fb\bttery.\fRefer\fto:\f B\bttery\fDisconnect\f\bnd\fConnect\f(414-
01 \f

B\bttery,\fMounting\f\bnd\fC\bbles,\fGener\bl\f
Procedures).\f
2. Remove\fthe\f\bccessory\fdrive\fbelt.\f
Refer\fto:\f Accessory\fDrive\fBelt \f(303-05A\f
Acc

essory\fDrive\f-\f2.0L\fDur\btec-HE\f
(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\fFuel\f
(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
3. \f
\f
\f
\f
\f
\f\f
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21. Inst\bll\fthe\f\bccessory\fdrive\fbelt.\fRefer\fto:\f Accessory\fDrive\fBelt \f(303-05A\f
Ac c

essory\fDrive\f-\f2.0L\fDur\btec-HE\f
(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\fFuel\f
(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
22. Connect\fthe\fb\bttery.\f
Refer\fto:\f B\bttery\fDisconnect\f\bnd\fConnect\f(414-
01\f

B\bttery,\fMounting\f\bnd\fC\bbles,\fGener\bl\f
Procedures).\f
\f\f
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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 - Oil Pan
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Installation
Materials
Removal
NameSpec\bf\bcat\bo\f
Engine\fOil\f-\f5W-30WSS-M2C913-B
Silicone\fSe\bl\bnt\fLBWSE-M4G323-A4\f/\f2U7J-M4G323-AA
1. R\bise\f\bnd\fsupport\fthe\fvehicle.\f\fRefer\fto:\f J\bcking\f(100-02\fJ\bcking\f\bnd\fLifting,\f
De s

cription\f\bnd\fOper\btion).\f
Refer\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des

cription\f\bnd\fOper\btion).\f
2. Remove\fthe\f\bccessory\fdrive\fbelt.\f
Refer\fto:\f Accessory\fDrive\fBelt \f(303-05E\f
Acc

essory\fDrive\f-\f2.0L\fDur\btorq-TDCi\f
(85kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(103kW/140PS)\f-\fDW,\fEmission\fRequirements:\f
St\bge\fIV,\fRemov\bl\f\bnd\fInst\bll\btion).\f
3. \f
4. \f
5. \f
\f\f
\f\f
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5.Tor\fue\b 28\fNm\f
6. Inst\bll\fthe\f\bccessory\fdrive\fbelt.\f Refer\fto:\f Accessory\fDrive\fBelt \f(303-05E\f
Ac c

essory\fDrive\f-\f2.0L\fDur\btorq-TDCi\f
(85kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(103kW/140PS)\f-\fDW,\fEmission\fRequirements:\f
St\bge\fIV,\fRemov\bl\f\bnd\fInst\bll\btion).\f
7. Fill\fthe\fengine\fwith\fengine\foil.\f
Material\b Engine\fOil\f-\f5W-30\f(WSS-M2C913-B) \f
\f\f
\f\f
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Requirements:\fSt\bge\fIV,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
2. Front\fDrive\fH\blfsh\bfts\f
Refer\fto:\f Front\fH\blfsh\bft\fLH \f(205-04\fFront\f
Dri

ve\fH\blfsh\bfts,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
Refer\fto:\f Front\fH\blfsh\bft\fRH \f(205-04\fFront\f
Dri

ve\fH\blfsh\bfts,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
3. Front\fSubfr\bme.\f
Refer\fto:\f Front\fSubfr\bme \f(502-00\fUni-
Bod

y,\fSubfr\bme\f\bnd\fMounting\fSystem,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
18.
Det\bch\fthe\f\bir\fconditioning\f(A/C)\fcompressor\f\bnd\f
secure\fto\fone\fside.\f
19. Refer\fto:\f Quick\fRele\bse\fCoupling \f(310-00\fFuel\f
Sys

tem\f-\fGener\bl\fInform\btion,\fGener\bl\f
Procedures).\f
20. General \bqui\fment: Mounting\ft\bble\fset\f
21 .

\f
22. \f
\f\f
\f\f
\f\f
\f\f
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12.Torque:\b 90\fNm\f
13. Refer\fto:\f Quick\fRele\bse\fCoupling \f(310-00\fFuel\f
Sy s

tem\f-\fGener\bl\fInform\btion,\fGener\bl\f
Procedures).\f
14. Torque:\b 28\fNm
\f
15. Inst\bll\fthe\ffollowing\fitems:\f 1. Front\fDrive\fH\blfsh\bfts\f
Refer\fto:\f Front\fDrive\fH\blfsh\bfts \f(205-04\f
Fr o

nt\fDrive\fH\blfsh\bfts,\fDescription\f\bnd\f
Oper\btion).\f
2. Front\fSubfr\bme.\f
Refer\fto:\f Front\fSubfr\bme \f(502-00\fUni-
Bod

y,\fSubfr\bme\f\bnd\fMounting\fSystem,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
3. C\bt\blytic\fConverter.\f
Refer\fto:\f C\bt\blytic\fConverter \f(309-00E\f
Ex h

\bust\fSystem\f-\f2.0L\fDur\btorq-TDCi\f
(85kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
\f\f
\f\f
\f\f
\f\f
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Engine - \b.\bL D\fratorq-TDCi
(1\b9kW/175PS) - DW - Engine - OverviewS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Description and Operation
The\f2.2L\fDur\btorq-TDCi\f(DW)\fdiesel\fengine\fextends\fthe\fr\bnge\fof\fTDCi\f4-cylinder\f
tu

rboch\brged\fdiesel\fengines.\f
Feat\fres

4-cylinder\fturbodiesel\fin-line\fengine\fwith\ftwo\foverhe\bd\fc\bmsh\bfts\f\bnd\f16\fv\blve\f
te

chnology\f\f

C\bst\firon\fcylinder\fblock\fwith\fc\bst-in\fcylinder\fliners\f\f

L\bdder\ffr\bme\ffor\fextending\fthe\fcylinder\fblock\f\f

B\bl\bnce\fsh\bft\funit\ffor\foptimum\frunning\fsmoothness\f\f

Two-p\brt\fcylinder\fhe\bd\fm\bde\ffrom\f\bluminium\f\f

Exh\bust\fc\bmsh\bft\fdriven\fby\f\b\ftiming\fbelt\f\f

Int\bke\fc\bmsh\bft\fdriven\fvi\b\f\b\ftiming\fch\bin\f(driven\fby\fthe\fexh\bust\fc\bmsh\bft)\f\f

V\blves\f\bctu\bted\fby\froller\fc\bm\ffollowers\fwith\fhydr\bulic\ft\bppets\f\f

Swirl\f\bnd\fch\brge\fducts\ffor\foptimum\fcombustion\funder\f\bll\foper\bting\fconditions\f\f

V\bri\bble-geometry\fturboch\brger\ffor\foptimum\fcylinder\fch\brging\f
F\fel system
Bosch\fcommon\fr\bil\fsystem\fwith\fm\bximum\ffuel\fpump\fpressure\fof\f1600\fb\br\f(\blso\fup\fto\f
18

00\fb\br\ffor\f\b\flimited\ftime)\f\f

Fuel\finjectors\fwith\fpiezo\ftechnology\f\f

Electric\ffuel\fpump\ffor\f\bssisting\fwith\ffilling\fof\fthe\fswirl\fpot\fin\fthe\ffuel\ft\bnk\f
Engine management
Bosch\f PCM\f(powertr\bin\fcontrol\fmodule) \f
EDC16CP39\f\f

Fuel\fmetering\fv\blve,\ffuel\fpressure\fregul\btor\f\bnd\ffuel\fpressure\fsensor\ffor\fefficient\f
re

gul\btion\fof\fthe\ffuel\fpressure\f\f

Turboch\brger\fv\bri\bble\fv\bne\felectric\bl\f\bctu\btor\f\f

Actu\btor\fmotor-controlled\f EGR
\f(exh\bust\fg\bs\frecircul\btion)\fv\blve\f\f

Actu\btor\fmotor-controlled\fint\bke\fm\bnifold\ffl\bp\fwith\fposition\fsensor\f\f

gener\btor\fcontrol\fvi\b\fLIN\fd\bt\b\fbus\fsystem\f\f

Oil\ftemper\bture\fsensor\f\bs\f\bn\finput\fv\bri\bble\ffor\fc\blcul\bting\fthe\foil\fqu\blity\f
Engine-emission control
Meets\fEURO\fIV\f\f

Actu\btor\fmotor-controlled\f EGR\f
v\blve\f\f

Int\bke\fm\bnifold\ffl\bp\fwith\fposition\fsensor\f\f

Bro\bdb\bnd\fL\bmbd\b\fprobe\ffor\fcorrecting\fthe\finjection\fvolume\f\bnd\ffor\foptimizing\fthe\f EGR\f
\f

Co\bted\f DPF\f(diesel\fp\brticul\bte\ffilter) \f
to\fminimize\frust\fp\brticle\femissions\f
Diagnosis
Vi\b\fthe\f DLC\f(d\bt\b\flink\fconnector) w
ith\fIDS\f(Integr\bted\fDi\bgnostic\fSystem) \f
Specification
T o

rque\f\bnd\fpower\foutput:\f
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renewed as individual parts.
NOTE: T\fe parts \bf t\fe cylinder \fead must n\bt be rew\brked.
B\bt\f cylinder \fead parts \fave been matc\fed t\b eac\f \bt\fer during pr\bducti\bn. Tw\b guide sleeves p\bsiti\bn t\fe cylinder \fead
parts exactly.
T\fe upper part \bf t\fe cylinder \fead is b\blted t\b t\fe l\bwer part \bf t\fe cylinder \fead and sealed as f\bll\bws:

using silic\bn sealer (seals t\fe \buter area),

using a ready-made gasket (seals t\fe swirl ducts and t\fe guides f\br t\fe fuel inject\brs).
T\fe upper \falves \bf t\fe cams\faft m\buntings are inc\brp\brated int\b t\fe upper part \bf t\fe cylinder \fead. T\fe cams\fafts run
directly in t\fe aluminium.
T\fe cams\fafts are made fr\bm cast ir\bn. T\fe intake cams\faft drives t\fe vacuum pump at t\fe rearward end. T\fe ex\faust
cams\faft drives t\fe fuel pump at t\fe rearward end. An O-ring pr\bvides t\fe seal in eac\f case.
T\fe l\bwer part \bf t\fe cylinder \fead is b\blted t\b t\fe cylinder bl\bck wit\f a t\btal \bf 10 b\blts. T\fe \bld cylinder \fead b\blts may n\bt
be reused during servicing.
Cylinder head gasket

Description
Cylinder \fead gasket t\fickness
Cylinder \fead gasket t\fickness
T\fe multi-
layer steel cylinder \fead gasket is available in f\bur t\ficknesses depending \bn t\fe pist\bn pr\btrusi\bn.
Camshaft and camshaft drive
Overview \bf t\fe c\bmp\bnents Item
C\bnnecting
r\bd
retaining
b\blts b
Number \bf cut\f\butsPist\bn pr\btrusi\bnCylinder head gasket thickness
10.55 - 0.60 mm1.25 +/
20.61 - 0.65 mm1.30 +/
30.66 - 0.70 mm1.35 +/
40.71 - 0.75 mm1.40 +/

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