2006 FORD S-MAX oil pressure

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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NOTE: Cylinder 1 is l\bcated \bn t\fe transaxle side \bf t\fe engine.
T\fe cylinder bl\bck is made fr\bm grey cast ir\bn and is
d\buble-walled. T\fis \felps t\b ac\fieve \fig\f strengt\f. It als\b f\brms a
blanket \bf air t\fat results in c\bnsiderable s\bund insulati\bn.
T\fe serial number \bf t\fe engine and t\fe engine c\bde are l\bcated \bn t\fe intake side \bf t\fe cylinder bl\bck (in line wit\f t\fe
sec\bnd cylinder).
T\fe running surfaces \bf t\fe cylinders are w\brked directly int\b t\fe cylinder bl\bck.
T\fere are tw\b \f\bles \bn t\fe cylinder bl\bck f\br t\fe guide bus\fings f\br securing t\fe cylinder \fead gasket and t\fe cylinder \fead.
Oil Spray Jets

Description
Oil spray n\bzzle retaining b\blt
Oil spray jet (4 \bff)
T\fe efficient c\bmbusti\bn pr\bvided by t\fe direct-
injecti\bn turb\bc\farged diesel engine means t\fat \fig\f temperatures are
transmitted t\b t\fe pist\bns.
T\fere is an \bil spray n\bzzle installed at t\fe l\bwer end \bf eac\f cylinder liner f\br c\b\bling t\fe pist\bns. T\fe \bil spray n\bzzles spray
engine \bil in a targeted manner under t\fe pist\bn cr\bwns.
T\fere are \bil passages integrated in t\fe pist\bn cr\bwns. T\fe sprayed engine \bil enters t\fese \bil passages and t\fus ensures t\fe
necessary pist\bn c\b\bling. Pist\bn c\b\bling is n\bt essential w\fen t\fe engine is c\bld. Lubricati\bn \bf t\fe crank gear and cams\faft
\fas a \fig\fer pri\brity \fere. F\br t\fis reas\bn, t\fe \bil spray n\bzzles \bnly \bpen if an \bil pressure \bf m\bre t\fan 0.5 bar is present at
t\fem.
Cylinder block extension Item
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Description
Cylinder bl\bck
Oil Pump Assembly
Retaining b\blt (4 pieces)
Pressure relief valve \f\busing
Oil pick up and strainer
M\bunting b\blt (1 \bff)
Oil pump \butlet p\brt
Oil pump supply t\b cylinder bl\bck
T\fe \bil pump is designed as a r\bt\br pump and is b\blted t\b t\fe balance s\faft unit using f\bur retaining b\blts. A furt\fer b\blt at
t\fe \bil strainer secures t\fe \bil pump wit\f t\fe \bil dipstick tube.
T\fe drive is pr\bvided by t\fe cranks\faft via a Simplex c\fain.
T\fe \bil pump generates a maximum permissible \bil pressure \bf appr\bx. 6.5 bar and a maximum delivery rate \bf 50 l/min.
A pressure relief valve wit\fin t\fe \bil pump \butlet pr\btects t\fe \bil pump and lubricati\bn system c\bmp\bnents fr\bm system \bver
pressure.
T\fe pressure relief valve \bpens at appr\bx. 8 bar. T\fe excess \bil runs directly back int\b t\fe \bil pan.
Oil filter/oil cooler \fnit Item
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Description
C\b\blant return
Oil filter \f\busing
Oil pressure switc\f
Oil c\b\bler
C\b\blant feed
T\fe \bil filter/\bil c\b\bler unit is l\bcated \bn t\fe intake side \bf t\fe engine, level wit\f t\fe t\fird cylinder.
T\fe \bil filter element (paper filter element) is l\bcated in t\fe \bil filter \f\busing.
T\fe c\b\blant is r\buted fr\bm t\fe cylinder bl\bck int\b t\fe \bil c\b\bler via t\fe c\b\blant feed. T\fe c\b\blant is r\buted t\b t\fe t\ferm\bstat
\f\busing \bf t\fe c\b\bling system via t\fe c\b\blant return.
Intake manifold
T\fe intake manif\bld is designed s\b t\fat t\fe c\farge air is r\buted t\b all eig\ft intake ducts in a c\bntr\blled manner.
Furt\ferm\bre, t\fe gas fr\bm t\fe p\bsitive crankcase ventilati\bn system and fr\bm t\fe EGR (ex\faust gas recirculati\bn)
returned t\b t\fe intake manif\bld. T\fe seal wit\f t\fe intake ducts at t\fe cylinder \fead is pr\bvided:

by means \bf \bne O-ring f\br eac\f \bf t\fe f\bur l\bwer swirl ducts,

by means \bf \bne rubber seal f\br eac\f \bf t\fe f\bur upper c\farge ducts.
Note: W\fen fitting t\fe intake manif\bld, ensure t\fat t\fe O-
rings/rubber seals are seated c\brrectly.
T\fe intake manif\bld is b\blted t\b t\fe cylinder \fead using a t\btal \bf seven retaining b\blts. Item
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REFER\fto:\fSpecific\btions \f(303-01G\fEngine\f
-\f2.2L\fDur\btorq-TDCi\f(129kW/175PS)\f-\f
DW,\fSpecific\btions).\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.\fPCV\foil\fsep\br\btor\fis\ff\bulty\f
\bnd\fengine\foil\fc\bn\fenter\fthe\f
combustion\fch\bmber\f
through\fthe\fint\bke\f
m\bnifold.\f
*
-
-
CHECK\fif\fthe\fPCV\fsystem\fis\foper\bting\f
correctly\f\bnd\frep\bir\f\bs\fnecess\bry.\fREFER\f
to:\f Engine\fEmission\fControl \f(303-08E\f
Eng

ine\fEmission\fControl\f-\f2.2L\fDur\btorq-
TDCi\f(129kW/175PS)\f-
\fDW,\fDi\bgnosis\f\bnd\f
Testing).\f
*
Turboch\brger\fse\bls.\f
*INSTALL\f\b\fnew\fturboch\brger.\fREFER\fto:\f
Turboch\brger \f(303-
04K\fFuel\fCh\brging\f\bnd\f
Controls\f-\fTurboch\brger\f-\f2.2L\fDur\btorq-
TDCi\f(129kW/175PS)\f-\fDW,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
*
D\bm\bged\fg\bskets\for\f
m\bting\fsurf\bces.\f Cylinder\fhe\bd\fg\bsket\fis\f
d\bm\bged\for\fm\bting\ff\bce\f\bre\f
w\brped.\fV\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.\fREFER\fto:\f
Cylinder\fHe\bd\f(303-01G\fEngine\f-\f2.2L\f
Dur

\btorq-TDCi\f(129kW/175PS)\f-\fDW,\f
Remov\bl\f\bnd\fInst\bll\btion).CHECK\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.\fREFER\fto:\f
V\blve\fStem\fSe\bls \f(303-01G\fEngine\f-\f2.2L\f
Dur

\btorq-TDCi\f(129kW/175PS)\f-\fDW,\f
Remov\bl\f\bnd\fInst\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\f
necess\bry.\fINSTALL\f\b\fnew\fcylinder\fblock\f
if\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
REFER\fto:\f Engine\fCooling \f(303-03F\f
Eng

ine\fCooling\f-\f2.2L\fDur\btorq-TDCi\f
(129kW/175PS)\f-\fDW,\fDi\bgnosis\f\bnd\f
Testing).\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
*
Engine\fwill\fnot\fB\bttery\for\fc\bbles.\f
*CHECK\fthe\fb\bttery,\fbr\bcket\f\bnd\fc\bbles.\f\f
*
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5.5.
Check\fthe\fengine\ffor\foil\fle\bks\fusing\f\b\fsuit\bble\fUV\fl\bmp.\f
6
. 6.
Rectify\f\bny\fle\bks\ffound\f\bnd\fcheck\fthe\fengine\ffor\foil\fle\bks.\f
M

eas\fre the compression press\fre
WARNING:\fDo\fnot\fc\brry\fout\f\bny\frep\birs\fto\fthe\ffuel\finje
ction\fsystem\fwithout\fchecking\f
th\bt\fthe\ffuel\fpressure\fh\bs\fdropped\fto\fzero\f\bnd\fth\bt\fthe\ffuel\ftemper\bture\fh\bs\feither\f
re\bched\f\bmbient\ftemper\bture\for\fis\fbelow\f30°C,\fwhichever\fis\fthe\fgre\bter.\fF\bilure\fto\ffollow\f
these\finstructions\fm\by\fresult\fin\fperson\bl\finjury.\f
NOTE:\fThe\fpowertr\bin\fcontrol\fmodule\f(PCM)\freceives\f\bn\ferror\fmess\bge\fwhen\fthe\ffuel\f
pump\frel\by\fis\fremoved\for\felectric\bl\fcomponents\f\bre\fdisconnected.\fThis\ferror\fmess\bge\f
must\fbe\fdeleted\ffrom\fthe\ff\bult\fmemory\fusing\fthe\fFord\fdi\bgnostic\fequipment\f\bfter\f
completing\fthe\fcompression\ftest.\f
NOTE:\fV\blve\fcle\br\bnce\fmust\fbe\fset\fcorrectly\fbefore\fperforming\f\b\fcompression\ftest.\fM\bke\f
sure\fthe\fengine\fis\f\bt\fthe\fnorm\bl\foper\bting\ftemper\bture.\f
NOTE:\fThe\fv\brying\fdesign\fof\fcompression\fchecking\fdevices\f\bnd\ffluctu\bting\fst\brter\fmotor\f
speeds\fnorm\blly\fonly\f\bllows\ffor\f\b\fcomp\brison\fto\fbe\fm\bde\fof\fthe\fcompression\fpressures\fin\f
\bll\fcylinders.\f
1. 1.
Using\fd\bt\blogger\fin\fthe\f F
ord\fdi\bgnostic\fequipment,\fcheck\fth\bt\fthe\ffuel\fpressure\f
h\bs
\fdropped\fto\fzero\f\bnd\fth\bt\fthe\ffuel\ftemper\bture\fh\bs\feither\fre\bched\f\bmbient\f
temper\bture\for\fis\fbelow\f30°C,\fwhichever\fis\fthe\fgre\bter.\f
2. \b.
R\bise\f\bnd\fsupport\fthe\fvehicle.\fREFER\fto:\f L
ifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des
cription\f\bnd\fOper\btion).\f
3. 3.
Remove\fthe\fengine\fundershield.\f
4

. 4.
Remove\fthe\fr\bdi\btor\fundershield.\f
\f\f
\f\f
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28.\b8.
Inst\bll\fthe\fr\bdi\btor\fundershield.\f
2
9. \b9.
Inst\bll\fthe\fengine\fundershield.\f
3

0. 30.
Lower\fthe\fvehicle.\f
3

1. 31.
Reset\fthe\fPCM\ff\bult\fmemory.\f
M

eas\fre the oil press\fre (\b1 113 0)
The\foil\fpressure\fdepends\fon\fv\brious\ff\bctors\f(engine\fspeed,\foil\ftemper\bture,\foil\fviscosity,\f
\bmount\fof\foil\ffilter\fcont\bmin\btion\fetc.).\f
Meas\fre the oil press\fre
1. 1.
R\bise\f\bnd\fsupport\fthe\fvehicle.\fREFER\fto:\f L
ifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des
cription\f\bnd\fOper\btion).\f
2. \b.
Remove\fthe\fengine\funder\fshield.\f \f
\f
\f\f
\f\f
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3.3.
Disconnect\fthe\foil\fpressure\fswitch\felectric\bl\fconnector.\f
4
. 4.
Remove\fthe\foil\fpressure\fswitch.\f
5

. 5.
Att\bch\fthe\foil\fpressure\fg\buge\fwith\fthe\foil\fpressure\fg\buge\fconnector.\f
6

. NOTE:\fMe\bsure\fthe\foil\fpressure\f\bt\fthe\fspecified\fengine\fspeed.\fMe\bsure\fthe\foil\f
pr

essure\f\bt\f\bn\foil\ftemper\bture\fof\f80°\fC.\f
NOTE:\fMe\bsure\fthe\foil\fpressure\f\bt\f2000\frpm\f\bnd\f\bt\f4000\frpm.\f
NOTE:\fOil\fpressure\f\bt\f2000\frpm:\f2.0\fb\br.\f
NOTE:\fOil\fpressure\f\bt\f4000\frpm:\f4.0\fb\br.\f
6. Check\fthe\foil\fpressure.\f
7. 7.
Det\bch\fthe\foil\fpressure\fg\buge\f\bnd\fthe\foil\fpressure\fg\buge\fconnector.\f \f
\f
\f\f
\f\f
\f\f
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